Cat 3054 Engine

TM 5-3895-382-24
TECHNICAL MANUAL
UNIT, DIRECT SUPPORT

AND GENERAL SUPPORT
MAINTENANCE MANUAL
PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS)
AND LUBRICATION INSTRUCTIONS
1-3
MILITARY-SPECIFIC
MAINTENANCE INSTRUCTIONS
2-1
Important Safety Information, SENR7733-07
3-1
Torque Specifications, SENR3130-06
4-1
Specifications, 3054 Engine, SENR5815-04
5-1
Systems Operation, Testing and Adjusting

3054 Engine, SENR5816-04
6-1
Disassembly and Assembly, 3054 Engine,

SENR6241-06
7-1
Disassembly & Assembly, 3054 Engine

Supplement KENR2604
8-1
Disassembly & Assembly, 3054 Engine

Supplement, KENR2644-01
9-1
Specifications, Propel System,

KENR2645-02
10-1
Systems Operation, Testing & Adjusting

Propel System, KENR2646-03
11-1
Specifications, Vibratory System,

KENR2647-02
12-1
Systems Operation, Testing & Adjusting,

Vibratory System, KENR2648-03
13-1
CATERPILLAR MODEL CS-433C
Specifications, Systems Operation, Testing &

Adjusting, Steering System, KENR2639-02
14-1
NSN 3895-01-456-2733 (Type I)

NSN 3895-01-456-2734 (Type III)
Specifications, Systems Operation, Testing &

Adjusting, Leveling Blade System,
KENR2718-02
15-1
Disassembly & Assembly, Machine Systems,

KENR2643-01
16-1
ROLLER, VIBRATORY,
SELF-PROPELLED,
Types I & III
Contract No. DAAE07-98-C-S007
Approved for public release;

distribution is unlimited.
REFERENCES
A-1
MAINTENANCE ALLOCATION CHART (MAC)
B-1
SCHEMATICS
C-1
ALPHABETICAL INDEX
HEADQUARTERS, DEPARTMENT OF THE ARMY

21 September 1999
Index-1
TM 5-3895-382-24
This section contains all WARNINGS contained in the military-specific supplemental data. All warnings contained in the
Commercial Off-The-Shelf (COTS) Manual are not included herein.
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU
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.
The following precautions MUST be followed to ensure personnel are safe when
engine is operated for any purpose.
DO NOT operate engine of vehicle in enclosed area without adequate ventilation.
DO NOT idle engine for long periods without ventilation.
DO NOT drive any vehicle with inspection plates, cover plates, or engine
compartment doors removed unless necessary for maintenance purposes.
NEVER sleep on the Roller when the engine is idling.
BE ALERT at all times during Roller operation for exhaust odors and exposure
symptoms. If either are present, IMMEDIATELY EVACUATE AND VENTILATE the
area. Affected personnel treatment shall be: expose to fresh air; keep warm, DO
NOT PERMIT PHYSICAL EXERCISE; if necessary, give artificial respiration as
described in FM 12-11 and get medical attention.
BE AWARE: neither the gas particulate filter unit nor field protection mask for
nuclear-biological-chemical protection will protect you from carbon monoxide
poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION
WARNING
Personnel hearing can be PERMANENTLY DAMAGED if exposed to constant high
noise levels of 85 dB (A) or greater. Wear approved hearing protection devices
when working within 20 ft (6.1 m) of Roller. Personnel exposed to high noise levels
shall participate in a hearing conservation program in accordance with TB MED
501. Hearing loss occurs gradually but becomes permanent over time.
WARNING
Do not turn vibratory system on while Roller is standing still on a very solid
surface. A loss of steering can be experienced which could result in injury to
personnel.
TM 5-3895-382-24
WARNING
Mount and dismount the Roller only where steps and/or handrails are provided.
Clean shoes and wipe hands before climbing on Roller.
mounting Roller.
Use handrails when
Inspect, clean, and have any necessary repairs made to steps prior to mounting
the Roller.
Always use "three-point contact" with Roller; face Roller when entering or
leaving operator's station. Three-point contact means that three out of four arms
and legs are in contact with Roller at all times during mount and dismount.
Never get on or off a moving Roller.
Never jump off the Roller.
Do not attempt to climb on or off the Roller while carrying tools or supplies.
TM 5-3895-382-24
WARNING
There is no clearance for personnel
between frame and yoke when
Roller turns. Severe injury or death
from crushing could occur.
Steering frame must be locked
before lifting, transporting, or
servicing Roller in articulation area
with engine running to prevent
serious injury or death from
crushing.
Unlock steering frame before
operation to prevent loss of
steering that may cause serious
injury or death to personnel.
WARNING
Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective
goggles and gloves; use only in a well-ventilated area; avoid contact with skin,
eyes, and clothes; and, do not breathe vapors. Keep away from heat or flame.
Never smoke when using solvent the flashpoint for drycleaning type III is 200 F
(93 C). Failure to do so may result in injury or death to personnel.
If personnel become dizzy while using cleaning solvent, immediately get fresh air
and medical help. If solvent contacts skin or clothes, flush with cold water. If
solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention. DO NOT use diesel fuel, gasoline, or benzene (benzol) for
cleaning.
DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPEN
FLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent
only in well-ventilated places.
USE CAUTION when using cleaning solvents. Cleaning solvents evaporate
quickly and can irritate exposed skin if solvents contact skin. In cold weather,
contact of exposed skin with cleaning solvents can cause frostbite.
DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning.
TM 5-3895-382-24
WARNING
Battery acid (Electrolyte) is extremely harmful. Always wear safety goggles and
rubber gloves, and do not smoke when performing maintenance on batteries.
Injury will result if acid contacts skin or eyes. Wear rubber apron to prevent
clothing being damaged.
Remove all jewelry such as rings, dog tags, bracelets, etc. If jewelry contacts
battery terminal, a direct short may result in instant heating of tools, damage to
equipment, and injury or death to personnel.
Turn battery disconnect switch off prior to performing maintenance in immediate
battery area or working on electrical system. Such disconnections prevent
electrical shock to personnel or equipment.
WARNING
Do not drain engine oil while engine is hot.
result
Severe injury to personnel may
Do not drain hydraulic oil while oil is hot. Severe injury to personnel may result.
Prolonged contact with lubricating oil, MIL-PRF-2104 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 slippery and can cause falls. To avoid injury, wipe up all spilled oil with
rags.
WARNING
When working on a running engine, provide shielding for exposed rotating parts.
Tools, Clothing, or hands can get caught and cause serious injury to personnel.
WARNING
Blade assembly weighs 1,000 lbs (454 kg). Keep clear of equipment when
equipment is being raised or lowered. Equipment may fall and cause serious
Do not allow heavy components to swing while hanging by lifting device.
Equipment may strike personnel and cause injury.
Exercise extreme caution when working near a cable or chain under tension. A
snapped cable, shifting or swinging load may result in injury or death to
personnel.
TM 5-3895-382-24
Each half of pad-foot shell weighs 1,000 lbs (454 kg). Keep clear of equipment when
equipment is being raised or lowered. Equipment may fall and cause serious injury or
death to personnel.
Do not allow heavy components to swing while hanging by lifting device. Equipment may
strike personnel and cause injury.
Exercise extreme caution when working near a cable or chain under tension. A snapped
cable, shifting or swinging load may result in injury or death to personnel.
Fuel is very flammable and can explode easily. To avoid serious injury or death:
Keep at least a B-C fire extinguisher within easy reach when working with fuel or fuel
system.
When refueling, stop engine, and apply parking brake. Ensure no open flame is near
area. Never smoke while working with fuel. Never add fuel when engine is running. Do
not have a driver seated when adding fuel.
Ground fuel funnel or nozzle against filler neck to prevent sparks and be sure to replace
fuel tank cap. After fuel is added, securely close fuel cap assembly; a loose cap assembly
can cause a fuel leak or be a fire hazard.
Never overfill the tank or spill fuel. If fuel is spilled, clean fuel up immediately. Before
starting vehicle, check that no fuel is spilled on or around vehicle.
Do not start or move Roller when anyone is under Roller. Severe injury or death to
personnel could result.
If NBC exposure is suspected, all air filter media will be handled by personnel wearing
full NBC protective equipment. Consult your unit NBC NCO for appropriate handling or
disposal instructions.
Change 1
e/(f blank)
TM 5-3895-382-24
INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATA
LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE:
The portion of text affected by the updates is indicated by a vertical line in the outer
margins of the page. Updates to illustrations are indicated by miniature pointing hands.
Updates to wiring diagrams are indicated by shaded areas.
Dates of issue for original and updated pages/work packages are:

Original...........21 September 1999
Change 1 .......15 September 2003
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 762 AND TOTAL
NUMBER OF WORK PACKAGES IS 403 CONSISTING OF THE FOLLOWING:
Page/WP No.
*Revision No.
Page/WP No.
*Revision No.
Page/WP No.
*Revision No.
Front Cover
1-19
9-1 9-16
Title
1-20
10-1 10-14
ad
1-21 1-51
11-1 11-52
1-52
12-1 12-12
1-53 1-94
13-1 13-44
2-1 2-49
14-1 14-20
2-50
15-1 15-14
i iv
2-51 2-52
16-1 16-110
2-53 2-54
A-1 A-2
vi
2-55 2-72
B-1 B-10
1-1 1-8
3-1 3-2
B-11
1-9
4-1 4-12
B-12
1-10 1-15
5-1 5-46
C-1 C-16
1-16
6-1 6-108
1-17
7-1 7-96
Index-1
Index 10
Back Cover
1-18
8-1 8-8
*Zero in this column indicates an original page or work package.
Change 1
A/(B blank)
TM 5-3895-382-24
CHANGE
No. 1
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 15 September 2003
UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL

FOR
ROLLER, VIBRATORY, SELF-PROPELLED,
Types I & III
NSN 3895-01-456-2733 (Type I)
NSN 3895-01-456-2734 (Type III)
Approved for public release; distribution is unlimited.
TM 5-3895-382-24, 21 September 1999, is changed as follows:

1.
2.
3.
4.
5.
File this sheet in front of the manual for reference.

New or changed material is indicated by a vertical bar in the margin of the page.
Minor changes to illustrations are indicated by a miniature pointing hand.
Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the art.
Remove old pages and insert new pages as indicated below.
Remove Pages
Insert Pages
e and f
A and B
v and vi
1-9 and 1-10
1-15 through 1-20
1-51 and 1-52
2-49 and 2-50
2-53 and 2-54
B-11 and B-12
Back Cover
e /(f blank)
A/(B blank)
v/(vi blank)i
1-9 and 1-10
1-15 through 1-20
1-51 and 1-52
2-49 and 2-50
2-53 and 2-54
B-11 and B-12
Back Cover
By Order of the Secretary of the Army:

PETER J. SCHOOMAKER
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
0306716
DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) 256547
requirements for TM 5-3895-382-24.
TM 5-3895-382-24
TECHNICAL MANUAL
HEADQUARTERS
No. 5-3895-382-24
Washington, DC
21 September 1999
UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL

FOR
ROLLER, VIBRATORY, SELF-PROPELLED,
Types I & III

NSN 3895-01-456-2733 (Type I)
NSN 3895-01-456-2734 (Type III)
Contract No. DAAE07-98-C-S007
REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the
procedures, please let us know. Submit your DA Form 2028-2 (Recommended Changes to Equipment
Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) website.
The Internet address is http://aeps.ria.army.mil. If you need a password, scroll down and click on
"ACCESS REQUEST FORM". The DA Form 2028 is located in the ONLINE FORMS PROCESSING
section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable
us to respond quicker to your comments and better manage the DA Form 2028 program. You may also
mail, fax or email your letter, DA Form 2028, or DA Form 2028-2 direct to: Commander, U.S. Army
Tank-automotive and Armaments Command, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630.
The email address is: amsta-ac-nml@ria.army.mil. The fax number is DSN 793-0726 or Commercial
(309) 782-0726.
TABLE OF CONTENTS
Page
CHAPTER 1
SERVICE UPON RECEIPT & UNIT PMCS ..............................................................1-1
Section I.
Section II.
Section III.
Service Upon Receipt .............................................................................................1-2

Preventive Maintenance Checks and Services (PMCS) ............................................1-3
Additional Maintenance Instructions ......................................................................1-21
CHAPTER 2
MILITARY-SPECIFIC MAINTENANCE INSTRUCTIONS ..........................................2-1
CHAPTER 3
IMPORTANT SAFETY INFORMATION, SENR7733-07 ............................................3-1
CHAPTER 4
TORQUE SPECIFICATIONS, SENR3130-06 ...........................................................4-1
CHAPTER 5
SPECIFICATIONS, 3054 ENGINE, SENR5815-04 ...................................................5-1
CHAPTER 6
SYSTEMS OPERA TION, TESTING AND ADJUSTMENT, 3054

ENGINE, SENR5816-04 .........................................................................................6-1
CHAPTER 7
DISASSEMBLY & ASSEMBLY, 3054 ENGINE, SENR6241-06 .................................7-1
TM 5-3895-382-24
TABLE OF CONTENTS (CONT)
Page
CHAPTER 8
DISASSEMBLY & ASSEMBLY, 3054 ENGINE SUPPLEMENT, KENR2604...............8-1
CHAPTER 9
DISASSEMBLY & ASSEMBLY, 3054 ENGINE SUPPLEMENT, KENR2644-01 ..........9-1
CHAPTER 10
SPECIFICATIONS, PROPEL SYSTEM, KENR2645-02 ..........................................10-1
CHAPTER 11
SYSTEMS OPERATION, TESTING & ADJUSTMENT, PROPEL SYSTEM,

KENR2646-03 .....................................................................................................11-1
CHAPTER 12
SPECIFICATIONS, VIBRATORY SYSTEM, KENR2647-02.....................................12-1
CHAPTER 13
SYSTEMS OPERATION, TESTING & ADJUSTMENT, VIBRATORY

SYSTEM, KENR2646-03.......................................................................................13-1
CHAPTER 14
SPECIFICATIONS, SYSTEMS OPERATION, TESTING & ADJUSTMENT,

STEERING SYSTEM, KENR2639-02 ....................................................................14-1
CHAPTER 15
SPECIFICATIONS, SYSTEMS OPERATION,

TESTING & ADJUSTMENT, LEVELING BLADE SYSTEM, KENR2718-02...............15-1
CHAPTER 16
DISASSEMBLY & ASSEMBLY, MACHINE SYSTEMS, KENR2643-01.....................16-1
APPENDIX A
REFERENCES ...................................................................................................... A-1
APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC) ....................................................... B-1
Section I.
Section II.
Section III.
Section IV.
Introduction ........................................................................................................... B-1

Maintenance Allocation Chart for CS-433C Self-propelled Vibratory Roller ................ B-4
Tools And Test Equipment for CS-433C Self-propelled Vibratory Roller................... B-11
Remarks for CS-433C Self-propelled Vibratory Roller............................................. B-12
APPENDIX C
SCHEMATICS ....................................................................................................... C-1
INDEX
ALPHABETICAL INDEX................................................................................... Index-1
ii
TM 5-3895-382-24
HOW TO USE THIS MANUAL
This manual is designed to help maintain the Caterpillar Model CS-433C, NSN 3895-01-456-2733 (Type I) and
NSN 3895-01-456-2734 (Type III), Self-propelled Vibratory Roller. This roller is a commercially available unit and is
altered slightly for military use. This is a Commercial Off-The-Shelf (COTS) manual with supplemental data to support
military-specific maintenance. Listed below are some of the special features that are included to help locate and use the
needed information:
Chapter One contains the Unit level Preventive Maintenance Checks and Services (PMCS).
Chapter Two contains maintenance instructions specific to the military model.
Chapters Three through Sixteen are the Commercial Off-The-Shelf manual from the manufacturer.
Appendix A lists any references used in this manual.
Appendix B contains the Maintenance Allocation Chart (MAC).
Appendix C contains the Schematics.
An alphabetical index is provided to help locate main items in the text.
FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

Read through this manual and become familiar with the contents.
Read entire procedure before attempting to perform any maintenance task.
Read all WARNINGS and CAUTIONS before performing any procedure.
Any information in Chapters 1 and 2 overrides any conflicting information contained in Chapters 3 through 16.
Any information in Paragraphs 1-1 through 1-13 overrides any conflicting information contained in Paragraph 1-14.
Any information in Chapter 9 overrides any conflicting information contained in Chapter 7.
GENERAL INFORMATION
1-1. SCOPE
a. Type of Manual. Maintenance Manual.
b. Model Number and Equipment Name.
Caterpillar Model CS-433C, Roller, Vibratory, Self-propelled,
NSN 3895-01-456-2733 (Type I) and NSN 3895-01-456-2734 (Type III).
c. Purpose of Equipment. The Self-propelled Vibratory Roller, from here on referred to as the Roller, is a selfpropelled roller designed to compact soil and gravel bases for parking lots, runways, streets, roads, and highways.
iii
TM 5-3895-382-24
1-2. MAINTENANCE FORMS AND RECORDS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738750, The Army Maintenance Management System (TAMMS) (Maintenance Management UPDATE).
1-3. DIFFERENCES BETWEEN MODELS
The following table summarizes the differences between the two models of the Roller covered in this manual.
Description
Type I
Pad-foot Shell Kit

Kit Includes:
Pad-foot Shells (2)
Bolts (8)
Washers (16)
Locknuts (8)
Universal Bumper
Bumper Assembly Includes:
Bumper (1)
Scraper Plates (4)
Scraper Plates (2)
Scrapers (12)
Bolts (24)
Washers (26)
Shims (3)
Bolts (5)
Bolts (3)
Washers (12)
Nuts (6)
Bolts (2)
Interchangeable Pad-foot Drum Kit
Pad-foot Drum Kit Includes:
Pad-foot Drum
Bumper
Removable Handrail
Also Required:
Bolt (6)
Washer (12)
Nut (6)
Standard Bumper
Pad-foot Drum Tiedowns
Tubeless Tires
Type III
X
X
X
X
X
X
X
X
X
X
X
iv
TM 5-3895-382-24
1-4. 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 the Roller be reported so that the problem can be corrected and improvements can be
made to prevent the problem in future items.
While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials,
such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a
corrosion problem.
This vehicle has been painted with a Chemical Agent Resistant Coating (CARC). Maintain this coating in
accordance with TM 43-0139 and TB 43-0242. Use black paint MIL-P-14105 on exhaust components. If a
corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency Report.
Use of keywords such as "corrosion," "rust," "deterioration," or "cracking" will ensure that the information is
identified as a CPC problem. Submit the form to the address specified in DA PAM 738-750.
1-5. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE

Command decision, according to the tactical situation, will determine when the destruction of the Roller will be
accomplished. A destruction plan will be prepared by the using organization unless one has been prepared by a
higher authority. For general destruction procedures for this equipment, refer to TM 750-244-6, Procedures for
Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-automotive and
Armaments Command).
1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your Roller needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us
what you don't like about your equipment. Let us know why you don't like the design or performance. Put it on
an SF368 (Product Quality Deficiency Report). Mail it to us at:
Commander,
US Army Tank-automotive and Armaments Command
ATTN: AMSTA-AC-NML
Rock Island, IL 61299-7630
A reply will be furnished to you. You may also provide DA Form 2028-2 information to TACOM via datafax
or e-mail.
TACOM's datafax number for AMSTA-AC-NML is:
DSN 793-0726
or commercial (309) 782-0726
The e-mail address is: amsta-ac-nml@ria.army.mil
The Army Electronic Product Support: http://aeps.ria.army.mil
1-7. PREPARATION FOR STORAGE AND SHIPMENT

Transportability information can be found in TM 5-3895-382-10.
v/(vi blank)
Change 1
TM 5-3895-382-24
CHAPTER 1
SERVICE UPON RECEIPT & UNIT PMCS
Para
Contents
Page
1-1.
1-2.
1-3.
1-4.
1-5.
1-6.
1-7.
1-8.
1-9.
1-10.
1-11.
1-12.
1-13.
1-14.
Checking Unpacked Equipment ..................................................................................................................1-2

Processing Unpacked Equipment ...............................................................................................................1-2
Cable Diagrams .........................................................................................................................................1-2
Preliminary Servicing and Adjustment of Equipment .....................................................................................1-2
PMCS Introduction .....................................................................................................................................1-3
PMCS Procedures .....................................................................................................................................1-3
Cleaning Agents .........................................................................................................................................1-5
Shortened Maintenance Instructions ............................................................................................................1-5
Additional Maintenance Inspections ............................................................................................................1-5
Leakage Classification and Definition ..........................................................................................................1-6
PMCS Column Entry Explanation ................................................................................................................1-6
General Lubrication Instructions ..................................................................................................................1-7
PMCS Table ..............................................................................................................................................1-8
Additional Maintenance Instructions ..........................................................................................................1-14
Torque Specification ...........................................................................................................................1-21
Cooling Specifications .........................................................................................................................1-23
Fuel Specifications .............................................................................................................................1-32
Scheduled Oil Sampling (SOS ) .......................................................................................................1-35
Lubricant Viscosities and Refill Capacities ...........................................................................................1-42
Maintenance Intervals ........................................................................................................................1-43
When Required ..................................................................................................................................1-45
Every 10 Service Hours or Daily ..........................................................................................................1-50
Every 50 Service Hours or Weekly.......................................................................................................1-61
Every 100 Service Hours or Monthly ....................................................................................................1-64
Initial 250 Service Hours or First 3 Months Operation ...........................................................................1-68
Every 500 Service Hours or 3 Months .................................................................................................1-82
Every 1000 Service Hours or 1 Year ...................................................................................................1-83
Every 2000 Service Hours or 1 Year ...................................................................................................1-89
Maintenance Records ........................................................................................................................1-92
Troubleshooting .................................................................................................................................1-92
Reference Materials ...........................................................................................................................1-93
1-1
TM 5-3895-382-24
Section I. SERVICE UPON RECEIPT
1-1. CHECKING UNPACKED EQUIPMENT

a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the
damage on SF 364, Report of Discrepancy.
b. Check the equipment against the packing slip to see if the shipment was complete. Report all discrepancies in
accordance with the instructions of DA Pam 738-750 or AR-750-1 as applicable.
1-2. PROCESSING UNPACKED EQUIPMENT

a. Refer to MAC (Appendix B) for list of tools and test equipment.
b. Dispose of waste products in accordance with local regulations.
1-3. CABLE DIAGRAMS

Refer to Appendix C for all hydraulic and electrical schematics.
1-4. PRELIMINARY SERVICING AND ADJUSTMENT OF EQUIPMENT

Perform all Operator PMCS procedures (TM 5-3895-382-10).
Troubleshoot any malfunctions or failures.
1-2
Start Roller and test all controls and switches.
TM 5-3895-382-24
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
1-5. PMCS INTRODUCTION

PMCS means systematic caring for, inspecting, and servicing equipment to keep it in good condition and to prevent
breakdowns. To be sure the Roller is ready for operation at all times, Roller must be inspected systematically so that
defects may be discovered and corrected before they result in serious damage or failure. Use a DA Form 2404
(Equipment Inspection and Maintenance Worksheet), or DA Form 5988E, to record any deficiencies. DO NOT record
faults that you fix.
Any information in Paragraphs 1-1 through 1-13 overrides any conflicting information in paragraph 1-14.
1-6. PMCS PROCEDURES

a. PMCS, Table 1-1, lists inspections and care required to keep your Roller in good operating condition. This table
is set up so you can do intervals of PMCS while walking around the Roller.
b. The "INTERVAL" column of Table 1-1 tells you when to do a certain check or service.
c. The "PROCEDURE" column of Table 1-1 tells you how to do required checks and services. Carefully follow these
instructions.
d. The "NOT FULLY MISSION CAPABLE IF:" column of Table 1-1 tells you when your Roller is non-mission capable
and why the Roller cannot be used.
e. When the Roller does not perform as required, refer to Troubleshooting.
f. When something looks wrong and you can't fix it, write it on your DA Form 2404, or DA Form 5988E.
IMMEDIATELY report it to your supervisor. When you do your PMCS, you will always need a rag or two. The following
checks are common to the entire Roller.
1-3
TM 5-3895-382-24
WARNING
Never smoke when using solvent; the flashpoint for drycleaning solvent Type III
is 200 F (93 C). Failure to do so may result in injury or death to personnel.
medical attention.
g. Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as
you work and as needed. Use drycleaning solvent (P-D-680, Type III) on all metal surfaces. Use soap and water when
you clean rubber or plastic material.
(1) Rust and Corrosion. Check Roller body and frame for rust and corrosion. If any bare metal or corrosion
exists, clean and apply a thin coat of oil. Report it to your supervisor.
(2) Bolts, Nuts, and Screws. Check all attaching hardware 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 a
bolt, nut, or screw you think is loose, tighten it or report it to your supervisor.
(3) 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.
(4) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and loose or
broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.
(5) Hoses and Fluid Lines. Look for chafing, wear, damage, and leaks, and make sure clamps and fittings are
tight. Wet spots show leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose
fitting or connector, tighten it. If something is broken or worn out, report it to your supervisor.
h. When you check for "operating condition," look at the component to see if it's serviceable.
1-4
TM 5-3895-382-24
1-7. CLEANING AGENTS
WARNING
DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning.
DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPEN
FLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent
only in well-ventilated places.
USE CAUTION when using cleaning solvents. Cleaning solvents evaporate
quickly and can irritate exposed skin if solvents contact skin. In cold weather,
contact of exposed skin with cleaning solvents can cause frostbite. Drycleaning
Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and
clothes; and do not breathe vapors. Keep away from heat or flame. Never
smoke when using solvent; the flashpoint for Type III drycleaning solvent is
200 F (93 C). Failure to do so may result in injury or death to personnel.
medical attention.
When cleaning grease buildup or rusty places, use a cleaning solvent.
apply a thin coat of light oil to affected areas.
Then
1-8. SHORTENED MAINTENANCE INSTRUCTIONS

Local conditions of extreme heat, dust, cold, or wetness dictate shorter service intervals.
1-9. ADDITIONAL MAINTENANCE INSPECTIONS
Additional maintenance inspections are required for the following reasons:
a. Prolonged storage. Rollers which have been stored for a period of three months or more should be inspected.
b. Initial preparation upon receipt.
c. Preparation for storage.
1-5
TM 5-3895-382-24
1-10. LEAKAGE CLASSIFICATION AND DEFINITION
It is necessary for you to know how fluid leakage affects the status of the Roller. The 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.
CAUTION
Equipment operation is allowable with minor leakages (Class I or II) except for
fuel leakage. 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 your PMCS.
Any fuel or class III leaks should be reported immediately to your supervisor.
a. CLASS I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being
checked/inspected.
c. CLASS III - Leakage of fluid great enough to form drops that fail from item being checked/inspected.
1-11. PMCS COLUMN ENTRY EXPLANATION
a. Item No. Column. The checks and services are numbered in interval order. Use the numbers in the "TM ITEM
NO." column of DA Form 2404, or DA Form 5988E, when recording faults that you don't immediately fix.
b. Interval Column. This column indicates when the lubrication, check, or service should be performed.
following lubrication interval symbols are used.
Q - quarterly
S - semiannually
A - annually
B - biennially
The
H - hours (operated)
|
c. Location, Item to be Checked or Serviced Column. The underlined items listed in this column are divided into
groups indicating the portion of the equipment of which they are a part, i.e. brakes, fuel, and engine. Under these
groupings a few common words are used to identify the specific item being checked.
d. Procedures Column. This column contains procedures required to perform the checks and services.
e. Not Fully Mission Capable If: Column. This column contains the criteria that causes the equipment to be
classified as NOT READY/NOT AVAILABLE because of inability to perform its primary mission. An entry in this column
will:
(1) Identify conditions that make the equipment not ready/available for readiness reporting purposes.
(2) Deny use of the equipment until corrective maintenance has been performed.
1-6
TM 5-3895-382-24
1-12. GENERAL LUBRICATION INSTRUCTIONS
WARNING
Do not start or move Roller when anyone is under Roller. Severe injury or death to
personnel could result.
NOTE
These instructions are mandatory.
a. Intervals. Intervals (on-condition or hard time) and the related man-hour times are based on normal operation.
The man-hour time specified is the time needed to do all the services prescribed for a particular interval. Individual hard
time intervals shall be applied during the warranty period and in the event AOAP laboratory support is not available. Oncondition (OC) oil sample intervals shall be applied unless changed by the Army Oil Analysis Program (AOAP) laboratory.
Change the hard time interval if lubricants are contaminated or if operating the equipment under adverse operating
conditions, including longer-than-usual operating hours. The calendar interval may be extended during periods of low
activity. If extended, adequate preservation precautions must be taken. Intervals shown in this lubrication section are
based on calendar and hourly times or calendar times and mileage. An example of a calendar and hourly lubrication is:
M/60 HR, in which M stands for monthly and 60 HR stands for 60 hours of vehicle operation. The lubrication is to be
performed at whichever interval occurs first for the Roller.
b. Determination of Operating Hours. The reading on the hourmeter is the basis of all lubrication intervals that are
based on hours of operation.
c. AOAP Sampling. Engine oil must be sampled at 50 hours of operation or 90 days, whichever occurs first, for
Active Army Units. Reserve and National Guard activities will use 50 hours or 180 days, whichever occurs first, as the
prescribed interval. Hydraulic oil will be sampled once a year. Sampling will be performed as prescribed by DA Pam 738750.
WARNING
Never smoke when using solvent; the flashpoint for drycleaning solvent type III
medical attention.
d. Warranty hard time Statement. For equipment under manufacturers' warranty, hard time oil service intervals
shall be followed for the duration of the warranty. Intervals shall be shortened when lubricants are known to be
contaminated or when operation is under adverse conditions (such as longer-than-usual operating hours, extended idling
periods, and extreme dust).
e. Clean Fittings Before Lubricating. Clean parts with drycleaning solvent (P-D-680, Type III) or equivalent. Dry
before lubricating. Dotted arrow points indicate lubrication on both sides of the Roller.
1-7
TM 5-3895-382-24
f. Lubrication After Fording. If fording occurs, lubricate all grease fittings (TM 5-3895-382-10) and oil can points
outside and underneath Roller.
g. Lubrication After High-Pressure Washing. After washing, lubricate all grease fittings and oil can points outside
and underneath the Roller.
h. Level of Maintenance. Operator can lubricate points authorized for Unit Maintenance when authorized by Unit
Maintenance.
i. Localized Views. A reference to the appropriate localized view is given after lubrication entries.
j. Oil Filter Statement. Oil filter(s) will be serviced/cleaned/changed when they are known to be contaminated or
clogged, service is recommended by AOAP laboratory analysis, or at prescribed hard time intervals as described in this TM.
1-13. PMCS TABLE

Refer to Table 1-1 for PMCS procedures for the Roller.
1-8
TM 5-3895-382-24
Unit Maintenance Lubrication Requirements
Lubricant
MIL Symbol
Location
Temperature Range
Capacity
(NATO Code)
Specification
GO 75W
Axle differential -25F (-32C) to -4F (-20C)
2.2 gallons
MIL-PRF-2105
(8.3 liters)
-4F (-20C) to 122F (50C)
GO 80W90
MIL-PRF-2105
-25F (-32C) to -4F (-20C)
GO 75W
Axle gear
.37 gallons
MIL-PRF-2105
reducer
(1.4 liters)
-4F (-20C) to 122F (50C)
GO 80W90
MIL-PRF-2105
GO 75W
Axle planetaries -25F (-32C) to -4F (-20C)
.8 gallons
MIL-PRF-2105
(3.2 liters)
-4F (-20C) to 122F (50C)
GO 80W90
MIL-PRF-2105
-25F (-32C) to 0F (-18C)
GO 75W
Drum gear
.5 gallons
MIL-PRF-2105
reducer
(2 liters)
0F (-18C) to 122F (50C)
GO, 75W
MIL-PRF-2105
-25F (-32C) to -4F (-20C)
GO 75W
Drum support
.5 gallons
MIL-PRF-2105
(1.9 liters)
housing
-4F (-20C) to 122F (50C)
GO 80W90
MIL-PRF-2105
-25F
(-32C)
to
0F
(-18C)
HO, Arctic
Hydraulic oil
19 gallons
MIL-PRF-46167 (72 liters)
tank
0F (-18C) to 122F (50C)
HO, SAE 10W
MIL-PRF-2104
-25F (-32C) to 5F (-15C)
EO, Arctic
Engine
2.3 gallons
MIL-PRF-46167 (9 liters)
crankcase
5F (15C) to 122F (50C)
EO, 15W40
MIL-PRF-2104
Vibratory
-4F (-20C) to 68F (20C)
GO, 80W90
13.5 gallons
Bearing
MIL-PRF-2105
(50 liters)
Reservoir
23F (-5C) to 122F (50C)
GO, 85W140
MIL-PRF-2105
EO = Engine Oil
GO = Gear Oil
HO = Hydraulic Oil
Interval
Manhour
First
250H,
1000H
or A
First
250H,
1000H
or A
First
250H,
1000H
or A
First
250H,
1000H
or A
0.1
1000H
or A
0.1
See
Note *
0.1
See
Note *
0.1
1000H
or A
0.2
0.1
0.1
0.1
* During warranty period, refer to PMCS table for hour/calendar oil change intervals. After warranty
period, refer to PMCS table and DA PAM 738-750 for AOAP sampling intervals. If AOAP laboratory
support is not available, use PMCS table hour/calendar oil change intervals.
Operators Coolant Requirements
Cooling System
During warranty period
Lubricant
MIL Symbol
(NATO Code)
Specification
ELC
Cooling System
After warranty expiration
CID A-A-52624
Location
Period
1-9
Capacity
2.9 gallons
(11 liters)
2.9 gallons
(11 liters)
Interval
500 H
A
500 H
A
Manhour
0.1
0.5
0.1
0.5
Change 1
TM 5-3895-382-24
Table 1-1. Unit Preventive Maintenance Checks and Services
Item
No.
Interval
100 H or
Monthly
Manhour
Location
Item to be
Checked or
Serviced
Drum Gear
Reducer
Procedure
NOTE
Move the drum with the plug in the 12:00
position down to the 3:00 or 9:00 position.
This will ensure there is no oil trapped in
the plug cavity to give a false FULL
reading.
a. Move the Roller until plug is either at the
3:00 or 9:00 position.
b. Remove plug.
c. Maintain gear lubricant to the bottom of
plug hole.
d. Clean and install plug.
1-10
Not Fully Mission

Capable If:
Oil level is low.
TM 5-3895-382-24
Table 1-1. Unit Preventive Maintenance Checks and Services - CONT.
Item
No.
Interval
Manhour
100 H or
Monthly
100 H or
Monthly
Location
Item to be
Checked or
Serviced
Drum Support
Assembly
0.1
Vibratory
Bearing
Reservoir
Procedure
a.
Remove plug located at the 8:00 position.
b.
Maintain gear lubricant to the bottom of

plug hole.
c.
Clean and install plug.
a.
Move the Roller until indicator boss is at its

lowest level.
b.
Remove check plug.
c.
Maintain lubricant to the bottom of plug

hole.
d.
If oil level is low, remove fill plug and add

lubricant until level with bottom of fill plug
hole.
e.
1-11
Not Fully Mission

Capable If:
Oil level is low.
Oil level is low.
TM 5-3895-382-24
Table 1-1. Unit Preventive Maintenance Checks and Services - CONT
Item
No.
Interval
100 H or
Monthly
Manhour
0.1
Location
Item to be
Checked or
Serviced
Procedure
Axle
Planetaries
Not Fully Mission

Capable If:
NOTE
Move the axle planetary with the plug in
the 12:00 position down to the 3:00 or 9:00
position. This will ensure there is no oil
trapped in the plug cavity to give a false
"FULL" reading.
a.
Move the Roller until plug is either at the

3:00 or 9:00 position.
b.
Remove plug.
c.

plug hole.
d.
e.
Repeat Steps (a) through (d) for other axle

planetary.
1-12
Oil level is low.
TM 5-3895-382-24
Item
No.
Interval
100 H or
Monthly
100 H or
Monthly
Manhour
0.1
0.1
Location
Item to be
Checked or
Serviced
Axle Gear
Reducer
Axle
Differential
Procedure
a.
Remove plug.
b.

plug hole.
c.
a.
Remove plug.
b.

plug hole.
c.
1-13
Not Fully Mission

Capable If:
Oil level is low.
Oil level is low.
TM 5-3895-382-24
Item
No.
Interval
Manhour
Location
Item to be
Checked or
Serviced
Procedure
Not Fully Mission

Capable If:
NOTE
Refer to DA Pam 738-750 for sampling
requirements.
Hard time intervals for engine oil
PMCS apply only during warranty
period. After expiration of warranty,
active and reserve Army Units will
send engine oil sample to an AOAP
laboratory for analysis after 50 hours or
quarterly, whichever comes first.
National Guard activities will use 50
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.
If AOAP laboratory support is not
available, change engine oil and filter
(page 1-72) after 250 hours of operation.
7
50 H or
Q
0.1
Engine Oil
Take engine oil sample for AOAP analysis

(page 1-7, page 2-20).
250 H
0.1
Engine Oil
Change oil and filter (page 1-72).
At First
250 H
0.1
Engine
At first oil change, notify Direct Support to

adjust valve lash.
10
At First
250 H
0.1
Hydraulic Oil
Filter
Change hydraulic oil filter (page 1-83).
11
At First
250 H
0.1
Drum Gear
Reducer
Change gear lubricant (page 1-84).
12
At First
250 H
0.1
Axle Gear
Reducer
13
At First
250 H
0.1
Axle
Planetaries
1-14
Faulty oil results

received from
AOAP lab "Do not
operate".
TM 5-3895-382-24
Table 1-1. Unit Preventive Maintenance Checks and Services CONT.
Item
No.
Interval
14
At First
250 H
15
250 H
or Q
Manhour
0.1
Location
Item to be
Checked or
Serviced
Procedure
Axle
Differential
Vee Belts
Check vee belts for excessive wear and belt

tightness (page 1-75). Replace or adjust
accordingly (page 7-89).
1-15
Not Fully Mission

Capable If:
Any vee belt is

loose, missing,
broken, greasy,
peeling, glazed,
cracked to the
belt fiber, has
more than one
crack (1/8 inch in
depth or 50% of
belt thickness), or
has frays more
than 2 inches
long.
TM 5-3895-382-24
Item
No.
Interval
Manhour
Location
Item to be
Checked or
Serviced
Procedure
Not Fully Mission

Capable If:
16
250 H
or Q
0.1
Batteries
a. Inspect/service batteries (page 1-76). Check Batteries are

battery cables for wear or damage
cracked,
(page 1-76) and (TM 9-6140-200-14).
connectors or
cables are worn
b. Clean battery box. Repaint battery box
or damaged.
where paint is missing.
17
250 H
or Q
0.5
Fuel System
a. Replace fuel/water separator element

(page 1-78).
b. Replace fuel filter element (page 1-77).
c. Clean fuel lift pump strainer and sediment
chamber (page 1-77).
d. Clean fuel tank cap and fill screen strainer
(page 1-80).
18
250 H
or Q
0.1
Hydraulic
Tank
Clean hydraulic tank breather (page 1-81).
19
500 H
or S
0.1
Cooling
System
Check coolant concentration. Add coolant if

concentration ratio is incorrect (page 1-24).
20
500 H
or S
0.1
Blade Cutting
Edge
a. Inspect blade cutting edge for loose or

missing bolts.
Cutting edge has

loose or missing
bolts.
b. Inspect cutting edge for damage such as

cracks or tears (page 1-49).
c. Inspect that cutting edges are not worn
beyond 1/8 in. from blade (page 1-49).
If NBC exposure is suspected, all air filter

media should be handled by personnel
wearing protective equipment. Consult your
unit NBC NCO for appropriate handling or
disposal instructions.
21
1,000 H
Change 1
0.1
Engine Air
Replace air cleaner primary and secondary
Intake System elements (page 1-52).
1-16
Edge is worn
beyond 1/8 in.
from blade.
TM 5-3895-382-24
Item
No.
Interval
Manhour
Location
Item to be
Checked or
Serviced
Procedure
Do not drain hydraulic oil while oil is

hot. Severe injury to personnel may
result.
Prolonged contact with lubricating oil,

MIL-PRF-2104 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 wellventilated to keep fumes to a minimum.
Oil is slippery and can cause falls. To

avoid injury, wipe up all spilled oil with
rags.
Refer to DA Pam 738-750 for

sampling requirements.
After expiration of warranty, active

and reserve Army Units and National
Guard activities will send a hydraulic
oil sample to an AOAP laboratory for
analysis once a year.

draining and refilling lubricants may
be changed by an AOAP laboratory.

available, change hydraulic oil and
filter (page 1-83) after 1,000 hours of
operation.
NOTE
22
1,000 H
or A
0.3
Hydraulic Oil
Change hydraulic oil and filter (page 1-83).
23
1000 H
or A
0.3
Drum Gear
Reducer
Change gear oil (page 1-84).
24
1000 H
or A
0.3
Axle
Planetary
1-17
Not Fully Mission

Capable If:
TM 5-3895-382-24
Item
No.
Interval
Manhour
Location
Item to be
Checked or
Serviced
Procedure
25
1000 H
or A
0.3
Axle
Differential
26
1000 H
or A
0.3
Drum Support Change gear oil (page 1-86).

Housing
27
1000 H
or A
0.3
Vibratory
Bearing
Reservoir
27.1 1000 H
or A
0.3
Axle Gear
Reducer
28
1000 H
or A
0.3
Steering Pivot Notify Direct Support Maintenance to check

and adjust steering pivot (page 14-17).
29
1,000 H
or A
0.1
Rollover
Protective
Structure
(ROPS)
Check for damage such as cracks or broken

welds. Check attaching bolts for tightness.
Ensure structural integrity; no compromising
dents, holes, or bends.
30
1,000 H
or A
0.1
Radiator
Pressure test radiator. Replace radiator cap

(Chapter 6).
NOTE
After expiration of warranty, active and
reserve Army Units and National Guard
activities will replace Extended Life
Coolant with standard ethyl-glycool
coolant.
31
1,000 H
or A
Change 1
0.5
Cooling
System
Not Fully Mission

Capable If:
Change coolant (page 1-90) if coolant is

incorrect. Inspect for leaks or loose hoses.
Check for excessive corrosion.
1-18
Protective
Structure (ROPS)
is damaged.
TM 5-3895-382-24
Item
No.
Interval
Manhour
Location
Item to be
Checked or
Serviced
Procedure
Not Fully Mission

Capable If:
NOTE
Refer to DA Pam 738-750 for

sampling requirements.
After expiration of warranty, active

and reserve Army Units and National
Guard activities will send a hydraulic
oil sample to an AOAP laboratory for
analysis once a year.

draining and refilling lubricants may
be changed by an AOAP laboratory.

available, change hydraulic oil and
filter (page 1-83) after 1,000 hours of
operation.
32
0.1
Hydraulic Oil
Take hydraulic oil sample for AOAP analysis

(page 2-25).
33
2,000 H
or B
0.1
Engine
Notify Direct Support to adjust valve lash.
1-19
Faulty oil results

received from
AOAP lab Do not
operate.
TM 5-3895-382-24
Table 1-2. FIRST 250H PMCS MANDATORY REPLACEMENT PARTS

ITEM
NO.
PART NUMBER
NSN
NOMENCLATURE
QTY
(11083) 7W2326
2940-01-080-3861
Filter, Oil, Engine
(11083) 1G8878
2910-01-438-7423
Filter, Oil, Hydraulic
(11083) 147-9544
5330-01-428-8818
Gasket, Valve Cover
Table 1-3. QUARTERLY PMCS MANDATORY REPLACEMENT PARTS

ITEM
NO.
PART NUMBER
NSN
NOMENCLATURE
QTY
(11083) 7W2326
2940-01-080-3861
Filter, Oil, Engine
(11083) 1G8878
2910-01-438-7423
(11083) 159-6102
2910-01-471-4630
Filter, Fuel
(11083) 138-3100
2910-01-454-2190
Filter, Fuel/Water Separator
Table 1-4. ANNUAL PMCS MANDATORY REPLACEMENT PARTS

ITEM
NO.
PART NUMBER
NSN
NOMENCLATURE
QTY
(11083) 1G8878
2910-01-438-7423
(11083) 6L8617
2930-00-904-9062
Cap, Radiator
Change 1
1-20
Section III. ADDITIONAL MAINTENANCE INSTRUCTIONS

1.14.
TM 5-3895-382-24
Torque Specifications
Torques for Standard Fasteners

For additional torque specifications, not included in this
section, refer to Torque Specifications, SENR3130,
available from your Caterpillar dealer.
NOTICE
The following charts give general torques for bolts,
nuts and taperlock studs of SAE Grade 5 or better
quality.
Torques for Ground Engaging Tool Bolts

Bolt Size
Inch
5/8
3/4
7/8
1
1 1/4
1
Recommended Torque
N
m
270 40
475 60
750 90
1150 150
2300 300
Torques for Bolts and Nuts
lb ft
200 30
350 45
550 65
850 110
1 220
Thread Size
Inch
1/4
5/6
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
These values are applicable only to Caterpillar cutting edge bolts.
Torques for Standard Hose Clamps Worm Drive

Band Type
NOTICE
The following chart gives the torques for initial
installation of hose clamps on new hose and for
reassembly or retightening of hose clamps on
existing hose.
Clamp Width
16 mm (.625 in)
13.5 mm (.531 in)
8 mm (.312 in)
Clamp Width
16 mm (.625 in)
13.5 mm (.531 in)
8 mm (.312 n)
1
Initial Installation
Torque on New Hose
1
lb ft
N
m
65
5
7.5 0.5
4.5 0.5
40 5
0.9 0.2
82
Reassembly or Retightening
Torque
1
lb ft
N
m
4.5 0.5
40 5
3.0 0.5
25 5
62
0.7 0.2
Standard Bolt and Nut Torque

1
N
m
12 30
25 6
479
70 15
105 20
160 30
215 40
370 50
620 80
900 100
1300 150
1800 200
2400 300
3100 350
lb ft
92
18 4.5
35 7
50 11
75 15
120 20
160 30
275 37
460 60
660 75
950 100
1325 150
1800 225
2300 250
Newton Meter (Nm) is approximately the same as 0.1 mkg.
Torques for Taperlock Studs

Thread Size
Inch
1/4
5/6
3/8
7/16
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 3/8
1 1/2
Maintenance Section
Standard Taperlock Stud Torque

1
N
m
83
17 5
35 5
45 10
65 10
110 20
170 30
260 40
400 60
500 70
650 80
750 90
870 100
lb ft
62
13 4
26 4
33 7
48 7
80 15
125 22
190 30
300 45
370 50
480 60
550 65
640 75
1-21
TM 5-3895-382-24
Torques for Metric Fasteners
Torques for Taperlock Studs
NOTICE
Be very careful never to mix metric with U.S.
customary (standard) fasteners.
Mismatched or
incorrect fasteners will cause machine damage or
malfunction and can result in personal injury.
METRIC ISO THREAD

Standard Taperlock Stud
Thread Size
Torque
Metric
1
lb ft
N
m
M6
83
62
M8
17 5
13 4
M10
35 5
26 4
M12
65 10
48 7
M16
11020
80 15
M20
170 30
125 22
M24
400 60
300 45
M30
650 80
480 60
M36
870 100
640 75
Original fasteners removed from the machine should

be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same size
and grade as the ones that are being replaced.
The material strength identification is usually shown
on the bolt head by numbers (8.8, 10.9, etc.). The
following chart gives standard torques for bolts and
nuts with Grade 8.8.
NOTE: Metric hardware must be replaced with

metric hardware. Check parts manual for
proper replacement.
ISO - International Standard Organization
Torques for Bolts and Nuts

2
METRIC ISO THREAD

Thread Size
Metric
M6
M8
M10
M12
M14
M16
M20
M24
M30
M36
Standard Torque
1
N
m
12 3
28 7
55 10
100 20
160 30
240 40
460 60
800 100
1600 200
2700 300
lb ft
92
20 5
40 7
75 15
120 20
175 30
340 40
600 75
1200 150
2000 225
1 Newton Meter (Nm) is approximately the same as 0.1 mkg.
ISO - International Standard Organization
Operation Section
1-22
TM 5-3895-382-24
Cooling System Specifications
General Coolant Information
NOTICE
Water that does not meet the minimum acceptable
limits will reduce engine service life when used in
cooling systems.
Many engine failures could be avoided with proper

cooling system maintenance.
Cooling system
maintenance is as important as fuel and lubricating
system maintenance. Coolant quality is as important as
the quality of fuel and lubricating oil.
If you are not sure of the content of the water, contact

your Caterpillar dealer, your local water department,
your agricultural agent, or an independent laboratory to
analyze the water.
The three main functions that coolant serves

are:
Adequate heat transfer and anti-boil protection
Cavitation erosion and corrosion protection
Freeze protection
Additives
Additives must be included in all coolant mixtures.
Additives help prevent the formation of rust, scale, and
mineral deposits.
Additives protect metals from
corrosion, prevent liner cavitation, and contain
antifoaming agents.
Additives are depleted during
engine operation and need to be replenished. Additives
can be replenished through the addition of supplemental
coolant additives (used with conventional coolants) or
Extender
(used
with
Caterpillar
Long
Life
Coolant/Antifreeze) .
Coolant is normally composed of three elements:
Water
Additives
Glycol
Water
Distilled or deionized water is recommended for use in
cooling systems. DO NOT use hard water, tap water, or
salt softened tap water in engine cooling systems. If
distilled or deionized water is NOT available, use water
that meets the minimum acceptable requirements.
Nitrites or nitrite and molybdate additives protect the

cylinder liner from cavitation corrosion. Nitrites are
depleted, creating the need for additives or Extender.
Additives and Extender also contain other inhibitors that
can be depleted from cooling systems.
MINIMUM ACCEPTABLE WATER

Water Content
Limits in grain per gallon

(parts per million)
Chloride
Sulfates
Total Hardness
Total Solids
pH
2.4 (40) maximum

5.9 (100) maximum
10 (170) maximum
20 (340) maximum
5.5 - 9.0
An insufficient additive concentration does not provide

adequate protection for cooling systems. An excessive
additive concentration can cause additives to drop out of
the solution, deposit inside the cooling system, or form a
gel in the radiator. Deposits can be in the form of sludge
and scale which accumulate on hot engine surfaces.
Deposits reduce cooling system effectiveness, or cause
water pump leaks.
To maintain conventional cooling system protection, it is
necessary to monitor supplemental coolant additive
concentration. Maintain the proper additive levels in the
cooling system.
Operation Section

1-23
TM 5-3895-382-24
Glycol
Coolant Recommendations
Engine coolant glycol is normally either ethylene or
propylene. Glycol raises the boiling point of water to
help prevent boil-over, provides freeze protection, helps
prevent water pump cavitation, and reduces cylinder
liner pitting.
Preferred - Caterpillar's Long Life Coolant/Antifreeze

(LLCA).
Recommended
Caterpillar's
Antifreeze/Coolant (DEAC).
NOTICE
For ambient temperatures requiring lower freeze
protection (higher than 50 percent glycol), use
ethylene glycol. DO NOT use propylene glycol.
Freeze
Protection
Anti-Boil
Protection
-15C (-5F)
-23C (-9F)
-37C (-35F)
-51C (-60F)
102C (216F)
104C (219F)
106C (223F)
107C (225F)
Percentage of
Ethylene Glycol
30%
40%
50%
60%
Freeze
Protection
-15C (-5F)
-24C (-9F)
-37C (-35F)
-57C (-60F)
Anti-Boil
Protection
104C (219F)
106C (223F)
108C (226F)
111C (232F)
Engine
Acceptable - Any low silicate coolant that meets Truck

Maintenance Council (TMC) Recommended Practice
(RP) 329, TMC RP330, or ASTM D4985 requirements
when used with supplemental coolant additives.
Proper freeze/boll protection requires the proper ratio of

glycol and acceptable water. Use the following charts to
determine glycol concentrations to mix with acceptable
water.
Percentage of
Propylene
Glycol
30%
40%
50%
60%
Diesel
Permitted - A mixture of acceptable water and a

supplemental coolant additive, where freeze protection is
not necessary.
Unacceptable - Any high silicate coolant that is classified
as meeting ASTM D3306.
NOTICE
Most commercial engine coolant/antifreezes are
formulated for gasoline engine applications and
have high silicate content. High silicates can lead to
cylinder liner cavitation and corrosion. Caterpillar
DOES NOT recommend high silicate coolants or
antifreezes.
NOTE: Due to individual engine applications, engine
cooling system maintenance practices may
need periodic evaluation.
NOTICE
Never operate without thermostats in the cooling
system. Thermostats maintain the engine coolant at
the proper operating temperature. Cooling system
problems can arise without thermostats.
Use the 1U-7298 Coolant Tester (C) or the 1U-7297

Coolant Tester ( F) to check the coolant solution
periodically to ensure adequate freeze/boil protection.
The refractometers give immediate, accurate readings
and can be used with ethylene or propylene glycol.
NOTICE
Never add coolant to an overheated engine. Allow
the engine to cool first. Do not add coolant too
quickly. Filling the cooling system at over 19 L
(5 US gal) per minute can create air pockets in the
cooling system. Engine damage can result.
NOTE: For more detailed specifications, refer to:

Know Your Cooling System, SEBD0518, and
Coolant and Your Engine, SEBD0970, or
contact your Caterpillar dealer.
When filling or adding coolant to the system, premix the

coolant solution prior to pouring it into the cooling
system. Pure, undiluted glycol will freeze at -23C
(-10F). Use a coolant solution that is in a range which
will provide protection to the lowest expected outside
(ambient) temperature and provide the required boil-over
protection.
Operation Section

1-24
TM 5-3895-382-24
Caterpillar's Long Life
Coolant/Antifreeze
AVAILABLE QUANTITIES OF CATERPILLAR LONG

LIFE COOLANT/ANTIFREEZE
Type
Size
Part Number
1
Premixed
Bulk
119-5148
208 K (55 US gal) 101-2845
3.8 L (1 US gal)
101-2844
2
Concentrate
3.8 L (1 US gal)
119-5150
Caterpillar's Long Life Coolant/Antifreeze anti-corrosion

package is different from the conventional antifreezes
that have been used. Long Life Coolant/Antifreeze is an
ethylene glycol based coolant/antifreeze containing
organic corrosion inhibitors and anti-foam agents with
fewer nitrites than conventional coolants.
Long Life Coolant/Antifreeze was specifically designed
for use in diesel engine cooling systems and natural gas
engine cooling systems.
Long Life Coolant/Antifreeze extends coolant life to 6000
service hours or four years, whichever comes first. One
addition of Caterpillar's Extender is required to maintain
Long Life Coolant/Antifreeze.
Premix 50 percent Long Life Coolant/Antifreeze with 50

percent water.
The LLCA Concentrate is used to increase the freeze

protection. The Concentrate is not intended to be used as a
mix.
NOTE: A 50 percent Long Life Coolant/Antifreeze

and 50 percent deionized water solution
provides freeze protection to -37C (-34F)
and anti-boil protection to 108C (226F). DO
NOT use Long Life Coolant/Antifreeze at
reduced concentrations (less than 50
percent), as the additives would be reduced
along with the antifreeze.
Long Life
Coolant/Antifreeze concentrate is available
to lower the coolant freeze point when used
in
arctic
conditions.
Long
Life
Coolant/Antifreeze concentration can be
increased to 60 percent for -52C (-62F)
freeze protection.
Major Long Life Coolant/Antifreeze advantages:
Twice the coolant life

Considerably less maintenance
Improved corrosion protection
Better aluminum protection
Better liner protection
Fewer additives (chemicals) and no chemical
drop out
Longer radiator life
Increased water pump seal life
Extender
Long Life Coolant/Antifreeze is available as a 50 percent

Long Life Coolant/Antifreeze and 50 percent deionized
water solution or in concentrate. See the table for
quantities that are available.
Extender should be added to the cooling system at the

3000 service hours or two years, whichever comes first.
See the table to determine the recommended amount of
Extender to add to Long Life Coolant/Antifreeze.
RECOMMENDED AMOUNT OF EXTENDER

BY COOLING SYSTEM CAPACITY
Recommended Amount
Cooling System Capacity
of Extender
22-30 L (6-8 US gal)
0.57 L (20 oz)
30-38 L (8-10 US gal)
0.71 L (24 oz)
38-49 L (10-13 US gal)
0.95 L (32 oz)
49-64 L (13-17 US gal)
1.2 L (40 oz)
Operation Section

1-25
TM 5-3895-382-24
Long Life Coolant/Antifreeze
Maintenance
Cooling
System
NOTICE
Do not use conventional coolant to top off a cooling
system using Long Life Coolant/Antifreeze.
NOTICE
Use only Caterpillar products or commercial
products that have passed Caterpillar's EC-1
specification for premixed or concentrated coolants.
Use only Caterpillar
Coolant/Antifreeze.
Extender
with
Long
Do not use supplemental coolant additives other

than extender in cooling systems filled with Long
Life Coolant/Antifreeze.
Life
If a cooling system using Long Life Coolant/Antifreeze
has been topped off with a small amount of conventional
coolant or if a supplemental coolant additive was added
to the system by mistake, the system will not be harmed.
Mixing Long Life Coolant/Antifreeze with other

products reduces the Long Life Coolant/Antifreeze
service life. Failure to follow the recommendations
included in this section can reduce cooling system
component life.
Should the cooling system become contaminated with

conventional coolant or supplemental coolant additive
exceeding 10 percent of the cooling system's total
capacity, perform one of the following actions:
In order to maintain the correct balance of antifreeze and

additives, care should be taken to maintain the proper
Long Life Coolant/Antifreeze concentration. Reducing
the amount of antifreeze lowers the proportion of
additive, thus lowering the coolants ability to protect the
cooling system from pitting, cavitation, erosion, and
deposits.
Drain the cooling system and refill the cooling

system with Long Life Coolant/Antifreeze, or
Maintain the cooling system as if the cooling

system is filled with conventional coolant.
Proper Long Life Coolant/Antifreeze Additions
Long Life Coolant/Antifreeze Cooling System Cleaning
NOTE: DO NOT add Long Life Coolant/Antifreeze

Concentrate as a makeup solution for routine
cooling system top-off. Adding concentrated
Long Life Coolant/Antifreeze increases the
concentration of glycol in the cooling
system.
NOTE: No cleaning agents are to be used when a

cooling
system
using
Long
Life
Coolant/Antifreeze is drained, flushed, and
refilled.
Clean water is the only system cleaning/flushing agent
required when Long Life Coolant/Antifreeze is drained
from the cooling system.
During normal maintenance, use a premixed solution of

approved water and Long Life Coolant/Antifreeze as a
top-off to the cooling system to bring the coolant to the
proper level. Use Long Life Coolant/Antifreeze or a
coolant that meets Caterpillar's EC-1 specification. If a
coolant that meets EC-1 is not available, use distilled or
de-ionized water as a make-up. Check the glycol level
of the cooling system with the 1U-7298 Coolant Tester
(C) or the 1U-7297 Coolant Tester (F). Use Long Life
Coolant/Antifreeze Concentrate to restore the proper
glycol concentration before the engine is exposed to
freezing temperatures.
Long Life Coolant/Antifreeze can be recycled. The

drained coolant mixture can be distilled to separate the
ethylene glycol and water for reuse. Contact your
Caterpillar dealer for more information.
After draining and refilling the cooling system, operate
the engine with the radiator filler cap removed until the
coolant reaches normal operating temperature and the
coolant level stabilizes.
Add coolant mixture as
necessary to fill the system to the proper level.
Maintenance Section

1-26
TM 5-3895-382-24
Converting a Cooling System from

Conventional Coolant to Long Life
Coolant/Antifreeze
Conventional Antifreeze/Coolant
Recommended - Caterpillar's Diesel
Engine Antifreeze/Coolant
NOTE: When the coolant is changed from

conventional
coolant
to
Long
Life
Coolant/Antifreeze, a Caterpillar cleaner
should be used. After the use of Caterpillar
cooling system cleaners, the system MUST
be thoroughly flushed with clean water.
NOTE: The
following
information
and
recommendations are for Caterpillar's Diesel
Engine Antifreeze/Coolant only.
Caterpillar's Diesel Engine Antifreeze/Coolant was
specifically designed for diesel engine cooling systems
and natural gas engine cooling systems. Diesel Engine
Antifreeze/Coolant is an alkaline type, ethylene glycol
based formula containing inorganic corrosion inhibitors
and anti-foam agents. Diesel Engine Antifreeze/Coolant
was formulated with the correct additive levels to protect
metal parts in diesel engines.
Diesel Engine
Antifreeze/Coolant will furnish adequate corrosion
protection, anti-foam protection, and cylinder liner/block
pitting protection. Use a 30 percent Diesel Engine
Antifreeze/Coolant
and
70
percent
acceptable
water/supplemental coolant additive solution.
To convert the cooling system from conventional coolant

to Long Life Coolant/Antifreeze, perform the following
procedure:
1.
Drain the coolant.
2.
Flush the system with clean water to remove any

debris.
3.
Use a Caterpillar cleaner to clean the system.

Follow the instructions on the label. Caterpillar
cleaner is available from your Caterpillar dealer.
4.
Drain the cleaner. Flush the cooling system with

clean water.
Major advantages of Diesel Engine Antifreeze/Coolant:
5.
Fill the cooling system with clean water. Operate

the engine until the cooling system temperature is
49 to 66C (120 to 150F).
6.
Drain and flush the cooling system with clean

water.
7.
Repeat Step 5 and Step 6.
8.
Fill the cooling

Coolant/Antifreeze.
9.
system
Minimal silicate content -High silicate coolants, used with

supplemental coolant additives, can cause a buildup of
solids over time. Build-up of solids can cause plugging,
loss of heat transfer, and water pump seal damage.
Diesel Engine Antifreeze/Coolant significantly reduces
solid residue build-up that causes inhibitor dropout and
water pump seal damage.
No need to add supplemental coolant additive on initial
fill -Supplemental coolant additive must be added with
other commercially available coolants.
with
Long
Life
Diesel Engine Antifreeze/Coolant is available from your
Caterpillar dealer in the following quantities:
Attach a label to the cooling system to indicate the

system has been converted to use Long Life
Coolant/Antifreeze.
CATERPILLAR ANTIFREEZE
COOLANT CONCENTRATE
Part No.
Size
8C-3684
3.8 L (1 US gal)
8C-3686
208 L (55 US gal)
Maintenance Section

1-27
TM 5-3895-382-24
Proper Antifreeze Concentrations
LIQUID SUPPLEMENTAL COOLANT ADDITIVE
Cooling System
Part Number
Initial Amount
Capacity
22-30 Liters
3P-2044
1 container
(6-8 US gal)
30-38 Liter
3P-2044
1 container
(8-10 US gal)
6V-3542
1 container
38-49 Liters
3P-2044
1 container
(10-13 US gal)
8T-1589
container
49-64 Liters
3P-2044
1 container
(13-17 US gal)
64-83 Liters
3P-2044
2 containers
(17-22 US gal)
8T-1589
1 container
83-114 Liters
3P-2044
3 container
(22-30 US gal)
8T-1589
1 container
114-163 Liters
3P-2044
5 containers
(30-44 US gal)
163-242 Liters
3P-2044
8 containers
(44-64 US gal)
Use the table to determine concentrations of Diesel

Engine Antifreeze/Coolant to mix with acceptable water
and supplemental coolant additive.
ANTIFREEZE CONCENTRATIONS (GLYCOL)

Protection Temperature
Protection to -15C (5F)
Protection to -23C (-9F)
Concentration
30% antifreeze and
70% water
40% antifreeze and
60% water
50% antifreeze and
50% water
60% antifreeze and
40% water
Acceptable Antifreeze/Coolant
Any low silicate coolant that meets Truck Maintenance
Council (TMC) Recommended Practice (RP) 329, TMC
RP330, or ASTM D4985 requirements when used with
supplemental coolant additives is acceptable.
Caterpillar recommends a minimum of 30 percent glycol

to 70 percent water/supplemental coolant additive for
proper corrosion protection. All Caterpillar engines with
air-to-air aftercooling (ATAAC) require a minimum
concentration of 30 percent glycol to prevent water pump
cavitation.
Only use supplemental coolant additive If you are not using

Caterpillar Diesel Engine Antifreeze/Coolant (DEAC). Do
not exceed the maximum concentration of six percent.
Check the concentration with a supplemental coolant
additive test kit.
Supplemental Coolant Additive
Supplemental cooling system additive contains

alkali. To prevent personal injury, do not drink,
avoid contact with the skin and eyes.
While 30 percent glycol is the minimum acceptable

volume, Caterpillar prefers a 50 percent glycol and 50
percent water/supplemental coolant additive mixture for
optimum performance.
NOTICE
The cooling system MUST contain supplemental
coolant additive for proper engine protection,
regardless of antifreeze concentration.
When using Diesel Engine Antifreeze/Coolant, no

supplemental coolant additive is necessary on initial fill
because supplemental coolant additive is in the Diesel
Engine Antifreeze/Coolant.
Supplemental coolant
additive must be added with commercial coolants
meeting ASTM D4985 at initial fill. Supplemental coolant
additive must be replenished with both Caterpillar Diesel
Engine Antifreeze/Coolant and other commercial
coolants at regular service intervals. Refer to the chart
for quantities of Caterpillar Liquid SCA to mix with ASTM
D4985 commercial coolants at initial fill.
NOTICE
DO NOT mix Caterpillar's supplemental coolant
additive or coolant additive elements with another
manufacturer's products. Select a cooling system
treatment and use it exclusively.
Maintenance Section

1-28
TM 5-3895-382-24
Supplemental coolant additive Is necessary for proper

conventional coolant maintenance.
Most coolant
solutions DO NOT contain sufficient supplemental
coolant additive for diesel engine application.
Test the coolant periodically to monitor supplemental

coolant additive levels. Use the 4C-9301 Test Kit to
check for Caterpillar supplemental coolant additive
concentration. The kit also provides cooling system
maintenance recommendations. This kit is specifically
designed for use with Caterpillar supplemental coolant
additives. The 8T-5296 Test Kit can also be used to
check for Caterpillar supplemental coolant additive
concentration.
NOTICE
Do not exceed the recommended six percent
supplemental
coolant
additive
concentration.
Excessive
supplemental
coolant
additive
concentration can form deposits on the higher
temperature surfaces of the cooling system,
reducing the engine's heat transfer characteristics.
Reduced heat transfer could cause cracking of the
cylinder head and other high temperature
components.
Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated
water pump seal wear.
Never use both liquid
supplemental coolant additive and the spin-on
element (if equipped) at the same time. The use of
those
additives
together
could
result
in
supplemental
coolant
additive
concentration
exceeding the recommended six percent maximum.
The tables list the par numbers and quantities of

supplemental coolant additive (liquid and sold) available
from your Caterpillar dealer. Follow the instructions on
the label.
LIQUID SUPPLEMENTAL COOLANT ADDITIVE
Cooling System
Part Number
Amount (Every
Capacity
250 Hours)
1
22-30 Liters
(6-8 US gal)
30-38 Liters
(8-10 US gal)
38-49 Liters
(10-13 US gal)
49-64 Liters
(13-17 US gal)
64-83 Liters
(17-22 US gal)
83-114 Liters
(22-30 US gal)
114-163 Liters
(30-44 US gal)
163-242 Liters
(44-64 US gal)
Use liquid supplemental coolant additive or a

supplemental coolant additive element (if equipped) to
maintain a three to six percent supplemental coolant
additive concentration in the coolant.
NOTE: Caterpillar test kits check for concentration

of nitrites in the coolant solution. Some
manufacturers'
supplemental
coolant
additive are phosphate based. Caterpillar
test kits provide inaccurate results with
phosphate based supplemental coolant
additive. Commercial supplemental coolant
additive products must contain silicates and
a minimum of 70 grams per 3.8 L
(1 US gal)(1200 ppm) nitrites. If another
manufacturer's
supplemental
coolant
additive is used, use that manufacturer's test
kit.
Follow
the
manufacturers
recommendations
for
cooling
system
treatment and test evaluation.
6V-3542
1 container
111-2372
1 container
111-2372
1 container
8T-1589
1 container
111-2372
6V-3542
1 container
1 container
3P-2044
1 container
3P-2044
6V-3542
1 container
1 container
3P-2044
2 containers
' Do not use a supplemental coolant additive element and a

liquid supplemental coolant additive at the same time. Do
not exceed the maximum concentration of six percent Check
the concentration with a supplemental coolant additive teat
kit.
Maintenance Section

1-29
TM 5-3895-382-24
NOTICE
Caterpillar's recommendation for proper coolant is a
minimum concentration of 30 percent glycol and 70
percent acceptable water and supplemental coolant
additive (three percent of the total mixture). This
recommendation will maintain cooling system
corrosion protection.
SUPPLEMENTAL COOLANT ADDITIVE ELEMENTS

Cooling System
Part Number
Amount (Every
1
Capacity
250 Hours)
22-30 Liters
111-2370
1 container
(6-8 US gal)
30-49 Liters
111-2369
1 container
(8-10 US gal)
49-64 Liters
9N-3368
1 container
(13-17 US gal)
64-83 Liters
111-2371
1 container
(17-22 US gal)
83-114 Liters
9N-3718
1 container
(22-30 US gal)
114-163 Liters
111-2371
2 containers
(30-44 US gal)
163-242 Liters
9N-3718
2 containers
(44-64 US gal)
1
Do not use a supplemental

liquid supplemental coolant
not exceed the maximum
Check the concentration
additive test kit.
In applications where freeze protection is not required, or

where antifreeze is not available, a coolant mixture of
acceptable water and supplemental coolant additive can
be used. A water/supplemental coolant additive system
should maintain a six to eight percent supplemental
coolant additive concentration. DO NOT exceed eight
percent maximum supplemental coolant additive
concentration.
Supplemental
coolant
additive
concentration levels must be monitored.
coolant additive element and a

additive at the same time. Do
concentration of six percent.
with a supplemental coolant
The 8T5296 Test Kit can be used to evaluate the

supplemental
coolant
additive
concentration
in
water/supplemental coolant additive coolant, with the
following modifications to label instruction Step 3 and
Step 5.
Permitted-Water/Supplemental Coolant Additive
STEP 3.
mark.
NOTICE
Never use water alone without supplemental coolant
additive or inhibited coolant.
Water alone is
corrosive at engine operating temperatures.
- Add tap water to the vial up to the 20 ml
STEP 5 -With the defined procedure, the six to eight

percent concentration will yield a 20 to 27 drop range.
Fewer drops indicate a low concentration of
supplemental coolant additive and more drops indicate a
high concentration.
Adjust the concentration
appropriately.
NOTICE
A mixture of water and supplemental coolant
additive does not protect against freezing or boiling.
If the supplemental coolant additive concentration is

greater than the maximum of eight percent: drain some
of the coolant, refill the system with acceptable water,
and retest the concentration level.
NOTICE
A coolant mixture of water and supplemental coolant
additive will cool and provide some protection to
engine components, but it will NOT provide normal
engine service life.
Maintenance Section

1-30
TM 5-3895-382-24
Conventional Cooling System Maintenance
Cooling System Cleaning
Check the antifreeze solution frequently in cold weather

to ensure adequate freeze protection.
Test the
concentration or submit a coolant sample to your
Caterpillar dealer in order to monitor the supplemental
coolant additive concentration in your engine's coolant
mixture every 250 service hours or monthly, whichever
comes first.
Supplemental coolant additive or a
maintenance additive element (if equipped) may be
needed every 250 service hours or monthly, whichever
come first.
Draining, cleaning, and flushing the cooling system

removes small particles, undesirable chemicals, scale,
and other deposit formations.
Not performing
maintenance on the cooling system can eventually
cause engine overheating problems that could result in
severe damage to engine and components.
NOTICE
To prevent over-inhibiting the engine's cooling
system, do not use both supplemental coolant
additive liquid and a supplemental coolant additive
element (if equipped) at the same time. Use one
method exclusively.
Caterpillar's Fast Acting Cooling System Cleaner is

designed to clean the system of harmful scale and
corrosion.
The cleaner dissolves mineral scale,
corrosion products, light oil contamination, and sludge.
Clean the cooling system if the system becomes

contaminated, if the engine overheats, or if foaming is
observed.
Fast Acting Cooling System Cleaner is available from

your Caterpillar dealer in the quantities listed. Follow the
product label directions for proper use.
When using Caterpillar Diesel Engine Antifreeze/Coolant

and supplemental coolant additive, the cooling system
should be drained, cleaned, flushed, and filed with new
coolant every 3000 service hours or every two years,
whichever come first. Refer to the topic Maintenance
Intervals in this manual.
CATERPILLAR FAST ACTING

COOLING SYSTEM CLEANER
Part Number
4C-4609
4C-4610
4C-4611
4C-4612
4C-4613
When
NOT
using
Caterpillar
Diesel
Engine
Antifreeze/Coolant and supplemental coolant additive,
the drain/flush procedure must be performed at least
every year.
Size
.47 L (.5 qt)
.95 L (1 qt)
3.8 L (1 US gal)
19 L (5 US gal)
208 L (55 US gal)
After you drain and you refill the cooling system, operate
the engine with the radiator filler cap removed until the
coolant reaches normal operating temperature and the
coolant level stabilizes.
Add coolant mixture as
necessary to fill the system to the proper level.
Maintenance Section

1-31
TM 5-3895-382-24
Fuel Specifications
WORLDWIDE FUEL SPECIFICATIONS

FOR DIESEL ENGINES
Specifications
Designated Fuels
American Standards (US)
No. 1-D
No. 2-D fuel oil
ASTM D975
No. 1 fuel oil and No. 2 fuel oil
ASTM D396
No. 1-GT fuel for the gas
turbine engine and No. 2-GT
ASTM D2880
fuel for the gas turbine engine
British Standards
Class A1 diesel fuel
Class A2 diesel fuel
Class B1 diesel fuel
BS 2869
Class C2 fuel for heating and
Class D fuel for heating
German Standards
Diesel fuel
Fuel Recommendations
NOTICE
Fill the fuel tank at the end of each day of operation
to remove moist air and prevent condensation.
Maintain a constant level in the tank (near the top) to
avoid drawing moisture into the tank as the level
decreases.
Do not fill the tank to the top. Fuel expands as it
warms, and may overflow.
Do not fill fuel filters with fuel before installing them.
Contaminated fuel causes accelerated wear to fuel
system parts.
DIN 51601
DIN 51603
Australia Standards
Use only fuel recommended in this section of this

manual.
Fuel grades recommended for use in
Caterpillar diesel engines are: No. 2-D diesel fuel with
low sulfur (0.05 percent maximum), or regular sulfur (0.5
percent maximum). No. 1 grades are acceptable.
AS 3570
Japanese Standards
The table lists worldwide fuel standards which meet

Caterpillar requirements.
JIS K2204
US Government
A-A-52557
ASTM D 396
US Military Standards
Automotive diesel fuel
Type 1 (spl) fuel oil

Type 1 fuel oil
Type 2 fuel oil
Type 3 fuel oil
Type 3 fuel oil
Type 3 (spl) fuel oil
US DF-1 diesel fuel
US DF-2 diesel fuel
US DF-20 diesel fuel
FS-1 fuel oil for heating and
FS-2 fuel oil for heating
Fuel, Naval Distillate
MIL-F-16884G
Aviation kerosene-type fuels meeting acceptable limits

may also be used as an engine fuel. The table lists
some of the acceptable kerosene-type fuels.
ACCEPTABLE KEROSENE FUELS
Standard
ASTM D 1655-97
MIL-DTL-5624T
MIL-T-83133D(1)
A-A-52557
Maintenance Section
Description
Aviation Turbine Fuel (JET A-1)
Aviation Turbine Fuel (JP-5)
(NATO Code No. F-44)
Aviation Turbine Fuel (JP-8)
(NATO Code No. F-34)
Grade DF-A (Arctic)
Fueling Specifications
1-32
TM 5-3895-382-24
Cetane Number
A minimum viscosity of 1.4 cSt at 38C (100F) is

required to properly lubricate Caterpillar fuel system
components. Kerosene-type fuels have a lower viscosity
for low temperature operation.
During average starting conditions, direct injection

engines require a minimum cetane number of 40. A
higher cetane value may be required for high altitude or
cold weather operation.
The kerosene-type fuels have less energy per unit

volume than diesel fuels, producing less peak power.
Filterability
More kerosene type fuel is needed than diesel fuel to do
the same amount of work.
Clean fuels should have no more than 0.1 percent of

sediment and water. Fuel stored for extended periods of
time may oxidize and form solids, causing filtering
problems.
Caterpillar diesel engines are capable of burning a wide

range of distillate fuels. Burning clean, stable blends of
distillate fuel meeting the listed requirements will provide
quality engine service life.
Pour Point
Fuel pour point should be at least 6C (10F) below the
lowest ambient temperature at which the engines must
start and operate. Lower pour points of No.1 or No.1-D
fuel may be necessary in extremely cold weather.
DISTILLED FUEL RECOMMENDATIONS

FOR DIESEL ENGINES
Specifications
REQUIREMENTS
Aromatics (ASTM D1319)
35% Max.
Ash (ASTM D482)
0.02% Max. Weight
Cetane Number
(ASTM D613)
Cloud Point (ASTM D97)
Gravity API (ASTM D287)

Pour Point (ASTM D97)
Sulfur (ASTM D2788,
D3605 or D1552)
Viscosity becomes
kinematic at 38C (100F)
(ASTM D445)
Water and Sediment
(ASTM D1796)
1
Cloud Point
The cloud point should be below the lowest ambient
temperature at which the engines must start and
operate, in order to prevent the fuel filter elements from
plugging with wax crystals. Refer to the topic Fuel
Problems
in
Cold
Weather
Recommendations,
SEBU5898, for additional information.
35 Minimum for PC Engines

40 Minimum for Dl Engines
Cloud point will not be
above the lowest expected
ambient temperature.
30 Minimum and 45 Maximum
6 (10f) Below Ambient Min.
0.5% Max.
See the topic "Sulfur
20.0 cSt Max
1.4 cSt Min.
Viscosity
Fuel viscosity affects the lubrication of fuel system
components and fuel atomization.
The provided
viscosity limits address both of those affects.
Additives
Fuel additives are generally not recommended or
needed for the specified fuels listed. Cetane improvers
can be used as necessary for direct injection engine
requirements. Biocides may be needed to eliminate
microorganism growth in storage tanks. In cold weather
conditions, treatment for entrained water may also be
necessary.
0.01% Max.
These requirements are the requirements when the fuel is

delivered to the fuel system.
NOTE: When economics or fuel availability dictate,

other fuel types may be burned in the engine.
Consult your Caterpillar dealer for more
information and advice on any specific fuel.
Consult your fuel supplier about the use of additives to

prevent incompatibility among additives already in the
fuel and the additives to be used.
Maintenance Section
1-33
TM 5-3895-382-24
Fuel Sulfur
The percentage of sulfur in fuel affects engine oil
recommendations. Fuel sulfur can change chemically
during combustion. The chemical change forms both
sulfurous acids and sulfuric acids. The adds contact
metal surfaces and cause corrosive wear to the
surfaces. Sulfur oxides formed during combustion also
produce particulate exhaust emissions.
Some lubricating oil additives contain alkaline
compounds which neutralize acids in combustion gases
and minimize corrosive wear. Reserve alkalinity in
lubricating oil is measured and defined with a Total Base
Number (TBN).
Periodically request fuel sulfur content information from
your fuel suppler. Fuel sulfur content can change with
each bulk delivery.
More information concerning fuel sulfur and lubrication
can be found in the topic Lubricant Specifications in this
manual.
Refer to Diesel Fuels and Your Engine, SEBD0717, or
contact your Caterpillar dealer for more information on
fuel selection and fuel properties.
Maintenance Section
1-34
TM 5-3895-382-24
Scheduled Oil Sampling (S
O
S)
Caterpillar recommends using Scheduled Oil Sampling
(SOS), at regularly scheduled intervals, to complement
a good preventive maintenance program.
S
O
S Analysis
The Caterpillar Scheduled Oil Sampling Program,

(SOS), was developed to help Caterpillar users realize
the highest possible value from their equipment by
minimizing repair costs and maximizing availability. The
SOS program is a series of diagnostic tests which
analyze used lubricating oils from the oil wetted
compartments of the equipment. By analyzing the used
oils, problems may be identified early, before extensive
component failure occurs. This reduces repair cost and
downtime.
The SOS program is coupled with a wide range of

repair options so that when a problem is identified, an
appropriate matched repair plan is available. This offers
the user a more complete service to minimize repair
costs and schedule down-time.
SOS can also
measure the effectiveness of the users maintenance
program.
Detectable failures are those caused by component

wear and gradual dirt contamination. Wear analysis is
not able to predict failures due to component fatigue,
sudden loss of lubrication, or sudden ingestion of a large
amount of dirt since failures of this nature occur too
rapidly.
SOS is composed of three basic tests:
Wear Analysis monitors the components wear rates by

measuring wear elements and contaminants found in the
used oil. Through monitoring the used oil, normal
component wear trends are determined. Many failures
can be identified when wear trends and/or contaminants
significantly exceed past trends.
Chemical and Physical Tests are used to determine

whether the used oil has been contaminated with water,
fuel or antifreeze and if these contaminants exceed
maximum limits.
Obtain SOS Sample

There are several methods used to obtain SOS
samples.
Oil Condition Analysis determines the degree of

deterioration of the used oil by measuring the amount of
sulfur products, oxidation, nitration and soot present in
the used oil. It also can monitor additive depletion and
detect ethylene glycol, Dowtherm and butyl cellosolve
contamination.
NOTE: Sampling methods recommended are in

preference order. If one of the first two
methods is not feasible, then use the drain
stream method.
Wear Analysis
Chemical and Physical Tests
Oil Condition Analysis
Use an in-line sampling valve.

Use a sampling gun inserted into the sump.
Use the drain stream method when changing oil.
Oil Condition Analysis can help regulate (reduce,

maintain or extend), oil change intervals for a specific
machine/engine in a given application. Oil Condition
Analysis must always be used with Wear Analysis and
the Chemical and Physical Tests.
When using the drain stream method to obtain an oil

sample, take the sample after some oil has drained out
and before the final drain oil. The oil at the beginning or
end of the drain stream is not mixed well enough to be
representative of circulating oil in the compartment and
may carry debris that can give false SOS analysis
results.
S-O-S INTERVAL CHART

Compartment
Interval
Engine Oil
250 Hours
Transmission Oil
500 Hours
Hydraulic Oil
500 Hours
Final Drive Oil
500 Hours
Consult your Caterpillar dealer for complete information
and assistance in establishing a Scheduled Oil Sampling
Program for your equipment.

O
S)
Maintenance Section
1-35
TM 5-3895-382-24
Lubricant Specifications
General Information
Caterpillar Diesel Engine Oil (DEO)(multi-grade)
Caterpillar recognizes and supports the American
Petroleum Institute (API) "Engine Oil Licensing and
Certification System" for engine oils.
The API
publication No. 1509, 13th edition, contains the detailed
information concerning this system. Engine oils bearing
the API symbol am licensed by the API.
Caterpillar DEO multi-grade oils are formulated with

detergents, dispersants, and sufficient alkalinity to
provide superior performance in Caterpillar diesel
engines. DEO multi-grade oils are blended in two
viscosity grades: SAE 10W-30 and SAE 15W-40. Refer
to the lubricant viscosity chart to choose the correct
viscosity grade based on ambient temperatures.
Multigrade oils provide the correct viscosity for a broad
range of operating temperatures and for cold engine
starts. Multi-grade oils are also effective in maintaining
low oil consumption and low levels of piston deposits.
Caterpillar DEO multi-grade oils are also qualified for
use in other diesel engines and in gasoline engines.
Consult the engine manufacturer's guide for the
recommended specifications, and compare to the
specifications of Caterpillar DEO multi-grade.
The
current Caterpillar DEO industry specifications are fisted
on the label and on the product data sheets.
Examples of the API symbol.

Diesel engine oil classifications CD, CD-2 and CE will
not be API licensed categories after January 1, 1996.
Caterpillar will only reference those categories that are
licensed by the API. The table summarizes the status of
the categories.
Cold Weather Lubricants

Multipurpose Tractor Oil (MTO)
STATUS OF SEVERAL OIL CLASSIFICATIONS

Obsolete
Current
CC, CD
CF
1
1
CD-2
CF-2
CE
CF-4, CG-4
1
Caterpillar Multipurpose Tractor Oil (MTO) is available

for use in the implement steering, hydraulic systems,
and steering control mechanisms of tractors, and for use
in the Caterpillar rear drive axles. It has an ambient
temperature range of -25C (-13F) to 40C (104F) in
these applications.
CD-2 and CF-2 are oil categories for two-cycle diesel

engines. These oils are NOT recommended for Caterpillar
engines.
For ambient conditions that are below -25C (-13F)

check with your supplier for commercially available
Multipurpose Tractor Transmission Fluids with the
required ambient temperature capability for your area
that meet Ford "M2C134-C/D" specifications.
Engine Lubricant Specifications

Caterpillar Oil
Caterpillar oils have been developed, tested, and
approved by Caterpillar to provide the performance and
life that has been designed and built into Caterpillar
diesel engines. Caterpillar oils am used for engine
development and factory fill.
Caterpillar oils are
available from Caterpillar dealers. Due to significant
variations in the quality and performance of
commercially available oils, Caterpillar recommends the
following oils:
NOTICE
Caterpillar Multipurpose Tractor Oil (MTO) is not the
same as Caterpillar Transmission/Drive Train Oil,
and does not meet Caterpillar's specifications for
TO-4 oil. Caterpillar MTO should not be used in
compartments which specify TO-4 oil.
Maintenance Section
1-36
TM 5-3895-382-24
Commercial Diesel Engine Oils
Some commercial oils meeting these API specifications

may require shortened oil change intervals as
determined by close monitoring of oil condition and wear
metals. The Caterpillar SOS Analysis Program is the
preferred testing method.
The performance of commercial diesel engine oils are

based on API categories. These API categories am
developed to provide commercial lubricants for a wide
variety of diesel engines that operate at various
conditions.
Consult your Caterpillar

recommendations.
If Caterpillar DEO (multi-grade) is not used, only use the

following commercial oils:
dealer
for
the
latest
oil
NOTICE
Failure to follow these oil recommendations can
cause shortened engine life due to deposits and/or
excessive wear.
Preferred - API CG-4

Allowed - API CF-4
Total Base Number (TBN) and Fuel Sulfur Levels For

Caterpillar Diesel Engines
API CG-4 oils are preferred for use in Caterpillar engines

because of the fuel sulfur level. API CG-4 is the only oil
category that evaluates oils with engine tests utilizing
0.05 percent sulfur fuel.
Caterpillar Prechamber Combustion Engines

The TBN for a new oil is dependent on the sulfur level of
the fuel used. For precombustion chamber (PC) engines
running on distillate fuel, the minimum new oil TBN
(by ASTM D2896) must be 20 times the fuel sulfur level.
The minimum TBN of new oil is 5, regardless of low fuel
sulfur level. See the illustration.
The following explanations of these API categories can

be used to make the proper choice of a commercial oil.
CG-4 - CG-4 is the newest oil category. CG-4 oils were
primarily developed for diesel engines that are operating
with 0.05 percent sulfur diesel fuel. All of the laboratory
engine tests for this category were performed with 0.05
percent sulfur diesel fuel. CG-4 also defines oils that
have superior soot dispersancy. CG-4 oils will provide
improved viscosity control and improved crankcase
cleanliness in applications where oil soot is a problem.
CG-4 oils should also be used in engines that contain
hydraulically actuated fuel injection pumps; these are the
first oils to pass industry tests for foam control and
viscosity shear loss. CG-4 oils must also pass recently
developed tests for metals corrosion, and wear. CG-4
oils can be used in all Caterpillar engines where CF-4
oils are recommended.
Oil TBN shown by ASTM D2896 (Y). Percent of fuel sulfur by

weight (X). New oil TBN (1). Change oil when the used oil
TBN limit (2) is reached.
CF-4 - CF-4 oils service a wide variety of modem diesel

engines. This oil classification was developed with 0.40
percent sulfur diesel fuel. The fuel used in the CF-4
tests represents the type of diesel fuels commonly
available world wide. CF-4 oils provide improved piston
deposit control and improved oil control when compared
to the CE category oils. CF-4 oils also provide improved
soot dispersancy compared to CD or CF category oils.
Maintenance Section
1-37
TM 5-3895-382-24
Caterpillar's 20 times rule for TBN (Reference: Oil and
Your Engine, SEBD0640) versus fuel sulfur was a
general requirement developed in the early 1980's for
Caterpillar prechamber combustion (PC) system
engines. Caterpillar still maintains 20 times TBN value
for PC engines. Engines built prior to 1990 can continue
to use single grade viscosity oil or commercial oils,
provided the engine operates satisfactorily.
In areas where the fuel sulfur exceeds 1.5 percent,

choose an oil with the highest TBN that is within the API
CF-4 or CG-4 categories, and shorten the oil change
period based on oil analysis. The oil analysis should
evaluate oil condition and wear metals. High TBN oils
that are not within the API CF-4 or CG-4 categories can
produce excessive piston deposits leading to a loss of oil
control and bore polishing.
Fuel sulfur neutralization of new oil formulations in direct

injection (DI) system engines is more effective. Field
results indicate that direct injection (DI) combustion
systems and the oils now recommended for those
engines will operate at an oil TBN equal to ten times the
fuel sulfur.
NOTICE
Operation at fuel sulfur levels over 1.5 percent may
require shortened oil change periods to maintain
adequate wear protection.
Engine Lubricant Viscosity

Recommendations
Caterpillar Direct Injection Diesel Engines

For direct injection engines running on distillate diesel
fuel, the minimum new oil TBN (by ASTM D 2896) must
be 10 times the fuel sulfur level, and the minimum TBN
is 5 regardless of low fuel sulfur level.
See the
illustration.
The proper SAE viscosity grade oil is determined by the

minimum outside temperature at cold engine start-up,
and the maximum outside temperature during engine
operation. Use the minimum temperature column in the
lubricant viscosities chart determine the oil viscosity
required for starting a cold soaked engine. Use the
maximum temperature column in the lubricant viscosities
chart to select the viscosity for operation at the highest
temperature anticipated. In general, use the highest
viscosity oil available that still meets the startup
temperature requirements.
PROTECTION OF SEVERAL ENGINE OIL VISCOSITIES

Engine Oil
Ambient Temperature
Viscosity Grade
Minimum
Maximum
SAE 0W-20
-40C (-40F)
10C (50F)
SAE 5W-30
-30C (-22F)
30C (86F)
SAE 5W-40
-30C (-22F)
40C (104F)
SAE 10W-30
-20C (-4F)
40C (104F)
SAE 15W-40
-15C (5F)
50C (122F)
Oil TBN shown by ASTM D2896 (Y). Percent of fuel sulfur by

weight (X). New oil TBN (1). Change oil when the used oil
TBN limit (2) is reached.
Maintenance Section
1-38
TM 5-3895-382-24
Synthetic Base Stock Oils
After-Market Oil Additives
Synthetic base stock oils are acceptable for use in

Caterpillar engines and machines if these oils meet the
performance requirements specified by Caterpillar for a
particular compartment.
Caterpillar does NOT recommend the use of aftermarket

oil additives.
After-market oil additives are not
necessary to achieve life predictions or to achieve rated
performance. Fully formulated finished oils are made up
of base stocks and commercial additive packages.
Synthetic base stock oils

non-synthetics in two areas:
generally
outperform
Improved
low
temperature
viscosity
characteristics, especially in Arctic conditions
These additive packages are blended into the base

stocks at precise percentages to provide finished oils
with performance characteristics that meet lubricant
industry standards.
Improved oxidation stability, especially at high

operating temperatures
Lubricant industry standard tests do not exist to evaluate

the performance of after-market oil additives.
Some synthetic base stock oils have performance

characteristics that enhance the service life of the oil.
However, Caterpillar does NOT recommend the
automatic extension of oil drain intervals for any oil,
including synthetic base stock oils. For Caterpillar diesel
engines, oil drain intervals can only be adjusted through
an oil analysis program that contains the following
elements: oil condition and wear metals (Caterpillar
SOS Oil Analysis preferred), trend analysis, fuel
consumption, and oil consumption.
There are also no lubricant industry standard tests to

evaluate the compatibility of these after-market additives
in a finished oil.
After-market additives could be
incompatible with the finished oil additive package, and
lower the performance of the finished oil. The aftermarket additive could fail to mix with the finished oil, and
produce a sludge in the crankcase.
Caterpillar
discourages the use of after-market additives in finished
oils.
To achieve all the performance that was built into a
Caterpillar engine, follow these guidelines:
Re-Refined Base Stock Oils

Re-refined base stock oils are acceptable for use in
Caterpillar engines and machines if these oils meet the
performance requirements specified by Caterpillar for a
particular compartment. Re-refined oils can be used
exclusively in a finished oil or in combination with new
base stocks.
The US Military and other heavy
equipment manufacturers have also accepted the use of
re-refined base stock oils with the same criteria.
The re-refining process should be adequate to remove

all wear metals and oil additives that were present in the
used oil.
This type of re-refining is generally
accomplished by vacuum distillation and hydrotreating
the used oil. Filtering alone is inadequate for producing
a high quality re-refined base stock from used oil.
Drum Support Housing, Vibratory Housing, Drum

Gear Reducer
Select the proper Caterpillar oil or commercial oil

that meets the compartment specifications.
Select the proper oil viscosity based on the
Engine Oil Viscosity Chart in this manual.
Service the engine at the specified interval with
new oil and oil filter.
Perform maintenance at the intervals specified
in this manual.
Use gear type oils with an ISO code of 19/16 or better

for cleanliness levels. Based on recent test data, this oil
type with the proper viscosity will fulfill the lubricant
requirements.
For commercial oils use API GL-5 or MIL-L-2105C.
Maintenance Section
1-39
TM 5-3895-382-24
Hydraulic Oil
Caterpillar Transmission/Drive Train Oil

(TDTO)(TO-4)
Cat Hydraulic Oil (HYDO) - Hydraulic System

Caterpillar TDTO TO-4 is balanced to give maximum
frictional material life in power shift transmissions. TO-4
oil specifications include frictional and gear wear
requirements. TO-4 oil is offered in several viscosity
grades, including SAE 50, for maximum component life
at high ambient temperatures and heavy duty cycles.
Cat Hydraulic Oil is formulated with a balanced additive

system, including detergents, rust inhibitors, antiwear
agents and defoamers. It will offer maximum protection
against mechanical wear, rusting and corrosive wear in
all hydraulic and hydrostatic transmission systems.
Cat Hydraulic Oil should be used to achieve maximum
life and performance from hydraulic system components
and hydrostatic transmissions. Use of Cat Hydraulic Oil
is recommended in most hydraulic and hydrostatic
systems.
NOTICE
TO-4 is formulated for transmissions and drive
trains only. Using TO-4 in an engine would result in
shortened engine life.
If higher viscosities are required because of high

ambient temperatures, the following Caterpillar oils can
be used:
Do not use engine oils for lubricating transmissions

or drive trains.
Failure to follow this
recommendation can cause shortened transmission
life due to material incompatibility and Inadequate
frictional requirements for disk materials.
Cat Diesel Engine Oil DEO (CF-4/CG-4)
Caterpillar does not currently offer multi-grade oils for

use in transmissions. Multi-grade oils which use high
molecular weight polymers as viscosity index improvers
lose their viscosity effectiveness (permanent and
temporary shear), and are therefore not recommended
for transmission and drive train compartments. The
Caterpillar TO-4 specification includes a test for
multigrade oil shear stability: oils that meet this
specification may be available in the future.
Cat Transmission/Drive Train Oil (TDTO)

Commercial Oils
If Cat oils cannot be used, the following commercial
classifications can be used in the hydraulic system:
API CF-4/SG
Transmission Lubricant Viscosity Recommendation
MIL-L-2104E
The following table lists TDTO viscosity grades,

quantities, and corresponding par numbers available
from your Caterpillar dealer.
Premium industrial hydraulic oils that have passed the

Vickers vane pump test (35VQ25) and/or have a
minimum of 0.09% zinc additive may also be used.
These oils should have antiwear, antifoam, antirust and
antioxidation additives for heavy duty use as stated by
the oil supplier.
ISO viscosity grade of 46 would
normally be selected.
CATERPILLAR TRANSMISSION/DRIVE TRAIN OIL

Caterpillar TDTO
SAE 10W
SAE 30
SAE 50
Maintenance Section
19 L
(5 US gal)
8T-9568
8T-9572
8T-9576
206 L
(55 US gal)
8T-9569
8T-9573
8T-9577
1-40
TM 5-3895-382-24
Caterpillar Lubricating Grease
Caterpillar Specialty Lubricants
The National Lubricating Grease Institute (NLGI)

classifies grease, based on ASTM D217-68 Worked
Penetration characteristics. Grease characteristics are
given a defined consistency number.
SPECIAL PURPOSE CATERPILLAR LUBRICANTS

Part Number
6V-4876
Caterpillar has grease and lubricants for all applications.

Your Caterpillar dealer can provide you with complete
information regarding the different types and sizes of
Caterpillar lubrication and special application products.
CATERPILLAR LUBRICATING
Part Number
Item
Bearing
2S-3230
Lubricant
Molybdenum
5P-0960
2
Grease
All-Purpose
1P-0808
2
Lubricant
Water and
4C-4774
Temperature
4
Resistant Grease
1
5P-3931
GREASE
Size
Size
Molykote Paste
1
Lubricant
High Temperature
2
Anti-Sieze
500 g (17.6 oz)

150 g (5.3 oz)
This lubricant is recommended for use on typical

components such as head bolt threads and washers.
This lubricant is recommended for mating connectors such

as exhaust manifold studs and exhaust manifold nuts.
411 g (14.5 oz)

Gear Oil (GO)
411 g (14.5 oz)
Cat Gear Oil (GO)
411 g (14.5 oz)
Cat Gear Oil offer maximum protection against the
scoring and pitting of gear teeth and rolling element
bearings.
454 g (16 oz)
NLGI No. 2 Grade services heavily loaded ball bearings and

roller bearings that are operating at high speeds, at extreme
pressure, and at temperatures from -34 to 163C
(-18 to 300F). Use this grease for bearings in the following
components electric motors, fan dives, starting motors,
alternators and generators. Also use this grease to pack
similar bearings in many other applications.
Cat Gear Oil can also provide excellent stability under

high temperature conditions and has superior low
temperature performance. It will also give protection
against rust and corrosion.
For those components needing oils with extreme
pressure (EP) additives in severe boundary lubrication,
the gear type oils provide this extra protection. The EP
additive is deposited as a solid film lubricant in heavily
loaded gear and bearing areas for added protection.
NGLI No. 2 Grade contains three percent of molybdenum

disulfide to five percent of molybdenum disulfide. This
grease is a multipurpose grease with an operating
temperature range from -28C to 149C (-18F to 300F).
Commercial Oils
NGLI No. 2 Grade of lithium grease has mechanical

stability. This grease resists oxidation. This grease also
protects the components from rust This grease also has
excellent breakaway torque. This grease is for light-duty
applications.
For example, this grease is suited for
automotive applications. This grease is for temperatures
up to 175C (350F).
4
Item
If Cat Gear Oil cannot be used, select an oil that meets:
API GL-5 specification oil

MIL-L-2105C specification oil
NLGI No. 2 Grade is highly resistant to water. This grease

meets the ASTM D-1264 Water Washout Test requirement.
This grease resists low temperatures and high temperatures.
This grease has a starting torque at 40C (-40F). This
grease is not a fluid at 316C (600F).
Maintenance Section
1-41
TM 5-3895-382-24
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
Refill Capacities
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment
or System
Engine
Crankcase
DEO
Hydraulic
System
HYDO
Oil
Viscosities
SAE 0W20
SAE 5W30
SAE 5W40
SAE 10W30
SAE 15W40
SAE 0W30
(SPC) 2
SAE 0W20
(SPC) 2
SAE 5W20
(SPC) 2
SAE 5W20
SAE 10W
SAE 15W30
SAE 15W40
SAE 30
REFILL CAPACITIES (APPROXIMATE)

1
Min
-40
-30
-30
-20
-20
C
Max
+10
+30
+40
+40
+50
Min
-40
-22
-22
-4
+5
F
Max
+50
+86
+104
+104
+122
-40
+20
-40
+68
-40
+10
-40
+50
-30
+10
-22
+50
-25
-20
-20
-15
+10
+10
+40
+40
+50
+50
-13
-4
-4
+5
+50
+50
+104
+104
+122
+122
Axle
Differential,
10W30
-25
+40
-13
+104
Axle Gear
Reducer MTO
Drum Support
80W90
-20
+20
-4
+68
Bearing Drum
Gear Reducer
85W140
-5
+50
+23
+122
Vibratory
Bearing
802140
-20
+50
-4
+122
Reservoir GO
1
When operating below 20C (4F), refer to Operation and
Maintenance
Manual,
SEBU5898,
"Cold
Weather
Recommendations". This is available from your Caterpillar
dealer.
2
Compartment
or System
Litters
U.S.
Gal.
Imperial
Gal.
Cooling System
11
2.9
2.4
Fuel Tank
170
44
37
Engine Oil w/Filter
6.9
1.8
1.5
Axle Differential
8.3
2.2
1.8
Hydraulic Tank Oil
72
19
16
Drum Front Gear Reducer
0.5
0.44
Rear Axle Gear Reducer
1.4
0.37
0.32
Axle Planetary (CS/CP-433C)

Drum Support Housing
3.2
0.8
0.7
1.9
0.5
0.42
Vibratory Housing
50
13.5
11.4
Special oils with synthetic base stocks that do not contain

polymer viscosity index improvers. The high viscosity index
of the synthetic" oils provide natural multiviscosity properties.
Maintenance Section
Lubricant Viscosities and Refill Capacities

1-42
TM 5-3895-382-24
Maintenance Intervals (Commercial Practice)
Use service hours or calendar interval, whichever occurs
first.
NOTE: Performance
of
all
maintenance items in
Management Schedule
responsibility.
Every 50 Service Hours or Weekly*
lubrication
and
the Maintenance
is the owner's
Oscillating Pins - Lubricate fittings......................... 1-61

Steering Pins - Lubricate fittings ........................... 1-61
Blade Cylinder Pivot Points Lubricate fittings.................................................. 1-62
Blade Pivot Pins - Lubricate fittings ...................... 1-62
Steering Cylinder Ends - Lubricate fittings ............ 1-63
When Required
Radiator Core - Clean .......................................... 1-45
Circuit Breaker/Fuses - Check/replace ................. 1-45
Tires - Check pressure........................................... 1-46
Wheel Nuts - Tighten ............................................ 1-46
Drum Scrapers - Adjust ........................................ 1-47
Drum Scrapers - Replace if damaged ................... 1-48
Platform Tilting - Adjust ....................................... 1-48
Cutting Edges - Check For Wear .......................... 1-49
Every 100 Service hours or Monthly *
Every 10 Service Hours or Daily*
Initial 250 Service Hours or First 3 Months
Walk-Around Inspection - Inspect machine .......... 1-50

Seat Belt - Inspect ................................................ 1-51
Engine Air Intake System - Check service
indicator/check/clean elements ........................... 1-51
Engine Crankcase - Check oil level ...................... 1-53
Hydraulic Oil System - Check filter
indicator/oil level ................................................ 1-54
Cooling System - Check coolant level ................... 1-55
Fuel Tank - Check level ........................................ 1-56
Water Separator - Drain water and sediment ......... 1-57
Indicators and Gauges - Test for proper
function ............................................................. 1-57
Back-Up Alarm - Check operation ......................... 1-58
Horn - Check operation ......................................... 1-58
Light Switch - Check operation ............................. 1-59
Neutral Start Switch - Check operation ................. 1-59
Hydraulic Hoses - Check condition ....................... 1-60
Operation
Hydraulic System - Change Filter ......................... 1-68
Drum Gear Reducer - Change gear lubricant ......... 1-68
Axle Gear Reducer - Change gear lubricant .......... 1-68
Axle Wheel Planetaries - Change gear
lubricant ............................................................ 1-69
Axle Differential - Change gear lubricant ............... 1-69
Engine Valve Lash - Check/adjust on new or
reconditioned engines at first oil change only ....... 1-70
Drum Gear Reducer - Check level ........................ 1-64

Axle Gear Reducer - Check level .......................... 1-64
Axle Planetaries - Check level .............................. 1-65
Axle Differential - Check level .............................. 1-65
Drum Support Housing - Check level ................... 1-66
Vibratory Bearing Reservoir - Check level ........... 1-66
Every 250 Service Hours or 3 Months*

O
S) - Obtain sample
for analysis ........................................................ 1-71
Engine Oil and Filter(s) - Change ......................... 1-72
Belts - Inspect/adjust ............................................ 1-75
Batteries - Clean/Check electrolyte level ................ 1-76
Fuel System - Clean strainer and sediment
chamber, change filter and water separator
element .............................................................. 1-77
Fuel Tank Cap and Fill Screen - Clean ................. 1-80
Hydraulic Tank Breather - Wash breather ............. 1-81
Every 500 Service Hours or 6 Months*
Blade Cutting Edges - Inspect ............................. 1-82
Cooling System - Add/Check coolant additive ....... 1-82
Maintenance Section
Maintenance Intervals
1-43
TM 5-3895-382-24
Every 1000 Service Hours or 1 Year*

Hydraulic System - Change oil/filter ...................... 1-83
Drum Gear Reducer - Change lubricant ................ 1-84
Axle Gear Reducer - Change lubricant .................. 1-85
Axle Planetary - Change lubricant ......................... 1-85
Axle Differential - Change lubricant ...................... 1-86
Drum Support Housing - Change lubricant ........... 1-86
Vibratory Bearing Reservoir Change lubricant................................................. 1-87
Steer Pivot - Adjust............................................... 1-88
Every 2000 Hours or 2 Years*
Engine Valve Lash - Check/Adjust ........................ 1-89
Cooling System - Clean and flush.......................... 1-90
Rollover Protective Structure (ROPS) Inspect............................................................... 1-91
*First Perform Previous Service Hour Items
NOTE: To prevent crankshaft and/or bearing
damage, crank engine to fill all filters (oil and
fuel) before staring engine.
Maintenance Section
Maintenance Intervals
1-44
TM 5-3895-382-24
When Required
Circuit Breaker/Fuses
Radiator Core
Reset/Replace
Clean
The circuit breaker and fuses are located on the front of
the right side operator's console. All fuses are 10 Amp.
Compressed air, high pressure water or steam can be

used to remove dust, leaves and general debris from;
radiator core. Clean as required by condition of radiator.
(1) Start Aid. (2) Backup Alarm. (3) Front Flood. (4)
Gauge. (5) Rear Flood Lamps. (6) Brake.
The use of compressed air is preferred.

Refer to "Know Your Cooling System", Form SEBD0518,
for the complete procedure and instructions.
(7) Vib ON/OFF. (8) Spare. (9) Key Start Switch. (10)
Forward Horn. (11) Spare. (12) Spare.
Fuses - They protect the electrical system from damage
caused by overloaded circuits. Change a fuse if the
element separates.
If the element of a new fuse
separates, have the circuit checked and repaired.
NOTICE
Replace fuses with the same type and size only.
Otherwise, electrical damage can result
If it Is necessary to replace fuses frequently, a
electrical problem may exist.
Contact your
Caterpillar dealer.
Maintenance Section
When Required
1-45
TM 5-3895-382-24
Tires
Check Pressure
Circuit Breaker - Push the button to reset

the circuit breaker. This circuit breaker is
located on the front of the right operator
console.
Tires should contain 138 kPa (20 psi) of air.
Alternator - 60 amps.
Wheel Nuts
Tighten
Torque the wheel nuts to 530 Nm (391 lb ft).
Maintenance Section
When Required
1-46
TM 5-3895-382-24
Drum Scrapers
Adjust
There are three types of drum scrapers.
Machines equipped with a smooth drum have either a
rubber blade in front and are of the drum or a single
steel scraper at the front of the drum.
Machines equipped with a padded drum use a single
scraper yoke mounted in front of the drum.
3.
1.
Adjust the scraper assembly by loosening the

bolts. On machines with a smooth drum and steel
scraper, adjust the scraper so that the steel
scraper is 13 mm (.5 in) from the drum surface.
2.
On machines with a smooth drum and a flexible

scraper (optional), adjust the scraper so that the
rubber blade is 7 mm (.25 in) from the surface of
the drum.
Maintenance Section
Machines with a padded drum move the scraper

yoke 19 mm (.75 in) from the surface of the drum.
When Required
1-47
TM 5-3895-382-24
Drum Scrapers
Platform Tilting
Replace if Damaged
Machines with smooth drum.
Adjust
Remove bolts and remove damaged scraper.

new scraper and install bolts.
Install
Machines with padded drum.
The platform can be tilted forward to permit access to

mechanical and hydraulic components.
1.
Drive the pin out of the tip from the retainer side of
tip. Remove the tip and the retainer.
2.
Clean the adapter, pin and retainer.

Install
retainer in the groove in the side opposite of the
adapter.
3.
Install a new tip over the adapter with the retainer

in place.
4.
Drive the pin through the retainer, adapter and tip

from the side opposite of the retainer.
1.
Maintenance Section
Remove two bolts (1) and nuts from platform deck.
When Required
1-48
TM 5-3895-382-24
Cutting Edges
Check For Wear
2.
Remove two bolts (2) and nuts from top of

platform.
3.
Attach an appropriate lifting device to hook (3).

Check all cutting edges and bottom wear plates for wear.
The cutting edges can be turned around and used again
one time.
4.
Remove bolts (4) and (5) and nuts from each side
of platform.
5.
Install bolt (4) and nut into center hole on each

side of platform.
6.
Lift platform until bottom holes are aligned. Install

bolt (5) and nut on each side of platform.
7.
Release tension on lifting hook (3).
NOTE: Lower the platform by reversing

procedure for tilting the platform.
the
Maintenance Section
When Required
1-49
TM 5-3895-382-24
Every 10 Service Hours or Daily
Walk-Around Inspection
Inspect Machine
1.
Inspect and replace lights, broken bulbs and

lenses.
2.
Inspect and remove any trash build-up in and

around the engine.
3.
Inspect and repair any cooling system or engine

component leaks.
4.
Check the fuel filters for water.
Maintenance Section
5.
Inspect steps and handholds for condition and

cleanliness. Repair or clean if necessary.
6.
Inspect the hydraulic system for leaks. Inspect the

tank, hoses, tubes, plugs, joints and fittings.
Correct any leaks.
7.
Be sure covers and guards are firmly in place.

Inspect for damage.
8.
Inspect operator's compartment for cleanliness

and remove all trash.
9.
Inspect and repair the instrument panel when

broken gauges and lights are found.
10.
Inspect hydraulic motors for leaks.
11.
Inspect the rubber isolation blocks, between the

vibratory drum and the machine frame for
damage, cracking or splitting. Refer to the Service
Manual or your Caterpillar dealer for the complete
isolation block replacement procedure.

1-50
TM 5-3895-382-24
Seat Belt
Engine Air Intake System
Inspect for Wear or Damage
Check Service Indicator
Always check condition of seat belt and mounting

hardware before operating machine. Replace any
damaged or worn parts.
Your engine may or may not be equipped with a

different indicator depending on your application.
NOTICE
Never service the air cleaner with the engine
running since this will allow dirt to enter the
engine.
Replace the seat belt after three years of usage,

regardless of appearance.
Seat belt and mounting hardware must be inspected for
wear or damage. Replace the belt or mounting
hardware if worn or damaged.
Maintenance Section
1-51
A service indicator is mounted on the air cleaner or in a

remote location. A colored piston showing in the
window indicates the need for servicing the air cleaner.
Observe the air cleaner service indicator. Clean or
replace the air cleaner when the green diaphragm
enters the red zone or the red piston locks in the visible
position. If the air cleaner indicator shows red at any
time, clean the filter element or install a new air cleaner
element.
TM 5-3895-382-24
Heavy Duty Air Cleaners Only
Remove and Install Air Cleaner Elements
Service the air cleaner using the air cleaner indicator

as the basis for determining the condition of the
elements.
If the air cleaner element becomes plugged, but does
not split, engine performance will deteriorate and output
power will be reduced.
Keep spare filter elements on hand for replacement.
For the procedure to clean or replace the optional
heavy duty air cleaner elements, refer to the topic
Cleaning Air Cleaner Elements.
Cleaning Air Cleaner Elements

If NBC exposure is suspected, all air filter media
should be handled by personnel wearing protective
equipment. Consult your unit NBC NCO for
appropriate handling or disposal instructions.
NOTICE
Do not clean the filter elements by bumping or
tapping them. Engine damage could result.
Do not use filter elements with damaged pleats,
gaskets or seals.
NOTE: Most air cleaner filter elements can be cleaned
with air, water or detergent. Have spare
elements on hand to use while cleaning used
elements.
1. Open the right access cover.

2. Release the cover fasteners and remove the end
cover on the air cleaner housing. Remove and
empty the dust collector cup.
Filter elements can be cleaned with pressure air - 205

kPa (30 psi) maximum, pressure water - 280 kPa (40
psi) maximum, or detergent washing.
3. Remove the air cleaner cover and element, and

cover the air inlet.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth. Inspect seals between the
lower body and the dust collector cup. Inspect seals
between the lower and upper bodies and install new
seals if necessary.
5. Inspect the replacement element for damage, dirt or
debris. Remove the covering from the air inlet and
install the new or cleaned, undamaged element.
Install lower body to upper body and tighten
retaining clamp(s).
1. Direct air or water along the pleats inside and

outside of filter element.
6. Install dust cup and tighten retaining clamp. Reset

the service indicator.
The element can be washed in warm water and

nonsudsing household detergent. Rinse inside and
outside the pleats and air dry fully.
Maintenance Section
Change 1
1-52
TM 5-3895-382-24
Engine Crankcase
NOTICE
Make sure you read and understand the information
in the Lubricant Specifications section of this
manual before you proceed with maintenance of the
crankcase lube oil system.
Check Oil Level
2.
Inspect the filter elements after cleaning. Do not

use a filter element with damaged pleats, gaskets
or seals.
3.
Wrap and store the clean filter elements in a

clean, dry place.
4.
Reset the service indicator.
For more information on air cleaner element cleaning,

refer to your Caterpillar dealer or OEM manufacturer.
1.
Check Precleaner (If Equipped)
NOTE: Refer to the Refill Capacities chart and

Lubricant Specifications to show the proper
amount and quality of oil to be used at oil
change time, and to determine the correct
level on the dipstick for your application.
Check the precleaner (if equipped) for accumulation of

dirt and debris. Remove any dirt and debris as needed.
NOTE: More frequent cleaning will be required in
dusty applications.
2.
Remove the wing nut and top cover of the precleaner

and check for an accumulation of dirt and debris. Clean
if necessary.
Check the oil level with the engine stopped. DO

NOT check the oil level with the engine running.
Maintain the oil level between the ADD (MIN) and

FULL (MAX) marks on the dipstick. Ensure that
the engine oil level is not above the FULL (MAX)
mark on the dipstick. DO NOT overfill to reach
above or, to top of FULL (MAX) mark on the
dipstick.
After cleaning, install the cover and wing nut.
Maintenance Section

1-53
TM 5-3895-382-24
NOTE: Operating your engine when the oil level is
above the FULL (MAX) mark could cause
your crankshaft to dip into the oil. If this
happens, the air bubbles created from the
crankshaft dipping into the oil will reduce the
lubricating characteristics of your oil and
could result in the loss of power.
Hydraulic Oil System

Check Charge Pressure Indicator
If the dipstick does not have a FULL (MAX) mark, refer

to calibrating the oil level gauge by consulting your
Caterpillar dealer before operating the engine.
3.
Remove the oil filler cap and add oil if necessary.

The minimum capacity (ADD oil mark) is 5.6 liter
(5.9 U.S. quart) for the 3054 engine. See Refill
Capacities and Lubricant Specifications for the
size of your engine crankcase and recommended
oil to use.
Verify the hydraulic charge pressure. With the engine

running at HIGH IDLE, observe the charge pressure
indicator. If the indicator light is on and the horn blows,
check the indicator on the hydraulic filter. If the indicator
is in the red zone, replace the filter. Refer to Hydraulic
Oil System, Every 1000 Service Hours or 12 Months.
NOTE: Remote mounted or auxiliary oil filters will

require additional oil than what the Refill
Capacities chart states. For all information
pertaining to auxiliary oil filters, refer to the
OEM filter manufacturers instructions.
NOTICE
If the charge pressure indicator is on and the
indicator on the filter is NOT in the red zone, the
cause for low charge pressure must be determined.
Contact your Caterpillar dealer.
Maintenance Section

1-54
TM 5-3895-382-24
Check Oil Level
Cooling System
NOTICE
Take extreme care to insure the cleanliness of
hydraulic oil. Keep hydraulic oil clean to extend
component life and assure maximum performance.
DO NOT OVERFILL.
NOTICE
Make sure you read and understand the Information
in the Cooling System Specifications section of this
manual before you proceed with maintenance of the
cooling system.
Check Coolant Level
1.
1.
Check the coolant level with the engine stopped

and cool.
2.
Remove the filler cap slowly to relieve any

pressure.
3.
Maintain the coolant level within 13 mm (1/2 inch)

below the bottom of the fill pipe or to the proper
level on the sight glass, if equipped.
Observe the hydraulic oil level when the oil is

WARM. Maintain oil level to the level mark on the
decal near sight gauge (1).
NOTE: Do not overfill. Hot oil will indicate an above

level condition.
2.
If the oil level is low, remove oil fill cap (2).
3.
Add oil through the fill tube while observing sight

gauge. Fill to the level indicator on the decal. Do
not overfill.
4.
Clean and install oil fill cap (2).
Maintenance Section

1-55
TM 5-3895-382-24
Fuel Tank
Check Level
4.
Inspect the filler cap. Replace the cap if gaskets

are damaged. Install the filler cap.
1.
NOTE: Ensure your replacement filler cap has the

same pressure rating as the old one. Refer
to the Parts Manual.
Observe the fuel level.
NOTICE
Fill the fuel tank at the end of each day of operation
to drive out moist air and to prevent condensation.
Do not fill the tank to the top. Fuel expands as it
gets warm and may overflow.
5.
Inspect and clean the radiator fins to keep them

free of dirt and debris.
2.
Maintenance Section
Remove the fuel cap to add fuel.

1-56
TM 5-3895-382-24
Water Separator
Indicators and Gauges
Drain Water and Sediment
Test for Proper Function
Water separator contains combustible materials or

explosive atmospheres; never light matches, smoke,
create sparks or use open flame. Personal injury or
death may result from explosion or fire.
NOTICE
The fuel system must be purged of air whenever; the
fuel system has run dry, the low pressure fuel lines
are disconnected, either of the fuel filters have been
drained or disconnected or any part of the low
pressure fuel system leaks during engine operation.
1.
1.
Look for broken gauge lenses or indicator lights,

switches, etc.
2.
Start the engine.
3.
With the engine running, all indicator lights should

be off. With the key ON and the engine NOT
started, all indicators should come on.
4.
Look for inoperative gauges.
5.
Stop the engine.
6.
Make any needed repairs before operating.
Open the left access cover.
2.
Turn the drain valve counterclockwise to open.
3.
Drain water
container.
and
sediment
into
NOTE: Always dispose of drained

established by local regulations.
suitable
fluids
4.
Close the drain valve.
5.
Close the access cover.
6.
Repeat this procedure for the primary fuel filter.
as
Maintenance Section

1-57
TM 5-3895-382-24
Back-up Alarm
Horn
Check Operation
Check Operation
Located at the rear of the machine.
Start the machine and depress the horn button. If the

horn does not sound, make needed repairs before
operating.
While the machine is running move the propel lever to

reverse. If the back-up alarm does not sound make any
needed repairs before operating.
Maintenance Section

1-58
TM 5-3895-382-24
Light Switch
Neutral Start Switch
Check Operation
Check Operation
Machine may suddenly lurch forward if the neutral

start switch is out of adjustment Personal injury or
death can result.
Be sure area is clear of all
personnel and equipment before performing this test
If the machine is equipped with lights, turn on the light

switch. Observe the lights and replace any that are not
working.
Maintenance Section
1.
Move the propel lever forward.
2.
Hold the key start switch in the start position while

slowly moving propel lever back toward
NEUTRAL.
3.
If machine attempts to start before the lever is in

NEUTRAL, the neutral start switch requires
adjustment. Do not operate machine until repairs
are made.

1-59
TM 5-3895-382-24
Hydraulic Hoses
Check Condition
Check all hoses, fittings and components for leaks.

NOTICE
Whenever inspection or maintenance work is
performed on the hydraulic system, all hydraulic
hoses and fittings must be checked.
Replace
damaged hoses immediately.
Maintenance Section

1-60
TM 5-3895-382-24
Every 50 Service Hours or Weekly
Oscillating Pins
Steering Pins
Lubricate Fittings
Lubricate Fittings
Located in the center of the machine.
Lubricate the fittings on the front and rear of the

oscillation pin. One fitting is located on left side of the
pivot housing and one at the top of the front plate.
Lubricate the steer pins fittings located on the rear frame

above and below the pivot housing.
Maintenance Section

1-61
TM 5-3895-382-24
Blade Cylinder Pivot Points
Blade Pivot Pins
Lubricate Fittings
Lubricate Fittings
Located in the rear of the blade arms.
Lubricate the fittings located at the top and bottom of the

blade cylinder.
Maintenance Section

1-62
TM 5-3895-382-24
Steering Cylinder Ends
Lubricate Fittings
1.
Lubricate fitting on each end of both steer cylinders.
2.
Total of four fittings.
Maintenance Section

1-63
TM 5-3895-382-24
Every 100 Service Hours or Monthly
You must read and understand the warnings and
instructions contained in the Safety Section of this
manual before performing any operation or maintenance
procedures.
Axle Gear Reducer

Check Level
Drum Gear Reducer

Check Level
Located under the rear of the machine in front of the

differential.
1.
Move the machine until the plug is either at the

three o'clock or nine o'clock position. Remove the
plug.
NOTICE
Rotate the drum with the plug in the 12:00 o'clock
position down to the 3:00 or 9:00 o'clock position.
This will insure there is no oil trapped in the plug
cavity and give a false "FULL" reading.
2.
Maintain gear lubricant to the bottom of the plug.
3.
Clean and install the plug.
Maintenance Section
1.
Remove fill/check plug located on front side of the

axle reducer case.
2.
Maintain gear lubricant to the bottom of fill/check

plug.
3.

1-64
TM 5-3895-382-24
Axle Planetaries
Axle Differential
Check Level
Check Level
Located under the rear of the machine.
1.
Move the machine until the fill/check plug is in

either the three o'clock or the nine o'clock position.
2.
Remove fill/check plug.
3.
Maintain gear lubricant to the bottom of plug.
4.
5.
Repeat procedure on other planetary.
Maintenance Section
1.
Remove fill/check plug located in center of the

differential case.
2.
Maintain gear lubricant to the bottom of plug.
3.

1-65
TM 5-3895-382-24
Drum Support Assembly
Vibratory Bearing Reservoir
Check Level
Check Level
1.
Remove plug located at approximately the eight

o'clock position.
1.
Move the machine until indicator boss (1) is at its

lowest level.
2.
Maintain gear lubricant to the bottom of level

indicator plug.
3.
2.
Remove check plug (2) and maintain lubricant to

the bottom of the opening.
Maintenance Section

1-66
TM 5-3895-382-24
3.
If necessary, remove fill plug (3) and add lubricant

until it is level with the bottom of the opening for
check plug (2).
4.
Install the check and fill plugs.
Maintenance Section

1-67
TM 5-3895-382-24
Initial 250 Service Hours or First Three Months Operation
Hydraulic System
Axle Gear Reducer
Change Filter
Change gear lubricant See the same topic in "Every

1000 Service Hours or One Year".
Change filter. See the same topic in "Every 1000

Service Hours or 1 Year".
Drum Gear Reducer
Change gear lubricant. See the same topic in "Every
1000 Service Hours or 1 Year".
Maintenance Section
Initial 250 Service Hours or First Three

Months Operation
1-68
TM 5-3895-382-24
Axle Planetaries
Axle Differential
Change gear lubricant. See the same topic in "Every

Change gear lubricant See the same topic in "Every

Maintenance Section

Months Operation
1-69
TM 5-3895-382-24
Engine Valve Lash
Check/Adjust
To prevent possible injury, do not use the starter

motor to turn the flywheel.
Hot engine components can cause bums. Allow
additional time for the engine to cool before
adjusting valve lash.
3054 Valve Location Schematic
Initial valve lash adjustment on new, rebuilt or
remanufactured engines is recommended at the first
scheduled oil change interval due to initial wear and
seating of valve train components.
Subsequent
adjustments should be made at Every 2000 Hour
interval.
See topics in the Every 2000 Hour maintenance interval

for additional information or the Service Manual or your
Caterpillar dealer for the complete valve adjustment
procedure.
This maintenance is recommended by Caterpillar as part

of a lubrication and preventive maintenance schedule to
provide maximum engine life.
Maintenance Section

Months Operation
1-70
TM 5-3895-382-24
Every 250 Service Hours or 3 Months
procedures.
Before proceeding with this maintenance, perform
previous maintenance interval requirements.
This maintenance is to be performed at the interval
specified in the Maintenance Schedule for your engine
model.
O
S)
Caterpillar recommends using one of the above
methods. If either of these methods are not possible,
then use a drain stream method when changing oil.
To compliment a good preventive maintenance program,

Caterpillar recommends using SOS at this scheduled
interval to monitor the condition of the engine oil and
maintenance requirements of your engine.
NOTE: When using the drain stream to obtain the oil

sample, do not sample from the beginning or
end of drain stream. The oil at the beginning
or end of the drain stream is not mixed well
enough to be representative of the oil in the
crankcase.
Obtain Sample
Each oil sample should be taken when the oil is warm
and well mixed to ensure that the sample is
representative of the oil in the crankcase. There are two
methods recommended to obtain SOS samples from
the engine crankcase.
Consult your Caterpillar dealer for complete information

and assistance in establishing an SOS program for
your engine.
Use the sampling valve, if installed on the engine,

for samples. The sample valve should be flushed
with oil to rinse the dirt and debris from the valve.
Oil Drain Intervals

Many conditions exist that may allow adjustment to the
normal oil change periods and can affect the selection of
an optimum oil change period.
The fundamental
requirement in this decision must be to maintain the lube
oil in an acceptable condition that provides continual
engine protection.
The quality and amount of oil
available is balanced against its ability to absorb
combustion by-products.
Use a sampling gun inserted into the sump.
NOTE: Refer to How to Take a Good Oil Sample,

PEHP6001, for a step-by-step explanation if
using this method of sampling crankcase oil.
Due to manufacturing tolerances, engine application and

maintenance variation, all engines do not consume fuel
and oil at the same rate. The amount of fuel consumed
is in direct relation to the maximum oil change interval
selected.
The Maintenance Schedule assumes the use of
SUPERIOR QUALITY API CF-4 (minimum) performance
oil, which has sufficient TBN for fuels with less than
0.5% sulfur.
Maintenance Section

1-71
TM 5-3895-382-24
Engine Oil and Filter(s)
All oils do not perform equally. A lower quality lube

oil would require that the oil change intervals be
reduced accordingly. If the sulfur content in the fuel
is greater than 1.5% by weight, use an oil with a
TBN of 30 and reduce oil change interval by one half
the interval recommended in the Maintenance
Schedule.
Change
NOTICE
Park the machine on a level surface to perform this
maintenance procedure.
It is also essential to include an SOS analysis of oil

condition before oil change period adjustment is
considered.
Refer to the Lubricant Specifications section and

Lubricant Viscosity chart in this manual for
recommended oil and quantity to use for your engine.
If the engine crankcase oil has reached its condemning

limits as established by the oil analysis program, refer to
the topic, Engine Oil and Filter(s), in this publication for
the procedure to change the crankcase oil and oil filter.
The oil and filter change interval is established by the

engine oil sump capacity. This maintenance should be
performed according to the SOS analysis result or the
interval listed in the Maintenance Schedule.
For more information on adjusting or extending oil

change intervals for specific applications, see your
Caterpillar dealer.
1.
Drain the crankcase with the engine stopped and the

oil warm to allow for the draining of waste particles
that are suspended in the oil. As the oil cools,
suspended waste particles will settle on the bottom
of the crankcase or oil pan and will not be removed
with the draining oil.
After the engine has been run at normal operating
water temperature, STOP the engine. Remove
the crankcase drain plug and O-ring (or open
crankcase drain valve and remove drain plug) and
allow the oil to drain. Inspect O-ring for damage,
replace if necessary.
An oil sample for SOS (Scheduled Oil Sampling)

analysis should have been obtained from the SOS
valve or can be obtained from the crankcase draining at
this time.
2.
Maintenance Section
Install the crankcase drain plug and O-ring (or

close crankcase drain valve and install drain plug).
If equipped with oil pan drain plug, tighten it to 34
5 Nm (25 4 lb ft).

1-72
TM 5-3895-382-24
Replace Filter(s)
3.
1.
Use a 2P-8250 Filter Wrench to remove the oil

filter.
Wipe the sealing surface of the filter mounting

base. Make sure all of the old gasket is removed.
NOTE: Change oil filter(s) at every oil change. Make

sure to use the correct Caterpillar oil filter(s)
for your engine arrangement.
NOTICE
Caterpillar oil filters are built to Caterpillar
specifications. Use of an oil filter not recommended
by Caterpillar could result in severe engine damage
to your engine bearings, crankshaft, etc., as a result
of the larger debris particles from unfiltered oil
entering your engine lubricating system.
Element with debris.

2.
Use a 4C-5084 Oil Filter Cutter (which replaced

the former 6V-7905 Service Tool) to cut the oil
filter open. Spread pleats apart and inspect the
element for metal debris. An excessive amount of
debris in the oil filter element may be indicative of
early wear or a pending failure.
Use a magnet to differentiate between the ferrous and

non-ferrous metals found in your oil filter element.
Ferrous metals may indicate wear on the steel and cast
iron parts of your engine. Non-ferrous metals may
indicate wear on the aluminum, brass or bronze parts of
your engine, such as crankshaft (main) bearings,
turbocharger bearings and cylinder head wear.
4.
Apply a small amount of clean engine oil to the

new filter gasket.
Due to normal wear, friction, etc., it is not uncommon to

find small amounts of debris in your oil filter element.
Consult your Caterpillar dealer to arrange for further
analysis if an excessive amount of debris is found in
your oil filter element.
Maintenance Section

1-73
TM 5-3895-382-24
NOTICE
Do NOT fill the oil filters with oil before installing
them. This oil would not be filtered and could be
contaminated.
Contaminated oil will cause
accelerated wear to engine components.
5.
Install the new filter(s) until the gasket contacts the

base. Tighten the filter 3/4 of a turn more by hand.
Do not over tighten.
Fill Crankcase
NOTICE
Either underfilling or overfilling of engine crankcase
oil can cause engine damage.
7.
Before starting the engine, ensure your oil level is

within the correct operating range on the dipstick.
NOTICE
To prevent crankshaft or bearing damage, crank
engine to fill all filters BEFORE starting. Do not
crank engine for more than 30 seconds.
6.
8.
Start and run the engine according to the

instructions in the Engine Starting section. Run at
LOW IDLE for two minutes to ensure the lube
system (including auxiliary filters, etc.) has oil and
the oil filter(s) are filled. Inspect for oil leaks.
9.
Stop the engine and allow the oil to drain back to

the sump for a minimum of 10 minutes.
10.
Remove the dipstick to check the oil level.

Maintain the oil level to the FULL (MAX) mark on
the dipstick.
Remove the oil filler cap to fill the crankcase with

new oil.
Refer to Lubricant Specifications,
Lubricant Viscosity and Refill Capacity charts for
the proper oil and quantity to use for your engine.
NOTICE
If equipped with an auxiliary oil filter or system,
extra oil must be added when filling the crankcase.
If the extra oil is not added, the engine may starve
for oil.
Follow the OEM filter manufacturers
recommendations.
Maintenance Section

1-74
TM 5-3895-382-24
Belts
Adjust Belts
Inspect/Adjust
Inspect the condition and adjustment of alternator belts
and fan drive belts.
Inspect all drive belts for wear and replace if they show
any signs of wear.
If one belt in a set requires replacement, always install a
new matched set of belts. Never replace just the worn
belt. If only the worn belt of a matched set is replaced,
the new belt will carry more of a load than the belts not
replaced, as it will not be stretched as much as the older
belts. The additional load on the new belt could cause it
to break and all the belts will fall in rapid succession.
3.
To adjust drive belts, loosen alternator pivot

fasteners (1) and adjusting bracket fasteners (2).
If belts are too loose, the belts vibrate and cause

unnecessary wear on the bets and pulleys.
4.
Adjust the alternator position in or out to obtain the

correct adjustment. Tighten fasteners (1) and (2).
If belts are too tight, unnecessary stresses are placed

upon the pulley bearings and belts which might shorten
the life of both.
5.
Check belt tension again to ensure correct

tension.
6.
If new belts are installed, check belt adjustment

again after 20 hours of engine operation. Replace
belts in matched sets only.
1.
Inspect the condition and adjustment of alternator

belts and fan drive belts.
2.
To check the belt tension, apply 45 Newtons (10

Ibs of force midway between the pulleys.
Correctly adjusted belts will deflect approximately
10 mm (3/8 inch).
If a Burroughs gauge is used, the correct tension is 355

N (80 lbs). If the tension is 220 N (50 lbs.) or below,
adjust tension.
Maintenance Section

1-75
TM 5-3895-382-24
Batteries
Battery or Battery Cable Replacement
Clean/Check Electrolyte Level (if required)
NOTE: When replacing batteries or battery cables,

use the following procedure:
Open the grill assembly and gateway door to access the

battery.
Tighten the battery retainers every 1000 hours on all
batteries.
BATTERY ELECTROLYTE CHART
Battery
Interval
Conventional
100 Hours
Low Maintenance
250 Hours
Maintenance Free
None Required
1.
1.
Turn the start switch to the OFF position.
2.
Turn off (open) all electrical loads.
3.
Disconnect the cable from ground (one cable

connects to frame and one to battery negative).
Be sure the cable cannot contact where it was just
removed.
4.
Disconnect the negative battery cable terminal at

the battery(s) that goes to the start switch. Two 12
volt batteries are involved, the negative side of two
batteries must be disconnected.
5.
Proceed with necessary system repairs.
6.
Reverse steps two through five.
Remove fill caps. Maintain electrolyte to bottom

on fill plug openings.
If addition of water is necessary, use distilled water. If

distilled water is not available use clean water that is low
in minerals. Do not use artificially softened water.
At proper charging rate, batteries should not require
more than 30 cc (1 ounce) water per cell per week.
Check the cell weekly in extreme temperatures, cell
water usage could be higher.
2.
Keep batteries clean.
3.
Loosen and remove cable clamps from all battery

terminals.
4.
Clean all battery terminals.
5.
Clean all cable clamps.
6.
Install and
terminals.
7.
Coat cable damps and terminals with 5N-5561

Silicone Lubricant. petroleum jelly or MPGM
grease.
tighten cable
clamps
to
battery
Maintenance Section

1-76
TM 5-3895-382-24
Fuel System
Replace Fuel Filter
Clean Fuel Lift Pump Strainer and Sediment Chamber
Stop the engine. Shut off the engine and close the
fuel supply valve, if equipped.
Shut off the fuel tank supply valve to the engine and
drain water and sediment from fuel tank.
Turn the Engine Control Switch to OFF position

and/or disconnect the battery when performing
maintenance on fuel filters.
1.
Remove the cover and seal from the top of the fuel
lift pump and remove the gauze strainer.
2.
Clean the screen, seal and cover with a

nonflammable solvent. Wipe the dirt and sediment
from the lift pump body.
3.
Install the screen after cleaning and assemble the

cover and seal.
1.
Remove all dirt from the fuel filter. Thoroughly

clean the outside surface of filter base.
2.
Loosen drain (3) on bottom of filter by turning

counterclockwise. Allow the fluid to drain into a
suitable container.
NOTE: Always dispose of drained fluids and fillers

as established by local regulations.
3.
Close drain valve (3).
4.
Loosen filter collar (1).
5.
Remove and discard fuel filter (2). Clean the

gasket sealing surfaces of the filter base. Make
sure the filter head seal is not worn or damaged.
Clean filler mounting surfaces inside the base.
6.
Install a new filter element.
NOTICE
DO NOT fill the fuel filter(s) with fuel before
installing. The fuel would not be filtered and could
be contaminated.
Contaminated fuel will cause
accelerated wear to fuel system parts.
Maintenance Section

1-77
TM 5-3895-382-24
Change Water Separator Element
Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire.
Change the element when it becomes contaminated

enough that the water level cannot be seen through the
transparent cover.
Stop the engine.
2.
Open the access door on the left side of the

machine.
3.
Clean the dirt from the separator and surrounding

area.
Maintenance Section
Turn drain valve (5) on the bottom of the water

separator counterclockwise to open.
5.
Drain water
container.
and
sediment
into
suitable
NOTE: Always dispose of drained fluids and filters

as established by local regulations.
Turn the disconnect switch OFF or disconnect the

battery when changing fuel filter or fuel water
separator elements. Drain the fuel from the fuel
water separator into a container before removing the
water separator retaining clamp.
1.
4.
6.
Close drain valve (5).
7.
Hold the bottom of the separator element (2) while

loosening collar (3).
8.
Remove bowl (4).
9.
Loosen collar (1).
10.
Remove and discard water separator element (2).
11.
Clean the inside surfaces of the filter head and

bowl (4). Inspect the O-ring on bowl (4) and the
seal on the filter head.
Replace if worn or
damaged.
12.
Install a new water separator element. Tighten

collar (1) to secure the water separator element.
13.
Install bowl (4). Tighten collar (3).
NOTE: Do not start the engine until all fuel system

service is complete. Refer to "Priming the
System" in this section for engine starting
procedure following fuel system service.
1-78
TM 5-3895-382-24
Priming the System

NOTICE
Do not crank the engine for more than 30 seconds.
Allow the starter to cool for two minutes before
cranking again.
After changing the fuel filters, prime (purge) the fuel

system to remove air bubbles from the system.
2.
Open the fuel valve and start the engine. It may

be necessary to prime the fuel system if the
engine does not start. Inspect for fuel leaks.
Crank the engine. If the engine will not start, or
once started continues to misfire or smoke, further
priming is necessary.
3.
If the engine starts, but runs rough, continue

running the engine at low idle until the engine runs
smoothly.
4.
If the engine will not start, loosen the fuel line nuts
at two of the nozzles to help purge fuel lines of air
before air bubbles enter injection nozzles.
5.
Crank the engine again until the fuel flows free of

air bubbles. Be sure to tighten each fuel line nut.
Tighten the union nuts to 18 4.5 Nm (13.3 3.3
lb ft). If the engine will start, then continue to run
the engine until fuel flows free without pockets of
air in the fuel lines.
DO NOT REMOVE the plug in the fuel filter base (for the
fuel pressure sending unit, if equipped) to release air
from the fuel system while priming. Periodic removal of
the plug will result in increased wear of the threads in the
fuel filter base and lead to fuel leakage.
NOTE: If priming pump lever cannot be operated,

the drive cam of fuel lift pump is at the point
of maximum cam lift.
Therefore the
crankshaft must be turned one revolution.
Ensure that the manual stop control is in the
RUN position or electrical stop control
(ignition key) is in "R" position.
1.
Operate the priming pump plunger located on fuel

lift pump for approximately two minutes or until a
resistance is felt.
Maintenance Section
1-79
TM 5-3895-382-24
Fuel Tank Cap and Fill Screen

Clean
1.
Remove the cap and strainer.
2.
Wash the cap and strainer in clean, nonflammable

solvent.
3.
Allow the breather inside the cap to dry, or use

pressure air to dry.
4.
Install the strainer and till cap.
Maintenance Section
1-80
TM 5-3895-382-24
Hydraulic Tank Breather

Wash Breather
The hydraulic tank breather is located at the top of the

hydraulic tank. The platform must be tilted to remove
the breather, see the topic, Platform Tilting, in the
When Required section.
1.
Remove breather assembly.
2.
Wash breather in clean, nonflammable solvent.
Maintenance Section
1-81
3.
Use pressure air to dry breather. Air should blow

through breather.
4.
If breather is restricted it must be replaced.
5.
Install clean breather assembly.
TM 5-3895-382-24

instructions contained the Safety Section of this manual
before performing any operation or maintenance
procedures.
Cooling System
Check/Add Coolant/Add Supplemental
Coolant Additive (As Required)
Before proceeding with this maintenance, perform all

Blade Cutting Edges
Inspect
Typical Example
Inspect blade cutting edges for loose or missing bolts.
Replace missing bolts and tighten bolts to the specified
torque. See "Torques for Ground Engaging Tools" chart.
Inspect blade cutting edges for damage or excessive
wear. Replace if necessary.
Maintenance Section
1-82
TM 5-3895-382-24
Every 1000 Service Hours or 1 Year

procedures.
Hydraulic System
Change Oil
4.
Add hydraulic oil. See the "Lubricant Viscosities

and Refill Capacities" chart.
5.
Maintain the oil level using the sight gage.
6.
Clean and install the filler cap.
Change Hydraulic Oil Filter

Operate the machine long enough to warm the oil.
1.
Remove the hydraulic tank fill cap slowly to relieve

pressure.
NOTICE
Take extreme care to insure the cleanliness of
hydraulic oil. Keep hydraulic oil clean to extend
component life and assure maximum performance.
2.
Remove the drain plug located in the bottom of the

hydraulic oil tank. Allow the oil to drain.
1.
NOTICE
The hydraulic oil tank contains approximately 72
liters (18.5 U.S. gal) of hydraulic oil.
Remove the filter element. Use care to avoid

spilling hydraulic oil from the filter element as it is
being removed.
2.
Apply a small amount of clean hydraulic oil to the

new filter gasket.
3.
3.
Install new filter element.

Tighten the filter
element by hand until the seal contacts the base.
Tighten an additional 3/4 turn.
Clean and install the drain plug.
Maintenance Section
1-83
TM 5-3895-382-24
Drum Gear Reducer

Change Gear Lubricant
4.
Observe the hydraulic oil level with the oil warm.

Maintain the oil level to the level mark on the decal
near the sight gauge. Add oil if necessary.
1.
Side of the front gear reducer is straight down.
NOTICE
Rotate the drum with the plug in the 12:00 o'clock
position down to the 3:00 or 9:00 o'clock position.
This will insure there is no oil trapped in the plug
cavity and give a false "FULL" reading.
Maintenance Section
1-84
2.
Remove plug (1) and allow the gear lubricant to

drain.
3.
Clean and install plug (1). Remove plug (2) which

is in either the three o'clock or nine o'clock
position.
4.
Add gear lubricant. See the "Lubricant Viscosities

5.
Maintain gear lubricant to the bottom of plug (2).
6.
Clean and install plug (2).
TM 5-3895-382-24
Axle Gear Reducer
Axle Planetary
Located under the rear of the machine in front of the

differential.
1.
Remove drain plug (1) and allow gear lubricant to

drain.
2.
Clean and install the drain plug.
3.
Remove fill/check plug (2) located on front side of

the gear reducer case.
4.
Add gear lubricant See the "Lubricant Viscosities

5.
Maintenance Section
1-85
1.
Move the machine until the plug is in the six

o'clock position. Remove the plug and allow the
gear lubricant to drain.
2.
Move the machine until the plug is in either the

three o'clock or the nine o'clock position. Add
gear lubricant. See the "Lubricant Viscosities and
Refill Capacities" chart.
3.
Maintain gear lubricant to the bottom of the plug.

Clean and install the plug.
4.
Repeat procedure on other planetary.
TM 5-3895-382-24
Axle Differential
Located under the rear of the machine.
1.
Remove drain plug (1) located at the bottom of the

differential and allow the gear lubricant to drain.
2.
Clean and install the drain plug (1).
3.
Remove fill/check plug (2) located in the center of

the differential.
4.
Add gear lubricant See the "Lubricant Viscosities

5.
6.
Maintenance Section
1-86
1.
Remove drain plug (1) located at the bottom of the

drum support housing and allow the gear lubricant
to drain.
2.
Clean and install drain plug (1).
3.
Remove fill plug (2) located at approximately the

eight o'clock position.
4.
Add gear lubricant through fill plug (2). See the

"Lubricant Viscosities and Refill Capacities" chart.
5.
Maintain gear lubricant to the bottom of fill plug

(2).
6.
Clean and install fill plug (2).
TM 5-3895-382-24
Vibratory Bearing Reservoir
2.
Remove drain/fill plug (1) and allow the lubricant to

drain. Dispose of used lubricant according to
local, state and federal regulations.
3.
Clean and install drain plug (1).
4.
Move the machine until the boss is at the bottom.
Change Lubricant
NOTE: To achieve adequa te draining, block the

drum up on the left side with an eight inch
block.
1.
Move the machine until the boss is at the top.
Maintenance Section
5.
Remove drain/fill plug (1) at the top of the drum
head.
1-87
6.
Add lubricant. See "Lubricant Specifications" in

the "Maintenance Section".
7.
Maintain lubricant to the center of sight gauge (2).

Sight gauge (2) is not visible in the photo, but is
located approximately 90 from fill plug (1).
8.
`TM 5-3895-382-24
Steer Pivot
Adjust
If excess movement is detected in the vertical steer pins,

adjust and reshim as necessary. Refer to the service
manual for the proper procedure.
Maintenance Section
1-88
TM 5-3895-382-24
Every 2000 Service Hours or 2 Years

manual,
before
performing
any
operation
or
maintenance procedures.
VALVE LASH SETTING

Intake
0.20 mm (.008 in)
Exhaust
0.45 mm (.018 in)
Before proceeding with this maintenance, perform all

Engine Valve Lash
Be sure the engine cannot be started while this

maintenance is being performed.
To prevent
possible injury, do not use the staring motor to turn
the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash.
Adjust the valve lash to the setting given in the chart

above. Refer to the Service Manual or your Caterpillar
dealer for the complete valve adjustment procedure.
Operation of Caterpillar engines with improper valve

adjustments will reduce engine efficiency. This
reduced efficiency could result in excessive fuel
usage and/or shortened engine component life.
This maintenance is recommended by Caterpillar as part

of a recommended preventive maintenance schedule to
provide maximum engine life.
Check/Adjust
Refer to the Engine Service Manual or your Caterpillar

dealer for the complete procedure to perform this
maintenance.
NOTICE
The procedures for engine valve lash should be
performed according to the information in the
Service Manual.
Measure the valve lash with the engine stopped. To
obtain an accurate measurement, allow at least 20
minutes for the valves to cool to engine cylinder
head and block temperature.
NOTE: Initial valve lash check and/or adjustment on
new or rebuilt engines is recommended at
the first scheduled oil change interval, or 400
Hours, whichever occurs first. This is due to
initial wear and seating of valve train
components.
Subsequent checks and
adjustments should be made at the Every
2000 Hour interval thereafter.
Maintenance Section
1-89
TM 5-3895-382-24
Cooling System
NOTICE
Do not perform this maintenance until you read and
understand the material in the Safety and Cooling
System Specifications sections of this publication.
This procedure is to be used for normal
maintenance of cooling system surfaces to return to
"like new" condition. For heavy build-up of scale
and deposits, a severe acid-type commercial cleaner
or mechanical cleaning will be required.
2.
Refer to Cooling System Specifications for additional
information regarding appropriate Flush/Fill for your
application.
Clean/Flush Coolant
Remove the drain plug from the side of cylinder

block. Open the drain valve on bottom of cooling
water system radiator and allow the coolant to
drain.
NOTE: If the cooling water system radiator does not

have a drain valve or plug, disconnect the
radiator bottom tank hose from the water
pump.
3.
Remove the block drain plug(s) from jacket water

heater (if equipped). Allow coolant to drain.
Dispose of used engine coolant or recycle. Various

methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Caterpillar
to reclaim the used coolant.
Contact Caterpillar Service Technology Group:
Typical Example
1.
Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Stop the engine and allow to cool. Loosen the

radiator filler cap slowly to relieve any pressure
and remove the cap.
Refer to Service Magazine article dated November 13,

1989 and/or Engine News article dated November 1989
for information regarding disposal and recycling of used
coolant.
Maintenance Section
1-90
TM 5-3895-382-24
Rollover Protective Structure

(ROPS)
Inspect
Repair of the ROPS may be performed only after

consulting the factory. Replace bolts using only the
size and torque recommended on the sign located
by the ROPS.
Look for any loose or damaged bolts. Replace damaged

bolts or missing bolts with original equipment parts only.
Retighten bolts to a torque of 460 60 Nm
(340 45 lb ft).
Replace ROPS mounting supports If the ROPS rattles or
makes a noise when the machine is operated on a rough
surface.
Do not straighten or repair by welding reinforcement
plates to the ROPS.
Contact your Caterpillar dealer for repair of cracks in
welds, castings or any metal section on the ROPS.
Maintenance Section
1-91
TM 5-3895-382-24
Maintenance Records
Caterpillar recommends that accurate maintenance
records be maintained. Accurate maintenance records
can be used for determining operating costs,
establishing maintenance schedules for other like
machines being operated in the same environment and
for a variety of other related business decisions.
Accurate maintenance records can also be used to show
compliance with the required maintenance practices and
intervals. Maintenance records are a key element of a
well managed maintenance program. With accurate
maintenance records your Caterpillar dealer can help
you fine tune the recommended maintenance intervals to
meet your specific operating situation. This should result
in lower operating cost.
The key elements to keep records on are:
Fuel Consumption
This is essential for determining when load-sensitive

items should be inspected or repaired and for
determining overhaul intervals.
Service Hours
This is essential for determining when revolutionsensitive items should be inspected or repaired.
Documents
The following types of documents should be kept as

proof of maintenance or repair for warranty and should
not be difficult to obtain and keep in the engine history
file. All documents should show date, service hours,
liters (gallons) of fuel consumed, unit number and engine
serial number. If the engine is sold, transfer the records
with the engine.
The following types of documents should be kept as
proof of maintenance or repair for warranty and should
not be difficult to obtain and keep in the engine history
file.
1.
Dealer work orders and itemized bills.
2.
Owner's repair orders.
3.
Owner's receipts.
4.
Maintenance log.
Maintenance Section
1-92
Maintenance Records
TM 5-3895-382-24
Troubleshooting
Troubleshooting a failure on an engine can be a difficult
procedure.
For a troubleshooting manual, see the
Service Manual for your machine. All repairs should be
made by a properly trained mechanic. Your Caterpillar
dealer has the personnel and special tools needed to
troubleshoot and make repairs to your machine.
See the Service Manual for a troubleshooting manual.
The list of problems, causes and corrections given in the
Service Manual, will only give an indication of where a
possible problem can be, and what repairs may be
needed.
Remember that a problem is not normally caused only
by one part, but by the relation of one part with other
pans.
The Service Manual can not give all possible problems
and corrections. The serviceman must find the problem
and its source, then make the necessary repairs.
Your Caterpillar dealer is equipped with the necessary
tools and personnel to provide assistance when
necessary.
Maintenance Section
1-93
Troubleshooting
TM 5-3895-382-24
Reference Materials
Caterpillar Reference Material

The following literature can be obtained through any
Caterpillar dealer.
Miscellaneous
SEBF8062 ....Guideline for Reusable Parts Cleaning
and Inspection of Air Filters
SEHS9031 ...Storage Procedure for Caterpillar Products
SEBU5614 ...Safety Manual
Oil
SEBD0640 ...Oil and Your Engine
SEBU5898 ...Cold
Weather
Operation and Maintenance Manual
SEBU6981 ...Emissions Warranty
Recommendations
All of the above publications are available through your

Caterpillar dealer.
SEBU6310 ...EMA Engine Oil Data Book

PEHP6001 ...How to Take a Good Oil Sample
SEHS7392 ...Storage of Diesel Engines
Additional Reference Material

ASTM D2896 TBN Measurements
ASTM D217-68 Worked Penetration
PEHP7504 ...Cat Engine Oil Spec Sheets

PEHP7505 ...Cat Diesel Engine Oil Spec Sheets
PEHP1020 ...Product Data Sheet for Cat Diesel Engine
Oil (CF-4)(N. America & Selected Int'l)
Oil (CF-4)(International Only)
ASTM D2982B
ASTM D3828A
ASTM D445 Kinematic Viscosity Testing

Oil (CD)
PEHP0002 ...Product Data Sheet for Cat Molybdenum
Grease (MPGM)
PEHP0003 ...Product Data Sheet for Cat Lithium
Grease (MPGL)
PEHP0017 ...Product Data Sheet
Purpose Grease (SPG)
PEWP9733 ...Cat Fluids Selector
for
Cat
ASTM D893
ASTM 4985-89 GM-6038M Specification
ASTM Specs can normally be obtained from your local
technological society, library or college.
SAE J313 Diesel Fuels
SAE J754 Nomenclature
Special
SAE J183 Classification

Society of Automotive Engineers (SAE) Specs can be
found in your SAE handbook or can be obtained from
your local library, college or technological society.
Fuel
SEBD0717 ...Diesel Fuels and Your Engine
SEHS7067 ...Fuels for Caterpillar Diesel Engines
Coolant
SEBD0518 ...Know Your Cooling System
SEBD0970 ...Coolant and Your Engine
Literature Section
1-94
Reference Materials
TM 5-3895-382-24
CHAPTER 2
Military-Specific Maintenance Instructions
Para
Contents
Page
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
2-8.
2-9.
2-10.
2-11.
2-12.
2-13.
2-14.
2-15.
2-16.
2-17.
2-18.
2-19.
Back-up Alarm Override Switch ..................................................................................................................2-2

Cold Starting Aid Replacement ...................................................................................................................2-3
Decontamination Kit Bracket Replacement ..................................................................................................2-7
Drum Interchange (Smooth/Pad-Foot) .........................................................................................................2-8
Engine Oil Sampling .................................................................................................................................2-20
Engine Oil Sampling Valve Replacement ...................................................................................................2-22
Handrail Replacement (Type III) ................................................................................................................2-24
Hydraulic Oil Sampling .............................................................................................................................2-25
Hydraulic Oil Sampling Valve Replacement ...............................................................................................2-27
Leveling Blade Replacement/Repair ..........................................................................................................2-29
NATO Receptacle Replacement ...............................................................................................................2-35
NATO Receptacle Cables Replacement ....................................................................................................2-39
Manual Brake Release Hand Pump Replacement ......................................................................................2-44
Manual Brake Release Needle Valve Replacement ....................................................................................2-47
Pad-foot Shell Installation/Removal ...........................................................................................................2-50
Rifle Mounting Bracket Replacement .........................................................................................................2-57
Seat Assembly Replacement ....................................................................................................................2-58
Seat Suspension Repair ...........................................................................................................................2-59
Stowage Box Replacement .......................................................................................................................2-72
2-1
TM 5-3895-382-24
2-1. BACK-UP ALARM OVERRIDE SWITCH
This Task Covers:
a. Removal
INITIAL SETUP
b. Installation
Tools and Special Tools

Tool Kit, General Mechanic's: Automotive
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Wrench, Torque (0-170 lb-ft)
NSN 5120-00-640-6364
Materials/Part
Lockwasher
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Battery disconnect switch turned OFF
(TM 5-3895-382-10)
Drum and wheels chocked
a. Removal.
(1) Open grill (1).
(2) Remove nut (2), lockwashers (3), and
switch (4) from bracket (5).
Discard
lockwasher.
(3) Tag, mark, and disconnect two wires (6
and 7) from switch (4).
(4) If damaged, removed two bolts (8),
washers (9) and bracket (5) from backup
alarm (10) and frame (11).
b. Installation.
(1) If removed, install bracket (5) to backup
alarm (10) and frame (11) with two
washers (9) and screws (8). Tighten bolts
to 40 lb-ft (55 Nm).
(2) Install two wires (6 and 7) on switch (4).
(3) Install switch (4) on bracket (5) with
lockwasher (3) and nut (2).
(4) Close grill (1).
Follow-on
chocks.
NOTE
Maintenance:
Remove
END OF TASK
2-2
TM 5-3895-382-24
2-2. COLD STARTING AID REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

Tool Kit, General Mechanics: Automotive
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Left and Right Side Door Assemblies Opened
a. Removal.
(1) Remove nut (1), washer (2), screw (3),

and washer (2) from frame (4).
(2) Remove five screws (5), washers (6), and
panel (7) from frame (4).
(3) Loosen wing nut (8) and remove ether
canister (9) from clamp (10) and valve
(11).
(4) Remove cap (12) from cap-holder (13).
(5) Install cap (12) on valve (11).
(6) Disconnect connector (14) from wiring
harness (15).
2-3
TM 5-3895-382-24
(7) Loosen connector (16) and remove tube

(17) from valve (11).
(8) Remove two screws (18), washers (19),
and clamp (10) from frame (4).
(9) Remove two screws (18), washers (19).
and valve (11) from frame (4).
(10) Remove nut (20), washer (21), bolt (22),
washer (21), tube (17), and clamp (23)
from clamp (24).
(11) Remove clamp (23) from tube (17).
(12) Remove clamp (24) from hose (25).

washer (27), tube (17), and clamp (29)
from clamp (30).
(14) Remove clamp (29) from tube (17).
(15) Remove clamp (30) from hose (31).
NOTE
Some coolant may leak from engine
while screws are removed.
(16) Remove two screws (32), clamps (33),
and tube (17) from engine assembly (34).
(17) Remove two clamps (33) from tube (17).
(18) Loosen connector (16) and remove tube
(17) from atomizer assembly (35).
(19) Remove atomizer assembly (35) and
adapter (36) from tube (37).
2-4
TM 5-3895-382-24
b. Installation.
(1) Install adapter (36) and
assembly (35) in tube (37).
atomizer
(2) Install tube (17) in atomizer assembly (35)

and tighten connector (16).
(3) Install two clamps (33) on tube (17).
(4) Install two screws (32), clamps (33), and
tube (17) on engine assembly (34).
(5) Install clamp (30) on hose (31).
(6) Install clamp (29) on tube (17).
(7) Install clamp (29) and tube (17) on clamp
(30) with washer (27), bolt (28), washer
(27), and nut (26). Tighten nut.
(8) Install clamp (24) on hose (25).

(9) Install clamp (23) from tube (17).
(10) Install clamp (23) and tube (17) on clamp
(24) with washer (21), bolt (22), washer
(21), and nut (20). Tighten nut.
(11) Install valve (11) on frame (4) with two
screws (18) and washers (19). Tighten
screws.
(12) Install clamp (10) from frame (4) with two
screws (18) and washers (19). Tighten
screws.
(13) Install tube (17) on valve (11) and tighten
connector (16).
2-5
TM 5-3895-382-24
(14) Connect connector (14) to wiring harness

(15).
(15) Remove cap (12) from valve (11).
(16) Install cap (12) on cap-holder (13).
(17) Install ether canister (9) in clamp (10) and
valve (11).
(18) Tighten ether canister (9) securely in
clamp (10).
(19) Tighten wing nut (8).

(20) Install panel (7) on frame (4) with five
screws (5) and washers (6). Snug, but do
not tighten screws.
(21) Install screw (3), two washers (2), and nut
(1) in panel (5) and frame (4).
(22) Tighten five screws (6) and nut (1).
NOTE
Follow-on Maintenance:
Close left and right side door assemblies.
Remove chocks.
END OF TASK
2-6
TM 5-3895-382-24
2-3. DECONTAMINATION KIT BRACKET REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Wrench, Torque (0-170 lb-ft).
NSN 5120-00-640-6364
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Decontamination kit removed
a. Removal.
(1) Remove strap (1) from bracket (2).
(2) Remove four bolts (3), washers (4), and
bracket (2) from plate (5).
b. Installation.
(1) Install bracket (2) on plate (5) with four
bolts (3) and washers (4). Tighten bolts to
40 lb-ft (55 Nm).
(2) Install strap (1) in bracket (2).
NOTE
Install decontamination kit
decontamination kit bracket.
in
Remove chocks.
END OF TASK
2-7
TM 5-3895-382-24
2-4. DRUM INTERCHANGE (SMOOTH/PAD-FOOT)

This Task Covers:
a. Removal of Smooth Drum
b. Cleaning/Inspection
c. Installation of Pad-foot Drum
INITIAL SETUP
d. Removal of Pad-foot Drum

e. Cleaning/Inspection
f. Installation of Smooth Drum

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Shop Equipment, Automotive Maintenance
and Repair: OM Common No. 1, Less Power
(SC 4910-95-A74), NSN 4910-00-754-0654,
Tool No. W32593
Container (1qt [0.91] minimum capacity)
Lifting Device (339 lbs [154 kg] capacity)
Wrench, Torque (0-600 lb-ft),
NSN 5120-00-221-7983,
(Included in W32593)
g. Smooth Drum Scraper

Adjustment
Materials/Parts
Cap and Plug Set, NSN 5340-00-450-5718
Locknuts (6)
Shims (as required)
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Steering pin locked (TM 5-3895-382-10)
Wheels and drum chocked
Leveling blade removed (Para 2-10)
Personnel Required
Four
2-8
TM 5-3895-382-24
a. Removal of Smooth Drum.
WARNING
Hydraulic oil is slippery and can
cause falls. To avoid injury, wipe up
spilled oil with rags.
NOTE
Tag and mark all hydraulic hoses
prior to removal.
Place
container
under
hose
assembly to catch any excess oil
draining from hoses.
(1) Tag and remove two hydraulic hoses (1)

from fittings (2). Cap hoses and fittings.
WARNING
Cylinder weighs 60 lbs (27 kg). Care
should be taken when handling
cylinder
to
prevent
injury
to
personnel.
washer (4), and cylinder (6) from bumper
assembly (7).
(3) Remove two screws (8), plates (9), clamp
halves (10), hoses (1), and clamp halves
(10) from bumper assembly (7).
2-9
TM 5-3895-382-24
WARNING
Bumper asse mbly weighs 339 lbs
(154 kg). Keep clear of equipment
when equipment is being raised or
lowered. Equipment may fall and
cause serious injury or death to
personnel.
Do not allow heavy components to
swing while hanging by lifting
device.
Equipment may strike
personnel and cause injury.
Exercise extreme caution when
working near a cable or chain
under tension. A snapped cable,
shifting or swinging load may
result in injury or death to
personnel.
Ensure that bumper assembly is
balanced during removal.
An
unbalanced bumper assembly can
quickly tip or fall causing personal
(4) Attach lifting device with minimum 339 lbs (154 kg) capacity to bumper assembly (7).
(5) Remove six locknuts (11), three washers (12), three washers (13), three bolts (14), three bolts (15), and six
washers (16), from bumper assembly (7) and yoke (17). Discard locknuts.
NOTE
Shims may be present left, right, both, or neither side(s) of yoke.
(6) Using lifting device, remove bumper assembly (7) and any shims (18) from yoke (17).
(7) Remove smooth drum assembly (Chapter 16).
(8) Remove drum support housing from smooth drum assembly (Chapter 16).
(9) Remove drum gear reducer from smooth drum assembly (Chapter 16).
2-10
TM 5-3895-382-24
b. Cleaning inspection.
WARNING
Never smoke when using solvent; the flashpoint for drycleaning solvent type III
solvent contact eyes, immediately flush eyes with water and get immediate
medical attention.
(1) Clean all metal parts with drycleaning solvent.
WARNING
Compressed air is used for cleaning purposes and shall not exceed 30 psi
(207 kPa).
Use only with effective chip guarding and personal protective
equipment (goggles, gloves, etc.).
(2) Dry all parts with compressed air.
(3) Inspect bumper assembly for rust, cracks, dents, bends, broken or cracked welds, and holes.
(4) Inspect drum assembly for rust, cracks, dents, bends, broken or cracked welds, and holes.
(5) Repair or replace all damaged parts.
2-11
TM 5-3895-382-24
c. Installation of Pad-foot Drum.

(1) Install drum gear reducer on pad-foot drum assembly (Chapter 16).
(2) Install drum support housing on pad-foot drum assembly (Chapter 16).
(3) Install pad-foot drum assembly (Chapter 16).
(4) Attach lifting device with minimum 222 lbs
(101 kg) capacity to bumper assembly (19).
WARNING
Bumper assembly weighs 222 lbs
(101 kg). Keep clear of equipment
when equipment is being raised or
lowered. Equipment may fall and
personnel.
device.
personnel.
An
unbalanced bumper assembly can
quickly tip or fall causing personal
(5) Using lifting device, position bumper assembly (19) in yoke (17).
NOTE
Shims may be used on left, right, both, or neither side(s) to center drum assembly
in yoke.
(6) Install shims (17) to center bumper assembly (19) in yoke (17).
(7) Install six washers (16), three bolts (15), three bolts (14), three washers (13), three washers (12), and
locknuts (11) in bumper assembly (19) and yoke (17). Snug, but do not tighten nuts.
(8) Position bumper assembly (19) to allow 9/16 in. (15mm) clearance between twelve scraper tips (20) and
drum surface.
(9) Tighten locknuts (11) to 340 lb ft (460 Nm).
2-12
TM 5-3895-382-24
WARNING
cylinder
to
prevent
injury
to
personnel.
(10) Install cylinder (6) on bumper assembly (19) with
washer (4), bolt (5), washer (4), and nut (3).
Tighten nut.
WARNING
NOTE
Place
container
under
hose
assemblies to catch any excess oil
(11) Remove caps and install two hoses (1) on
fittings (2). Tighten hoses.
(12) Install two clamp halves (10), hoses (1), clamp
halves (10), and plates (9) on bumper assembly
(19) with two screws (8). Tighten screws to 340
lb-ft (460 Nm).
(13) Install leveling blade assembly (Para 2-10).
(14) Fill drum gear reducer, drum support housing,
and vibratory bearing reservoir (Para 1-14).
(15) Start engine (TM 5-3895-382-10) and check for
leaks.
(16) Check for clearance between top of blade assembly and hoses when blade is in full up position.
(17) If clearance is needed, loosen screws (8) and adjust hoses (1). Tighten screws.
(18) Remove chocks.
2-13
TM 5-3895-382-24
d. Removal of Pad-foot Drum.
WARNING
NOTE
Tag and mark all hydraulic hoses
prior to removal.
Place container under hose
assembly to catch any excess
fluid draining from hoses.
(1) Tag and remove two hydraulic hoses (1) from

fittings (2). Cap hoses and fittings.
WARNING
cylinder
to
prevent
injury
to
personnel.
(2) Remove nut (3), washer (4), bolt (5), washer (4),
and cylinder (6) from bumper assembly (19).
(3) Remove two screws (8), plates (9), clamp halves
(10), hoses (1), and clamp halves (10) from
bumper assembly (19).
2-14
TM 5-3895-382-24
WARNING
Bumper assembly weighs 222 lbs

(101 kg).
Keep clear of
equipment when equipment is
being
raised
or
lowered.
Equipment may fall and cause
serious injury or death to
personnel.
Do not allow heavy components

to swing while hanging by lifting
device.

or a shifting or swinging load
may result in injury or death to
personnel.

An
unbalanced bumper assembly
can quickly tip or fall causing
personal injury or death to
personnel.
(4) Attach lifting device with minimum 222 lb (101 Kg) capacity to bumper assembly (19).
(5) Remove six locknuts (11), three washers (12), three washers (13), three bolts (14), three bolts (15), and six
washers (16), from bumper assembly (19) and yoke (17). Discard locknuts.
NOTE
Shims may be present left, right, both, or neither side(s) of yoke.
(6) Using lifting device, remove bumper assembly (19) and any shims (18) from yoke (17).
(7) Remove smooth drum assembly (Chapter 16).
(8) Remove drum support housing from smooth drum assembly (Chapter 16).
(9) Remove drum gear reducer from smooth drum assembly (Chapter 16).
2-15
TM 5-3895-382-24
e. Cleaning/Inspection.
WARNING
Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective goggles and
gloves; use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and, do
not breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the
flashpoint for drycleaning solvent type III is 200 F (93C). Failure to do so may result in injury
or death to personnel.
If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical
help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes,
immediately flush eyes with water and get immediate medical attention.
WARNING
Compressed air is used for cleaning purposes and shall not exceed 30 psi (207 kPa). Use only
with effective chip guarding and personal protective equipment (goggles, gloves, etc.).
(3) Inspect bumper assembly for rust, cracks, dents, bends, broken or cracked welds, and holes.
(4) Inspect drum assembly for rust, cracks, dents, bends, broken or cracked welds, and holes.
2-16
TM 5-3895-382-24
f. Installation of Smooth Drum.
(1) Install drum gear reducer on smooth drum assembly (Chapter 16).
(2) Install drum support housing on smooth drum assembly (Chapter 16).
(3) Install smooth drum assembly (Chapter 16).
(4) Attach lifting device with minimum 339 lbs (154
kg) capacity to bumper assembly (7).
WARNING
Bumper assembly weighs 339 lbs (154 kg).
Keep clear of equipment when equipment
is being raised or lowered. Equipment may
fall and cause serious injury or death to
personnel.
Do not allow heavy components to swing
while hanging by lifting device. Equipment
may strike personnel and cause injury.
Exercise extreme caution when working
near a cable or chain under tension. A
snapped cable, shifting or swinging load
may result in injury or death to personnel.
Ensure that bumper assembly is balanced during removal. An unbalanced bumper assembly
can quickly tip or fall causing personal injury or death to personnel.
(5) Using lifting device, position bumper assembly (7) in yoke (17).
NOTE
Shims may be used on left, right, both, or neither side(s) to center drum assembly in yoke.
(6) Install shims (18) to center bumper assembly (7) in yoke (17).
(7) Install six washers (16), three bolts (15), three bolts (14), three washers (13), three washers (12), and locknuts
(11) in bumper assembly (7) and yoke (17). Tighten nuts to 340 lb-ft (460 Nm).
2-17
TM 5-3895-382-24
WARNING
Cylinder weighs 60 lbs. (27 kg). Care
cylinder
to
prevent
injury
to
personnel.
(8) Install cylinder (6) on bumper assembly (7) with
washer (4), bolt (5), washer (4), and nut (3).
Tighten nut.
WARNING
NOTE
Place
container
under
hose
assemblies to catch any excess oil
(9) Remove caps and install two hoses (1) on
fittings (2). Tighten hoses.
(10) Install two clamp halves (10), hoses (1), clamp
halves (10), and plates (9) on bumper assembly
(7) with two screws (8). Tighten screws to 40 lbft (55 Nm).
(11) Install leveling blade assembly (Para 2-10).
(12) Fill drum gear reducer, drum support housing,
and vibratory bearing reservoir (Para 1-14).
(13) Start engine (TM 5-3895-382-10) and check for
leaks.
(14) Check for clearance between top of blade
assembly and hoses when blade is in full up
position.
(15) If clearance is needed, loosen screws (8) and adjust hoses (1). Tighten screws.
(16) Remove chocks.
(17) Adjust smooth drum scraper (subparagraph g).
2-18
TM 5-3895-382-24
g. Smooth Drum Scraper Adjustment.

NOTE
Locknuts must be discarded after loosening.
(1) Remove locknut (1) and washer (2) from
carriage bolt (3), adjustment bar (4), and scraper
(5). Discard locknut.
(2) Install washer (2) and new locknut (1) on
carriage bolt (3), adjustment bar (4), and scraper
(5). Snug, but do not tighten locknut.
(3) Repeat Steps (1) and (2) for the three remaining
adjustment bars (4).
(4) Position scraper (5) to allow 9/16 in. (15 mm)
clearance between edge of scraper and drum
surface (6).
(5) Tighten locknuts to 120 lb-ft (160 Nm).
NOTE
Follow-on Maintenance: Remove chocks.
END OF TASK
2-19
TM 5-3895-382-24
2-5.
ENGINE OIL SAMPLING
This Task Covers: Sampling
INITIAL SETUP
Container (1 qt [0.91] minimum capacity)
General Safety Instructions

If engine has recently been in operation, allow
time for cooling before performing procedure.
Avoid prolonged skin contact with oil.
Work in a well-ventilated area.
Equipment Condition
Right side door assembly opened
(TM 5-3895-382-10)
Steering pin locked
(TM 5-3895-382-10)
WARNING
Do not drain engine oil while engine is hot. Severe injury to personnel may
result.
Prolonged contact with lubricating oil, MIL-PRF-2104, 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.
rags.
There is no clearance for personnel between frame and yoke when Roller turns.
Severe injury or death from crushing could occur.
Steering frame must be locked before lifting, transporting, or servicing Roller

in articulation area with engine running to prevent serious injury or death from
crushing.
Unlock steering frame before operation to prevent loss of steering that may
cause serious injury or death to personnel.
When working on a running engine, provide shielding for exposed rotating

parts. Tools, clothing, or hands can get caught and cause serious injury to
personnel.
CAUTION
Sample engine oil 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 disproportionate
sample collection.
NOTE
Refer to DA Pam 738-750 for sampling requirements.
2-20
TM 5-3895-382-24
(1) Start engine and run engine at low idle (TM 5-3895-382-10).
(2) Remove engine oil sampling valve drain cap (1) from engine oil sampling valve (2).
(3) Place container with 1 qt (0.9 1) minimum capacity under engine oil sampling valve (2).
(4) Turn and hold knurled knob (3) in direction of arrow until engine oil sample is collected. Release knob when
sample has been collected.
(5) Install engine oil sampling valve drain cap (1) on engine oil sampling valve (2).
(6) Shut engine off (TM 5-3895-382-10).
(7) Submit engine oil sample to your local Army Oil Analysis Program (AOAP) laboratory for analysis.
NOTE
Unlock steering pin (TM 5-3895-382-10).
Check engine oil level (TM 5-3895-382-10).
Close right side door assembly (TM 5-3895-382-10).
Remove chocks.
END OF TASK
2-21
TM 5-3895-382-24
2-6.
ENGINE OIL SAMPLING VALVE REPLACEMENT
This Task Covers:
a. Removal
b. Installation
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364
Materials/Parts
Compound, Sealing: Pipe Thread (61603),
Type A NSN 8030-01-054-0740
Seal
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Engine oil drained
a. Removal.
(1) Remove engine oil sampling valve drain cap (1) from engine oil sampling valve (2).
(2) Place container with 1 qt (0.9 1) minimum capacity under engine oil sampling valve (2).
(3) Turn and hold knurled knob (3) in direction of arrow and allow remainder of engine oil to drain.
drained oil in accordance with local regulations.
Dispose of
(4) Disconnect hour meter pressure switch connector (4) from connector (5).
(5) Remove hour meter pressure switch (6) from tee (7).
(6) Loosen locking nut (8) on engine oil sampling valve (2) and remove engine oil sampling valve from adapter (9).
(7) Remove seal (10) from engine oil sampling valve (2). Discard seal.
(8) If damaged, remove adapter (9) from tee (7).
2-22
TM 5-3895-382-24
(9) If damaged, remove elbow (11) from tee (7).
(10) If damaged, remove tee (7) and connector (12) from oil filter head assembly (13).
(11) If damaged, remove connector (12) from tee (7).
b. Installation.
WARNING
Adhesives, solvents, and sealing
compounds can burn easily, can give
off harmful vapors, and are harmful
to skin and clothing. To avoid injury
or death, keep away from open fire
and use in a well-ventilated area. If
adhesive,
solvent,
or
sealing
compound gets on skin or clothing,
wash immediately with soap and
water.
(1) If removed, apply sealing compound to threads of connector (12) and install on tee (7).
(2) If removed, apply sealing compound to threads of tee (7) and install in oil filter head assembly (13).
(3) If removed, apply sealing compound to threads of elbow (11) and install in elbow (11).
(4) Apply sealing compound to threads of adapter (9) and install in elbow (11).
NOTE
When installing engine oil sampling valve, position drain of valve downward to
ease in collection of sample.
(5) Install seal (10) on engine oil sampling valve (2).
(6) Install on adapter (9). Tighten locking nut (8).
(7) Install hour meter pressure switch (6) on tee (7) and tighten to 7 lb-ft (22 Nm).
(8) Connect hour meter pressure switch connector (4) to connector (5).
(9) Install engine oil sampling valve drain cap (1) on engine oil sampling valve (2).
NOTE
Fill engine to capacity with engine oil.
Start engine (TM 5-3895-382-10) and check for leaks.
Remove chocks.
END OF TASK
2-23
TM 5-3895-382-24
2-7.
HANDRAIL REPLACEMENT (TYPE III)
This Task Covers:
a. Removal
b. Installation
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Wrench, Torque (0-170 lb-ft), NSN 5120-00640-6364, (Included in T13152 and W32593)
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Personnel Required
Two
a. Removal.
WARNING
Handrail weighs 33 lbs (15 kg).

Care should be taken when
handling left and right handrails
to prevent injury to personnel.
Failure to hold handrail assembly

in place during removal will allow
handrail assembly to fall and may
personnel.
NOTE
Note position of handrail assembly
before removal.
(1) While assistant holds handrail assembly (1),
remove six nuts (2), washers (3) bolts (4),
washers (3) and handrail assembly (1) from
operator platform (5).
b. Installation.
(1) While assistant positions handrail assembly (1),
install handrail assembly on operator platform
(5) with six bolts (4), twelve washers (3) and six
nuts (2). Tighten nuts to 40 lb-ft (55 Nm).
Follow-on
chocks.
NOTE
Maintenance:
Remove
END OF TASK
2-24
TM 5-3895-382-24
2-8.
HYDRAULIC OIL SAMPLING
This Task Covers: Sampling
INITIAL SETUP
Oil sample bottle
Equipment Condition
Hydraulic system at operating temperature
Steering pin locked (TM 5-3895-382-10)

Avoid prolonged skin contact with hydraulic oil.
Work in a well-ventilated area.
WARNING
Do not drain hydraulic oil while oil is hot.

result.
Prolonged contact with lubricating oil, MIL-L-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.
Hydraulic oil is slippery and can cause falls. To avoid injury, wipe up all spilled
hydraulic oil with rags.
rags.
There is no clearance for personnel between frame and yoke when Roller turns.
Severe injury or death from crushing could occur.
Steering frame must be locked before lifting, transporting, or servicing Roller

in articulation area with engine running to prevent serious injury or death from
crushing.
Unlock steering frame before operation to prevent loss of steering that may
cause serious injury or death to personnel.
When working on a running engine, provide shielding for exposed rotating

parts. Tools, clothing, or hands can get caught and cause serious injury to
personnel.
Severe injury to personnel may
CAUTION
Sample hydraulic oil 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 hydraulic reservoir and cannot be removed by draining the oil.
Failure to follow this recommendation procedure can result in disproportionate
sample collection.
NOTE
Refer to DA Pam 738-750 for sampling requirements.
2-25
TM 5-3895-382-24
2-8.
HYDRAULIC OIL SAMPLING (CONT)
(1) Remove five screws (1), washers (2), and panel (3) from frame assembly (4).
(2) Remove hydraulic oil sampling valve drain cap (5) from hydraulic oil sampling valve (6).
(3) Start engine (TM 5-3895-382-10).
(4) Place container with 1 qt (0.91) minimum capacity under hydraulic oil sampling valve (6).
(5) Turn and hold knurled knob (7) in direction of arrow until hydraulic oil sample is collected. Release knob when
sample has been collected.
(6) Install hydraulic oil sampling valve drain cap (5) on hydraulic oil sampling valve (6).
(7) Shut engine OFF (TM 5-3895-382-10).
(8) Install panel (3) on frame assembly (4) with five washers (2) and screws (1).
(9) Submit hydraulic oil sample to your local Army Oil Analysis Program (AOAP) laboratory for analysis.
NOTE
Unlock steering pin (TM 5-3895-382-10).
Check hydraulic oil level (TM 5-3895-382-10).
Close right side door assembly (TM 5-3895-382-10).
Remove chocks.
END OF TASK
2-26
TM 5-3895-382-24
2-9.
HYDRAULIC OIL SAMPLING VALVE REPLACEMENT
This Task Covers
a. Removal
b. Installation
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364, (Included in T13152
and W32593)
Materials/Parts
Compound, Sealing: Lubricating, anaerobic
single component (05972) loctite 271
(MIL-S-46163) type 1 grade 10 cc bottle,
NSN 8030-00-148-9833
Seal
Equipment Condition
Engine OFF
Hydraulic oil tank drained
a. Removal.
WARNING
Hydraulic oil is slippery and can cause falls.
hydraulic oil with rags.
To avoid injury, wipe up spilled
(2) Remove hydraulic oil sampling valve drain cap (5) from hydraulic oil sampling valve (6).
(3) Place container with 1 qt (0.9 1) minimum capacity under hydraulic oil sampling valve (6).
(4) Turn and hold knurled knob (7) in direction of arrow and allow remainder of hydraulic oil to drain. Dispose of
drained hydraulic oil in accordance with local regulations.
(5) Loosen locking nut (8) on hydraulic oil sampling valve (6) and remove hydraulic oil sampling valve from manifold
(9).
(6) Remove seal (10) from hydraulic oil sampling valve (6). Discard seal.
2-27
TM 5-3895-382-24
b. Installation.
WARNING
to skin and clothing. To avoid injury
adhesive,
solvent,
or
sealing
compound gets on skin or clothing,
water.
(1) Install seal (10) on hydraulic oil sampling valve
(6).
NOTE
When
installing
hydraulic
oil
sampling valve, position drain of
valve down for ease in sample
collection.
(2) Apply sealing compound to threads of hydraulic

oil sampling valve (6) and install on manifold (9).
Tighten locking nut (8).
(3) Install hydraulic oil sampling valve drain cap (5)
on hydraulic oil sampling valve (6).
(4) Install panel (3) on frame assembly (4) with five
washers (2) and screws (1).
NOTE
Fill hydraulic tank.
Start engine and check for leaks.
Remove chocks.
END OF TASK
2-28
TM 5-3895-382-24
2-10. LEVELING BLADE REPLACEMENT/REPAIR
This Task Covers:
a. Removal
c. Cleaning/Inspection
b. Disassembly
d. Assembly
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Shop Equipment, Automotive Maintenance and
Repair: OM Common No. 1, Less Power (SC
4910-95-A74), NSN 4910-00-754-0654, Tool
No. W32593
NSN 5120-00-221-7983, (Included in
W32593)
Lifting Device (800 lbs [363 kg] minimum
capacity)
e. Installation
Personnel Required
Two
Equipment Condition
Blade lowered (TM 5-3895-382-10)
Engine OFF (TM 5-3895-382-10)
Drums and wheels chocked
Materials/Parts
Locknuts (6)
Locknuts (4)
Locknuts (14)
Locknut (1)
2-29
TM 5-3895-382-24
a. Removal.
(1) Remove locknut (1), washer (2), bolt (3), washer (2), and cylinder rod (4) from blade assembly (5). Discard
locknut.
WARNING
Blade assembly weighs 800 lbs (363 kg). Keep clear of equipment when

Equipment may strike personnel and cause serious injury or death.
personnel.
(2) Attach lifting device to blade assembly (5). Snug lifting device to support blade assembly.
(3) Remove six locknuts (6), washers (7), bolts (8), and washers (7) from blade assembly (5).
NOTE
Shims may be present on left, right, both, or neither side(s).
(4) Using lifting device, remove blade assembly (5) and shims (9) from yoke (10).
2-30
TM 5-3895-382-24
b. Disassembly.
(1) Remove four locknuts (11), washers (12), two wear plates (13), and four plow bolts (14) from blade assembly (5).
Discard locknuts.
(2) Remove fourteen locknuts (15), washers (16), midsection cutting edge (17), two cutting edges (18), and fourteen
plow bolts (19) from blade assembly (5). Discard locknuts.
(3) Remove two nuts (20), washers (21), plates (22), bars (23), plates (22), bolts (24), and washers (21) from blade
assembly (5).
(4) Remove two bushings (25), four spacers (26), retaining rings (27), and two bushings (28) from blade assembly
(5).
(5) Remove pipe plug (29) and terminal bushing (30) from blade assembly (5).
2-31
TM 5-3895-382-24
c. Cleaning/Inspection.
WARNING
Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable.

Wear
protective goggles and gloves; use only in a well-ventilated area; avoid contact
with skin, eyes, and clothes; and, do not breathe vapors. Keep away from heat
or flame. Never smoke when using solvent; the flashpoint for type III
drycleaning solvent is 200 F (93 C). Failure to do so may result in injury or
death to personnel.
If personnel become dizzy while using cleaning solvent, immediately get fresh
air and medical help. If solvent contacts skin or clothes, flush with cold water.
If solvent contacts eyes, immediately flush eyes with water and get immediate
medical attention.
WARNING
Compressed air is used for cleaning purposes and shall not exceed 30 psi (207
kPa). Use only with effective chip guarding and personal protective equipment
(goggles, gloves, etc.).
(3) Inspect blade assembly for rust, cracks, dents, bends, broken or cracked welds, and holes.
2-32
TM 5-3895-382-24
d. Assembly.
(1) Install terminal bushing (30) and pipe plug (29) on blade assembly (5).
(2) Install two bushings (28), four retaining rings (27), spacers (26), and bushings (25) on blade assembly (5).
NOTE
A bolt may used to align holes and hold the bar between the plates.
(3) Install two washers (21), plates (22), bolts (24), bars (23), plates (22), washers (21), and nuts (20) on blade
assembly (5). Snug, but do not tighten nuts.
(4) Install fourteen plow bolts (19), midsection cutting edge (17), two cutting edges (18), fourteen washers (16), and
locknuts (15) on blade assembly (5).
(5) Install four plow bolts (14), two wear plates (13), four washers (12) and locknuts (11) on blade assembly (5).
2-33
TM 5-3895-382-24
e. Installation.
WARNING
Blade assembly weighs 800 lbs (363 kg). Keep clear of equipment when

Equipment may strike personnel and cause injury or death.
personnel.
(1) Using lifting device, position blade assembly (5) in yoke (10).
(2) Determine amount of shims required to center blade assembly (5) in yoke (10).
NOTE
Any bolts used for placement of bar during assembly should be removed
during installation of blade assembly to yoke.
Shims are required if gap between yoke and blade assembly is greater than
2mm.
(3) Install six washers (7), bolts (8), washers (8), and nuts (6) in plates (22), any shims (9), and yoke (10).
(4) Tighten two nuts (20) to 340 lb-ft (460 Nm).
(5) Install cylinder rod (4) on blade assembly (5) with washer (2), bolt (3), washer (2), and locknut (1).
locknut to 340 lb-ft (460 Nm).
NOTE
END OF TASK
2-34
Tighten
TM 5-3895-382-24
2-11. NATO RECEPTACLE REPLACEMENT
This Task Covers:
a. Removal
b. Installation
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364, (Included in T13152
and W32593)
Materials/Parts
Tags, Identification (MIL-S-29190) 1,000 per
carton, NSN 8135-00-178-9200
Lock Washers (4)
Locknuts (4)
Equipment Condition
Engine OFF (TM 5-3895-379-10)
WARNING
Battery acid (Electrolyte) is extremely harmful. Always wear safety goggles

and rubber gloves, and do not smoke when performing maintenance on
batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to
protect clothing from being damaged.
Exercise extreme caution when working under tilt platform. Falling platform
could result in serious injury or death to personnel.
Turn battery disconnect switch off prior to performing maintenance in

immediate battery area or working electrical system. Such disconnections
prevent electrical shock to personnel or equipment.
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 the machine. Allowing
cable ends to contact each other or machine can result in damage to battery or
electrical system.
2-35
TM 5-3895-382-24
2-11.
NATO RECEPTACLE REPLACEMENT (CONT)
a. Removal.
(1) Turn battery disconnect switch (1) to OFF position.

(2) Turn and pull latch assembly (2) and lower grill (3).
(3) Lift battery cover (4).
NOTE
Tag and mark all wires prior to removal.
(4) Loosen nut (5) and remove cable (6) from negative (-) terminal (7) on battery (8).
2-36
TM 5-3895-382-24
NOTE
(6) Slide cable cover (13) back and away from positive (+) terminal (14).
(7) Remove cap (15) from NATO receptacle (16).
(8) Remove two screws (17), lock washers (18), and two cables (19) from NATO receptacle (16).
washers.
Discard lock
(9) Remove four locknuts (20), washers (21), screws (22), and one rope clamp (23) and NATO receptacle (16) from
frame assembly (12). Discard locknuts.
b. Installation.
(1) Install NATO receptacle (16) (+ side up) and rope clamp (23) on frame assembly (12) with four screws (22),
washers (21) and locknuts (20).
(2) Install two cables (19) on NATO receptacle (16) with two lock washers (18) and screws (17).
(3) Install cap (15) on NATO receptacle (16).
2-37
TM 5-3895-382-24
2-11.
NATO RECEPTACLE REPLACEMENT (CONT)
(4) Install panel (11) on frame assembly (12) with five screws (9) and washers (10).
(6) Install cable (6) on negative (-) terminal (7) of battery (8) and tighten nut (5).
(7) Raise and close grill (3).
(8) Turn and push latch assembly (2) to lock grill in place.
NOTE
END OF TASK
2-38
TM 5-3895-382-24
2-12. NATO RECEPTACLE CABLES REPLACEMENT
This Task Covers:
a. Removal
b. Installation
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Materials/Parts
carton, NSN 8135-00-178-9200
Equipment Condition
Engine OFF (TM 5-3895-379-10)
WARNING
Battery acid (Electrolyte) is extremely harmful. Always wear safety goggles

and rubber gloves, and do not smoke when performing maintenance on
batteries. Injury will result if acid contacts skin or eyes. Wear rubber apron to
prevent clothing being damaged.
Turn battery disconnect switch off prior to performing maintenance in

immediate battery area or working on electrical system. Such disconnections
prevent electrical shock to personnel or equipment.
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 the machine. Allowing
cable ends to contact each other or machine can result in damage to battery or
electrical system.
2-39
TM 5-3895-382-24
2-12.
NATO RECEPTACLE CABLES REPLACEMENT (CONT)
a. Removal.
(1) Turn battery disconnect switch (1) to OFF position.

(2) Turn and pull latch assembly (2) and lower grill (3).
NOTE
(4) Loosen nut (5) and remove cable (6) from negative (-) terminal (7) on battery (8).
2-40
TM 5-3895-382-24
NOTE
Tag and mark all wires prior to
removal.
(6) Slide cable cover (13) back and away from
positive (+) terminal (14).
(7) Remove two screws (15), lock washers (16),
and two cables (17) and (18) from NATO
receptacle (19). Discard lock washers.
(8) Remove screw (20), plate (21), two clamp
halves (22), and plate (23) from two cables (17)
and (18) and clip (24).
(9) If damaged, remove clip (24) from hose (25).
(10) Open left side door assembly.
(11) Slide cable cover (26) back and away from
positive (+) terminal (27).
NOTE
Depending upon installation, other
cables may need to be removed from
starter.
(12) Remove nut (28) and positive cable (17) from
starter assembly (29).
(13) From under roller, remove nut (30), lock washer
(31) and negative cable (18) from battery
disconnect switch (1).
(14) Remove screw (32), plate (33), two clamp
halves (34), and two cables (17) and (18) from
plate (35).
(15) Remove cables (17) and (18) from roller.
2-41
TM 5-3895-382-24
b. Installation.
NOTE
Boot end of cable goes to NATO
receptacle.
(1) From under roller, feed positive cable (17) up to
starter assembly (29), going over solenoid.
(2) From beside roller, install positive cable (17) on
starter assembly (29) with nut (30). Tighten nut.
(3) Slide cable cover (26) over positive (+) terminal
(27).
(4) From under roller, install negative cable (18) on
battery disconnect switch (1) with lock washer
(31) and nut (30).
(5) Feed cables (17) and (18) to NATO receptacle
(19).
(6) From beside roller, install two cables (17) and

(18) on NATO receptacle (19) with two lock
washers (16) and screws (15).
(7) Slide cable cover (13) over positive (+) terminal
(14).
(8) If removed, install clip (24) on hose (25).
(9) Install screw (20), plate (21), two clamp halves
(22), and plate (23) on clip (24) and two cables
(17) and (18).
(10) From under roller, install two cables (17) and
(18) on plate (35) with two clamp halves (34),
plate (33), and screw (32).
(11) Close left side door assembly.
2-42
TM 5-3895-382-24
(12) Install panel (11) on frame assembly (12) with five screws (9) and washers (1).
(14) Install cable (6) on negative (-) terminal (7) of battery (8) and tighten nut (5).
(15) Raise and close grill (3).
(16) Turn and push latch assembly (2) to lock grill in place.
NOTE
END OF TASK
2-43
TM 5-3895-382-24
2-13. MANUAL BRAKE RELEASE HAND PUMP REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364
Container (1 qt [0.9 1] minimum capacity)
Materials/Parts
Seals (2)
Seals (2)
Tags, Identification (MIL-S-29190)
1,000 per carton, NSN 8135-00-178-9200
Equipment Condition
Engine OFF (TM 5-3895-379-10)
Hydraulic tank drained
Right door assembly opened
2-44
TM 5-3895-382-24
a. Removal.
WARNING
Hydraulic oil is very slippery and can
(1) Place a container with 1 qt (0.91) minimum
capacity under hand pump (1).
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.
(2) Remove hose assembly (2) and seal (3) from
elbow (4). Discard seal.
elbow (6). Discard seal.
(4) Remove two nuts (7), washers (8), bolts (9), and
hand pump (1) from bracket (10).
(5) Loosen nut (11) and remove elbow (4) from

hand pump (1).
(6) Remove seal (12) from elbow (4). Discard seal.
(7) Loosen nut (13) and remove elbow (6) from
hand pump (1).
(8) Remove seal (12) from elbow (6). Discard seal.
2-45
TM 5-3895-382-24
b. Installation.
(1) Install seal (12) on elbow (6).
(2) Install seal (3) in elbow (6).
(3) Install seal (12) on elbow (4).
(4) Install seal (3) in elbow (4).
(5) Install elbow (4) and elbow (6) in hand pump (1).
(6) Position elbows (4) and (6) in original direction.
(7) Tighten nuts (11) and (13).
(8) Install hand pump (1) on bracket (10) with two
washers (8), bolts (9), and nuts (7). Tighten
nuts to 7-11 lb-ft (9-15 Nm).
(9) Install hose assembly (2) on elbow (4).
(10) Install hose assembly (5) on elbow (6).
NOTE
Close right door assembly.
Remove chocks.
END OF TASK
2-46
TM 5-3895-382-24
2-14. MANUAL BRAKE RELEASE NEEDLE VALVE REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364
Materials/Parts
Seals (2)
Seals (2)
carton, NSN 8135-00-178-9200
Equipment Condition
Engine OFF (TM 5-3895-379-10)
Hydraulic tank drained
a. Removal
(1) Remove nut (1), washer (2), screw (3), and washer (2) from frame (4).
(2) Remove five screws (5), washers (6), and panel (7) from frame (4).
WARNING
Hydraulic oil is very slippery and can cause falls. To avoid injury, wipe up spilled
oil with rags.
(3) Place a container with 1 qt (0.91) minimum capacity under needle valve (8).
2-47
TM 5-3895-382-24
NOTE
Tag and mark all hoses prior to
removal.
Cap all hoses after removal.
Inspect all hoses, lines, and fittings
for cracks, bends, nicks, dents,
stripped
threads,
and
cuts.
Replace all damaged parts.

tee (11). Discard seal.
tee (11). Discard seal.
adapter (15). Discard seal.
(7) Remove locknut (16) and adapter (15) from
bracket (17). Discard locknut.
(8) Remove adapter (15) and seal (10) from

connector (18). Discard seal.
(9) Remove connector (18) and seal (10) from
needle valve (8). Discard seal.
(10) Loosen nut (19) and remove tee (11) and seal
(10) from needle valve (8). Discard seal.
2-48
TM 5-3895-382-24
b. Installation.
(1) Install three seals (10) on tee (11).
(2) Install tee (11) in needle valve (8).
(3) Position tee (11) in original position and tighten
nut (19).
(4) Install two seals (10) on connector (18).
(5) Install connector (18) in needle valve (8).
(6) Install seal (14) in adapter (15).
(7) Install adapter (15) on connector (18).
(8) Install adapter (15) in bracket (17) with locknut
(16).
(9) Install hose assembly (13).
(10) Install hose assemblies (9) and (12) on tee (11).
(11) Install panel (7) on frame (4) with five screws (5)
and washers (6). Snug, but do not tighten
screws.
(12) Install screw (3), two washers (2), and nut (1) in
panel (7) and frame (4).
(13) Tighten five screws (5) and nut (1).
NOTE
Start engine and check for leaks.
Close right door assembly.
Remove chocks.
END OF TASK
2-49
TM 5-3895-382-24
2-15. PAD-FOOT SHELL INSTALLATION/REMOVAL

This Task Covers:
a. Installation
b. Removal
INITIAL SETUP
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Shop Equipment, Automotive Maintenance
and Repair: OM Common No. 1, Less Power
(SC 4910-95-A74), NSN 4910-00-754-0654,
Tool No. W32593
Lifting Device (1,000 lbs [454 kg] capacity)
NSN 5120-01-113-9564, (Included in
W32593)
Equipment Condition
Roller on level surface
Hole in drum at 12:00 position
Engine OFF
Personnel Required
Four
Materials/Parts
Locknuts (8)
a. Installation.
(1)
Remove twenty-four bolts (1), washers (2), twelve scrapers (3), four scraper plates (4), and two scraper
plates (5) from bumper assembly (6).
(2)
Remove two screws (7) and washers (8) and install four scraper plates (4) and two scraper plates (5)
on mounting posts (9).
(3)
Install two screws (7) and washers (8) in bumper assembly (6) to hold plates (4 and 5) in place.
Change 1
2-50
TM 5-3895-382-24
WARNING
Each half of pad-foot shell weighs
1,000 lbs (454 kg). Keep clear of
being raised or lowered. Equipment
may fall and cause serious injury or
death to personnel.
device.
personnel and cause injury or
death.
personnel.
(4) Attach lifting device with minimum 1,000 lbs
(454 kg) capacity to lifting eyes of pad-foot shell
half (10).
(5) Position pad-foot shell half (10) on top of drum
assembly (11).
(6) Align slot in pad-foot shell half (10) with hole in
drum assembly (11).
(7) Align edges of shell half (10) flush with edges of
drum assembly (11).
(8) Install four washers (12), two bolts (13) and
locknuts (14) in pad-foot shell half (10) and drum
assembly (11). Snug, but do not tighten nuts.
(9) Remove lifting device.
2-51
TM 5-3895-382-24
(10) Start engine (TM 5-3895-382-10).

(11) Raise leveling blade (M 5-3895-382-10).
CAUTION
Keep debris from getting between
drum surface and mating surface of
pad-foot shell half Debris caught
between surface will not allow proper
seating of shell to drum.
Poor
equipment performance and damage
to equipment could result.
(12) Drive Roller forward until pad-foot shell half (10)
is beneath drum assembly (11) with bolt anchor
points (15) at 3:00 and 9:00 positions.
(13) Lower leveling blade (TM 5-3895-382-10).
(14) Set parking brake (TM 5-3895-382-10).
half (16).
(17) Position pad-foot shell half (16) on top of drum
assembly (11) and pad-foot shell half (10).
(18) Align edges of shell half (16) flush with edges of
drum assembly (11).
(19) Align mounting holes of pad-foot shell halves (10
and 16) and remove lifting device.
2-52
TM 5-3895-382-24
(20) Install twelve washers (17), six bolts (18) and nuts (19) in mounting holes of pad-foot shell
halves (10 and 16). Tighten nuts to maintain uniform gaps between shell halves along both joints.
(21) Tighten two locknuts (14) to 340 lb-ft (460 Nm).
(22) Tighten six nuts (19) to 340 lb-ft (460 Nm).
(23) Start engine and raise levelling blade (TM 5-3895-382-10).
(24) Drive Roller slowly for 1 minute.
(25) Lower leveling blade, apply parking brake and shut engine off (TM 5-3895-382-10).
(26) Tighten six nuts (19) and two locknuts (14) to 340 lb-ft (460 Nm).
NOTE
Typically, two to four repetitions are required to seat pad-foot shell to drum assembly.
(27) Repeat steps (23) through (26) until nuts retain tightness of 340 lb-ft (460 Nm).
NOTE
Snug, but do not tighten scraper mounting bolts until after pad-foot shell is installed and
scrapers are properly adjusted.
(28) Install twelve scrapers (3) on bumper assembly (6) with twenty-four washers (2) and bolts (1). Snug,
but do not tighten bolts.
(29) Position twelve scrapers (3) to allow 9/16 in. (15mm) clearance between scraper tip and drum surface.
2-53
Change 1
TM 5-3895-382-24
(30) Tighten bolts (1) to 340 lb-ft (460 Nm).
(31) Start engine and raise leveling blade (TM 5-3895-382-10).
(32) Drive Roller with vibratory system operating on dirt surface for 30 to 60 minutes.
(33) Lower leveling blade, apply parking brake and shut engine off (TM 5-3895-382-10).
(34) Tighten six nuts (19) and two locknuts (14) to 340 lb-ft (460 Nm).
(35) Repeat steps (23) through (26) until locknuts retain tightness of 340 lb-ft (460 Nm).
(36) Install six locknuts (20) to 100 lb-ft (136 Nm).
b. Removal.
(1)
Start engine and raise leveling blade (TM 5-3895-382-10).
(2)
Move Roller forward until joint where two pad-foot shell halves (10 and 13) meet is at 9:00 and 3:00
positions.
(3)
Lower leveling blade (TM 5-3895-382-10).
(4)
Set parking brake (TM 5-3895-382-10).
(5)
Shut engine off (TM 5-3895-382-10).
(6)
Remove twenty-four bolts (1), washers (2), and twelve scrapers (3) from bumper assembly (6).
(7)
Remove six bolts (18), locknuts (20), six nuts (19), and twelve washers (17) from mounting holes of
pad-foot shell halves (10 and 16). Discard locknuts.
Change 1
2-54
TM 5-3895-382-24
WARNING
Each half of pad-foot shell weighs
1,000 lbs (454 kg). Keep clear of
being
raised
or
lowered.
Equipment may fall and cause
serious
injury
or
death
to
personnel.
device.
personnel.
half (16).
(9) Remove pad-foot shell half (16) from drum
assembly (11) and remove lifting device.
(10) Start engine and
(TM 5-3895-382-10).
raise
leveling
blade
NOTE
Pad-foot shell half will follow drum.
(11) Drive Roller backward until pad-foot shell half
(10) is on top of drum assembly (11) and lifting
eyes are at 12: 00 position.
(12) Set parking brake (TM 5-3895-382-10).
(14) Attach lifting device with minimum 1,000 lb (454
kg) capacity to lifting eyes of pad-foot shell half
(10).
(15) Remove two locknuts (14), four washers (12),
and bolts (13) from drum assembly (11) and
pad-foot shell half (10). Discard locknuts.
(16) Using lifting device, remove pad-foot shell half
(10) from drum assembly (11).
(17) Remove lifting device.
2-55
TM 5-3895-382-24
(18) Remove two screws (7) and washers (8) from bumper assembly (6).
(19) Remove four scraper plates (4) and two scraper plates (5) from mounting posts (9).
(20) Install two screws (7) and washers (8) in bumper assembly (6).
NOTE
Center plates should be installed before outer plates to allow correct positioning of
all plates.
(21) Install four scraper plates (4), two scraper plates (5), and twelve scrapers (3) on bumper assembly (6) with
twenty-four bolts (1) and washers (2). Snug, but do not tighten bolts.
(22) Position four scraper plates (4) and two scraper plates (5) to allow 9/16 in. (15mm) clearance between scraper
plate tips and drum surface.
(23) Tighten bolts (1) to 340 lb-ft (460 Nm).
NOTE
END OF TASK
2-56
TM 5-3895-382-24
2-16. RIFLE MOUNTING BRACKET REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Wrench, Torque (0-170 lb-ft).
NSN 5120-00-640-6364, (Included in T13152
and W32593)
Equipment Condition
Engine OFF (TM 5-3895-379-10)
a. Removal. Remove six nuts (1), washers (2), screws (3), washers (2), and rifle mount (4) from operator platform
(5).
b. Installation. Install rifle mount (4) on operator platform (5) with six screws (3), twelve washers (2), and six nuts
(1). Tighten nuts to 9 lb-ft (12 Nm).
NOTE
END OF TASK
2-57
TM 5-3895-382-24
2-17. SEAT ASSEMBLY REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

Tool Kit, General Mechanic's: Automotive,
(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364,
(Included in T13152 and W32593)
Equipment Condition
Engine OFF (TM 5-3895-382-10)
Materials/Parts
Locknuts (4)
a. Removal. Remove four locknuts (1), and seat assembly (2) from seat suspension assembly (3). Discard locknuts.
b. Installation. Install seat assembly (2) on seat suspension assembly (3) with four locknuts (1). Tighten locknuts to 15
to 25 lb-ft (20 -34 Nm).
NOTE
END OF TASK
2-58
TM 5-3895-382-24
2-18. SEAT SUSPENSION REPAIR

This Task Covers:
a. Disassembly
INITIAL SETUP
b. Assembly

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
Screwdriver Attachment, Socket Head
Tool Number 1U8011 (11083).
NSN 5120-01-367-3539
Materials/Parts
Compound, Retaining: Loctite 496
Grease (GAA)
Locknuts (12)
Locknuts (4)
Locknut
Locknuts (2)
Personnel Required
Two
Equipment Condition
Seat suspension assembly removed
Several components are under spring tension.
Use care when repairing seat suspension
assembly.
a. Disassembly.
(1) Lift up on height adjustment lever (1) to release spring tension.

(2) Turn knob (2) to left to release spring tension.
(3) Remove spring pin (3) and knob (2) from bevel gear (4).
2-59
TM 5-3895-382-24
(4) Remove four bolts (5) and channel (6) from left
angle assembly (7) and right angle assembly
(8).
(5) Remove four locknuts (9), washers (10), left
angle assembly (7), and right angle assembly
(8) from two links (11). Discard locknuts.
(6) Remove two locknuts (12), washers (13), and link (14) on left side of seat suspension assembly (15) from two
links (11). Discard locknuts.
(7) Remove two locknut (12) and washers (13) on right side of seat suspension assembly (15) from two links (11).
Discard locknuts.
WARNING
Use care when removing link. Height adjustment lever is under spring tension and
could cause injury to fingers or hand.
(8) While assistant lifts up on height adjustment lever (1), remove link (14) on right side of seat suspension assembly
(15) from two links (11).
2-60
TM 5-3895-382-24
(9) Pry ends of two torsion springs (16) on right side

of seat suspension assembly (15) from two links
(11).
(10) Using a socket wrench screwdriver attachment,
remove four bolts (17), two links (11) and two
torsion springs (16).
(11) Drive spring pin (18) from latch assembly (19).

(12) Remove height adjustment lever (1), latch assembly (19), and spring (20) from upper housing assembly (21).
(13) Remove cap (22) from height adjustment lever (1).
(14) Remove twenty-four fasteners (23), plate (24), and boot (25) from seat suspension assembly (15).
2-61
TM 5-3895-382-24
WARNING
Use care when removing shaft. Upper housing assembly is under spring tension
and could cause injury to personnel.
(15) While assistant compresses seat suspension assembly (15), remove drive shaft (26) from push-on nut (27) and
upper housing assembly (21). Discard push-on nut.
(16) Drive shaft (26) from push-on nut (27) and lower housing assembly (28). Discard retainer.
(17) Remove gear assembly (29) and flat washer (30) from upper housing assembly (21).
(18) Remove bevel gear (31) from angle bracket (32)
and upper housing assembly (21).
(19) Remove two locknuts (33), square neck bolts
(34), and angle bracket (32) from upper housing
assembly (21). Discard locknuts.
2-62
TM 5-3895-382-24
(20) Remove upper housing assembly (21) from arm

(35).
(21) Remove spring (36) from lower housing
assembly (28) by turning spring to right until
spring clears tabs.
(22) Remove arm (35) from lower housing assembly
(28) while sliding indicator (37) from spring pin
(38).
(23) Remove four locknuts (39), bolts (40), left hand
angle (41), and right hand angle (42) from lower
housing assembly (28). Discard locknuts.
2-63
TM 5-3895-382-24
(24) Remove four roller guides (43) from arm (35).

NOTE
Note position of spacers prior to
removal.
(25) Remove spacer (44), spacer (45), and spacer
(46) from arm (35).
(26) Remove four sleeve bearings (47) from arm
(35).
(27) Remove indicator (37) from arm (35).
(28) Remove two roller pads (48) from upper housing

assembly (21).
(29) Remove two bumper assemblies (49) from
upper housing assembly (21).
(30) Remove locknut (50), bolt (51), and shock

absorber (52) from lower housing assembly (28).
Discard locknut.
(31) Remove two sleeve bearings (53) from shock
absorber (52).
(32) Remove two roller pads (54) from lower housing
assembly (28).
(33) Remove two bumper assemblies (55) from lower
housing assembly (28).
(34) Remove spring pin (38) from lower housing
assembly (28).
(35) Remove groove pin (56), spacer (57), and plate
assembly (58) from gear assembly (29).
2-64
TM 5-3895-382-24
b. Assembly
NOTE
Plate assembly should be positioned
at least halfway down threads of gear
assembly.
(1) Install plate assembly (58), spacer (57), and
groove pin (56) on gear assembly (29).
(2) Install spring pin (38) in lower housing assembly
(28) allowing pin to protrude from front of lower
housing assembly.
(3) Install two bumper assemblies (55) in lower

(4) Install two roller pads (54) in lower housing
assembly (30).
(5) Install two sleeve bearings (53) in shock

absorber (52).
(6) Install shock absorber (52) on lower housing
assembly (28) with bolt (51), and locknut (50).
Tighten locknut to 7.4 to 16.2 lb-ft (10 - 22 Nm).
(7) Install two bumper assemblies (49) in upper

(8) Install two roller pads (48) in upper housing
assembly (21).
2-65
TM 5-3895-382-24
(9) Install indicator (37) on arm (35).

(10) Install four sleeve bearings (47) on arm (35).
(11) Install spacer (46), spacer (45), and spacer (44)
on arm (35).
(12) Install bur roller guides (43) on arm (35).
(13) Slide indicator (37) into spring pin (38) while

installing arm (35) in lower housing assembly
(28).
WARNING
to skin and Clothing. To avoid injury
adhesive,
solvent,
or
sealing
compound gets on skin or Clothing,
water.
(14) Apply sealant to threads of four bolts (40).

(15) Install left hand angle (41) and right hand angle (42) on lower housing assembly (28) with four bolts (40) and
locknuts (39). Tighten nuts to 7.4 to 16.2 lb-ft (10 - 22 Nm).
(16) Install shaft (26) in lower housing assembly (28) and arm (35) with retainer (27).
(17) Install spring (36) in lower housing assembly (28) by compressing and turning spring to right until spring is
securely seated in all three tabs.
2-66
TM 5-3895-382-24
(18) Install upper housing assembly (21) on arm (35) by sliding arm and roller guides (43) in channel of upper housing
assembly.
NOTE
Ensure that arm is under shaft of bevel gear when bevel gear is installed.
(19) Install angle bracket (32) on upper housing
assembly (21) with two square neck bolts (34)
and locknuts (33). Do not tighten locknuts.
(20) Install bevel gear (31) in angle bracket (32) and
(21) Apply grease to teeth of bevel gear (31).
2-67
TM 5-3895-382-24
(22) Install flat washer (30) and gear assembly (29) on upper housing assembly (21).
WARNING
Use care when installing drive shaft. Upper housing assembly will be under spring
tension and could cause injury to personnel.
NOTE
Rod of shock absorber must be fully extended to align hole for installation of
rods.
Ensure that square shoulder of drive shaft is fully seated in square hole of upper
housing assembly before installing push-on nut.
(23) While assistant compresses seat suspension assembly (15), install drive shaft (26) in upper housing assembly
(21), arm (35), and shock absorber (52) with push-on nut (27).
(24) Install boot (25) and plate (24) on upper housing
assembly (21) and lower housing assembly (28)
with twenty-four fasteners (23).
2-68
TM 5-3895-382-24
(25) Position torsion spring (16) and one link (11) on

rear mounting bracket of upper housing
assembly (21).
(26) Install ends of torsion spring (16) in right side of
upper housing assembly (21) and link (11).
WARNING
to skin and Clothing. To avoid injury
adhesive,
solvent,
or
sealing
compound gets on skin or Clothing,
water.
(27) Apply sealant to threads of bolts (17).

(28) Install torsion spring (16) and link (11) on upper housing assembly (21) with two bolts (17), using socket wrench
screwdriver attachment.
(29) Position link (14) on link (11) on right side of seat suspension assembly (15) ensuring that hole is fully seated on
shoulder of stud.
(30) Apply sealant to threads of locknut (12).

(31) Install link (14) on link (11) with washer (13) and
locknut (12).
(32) Install cap (22) on height adjustment lever (1).
(33) Install spring (20), latch assembly (19), and
height adjustment lever (1) in upper housing
assembly (21).
(34) Install spring pin (18) in latch assembly (19) and
height adjustment lever (1).
2-69
TM 5-3895-382-24
(35) Position link (14) on link (11) on right side of
seat suspension assembly (15) ensuring that
hole is fully seated on shoulder of stud.
(36) Apply sealant to threads of locknut (12).
(37) Install link (14) on link (11) with washer (13) and
locknut (12).
(38) Position link (14) on fingers of latch assembly
(19).
(39) Position torsion spring (16) and link (11) on
(40) Install ends of torsion spring (16) in left side of
upper housing assembly (21) and link (11).
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful
vapors, and are harmful to skin and Clothing. To avoid injury or death, keep away
from open fire and use in a well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or Clothing, wash immediately with soap and water.
(41) Apply sealant to threads of bolts (17).

(42) Install torsion spring (16) and link (11) on upper
housing assembly (21) with two bolts (17), using
socket wrench screwdriver attachment.
(43) Position link (14) on links (11) on left side of seat
suspension assembly (15) ensuring that holes
are fully seated on shoulder of stud.
(44) Apply sealant to threads of locknuts (12).
(45) Install link (14) on links (11) with two washers
(13) and locknuts (12). Tighten locknuts to 7.4
to 16.2 lb-ft (10 - 22 Nm).
2-70
TM 5-3895-382-24
(46) Install left angle assembly (7), and right angle

assembly (8) on two links (11) with four washers
(10) and locknuts (9). Tighten nuts to 7.4 to
16.2 lb-ft (10 - 22 Nm).
(47) Install channel (6) from left angle assembly (7)
and right angle assembly (8) with four bolts (5).
Tighten bolts to 7.4 to 16.2 lb-ft (10 - 22 Nm).
(48) Install knob (2) on bevel gear (4) with spring pin
(3).
(49) Adjust angle bracket (32) so that bevel gear (4)
fits snugly against gear assembly (29) and knob
(2) feels firm.
(50) Tighten locknuts (33).
NOTE
Follow-on Maintenance: Install seat suspension assembly.
END OF TASK
2-71
TM 5-3895-382-24
2-19. STOWAGE BOX REPLACEMENT

This Task Covers:
a. Removal
INITIAL SETUP
b. Installation

(SC 5180-90-N26), Tool Number W33004,
NSN 5180-00-177-7033
NSN 5120-00-640-6364,
(Included in T13152 and W32593)
Equipment Condition
Engine OFF (TM 5-3895-382-10)
a. Removal
(1) Open lid (1) of stowage box (2).
(2) Remove four nuts (3), washers (4), bolts (5), washers (4), and stowage box (2) from two plates (6).
(3) Remove four bolts (7), washers (8), and two plates (6) from frame (9).
b. Installation.
(1) Install two plates (6) on frame (9) with four washers (8) and bolts (7). Tighten nuts to 40 lb-ft (55 Nm).
(2) Install stowage box (2) on two plates (6) with four bolts (4), eight washers (5), and four nuts (3). Tighten nuts to
40 lb-ft (55 Nm).
(3) Close lid (1) of stowage box (2).
NOTE
END OF TASK
2-72
TM 5-3895-382-24
SENR7733-07
CHAPTER 3
Important Safety Information
Do not wear loose clothing or jewelry that can catch on parts of
the product.
Improper operation, lubrication, maintenance or repair of
this product can be dangerous and could result in injury
or death.
Pressurized Items
1.
Relieve all pressure in air, oil or water systems before

any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are
blocked correctly and be alert for possible pressure
when disconnecting any device from a system that
utilizes pressure.
2.
Lower the bucket, blade, ripper or other attachments to

the ground before performing any work on the machine.
If this cannot be done, make sure the bucket, blade,
ripper or other attachment is blocked correctly to
prevent it from dropping unexpectedly.
3.
Loose or damaged fuel, lubricant and hydraulic lines,

tubes and hoses can cause fires. Do not bend or strike
high pressure lines or install ones which have been bent
or damaged. Check lines, tubes and hoses carefully.
Do not use your bare hand to check for leaks. Pin hole
leaks can result in a high velocity fluid stream that will
be invisible close to the hose, tube or line. This fluid
can penetrate the skin and cause personal injury. Use a
board or cardboard to check for leaks.
Do not operate or perform any lubrication, maintenance or

repair on this product, until you have read and understood
the operation, lubrication, maintenance and repair
information.
Safety precautions and warnings are provided in this manual
and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and
followed by a "Signal Word" such as "WARNING" as shown
below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is involved.
The person servicing the product may be unfamiliar with many
of the systems on the product. This makes it important to use
caution when performing service work. A knowledge of the
system and/or components is important before the removal or
disassembly of any component.
Mounting and Dismounting

Use steps and handholds when mounting or dismounting a
machine. Clean any mud or debris from steps, walkways or
work platforms before using. Always face machine when using
steps, handholds and walkways. When it is not possible to use
the designed access system, provide ladders, scaffolds, or
work platforms to perform safe repair operations.
Because of the size of some of the product components, the

service person should check the weights noted in this manual.
Use proper lifting procedures when removing any components.
Hot Fluids and Parts
Following is a list of basic precautions that should always be

observed.
1.
To avoid burns, be alert for hot pans on machines which

have just been stopped and hot fluids in lines, tubes and
compartments.
2.
Be careful when removing fill caps, breathers and plugs

on the machine. Hold a rag over the cap or plug to
prevent being sprayed or splashed by liquids under
pressure. The danger is even greater if the machine
has just been stopped because fluids can be hot.
Safety Signs
Read and understand all Warning signs on the product before
operating, lubricating or repairing this product. Replace any
damaged, illegible or missing warning plates, signs or decals.
Protective Equipment
Always wear a hard hat, protective glasses, protective shoes
and other protective equipment as required by job conditions
when working around this product.
In particular, wear
protective glasses when pounding on any part of the product or
its attachments with a hammer or sledge. Use welder's gloves,
hood/goggles, apron and other protective clothing appropriate
to the welding job being performed.
Lifting
Use a hoist when lifting components which weigh 23 kg (50 lb)
or more, to avoid back injury. Make sure all chains, hooks,
slings, etc., are in good condition and are in the correct
capacity. Be sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting operation.
3-1
TM 5-3895-382-24
against other parts during operation. Shields that
protect against oil spray onto hot exhaust components
in the event of a line, tube or seal failure must be
installed correctly.
Repair
1.
Disconnect battery and discharge any capacitors before

starting to work on the product. Attach a "Do Not
Operate" tag in the Operators Compartment.
2.
If possible, make all repairs with the machine parked on

a level, hard Surface. Block machine to prevent it from
rolling while working on or under machine.
3.
Do not work on any machine that is supported only by

lift jacks or a hoist. Always use blocks or jack stands to
support the machine before performing any service or
disassembly.
4.
Be careful when removing cover plates. Gradually back

off the last two bolts or nuts located at opposite ends of
the cover or device. Then, pry the cover lose to relieve
any spring or other pressure, before removing the last
two bolts or nuts completely.
5.
Always use tools that are in good condition and be sure

you understand how to use them before performing any
service work.
6.
Replace all fasteners with same part number. Do not

use a lesser quality fastener if replacements are
necessary.
12.
Do not operate a machine if any rotating part is

damaged or contacts any other part during operation.
Any high speed rotating component that has been
damaged or altered should be checked for balance
before reusing. Make sure all protective devices
including guards and shields are properly installed and
functioning correctly, before starting the engine or
operating the machine.
13.
On track-type machines, be careful when servicing or

separating tracks. Chips can fly when removing or
installing a track pin. Wear protective glasses. Track
can unroll very quickly when separated. Keep away
from front and rear of machine. The machine can move
unexpectedly when both tracks are disengaged from the
sprockets. Block the machine to prevent it from moving.
Chips can fly also from bucket or ripper teeth or
anywhere a pin is being removed or installed.
Asbestos Information
7.
8.
9.
Caution should be used to avoid breathing dust that may be

generated when handling components containing asbestos
fibers. If this dust is inhaled, it can be hazardous to your
health. Components in Caterpillar products that may contain
asbestos fibers are brake pads, brake band and lining
assemblies, clutch plates and some gaskets. The asbestos
used in these components is usually bound in a resin or sealed
in some way. Normal handling is not hazardous as long as
airborne dust which contains asbestos is not generated.
Repairs which require welding should be performed only

with the benefit of the appropriate reference information
and
by
personnel
adequately
trained
and
knowledgeable in welding procedures. Make reference
to "Techniques of Structural Repair Course",
SEGV2549. Determine type of metal being welded and
select correct welding procedure and electrodes, rods or
wire to provide a weld metal strength equivalent at least
to that of parent metal.
If dust which can contain asbestos is present, there are several

common sense guidelines that should be followed:
Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it be
damaged in operation by contacting sharp corners, or
by rubbing against some object or hot surface. Do not
connect wiring to a line containing fluid.
Be sure all protective devices including guards and
shields are properly installed and functioning correctly
before starting a repair. If a guard or shield must be
removed to perform the repair work, use extra caution.
Repair any lose or damaged fluid lines, tubes or hoses
because leaks can cause fires.
10.
Always use lift arm supports to keep lift arms raised.

Keep the attachment tilted down when maintenance or
repair work is performed which requires the lift arms in
the raised position.
11.
Tighten connections to the correct torque. Make sure

that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing
3-2
1.
Never use compressed air for cleaning.
2.
Avoid brushing or grinding of asbestos containing

materials.
3.
For clean up, use wet methods or a vacuum equipped

with a high efficiency particulate air (HEPA) filter.
4.
Use exhaust ventilation on permanent machining jobs.
5.
Wear an approved respirator if there is no other way to

control the dust.
6.
Comply with applicable rules and regulations for the

work place (for example in the U.S.A., OSHA
requirements as set forth in 29 CFR 1910.1001).
7.
Follow environmental rules and regulations for disposal

of asbestos.
8.
Avoid areas where asbestos particles may be in the air.
TM 5-3895-382-24
SENR3130-06
September 1997
CHAPTER 4
Specifications
4-1
TM 5-3895-382-24
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury
or death could occur to you or other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as shown below.

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating technique that is
not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should
also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair
procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written.
The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service given to the product. Obtain the complete and most current information before starting any job.
Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see
the Service Manual Contents Microfiche, REG1139F.
4-2
TM 5-3895-382-24
Table of Contents
Specifications Section
General Torque Information ........................................................4-4
Standard Torque for Metric Fasteners .......................................4-4
Standard Torque for Inch Fasteners ..........................................4-4
Standard Torque for O-Ring Face Seal Fittings
and 37 Degree Flared Fittings ............................................4-5
O-Ring Face Seal Fittings ............................................................4-6
Fitting Installation ..........................................................................4-6
Torques for Flared and O-Ring Fittings.....................................4-7
Air Conditioning Fittings ...............................................................4-8
Tapered Pipe Thread Fittings ......................................................4-9
Tightening Other Fittings ..............................................................4-9
Torques for Standard Hose Clamps - Worm Drive
Band Type ........................................................................... 4-10
Torque for Constant Torque Hose Camps ............................. 4-10
Index Section
Index............................................................................................. 4-11
4-3
TM 5-3895-382-24
Table 2
Metric Taperlock Studs
General Torque Information

SMCS Code: 7553
Thread Size
Metric
Standard Torque
M6
8 3 Nm (6 2 lb-ft)
M8
17 5 Nm (13 4 lb-ft)
Mismatched or incorrect fasteners can result in damage or

malfunction, or possible injury.
M10
35 5 Nm (26 4 lb-ft)
M12
65 10 Nm (48 7 lb-ft)
Take care to avoid mixing metric dimensioned fasteners

and inch dimensioned fasteners.
M16
110 20 Nm (80 15 lb-ft)
M20
170 30 Nm (125 22 lb-ft)
Exceptions to these torques are given in the Service Manual, if

necessary.
M24
400 60 Nm (300 44 lb-ft)
M30
750 80 Nm (550 60 lb-ft)
Prior to installation of any hardware, ensure that components

are in near new condition. Bolts and threads must not be worn
or damaged. Threads must not have burrs or nicks. Hardware
must be free of rust and corrosion. Clean the hardware with a
noncorrosive cleaner. Do not lubricate the fastener threads
except for the rust preventive. The rust preventive should be
applied by the supplier of that component for purposes of
shipping and storage. Other applications for lubricating
components may also be specified in the Service Manual.
M36
1200 150 Nm (880 110 lb-ft)
Standard Torque for Inch Fasteners

SMCS Code: 7553
Table 3
Inch Nuts and Bolts
Thread Size
Inch
Standard Torque for Metric Fasteners

SMCS Code: 7553
Table 1
Metric Nuts and Bolts
Standard Torque
1/4
12 3 Nm (9 2 lb-ft)
5/16
25 6 Nm (18 4 lb-ft)
3/8
47 9 Nm (35 7 lb-ft)
7/16
70 15 Nm (50 11 lb-ft)
Thread Size
Metric
Standard Torque
1/2
105 20 Nm (75 15 lb-ft)
M6
12 3 Nm (9 2 lb-ft)
9/16
160 30 Nm (120 22 lb-ft)
M8
28 7 Nm (21 5 lb-ft)
5/8
215 40 Nm (160 30 lb-ft)
M10
55 10 Nm (41 7 lb-ft)
3/4
370 50 Nm (275 37 lb-ft)
100 20 Nm (75 15 lb-ft)
7/8
620 80 Nm (460 60 lb-ft)
160 30 Nm (120 22 lb-ft)
900 100 Nm (660 75 lb-ft)
240 40 Nm (175 30 lb-ft)
1 1/8
1300 150 Nm (960 110 lb-ft)
M20
460 60 Nm (340 44 lb-ft)
1 1/4
1800 200 Nm (1320 150 lb-ft)
M24
800 100 Nm (590 75 lb-ft)
1 3/8
2400 300 Nm (1780 220 lb-ft)
M30
1600 200 Nm (1180 150 lb-ft)
1 1/2
3100 350 Nm (2280 260 lb-ft)
M36
2700 300 Nm (2000 220 lb-ft)
M12
M14
M16
4-4
TM 5-3895-382-24
Table 4
Table 5
Inch Taperlock Studs
Ferrous Straight Thread O-Ring Fitting Torques for

Mating with Ferrous Materials
Thread Size
Inch
Standard Torque
1/4
8 3 Nm (6 2 lb-ft)
5/16
17 5 Nm (13 4 lb-ft)
3/8
35 5 Nm (26 4 lb-ft)
7/16
45 10 Nm (33 7 lb-ft)
1/2
65 10 Nm (48 7 lb-ft)
5/8
110 20 Nm (80 15 lb-ft)
3/4
170 30 Nm (125 22 lb-ft)
7/8
260 40 Nm (190 30 lb-ft)
400 60 Nm (300 44 lb-ft)
1 1/8
525 60 Nm (390 44 lb-ft)
1 1/4
750 80 Nm (550 60 lb-ft)
1 3/8
950 125 Nm (700 90 lb-ft)
1 1/2
1200 150 Nm (880 110 lb-ft)
Standard Torque for O-Ring Face Seal Fittings and

37 Degree Flared Fittings
SMCS Code: 7553
Outer Diameter
of the
Nominal Tube
Thread Size
Inch
Standard
Torque
3.18 mm
(.125 inch)
5/16 - 24
5.0 1.5 Nm
(4 1 lb-ft)
4.76 mm
(.188 inch)
3/8 - 24
12 2 Nm
(9 1 lb-ft)
6.35 mm
(.250 inch)
7/16 - 20
22 2 Nm
(16 1 lb-ft)
7.94 mm
(.312 inch)
1/2 - 20
30 3 Nm
(22 2 lb-ft)
9.52 mm
(.375 inch)
9/16 - 18
48 5 Nm
(35 4 lb-ft)
12.70 mm
(.500 inch)
3/4 - 16
82 8 Nm
(60 6 lb-ft)
15.88 mm
(.625 inch)
7/8 - 14
143 15 Nm
(105 11 lb-ft)
19.05 mm
(.750 inch)
1 1/16 - 12
190 20 Nm
(140 15 lb-ft)
22.22 mm
(.875 inch)
1 3/16 - 12
250 25 Nm
(185 18 lb-ft)
25.40 mm
(1.000 inch)
1 5/16 - 12
300 30 Nm
(220 22 lb-ft)
31.75 mm
(1.250 inch)
1 5/8 - 12
350 30 Nm
(260 22 lb-ft)
38.10 mm
(1.500 inch)
1 7/8 - 12
430 40 Nm
(320 30 lb-ft)
50.80 mm
(2.000 inch)
2 1/2 - 12
450 45 Nm
(330 33 lb-ft)
NOTE: Use 50 percent of the torque

values from Table 5 when the
fitting, the plug or the port
material is nonferrous.
Illustration 1
(A) O-ring face seal. (B) 37 degree flare. (C) O-ring plug with a
hexagon head. (1) O-ring seal. (2) Hexagon head.
4-5
TM 5-3895-382-24
proper function of the machine.
The sealing surfaces of the tube
assembly or hose assembly
should be secured squarely. The
sealing surfaces of the tube
assembly or hose assembly
should be tightened to the
serviced
component
(control
valve, cylinder, hydraulic motor,
etc). Perform this procedure prior
to the final tightening of any
clamps or clips that are used in
order to fasten the tube assembly
or the hose assembly to the
machine.
O-Ring Face Seal Fittings

SMCS Code: 7553
Installation of the Hydraulic Line

1.
For a metal tube to hose installation, install the tube and

tighten all bolts finger tight at the rigid end.
2.
Install the hose and tighten all bolts finger tight.
3.
Put the hose in a position so that the hose does not

make contact with the machine or with another hose.
4.
Tighten the bolts on both connections to the specified

torque.
Illustration 2
O-ring face seal fittings.
(1) O-ring face seal fitting. (2) O-ring groove. (3) Nut for the O-ring
face seal. (4) O-ring seal. (5) Straight thread O-ring fitting.
Table 6
Ferrous Straight Thread O-Ring Fitting
Thread Size
Inch
Standard Torque
5.
Start the engine.
9/16 - 18
25 3 Nm (18 2 lb-ft)
6.
Move the implement control levers to all of the positions.
11/16 - 16
37 4 Nm (27 3 lb-ft)
7.
13/16 - 16
54 5 Nm (40 4 lb-ft)
1 - 14
86 8 Nm (65 6 lb-ft)
Look at the hose during movement of the implement.

Ensure that the hose is not in contact with the machine
or other hoses. Shut off the engine.
1 13/16 - 12
125 15 Nm (90 11 lb-ft)
8.
1 7/16 - 12
165 15 Nm (120 11 lb-ft)
If necessary, put the hose in a new position so that the

hose will not make contact when the machine
implement is moved.
1 11/16 - 12
200 20 Nm (150 15 lb-ft)
2 - 12
225 20 Nm (165 15 lb-ft)
Assembly of the Fittings with Straight Threads and

O-Ring Seals
Fitting Installation
This type of fitting is used in many applications. The tube end

of the fitting will be different in design so that the fitting can be
used in many different applications. However, the same
installation procedure for the fitting can be used. If the tube
end of the fitting body and the illustration (elbow or straight
body) match, it is necessary to assemble the sleeve on the
tube before connecting the tube to the end.
SMCS Code: 7553

NOTE: The tightening sequence of the
fasteners that attach a tube
assembly or hose assembly to the
machine is very critical to the
4-6
TM 5-3895-382-24
Torques for Flared and O-Ring Fittings
SMCS Code: 7553
The torques that are shown in Table 7 and in Table 8 should
be used on the nut of the following fittings: 37 degree flared
fittings, 45 degree flared fittings, inverted flared fittings, O-ring
plugs for a recessed drive, O-ring fittings for the air
conditioning, and swivel nuts. The torques should be used for
applications that allow the following working pressures: 7750 to
34,450 kPa (1125 to 5000 psi). The torque depends on the
size of the fitting and the type of the fitting.
37 Degree Flared Fittings
Illustration 3
Elbow body assembly
Illustration 4
(1) End of the fitting body that connects to the tube. (2) Fitting body.
(3) Locknut. (4) Backup washer. (5) O-ring seal. (6) End the fitting
that goes into the other part.
1.
Put locknut (3), backup washer (4) and O-ring seal (5)
as far back on fitting body (2) as possible. Hold these
components in this position. Turn the fitting into the part
that is used for the fitting. Turn the fitting until backup
washer (4) contacts the surface of the part that is used
for backup washer (4).
2.
To put the fitting assembly in the correct position, turn

fitting body (2) outward to a maximum of 360 degrees.
Tighten locknut (3) to the torque that is shown in the
correct chart for the fitting that is used.
(1) 37 degree flared fitting. (2) Swivel nuts.
NOTE: If the fitting is a connector

(straight fitting), the hex on the
body takes the place of the
locknut. To install this type of
fitting, tighten the hex against the
face of the part for the hex.
4-7
TM 5-3895-382-24
Table 7
Table 8
Nuts for 37 Degree Flared Fittings

Outer Diameter
Thread Size
Standard
Of the
Inch
Torque
Nominal Tube
3.18 mm
5.0 1.5 Nm
5/16
(.125 inch)
(4 1 lb-ft)
4.76 mm
11 2 Nm
3/8
(.188 inch)
(8 1 lb-ft)
6.35 mm
16 4 Nm
7/16
(.250 inch)
(12 3 lb-ft)
7.94 mm
20 5 Nm
1/2
(.312 inch)
(15 4 lb-ft)
9.52 mm
25 5 Nm
9/16
(.375 inch)
18 4 lb-ft)
9.52 mm
35 5 Nm
5/8
(.375 inch)
(26 4 lb-ft)
12.70 mm
50 7 Nm
3/4
(.500 inch)
(37 5 lb-ft)
15.88 mm
65 7 Nm
7/8
(.625 inch)
(48 5 lb-ft)
19.05 mm
100 10 Nm
1 1/16
(.750 inch)
(75 7 lb-ft)
22.22 mm
120 10 Nm
1 3/16
(.875 inch)
(90 7 lb-ft)
25.40 mm
135 15 Nm
1 5/16
(1.000 inch)
(100 11 lb-ft)
31.75 mm
180 15 Nm
1 5/8
(1.250 inch)
(135 11 lb-ft)
38.10 mm
225 15 Nm
1 7/8
(1.500 inch)
(165 11 lb-ft)
50.80 mm
320 30 Nm
2 1/2
(2.000 inch)
(240 22 lb-ft)
45 Degree Flared Fittings and

45 Degree Inverted Flare Fittings
Outer Diameter
Thread Size
Standard
Of the
Inch
Torque
Nominal Tube
3.18 mm
5.0 1.5 Nm
5/16
(.125 inch)
(4 1 lb-ft)
4.76 mm
8 1.5 Nm
3/8
(.188 inch)
(6 1 lb-ft)
6.35 mm
11 2 Nm
7/16
(.250 inch)
(8 1 lb-ft)
7.94 mm
17 3 Nm
1/2
(.312 inch)
(13 2 lb-ft)
9.52 mm
30 3 Nm
5/8
(.375 inch)
(22 2 lb-ft)
11.11 mm
30 3 Nm
1 1/16
(.438 inch)
(22 2 lb-ft)
12.70 mm
38 4 Nm
3/4
(.500 inch)
(28 3 lb-ft)
15.88 mm
50 5 Nm
7/8
(.625 inch)
(37 4 lb-ft)
19.05 mm
90 8 Nm
1 1/16
(.750 inch)
(65 6 lb-ft)
22.22 mm
100 10 Nm
1 1/14
(.875 inch)
(75 7 lb-ft)
Air Conditioning Fittings

SMCS Code: 7553
NOTE: Note: Use 50 percent of the torque values from

Table 7 when the fitting, the plug or the port
material is nonferrous.
45 Degree Flared and 45 Degree Inverted Flare Fittings
Illustration 6
(1) O-ring seal. (2) 45 degree flare fitting.
Illustration 5
(1) 45 degree inverted flared fittings. (2) 45 degree flared fittings.
4-8
TM 5-3895-382-24
Tightening Other Fittings
Table 9
SMCS Code: 7553
Air Conditioning Fittings
45 Degree Flare
O-Ring Fitting End
Fitting End
Steel
Aluminum
Thread
Standard
Tubes
Tubes
Size
Torque
Standard
Standard
Inch
Torque
Torque
14 4 Nm
30 3 Nm
23 3 Nm
5/8 18
(10 3 lb-ft)
(22 2 lb-ft)
(17 2 lb-ft)
27 4 Nm
52 5 Nm
33 4 Nm
3/4 - 16
(20 3 lb-ft)
(38 4 lb-ft)
(24 4 lb-ft)
40 4 Nm
60 7 Nm
38 4 Nm
7/8 14
(30 3 lb-ft)
(44 5 lb-ft)
(28 3 lb-ft)
45 5 Nm
75 8 Nm
50 5 Nm
1 1/16 - 14
(33 4 lb-ft)
(55 6 lb-ft)
(37 4 lb-ft)
Hi Duty Tube Filings (Shear Sleeve)
Illustration 7
After the tube has been put through the nut and after the tube
makes contact against the tube shoulder in the fitting body,
turn the nut with a wrench until a small decrease in torque is
felt. The small decrease in torque indicates that the sleeve has
been broken off of the nut. Hold the tube in order to prevent
the tube from turning. Tighten the nut for an additional 1 1/2
tuns.
Tapered Pipe Thread Fittings

SMCS Code: 7553
Table 10
Hi Seal Fittings
Tapered Pipe for Thread Fittings

Thread Size
Of the Pipe
Inch
1/16 27
1/8 27
1/4 - 18
3/8 18
1/2 - 14
3/4 - 14
1 11 1/2
1 1/4 11 1/2
1 1/2 11 1/2
2 11 1/2
Standard Torque
Threads with
5P 3413
Pipe Sealant
10 Nm (7 lb-ft)
16 Nm (12 lb-ft)
20 Nm (15 lb-ft)
35 Nm (26 lb-ft)
45 Nm (33 lb-ft)
60 Nm (44 lb-ft)
75 Nm (55 lb-ft)
90 Nm (65 lb-ft)
110 Nm (80 lb-ft)
130 Nm (95 lb-ft)
Threads without
Pipe Sealant
10 Nm (7 lb-ft)
16 Nm (12 lb-ft)
25 Nm (18 lb-ft)
45 Nm (33 lb-ft)
60 Nm (44 lb-ft)
75 Nm (55 lb-ft)
90 Nm (65 lb-ft)
110 Nm (80 lb-ft)
130 Nm (95 lb-ft)
160 Nm (120 lb-ft)
Illustration 8
Put the nut and the sleeve over the tubing so that the end of
the sleeve that is short and heavy is facing the end of the
tubing. Put the tube end against the counterbore in the body of
the fitting and tighten the nut until the nut is over the last thread
on the body. The remainder of the space is used whenever
the fitting is removed and installed again.
NOTE: Use 50 percent of the torque values from Table 10

when the fitting, the plug or the port material is
nonferrous.
Tube Fittings that are Not Flared
Illustration 9
4-9
TM 5-3895-382-24
Put the nut and the sleeve over the tube. The head of the
sleeve or the shoulder end of the sleeve should be next to the
nut. Push the tube into the counterbore of the filing body as far
as possible. Turn the nut clockwise until the sleeve holds the
tube and until the sleeve prevents the tube from moving.
Tighten the nut for an additional 1 1/4 turns. The sleeve
should be seated and the sleeve should give a locking action.
When it is necessary to assemble the tube fitting again, put the
sleeve over the tube and tighten the nut until a sudden
increase in torque is felt. Next, tighten the fitting for an
additional 1/6 to 1/3 turn in order to seat the sleeve.
Table 11
Width of Clamp
7.9 mm (.31 inch)
13.5 mm (.53 inch)
15.9 mm (.63 inch)
0.9
4.5
7.5
Width of Clamp
7.9 mm (.31 inch)
13.5 mm (.53 inch)
15.9 mm (.63 inch)
Flex Fittings
0.7
3.0
4.5
Initial Installation
Torque On New Hose
0.2 Nm (8 2 lb-in)
0.5 Nm (40 4 lb-in)
0.5 Nm (65 4 lb-in)
Reassembly or
Retightening Torque
0.2 Nm (6 2 lb-in)
0.5 Nm (27 4 lb-in)
0.5 Nm (40 4 lb-in)
Torque for Constant Torque Hose

Clamps
SMCS Code: 7553
Use a constant torque hose clamp in place of any standard
hose clamp. Ensure that the constant torque hose clamp is the
same size as the standard hose damp. Due to extreme
temperature changes, the hose will heat set. Heat setting can
cause hose clamps to loosen. Loose hose clamps can result
in leaks. There have been reports of component failures that
have been caused by hose clamps that have loosened. The
constant torque hose clamp will help prevent these failures.
Illustration 10
Put the nut and the sleeve over the tubing and push the tube
into the counterbore of the fitting body as far as possible.
Tighten the nut until the nut is against the hex part of the fitting
body.
Torques for Standard Hose

Clamps - Worm Drive Band Type
SMCS Code: 7553
Illustration 12
Use a torque wrench for proper installation of the constant

torque hose clamps. The constant torque hose clamp is
installed correctly under the following conditions:
Illustration 11
4-10
Screw tip (1) extends 6.35 mm (.250 inch)(X) beyond

the housing.
The belleville washers are collapsed nearly flat after

screw (2) is tightened to a torque of 11 1 Nm (98 9
lb-in).
TM 5-3895-382-24
Index
A
Air Conditioning Fittings ...............................................................4-8
F
Fitting Installation ..........................................................................4-6
Assembly of the Fittings with Straight Threads
and O-Ring Seals .................................................................4-6
Installation of the Hydraulic Line.........................................4-6
G
General Torque Information ........................................................4-4
I
Important Safety Information .......................................................4-2
O
O-Ring Face Seal Fittings ............................................................4-6
S
Specifications Section ..................................................................4-4
Standard Torque for Inch Fasteners ..........................................4-4
Standard Torque for Metric Fasteners .......................................4-4
Standard Torque for O-Ring Face Seal Fittings
and 37 Degree Flared Fittings ............................................4-5
T
Table of Contents..........................................................................4-3
Tapered Pipe Thread Fittings .....................................................4-9
Tightening Other Fittings ..............................................................4-9
Flex Fittings ........................................................................ 4-10
Hi Duty Tube Fittings (Shear Sleeve) ................................4-9
Hi Seal Fittings ......................................................................4-9
Tube Fittings that are Not Flared .......................................4-9
Torque for Constant Torque Hose Clamps ........................... 4-10
Torques for Flared and O-Ring Fittings ....................................4-7
37 Degree Flared Fittings ...................................................4-7
45 Degree Flared and 45 Degree Inverted
Flare Fittings ......................................................................4-8
Torques for Standard Hose Clamps - Worm Drive
Band Type ........................................................................... 4-10
4-11/(4-12 blank)
TM 5-3895-382-24
SENR5815-04
February 1999
CHAPTER 5
Specifications
3054 Engine for Caterpillar Built

Machines
7BJ1-Up (Engine)
5HK1-Up (Engine)
9RM1-Up (Engine)
NOTES:
This chapter contains specifications that may be helpful in performing maintenance found in Chapters 6, 7, 8, and 9.
Additional information may be found in:
Chapter 3, Important Safety Information
Chapter 4, Torque Specifications
Discard all locking-type fasteners (i.e. lock washers, lock nuts, locking tab washers, etc.) when removed. Replace all locking-type
fasteners with new ones.
5-1
TM 5-3895-382-24


Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on
the product are therefore not all inclusive. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the
product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
5-2
TM 5-3895-382-24
Table of Contents
Engine Design ...............................................................................................5-4
Fuel Injection Pump......................................................................................5-5
Fuel Injection Nozzles .................................................................................5-8
Fuel Transfer Pump................................................................................... 5-11
Valve Rocker Arms and Lifters ................................................................ 5-12
Valve Mechanism Cover .......................................................................... 5-12
Cylinder Head Valves ................................................................................ 5-12
Cylinder Head............................................................................................. 5-16
Turbocharger ............................................................................................. 5-20
Exhaust Manifold........................................................................................ 5-21
Muffler .......................................................................................................... 5-22
Camshaft .................................................................................................... 5-22
Engine Oil Filter Base................................................................................ 5-23
Engine Oil Relief Valve .............................................................................. 5-23
Engine Oil Pump ........................................................................................ 5-24
Engine Oil Pressure................................................................................... 5-25
Engine Oil Pan............................................................................................ 5-25
Water Temperature Regulator ................................................................ 5-25
Water Pump................................................................................................ 5-26
Cylinder Block............................................................................................. 5-27
Crankshaft . ................................................................................................. 5-29
Crankshaft Seals ....................................................................................... 5-30
Connecting Rod.......................................................................................... 5-31
Piston and Rings ....................................................................................... 5-33
Housing (Front) .......................................................................................... 5-36
Gear Group (Front) ................................................................................... 5-36
Flywheel and Flywheel Housing Runout ............................................... 5-37
Belt Tension Chart .................................................................................... 5-40
Fan Drive ..................................................................................................... 5-40
Alternator and Regulator........................................................................... 5-41
Electric Starting Motor ............................................................................... 5-42
Index Section
Index ............................................................................................................ 5-45
5-3
TM 5-3895-382-24
Valve Lash
Engine Design
SMCS Code: 1201
Inlet valve .................................................0.20 mm (.008 inch)

Exhaust valve ..........................................0.45 mm (.018 inch)
Type 1 Engines and 9RM Engines
When the crankshaft Is viewed from the front of the engine the
crankshaft rotates in the following
direction: ........................................................................... Clockwise
When the camshaft is viewed from the front of the engine the
camshaft rotates in the following
NOTE: The front end of the engine is opposite the

flywheel end. The left side and the right side
of the engine are viewed from the flywheel
end. The No. 1 cylinder is the front cylinder.
Type 2 Engines and 7BJ Engines
Illustration 1
Cylinder and valve location for Type 1 engines and 9RM engines.
(A) Exhaust valves
(B) Inlet valves
NOTE: Type 1 engines can be identified in two ways. The

first method refers to Illustration 1. When the
valve cover is removed, look at the cylinder head
valves. Type 1 engines have two exhaust valves
in a row and two inlet valves that are in a row.
The second method does not require the removal
of the valve cover. Refer to the inlet manifold and
the exhaust manifold. Type 1 engines have two
exhaust ports in a row and two inlet ports that are
in a row.
Illustration 2
Cylinder and valve location for Type 2 engines and 7BJ engines.
(A) Exhaust valves
(B) Inlet valves
Type .................................................. Four cylinder and four stroke

Combustion system ................................................Direct injection
Nominal Bore .................................................100 mm (3.937 inch)
Stroke ................................................................127 mm (5.00 inch)
Capacity...................................................................4 liters (243 in 3)
Compression Ratio .....................................................................16:1
Number of cylinders ........................................................................ 4
Arrangement of cylinders .......................................................in-line
Firing Order ......................................................................... 1, 3, 4, 2

valves. Type 2 engines alternate the exhaust
valves and the inlet valves.
The second method does not require the removal
of the valve cover. Refer to the inlet manifold and
the exhaust manifold. Type 2 engines alternate
the exhaust ports and the inlet ports.
Stroke ................................................................127 mm (5.00 inch)
Capacity...................................................................4 liters (243 in 3)
5-4
TM 5-3895-382-24
Compression Ratio ..............................................................17.25:1
Number of cylinders ......................................................................... 4
Arrangement of cylinders ........................................................in-line
Firing Order .......................................................................... 1,3, 4, 2
Valve Lash
Inlet valve ..........................................0.20 mm (.008 inch)
Exhaust valve ...................................0.45 mm (.018 inch)
Fuel Injection Pump (Bosch and Stanadyne)
When the crankshaft is viewed from the front of the engine the
When the camshaft is viewed from the front of the engine the
camshaft rotates in the following
flywheel end. The left side and the right side of
the engine are viewed from the flywheel end. The
No. 1 cylinder is the front cylinder.
Fuel Injection Pump
Illustration 3
Fuel Injection Pump (Typical Example).
SMCS Code: 1251
(1)
NOTE: For a complete description of Type 1 and Type 2

engines, refer to the Specifications Module,
"Engine Design" for more information.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
5-5
Tighten the cover bolts to the following

torque: .................................................................. 4 to 5 Nm
(35 to 45 lb-in)
Terminals of the solenoid
Tighten the nut for the fuel return line
connection to the following torque:................... 5 to 6 Nm
(45 to 53 lb-in)
Tighten the locking nuts for the adjustment
screws of the high idle and the low idle to the
following torque: ..............................................4 to 4.5 Nm
(35 to 40 lb-in)
Tighten the nut for the torque screw to the
(26 to 30 lb-in)
Tighten the nut of the pivot shaft to the following
torque: ...............................................................2.3 to 3 Nm
(20 to 25 lb-in)
Tighten the flange nuts to the following
torque:.........................................................28 Nm (21 lb-ft)
Tighten the screw for the cover of the timing line
to the following torque: ................................1.5 to 2.5 Nm
(13 to 21 lb-in)
Tighten the locking nut of the adjustment screw
for the timing advance to the following
torque: ............................................................5.6 to 6.5 Nm
(50 to 60 lb-in)
Tighten the plug for the piston hole to the
following torque: ......................................24.3 to 30.0 Nm
(18 to 22 lb-ft
TM 5-3895-382-24
(11)
Tighten the head locking screw to the

following torque: ................3.0 to 3.6 Nm (27 to 35 lb-in)
(12) Tighten the discharge fitting to the following
torque: ............................. 70.5 to 81.4 Nm (52 to 60 lb-ft)
(13) Tighten the fuel line nut to the following
torque: ........................................................18 Nm (13 lb-ft)
(14) Tighten the end cap of the transfer pump to the
following torque: ...................41 to 50 Nm (30 to 37 lb-ft)
(15) Tighten the nut of the end cap for the transfer
pump to the following torque: .................18 Nm (13 lb-ft)
Tighten the nut of the drive gear (not shown) to the
following torque: ...................................................80 Nm (59 lb-ft)
Table 1
Part Number
For Fuel
Injection Pump
6I-1173
6I-1216
6I-2477
101-3876
101-4359
108-9623
110-8005
114-2472
114-4340
115-1163
119-1536
119-7294
119-7295
121-3223
123-2937
127-2230
130-1416
130-5392
130-3774
148-2950
152-3934
156-0218
Part Number
For Reman
Pump
OR-4540
OR-4541
OR-4542
OR-8297
OR-8298
-
Timing Chart For Fuel Injection Pumps

Supplier Part
Type of
Code Letters
Number
Engine
On Fuel Pump
2643U201
2643U201
2643U203
2643U204
2643U205
2643U206
2643U207
2643U212
2643U209
2643U208
2643U215
2643U213
2643U214
2644C108
2644C701
2644C702
2643U222
2643U221
2643U220
U2644F402
U2644F101
U2644C712
3054 NA
3054 T
3054 T
3054 NA
3054 T
3054 T
3054 NA
3054 T
3054 T
3054 NA
3054 NA
3054 T
3054 T
3054
3054
3054 T
3054 T
3054 T
3054 NA
3054
3054
3054
(1) NA Naturally Aspired, T Turbocharged
5-6
KM
LM
MM
SM
TM
ZM
AC
HC
TM
SM
KM
LM
MM
SC
UC
LM
KM
-
Engine Check
Angle (TC)
(Degrees)
282
282
282
282
282
282
282
282
282
282
282
283
283
n/a
n/a
294
282
283
282
n/a
n/a
n/a
Pump Mark
Angle
(Degrees)
290
292
295
291
290.5
289
291
291
290.5
291
290
295
295
n/a
n/a
340
295
295
290
n/a
n/a
n/a
TM 5-3895-382-24

Fuel Injection Pump (Lucas DP200 Series)
Illustration 5
Positions Of The Locking Spacer (Lucas DP200 Series).
Before the crankshaft is turned or the fuel injection pump is

installed, move the locking spacer (3) under the locking screw
(4). Refer to position (A) that is in Illustration 5. This position
ensures that the pump drive shaft is released.
(5)
(6)
Illustration 4
Fuel Injection Pump (Lucas DP200 Series).
(1) O-ring
(2) Hub nut
(7)
NOTE: Do not release the hub nut from the fuel injection
pump. The fuel pump hub is positioned t the
pump shaft in order to ensure that the fuel pump
is in the correct position for timing. If the hub is
removed, the hub will need to be accurately
positioned to the pump shaft.
Accurate
positioning requires the use of special equipment
by a Caterpillar Dealer.
(8)
(9)
(3)
(10)
(11)
(12)
(13)
Locking spacer
The drive shaft of the fuel injection pump must not be turned
without the spacer in position under the locking screw (4).
(4)
Tighten the locking screw to the following

torque: ........................................................... 10 Nm(7 lb-ft)
The locking screw prevents the rotation of the drive shaft.
5-7
Tighten the adjustment screw for low idle to the

(35 to 40 lb-in)
Tighten the adjustment screw for high idle to the
following toque: ................................................4 to 4.5 Nm
(35 to 40 lb-in)
Tighten the fitting for the fuel return line
connection to the following torque:................... 5 to 6 Nm
..........................................................................(44 to 53 lb-in)
Electrical connection for the stop solenoid
Tighten the fitting for the fuel supply connection
to the following torque: ............................22 Nm (16 lb-ft)
torque: ........................................................28 Nm (21 lb-ft)
Tighten the nuts for the fuel line to the
following torque: .......................................22 Nm (16 lb-ft)
Electrical connection for cold starting aid
Tighten the fittings for the fuel discharge lines
to the following torque: ...........................70.5 to 81.4 Nm
(52 to 60 lb-ft)
TM 5-3895-382-24
Fuel Injection Pump (Stanadyne)
(8) Tighten the nuts for the fuel line to the following
torque: ....................................................................22 Nm (16 lb-ft)
(9) Adjustment screw for advance timing
NOTE: The fuel injection pump must be installed after the
following function has been performed: The
engine must be set to he top center compression
position on number 1 cylinder.
Fuel Injection Nozzles

SMCS Code: 1254

Illustration 6
Fuel Injection Pump (Stanadyne).
Hub nut (not shown)
NOTE: Do not release the hub nut from the fuel injection
pump. The fuel pump hub is positioned to the
pump shaft in order to ensure that the fuel pump
is in the correct position for timing. If the hub is
removed, the hub will need to be accurately
positioned to the pump shaft.
Accurate
positioning requires the use of special equipment
by a Caterpillar Dealer.
(1)
(2)
(4)
connection to the following torque: .................. 5 to 6 Nm

(44 to 53 lb-in)
Tighten the adjustment screw for the low idle to
the following torque: ........................................4 to 4.5 Nm
(35 to 40 lb-in)
Tighten the adjustment screw for the high idle
(5)
to the following torque: ...................................4 to 4.5 Nm

(35 to 40 lb-in)
(3)
(6)
(7)
Illustration 7
injector nozzle
(1) Connection for the union nut of the supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Clamp
(4) Seal
(5) Spacer
(6) Fuel injector assembly
(7) Seat washer
Electrical connection for the stop solenoid

Tighten the fitting for the fuel return line
(1)
torque: ........................................................28 Nm (21 lb-ft)

Tighten the nut for the end cap t the following
torque: ........................................................22 Nm (16 lb-ft)
Tighten the fittings for the fuel discharge to the
(2)
Tighten the union nut of the high pressure fuel

line (not shown) to me following
torque: .....................................................18 Nm (13.3 lb-ft)
Tighten the banjo bolts of the leak off tubing
(3)
(not shown) to the following torque: .....................9.5 Nm

(84 lb-in)
Tighten the flange bolts (not shown) for the
clamp to the following torque: ..................12 Nm (9 lb-ft)
following torque:.......................................70.5 to 81.4 Nm

(52 to 60 lb-ft)
5-8
TM 5-3895-382-24
NOTE: Remove the original seat washer from the

threaded hole for the fuel injection nozzle which is
located in the cylinder head. If the original seat
washer is not removed, the projection of the
nozzle will be incorrect when a new seat washer is
installed. Do not reuse the seal (4) and the seat
washer (7).
Table 2
Service Settings For Fuel Injector Nozzle
(1)
Code
Minimum and Maximum Pressure
HU"
21500 to 22300 kPa (3118 to 3235 psi)
"HV"
24470 25300 kPa (3550 3670 psi)
"HZ
21500 to 22300 kPa 3118 to 3235 psi)
"JN
24470 25300 kPa (3550 3670 psi)
JB"
24470 25300 kPa (3550 3670 psi)
JE
21500 to 22300 kPa (3118 to 3235 psi)
JF"
24470 25300 kPa (3550 3670 psi)
"JG"
24470 23300 kPa (3260 3380 psi
"JH"
24470 25300 kPa (3550 3670 psi)
JJ"
24470 25300 kPa (3550 3670 psi)
JK
21500 to 22300 kPa (3118 to 3235 psi)
JL
24470 25300 kPa (3550 3670 psi)
JR"
24470 25300 kPa (3550 3670 psi)
"JS
24470 25300 kPa (3550 3670 psi)
JT
24470 25300 kPa (3550 3670 psi)
JU"
21500 to 22300 kPa (3118 to 3235 psi)
JY
24470 25300 kPa (3550 3670 psi)
NJ"
21500 to 22300 kPa (3118 to 3235 psi)
"NK
21970 22800 kPa (3185 3310 psi)
"NL
21970 22800 kPa (3185 3310 psi)
NM
22470 23300 kPa (3260 3380 psi)
NN
22470 23300 kPa (3260 3380 psi)
NP
21500 to 22300 kPa (3118 to 3235 psi)
NR
22470 23300 kPa (3260 3380 psi)
"NS
24470 25300 kPa (3550 3670 psi)
"NT
22470 23300 kPa (3260 3380 psi
"NU
21500 to 23000 kPa (3118 to 3235 psi)
NV
21500 to 22300 kPa (3118 to 3235 psi)
"NW
21500 to 22300 kPa (3118 to 3235 psi)
Bench test the fuel injection nozzles at a

temperature of 18 to 20 C (64 to 70 F).
NOTE: Use clean SAE J-967 oil (ISO 4113) when you are
conducting the test. The oil is available in 5
gallon containers (6V-6068 Calibration Fluid) and
55 gallon containers (6V-6067 Calibration Fluid).
If dirty oil is used for the test, the components of
the fuel injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure
Adjustment, Back Leakage Test, Nozzle and Seat
Test".
(1) The code letters are stamped on the side of the fuel injector
body. The code letters are located below the connection
for the nut of the high-pressure fuel line.
NOTE: Ensure that the new fuel injection nozzles have
the same identification code as the nozzles which
were originally installed in the cylinder head.
Leakage in 10 seconds ........................................................0 drops
5-9
TM 5-3895-382-24
(5) Seat washer


located in the cylinder head. If the original seat
washer is not removed, the projection of the
nozzle will be incorrect when a new sea washer is
installed. Do not reuse the seat washer (5).
Bench test the fuel injection nozzles at a
temperature of 18 to 20 C (64 to 70 F).
NOTE: Use dean SAE J-967 oil (ISO 4113) when you are
conducting the test. The oil is available in 5
gallon containers (6V-6068 Calibration Fluid) and
55 gallon containers (6V-6067 Calibration Fluid).
If dirty oil is used for the test, the components of
the fuel injection nozzle will be damaged.
Refer to Testing And Adjusting, "Pressure
Adjustment, Back Leakage Test, Nozzle and Seat
Test".
Illustration 8
Fuel injector nozzle.
(1) Connection r the union nut of the fuel supply line
(2) Threaded hole for the banjo bolt of the leak off line
(3) Nut of the fuel injection nozzle
(4) Wire clip
(5) Seat washer
(1)
(2)
(3)
Tighten the union nut of the high pressure fuel

line (not shown) t the following
torque: ........................................................22 Nm (16 lb-ft)
Tighten the banjo bolts of the leak off tubing
(not shown) to the following torque: .....................9.5 Nm
(84 lb-in)
Tighten the nut of the fuel injection nozzle to the
NOTE: When the fuel injection nozzle is installed, put a

2.0 mm (.08 inch) bead of 4C-5591 Anti- Seize
Compound on the first two threads of the gland
nut. Do not rotate the fuel injection nozzle after
installation. The seal which is made by the antiseize compound may break. A broken seal may
allow leakage pat the seat of the fuel injector.
(4) Wire clip
5-10
TM 5-3895-382-24
Table 3
Fuel Transfer Pump
SMCS Code: 1256
Service Settings For Fuel Injector Nozzles

Code (1)
Minimum and Maximum Pressure Settings
"KB
29570 to 30400 kPa (4290 to 4412 psi)
"KC"
28570 to 29400 kPa (4145 to 4267 psi)
KD"
28570 to 29400 kPa (4145 to 4267 psi)
"KE
29070 to 29900 kPa (4220 to 4340 psi)
"KP
29070 to 29900 kPa (4220 to 4340 psi)
KG"
29570 to 30400 kPa (4290 to 4412 psi)
"KH"
28570 to 29400 kPa (4145 to 4267 psi)
KJ"
24470 to 25300 kPa (3550 to 3672 psi
"KK"
29570 to 30400 kPa (4290 to 4412 psi)
KC
29570 to 30400 kPa (4290 to 4412 psi)
"KM
29570 to 30400 kPa (4290 to 4412 psi)
"KN"
28570 to 29400 kPa (4145 to 4267 psi)
KP"
29570 to 30400 kPa (4290 to 4412 psi)
KR
28570 to 29400 kPa (4145 to 4267 psi)
"KT"
28570 to 29400 kPa (4145 to 4267 psi)
KS" (2)
"KU
28970 to 29800 kPa (4205 to 4325 psi)
"KW
24470 to 25300 kPa (3550 to 3672 psi)
NX"
28570 to 29400 kPa (4145 to 4267 psi)
"NY
28570 to 29400 kPa (4145 to 4267 psi)
"NZ
28570 to 29400 kPa (4145 to 4267 psi)
PA" (2)
PB
28570 to 29400 kPa (4145 to 4267 psi)
"RZ
24470 to 25300 kPa (3550 to 3672 psi)
"SA"
24470 to 25300 kPa (3550 to 3672 psi)
SB"
24470 to 25300 kPa (3550 to 3672 psi)
"SC"
24470 to 25300 kPa (3550 to 3672 psi)
Illustration 9
Fuel lift pump.
Method of drive ................................................................. Camshaft

Output pressure during the first ten seconds of cranking:
Normal pressure ........................42 to 70 kPa (6 to 10 psi)
Minimum pressure .................................... 30 kPa (4.4 psi)
The engine may be equipped with four mounting bolts or four
studs with nuts. Tighten to the following
torque: ....................................................................22 Nm (16 Ib-ft)
(1) The code letters are stamped on the side of the fuel
injector body. The code leer are located below the
connection for the nut of the high-pressure fuel line.
(2) Consult your nearest Caterpillar Dealer.
Apply 4C-4030 Thread Lock Compound to the first three

threads of the mounting bolts or nuts and studs.
NOTE: Ensure that the new fuel injection nozzles have the
same identification code as the nozzles which
were originally installed in the cylinder head.
Refer to the Testing And Adjusting, "Fuel Lift Pump Pressure

Test" in order to test the operation of the fuel lift pump.
Leakage in 10 seconds .......................................................0 drops
NOTE: When the fuel lift pump is installed on the engine,

ensure that the camshaft is on minimum lobe lift
and that the bolts are evenly tightened. Failure to
follow this procedure can cause the loss of
maximum engine power and damage to the fuel It
pump.
5-11
TM 5-3895-382-24
Valve Rocker Arms and Lifters
Valve Mechanism Cover
SMCS Code: 1102; 1123; 1209
SMCS Code: 1107
Illustration 11
Valve Cover.
(1)
Tighten the screws that hold the valve cover to the

cylinder head to the following torque:
Plastic cover ............................................... 20 Nm (15 lb-ft
Aluminum cover ......................................... 30 Nm (22 lb-ft
Illustration 10
(1)
Inside diameter of rocker arm ............19.06 to 19.10 mm

(.751 to .752 inch)
Diameter of rocker arm bore for
bearing ...............................................................22.23 to 22.26 mm
(.875 to .876 inch)
Outside diameter of bearing .......................22.280 to 22.310 mm
(.8770 to .8785 inch)
Interference fit of bearing in rocker
arm ..................................................................... 020 to 0.089 mm
(.0008 to .0035 inch)
Rocker arm clearance on rocker
shaft ...................................................................... 0.03 to 0.09 mm
(.001 to .004 inch)
Maximum permissible clearance .....................................0.13 mm
(.005 inch)
(2)
Diameter of rocker shaft ......................19.01 to 19.04 mm
(.749 to .750 inch)
(3)
Install the seal in the cylinder head before the rocker
shaft is installed.
Cylinder Head Valves

SMCS Code: 1105

5-12
TM 5-3895-382-24
NOTE: When new valve guides are installed, new valves

and new valve seat inserts must be installed. The
valve guides and the valve seat inserts are
supplied as partially finished parts.
The
unfinished valve guides and unfinished valve seat
inserts are installed in the cylinder head. Then,
the guides and inserts are cut and reamed in one
operation with special tooling. This procedure
ensures the concentricity of the valve seat to the
valve guide in order to create a sea that is tight.
Refer to the Disassembly and Assembly Manual
for removal and installation procedures.
(5)
Diameter of the exhaust valve

stem ............................................................. 9.43 to 9.46 mm
(.371 to .372 inch)
Clearance of valve in valve guide ...................... 0.05 to 0.13 mm
(.002 to .005 inch)
Maximum permissible clearance of valve in valve
guide ................................................................0.15 mm (.006 inch)
Overall length of the exhaust
valve ..............................................................123.07 to 123.57 mm
(4.845 to 4.865 inch)
(6)
Diameter of the inlet valve
stem ........................................................9.460 to 9.490 mm
(.3724 to .3735 inch)
Clearance of valve in the valve
guide ...................................................................... 0.02 to 0.10 mm
(.001 to .004 inch)
guide ................................................................0.13 mm (.005 inch)
Overall length of the inlet
valve ..............................................................122.66 to 123.07 mm
(4.829 to 4.845 inch)
(7)
Exhaust valve face angle ................................. 45 degrees
Valve seat angle ................................................ 46 degrees
(8)
Diameter of the exhaust
valve ........................................................37.26 to 37.52 mm
(1.467 to 1.477 inch)
Valve depth below the cylinder head face
Minimum ...........................................................1.28 mm (.050 inch)
Maximum ..........................................................1.83 mm (.072 inch)
Service wear limit............................................2.08 mm (.082 inch)
(9)
Diameter of the inlet valve ...................44.86 to 45.11 mm
(1.766 to 1.776 inch)
Minimum ...........................................................1.27 mm (.050 inch)
Illustration 12
Inlet valves and exhaust valves.
Double valve springs:
(1)
Outer spring
Length under test force .....................35.8 mm (1.41 inch)
Test force ...................................176 to 195 N (40 to 44 lb)
(2)
Inner spring
Length under test force .....................34.0 mm (1.34 inch)
Test force ..................................... 89 to 104 N (20 to 23 lb)
Single valve springs (not shown)
Length under test force ......................40.0 mm (1.57 inch)
Test force....................................310 to 344 N (70 to 77 lb)
Free length after test ..........................53.4 mm (2.10 inch)
(3)
Valve spring recess for the vale spring
(4)
Valve guides for the inlet and exhaust valves
Inside diameter ......................................... 9.51 to 9.56 mm
(.374 to .376 inch)
Outside diameter ..............................15.900 to 15.910 mm
(.6260 to .6265 inch)
Bore diameter in cylinder head for valve
guide ......................15.87 to 15.89 mm (.625 to .626 inch)
Interference fit of valve guide in cylinder
head ..........................0.03 to 0.07 mm (.001 to .003 inch)
Overall length of valve guide
Inlet ................................................. 57.94 mm (2.281 inch)
Exhaust ..............................................61.1 mm (2.406 inch)
Projection of valve guide above valve spring
recess (3) .............................................15.1 mm (.595 inch)
5-13
TM 5-3895-382-24
Maximum ..........................................................1.60 mm (.063 inch)
Service wear limit............................................1.85 mm (.073 inch)
(10) Inlet valve face angle............................................. 45 degrees
Valve seat angle ............................................................ 46 degrees
The valve lash is the following value when the engine
is hot or cold:
Inlet valves............................................0.20 mm (.008 inch)
Exhaust valves ....................................0.45 mm (.018 inch)
Illustration 14
Angles and dimensions of the valve seat insert.
(12) Valve seat insert
(D) Included angle of the faces
(E) Dimension of chamfer
(F) Vertical angle of chamfer
Illustration 13
Recess for a valve insert.
(11)
Machine the recess in the head for valve seat inserts to

the following dimensions:
(D) Included angle of the faces of the valve seat insert

Naturally aspirated engine ................................ 88 degrees
Turbocharged engine .....................................118 degrees
Inlet
(A) ................................................................ 7.19 to 7.32 mm
...............................................................(0.283 to 0.288 inch)
(B) .......................................................51.220 to 51.240 mm
.......................................................... (2.0167 to 2.0175 inch)
(C) Maximum radius ..........................0.38 mm (.015 inch)
(E) Dimension of chamfer for all

engines ................................................1.10 0.20 mm
(.043 .008 inch)
(F) Angle of chamfer from the vertical for all
engines ........................................................ 30 degrees
Exhaust
(A) ................................................................ 9.52 to 9.65 mm

...................................................................(.375 to .380 inch)
(B) .......................................................42.620 to 42.650 mm
.......................................................... (1.6779 to 1.6790 inch)
(C) Maximum radius ...........................0.38 mm (.015 inch)

NOTE: When a new valve seat insert is installed, a new

valve and valve guide must be installed. Refer to
the Disassembly and Assembly for removal and
installation procedures.
5-14
TM 5-3895-382-24
NOTE: When new valve guides are installed, new valves

and new valve sea inserts must be installed. The
valve guides and the vale sea insets are supplied
as partially finished parts. The unfinished valve
guides and unfinished valve seat inserts are
installed in the cylinder head. Then, the guides
and insets are cut and reamed in one operation
with special tooling. This procedure ensures the
concentricity of the valve sea to the valve guide in
order to create a seal that is tight. Refer to the
Disassembly and Assembly Manual for removal
and installation procedures.
(4)
Diameter of the exhaust valve

stem ............................................................ 8.94 to 8.96 mm
(.352 to .353 inch)
Clearance of valve in valve
guide .......................................................0.040 to 0.084 mm
(.0026 to .0033 inch)
guide ................................................ 0.104 mm (.0041 inch)
Overall length of the exhaust
valve.....................................................122.65 to 123.30 mm
(4.829 to 4.854 inch)
(5)
Diameter of the inlet valve
stem .........................................................8.953 to 8.975 mm
(.3525 to .3533 inch)
Clearance of valve in the valve
guide .......................................................0.025 to 0.069 mm
(.001 to .003 inch)
guide ................................................ 0.089 mm (.0035 inch)
Overall length of the inlet
valve.....................................................122.65 to 123.30 mm
(4.829 to 4.854 inch)
(6)
Exhaust valve
Valve face angle in a turbocharged
engine ................................................................. 30 degrees
Valve seat angle in a turbocharged
engine .................................................................. 31 degrees
(7)
Exhaust valve head
diameter..................................................40.88 to 41.12 mm
(1.609 to 1.619 inch)
Illustration 15
Inlet valves and exhaust valves.
(1)
(2)
(3)
Single valve springs

Test force ...................................246 to 277 N (55 to 62 lb)
Valve spring insert for the valve spring
Valve guides
Inside diameter of finished valve
guide ........................................................... 9.00 to 9.02 mm
(.354 to .355 inch)
Outside diameter of inlet
valve ........................................................13.03 to 13.05 mm
(.513 to .514 inch)
Outside diameter of exhaust
valve.........................................................14.03 to 14.05 mm
(.552 to .553 inch)
Bore diameter in the cylinder head for the
inlet valve guide ....................................13.00 to 13.03 mm
(.512 to .513 inch)
Bore diameter in the cylinder head for the
exhaust valve guide .........................14.000 to 14.027 mm
(.5512 to .5522 inch)
Interference fit of valve guide in the cylinder
head ........................................................0.007 to 0.047 mm
(.0003 to .0019 inch)
Overall length of inlet and exhaust valve
guides ............................................... 51.25 mm (2.012 inch)
Projection of valve guide above the valve spring
recess (2)................................................14.85 to 15.15 mm
(.585 to .596 inch
Minimum ..............................................1.50 mm (.059 inch)

Maximum .............................................1.80 mm (.071 inch)
Service wear limit ...............................2.05 mm (.081 inch)
5-15
TM 5-3895-382-24
(8)
Diameter of the inlet valve ...................42.88 to 43.12 mm

...............................................................(1.688 to 1.698 inch)
Minimum ..............................................1.40 mm (.055 inch)
Maximum .............................................1.70 mm (.067 inch)
Service wear limit................................1.95 mm (.077 inch)
(9)
Inlet valve
Naturally aspirated engine
Valve face angle................................................. 45 degrees
Turbocharged engine
Valve face angle................................................. 30 degrees
(10) The valve lash is the following value when the engine is
hot or cold:
Inlet valves ...........................................0.20 mm (.008 inch)
Exhaust valves.....................................0.45 mm (.018 inch)
NOTE: When a new valve seat insert is installed, a new

valve and valve guide must be installed. Refer to
Disassembly and Assembly for removal and
installation procedures.
Illustration 17
Angles an dimensions of the valve seat insert.
(D) Included angle of the faces
(E) Dimension of chamfer
(F) Vertical angle of chamfer
(12)
Illustration 16
Recess for a valve inset
(11)
Machine the recess in the head for vale seat inserts to

the following dimensions:
Inlet
(A) ........................................................10.585 to 10.715 mm
(0.4167 to 0.4219 inch)
(B) ........................................................45.535 to 45.560 mm
(1.7927 to 1.7937 inch)
Exhaust
(A) ........................................................10.585 to 10.715 mm
(.4167 to .4219 inch)
(B) ........................................................43.535 to 43.560 mm
(1.7140 to 1.7150 inch)
Valve seat insert

(D) Included angle of the faces of the valve seat
insert
Naturally aspirated engine ....................... 88 degrees
Turbocharged engine .............................118 degrees
(E) Dimension of chamfer for all
engines ................................................1.10 0.20 mm
(.043 .008 inch)
(F) Angle of chamfer from the vertical for all
engines ........................................................ 30 degrees
Cylinder Head
SMCS Code: 1100

5-16
TM 5-3895-382-24
Illustration 18
Bolt tightening sequence for the cylinder head.
Illustration 19
Bolts, nuts, and components of the cylinder head.
Use the following procedure in order to tighten the

cylinder head bolts:
1.
(1)
Put engine oil on the threads of the bolts and the nuts.
Tighten bolts (1) through bolts (22) in a numerical
sequence in Illustration 18.
NOTE: When the fuel injection nozzle is removed, the

following items must be replaced: dust seal and
seat washer.
Toque for the bolts .................................110 Nm (81 lb-ft)

2.
Tighten bolts (1) through bolts (2) again in a numerical

sequence.
Torque for bolts ......................................110 Nm (81 lb-ft)
3.
Rotate bolts (1) through bolts (22) in a numerical

sequence to the following values:
a.
Tighten the bolts of medium length "M" to the

following value.
Rotate the bolts in a clockwise
direction: ...................................................180 degrees
c.
Tighten the bolts of long length "L" to the

following value.
direction:....................................................210 degrees
(2)
Tighten the nuts for fuel line to the following

torque:.........................................................18 Nm (13 lb-ft)
(3)
Tighten the bolts that hold the rocker shaft to the

cylinder head to the following torque:
Begin tightening the inner bolts. Then tighten the bolts
by working toward the end of the shaft.
Tighten the bolts of short length "S" to the following

value.
b.
Tighten the nuts that hold fuel injectors to the

Cast iron or steel bracket ................75 Nm (55 lb-ft)

Aluminum bracket ............................40 Nm (30 lb-ft)
(4)
Valve lash
Inlet .......................................................0.20 mm (.008 inch)
Exhaust.................................................0.45 mm (.018 inch)
(5)
Maximum permissible nozzle projection below
cylinder head face after resurfacing ....................4.45 mm
(.175 inch]
Maximum allowance for resurfacing ...............................0.30 mm
................................................................................ (.012 inch)
(6)
Depth of new cylinder head .............102.79 to 103.59 mm
(4.047 to 4.078 inch
Minimum depth of cylinder head after
resurfacing ...................................................................... 102.48 mm
(4.035 inch
5-17
TM 5-3895-382-24
Illustration 20
Positions for measuring the bow of the cylinder head (typical example)
Illustration 21
Bolt tightening sequence for the cylinder head
Maximum permissible amount of bow (curve of cylinder head)
Use the following procedure in order to tighten the cylinder

head bolts:
Naturally aspirated engines

1.
A.............................................................0.08 mm (.003 inch)
B.............................................................0.15 mm (.006 inch)
C.............................................................0.15 mm (.006 inch)
Put engine oil on the threads of bolts. Tighten bolts (1)

through bolts (22) in a numerical sequence in Illustration 21.
Torque for bolts ........................................110 Nm (81 lb-ft)
Turbocharged engines
2.
A.............................................................0.13 mm (.005 inch)

B.............................................................0.25 mm (.010 inch)
C.............................................................0.25 mm (.010 Inch)
Tighten bolts (1) through bolts (22) again in a numerical

sequence.
Torque for bolts ........................................110 Nm (81 lb-ft)
3.
Tighten the bolts of the inlet manifold (not shown) to the

following torque: ...................................................44 Nm (32 lb-ft)
Rotate bolts (1) through bolts (26) in a numerical

sequence to the following values:
a.
Tighten exhaust manifold nuts (not shown) to the following

torque:
Tighten the bolts of short length "S" to the

following value.
Plated..........................................................44 Nm (32 lb-ft)

Plain ............................................................50 Nm (37 lb-ft)
b.

Tighten the bolts of medium length "M" to the

following value.
c.
Tighten the bolts of long length "L" to the

following value.
direction .....................................................210 degrees
5-18
TM 5-3895-382-24
Illustration 23
Positions for measuring the bow of the cylinder head (typical example)
Maximum permissible amount of bow (curve of the cylinder

head)
Illustration 22
Bolts, nuts, and components of the cylinder head
NOTE: When the fuel injection nozzle is removed, the

following items must be replaced: dust seal and
seat washer.
(1)
(2)
A.............................................................0.08 mm (.003 inch)

B.............................................................0.15 mm (.006 inch)
C.............................................................0.15 mm (.006 inch)
Tighten the bolts that hold the rocker shaft to the

cylinder head to the following torques:
Tighten the bolts for the inlet manifold (not shown) to the
following torque:....................................................44 Nm (32 lb-ft)
Begin tightening the inner bolts. Then tighten the bolts

by working toward the end of the shaft.
Tighten the nuts for the exhaust manifold (not shown) to the
following torque:
Cast iron or steel bracket.........................75 Nm (55 lb-ft)

Aluminum bracket.....................................40 Nm (30 lb-ft)
Plated..........................................................44 Nm (32 lb-ft)

Plain ............................................................50 Nm (37 lb-ft)
Valve lash
Inlet........................................................0.20 mm (.008 inch)
Exhaust.................................................0.45 mm (.018 inch)
(3)
Maximum permissible nozzle projection below cylinder

head face after resurfacing....................................4.45 mm
(.175 inch)
Maximum allowance for resurfacing ...............................0.30 mm

(.012 inch)
(4)
Depth of new cylinder

head ....................................................102.79 to 103.59 mm
(4.047 to 4.078 inch)
Minimum depth of cylinder head after

resurfacing....................................................................... 102.48 mm
(4.035 inch)
5-19
TM 5-3895-382-24
(5)
Turbocharger
SMCS Code: 1052
Turbine wheel assembly

Minimum journal outside diameter .................. 10.152 mm
(.3997 inch)
Turbocharger
Ring groove diameter (minimum).................... 14.401 mm

(.5670 inch)
Ring groove width (maximum) ...........................1.740 mm
(.0685 inch)
Hub outside diameter (minimum).................... 17.323 mm
(.6820 inch)
(6)
End play for shaft

Minimum permissible end play.................................03 mm
(.001 inch)
Maximum permissible end play................................10 mm
(.004 inch)
(7)
Compressor wheel
Bore inside diameter (maximum)........................6.353 mm
(.2501 inch)
(8)
Backplate assembly
Seal inside diameter (maximum) .................... 12.713 mm
(.5005 inch)
Illustration 24
(1)
Flatness from the backplate to the mating surface of the

center
housing
is
within
the
following
value:....................................................013 mm (.0005 inch)
Put oil on the threads of the nut and put oil on the seat
face.
Tighten the impeller nut to the following
torque: ....................................2 to 2.3 Nm (18 to 20 lb-in)
(9)
Thickness (maximum)....................................... 18.339 mm

(0.7220 inch)
Tighten the nut again to the following

value: .................................................................110 degrees
Bore inside diameter (maximum)........................6.363 mm

(.2505 inch)
NOTE: Do not bend or add stress to the shaft when the

nut is tightened.
(2)
(3)
(4)
Thrust collar
Thrust bearing groove width

(maximum) ..................................... 4.440 mm (.1748 inch)
Tighten the bolts, which hold the back plate, to the

following torque: ........................................ 8.5 to 10.2 Nm
(75 to 90 lb-in)
Thrust bearing groove diameter

(minimum) ...................................... 9.398 mm (.3700 inch)
Put 5P-3931 Anti-Seize Compound on the threads.

Tighten the bolts, which hold the compressor housing to
the center section, to the following
torque: .......................................................15.3 to 18.7 Nm
(12 to 14 lb-ft)
Piston ring groove width (maximum) .................1.659 mm

(.0653 inch)
(10)
Thrust bearing
Thickness (minimum)...........................................4.359 mm
(0.1716 inch)
Put 5P-3931 Anti-Seize Compound on the threads.

Tighten the bolts, which hold the turbine housing to the
center section, to the following
torque: .......................................................18.6 to 20.4 Nm
(14 to 15 lb-ft)
Bore inside diameter (maximum)..................... 10.922 mm

(.4300 inch)
(11)
Radial play (side to side movement) for shaft

Minimum permissible radial play
(side to side movement)........................08 mm (.003 inch)
Maximum permissible radial play (side to side
movement) ............................................15 mm (.0059 inch)
5-20
TM 5-3895-382-24
(12)
Center housing
Bearing inside diameter

(maximum) ....................................15.806 mm (.6223 inch)
Seal inside diameter (maximum)..................... 17.805 mm
(.7010 inch)
Put 5P-3931 Anti-Seize Compound on the threads. Tighten
the bolts, which hold the turbocharger to the manifold (not
shown), to the following
torque: .......................................................55 5 Nm (40 4 lb-ft)
Exhaust Manifold
Illustration 27
Bolt tightening sequence for Type 2 engines and 7BJ engines
SMCS Code: 1059
Refer to Illustration 27 for the tightening sequence. Tighten the

12 nuts for the exhaust manifold gradually to the following
torque: ....................................................................33 Nm (24 lb-ft)
Illustration 26
Bolt tightening sequence for Type 1 engines and 9RM engines.
The exhaust manifold mounted to the cylinder head.

plated nuts for the exhaust manifold to the following
torque:.....................................................................44 Nm (33 lb-ft)
nuts that are not plated for the exhaust manifold to the
following torque:....................................................50 Nm (37 lb-ft)
5-21
TM 5-3895-382-24
Muffler
Maximum permissible end play of a worn
camshaft ........................................................0.53 mm (0.021 inch)
SMCS Code: 1062
(3)
(
(4)
Tighten the bolt that holds the camshaft gear on the

camshaft to the following torque: ...........................78 Nm
(58 lb-ft)
Camshaft thrust washer
Thickness of thrust washer ..................... 5.49 to 5.54 mm
(0.216 to 0.218 inch)
Cylinder block recess depth for thrust
washer ........................................................ 5.46 to 5.54 mm
(0.215 to 0.218 inch)
Relationship of thrust washer to cylinder block
front face .................................................-0.05 to +0.08 mm
(-0.002 to +0.003 inch)
Illustration 28
(1)
Tighten the nuts to the following

torque: ...........................................30 7 Nm (22 5 lb-ft)
(2)
Tighten the bolts and the nuts to the following

torque: ........................................ 55 10 Nm (41 7 lb-ft)
(5)
Diameter of camshaft journals

Table 4
Diameters of Camshaft Journals
Camshaft
Journal Number
Camshaft
Standard
Diameter
Service Limit
Diameter (1)
50.710 to 50.740
mm (1.9965 to
1.9975 inch)
50.660 mm
(1.9945 inch)
50.460 to 50.480
mm (1.9865 to
1.9875 inch)
50.410 mm
(1.9845 inch)
49.950 to 49.980
mm (1.9965 to
1.9675 inch)
49.900 mm
(1.9645 inch)
SMCS Code: 1210
(1) The service limit the maximum or the minimum dimension which s
specified for a par. A part which has reached the service limit must
be replaced.
Internal clearance of the journal ........................ 0.06 to 0.14 mm

(0.002 to 0.006 inch)
(6)
Tappet
Shank diameter ....................................18.99 to 19.01 mm
(0.748 to 0.749 inch)
Diameter of bore in block for
tappet .....................................................19.05 to 19.08 mm
(0.750 to 0.751 inch)
Running clearance between tappet and
block ........................................................... 0.04 to 0.09 mm
(0.002 to 0.004 inch)
Illustration 29
(1)
Pushrod
(2)
End play of a new camshaft ................... 0.10 to 0.41 mm

(0.004 to 0.016 inch)
5-22
TM 5-3895-382-24
Engine Oil Filter Base

SMCS Code: 1306
Illustration 31
(1)
Oil filter base
Camshaft lobe lift
(2)
Oil cooler
To determine lobe lift, use the procedure that follows:
The bypass valve in the oil filter base opens at the

following pressure: ................................55 to 83 kPa (8 to 12 psi)
Illustration 30
1.
Measure the height (B) of the camshaft lobe.
2.
Measure the base circle (C).
The bypass valve in the oil cooler opens at the

following pressure: ............................................... 172 kPa (25 psi)
3.
Subtract the base circle (C) from the height (B) of the
lobe. The difference is the actual lobe lift (A).
Engine Oil Relief Valve
Specified camshaft lobe lift (A)
SMCS Code: 1315
4.
Inlet.....................................7.62 to 7.69 mm (0.300 to 0.303 inch)

Exhaust .............................7.71 to 7.79 mm (0.304 to 0.307 inch)
Minimum permissible height of lobes ..............................7.37 mm
(0.290 inch)
Illustration 32
5-23
TM 5-3895-382-24
The relief valve for the engine oil pressure should open at the
following pressure setting:
Engine Oil Pump

SMCS Code: 1304
Engines that are not equipped with piston

cooling jets ...........................340 to 395 kPa (49 to 57 psi)
Engines that are equipped with piston cooling
jets .........................................415 to 470 kPa (60 to 68 psi)
Engines that are equipped with counter
balancer...................................................... 523 kPa (76 psi)
(1)
Spring
Length under test force for engines that are equipped
with counter balancer .............................................42.7 mm
(1.681 inch)
Illustration 33
Oil pump cover
Test force........................................................ 15.9 to 23.1 N

(3.6 to 5.2 lb)
(1)
Test force with engines that are equipped with counter

balancer ................................................................34 to 38 N
(7.6 to 8.5 lb)
(2)
Tighten the cover bolts to the following

torque: ........................................................28 Nm (21 lb-ft)
When the pump is mounted to a balancer unit, tighten the

single bolt on the oil pump cover (not shown) to the following
torque: ....................................................................22 Nm (16 lb-ft)
Outside diameter of plunger................18.16 to 18.18 mm

(.715 to .716 inch)
Type ....................................................Gear driven differential rotor
Outside diameter of plunger with engines that are

equipped with counter balancer .....................15.95 to 15.98 mm
(.628 to .629 inch)
Number of lobes
Inner rotor.............................................................................. 6
Outer rotor ............................................................................. 7
Clearance of plunger in bore .............................. 0.06 to 0.11 mm

(.002 to .004 inch)
Clearance of plunger in bore with engines that are
equipped with counter balancer.......................... 0.02 to 0.08 mm
(.0008 to .0031 inch)
(3)
Diameter of the bore in the valve

housing ...................................................18.24 to 18.27 mm
(.718 to .719 inch)
Diameter of the bore in the valve housing with engines that are
equipped with counterbalancer.......................16.00 to 16.03 mm
(.630 to .631 inch)
(4)
Tighten the bolt to the following

torque: ............................................44 5 Nm (32 4 b-ft)
Illustration 34
Clearance for the outer rotor body (Typical Example)
Clearance of the outer rotor to the body

The balancer unit is not installed ........... 0.15 to 0.34 mm
(.006 to .013 inch)
The balancer unit is installed .................. 0.31 to 0.45 mm
(.012 to .018 inch)
5-24
TM 5-3895-382-24
Engine Oil Pan

SMCS Code: 1302
Illustration 35
Clearance for the inner rotor body (Typical Example)
Clearance of inner rotor to outer

rotor ....................................................................0.040 to 0.130 mm
(.0015 to .0050 inch)
Illustration 36
Oil Pan (Typical Example)
End play of rotor assembly.................................. 0.03 to 0.10 mm

(.001 to .004 inch)
Engine Oil Pressure

SMCS Code: 1924
(1)
Tighten the bolts and the nuts of the oil pan to the
(2)
Tighten the drain plug of the oil pan to the following

torque: ........................................................34 Nm (25 lb-ft)
Water Temperature Regulator
The minimum oil pressure at low idle with an ambient

temperature of 18 to 20 C (64 to 68 F) is the following
value: ............................................................................62kPa (9 psi)
SMCS Code: 1355
The minimum oil pressure at high idle and at normal operating

temperature is the following value:
Turbocharged engine .............................. 280 kPa (40 psi)
Tighten the oil pressure switch, which is located on the left side
of the engine block, to the following
torque:................................................7 to 12 Nm (62 to 107 lb-in)
Illustration 37
Opening temperature .........................77 to 85 C (171 to 185 F)

Full open temperature .......................92 to 98 C (198 to 208 F)
5-25
TM 5-3895-382-24
Tighten the fittings with pipe threads, which are installed in the
regulator housing, to the following
torque:..................................................... 44 11 Nm (32 8 lb-ft)
Pressure Cap
Illustration 38
Maximum relief pressure...........................................48 kPa (7 psi)
Water Pump
Illustration 39
SMCS Code: 1361
(1)
Outside diameter of shaft for drive

gear .........................................................15.91 to 15.92 mm
(.626 to .627 inch)
(2)
Diameter of bore of drive

gear ........................................................15.86 to 15.88 mm
(.624 to .625 inch)

Interference fit of drive gear on

shaft ........................................................................ 0.03 to 0.06 mm
(.001 to .002 inch)
(3)
Diameter of bore of impeller................15.87 to 15.89 mm

(.625 to .626 inch)
Outside diameter of shaft for

impeller ..............................................................15.91 to 15.92 mm
(.626 to .627 inch)
Interference fit of impeller on
shaft ........................................................................ 0.02 to 0.05 mm
(.001 to .002 inch)
(4)
Diameter of bearing .........................29.990 to 30.000 mm

(1.1807 to 1.1811 inch)
Diameter of bore for bearing ......................29.960 to 29.980 mm

(1.1795 to 1.1803 inch)
Interference fit of bearing in pump
body ....................................................................0.010 to 0.040 mm
(.0004 to .0016 inch)
5-26
TM 5-3895-382-24
(5)
The water pump must be assembled in order to

correctly measure the distance from the impeller boss to
the front face of the pump body.
Distance ..........................................................8.1 to 8.5 mm
(.32 to .34 inch)
(6)
The water pump must be assembled in order to

correctly measure the distance of the gear from the rear
face of the pump body.
Distance ..........................................................0.6 to 2.6 mm
(.02 to .10 inch)
Outside diameter of cylinder

liner .................................................................104.25 to 104.28 mm
(4.105 to 4.106 inch)
Inside diameter of cylinder
liner .................................................................100.00 to 100.03 mm
(3.937 to 3.938 inch)
The cylinder liner needs to be ground when the
following maximum diameter of wear
exists: ...............................................................0.25 mm (.010 inch)
Interference fit of liner in cylinder block ...................... 0.03 mm

( .001 inch)

The projection of the liner flange can be 0.10 mm (.004 inch)

above to 0.10 mm (.004 inch) below the face of the cylinder
block.
NOTE: The water pump for Type 2 engines and 7BJ

engines is not serviceable.
Contact your
Caterpillar
dealer
for
more
replacement
information.
NOTE: The projection of the liner flange is the relative

position of the liner flange to the top face of the
cylinder block.
Flange thickness of cylinder liner ...................... 3.81 to 3.86 mm
(.150 to .152 inch)
Cylinder Block
NOTE: A cylinder liner that has been replaced must be

partially machined. Service personnel that have
special training must use specialized equipment
in order to replace a cylinder liner.
SMCS Code: 1201
Cylinder Block
The following steps are required for installation of a cylinder

liner:
1.
The cylinder liner must have a press fit into the bore of
the cylinder block.
2.
Bore the cylinder liner.
3.
Hone the cylinder liner by using a diamond hone.
4.
Hone the cylinder liner by using a silicon carbide base.
5.
Hone the cylinder liner by using a silicon carbide

plateau.
Cylinder liner that has been replaced before boring and

installation
The cylinder liner must have a press fit into the
bore of the cylinder block to the following
dimension: ..............................................0.050 0.025 mm
(.0020 .0010 inch)
Illustration 40
Typical Engine Block
(1)
The cylinder liner has the following characteristics:
Dry
Interference fit
Flanged
Flame Ring
Bore of cylinder liner that has been

replaced ................................................99.288 0.126 mm
(3.9090 0.0050 inch)
The internal surface of the cylinder liner that has been replaced
has new specifications. After boring, the cylinder liner that has
been replaced has the following specifications:
Internal diameter .............................................99.899 0.025 mm
(3.9330 0.0010 inch)
5-27
TM 5-3895-382-24
Grade of surface finish ........................RA 3.6 0.4 micrometers
(5)
Tighten the bolts from the rear oil seal housing to the
bridge to the following torque: ................................22 Nm
(16 lb-ft)
(6)
Diameter of bores in cylinder block for main

bearings .............................................80.416 to 80.442 mm
(3.1660 to 3.1670 inch)
(7)
Tighten the bolts for the main bearing caps to the

following torque:.............................................265 40 Nm
(195 30 lb-ft)
(8)
Tighten the bolts to the bridge under the cylinder block

to the following torque: ............................................16 Nm
(12 lb-ft)
Maximum variation of concentric diameter and

taper ................................................ 0.020 mm (.0008 inch)
has new specifications. The internal surface of the cylinder
liner that has been replaced after diamond hone has the
following specifications:
Hone angle ......................................................... 35 degrees
Internal diameter .......................99.950 mm (3.9350 inch)
Grade of surface finish ............RA 2.6 0.4 micrometers
taper ................................................ 0.012 mm (.0005 inch)
liner that has been replaced after silicon carbide base hone
has the following specifications:
Total height of cylinder block between top and bottom faces

(not shown) ...................................................441.12 to 441.33 mm
(17.367 to 17.375 inch)
Piston Cooling Jets (If Equipped)
Hone angle ......................................................... 35 degrees

Internal diameter .....................100.012 mm (3.9375 inch)
Grade of surface finish ...........RA 1.3 to 1.6 micrometers
taper ................................................ 0.010 mm (.0004 inch)
liner that has been replaced after silicon carbide plateau hone
has the following specifications:
Internal diameter .....................100.017 mm (3.9377 inch)
Grade of surface
finish ..................................... RA 0.65 to 1.30 micrometers
(2)
Diameter
of
bore
in
cylinder
block
for
liner ...............104.20 to 104.23 mm (4.103 to 4.104 inch)
Depth of recess for cylinder liner

flange ....................................3.81 to 3.91 mm (.150 to .154 inch)
Illustration 41
Diameter of recess for flange of cylinder

liner ...........................107.82 to 107.95 mm (4.245 to 4.250 inch)
(1)
Cylinder wall
(3)
Tighten the bolts from the rear oil seal housing to

the
cylinder
block
to
the
following
torque: ........................................................22 Nm (16 lb-ft)
(2)
Tighten the piston cooling jets to the following

torque: ........................................................27 Nm (20 lb-ft)
(4)
Diameter
of
bore
in
cylinder
block
for
number
1
journal
of
the
camshaft
front
bearing .............55.56 to 55.59 mm (2.188 to 2.189 inch)
NOTE: Ensure that the piston cooling jet is positioned

correctly on the dowel in the cylinder block (not
shown).
(3)
Diameter of bearing bore for

camshaft .......................50.79 to 50.85 mm (2.000 to 2.002 inch)
Diameter of bore for number 2
journal ..........................50.55 to 50.60 mm (1.990 to 1.992 inch)
Diameter of bore for number 3
journal ..........................50.04 to 50.09 mm (1.970 to 1.972 inch)
5-28
Use a rod with a diameter of 1.70 mm (0.067 inch) in

order to check the alignment of the piston cooing jet.
The rod must extend beyond the top of the cylinder.
TM 5-3895-382-24
(4)
Diameter of the rod ...................14.00 mm (0.550 inch)
Thickness of the bearing at the center
Dimensions for the center of diameter
All bearings ...................................2.083 to 2.086 mm

(.0820 to .0821 inch)
(5)........................................................... 33 mm (1.3 inch)

(4)
Crankshaft gear
(5)
End play of the crankshaft ...................... 0.05 to 0.38 mm

(.002 to .015 inch)
(6)........................................................... 21 mm (.8 inch)
Crankshaft
Maximum permissible end play.........................................0.51 mm

(0.020 inch)
SMCS Code: 1201
(6)
Width of the connecting rod

journal ....................................................40.35 to 40.42 mm
(1.589 to 1.591 inch)
Connecting rod journal diameter of

flange .............................................................133.27 to 133.37 mm
(5.247 to 5.251 inch)
Depth of recess for connecting rod
bearing ...............................................................20.22 to 20.98 mm
(.796 to .826 inch)
Bore of recess for connecting rod
bearing ...............................................................46.96 to 46.99 mm
(1.849 to 1.850 inch)
Measure the connecting rod journals on the crankshaft. See
the following chart for the dimensions.
Illustration 42
Crankshaft and main bearing journals
Table 5
Connecting Rod Bearing Journal
NOTE: If a crankshaft that was not originally induction

hardened has been remachined, then the
crankshaft must be rehardened. Use one of the
process that follow for 20 hours in order to
reharden the crankshaft: nitrocarburizing process
and nitriding process.
(1)
Connecting rod bearing
(2)
Top and bottom thrust washer thickness
If the bearing journal has

been ground beyond this
size, then regrind the
bearing journals to the
next undersize journal.
Original Size Journal
Undersize Journal
0.25 mm (0.010 inch)
Undersize Journal
0.51 mm (0.020 inch)
Undersize Journal
0.76 mm (0.030 inch)
Standard .................................................... 2.26 to 2.31 mm

(.089 to .091 inch)
Oversize ..................................................... 2.45 to 2.50 mm
(.096 to .098 inch)
(3)
63.43 mm (2.497 inch)
63.47 to 63.49 mm
(2.499 to 2.500 inch)
63.22 to 63.24 mm
(2.489 to 2.490 inch)
62.96 to 62.98 mm
(2.479 to 2.480 inch)
62.71 to 62.73 mm
(2.469 to 2.470 inch)
Connecting rod bearings are available for remachined journals

with the following undersize dimensions:
Main bearing clearance

All bearings ...........................................0.057 to 0.117 mm
(.0022 to .0046 inch)
Undersize..............................................................0.25 (.010)
Undersize .............................................................0.51 (.020)
Undersize .............................................................0.76 (.030)
Bearing width
(7)
Center bearing ..............................36.32 to 36.70 mm

(1.430 to 1.445 inch)
All other bearings .........................31.62 to 31.88 mm
(1.245 to 1.255 inch)
Dimensions of main journals which are the standard,

original size
Width of front journal ...........................36.93 to 37.69 mm
(1.454 to 1.484 inch)
5-29
TM 5-3895-382-24
Width of center journal ....................................44.15 to 44.22 mm

(1.738 to 1.741 inch)
Crankshaft Seals
SMCS Code: 1160
Width of all other journals ...............................39.24 to 39.35 mm

(1.545 to 1.549 inch)
Front Oil Seal
Measure the main bearing journals on the crankshaft. See the

following chart for dimensions.
Table 6
Main Bearing Journal
If the bearing journal has
been ground beyond this
size, then regrind the
bearing journals to the
next undersize journal.
Original Size Journal
Undersize Journal
0.25 mm (0.010 inch)
Undersize Journal
0.51 mm (0.020 inch)
Undersize Journal
0.76 mm (0.030 inch)
76.12 mm (2.996 inch)
76.16 to 76.18 mm
(2.998 to 2.999 inch)
75.91 to 75.93 mm
(2.988 to 2.989 inch)
75.65 to 75.67 mm
(2.978 to 2.979 inch)
75.40 to 75.42 mm
(2.968 to 2.969 inch)
Tighten the bolts for the main bearing journal to the following
torque: ............................................................... 265 Nm (195 lb-ft)
Illustration 43
Installation of the front oil seal and wear sleeve for the crankshaft
Main bearings are available for remachined journals with the

following undersize dimensions:
(1) Crankshaft pulley

(2) Front oil seal
(3) Hub of crankshaft pulley
(4) Wear sleeve
(5) Face front oil seal housing
(A) Depth of front oil seal
Undersize .............................................................0.25 (.010)

Undersize..............................................................0.25 (.010)
Undersize .............................................................0.25 (.010)
The front oil seal (2) is normally installed to a depth of 7.00

0.25 mm (0.2756 0.0098 inch) (A) from the face of the front
oil seal housing (5). The oil seal may cause wear on the hub
of the crankshaft pulley (3). This wear may allow oil leakage
past the oil seal. If this situation occurs, the front oil seal can
be installed to a depth of 9.3 mm (0.37 inch) from the face of
the front oil seal housing.
Tighten the retaining bolts of the crankshaft pulley (not shown)

to the following torque: ..................................................... 115 Nm
(85 lb-ft)
Apply Locktite 2431 to the bolts of the crankshaft damper.
Tighten the bolts (not shown) to the following torque:
M8 bolts ......................................................35 Nm (26 lb-ft)
M12 bolts ....................................................75 Nm (55 lb-ft)
If a wear sleeve (4) is installed, the front oil seal is installed to a

depth of 9.30 mm (0.366 inch) from the face of the front oil seal
housing. When the wear sleeve is installed, the flange of the
wear sleeve does not require removal. If a wear sleeve is
installed, a new front oil seal must be installed.
Tighten the bolts of the rear oil seal housing to the cylinder
block (not shown) to the following
torque:.....................................................................22 Nm (16 lb-ft)
Tighten the bolts of the rear oil seal housing to the bridge (not
shown) to the following torque:
M6 ................................................................13 Nm (10 lb-ft)
M8 ................................................................18 Nm (13 lb-ft)
5-30
TM 5-3895-382-24
(4)
Connecting Rod
SMCS Code: 1218
Bearings are available for remachined journals of the

crankshaft which have the following undersize
dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)

0.76 mm (.030 inch)

Shell thickness ..................................................1.835 to 1.842 mm
(.0723 to .0726 inch)
Width of connecting rod bearing ....................31.62 to 31.88 mm
(1.245 to 1.255 inch)
Bearing clearance ............................................0.035 to 0.081 mm
(.0014 to .0032 inch)
(5)
Inside diameter of rod for
bearing ...........................................................67.210 to 67.220 mm
(2.6460 to 2.6465 inch)
(6)
Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following

torque: ..................................................................125 Nm (92 lb-ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following
torque: ............................................................... 155 Nm (114 lb-ft)
Illustration 44
Connecting Rod And Bearings
Turbocharged Engines
Naturally Aspirated Engines

(1)
(2)

bearing ...............................................38.89 to 38.92 mm
(1.531 to 1.532 inch)
Outside diameter of bearing for piston
pin .......................................................38.94 to 39.03 mm
(1.535 to 1.536 inch)

bearing....................................................42.07 to 42.09 mm
(1.656 to 1.657 inch)
(2)

pin .......................................................42.160 to 42.190 mm
(1.6600 to 1.6613 inch)
Inside diameter of bearing for piston pin after

reaming ..........................................................38.120 to 38.140 mm
(1.5008 to 1.5015 inch)

reaming ...........................................................34.940 to 34.960 mm
(1.3758 to 1.3765 inch)
Clearance between small end bearing and

piston pin ............................................................0.020 to 0.043 mm
(.0008 to .0017 inch)
Clearance between small end bearing and

piston pin ............................................................0.020 to 0.043 mm
(.0008 to .0017 inch)
(3)
(1)
(3)
Distance between center of piston pin and center of

crankshaft bearing ...........................219.05 to 219.10 mm
(8.624 to 8.626 inch)
Distance between center of piston pin and center

of crankshaft bearing .......................219.05 to 219.10 mm
(8.624 to 8.626 inch)
(4)
Bearings are available for remachined journals of the
crankshaft which have the following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)
5-31
TM 5-3895-382-24

(.0723 to .0726 inch)
Width of connecting rod
bearing ...............................................................31.55 to 31.88 mm
(1.240 to 1.255 inch)
(.0012 to .0032 inch)
(5)
bearing ...........................................................67.210 to 67.220 mm
(2.6460 to 2.6465 inch)
(6)

torque: ..................................................................125 Nm (92 lb-ft)
torque: ............................................................... 155 Nm (114 lb-ft)
Illustration 45
Connecting Rod and Bearings
NOTE: If piston cooling jets are installed, the piston and

the connecting rod assembly must be turned
when the piston and rod assembly are installed.
Turning the piston and connecting rod assembly
will prevent the connecting rod from hitting and
damaging the piston cooling jet.
When the
connecting rod has passed the piston cooling jet,
turn the connecting rod until the arrow or "Front"
mark on the top of the piston is toward the front of
the engine.
The piston height is controlled by the length of the connecting

rod. Connecting rods are supplied in six grades of length. The
different grades of length are manufactured by machining the
hole in the piston pin bearing in an off-center position. The
different grades of length are created by the following method:

Machining the center of the hole in the piston pin.
Machining the center of the hole in the bearing.
If the connecting rod is replaced, ensure that the same

grade of length as the original connecting rod is used.
However, if the crankshaft or the cylinder block is replaced, the

required grade of length of the connecting rods may change.
A correct grade of length of a connecting rod can be ordered
for replacement. The connecting rod includes the piston pin
bearing. The piston pin bearing is machined in order to create
the correct grade of length. The piston pin is installed in the
connecting rod at the factory.
Table 7 provides the
specifications for the grade of length.
NOTE: The length of the connecting rod is determined by
the following method: The bearing for the
crankshaft journal must be removed and the
piston pin must be installed. The original grade of
length of the connecting rod is determined when
the original piston pin is installed.
5-32
TM 5-3895-382-24
Table 7
Grade of
Length
Color
Red
G"
Orange
H"
White
Green
'K"
Purple
"L"-
Blue
Clearance between small end bearing and piston

pin ........................................................................0.023 to 0.044 mm
(.0009 to .0017 inch)
Length of the
Connecting
Rod
165.728 to
165.761 mm
(6.5247 to
6.5265 inch)
165.682 to
165.715 mm
(6.5229 to
6.5247 inch)
165.637 to
165.670 mm
(6.5211 to
6.5229 inch)
165.591 to
165.624 mm
6.5193 to
6.5211 inch)
165.545 to
165.578 mm
(6.5175 to
6.5193 inch)
165.499 to
165.532 mm
(6.5157 to
6.5175 inch)
Determine the distortion of a connecting rod.
Replace the piston pin bearing.
(2)
Bearing for connecting rod journal

(.0012 to .0032 inch)
(5)

bearing ...............................................67.210 to 67.220 mm
(2.6460 to 2.6465 inch)
(6)

torque: ..................................................................125 Nm (92 lb-ft)
torque: ............................................................... 155 Nm (114 lb-ft)
NOTE: If piston cooling jets are installed, the piston and
the connecting rod assembly must be turned
when the piston and rod assembly are installed.
Turning the piston and connecting rod assembly
will prevent the connecting rod from hitting and
damaging the piston cooling jet.
When the
connecting rod has passed the piston cooling jet,
turn the connecting rod until the arrow or Front
mark on top of the piston is toward the front of the
engine.
Piston and Rings

SMCS Code: 1214; 1215
(1)
(4)
Width of connecting rod bearing ....................31.55 to 31.88 mm

(1.240 to 1.255 inch)
Refer to the Testing and Adjusting manual for the following

procedures:
Determine the length of the connecting rod.
Distance between center of piston pin and center of

crankshaft bearing ...........................219.05 to 219.10 mm
(8.624 to 8.626 inch)

(.0723 to .0726 inch)
If a piston pin bearing requires replacement but the connecting

rod does not require replacement, a new piston pin bearing
can be ordered. This bearing is partially finished. The hole in
the bearing must be machined off-center to the correct
distance in order to create a connecting rod assembly that is
the correct grade of length.
(3)

bearing ...................................................43.01 to 43.04 mm
(1.693 to 1.694 inch)

Engine Design for more information.

pin ...........................................................43.11 to 43.15 mm
(1.697 to 1.699 inch)

reaming ..........................................................39.723 to 39.738 mm
(1.5639 to 1.5645 inch)
5-33
TM 5-3895-382-24
Clearance between groove and intermediate
ring........................................................................... 0.06 to 0.09 mm
(.002 to .003 inch)
Clearance between the ends of the intermediate ring
with a cylinder liner without any wear ............... 0.30 to 0.76 mm
(.012 to .030 inch)
(3)
Width of groove in piston for oil control

ring ..........................................................4.030 to 4.060 mm
(.1587 to .1598 inch)
Thickness of oil control ring ............................3.980 to 3.990 mm

(.1566 to .1571 inch)
Clearance between groove and oil control
ring........................................................................... 0.04 to 0.08 mm
(.002 to .003 inch)
Clearance between the ends of oil control ring with a
cylinder liner without any wear ........................... 0.38 to 0.84 mm
(.015 to .033 inch)
(4)
Illustration 46
Piston and rings
Diameter of new piston pin .............34.920 to 34.925 mm

(1.3748 to 1.3750 inch)
NOTE: The word "Front" or an arrow which is marked on

the piston crown must be toward the front of the
engine. If the piston crown is not marked, put the
narrowest side of the piston crater toward the
side of the engine with the fuel injection pump.
The shortest distance between the edge of the
piston crater and the edge of the piston is the
narrowest side of the piston crater.
Bore in piston for pin ....................................34.928 to 34.934 mm

(1.3751 to 1.3754 inch)
NOTE: Be sure that the ring end gaps of all the piston
rings have 120 degrees spacing from each other.
(1)
Piston height above cylinder block

(not shown) ........................................................... 0.14 to 0.36 mm
(.005 to .014 inch)
Shape of top ring .....................................................................Taper
NOTE: Refer
to
Systems
Operation,
"General
Information" for the location of the serial number.
Clearance between the ends of top ring in a cylinder liner

without any wear .................................................. 0.35 to 0.75 mm
(.014 to .030 inch)
Naturally Aspirated Engines

(1)
Shape of groove in piston for top ring ......................Taper
(2)
Width of groove in piston for top

ring............................................................... 2.57 to 2.59 mm
(.101 to .102 inch)
Width of groove in piston for intermediate

ring .............................................................. 2.56 to 2.58 mm
(.101 to .102 inch)
Thickness of intermediate ring ........................... 2.48 to 2.49 mm

(.097 to .098 inch)
Thickness of top ring ........................................... 2.48 to 2.49 mm

(.097 to .098 inch)
Clearance between groove and intermediate

ring........................................................................... 0.07 to 0.11 mm
(.003 to .004 inch)
Clearance between groove and piston

ring........................................................................... 0.08 to 0.11 mm
(.003 to .004 inch)
Clearance between the ends of the top ring with a cylinder liner
(.016 to .033 inch)
Clearance between the ends of an intermediate

ring in a cylinder liner without any
wear ........................................................................ 0.30 to 0.76 mm
(.012 to .030 inch)
(2)
(3)
Width of groove in piston for intermediate

ring .............................2.55 to 2.57 mm (.100 to .101 inch)
Thickness of intermediate ring............................ 2.48 to 2.49 mm

(.097 to .098 inch)
Width of groove in piston for oil control

ring ..........................................................4.040 to 4.060 mm
(.1591 to .1598 inch)
Thickness of oil control ring ................................ 3.98 to 3.99 mm

(.156 to .157 inch)
Clearance between groove and oil control
ring........................................................................... 0.05 to 0.08 mm
(.002 to .003 inch)
5-34
TM 5-3895-382-24
Clearance between the ends of an oil control ring in a cylinder

liner without any wear .......................................... 0.38 to 0.84 mm
(.015 to .033 inch)
(4)
Shape of groove in piston for top ring ..................................Taper

Shape of top ring .....................................................................Taper
Clearance between the ends of the top ring in a cylinder liner
(.011 to .025 inch)
(1)
Diameter of new piston pin .............38.095 to 38.100 mm

(1.4998 to 1.5000 inch)

(1.5000 to 1.5004 inch)
(not shown) ........................................................... 0.14 to 0.36 mm
(.005 to .014 inch)
Top piston ring
NOTE: Install the word "TOP" toward the top of the

piston. New top rings have a red identification
mark which must be on the left of the ring gap
when the intermediate ring is installed on an
upright piston.
(2)
Intermediate ring
Width of groove in piston for
intermediate ring ................................................... 2.56 to 2.58 mm
(0.101 to 0.102 inch)
Thickness of intermediate ring ........................... 2.48 to 2.49 mm
(0.097 to 0.098 inch)
Clearance between groove and
intermediate ring.................................................... 0.07 to 0.11 mm
(.003 to .004 inch)
Clearance between the ends of an intermediate
ring in a cylinder liner without any
wear ........................................................................ 0.40 to 0.65 mm
(.016 to .026 inch)
NOTE: Install the word "TOP" toward the top of the
piston. New intermediate rings have a green
identification mark which must be on the left of
the ring gap when the intermediate ring is
installed on an upright piston.

(3)
Oil control ring
Width of groove in piston for oil

control ring ............................................................. 3.54 to 3.56 mm
(.139 to .140 inch)
Thickness of oil control ring ................................ 3.47 to 3.49 mm
(.136 to .137 inch)
Clearance between groove and oil
control ring ............................................................. 0.05 to 0.09 mm
(.002 to .004 inch)
Clearance between the ends of an oil control ring in a cylinder
liner without any wear .......................................... 0.38 to 0.83 mm
(.015 to .033 inch)
NOTE: A pin is used in order to hold both ends of the
spring of the oil control ring in position. The ends of
the spring of the oil control ring must be 180
degrees opposite the end gap of the oil control ring.
Illustration 47
NOTE: The word "Front" or an arrow which is marked on

the piston crown must be toward the front of the
engine. If the piston crown is not marked, put the
narrowest side of the piston crater toward the
side of the engine with the fuel injection pump.
The shortest distance between the edge of the
piston crater and the edge of the piston is the
narrowest side of the piston crater.
NOTE: Be sure that the ring end gaps of all the piston
rings have 120 degrees spacing from each other.
(4)
Diameter of new piston pin..............39.694 to 39.700 mm

(1.5628 to 1.5630 inch)
(1.5631 to 1.5633 inch)
NOTE: Refer
to
Systems
Operation,
"General
Information" for the location of the serial number.

(not shown) ........................................................... 0.36 to 0.50 mm
(.014 to .020 inch)
5-35
TM 5-3895-382-24
Housing (Front)
SMCS Code: 1151
Illustration 49
Oil Seal Housing
(5)
Tighten the bolts for the oil seal housing (3) to the
Gear Group (Front)

SMCS Code: 1206
Illustration 48
Timing Case And Cover
(1)
Timing case
Tighten the bolts (not shown) for the timing case to the cylinder
block to the following torques:
M8 (not shown)..........................................22 Nm (16 lb-ft)
M10 (not shown)........................................44 Nm (32 lb-ft)
Tighten the bolts and the nuts for the cover of the timing case
to the following torques:
(2)
M8 bolts ......................................................22 Nm (16 lb-ft)
(3)
M8 nuts (not shown) for bolts..................22 Nm (16 lb-ft)
(4)
Oil seal housing
Illustration 50
(1)
Fuel pump drive gear:

Bore ..................36.00 to 36.06 mm (1.417 to 1.420 inch)
Tighten the four bolts to the
Tighten the two torque screws to the
following torque: ........................................... 9 Nm (7 lb-ft)
NOTE: The torque screws retain the timing plate on the

front of the gear. This plate is installed in the
factory after the fuel injection timing has been
accurately set to the top center position on the
compression stroke of number 1 cylinder. If the
timing plate is moved, the timing of the fuel
injection pump must be set.
5-36
TM 5-3895-382-24
NOTE: The crankshaft must not be turned unless the fuel

pump gear is installed.
(7)
Inside diameter of bearing...............22.230 to 22.260 mm

(0.8750 to 0.8766 inch)
Outside diameter of idler gear
shaft.........................................................22.19 to 22.21 mm
(0.873 to 0.874 inch)
Clearance of gear on shaft ..................0.020 to 0.066 mm
(.0008 to .0026 inch)
NOTE: Do not remove the nut that retains the hub of the
fuel injection pump to the shaft of the fuel
injection pump. If the hub is removed, the hub
must be positioned by correctly trained personnel
that use special test equipment.
(2)
Camshaft gear
Diameter of gear bore .....................34.930 to 34.950 mm
(1.3752 to 1.3760 inch)
Outside diameter of camshaft
hub ......................................................34.900 to 34.920 mm
(1.3741 to 1.3747 inch)
Clearance between gear and
camshaft hub ........................................0.008 to 0.048 mm
(.0003 to .0019 inch)
(3)
Tighten the bolt for the camshaft gear to the following

torque:.........................................................78 Nm (58 lb-ft)
(4)
Idler gear and hub
Oil pump idler gear
Idler gear end play ............................................0.012 to 0.643 mm

(.0005 to .0253 inch)
Timing gear backlash (minimum) ....................................0.08 mm
(.003 inch)
Flywheel and Flywheel Housing Runout

SMCS Code: 1156; 1157
Diameter of bore of gear .....................57.14 to 57.18 mm

(2.250 to 2.251 inch)
Width of gear and split bearing
assembly ................................................30.14 to 30.16 mm
(1.186 to 1.187 inch)
Inside diameter of gear
bearing ...................................................50.78 to 50.80 mm
(1.999 to 2.000 inch)
Outside diameter of gear
hub ..........................................................50.70 to 50.74 mm
(1.996 to 1.998 inch)
Clearance of bushing on hub ................. 0.04 to 0.10 mm
(.002 to .004 inch)
Idler gear end play .................................... 0.10 to 0.20 mm
(.004 to .008 inch)
Maximum permissible end play ............................0.38 mm
(0.015 inch)
Backlash (minimum) ..........................0.08 mm (.003 inch)
(5)
(6)
Illustration 51
(1)
Tighten the bolts of the idler gear to the following

torque..........................................................44 Nm (32 lb-ft)
Tighten the bolts of the flywheel housing to the following

torque:
The M10 bolts for the cast iron flywheel
housing ......................................................44 Nm (32 lb-ft)
The M12 bolts that are stamped "8.8" for the
cast iron flywheel housing .......................75 Nm (55 lb-ft)
cast iron flywheel housing........................63 Nm (46 lb-ft)
cast iron flywheel housing ......................115 Nm (85 b-ft)
Crankshaft gear
Diameter of gear bore .....................47.625 to 47.650 mm
(1.8750 to 1.8760 inch)
Outside diameter of crankshaft for
gear .....................................................47.625 to 47.645 mm
(1.8750 to 1.8758 inch)
Clearance of gear on crankshaft for
a press fit ................................................0.015 0.035 mm
(.0006 .0014 inch)
The M10 bolts that are for the aluminum

flywheel housing .......................................70 Nm (52 lb-ft)
5-37
TM 5-3895-382-24
(2)
The maximum temperature for heating the flywheel ring

gear for installation .....................................250 C (482 F)
(3)
Tighten flywheel bolts to the following

torque: ......................................................105 Nm (77 lb-ft)
Bore Runout
Flywheel Housing Runout

Face Runout
Illustration 53
Bore Runout Check
Maximum permissible bore runout of the flywheel

housing ............................................................0.20 mm (.008 inch)
Refer to Testing and Adjusting, Flywheel and Flywheel
Housing for the correct procedure to measure the runout.
Illustration 52
Face Runout Check
Flywheel Runout
Maximum permissible face runout of the flywheel

housing .............................................................0.20 mm (.008 inch)
Face Runout
Refer to Testing and Adjusting, "Flywheel and Flywheel

Housing" for the correct procedure to measure the runout.
Illustration 54
Face Runout Check
5-38
TM 5-3895-382-24

housing ............................................................0.20 mm (.008 inch)
Housing".
Outside Diameter Runout
Illustration 55
Outside Diameter Runout Check

housing .............................................................0.30 mm (.012 inch)
Housing" for the correct procedure to measure the runout.
5-39
TM 5-3895-382-24
Belt Tension Chart

SMCS Code: 1357
Table 8
Belt Tension Chad
Gauge Reading
Belt Size
3/8
1/2
5V
11/16
3/4
15/16
8K
6PK
Belt Width
Belt Tension
Initial (1)
Belt Tension
Used (2)
10.72 mm (0.422 Inch)

445 22 N (100 5 lb)
400 22 N (90 5 lb)
13.89 mm (0.547 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
15.88 mm (0.626 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
17.48 mm (0.688 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
19.05 mm (0.750 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
23.83 mm (0.983 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
27.92 mm (1.099 Inch)
489 44 N (110 10 lb)
800 22 N (180 5 lb)
20.94 mm (0.824 Inch)
467 44 N (105 10 lb)
667 22 N (150 5 lb)
Measure the tension of the belt that is farthest from the engine.
Borroughs
Gauge Number
Old
New
Gauge
Gauge
Number
Number
BT-33-95
BT-33-97
BT-33-95
BT-33-97
BT-33-72
BT-33-72C
BT-33-72
BT-33-72C
BT-33-72
BT-33-72C
BT-33-72
BT-33-77
-----BT-33-109
-----BT-33-109
(1) Belt Tension Initial is for a new belt.

(2) Belt Tension Used for a belt with over 30 minutes of operation at the rated speed.
(1)
Fan Drive
SMCS Code: 1359
Bore of housing for

bearing ...............................................41.965 to 41.978 mm
(1.6522 to 1.6537 inch)
Outside diameter of bearing ...........................41.99 to 42.00 mm

(1.653 to 1.654 inch)
Interference fit of bearing in
housing ..............................................................0.009 to 0.035 mm
(0.0004 to 0.0014 inch)
(2)
Bore of hub.........................................21.938 to 21.958 mm

(0.8637 to 0.8645 inch)
Outside diameter of shaft.............................21.987 to 22.000 mm

(0.8656 to 0.8661 inch)
Interference fit of shaft in hub .........................0.029 to 0.062 mm
(0.0011 to 0.0024 inch)
Maximum permissible end play of shaft ..........................0.20 mm
(0.008 inch)
(3)
Illustration 56
5-40
Install the hub on the shaft to the

dimension (3).....................................115.3 mm (4.54 inch)
TM 5-3895-382-24
Tighten the bolts for the fan drive housing

(not shown) to the following torque:...................44 Nm (32 lb-ft)
Tighten the bolts for the fan drive pulley
(not shown) to the following torque:...................22 Nm (16 lb-ft)
Tighten the bolts for the fan (not shown) to the
following torque:
M8 ................................................................22 Nm (16 lb-ft)
M10..............................................................44 Nm (32 lb-ft)
Alternator and Regulator

SMCS Code: 1405; 1410
Illustration 58
End view of the 12 volt alternator which shows the electrical
connections
Illustration 57
Typical alternator (side view)
Illustration 59
End view of the 24 volt alternator which shows the electrical
connections
NOTE: Test the battery with a carbon pile 4C-4911

Battery Load Tester in order to measure the
maximum output from the alternator.
The rotation of the alternator is clockwise when the alternator
is viewed from the pulley.
The regulator of the alternator is sealed.
Polarity .............................................. Negative ground to the case
Type of brushes .....................................................................Sealed
5-41
TM 5-3895-382-24
(1)
(2)
Tighten the pulley nut to the following

torque:...............................................................45 to 55 Nm
(33 to 40 lb-ft)
24 volt Alternator at 25C (77F)

Rpm ...........................................................1500 to 8000 rpm
Positive terminal
load .................................... 2 amperes to maximum output
Minimum full load current at
5000 rpm ........................................................... 47 amperes
1500 rpm ........................................................13.5 amperes
Output voltage .............................................................1 volts
Maximum leakage current with
load of 18000 ohm ............................... 220 microamperes
Load range .....................................................0 to 1 ampere
Tighten the terminal nut "W" to the following

torque:................................................................2 to 2.5 Nm
(17 to 22 lb-in)
The "W" terminal is the source of the alternating current from

the stator.
NOTE: The peak voltage at the W terminal must not be
less than the output voltage at the B+ terminal.
The peak voltage at the W must not be more
than two volts greater than the B+ terminal.
(3)
Alignment of the alternator pulley to the

crankshaft pulley.......................................... 2.4 mm (0.095 inch)
Tighten terminal nut "D+" to the following

torque: .......................................................1.45 to 1.95 Nm
(13 to 17 lb-in)
Electric Starting Motor
The "D+" terminal is the field excitation terminal. The battery

must be connected in order to energize the circuit.
(4)
SMCS Code: 1453
Terminal nut "B+"

Tighten terminal nut "B+" on the 12 volt
alternator to the following
torque: .....................................3.5 0.9 Nm (31 8 lb-in)
Tighten terminal nut "B+" on the 24 volt
torque: .................................7.75 0.25 Nm (69 2 lb-in)
(5)
Tighten terminal nut "B-" on the 24 volt

torque: .....................................3.6 0.8 Nm (32 7 lb-in)
12 volt Alternator at 25C (77F)

Rpm ...........................................................1500 to 8000 rpm
Positive terminal
load .................................... 2 amperes to maximum output
5000 rpm .........................................................48.6 amperes
1500 rpm .........................................................20.7 amperes
Illustration 60
Typical Starting Motor (Side View)
Output voltage ...................................................14 .5 volts

Rated voltage ............................................................12 volts
Maximum leakage current with
load of 18000 ohm ............................... 220 microamperes
Load range .....................................................0 to 1 ampere
5-42
TM 5-3895-382-24
Install shims or remove shims in order to adjust the armature
end play to the correct specification.
Commutator
New diameter .........................................45 mm (1.77 inch)
Minimum diameter .............................42.5 mm (1.67 inch)
Start Relays
9G-4368 Relay
Illustration 61
End view of the typical starting motor which shows the electrical
connections
12 Volt Starting Motor

No load conditions at 25 C (77 F)
Rpm of shaft..................................................7000 minimum
Current draw .................................130 amperes maximum
Voltage ................................................................... 11.5 volts
Rated voltage ............................................................12 volts
(1)
Tighten the battery terminal nut to the following

torque: ....................................24 to 32 Nm (18 to 24 lb-ft)
(2)
Tighten the nut for the switch terminal to the

following torque:...................1.0 to 1.3 Nm (9 to 12 lb-in)
Illustration 62
(1)
Resistance between "C1" terminal and

"C2" terminal with the battery ................................. 0 ohms
NOTE: There must be no polarity between the terminal

"C1" and terminal "C2" without battery current.
Tension of the spring for the motor

brush ............................................... 8.34 to 11.00 N (1.9 to 2.5 lb)
(2)
Minimum resistance of the starter cable

at 200 C (392 F) and at 12 volts ........................... 0.0017 ohms
24 Volt Starting Motor

No load conditions at 25 C (77 F)
Rpm of shaft..................................................7000 minimum
Current draw ...................................85 amperes maximum
Voltage .......................................................................23 volts
Rated...........................................................................24 volts
Minimum pull-in voltage ......................................................18 volts
Brush length:
Minimum brush length .........................15.5 mm (.61 inch)
Armature end play .....................................................0.1 to 0.3 mm
(.004 to .012 inch)
5-43
Resistance between "W1" terminal and

W2 terminal ................................................15 1.5 ohms
TM 5-3895-382-24
069-5466 Relay
Illustration 63
(1)
Resistance between
terminals 4, 7, 6 and 9..............................................9 ohms
(2)
Resistance between
terminal "A" and terminal "B".......................30 to 34 ohms
5-44
TM 5-3895-382-24
ALPHABETICAL INDEX
A
Alternator and Regulator .......................................................... 5-41
Fuel Injection Pump......................................................................5-5

Type 1 Engines and 9RM Engines ........................................5-5
Type 2 Engines and 7BJ Engines .........................................5-7
Fuel Transfer Pump................................................................... 5-11
B
Belt Tension Chart .................................................................... 5-40
G
Gear Group (Front) ................................................................... 5-36
C
Camshaft ..................................................................................... 5-22
Connecting Rod.......................................................................... 5-31
Type 1 Engines and 9RM Engines ..................................... 5-31
Type 2 Engines and 7BJ Engines ....................................... 5-32
Crankshaft ................................................................................... 5-29
Crankshaft Seals ....................................................................... 5-30
Front Oil Seal.......................................................................... 5-30
Cylinder Block ............................................................................ 5-27
Cylinder Block......................................................................... 5-27
Piston Cooling Jets (If Equipped) ....................................... 5-28
Cylinder Head............................................................................. 5-16
Cylinder Head Valves ................................................................ 5-12
Type 2 Engines and 7BJ Engines ...................................... 5-14
E
Electric Starting Motor .............................................................. 5-42
12 Volt Starting Motor ........................................................... 5-42
24 Volt Starting Motor ........................................................... 5-43
Start Relays ............................................................................. 5-44
Engine Design ..............................................................................5-4
Type 1 Engines and 9RM Engines .........................................5-4
Type 2 Engines and 7BJ Engines ..........................................5-4
Engine Oil Filter Base................................................................ 5-23
Engine Oil Pan............................................................................ 5-25
Engine Oil Pressure................................................................... 5-25
Engine Oil Pump ........................................................................ 5-24
Engine Oil Relief Valve .............................................................. 5-23
Exhaust Manifold ....................................................................... 5-21
Type 2 Engines and 78J Engines ........................................ 5-21
F
Fan Drive ..................................................................................... 5-40
Flywheel and Flywheel Housing Runout ............................... 5-37
Flywheel Housing Runout .................................................... 5-38
Flywheel Runout..................................................................... 5-38
Fuel Injection Nozzles ..................................................................5-8
H
Housing (Front)........................................................................... 5-36
I
Important Safety Information .......................................................5-2
M
Muffler .......................................................................................... 5-22
P
Piston and Rings ........................................................................ 5-33
S
Specifications Section ..................................................................5-4
T
Table of Content ...........................................................................5-3
Turbocharger ............................................................................. 5-20
Turbocharger .......................................................................... 5-20
V
Valve Mechanism Cover .......................................................... 5-12
Valve Rocker Arms and Lifters ................................................ 5-12
W
Water Pump................................................................................ 5-26
Water Temperature Regulator ................................................. 5-25
Pressure Cap ......................................................................... 5-26
5-45/(5-46 blank)
TM 5-3895-382-24
SENR5816-04
February 1999
CHAPTER 6
Systems Operation
Testing and Adjusting

Machines
7BJ1-Up (Engine)
5HK1-Up (Engine)
9RM1-Up (Engine)
NOTES:
This chapter contains Testing and Adjusting instructions. Additional information may be found in:
Chapter 5, Specifications, 3054 Engine
Chapter 7, Disassembly & Assembly, 3054 Engine
Discard all Iocking-type fasteners (i.e. lock washers, lock nuts, locking tab washers, etc.) when removed. Replace all
locking-type fasteners with new ones.
6-1
TM 5-3895-382-24

operation, lubrication, maintenance and repair Information.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this
publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also
ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures
you choose.
6-2
TM 5-3895-382-24
Table of Contents
Systems Operation Section
Engine Design ...............................................................................6-4
General Information......................................................................6-5
Fuel System ................................................................................ 6-10
Air Inlet and Exhaust System ................................................... 6-19
Lubrication System .................................................................... 6-22
Cooling System .......................................................................... 6-23
Electrical System ........................................................................ 6-24
Testing and Adjusting Section

Troubleshooting
Troubleshooting.......................................................................... 6-26

Fuel System ................................................................................ 6-49
Cooling System .......................................................................... 6-81
Belt Tension Chart ..................................................................... 6-86
Basic Block.................................................................................. 6-86
Index Section
Index...........................................................................................6-107
6-3
TM 5-3895-382-24
flywheel end. The left and right side of the engine
are determined from the flywheel end.
The
Number 1 cylinder is the front cylinder.
Systems Operation Section

Engine Design
SMCS Code: 1000
When the crankshaft is viewed from the front of the engine, the
NOTICE
Failure to follow recommended procedures for handling or
transporting engines can lead to engine damage.
To avoid possible engine damage, use the following
procedure.
When you are lifting or moving the engine, use the following
procedures in order to prevent engine damage:
1.
Do not tilt the engine to an extreme angle unless the

lubricating oil is first drained from the oil pan.
(A) Exhaust valves

(B) Inlet valves
2.
Do not turn the engine onto a side or an end surface

unless the lubricating oil is first drained from the oil pan.
NOTE: Type 1 engines can be identified in two ways.

Method 1 refers to Illustration 1. When the valve
cover is removed, look at the cylinder head
3.
If the oil is not drained prior to tilting the engine or

turning the engine onto a side or an end surface, the
lubricating oil from the oil pan can enter the closed
crankcase breather system and flow into the intake
manifold and the cylinder bores. This situation could
cause a hydraulic lock in the engine. Hydraulic lock can
damage the engine.
4.
The engine oil should be refilled to the correct level

before the engine is started.
Illustration 1
Cylinder and valve location for Type 1 engines and 9RM engines
Method 2 does not require the removal of the

valve cover. Refer to the inlet manifold and the
exhaust manifold. Type 1 engines have two
exhaust ports in a row and two inlet ports that are
in a row.
Type................................................... Four cylinder and four stroke

Combustion system .................................................Direct injection
Bore..................................................................100 mm (3.937 inch)
Stroke.................................................................127 mm (5.00 inch)
Displacement..........................................................4 liters (243 in 3)
Compression Ratio .....................................................................16:1
Number of cylinders ......................................................................... 4
Arrangement of cylinders ........................................................in-line
Firing Order.......................................................................... 1, 3, 4, 2
6-4
TM 5-3895-382-24
direction ............................................................................. Clockwise
NOTICE
Failure to follow recommended procedures for handling or
transporting engines can lead to engine damage.
To avoid possible engine damage, use the following
procedure.
When you are lifting or moving the engine, use the following
procedures in order to prevent engine damage:
Illustration 2
Cylinder and valve location for Type 2 engines and 7BJ engines
(A) Exhaust valves
(B) Inlet valves
NOTE: Type 2 engines can be identified in two ways.

Method 1 refers to Illustration 2. When the valve
cover is removed, look at the cylinder head
Method 2 does not require the removal of the
valve cover. Refer to the inlet manifold and the
exhaust manifold. Type 2 engines alternate the
exhaust ports and the inlet ports.
1.
Do not tilt the engine to an extreme angle unless the

lubricating oil is first drained from the oil pan.
2.
Do not turn the engine onto a side or an end surface

unless the lubricating oil is first drained from the oil pan.
3.
If the oil is not drained prior to tilting the engine or

turning the engine onto a side or an end surface, the
lubricating oil from the oil pan can enter the closed
crankcase breather system and flow into the intake
manifold and the cylinder bores. This situation could
cause a hydraulic lock in the engine. Hydraulic lock can
damage the engine.
4.
The engine oil should be refilled to the correct level

before the engine is started.
General Information
SMCS Code: 1000
Bore .................................................................100 mm (3.937 inch)
The engine is a diesel engine which is controlled with a

mechanically actuated fuel injection pump. The four engine
cylinders are arranged in-line.
Stroke ................................................................127 mm (5.00 inch)

Displacement..........................................................4 liters (243 in 3)
The cylinder head assembly has one inlet valve and one
exhaust valve for each cylinder. The ports for the inlet and the
exhaust valves are on the right side of the cylinder head. Each
cylinder valve has a single valve spring. Each cylinder has a
piston cooling jet that is installed in the cylinder block. The
piston cooling jet sprays lubricating oil onto the inner surface of
the piston in order to cool the piston. The ports for the inlet
and the exhaust valves are on the right side of the cylinder
head.

Firing Order.......................................................................... 1, 3, 4, 2
flywheel end. The left and right side of the engine
are determined from the flywheel end.
The
Number 1 cylinder is the front cylinder.
The pistons have a Fastram combustion chamber in the top of

the piston in order to provide an efficient mix of fuel and air.
The piston pin is off-center in order to reduce the noise level.
6-5
TM 5-3895-382-24
The pistons have two compression rings and an oil control ring.
The groove for the top ring has a hard metal insert in order to
reduce wear of the groove. The skirt has a layer of graphite in
order to reduce wear.
Either a Lucas DP 200 Series fuel injection pump is installed

on the engine, or a Stanadyne fuel injection pump is installed
on the engine. Both pumps conform to requirements for
emissions. Both the pump timing and the high idle are preset
at the factory. Adjustments to the pump timing and high idle
should only be made by personnel which have had the correct
training. The fuel injection pumps have mechanical governors
in order to control the engine rpm.
The correct piston height is important in order to ensure that

the piston does not contact the cylinder head. The correct
piston height also ensures the efficient combustion of fuel
which is necessary in order to conform to requirements for
emissions.
Coolant from the bottom of the radiator passes through the

centrifugal coolant pump. The pump is driven by a gear. The
gear of the pump is driven by the gear of the fuel injection
pump.
A piston and connecting rod are matched to each cylinder.

The piston height is controlled by the length of the connecting
rod. Seven different lengths of connecting rods are available in
order to attain the correct piston height. The different lengths
of connecting rods are made by machining the small end
bearing off-center in order to form an eccentric bearing. The
amount of the eccentricity of the bearing creates the different
lengths of the connecting rods. Two heights of pistons are
available in order to attain the correct piston height. The piston
heights match specific lengths of pistons.
If equipped, an air compressor is located on the left side of the

engine. The air compressor is mounted directly to the rear
face of the timing case. The air compressor is driven by the
main idler gear through an idler gear for the compressor. The
cylinder head of the air compressor is cooled by coolant from
the engine. The air compressor is lubricated by the lubrication
system of the engine.
NOTE: Always refer to the engine identification number

in order to get the correct new parts.
The crankshaft has five main journals. End play is controlled
by thrust washers which are located on both sides of the center
main bearing.
The timing case is made of aluminum. The timing gears are
stamped with timing marks in order to ensure the correct
assembly of the gears. When the number 1 piston is at the top
center position on the compression stroke, the marked teeth of
the following components will match the marks that are on the
idler gear crankshaft, camshaft and fuel Injection pump. There
is no timing mark on the rear face of the timing case.
The crankshaft gear turns the idler gear which then turns the
following gears:
the camshaft gear

the fuel injection pump
a lower idler gear which turns the gear of the lubricating
oil pump
The camshaft and the fuel injection pump run at half the rpm of
the crankshaft.
The cylinder block provides support for the full length of the dry
cylinder liners. The cylinder liners are a press fitted part. The
cylinder liners are pressed into the cylinder block. The cylinder
liners have a flame ring above the flange.
6-6
TM 5-3895-382-24
Engine and Components
Left Front View
Illustration 3
Table 1
(1) Valve cover
(4) Fuel injection nozzle
(7) Fan drive housing
(2) Water temperature

regulator housing
(5) Fuel filter
(8) Water pump
(11) Oil level gauge
(3) Oil filter cap
(6) Lubricating oil cooler
(9) Fuel injection pump
(12) Oil filter
6-7
TM 5-3895-382-24
Right Rear View
Illustration 4
Table 2
(1) Air inlet heater
(4) Turbocharger
(7) Turbocharger oil drain
(10) Starter motor
(2) Alternator
(5) Flywheel housing
(8) Turbocharger oil supply
(11) Oil pan
(3) Wastegate
(6) Fuel lift pump
(9) Flywheel
Engine Serial Numbers

engines, refer to the Systems Operation, Testing
and Adjusting Module, "Engine Design" for more
information.
6-8
TM 5-3895-382-24
Illustration 6
Engine serial number location for Type 2 engines and 7BJ engines
Illustration 5
Engine serial number location for Type 1 engines and 9RM engines
(1) Engine Serial Number Plate
(1) Engine Serial Number Plate
The engine serial number is located on the left side of the

cylinder block.
The engine serial number is located on the left side of the

cylinder block.

information.
6-9
TM 5-3895-382-24
Fuel System
SMCS Code: 1250
Illustration 7
Diagram of the bask fuel system (typical example)
Table 3
(1) Fuel injector nozzles
(4) Fuel return line from fuel filter
(7) Fuel filter
(2) Fuel return line from fuel

injection nozzles

injection pump
(8) Fuel transfer pump
(11) High pressure fuel lines
(6) Supply line
(9) Water separator
(12) Fuel tank
6-10
TM 5-3895-382-24
Table 4
When the engine is cranking, the fuel is pulled from the fuel
tank (12) through the water separator (9) by the fuel transfer
pump (8). When the fuel goes through the water separator,
any water in the fuel will go to the bottom of the bowl. The fuel
transfer pump sends the fuel at a low pressure to the fuel filter
(7). From the fuel filter, the fuel goes through the supply line
(6) to the fuel injection pump (10).
(1) Fuel injection nozzle

injection nozzles
(3) High pressure fuel lines
(4) Fuel filter
(5) Supply line

injection pump
The fuel injection pump sends fuel through the high pressure
fuel lines (11) to each of the fuel injection nozzles (1). The fuel
injection nozzle sprays fuel into the cylinder. Fuel which is not
used by the fuel injection pump goes through the fuel return
line (5) to the inlet side of the fuel filter (7). Leakage from the
fuel injection nozzles flows through the fuel return line (2) to
the top of the fuel filter (7), back to the fuel tank (12), and
through the fuel return line (4).
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 fuel injection
pump is full of fuel that is free of air.
The system must be primed when any part of the system is
drained of fuel. The following list contains examples of both
service and repairs when you must prime the system:
The fuel filter is changed.
The fuel line is removed.
The fuel injection pum p is removed.
Illustration 9
Fuel system components (right side)
(9) Fuel supply line
There is a small filter screen in the fuel transfer pump (10).

The pump has a lever which is manually operated in order to
remove the air from the fuel system. In order to release air
from the system, the orifice in the cover of the fuel filter (4) is in
the inlet side of the filter. The orifice is connected to the fuel
tank by the fuel return line from the fuel filter (4).
The air inlet heater is an electrically operated device. The air
inlet heater ignites a controlled amount of diesel fuel in the inlet
manifold in order to heat the inlet air. A heater coil in the air
inlet heater expands a delivery valve holder in order to allow
the fuel to flow into the heater. The fuel is ignited by the hot
coil. The combustion heats the air which passes through the
air inlet manifold when the starter motor is operated.
The air inlet heater (8) is installed in the inlet manifold. The air
inlet heater is controlled by a remote mounted control switch.
Illustration 8
Fuel system components (left side)
6-11
TM 5-3895-382-24
NOTE: If there is no fuel flow through the valve body of
the air inlet heater, the fuel injection pump could
be damaged. The fuel supply line to the heater
must also be free of air in order to prevent
damage. An air inlet heater that is damaged will
allow the fuel to drain into the inlet manifold when
the engine is running. This condition could cause
exhaust smoke. Excessive fuel could also cause
an overspeed condition.
Fuel flows under high pressure from the fuel injection pump
through the hole in the fuel inlet (1). The fuel then goes around
the needle valve (9) which fills the inside of the nozzle (10) with
fuel. The pressurized fuel pushes the needle valve (9) and the
spring (5) for the pressure adjusting screw. When the force of
the fuel pressure is greater than the force of the spring (5), the
needle valve (9) will lift up. When the needle valve (9) opens,
fuel under high pressure will go through the orifices (11) into
the cylinder.
Fuel Injector Nozzles For Type 1 Engines and 9RM
When the fuel is sent to the cylinder, the force of the fuel
pressure in the nozzle body will decrease. The force of the
spring (5) will then be more than the force of the fuel pressure
in the nozzle body. The needle valve (9) will move quickly to
the closed position. Needle valve (9) has a close fit with the
inside of the nozzle. The close fit makes a positive seal for the
valve.

information.
When the fuel is sent to the cylinder, a small quantity of fuel

will leak past the valve guide. This fuel lubricates the moving
parts of the fuel injection nozzle. This fuel then goes through a
passage in the body (6) to the fuel return (3). This excess fuel
is returned to the fuel tank.
Fuel Injector Nozzles For Type 2 Engines and 7BJ

information.
Illustration 10
Fuel injector nozzles (typical example)
Table 5
(1)
(2)
(3)
(4)
(5)
(6)
Fuel inlet
Cap nut
Fuel return
Pressure adjusting screw
Spring
Body
(7) Spindle for spring

(8) Retaining nut for fuel injection
nozzle
(9) Needle valve
(10) Nozzle
(11) Orifices
(12) Seat washer
6-12
TM 5-3895-382-24
When the needle valve opens, fuel under high pressure will
flow through the nozzle orifices (6) into the cylinder. The fuel is
injected into the cylinder through the orifices in the nozzle end
as a very fine spray. When the fuel is injected into the cylinder,
the force of the fuel pressure in the nozzle body will decrease.
The force of the spring will then be greater than the force of the
fuel pressure that is in the nozzle body. The needle valve will
move quickly to the closed position.
The needle valve has a close fit with the inside of the nozzle.
This makes a positive seal for the valve.
When the fuel flows to the cylinder, a small quantity of fuel will
leak by the valve guide. This fuel lubricates the moving parts
of the fuel injection nozzle. This fuel then goes through a
passage in the fuel injector holder (3) to the fuel return line (2).
This excess fuel is then returned to the fuel tank.
Fuel Injection Pump

General Operation
The fuel injection pump is a pressurized system that is totally
enclosed. The pump sends the correct amount of fuel under
high pressure at the correct time through the fuel injection
nozzles to the individual cylinders. The correct timing occurs
near the end of the compression stroke. The fuel injection
pump regulates the amount of fuel that is delivered to the fuel
injection nozzles. This action controls the engine rpm by the
governor setting or the position of the throttle control.
Illustration 11
Fuel injector nozzle (typical example)
Table 6
(1) Fuel inlet
(2) Fuel return line
(3) Fuel injector holder
The fuel lines to the fuel injection nozzles are equal lengths.
This ensures even pressure and correct injection timing at
each fuel injection nozzle.
(4) Fuel injector nozzle

(5) Seat washer
(6) Orifices
During operation, extra fuel is used as coolant and lubricant for

pump parts that move. The extra fuel is circulated through the
pump housing. The extra fuel is then returned to the fuel tank.
Return lines also carry away any air that is trapped in the fuel
injection nozzles or of the fuel injection pump housing.
Each fuel injection nozzle is fastened to the cylinder head by a

gland nut on the fuel injector holder (3). Fuel injection nozzles
are not serviceable except for removal of the fuel injector
nozzle (4) in order to clean the orifice (6).
The operating pressure of the fuel injection nozzle is set and
tested at the factory. Refer to the Specifications, "Fuel Injector
Nozzles" for the pressure settings of the fuel injector nozzles.
The fuel injection pump forces the fuel to flow under high
pressure to the hole in the fuel inlet (1). The fuel then flows
around a needle valve within the fuel injector holder (3) which
causes the fuel injection nozzle (4) to fill with fuel. The
pressure of the fuel pushes the needle valve and a spring.
When the force of the fuel pressure is greater than the force of
the spring, the needle valve will lift up.
6-13
TM 5-3895-382-24
Fuel Flow
The fuel injection pump pumps the fuel from the fuel tank
through filters. The fuel flows through the center of the rotor of
the injection pump into a circular groove on the rotor. The fuel
then flows to the automatic advance and through a connecting
passage to the metering valve. The radial position of the
metering valve is controlled by the governor.
The metering valve regulates the flow of the fuel to the
discharge ports. When the rotor revolves, the two inlet
passages of the rotor match up to the discharge ports which
are located in the hydraulic head. The discharge ports allow
the fuel to flow into the pumping chamber. When the rotor
rotates further, the discharge port of the rotor matches up with
one of the outlets of the hydraulic head. When the discharge
port is opened, the rollers contact the lobes of the cam which
forces the plungers together. Fuel that is trapped between the
plungers is then pressurized. Then, the fuel flows to the fuel
injection nozzle. The fuel injection nozzle delivers the fuel to
the cylinder.
Illustration 12
Diagram of the operation of a fuel injection pump
Table 7
(1) Drive shaft
(2) Gear
(3) Control sleeve
(4) Solenoid
(5) Cam
(6) Plunger spring
(7) Plunger
(8) Deliver Valve
When fuel reaches the discharge ports, slots on the rotor allow
the fuel and any air which is entrapped to flow into the cavity of
the pump housing. A passage in the hydraulic head connects
the outlet side of the transfer pump with the pump housing.
This passage vents the air from the fuel injection pump through
the fuel return line. This passage also allows some fuel to leak
back to the fuel tank through the fuel return line.
The fuel injection pump transfers fuel to the fuel injection

nozzles at high pressure. A cam (5) is driven from the engine
by a gear (2). Lobes on the cam (5) cause the plunger to
reciprocate. The reciprocating motion first draws the fuel. The
reciprocating motion then pressurizes the fuel.
The plunger (7) also rotates with the cam (5) in order to
sequentially align the discharge groove of the cam with each of
the ports on the fuel injector pump. The plunger (7) moves a
distance which is established by the lobes of the cam.
The fuel which leaks back to the fuel tank performs the
following function before being discharged through the fuel
return line:
The effective stroke is established by the position of the control

sleeve. When the control sleeve is moved to the left prior to
injection of the fuel, the spill port is uncovered. Uncovering the
spill port reduces the amount of fuel that is delivered to the
cylinder. When the control sleeve is moved to the right prior to
injection of the fuel, the spill port is covered. Covering the spill
port increases the amount of fuel that is delivered to the
cylinder.
The pump also includes an internal timer (not shown). The
timer allows early fuel injection by advancing the plunger. The
plunger is advanced in relation to the camshaft. The solenoid
(4) is normally closed. When the voltage is applied, the
plunger moves in order to block the fuel delivery which stops
the engine.
The housing is filled with fuel, which helps prevent

any buildup of air.
The internal components are lubricated.
The fuel injection pump is cooled.
Small air bubbles are removed.
When the fuel injection pump is operating normally, the

housing must be completely full of fuel. The fuel injection
pump is self-lubricating.
Fuel Injection Pump For Type I Engines and 9RM

and Adjusting Module, "Engine Design for more
information.
6-14
TM 5-3895-382-24
Illustration 13
Table 8
(1) Drive shaft
(5) Internal cam ring
(9) Transfer pump
(13) Plungers
(2) Bushing of the drive shaft
(6) Rollers
(10) Pressure Regulator
(14) Hydraulic head
(3) Governor flyweights
(7) Metering valve
(11) Housing
(15) Delivery valve
(4) Governor
(8) Discharge fitting
(12) Timing advance
(16) Distributor rotor
The Stanadyne fuel injection pump on Type 1 engines is a

serviceable part.
The drive end of the distributor rotor (16) has two or four
plungers (13). The plungers (13) are moved toward each other
simultaneously by an internal cam ring (5) through rollers (6)
and shoes. The rollers and shoes are positioned in slots at the
drive end of distributor rotor (16).
The main rotating components are drive shaft (1), distributor

rotor (16), transfer pump (9) and governor (4). The drive shaft
(1) engages the distributor rotor (16) in the hydraulic head (14).
6-15
TM 5-3895-382-24
The transfer pump (9) is located at the rear of distributor rotor
(16) in the end cap. The end cap also contains the strainer for
the fuel inlet and the pressure regulator (10) for the transfer
pump. The transfer pump has a positive displacement vane.
The pressure that is generated by the transfer pump is
automatically compensated for the effects of viscosity due to
temperature changes and fuel grades. The distributor rotor
(16) has a single axial bore with the following passages:
Two charging ports
One discharge port
The single discharge port serves all of the head outlets to the
fuel injection lines. The hydraulic head (14) contains the
following components:
The bore for the rotor
The bore for the metering valve (7)
The charging ports
The discharge fittings (8) of the head
Illustration 14
Components of the fuel injection pump (Lucas DP200 Series)
Table 9
(1)
(2)
(3)
(4)
(5)
(6)
O-ring
Hub nut
Locking spacer
Locking screw
Low idle adjustment screw
High idle adjustment
screw
(7) Connection for the fuel
return
The high pressure fuel lines to the fuel injection nozzles are
fastened to these discharge fittings (8). The fuel injection
pump contains a mechanical governor (4). The centrifugal
force of the governor flyweights (3) that are in the retainer is
transferred in order through the following items: a sleeve to the
governor arm, linkage, and metering valve (7). The timing
advance (12) is a hydraulic mechanism. The timing advance
unit performs one of the following functions:
Advance the delivery of fuel
Retard the delivery of fuel
(8) Electrical connection for

stop solenoid
(9) Fuel supply connection
(10) Mounting flange
(11) The fuel discharge lines
that supply fuel to the
fuel injector nozzles.
(12) Screw for adjustment of
timing advance
(13) Fittings for fuel discharge
The Lucas DP200 Series fuel injection pump is not a

serviceable part. The internal adjustment for the pump timing
is tamper proof. The adjustment for high idle is preset at the
factory. High idle should only be adjusted by personnel with
the correct training. The low idle is adjustable. The fuel
injection pump has a boost control and an engine stop
solenoid. The pump also has a self-vent feature which
removes air from the pump.
An electrical stop solenoid is contained inside the governor

housing. The electrical ground is on top of the governor
housing. The supply connections are on the top of the
governor housing. When the voltage is applied, the plunger of
the solenoid moves in order to block the flow of fuel to the
engine. When the fuel flow is stopped, the engine stops.
The fuel injection pump has a cold starting aid. The cold
starting aid advances the timing of the pump when the engine
is cold. The cold starting aid is electrically operated. The cold
starting aid should only be adjusted by personnel with the
correct training.
Fuel Injection Pump (Lucas DP200 Series) On Type 2

Engines and 7BJ
information.
6-16
TM 5-3895-382-24
The cold starting aid is connected by a shaft to the advance
lever for the timing of the fuel injection pump. The cold starting
aid and the advance lever are internal components of the
Lucas DP200 Series fuel injection pump.
The fuel injection pump has an electrically operated cold

starting aid which holds the timing of the pump in an advanced
position when the engine is cold. The advance lever of the
pump is enclosed within the pump housing. The cold starting
aid should only be adjusted by personnel with the correct
training.
Fuel Injection Pump (Stanadyne) On Type 2 Engines

and 7BJ
The cold starling aid is connected by a shaft to the advance

lever for the timing of the fuel injection pump. The cold starling
aid and the advance lever are internal components of the
Stanadyne fuel injection pump.

information.
A temperature switch is installed in the coolant passage which

is located at the rear of the timing case. The temperature
switch sends current to the electrical connection of the cold
starling aid (not shown) when the engine is started and when
the engine is below normal operating temperature. The body
contains a wire coil with high electrical resistance. The wire
coil surrounds an element which is filled with wax. The wire
coil heats the wax which then expands. The expansion of the
wax forces a rod to move the lever of the timing advance. The
lever continuously adjusts the pump to the correct timing for
the normal operating temperature.
Illustration 15
Components of the fuel injection pump (Stanadyne)
Table 10
(1) Electrical connection for stop
solenoid
(2) Connection for the fuel return
(3) Adjustment screw for low idle
(4) Adjustment screw for high idle
(5) Range nut
(6) Nut for end cap

(7) Fitting for fuel discharge
(8) Fuel line connection to
fuel injection nozzles
(9) Screw for adjustment
timing advance
The Stanadyne fuel injection pump on Type 2 engines is not a

serviceable part. The adjustment for the timing of the fuel
injection pump is made internally. The adjustment is tamper
proof. The low idle is adjustable. The adjustment for high idle
is preset at the factory. High idle should only be adjusted by
personnel with the correct training. The pump has a boost
control and an engine stop solenoid. The design of the pump
will automatically remove air from the pump.
6-17
TM 5-3895-382-24
Cold Start Advance Unit
Lucas Fuel Injection Pump and Bosch

Fuel Injection Pump
The following rotary fuel injection pumps may have a cold start
advance unit: Stanadyne, Lucas and Bosch. The cold start
advance holds the timing of the fuel injection pump in an
advance position when the engine is cold.
When the engine is cold, the coolant temperature switch is

open. The coolant temperature switch will then interrupt the
electrical current that goes to the wax motor. The wax motor is
in the fuel injection pump. The fuel injection pump timing is
then in the advanced position for reduced white smoke and
improved emissions. Once the coolant temperature rises, the
switch closes. The fuel injection timing is retarded.
The cold start advance unit is on the rear of the timing case on
the left side of the engine.
Stanadyne Fuel Injection Pumps
If a wire is disconnected or if the switch fails in the open

position, the engine will run with advanced timing. The engine
will have higher cylinder pressure and engine damage may
result.
When the engine is cold, the coolant temperature switch is

closed. When the switch is closed, a 12 volt current is carried
to the solenoid. The solenoid is on the lower rear part of the
fuel injection pump. The solenoid is then actuated, resulting in
the advance of the injection timing. This produces reduced
white smoke and reduced emissions during cold weather
operation. When the coolant temperature reaches a certain
temperature, the switch opens. When the switch is open, the
switch stops the electrical current to the solenoid. The fuel
injection timing is then returned to the normal running mode.
If the switch fails in the closed mode, the engine will run in the
retarded mode. The engine will then be more difficult to start.
The engine will also emit white smoke.
The engine will run in the retarded mode at all times if one of
the following events occur: A wire is disconnected and the
switch fails in the open mode. The engine will then be more
difficult to start. The engine will then emit white smoke.
If the switch fails in the closed mode, the engine will run in the
advanced timing mode at all times. The result will be higher
cylinder pressure and possible engine damage.
6-18
TM 5-3895-382-24
The exhaust stroke and the timing of the valve mechanism
pushes combustion gases out of the open exhaust valve
through the exhaust manifold (1). The exhaust gases flow
through the blades of the turbocharger turbine wheel (6) which
causes the turbine wheel and the compressor wheel to turn.
Then, the exhaust gases flow through the exhaust outlet (7) of
the turbocharger to the outside.
Air Inlet and Exhaust System

SMCS Code: 1050
The air inlet system is also equipped with a crankcase

ventilation system. The intake strokes of the pistons pull in
atmospheric air to the crankcase.
Turbocharger
A turbocharger increases the temperature and the density of
the air that is sent to the engine cylinder. This condition
causes a lower temperature of ignition to develop earlier in the
compression stroke. The compression stroke is also timed in a
more accurate way with the fuel injection. Surplus air lowers
the temperature of combustion. This surplus air also provides
internal cooling.
Illustration 18
Air inlet and exhaust system (typical example)
(1) Exhaust manifold
(2) Inlet manifold
(3) Engine cylinders
(4) Air inlet
(5) Turbocharger compressor wheel
(6) Turbocharger turbine wheel
(7) Exhaust outlet
A turbocharger improves the following aspects of engine

performance:
Engines which are naturally aspirated pull outside air through

an air cleaner directly into the inlet manifold (2). The air flows
from the inlet manifold to the engine cylinders (3). The fuel is
mixed with the air in the engine cylinders. After the fuel
combustion occurs in the engine cylinder, the exhaust gases
flow directly to the outside air through the exhaust manifold (1).
Turbocharged engines pull outside air through an air cleaner
into the air inlet (4) of the turbocharger. The suction is caused
by the turbocharger compressor wheel (5).
Then, the
turbocharger compressor wheel compresses the air. The air
flows through the inlet manifold (2) which directs an even
distribution of the air to each engine cylinder (3). Air is pulled
into the engine cylinder (3) during the intake stroke of the
piston. Then, the air is mixed with fuel from the fuel injection
nozzles.
Each piston makes four strokes:
1.
2.
3.
4.
Intake
Compression
Power
Exhaust
The sequence of the strokes by all of pistons in all of the

engine cylinders provides constant air flow to the inlet system
during the engine operation.
6-19
Power output is increased.
Fuel efficiency is increased.
Engine torque is increased.
Durability of the engine is increased.
Emissions of the engine are increased.
TM 5-3895-382-24
bearing housing of the turbocharger. The oil is returned
through the oil outlet port (10) to the oil pan.
Some turbochargers have a wastegate. The wastegate is
controlled by the boost pressure. This allows some of the
exhaust gases to bypass the turbine rotor at higher engine
speeds. The wastegate is a type of flapper valve that
automatically opens at a preset level of boost pressure in order
to allow exhaust gas to flow around the turbine. The
wastegate allows the design of the turbocharger to be more
effective at lower engine speeds.
The wastegate is controlled by a diaphragm which is open to
the atmosphere on one side and open to the manifold pressure
on the other side.
The wastegate normally opens at
approximately 74 kPa (10.7 psi). The relief valve opens at 150
kPa (21.8 psi).
An air/fuel ratio control is installed between the turbocharger
and the fuel injection pump. The air/fuel ratio control performs
the following functions:
The fuel is limited on acceleration in order to prevent an

overspeed condition.
The generation of black smoke is reduced.
The fuel efficiency is improved and emissions are

reduced at low boost when the fuel rack is limited for
low power output.
Illustration 19
Components of a turbocharger (typical example)
Table 11
(1) Air inlet
(2) Compressor housing
(3) Compressor wheel
(4) Bearing
(5) Oil inlet port
(6) Bearing
(7) Turbine housing

(8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
The air/fuel ratio control is a nonserviceable part. Adjustment

and repairs should only be done by a Caterpillar Dealer.
A turbocharger is installed between the exhaust and intake

manifolds. The turbocharger is driven by exhaust gases which
flow through the exhaust inlet (11). The energy of the exhaust
gas turns the turbine wheel (8). Then, the exhaust gas flows
out of the turbine housing (7) through the exhaust outlet (9).
Cylinder Head And Valves

The valves and the valve mechanism control the flow of the air
and the exhaust gases in the cylinder during engine operation.
The cylinder head assembly has two valves for each cylinder.
Each valve has one valve spring. The ports for the inlet and
exhaust valves are on the right side of the cylinder. Steel valve
seat inserts are installed in the cylinder head for both the inlet
and the exhaust valves. The valve seat inserts can be
replaced.
The turbine wheel and the compressor wheel (3) are installed
on the same shaft. Therefore, the turbine wheel and the
compressor wheel rotate at the same rpm. The compressor
wheel is enclosed by the compressor housing (2). The
compressor wheel compresses the inlet air (1). The inlet air
flows into the engine cylinders through the inlet valves of the
cylinders.
The valves move along phosphated steel guides in order to

reduce friction and wear. The valve guides can be replaced.
The exhaust valve guide has a counterbore in order to prevent
the seizure of the valve stem. The seizure of the valve stem is
caused by a buildup of carbon under the head of the valve.
The oil from the main gallery of the cylinder block flows through
the oil inlet port (5) in order to lubricate the turbocharger
bearings (4) and (6). The pressurized oil passes through the
6-20
TM 5-3895-382-24
The inlet and the exhaust valves are opened and closed by the
rotation and movement of the following components:
Crankshaft
Camshaft
Valve lifters
Pushrods
Rocker arms
Valve springs
The camshaft gear is driven by the crankshaft gear. The

camshaft and the crankshaft a timed together. When the
camshaft turns, the valve lifters a moved up and down. The
pushrods move the rocker arms. The rocker arms make the
inlet and exhaust valves open and close in sequence with the
firing order of the engine. The valve springs push the valves
back to the closed position.
6-21
TM 5-3895-382-24
Lubrication System
SMCS Code: 1300
Illustration 20
Flow Diagram Of The Engine Oil Lubrication System
Table 12
(1) Reduced pressure
(3) Baffle type oil cooler

(if equipped)
(5) Cooling lines for

water
(7) Suction
(2) Splash and drain
(4) High pressure
(6) Engine oil pump
(8) Oil filter
6-22
(9) Canister type oil cooler

(if equipped)
TM 5-3895-382-24
Pressure for the lubrication system is supplied by an engine oil
pump (6) which uses rotors. The engine oil pump is driven
through an idler gear from the crankshaft gear. The engine oil
pump has an inner rotor and an outer rotor. The axes of
rotation of the rotors are off-center relative to each other.
There is a key between the inner rotor and the drive shaft.
passage in the cylinder block to the cylinder head. The oil then
flows into the rocker arm shaft at a reduced pressure (1) to the
bearings of the rocker arm levers. The valve stems, the valve
springs and the vale lifters are lubricated by the splash and the
mist of the oil.
The hub of the idler gear is lubricated by oil from the oil gallery.
The timing gears are lubricated by the splash of the oil (2).
The inner rotor has six lobes which mesh with the seven lobes
of the outer rotor. When the inner lobe rotates, the distance
increases between the lobes of the outer rotor and the lobes of
the inner rotor in order to create suction. When the distance
decreases between the lobes, pressure is created.
The turbocharger is lubricated by oil from the oil filter through

the engine block. An external line from the engine block
supplies oil to the turbocharger. The oil then flows through a
line to the oil pan.
Lubricating oil from the oil pan flows through a strainer and a
line to the suction side (7) of the engine oil pump. The
lubricating oil flows from the outlet side of the pump through a
line to a relief valve. The relief valve is installed near the
bottom of the left side of the cylinder block.
Piston cooling jets are installed in turbocharged engines. The

piston cooling jets are connected to the oil gallery. The piston
cooling jets spray lubricating oil on the underside of the pistons
in order to cool the pistons.
The relief valve on the engine oil pump opens if the oil
pressure is too high. The lubricating oil which flows through
the relief valve is returned to the oil pan. The lubricating oil
which flows past the relief valve goes to the baffle type oil
cooler (3), if equipped. The baffle type oil cooler has seven
cooling plates. If the engine is equipped with a canister type oil
cooler (9), the lubricating oil then flows from the relief valve of
the engine oil pump to the oil filter. Then, the oil flows through
the canister type oil cooler which is cooled by water flowing
through supply and return lines (5) from the water pump.
Cooling System
SMCS Code: 1350
The coolant flows from the bottom of the radiator to the
centrifugal water pump. The water pump is installed on the
front of the timing case. The water pump is driven by a gear
The gear of the fuel injection pump drives the gear of the water
pump.
The water pump forces the coolant through a passage in the
timing case to the front of the cylinder block. The coolant flows
to a passage in the left side of the cylinder block. The coolant
then flows to the rear of the cylinder block.
The oil cooler (3) or (9) and the oil filter (8) are installed on the
left side of the cylinder block.
The oil flows from the oil filter through a passage drilled across
the cylinder block to the oil gallery. The oil gallery is drilled
through the total length of the left side of the cylinder block.
The oil cooler is installed on the left side of the engine. A line
is connected between the housing of the water temperature
regulator and the oil cooler. Some of the coolant from the
water pump flows through this line to the following
components:
Lubricating oil flows from the oil gallery through high pressure
passages (4) to the main bearings of the crankshaft. The oil
then flows through passages in the crankshaft to the large end
bearings of the connecting rod. The pistons and the cylinder
bores are lubricated by the splash and the mist of the oil (2).
Lubricating oil flows from the main bearings through high
pressure passages (4) in the cylinder block to the journals of
the camshaft. The oil flows from the center journal of the
camshaft at a reduced pressure. The oil flows through a
6-23
1.
the plates of the cooler
2.
a line to the cylinder block
3.
the coolant passages for the cylinders
4.
the cylinder head
TM 5-3895-382-24
The coolant exits the cylinder head at the front. The coolant
then flows into the housing of the water temperature regulator.
If the water temperature regulator is closed, the coolant goes
directly through a bypass to the inlet side of the water pump. If
the water temperature regulator is open, the bypass is closed
and the coolant flows to the top of the radiator.
the engine. The electrical contacts in the solenoid close the

circuit between the battery and the starting motor barely before
the pinion engages the ring gear. This causes the starting
motor to rotate. This type of activation is called a positive shift.
When the engine begins to run, the overrunning clutch of the
pinion drive prevents damage to the armature. Damage to the
armature is caused by excessive speeds. The clutch prevents
damage by stopping the mechanical connection. However, the
pinion will stay meshed with the ring gear until the ignition
switch is released. A spring in the overrunning clutch returns
the clutch to the rest position.
Electrical System
SMCS Code: 1400; 1550; 1900
The electrical system is a negative ground system.
The charging circuit operates when the engine is running. The
alternator in the charging circuit produces direct current for the
electrical system.
Alternator
Starting Motor
Illustration 22
Alternator
(1)
Illustration 21
Starting Motor
(1)
(2)
Shaft for mounting the pulley
The alternator produces the following electrical output:
Terminal for connection of the battery cable

Terminal for connection of the ignition switch
three-phase
full-wave
The starting motor turns the engine flywheel. The rpm must be
high enough in order to initiate a sustained operation of the fuel
ignition in the cylinders.
rectified
The starting motor has a solenoid. When the ignition switch is

activated, voltage from the electrical system will cause the
solenoid to move the pinion toward the flywheel ring gear of
The alternator has brushes. The alternator is an electromechanical component. The alternator is driven by a belt from
the fan drive pulley. The alternator charges the storage battery
during the engine operation.
6-24
TM 5-3895-382-24
The alternator is cooled by an external fan which is mounted
behind the pulley. The fan pulls air through the holes in the
back of the alternator. The air exits the front of the alternator.
Most models have a circuit breaker. The circuit breaker is a

switch that opens the circuit if the current in the electrical
system is higher than the rating of the circuit breaker. The
metal disc (2) is activated by heat. The metal disc has contact
points which complete the electrical circuit through the circuit
breaker. If the current in the electrical system gets too high,
the metal disc will get hot. This heat causes a distortion of the
metal disc. This distortion causes the contact points to open
the circuit. A circuit breaker that is open can be reset when the
metal disc becomes cooler. Push the reset button (1) in order
to close the contact points and reset the circuit breaker.
The alternator converts the mechanical energy and the

magnetic energy into alternating current and voltage. This
conversion is done by rotating a direct current electromagnetic
field on the inside of a three-phase stator.
The
electromagnetic field is generated by electrical current flowing
through a rotor. The stator generates alternating current and
voltage.
The alternating current is changed to direct current by a threephase, full-wave rectifier. Direct current flows to the output
terminal of the alternator. The rectifier has three exciter
diodes. The direct current is used for the charging process.
A solid state regulator is installed on the rear end of the
alternator. Two brushes conduct current through two slip rings.
The current then flows to the rotor field. A capacitor protects
the rectifier from high voltages.
The alternator is connected to the battery through the ignition
switch. Therefore, alternator excitation occurs when the switch
is in the ON position.
Circuit Breakers
Illustration 23
Circuit Breaker With Reset Button
(1)
(2)
(3)
(4)
(5)
Reset button
Metal disc in the open position
Contacts
Metal disc in closed position
Battery circuit terminals
6-25
TM 5-3895-382-24
Testing and Adjusting Section
Problem 1
Troubleshooting
The engine is difficult to start. If the engine starts, the

engine runs rough.
Troubleshooting
SMCS Code: 1000
Probable Cause

information.
1.
Make sure that the seals and the mating surface of the
cylinder head are clean. The seal that is formed by the
anti-seize compound on the threads of the fuel injector
nozzle may be broken. Make sure that the fuel injector
nozzle is tightened to the correct torque in the threaded
hole of the cylinder head.
Troubleshooting can be difficult. The most common problems

are identified in this troubleshooting manual. The symptoms,
causes, and guidance for solving the problems are given.
Sometimes additional repair work is required beyond the repair
which is recommended. Frequently, a problem does not exist
in isolation. The problem can be a result of wear or damage to
several parts which operate together as part of a system.
2.
All possible problems and the probable causes cannot be

listed. The serviceman must follow a logical process of
eliminating possible causes and identifying the specific causes
of the problems.
3.
The connections of the high pressure fuel line leak.

Tighten the fittings of the high pressure fuel line.
4.
NOTE: Be careful when you are handling the fuel injector

nozzles in order to prevent damage to the orifices,
threads, and other surfaces. When a fuel injector
nozzle is installed, make sure that all surfaces and
threads are clean.
The fuel injector nozzle does not operate correctly.
NOTE: This step does not include Type 2 engines and

7BJ engines. The fuel injector nozzles for these
engine serial numbers are not serviceable.
Adjustment of these fuel injector nozzles should
not be made. If any problems with the internal
components of these fuel injector nozzles exist,
the fuel injector nozzle should be replaced.
The procedures which require disassembly or the adjustment

of the fuel injector nozzle only relate to the following engines:
Make sure that the mounting bolts for the clamp and the
components of the fuel injector nozzle are tightened to the
correct torques. Make sure that the seal and the spacer are
positioned correctly. Test the fuel injector nozzle on a nozzle
tester.
Do not disassemble the fuel injector nozzles and do not adjust

the fuel injector nozzles on the following engines:
Extra seat washers were not removed from the threaded

recess in the cylinder head for the fuel injector nozzle.
Debris exists on the mating surface of the cylinder head
with the seat washer.
Remove any extra seat washer or debris.
Troubleshooting The Fuel Injector Nozzles On The

Engine
The fuel injector nozzle does not seal correctly in the

cylinder head.

5.
Replace the fuel injector nozzle on Type 2 engines and 7BJ

engines if the fuel injector nozzle does not operate correctly.
These fuel injector nozzles are not serviceable parts.
The incorrect fuel injector nozzle is installed.

Make sure that all fuel injector nozzles have the correct
identification code for the engine.
Refer to
Specifications, "Fuel Injection Nozzles".
Refer to Specifications, "Fuel Injection Nozzles" for additional

information.
6-26
TM 5-3895-382-24
6.
Problem 2
A connection of the fuel return line leaks.

Inspect all connections of the low pressure fuel line for
tightening to the correct torque.
The engine exhaust has too much black smoke or

the engine overheats.
Probable Cause
Problem 4
1.
The engine has the following symptoms: knocks, runs

uneven, and misfires.
Extra seat washer were not removed from the threaded

with the sea washer.
Probable Cause
1.

2.
Refer to Problem 1.
Refer to Problem 1.
3.
The fuel injector nozzle does not seal in the cylinder

head.
2.

identification code for the engine.
Refer to
Specifications, "Fuel Injection Nozzles".

with the sea washer.
3.
Problem 3

The engine has lost power and the engine uses too much
fuel.
4.
Probable Cause
Refer to Problem 1.
1.
Test the fuel injector nozzle on a nozzle tester.
The fuel injector nozzle does not seal in the cylinder

head.
5.
Refer to Problem 1.
2.
code for the engine.

with the seat washer.
6.
Troubleshooting Fuel Injector Nozzles On A Nozzle

Tester

4.
NOTE: Be careful when you are handling the fuel injector

nozzles in order to prevent damage to the orifices,
threads, and other surfaces. When a fuel injector
nozzle is installed, make sure that all surfaces and
threads are clean.

Refer to Problem 1.
Test the fuel injector nozzle on a nozzle tester.
5.
A restriction exists in the high pressure fuel line.

Inspect all high pressure fuel lines for damage.

3.
The procedures which require disassembly or the adjustment

of the fuel injector nozzle only relate to the following engines:
code for the engine.
6-27
TM 5-3895-382-24
Do not disassemble the fuel injector nozzles and do not adjust
the fuel injector nozzles on the following engines:
Clean the passage in order to remove any carbon

buildup or other debris.
7.
The cap nut is too tight.

Adjust the cap nut to the correct torque.
Replace the fuel injector nozzle on Type 2 engines and 7BJ

engines if the fuel injector nozzle does not operate correctly.
These fuel injector nozzles are not serviceable parts.
Troubleshooting The Turbocharger
Problem 1
Problem 1
Back Leakage
Not Enough Power
Probable Cause
Probable Cause
1.
1.
Fuel leaks through the cap nut or the retaining nut.

Make sure that the threads are clean. Tighten the nuts
to the correct torque.
2.
The element of the air filter is dirty.

The element must be cleaned or replaced.
Debris or damage exists on the needle valve or the

body.
2.
A restriction exists in the tube between the air filter and

the turbocharger.
3.
An air leak or a restriction exists in the line between the

turbocharger and the intake manifold.
Visually inspect the needle and the body of the valve for
carbon pitting, scoring, or other damage.
The component must be repaired or replaced.
Problem 2
4.
The fuel injector nozzle does not inject fuel in the correct
quantity or in the correct pattern.
Probable Cause
1.
5.
Correctly position the turbocharger and tighten the

clamps and bolts.
6.
3.
The fuel injector nozzle is stuck.
The intake manifold is cracked, loose or the flange is

distorted.
Debris or damage exists on the fuel injector nozzle.
The intake manifold must be repaired or replaced.
The orifices are blocked.
7.
Inspect the orifices for carbon buildup. The fuel injector

nozzle must be cleaned or replaced.
4.
The exhaust manifold is cracked, loose, or the flange is

distorted.
The exhaust manifold must be repaired or replaced.
The spring is damaged.
8.
Replace the spring or the fuel injector nozzle.

5.
The turbocharger is loose or the clamps and bolts on

the turbocharger are loose.
The setting of the opening pressure is incorrect.

Test the setting of the opening pressure. Adjust the
setting to the correct pressure.
2.
A restriction exists in the exhaust system.
The turbine housing is damaged or restricted.

The turbine housing must be repaired or replaced.
The needle valve or the body is damaged. The fuel

injector nozzle makes a noise which is caused by
vibration when the fuel is injected.
9.
Visually inspect the needle valve and the body for

carbon pitting, scoring, or other damage.
10.
The bearings of the turbocharger are worn.

Replace the bearings.
Excessive dirt exists in the compressor housing.
Clean the compressor housing.
6.
The passage for the fuel return is obstructed.
6-28
TM 5-3895-382-24
11.
Carbon has collected behind the rotor of the turbine.
The drain pipe must be repaired or replaced.
Remove the carbon.

12.
6.
Air or combustion gas is leaking through the seals of the

turbocharger.
7.
The fuel injection pump is not operating correctly.

The fuel injection pump must be repaired or replaced.
13.
The fuel injector nozzles are worn or damaged.

8.
The fuel injector nozzles must be repaired or replaced.

14.
The inlet valves and the exhaust valves are burned.

9.
Replace the inlet valves and the exhaust valves.
Determine the cause of the damage to the valves.
15.
16.
17.

Remove the carbon.
The piston rings are worn.
Problem 3
Replace the piston rings.
Blue Smoke
The actuator of the wastegate is not operating correctly.
Probable Cause
The actuator must be adjusted or replaced.
1.
The valve of the wastegate is not operating correctly.

The valve must be repaired or replaced.
2.
Problem 2
The crankcase breather is restricted.

The crankcase breather (if equipped), or the tubing must
be cleaned or replaced.
Black Smoke
Probable Cause
3.

the turbocharger.
1.

The element must be cleaned and replaced.
2.
4.

the turbocharger.

clamps and bolts.

5.
3.


distorted.

clamps and bolts.
4.
6.

distorted.

7.
5.
The drain pipe for the lubricating oil is restricted.

turbocharger.
Replace the seals.
6-29
TM 5-3895-382-24
8.
6.

9.
7.

10.

8.
Remove the carbon.

11.

Excessive anti-corrosion fluid exists in the turbocharger.

This condition only exists on a new engine which has
not been operated.
9.
Clean the turbocharger in order to remove the

anticorrosion fluid.
10.
Lubricating oil is leaking from the supply line.

The supply line must be repaired or replaced.
The high idle operates for an excessive period of time.
12.

11.
13.
A restriction exists in the bearing housing of the

turbocharger.

turbocharger
The bearing housing must be repaired or replaced.
Problem 5
Excessive Lubricating Oil At The End Of The Turbine
Problem 4
Probable Cause
High Consumption of Lubricating Oil

1.
Probable Cause
1.


2.

2.

3.

be repaired or replaced.
3.

clamps and bolts.
The turbocharger is loose or the damps and bolts on the

turbocharger are loose.
4.

clamps and bolts.

The drain pipe must be cleaned or replaced.
4.
The incorrect type of lubricating oil is being used.

5.
Drain the lubricating oil. Install the correct type and the
quantity of lubricating oil.
5.

The turbine housing must be cleaned or replaced.
6.

6-30
TM 5-3895-382-24
7.
6.

turbocharger.
Remove the carbon.

Replace the seals.
8.

7.

9.

not been operated.
8.


10.
9.

11.
10.

turbocharger.

not been operated.

11.
Problem 6

Excessive Lubricating Oil At The Compressor End

12.
Probable Cause
1.

turbocharger
Replace the element of the air filter.
Problem 7
2.
Lubricating oil exists in the exhaust manifold.

3.
Probable Cause
1.

the turbocharger.

The component must be cleaned and replaced.

4.
2.
An air leak or restriction exists in the line between the



3.
5.


4.

clamps and bolts.

6-31
TM 5-3895-382-24
5.
Drain the lubricating oil. Replace the oil filter. Install the
correct type of lubricating oil.

5.
6.
The oil supply line from the oil pan is restricted.

The oil supply line must be repaired or replaced.
6.
7.

Remove the carbon.
8.
The engine rpm increases too rapidly when the engine

is started.
Check the fuel injection pump for correct operation and
settings.

7.
The high idle operates an insufficient period of time.

9.

settings.

10.
8.

turbocharger.

9.
10.
Not Enough Lubrication
A restriction exists in the lubricating oil filter.

Clean the oil filter base and the housing for the oil filter.
Check the operation of the bypass valve in the oil filter
base. Replace the oil filter.
Probable Cause
11.

clamps and bolts.
2.

turbocharger.
Problem 8
1.
Lubricating oil is leaking from the oil supply line.
The engine stopped too soon from a high load condition.

Check the following components for correct operation or
damage:
The flow of lubricating oil is delayed to the turbocharger

when the engine is started. Insufficient oil flows to the
turbocharger when the engine is running.
Check the following components for correct operation:
compressor impeller of the turbocharger

coolant system
fuel injection pump
air/fuel ratio control
wastegate
valve lash
fuel injector nozzles
oil pump
the engine oil bypass valve
the bypass valve in the oil filter base
oil filter
viscosity of the oil
restrictions in oil lines
3.
The lubricating oil is dirty.
Probable Cause
Drain the lubricating oil. Install the correct type of

lubricating oil. Replace the oil filter.
1.
4.
Problem 9
The inside of the intake manifold is wet.

The element must be cleaned or replaced
The incorrect type of lubricating oil is installed.
6-32
TM 5-3895-382-24
2.
15.

3.

turbocharger.
The element of the air filter is not sealed correctly A

connection between the air filter and the turbocharger is
loose.
16.
Inspect the element of the air filter and the air supply
line to the turbocharger for correct installation.
17.
Fuel leakage exists from the air inlet heater.

Test the air inlet heater for leakage.
The backplate of the compressor is cracked.
Replace the backplate.
4.
5.

the turbocharger.
Problem 10
Damaged Compressor Impeller Of The Turbocharger
An air leak or restriction exists in the line between the

Probable Cause
1.

6.


7.

2.

damps and bolts.
distorted.
10.
11.
The drain line for the lubricating oil is restricted.
4.
The drain line must be repaired or replaced.
The flow of the lubricating oil is delayed to the

turbocharger when the engine is started. Insufficient oil
flows to the turbocharger when the engine is running.
oil pump

turbocharger.
oil filter
5.
Replace the seals.

12.
13.

14.

damps and bolts.
The exhaust manifold must be repaired or replace.

9.

the turbocharger.
3.
8.
The element of the air filter is not sealed correctly. A

loose.

6-33
TM 5-3895-382-24
6.
7.
8.
Problem 11
Damaged Turbine Rotor
Probable Cause
1.

2.

9.

is started.
3.
The period of time at high idle is insufficient.
12.
13.
oil pump

turbocharger.
oil filter
4.
14.

Check the fuel Injection pump for correct operation and

settings.
11.

damps and bolts.
Check the fuel Injection pump for correct operation and

settings.
10.

5.

damage:
coolant system
fuel injection pump
wastegate
valve lash

6.

7.

8.

9.
6-34
TM 5-3895-382-24
10.

is started.
Problem 12
The rotating assembly of the turbocharger does not rotate
freely.

settings.
Probable Cause
11.

1.
settings.
12.
The fuel injection pump is not operating correctly.

loose.

2.
13.
The inlet valves and the exhaust vales are burned.

the turbocharger.
Replace the inlet valves and the exhaust valves.

Determine the cause of the damage to the valves.

3.
14.

4.
15.

turbocharger.

damps and bolts.

16.
5.
17.


oil pump

damage:
oil filter
6.
coolant system
fuel injection pump
wastegate
valve lash

7.

6-35
TM 5-3895-382-24
8.
9.
10.
Problem 13
Worn Bearings, Bearing Bores, and Journals
Probable Cause
1.

the turbocharger.

2.
11.

3.
12.

Remove the carbon.
13.

clamps and bolts.

is started.
4.

settings.
14.
15.

oil pump

settings.
oil filter
5.

turbocharger.
17.


16.


18.

damage:
coolant system
fuel injection pump
wastegate
valve lash
6.

7.

8.

is started.
settings.
9.

settings.
6-36
TM 5-3895-382-24
10.
6.


11.

damps and bolts.

7.

distorted.
12.

8.
damage:

distorted.
The exhaust manifold must be repaired or replaced.
coolant system
fuel injection pump
wastegate
valve lash
9.
Problem 14
The turbocharger makes excessive noise.
Probable Cause
1.
oil pump
oil filter
10.


2.
11.

loose.
12.
13.

An air leak or a restriction exists in the line between the

14.


5.


the turbocharger.
4.

3.

15.

6-37
TM 5-3895-382-24
16.
2.
Remove the carbon.

17.
18.
19.

is started.
oil pump

settings.

settings.
oil filter viscosity of the oil restrictions in oil lines
3.


20.

turbocharger.
4.
5.
22.
6.
coolant system
fuel injection pump
wastegate
valve lash
7.

settings.
8.

9.

10.

damage:
Problem 15
Sludge Or Carbon Deposits In The Bearing Housing
Probable Cause
1.


damage:



21.


be replaced.
6-38
coolant system
fuel injection pump
air/fuel ratio control.
TM 5-3895-382-24
wastegate
valve lash
25.
The engine does not crank when the following events

occur:
The starting motor is activated.
Troubleshooting The Engine
The pinion gear engages the ring gear.
The flywheel begins to turn.
26.
The starting motor continues to run after the ignition

switch is released.
When you are troubleshooting the engine, refer to

Specifications, and Testing and Adjusting for additional
information.
1.
The engine will not start.
2.
The engine starts. The engine runs for a brief period of

time. Then, the engine stops.
27.
The pinion gear does not disengage after the engine

starts to run.
3.
The engine misfires or the engine runs rough.
28.
The alternator does not charge the battery.
4.
The engine runs evenly, but the engine loses power.
29.
5.
The engine does not have enough power.
The rate of charging of the battery by the alternator is

slow or uneven.
6.
The engine has excessive vibration.
30.
The alternator charges the battery at a voltage that is

too high.
7.
The engine has excessive combustion noise.
31.
The alternator is noisy.
8.
The engine has valve compartment noise.
9.
The engine has oil in the cooling system.
Problem 1
10.
The engine knocks.
The engine will not start.
11.
The rocker arm has little movement and valve lash

exceeds the specification.
Probable Cause
12.
The valve is loose.
13.
Oil condenses at the exhaust.
14.
The valve lash is less than the specification.
15.
Engine components have early wear.
16.
Coolant is in the lubrication oil.
17.
The engine exhausts too much black smoke or gray

smoke.
18.
The engine exhausts too much white smoke or blue

smoke.
19.
The engine has low oil pressure.
20.
The engine uses too much lubrication oil.
21.
The engine coolant is too hot.
22.
The exhaust temperature is too high.
23.
The starting motor does not turn or the starting motor

turns too slowly.
24.
The starting motor turns, but the pinion gear does not
engage flywheel ring gear.
Troubleshooting Problems
1.
The engine starting procedure was incorrectly followed.

Make sure that the engine starting procedure is correctly
followed.
2.
The Fuel Stop Control is in the "NO FUEL" position.

Turn the Fuel Stop Control to the "RUN" position. Make
sure that the linkage of the fuel rack operates correctly.
3.
The fuel level is low in the tank.

system.
Air is in the fuel
Fill the fuel tank with fuel. Remove the air from the fuel
system.
4.
The fuel is contaminated.

The fuel contains water, dirt, ice or wax.
5.
The cranking speed is too slow.

The engine oil is too thick. The connections of the
battery cables to the starting motor are loose.
6-39
TM 5-3895-382-24
6.
The cold starting aid for the fuel injection pump does not
operate correctly.
12.
Run the engine at the rpm that gives maximum misfiring

or rough running. Then, loosen a fuel line nut on the
injection line for each cylinder. Loosen one nut at a
time. Then, tighten that nut before loosening the next
fuel line nut. If loosening the fuel line nut does not affect
the operation of the engine, the fuel injector nozzle is
probably defective. Test the fuel injector nozzle for that
cylinder. Replace the defective fuel injector nozzle.
Inspect the cable connection and the electrical

connection of the cold starting aid. Test the cold
starting aid for correct operation.
7.
The fuel shutoff solenoid is not operating correctly.

Make sure that the fuel shutoff solenoid operates
correctly. Replace a fuel shutoff solenoid that is
defective.
8.
Make sure that all of the fuel injector nozzles are the
correct type for the engine. Test the pressure setting of
the fuel injector nozzles.
The fuel transfer pump is not operating correctly. The

fuel transfer pump was installed when the lobe of the
camshaft was at maximum lift.
Make sure that the fuel injector nozzles are properly

sealed in the threaded ports. Make sure that the fuel
injector nozzles are correctly aligned in the threaded
ports and tightened to the correct torque. Ensure that
seat washers are installed on the fuel injector nozzles
correctly. Make sure that the bottoms of the threaded
ports are clean and free of debris. Make sure that the
bottoms of the threaded ports do not contain extra seat
washers.
Check the fuel pressure when the engine is cranking.

Remove the fuel transfer pump if the fuel pressure is too
low. The fuel transfer pump must be repaired or
replaced.
Install the fuel transfer pump with the lobe of the
camshaft on minimum lift. Tighten the mounting bolts
evenly.
13.
9.
The fuel filter or the fuel lines are restricted. Excess

water has built up in the fuel filter.
14.
The operation of the fuel injection pump is not correct.
The cylinders have low compression.

Starting the engine may be difficult in warm weather.
The engine may not start in cold weather. Low
compression is most frequently caused by the following
conditions:
Check the timing of the fuel injection pump. Adjust the

timing or replace the fuel injection pump. Check the
timing of the drive gear for the fuel injection pump with
the idler gear. The fuel injection pump must be repaired
or replaced.
Make sure that the high pressure fuel lines are
connected to the fuel injector nozzles in the correct
over.
Make sure that the mounting bolts of the fuel injection
pump are tightened to the correct torque. Inspect the
fuel lines for leaks or restrictions. The damaged fuel
lines or fittings must be repaired or replaced.
11.
The air inlet heater is defective.

Test the air inlet heater. Replace the air inlet heater if
the air inlet heater fails the test.
Check fuel lines and the fuel filter. Drain any water from
the fuel filter.
10.
A fuel injector nozzle is not operating correctly.
The linkage of the accelerator or governor is defective.

Tighten the retaining bolt If the accelerator lever on the
fuel injection pump is loose. Adjust the cable for the
accelerator lever if the accelerator lever moves to the
stops. The linkage for the governor must be repair or
replaced.
6-40
Cylinder liners are worn.
Piston rings are worn.
The fuel injector nozzles are not seated correctly.
The valve lash requires adjustment.
The fuel injection pump timing is incorrect.
The engine timing is incorrect.
When an inlet valve or an exhaust valve is fully seated,

gases leak past the valve head.
TM 5-3895-382-24
6.
Problem 2
The engine starts and the engine runs briefly. The engine
stops.
The engine mounts are not correctly tightened or

mounted correctly. This condition also causes vibration.
Check the engine mounts for correct positioning. Check
the bolts of the engine mounts for correct tightening.
Probable Cause
7.
1.
The fuel filter or the fuel lines are restricted. Excess

water has built up in the fuel filter.
Drain any water from the fuel tank or the fuel filter, If the
fuel is contaminated by dirt, ice or wax, replace the fuel.
For the proper removal and disposal of fuel, refer to the
Disassembly and Assembly manual.
Check the fuel lines and the fuel filter. Replace the fuel
filter. Drain any water from the fuel filter.
2.
8.
The operation of the fuel transfer pump is not correct.

Refer to Problem 1.
Refer to Problem 1.
3.
The fuel is contaminated with water, dirt, ice or wax.
The air inlet or the exhaust system is restricted.
Problem 4
Inspect the air inlet and the exhaust systems. Remove

any restrictions.
The engine runs evenly, but the engine loses power.

Probable Cause
4.
Air is in the fuel system.

1.
Find the air leak in the fuel system. Repair the fuel
system.
Refer to Problem 1.
2.
Problem 3
3.
Probable Cause
2.
Make sure that the fuel tank has enough fuel. Look for
leaks or defective bends in all of the fuel supply lines.
Test the outlet pressure of the fuel transfer pump.
4.
5.
5.
The air cleaner is restricted.

The air cleaner must be repaired or replaced.
Remove the air from the fuel system. Make sure that
the fittings of the fuel lines are aligned and tightened
correctly.
The valve lash is not correct.

6.
The fuel transfer pump is not operating correctly. The

fuel transfer pump is installed with the lobe of the
camshaft on maximum lift.
Refer to Problem 1.
Refer to Problem 1.
Adjust the valve lash.

4.

The fuel pressure is low.
Find the air leak in the fuel system. Repair the air leak.
3.

Refer to Problem 1.
1.
A fuel injector nozzle does not operate correctly.

Refer to Problem 1.
6-41
TM 5-3895-382-24
Problem 5
Problem 7
The engine does not have enough power.
The engine has excessive combustion noise.
Probable Cause
Probable Cause
1.
1.
Fuel of poor quality is in the fuel system.

Remove the fuel from the fuel tank. Install a new fuel
filter. Put a good grade of clean fuel in the fuel tank.
For the proper procedures for the removal and disposal
of fuel, refer to the Disassembly and Assembly manual.
Fuel of poor quality is in the fuel system.

Refer to Problem 5.
2.
A fuel injector nozzle is defective.

Refer to Problem 1.
2.
The fuel pressure is low.
Problem 8
Make sure that sufficient fuel is in the fuel tank. Look for
leaks or defective bends in the fuel line between the fuel
tank and the fuel transfer pump. Remove any air in the
fuel system. Check the outlet pressure of the fuel
transfer pump.
The engine has valve compartment noise.

Probable Cause
1.
3.
Adjust the linkage for full travel.

pans.
4.
Valve springs or locks are broken.
The accelerator linkage is not properly adjusted.

Install new parts. Broken locks can cause the valve to
slide into the cylinder. Major damage to the engine can
occur.
Replace defective
2.
The bolts and nuts, which hold the rocker arm

assembly, are loose.

Tighten the bolts or nuts.
5.

3.
The valve lash exceeds the specification.
Refer to Problem 1.
6.
Problem 9
Refer to Problem 1.
Oil is In the cooling system.
Problem 6
Probable Cause
The engine has excessive vibration.
1.
The cylinder head gasket is defective.
Probable Cause
Install a new cylinder head gasket.
1.
The bolts for the pulley are loose.

2.
The oil cooler is defective.
Tighten the bolts.

Replace the oil cooler.
2.
The pulley is defective.

Install a new pulley.
3.
The engine mounts are loose, worn or defective.

Tighten all mounting bolts. Install new parts.
6-42
TM 5-3895-382-24
Problem 10
8.
The bolts and the nuts that hold the rocker arm
assembly are loose.
9.
Tighten the bolts and the nuts.
Engine knock occurs.

Probable Cause
Problem 12
1.
The main bearing is damaged.

The valve is loose.
2.
Inspect the main bearings and the bearing surface of

the crankshaft. Replace damaged parts.
Probable Cause
The crankshaft is damaged.
1.
Replace the crankshaft. Clean the engine thoroughly.
The spring lock for the valve is broken.

Replace the spring lock. Broken locks can cause the
valve to slide into the cylinder. Major engine damage
can result.
Problem 11
2.
The rocker arm has insufficient movement and the valve

lash exceeds the specification.
The valve springs are broken or damaged.

Install new valve springs.
Probable Cause
Problem 13
1.
Lubrication of
inadequate.
internal
engine
components
is
Oil condenses at the exhaust
Check lubrication of the valves. There must be a strong

flow of oil at engine high rpm, but only a small flow at
low rpm. Oil passages must be clean.
2.
Probable Cause
1.
Rocker arm parts are worn.
Look at both ends of the rocker arm shaft. Be sure that

a plug is installed in each end.
If there is too much wear, install new parts or rocker

arms. Adjust the valve lash.
3.
4.
5.
2.
The end of the valve stem is worn.
The valve guides are worn.

Install new valve guides. Recondition the cylinder head.
Install new valves. Adjust the valve lash.
3.
The valve lash exceeds the specification.
4.
Measure the valve lash. Adjust the valve lash.
Problem 14
The pushrods are worn.
The valve lash is less than the specification.
If there is too much wear, install new pushrods. Adjust

the valve lash.
Probable Cause
1.
6.
The valve compartment contains too much oil.
The valve seat or the face of the valve is worn.
The valve lifters are worn.

Recondition the cylinder head. Adjust the valve lash.
If there is too much wear, install new valve lifters.
7.
The lobes of the camshaft are worn.

Measure the valve lash. Check for free movement of
the valves. Check for bent valve systems. Check for
wear on the valve lifters. Replace defective parts.
6-43
TM 5-3895-382-24
Problem 15
Problem 17
The engine has early wear.
The engine exhaust has too much black smoke or gray

smoke.
Probable Cause
Probable Cause
1.
Dirt is in the lubrication oil.

1.
Remove the dirty lubrication oil. Install a new oil filter.
Put clean oil in the engine.
2.
Refer to Problem 1.
Leaks exist in the air inlet system.
2.
Inspect all gaskets and connections. The components

must be repaired or replaced.

Refer to Problem 1.
3.
3.
Fuel leaks into the lubrication oil. Fuel leaks will cause
high fuel consumption and low engine oil pressure.

Refer to Problem 1.
Fuel leaks into the crankcase from the fuel transfer

pump.
Fuel leaks past the valve in a fuel Injector nozzle.
The pressure setting of the fuel injector nozzles is too

high.
The seal at the front of fuel injection pump is defective.
Fuel leaks into the air inlet manifold from the air inlet
heater.
Problem 18
Adjust the component. Replace a damaged component.
The engine exhaust has too much white smoke or blue

smoke.
4.
Check the air cleaner for restrictions. The air cleaner

must be cleaned or replaced.
5.
Probable Cause
Coolant is In the lubrication oil.
1.
Probable Cause
2.

Refer to Problem 3.
The cylinder head is cracked or defective.
3.
Install a new cylinder head.

3.
The engine contains too much lubrication oil.

Drain the excess oil from the oil pan.
The cylinder head gasket is defective.

Install a new cylinder head gasket.
2.
The air inlet heater does not operate or fuel leaks from
the air inlet heater.
Test the air inlet heater. Check the operation of the
control switch for the air inlet heater.
Problem 16
1.
The inlet air is restricted.
The fuel injection timing is not correct.

Adjust the timing of the fuel injection pump.
The cylinder block is cracked or defective.
4.
Install a new cylinder block.

Replace the valve guides. Check the flatness of the
cylinder head. Recondition the cylinder head if the
flatness is out of tolerance.
6-44
TM 5-3895-382-24
5.
6.
Problem 20
The engine uses too much lubrication oil.
The engine consistently runs below the normal

operating temperature.
The water temperature
regulator is defective.
Probable Cause
1.
Replace the water temperature regulator.
Drain the excess oil from the oil pan.

2.
Problem 19
The engine has low oil pressure.
2.
3.
3.
The oil filter is restricted.

Refer to Problem 18.
Install a new oil filter. Replace the lubricating oil in the

engine with clean oil. Check the operation of the
bypass valve for the filter.
4.
Fuel is in the lubricating oil.
Problem 21
Determine the source of the fuel. Refer to Problem 15.
The engine coolant is too hot.
Too much clearance exists between the bore of the

rocker arm and the rocker shaft.
Probable Cause
Replace worn parts.
1.
Check for adequate lubrication of the rocker arms.
Replace parts which are worn.
4.
Oil lines have leaks.

Find the source of the oil leaks. Repair the line or fitting.
Probable Cause
1.
The engine contains too much lubrication oil.
The air flow through the radiator is restricted.

Clean the exterior of the radiator in order to remove all
restrictions.
The suction pipe for the oil pump is defective.

2.
The coolant level in the engine is low.
Replace the suction pipe.

Add coolant into the radiator to the correct level.
5.
The engine oil bypass valve does not operate correctly.

3.
The pressure cap is defective.
Clean the bypass valve. Replace defective parts.

6.
Test the operation of the pressure cap.

defective pressure cap.
The oil pump does not operate correctly.

The oil pump must be repaired or replaced.
7.
4.
Too much clearance exists between the crankshaft and

the crankshaft bearings.
Replace a
Gases from combustion are in the coolant.

Find the source of the entry of the gases from
combustion into the coolant system. Repair the source
of the problem.
Replace the crankshaft or the crankshaft bearings.

5.
8.
Too much clearance exists between the camshaft and

the camshaft bearings.
The water temperature regulator is defective.

Test the water temperature regulator for correct
operation. Replace a defective water temperature
regulator.
Replace the camshaft or the camshaft bearings.

6.
The water pump is defective.

The water pump must be repaired or replaced.
6-45
TM 5-3895-382-24
7.
The engine is operating with too much load.
5.
Reduce the load.

8.
An excessive voltage drop exists in the cables or across

the terminals in the circuits for the starting motor. The
cables are loose at the terminals, corroded, or cracked.
The terminals are corroded or broken.
The timing of fuel injection pump is incorrect.

Inspect the cables and terminals for loose connections,
corrosion or other damage.
Adjust the timing.
Problem 22
Problem 24
The exhaust temperature Is too high.
The staring motor turns, but the pinion gear does not
engage the flywheel ring gear.
Probable Cause
Probable Cause
1.
A restriction exists in the air inlet or the exhaust system.

1.
The pinion drive or the overrunning clutch is defective.
Remove the restriction.

Replace the pinion drive or the overrunning clutch.
2.
The timing of the fuel injection pump is incorrect.

2.
The ring gear of the flywheel is damaged.
Adjust the timing of the fuel injection pump.

Replace the ring gear of the flywheel.
Problem 23
The staring motor does not turn.
slowly turns.
3.
Replace the shift lever or the linkage.

4.
Probable Cause
1.
The starting motor solenoid is damaged.

Replace the starting motor solenoid.
The battery is discharged.

5.
Charge the battery. Replace a defective battery.

Clean all cable terminals and battery posts. Apply the
1 U-8267 Battery Saver and Cleaner on the cable
clamps and the battery posts. lighten the cable clamps
on the battery posts.
2.
The shift lever or the linkage is damaged.
The starting motor
The armature or idler gear of the starting motor is

damaged.
Replace the armature or idler gear.
Problem 25
The terminals or the brushes of the starting motor have

a short circuit to ground.
The engine does not crank when the staring motor is

activated. The pinion gear engages the ring gear and the
flywheel begins to turn.
Find the short circuit. Repair the short circuit.

Probable Cause
3.
The brushes of the starting motor do not seat against

the commutator correctly.
1.
The brushes am worn, broken, oily or dirty. The

brushes must be cleaned or replaced. Clean the brush
holders.
4.
The battery has a low charge.

Refer to Problem 23.
2.
The ignition switch, the starting motor solenoid, or the

start relay is damaged.
The brush pressure on the commutator of the starting

motor is inadequate.
Check the tension of the spring for the brush. Refer to
Problem 23.
Replace the ignition switch, the starting motor solenoid,

or the star relay.
3.
The star relay is defective.

Replace the start replace.
6-46
TM 5-3895-382-24
4.
An excessive voltage drop exists in the cables or across

the terminals in the circuits for the starting motor. The
cables are loose at the terminals, corroded, or cracked.
The terminals are corroded or broken.
2.
Inspect the pulley for wear and damage. Tighten the

nuts of the pulley to the correct torque. Replace a
damaged pulley.
Inspect the cables and terminals for loose connections,

corrosion or other damage. Replace damaged pads.
5.
The drive pulley for the alternator is loose or worn.
3.
The electrical cables and connections in the charging

and starting circuits are loose or damaged.
The overrunning clutch for the pinion drive slips.

Inspect all cables and connections. All connections
must be clean and tight. Apply the 1U-8267 Battery
Saver and Cleaner to the cable terminals and the
connections. Replace defective parts.
Replace the overrunning clutch.
Problem 26
4.
The starting motor continues to run after the ignition
switch is released.
The regulator or the field winding of the rotor in the

alternator is defective.
The alternator must be repaired or replaced.
Probable Cause
Problem 29
1.
The ignition switch, the start relay, or the starting motor

solenoid is defective.
The alternator charge rate is slow or the alternator charge

rate is not regular.
Replace the ignition switch, the start relay, or the

starting motor solenoid.
Probable Cause
1.
Problem 27
Inspect the drive belt for wear and damage. The drive
belt must be adjusted or replaced.
The pinion gear does not disengage after the engine starts
to run.
2.
Probable Cause
1.
The drive pulley for the alternator is loose or worn.

damaged pulley.
The return spring of the pinion solenoid is damaged.

Replace the return spring of the pinion solenoid.
2.
The drive belt for the alternator is loose.
3.
The shift lever or the linkage is damaged.
The electrical cables and connections in the charging

and starting circuits are loose or damaged.
Replace the shift lever or the linkage.

3.
Inspect all cables and connections. All connections

must be clean and tight. Apply the 1U-8267 Battery
Saver and Cleaner to the cable terminals and the
connections. Replace defective parts.
The ignition switch or the start relay is defective.

Replace the ignition switch or the start relay.
4.
Problem 28
The alternator does not charge the battery.
Replace the regulator or the rectifier.
Probable Cause
1.
The regulator or the rectifier for the alternator is

defective.
5.
The drive belt for the alternator is loose.
The brushes of the alternator are worn or dirty.

The brushes must be cleaned or replaced.
Inspect the drive belt for wear and damage. The drive
belt must be adjusted or replaced.
6-47
TM 5-3895-382-24
Problem 30
The alternator charges the battery at a voltage that is too
high.
Probable Cause
1.
The alternator or the regulator has loose electrical

connections.
Tighten all electrical connections to the alternator and
the regulator.
2.
The regulator is defective.

Replace the regulator.
Problem 31
The alternator is noisy.
Probable Cause
1.
The drive belt for the alternator is worn or damaged.

Replace the drive belt for the alternator.
2.
The drive pulley for the alternator Is loose or worn.

damaged pulley.
3.
The drive belt and the drive pulley are not in alignment.
Adjust the alignment.
4.
The bearings of the alternator are worn or damaged.

6-48
TM 5-3895-382-24
Basic Operation
Fuel System
The air inlet heater frequently appears to leak because the

ignition coil (9) is wet. The air inlet heater may be wet because
the diesel fuel does not burn completely. This condition is
normal. This condition does not indicate that the ball valve (6)
has fuel leakage. If a leak is suspected, perform the leakage
test.
SMCS Code: 1250

Tests For The Air Inlet Heater
Check the heater operation by determining if the inlet manifold

is warm to the touch near the heater after approximately ten
seconds of operation. The inlet manifold should be warm.
Inspect the fuel tank and the fuel supply line (2) to the air inlet
heater for restrictions and leakage of fuel. Fuel flow through
the heater should be 3.5 to 5.9 cc/min (0.21 to 0.36 cu in/min).
Check the fuel shutoff valve for correct operation. A poor seal
on the fuel shutoff valve can cause air to enter the system
which will cause extra cranking of the engine before starting.
Be sure that all fuel connections are not leaking air.
Make sure that the battery condition and the battery charge are
satisfactory. Make sure that all electrical connections are tight.
The electrical system can have reduced voltage if the following
conditions exist:
Illustration 24
Right side of the engine.
(3) Fuel lift pump
a discharged battery
a loose connection
Reduced voltage may cause slow cranking of the starter motor

and failure of the heater unit to be activated.
NOTE: Do not operate the air inlet heater for a long
period of time. Operating the air inlet heater for a
long period of time can cause the components to
get too hot. Excessive heat can damage the
components.
Leak Test For The Air Inlet Heater

Use the following procedure in order to test for a leak in the air
inlet heater.
1.
Illustration 25
(4) Electrical connection
(5) Fuel inlet
(6) Ball valve
(7) Valve holder
(8) Wire coil
(9) Ignition coil
The air inlet heater (1) is located In the air inlet manifold on the
right side of the engine.
6-49
Disconnect the fuel supply line (2) and the electrical

connection on the air inlet heater. Be sure that the
electrical connector is insulated from contact with metal
engine components. Remove the air inlet heater from
the manifold. Place a suitable plug in the manifold in
order to prevent debris from entering the air inlet
manifold .
TM 5-3895-382-24
2.
3.
4.
Connect the fuel supply line to the air inlet heater.

Loosely tighten the connection fitting. Operate the
priming lever of the fuel transfer pump until only fuel
which is free of air flows from the connection. Tighten
the connection fitting.
Start the engine and operate the engine at low speed.
Check that there is no fuel leakage from the valve of the
air inlet heater.
If leakage exists, the air inlet heater must be replaced.
If no fuel leakage occurs, remove the plug from the
intake manifold and disconnect the fuel supply line from
the air inlet heater. Install the air inlet heater in the air
inlet manifold. Connect the fuel supply line to the
heater. Operate the priming lever of the fuel transfer
pump until only fuel which is free of air flows from the
connection. Connect the electrical wire connector.
Use this test in order to test for leakage of fuel in the air inlet
heater if a pressurized air supply is available.
2.
Connect the clamp lead of a 5P-7277 Voltage Tester to

a good ground connection.
3.
Connect the probe end of the tester to the disconnected

electrical wire.
4.
The light of the tester turns on in order to indicate that

electrical continuity to the air inlet heater exists.
5.
Connect an 8T-0900 Ammeter between the electrical

supply and the air inlet heater. Turn the ignition switch
to the ON position. Activate the switch for the air inlet
heater. The normal current is 16 to 18 amperes at 12
volts.
Pressure Test For The Fuel Transfer

Pump
NOTE: Damage can be caused to the air inlet heater if air

with more pressure than 140 kPa (20 psi) is used.
2.
Disconnect the electrical wire from the air inlet heater.
NOTE: A cold engine should start after the heater coil

has operated for 20 seconds. If the engine does
not start but the air inlet heater and the area of the
inlet manifold around the air inlet heater are
warm, either the staring procedure has not been
done correctly or the problem is not caused by
the air inlet heater.
Leak Test For The Air Inlet Heater On The Engine
1.
1.
The fuel transfer pump is located on the right side of the

engine.
Remove the air inlet heater from the inlet manifold.

Connect an air supply to the fuel inlet passage. The
maximum pressure of the air supply should be 140 kPa
(20 psi).
The pressure test measures the output pressure of the fuel

transfer pump. Low fuel pressure and starting difficulty may be
indications of problems with the fuel lift pump.
Put the air inlet heater in a container of clean diesel fuel

for ten seconds. No air bubbles should be visible from
the air inlet heater. If the air inlet heater is not defective,
remove the fuel from the air inlet heater. Reinstall the
air inlet heater in the air inlet manifold. If leakage of air
occurs, install a new air inlet heater.
Electrical Test
1.
Put a pressure gauge in the outlet of the fuel transfer

pump.
2.
Disconnect the fuel injection pump solenoid wire (if

equipped). Put the fuel shutoff lever in the fuel shutoff
position.
3.
Crank the engine for ten seconds.

Record the
maximum pressure. The pressure indication on the
gauge should be in the following ranges:
Table 1
5P-7277
8T-0900
Tools Needed
Voltage Tester
Clamp-on Ammeter
Maximum pressure ...................42 to 70 kPa (6 to 10 psi)

Minimum pressure .................................... 30 kPa (4.4 psi)
1
1
4.
Conduct this test in order to determine if sufficient electrical

current is provided to the air inlet heater for proper operation.
6-50
Observe the amount of time for the maximum pressure

that was recorded during cranking to decrease by onehalf. If the time is less than thirty seconds, the fuel
transfer pump must be replaced or repaired.
TM 5-3895-382-24
Table 2
Date Code Months
Code
"A
"B"
"C"
"D"
"E"
"F
"G"
"H"
'"J
"K
"L
"M"
Illustration 26
Fuel transfer pump.
(1) Location of the date code
(2) Strainer
(3) Cover and seal
5.
If the pressure is less than the minimum pressure, the

fuel transfer pump must be repaired or replaced.
6.
If the pressure is low, remove the cover and seal (3).

Inspect the strainer (2) for debris.
Month
January
February
March
April
May
June
July
August
September
October
November
December
Assemble the fuel transfer pump. Ensure that the cover

of the fuel transfer pump is secure so that air cannot
enter the system.
Remove air from the fuel transfer pump. Refer to
"Remove Air From The Fuel System" in this manual.
Clean the cover, the seal, and the strainer with a

nonflammable solvent. Carefully wash any debris from
the chamber of the pump.
The date code is a four digit code that identifies the
following items: month, date and year of manufacture.
An example of the date code is "6K01":
The "6" represents 1996 as the year.
The "K" represents October as the month.
The "01" represents the first day of the month.
Illustration 27
Inspect the components of the fuel transfer pump.
(4) Pivot pin
(5) Link arm
(6) Rocker lever
7.
Measure the fuel pressure again. If the pressure

remains low, remove the pump from the engine. Inspect
the installation of the pivot pin in the rocker lever and
the link arm.
If the pivot pin (4) fits loosely in the rocker lever (5) and
link arm (6), replace the fuel transfer pump. If the pivot
pin, the rocker lever, or the link arm are damaged,
replace the fuel transfer pump.
6-51
TM 5-3895-382-24
8.
Install the fuel transfer pump on the cylinder block.

Clean the threads of the bolts or the studs and nuts.
Apply 4C-4030 Thread Lock Compound to the first three
threads of the bolts or Suds. Refer to Specifications,
"Fuel Transfer Pump" for the torque for tightening the
bolts or the nuts and studs.
NOTE: Place a suitable collar near the top of the valve in

order to hold the valve if the crankshaft is rotated
too far. Use care in rotating the crankshaft. The
number 1 inlet valve will be held in position on top
of the piston. If the crankshaft is not properly
positioned, the valve may fall from the cylinder
head.
Setting The Top Center

Compression Position For No. 1
Piston
6.
Allow the valve to be held by the top of the piston.
7.
Fasten a dial indicator (2) to the cylinder head. The

contact of the dial indicator must be in contact with the
top of the valve stem. The dial indicator must indicate a
reading which is greater than zero. Slowly rotate the
crankshaft in a clockwise direction until the clockwise
movement of the dial indicator pointer stops.
8.
Make a suitable temporary mark on the crankshaft

pulley or the damper in order to align the mark with the
temporary pointer. Continue to rotate the crankshaft in
a clockwise direction until the dial indicator pointer
barely begins to move in a counterclockwise direction.
Make another temporary mark on the pulley or the
damper in order to align the mark with the temporary
pointer. Mark the center point between the two marks
on the pulley or the damper. Remove the other two
marks.
9.
Rotate the crankshaft by approximately 45 degrees in a

counterclockwise direction when you face the engine
from the front. Then rotate the crankshaft in a clockwise
direction until the mark on the pulley or the damper is
aligned with the pointer. Number 1 piston is now at the
top center on the compression stroke.
Set The Top Center Position By

Temporary Marks On Type 1 Engines and
9RM Engines
information.
Set The Top Center Position By Reverse

Pin Timing On Type 2 Engines and 7BJ
Engines
Illustration 28
Setting top center compression position.
(1) Temporary pointer

(2) Dial indicator
1.
Fasten a temporary pointer (1) to the cover of the timing

case. Put the tip of the pointer close to the outer edge
of the crankshaft pulley or the damper.
2.
Rotate the crankshaft in a clockwise direction when you

face the front of the engine. Rotate the crankshaft until
the pushrod for the inlet valve of the rear cylinder begins
to lift the rocker lever.

information.
Table 3
3.
Remove the rocker cover.
4.
Remove the spring clip and the spacer from the front of
the rocker shaft. Release the fasteners of the two front
pedestals of the rocker shaft. Remove the front rocker
lever. Tighten the fasteners of the pedestals on the
rocker shaft.
5.
Remove the valve springs from the front valve.
150-3993
Tools Needed
Timing Pin
(Lucas and Stanadyne)
The timing position that was set at the factory is used to set the
engine at the top center on the number 1 cylinder of the
compression stroke before the fuel injection pump is removed.
6-52
TM 5-3895-382-24
NOTE: Do not remove the hub nut (3) from the shaft of
the fuel injection pump. The hub of the fuel pump
is installed on the shaft of the pump in the factory
in order to ensure that the fuel pump is in the
correct position for timing. If the hub is removed,
the hub will need to be accurately installed to the
shaft of the pump by the use of special equipment
at a Caterpillar Dealer.
NOTE: Do not release the torx screws (2). If the torx
screws are released and the timing plate is
moved, the timing position that is set at the
factory will be lost.
If the torx screws are
released, the engine must be set to top center of
the number 1 cylinder on the compression stroke
before the torn screws are tightened.
Illustration 29
Fuel injection pump with timing pin (typical example).
1.
Remove the fuel injector nozzles, the water pump, and

the cover for the gear of the fuel injection pump.
2.
Rotate the crankshaft in a clockwise direction until the

inlet valve on the number 1 cylinder closes. Slowly
rotate the crankshaft until the slot for the timing gear (5)
and the hub slot (6) are aligned with the hole in the
pump body (4).
(1) Timing pin

(3) Hub nut
(4) Hole in the pump body
(6) Hub slot
NOTE: The position of the slot for the timing gear, the
hub slot, and the hole in the pump body is on the
bottom of the fuel injection pump. The slot is for
inserting the timing pin. The position of the slot is
for the Lucas fuel injection pump and the
3.
Illustration 30
Timing gear and hub of the fuel injection pump (Lucas and
Stanadyne).
Table 4
(1) Timing pin
(2) Torx screws
(3) Hub nut
(4) Hole in the pump body

(5) Slot for the timing gear
(6) Hub slot
6-53
Insert the timing pin (1) through the timing gear and the
hub slot. Push the timing pin (1) into the hole of the
pump body (4) as far as possible. When the pin is
inserted all the way, the engine is at the top center of
the number 1 cylinder on the compression stroke. No
resistance should be felt when the timing pin is inserted
into the hole of the pump body (4). The pin should be
inserted all the way into the hole of the pump body.
TM 5-3895-382-24
Illustration 32
Setting top center compression position.
(1) Temporary pointer
(2) Dial Indicator
Illustration 31
Engine timing gears.
(1) Timing gear for the fuel injection pump
(2) Timing gear for the camshaft
(3) Timing gear for the crankshaft
NOTE: Damage to the timing case can occur If the

following event occurs: the crankshaft (3) is
rotated when the fuel injection pump is removed
from the engine. If the crankshaft needs to be
rotated, the fuel injection pump must be installed
and the fasteners for the gear tightened.
1.
Fasten a temporary pointer (1) to the front of the timing

cover. Put the tip of the pointer close to the edge of the
damper on the crankshaft or close to the edge of the
pulley.
2.
Remove the fuel injector nozzles and the rocker cover.
3.
Rotate the crankshaft clockwise when you face the front

of the engine. Rotate the crankshaft until the pushrod
for the inlet valve of the rear cylinder begins to tighten.
NOTE: Be careful when you rotate the crankshaft. The

number 1 inlet valve will be held in position on top
of the piston. If the crankshaft is not positioned
properly, the valve may fall from the cylinder
head.
NOTE: Perform the following functions after the fuel

injection pump has been removed and the
crankshaft has been rotated: Remove the timing
case cover. The timing marks on the face of the
timing gears must be aligned. Aligning the timing
marks of all the timing gears will approximately
set the top center of the number 1 cylinder on the
compression stroke. Then, the timing pin can be
inserted.
Set The Top Center Position By The

Alternate Method
4.
Rotate the crankshaft further by 1/2 of a turn in a

clockwise direction. Insert a suitable lever between the
rocker lever and the valve spring cap of the number 1
inlet valve. Open the inlet valve. Put a spacer that is
approximately 5 mm (0.2 inch) thick between the valve
stem and the rocker lever.
5.
Slowly rotate the cranks haft in a counterclockwise

direction until the piston makes contact with the open
valve. Make a temporary mark on the damper or the
pulley in order to align accurately with the tip of the
pointer.
6.
Rotate the crankshaft in a clockwise direction by one or

two degrees. Remove the spacer that is between the
valve stem and the rocker lever. Rotate the crankshaft
by 1/4 of a turn in a counterclockwise direction. Put a
spacer that is approximately 5 mm (0.2 inch) thick
between the valve stem and the rocker lever.
Table 5
150-3993
Tools Needed
Timing Pin
6-54
TM 5-3895-382-24
7.
Slowly rotate the crankshaft clockwise until the piston

makes contact with the open valve. Make another
temporary mark on the damper or the pulley in order to
align accurately with the tip of the pointer.
8.
Make a temporary mark at the center point between the

two marks on the damper or the pulley. Remove the
other two marks. Rotate the crankshaft by 1/8 of a turn
in a counterclockwise direction. Remove the spacer
between the valve stem and the rocker lever.
9.
Slowly rotate the crankshaft in a clockwise direction until

the mark on the damper or the pulley, which was made
in Step 8, aligns with the tip of the pointer. The number
1 piston is now at the top center on the compression
stroke.
3.
Align the key that is in the adapter with the keyway that
is in the gear of the fuel injection pump. Install the
adapter to the gear. Ensure that the adapter is against
the rear face of the timing case. Secure the adapter to
the gear with the nut which is supplied with the adapter.
Setting The Engine Timing Mark On

Illustration 34
Engine timing tool from the 9U-6188 Timing Fixture Group.

information.
(1) Pointer
(2) Screw
(3) Shaft
(4) Screw
(5) Screw
Table 6
9U-6188
Tools Needed
Timing Fixture Group
1.
Set the piston of number 1 cylinder top center on the

compression stroke.
2.
Remove the fuel injection pump and the gasket.
4.
Loosen the screw (5). Set the engine timing tool to the
correct engine check angle. Refer to the Specifications,
"Fuel Injection Pump" for the correct engine check
angle. Tighten the screw (5). Loosen the screw (4).
Install the splined shaft (3) into the engine timing tool.
Loosen the screw (2). Install the pointer (1) and tighten
the screw (2).
5.
Install the splined shaft of the engine timing tool into the
adapter. Slide the engine timing tool along the splined
shaft until the engine timing tool rests against the
adapter. Tighten the screw (4).
6.
Loosen the screw (2). Slide the pointer forward until the
flat face rests against the rear face of the timing case.
Tighten the screw (2). If the mark on the timing case is
correct, the mark will align with the top edge of the
pointer (1). If the mark is not correct, remove the engine
timing tool and remove the mark on the timing case.
Install the engine timing tool. Ensure that the pointer
rests against the timing case. Make a new mark on the
timing case. Make the new mark along the top of the
straight edge of the pointer.
7.
Remove the engine timing tool and the adapter.
8.
Install a new gasket on the fuel injection pump. Install

the fuel injection pump on the engine.
Illustration 33
Adapter from the 9U-6188 Timing Fixture Group.
6-55
TM 5-3895-382-24
9.
Remove the dial gauge from the valve overlap. The

valve overlap is the period between the opening of the
inlet valve and closing of the exhaust valve. Set the
valve lash for the inlet valve of the number 1 cylinder.
Refer to Specification, "Cylinder Head Valves" for the
correct valve lash. Install the rocker cover.
Timing Of The Fuel Injection Pump

Type 1 and 9RM Engines With Stanadyne
Fuel Injection Pump
NOTE: For a complete description of Type I and Type 2
information.
Illustration 36
(2) Number 1 outlet
3.
Table 7
9U-6188
9U-6189
SP-4150
Tools Needed
Timing Fixture Group
Drive Adapter
Nozzle Test Group
Install the 5P-4150 Nozzle Testing Group to the number

1 outlet (2). Operate the hand pump until a pressure of
5065 kPa (735 psi) is indicated on the gauge.
1
1
1
The fuel injection pump must be timed if any of the following

conditions exist:
The performance of the fuel injection pump is not

correct.
The locking bolt is loosened after the fuel injection pump

has been removed from the engine.
1.
Remove the fuel injection pump.
Illustration 37
Engine timing tool from the 9U-6188 Timing Fixture Group
(3) Sleeve
(4) Screw
(5) Pointer
(6) Screw
Illustration 35
(1) 9U-6189 Drive Adapter
2.
Install the 9U-6189 Drive Adapter (1) to the drive shaft

of the fuel pump. Fasten the drive adapter with the nut
of the fuel pump gear.
6-56
4.
Turn the shaft of the fuel pump in a clockwise direction

from the drive end of the pump until the pin in the shaft
aligns with number 1 outlet. Position the sleeve (3) for
the engine timing tool on the fuel injection pump. Install
the engine timing tool on the adapter. The adapter is on
the fuel pump drive shaft.
5.
Turn the shaft of the fuel pump until the fuel pressure
prevents movement of the shaft. The fuel must flow
through the delivery valve in the fuel pump before the
fuel pressure will prevent movement of the shaft. In this
position, the fuel pump is set at the start of fuel injection
from the number 1 outlet.
TM 5-3895-382-24
6.
Loosen the screw (6) on the engine timing tool. Set the
engine timing tool to the correct angle. Refer to the
Specifications, "Fuel Injection Pump" for the pump mark
angle. Tighten the screw (6).
7.
Loosen the screw (4). Slide the pointer (5) forward until
the pointer is over the center of the pump flange. Check
that the mark on the flange is in the center of the slot in
the pointer.
8.
If the mark on the flange is not correct, remove the

engine timing tool. Remove the mark on the flange.
Install the engine timing tool. Ensure that the fuel pump
is at the start of fuel injection for number 1 cylinder.
Loosen the screw (4). Slide the pointer forward to the
complete width of the flange. Tighten the screw (4).
Use the slot that is in the pointer in order to make a new
mark on the flange of the pump.
9.
Remove the engine timing tool, the sleeve, and the

adapter.
10.
Disconnect the 5P-4150 Nozzle Test Group from the

number 1 outlet (2).
11.
Illustration 38
Timing gear and hub o the fuel injection pump (Lucas and
Stanadyne).
Table 9
(1) Timing pin
(2) Torx screws
(3) Hub nut
Install the fuel injection pump. Eliminate the air from the
fuel system.
This procedure can only be used when the engine is set to the
top center position on number one cylinder on the compression
stroke. Refer to the "Setting The Top Center Position By The
Alternate Method" in the Systems Operation, Testing and
Adjusting manual for more information.
Timing Of The Fuel Injection Pump On

information.
NOTE: Do not remove the hub nut (3) from the shaft of
the fuel injection pump. The hub of the fuel
injection pump is installed on the shaft in the
factory in order to ensure that the fuel injection
pump is in the correct position for timing. If the
hub is removed, the hub must be accurately
installed to the pump shaft by the use of special
equipment at a Caterpillar Dealer.
Table 8
150-3993
Tools Needed
Timing Pin
(4) Hole in pump body

(5) Slot for timing gear
(6) Slot for hub
NOTE: Do not release the torx screws (2). If the torx

screws are released and the timing plate is
moved, the timing position that is set at the
factory will be lost. If the timing position is lost,
the engine must be set to the top center position
on the number 1 cylinder on the compression
stroke before the torx screws are tightened.
6-57
1.
Set the piston of number one cylinder on the

compression stroke.
2.
Remove the coolant pump.
TM 5-3895-382-24
3.
Insert the timing pin (1) through the slot for the timing
gear (5). Continue to insert the timing pin through the
slot for the hub (6). Push the pin all the way into the
hole of the pump body (4). If the pin can be inserted all
the way, the pump timing is correct. Resistance should
not occur until the pin is inserted all the way into the
hole of the pump body.
4.
Remove the timing pin.
5.
If the timing pin cannot be inserted all the way into the
hole of the pump body, perform the following function:
Ensure that the engine is correctly set at the top center

position of the number one cylinder on the compression
stroke.
6.
The fuel pump must be set by a Caterpillar Dealer when

the following conditions exist:
The engine is set correctly at the top center.

The pin cannot be easily inserted.
The pin cannot be inserted all the way into the hole of
the pump body.
Use the following procedure in order to remove air from the

fuel system:
Illustration 39
(1) Vent plug
(2) Fuel filter base
1.
Loosen the vent plug (1) on top of fuel filter base (2).
Refer to Disassembly And Assembly, "Fuel Injection Pump" for

removal and installation procedures.
Remove Air From The Fuel System

Remove Air From The Fuel System On Type
1 Engines and 9RM Engines
information.
If air enters the fuel system, the air must be purged before the
engine can be started.
Illustration 40
Air can enter the fuel system when any of the following events
occur:
2.
The fuel tank is drained during normal operation.

The low pressure fuel lines are disconnected.
A par of the low pressure fuel system leaks during
engine operation.
The fuel filter is replaced.
Operate the priming lever on the bottom of the fuel

transfer pump (3) until fuel, which is free of air, flows
from the vent plug. Tighten the vent plug.
NOTE: If the drive cam of the fuel transfer pump is at

maximum lift, the priming lever cannot be
operated. The crankshaft must be rotated one
revolution.
6-58
TM 5-3895-382-24
Remove Air From The Fuel System On Type
2 Engines and 7BJ Engines
information.
If air enters the fuel system, the air must be purged before the
engine can be started. Air can enter the system when the
following events occur:
The fuel tank is empty or the tank has been partially

drained.
The low pressure fuel lines are disconnected.
A leak exists in the low pressure fuel system.
The fuel filter is replaced.
Illustration 41
(4) Nut for the fuel line to the air inlet heater
3.
If the fuel line for the air inlet heater has been drained,
loosen the nut for the fuel line nut (4) at the air inlet
heater. Operate the priming lever on the bottom of the
fuel transfer pump (3) until fuel, which is free of air,
flows from the fuel line. Tighten the nut for the fuel line
to the air inlet heater (4) to a torque of 22 Nom (16 Ib-ft).
Use the following procedure in order to remove air from the

fuel system:
1.
Fuel filter and venting the fuel filter
Illustration 43
Fuel filter and filer assembly (Lucas Fuel Systems).
(1) Vent plug
(2) Fuel filter and fuel filter head assembly
Illustration 42
(5) Nuts for the fuel line to the fuel injector nozzles
4.
Air from the fuel lines is also removed by loosening the

nuts for the fuel line nuts (5) at the fuel injector nozzles.
Operate the starting motor until the fuel, which is free of
air, flows from the fuel line. Tighten the nuts for the fuel
lines (5) to a torque of 22 Nom (16 Ib-ft).
NOTE: If the starting motor is operated too long in order

to purge the air from the fuel system, parts can be
damaged. Damage to the fuel injection pump, the
battery, and the staring motor can occur.
Illustration 44
6-59
TM 5-3895-382-24
a. Lucas fuel systems
Loosen the vent plug (1) on top of the fuel filter and
filter bases. Operate the priming lever on the bottom
of the fuel transfer pump (3) until fuel, which is free of
air, flows from the vent plug. Tighten the vent plug.
Illustration 46
(4) Nut for the fuel line to the air inlet heater
2.
Illustration 45
Fuel filter and filter assemblies (Stanadyne Fuel System).
(1) Vent plug for the fuel filter (if equipped)
(2) Vent plug for the fuel filter
If the fuel line for the air inlet heater has been drained,
loosen the fuel line nut (4) at the air inlet heater.
from the fuel line. Tighten the fuel line nut (4) to a
torque of 22 Nm (16 lb-ft).
b. Stanadyne fuel system

Loosen the vent plug (1) on top of the fuel filter base.
Loosen the vent plug (2) on top of the fuel filter.
NOTE: If the drive cam of the fuel transfer pump is in the
position of maximum cam lift, the priming lever
will not operate. The crankshaft must be rotated
one revolution.
Illustration 47
(5) Nuts for the fuel line to the fuel injector nozzles
3.
Loosen the connections for the high pressure fuel lines

on two fuel injector nozzles. Operate the starting motor
until fuel, which is free of air, flows from the fuel line.
Tighten the fuel line nuts (5) to a torque of 22 Nom (16
Ib-ft).
NOTE: Damage to the fuel injection pump, the battery,

and the starter motor can occur if the starter
motor is used excessively to purge the air from
the fuel system.
4.
6-60
The engine is now ready to start. If the engine stops or

if the engine runs roughly, check for air in the fuel
system. If air is in the fuel system, leakage in the low
pressure fuel system probably exists.
TM 5-3895-382-24
NOTE: Operate the engine at low idle for a minimum of
five minutes immediately after air has been
removed from the fuel system. Running the
engine for this period of time will help ensure that
the pump is completely free of air. Damage to the
internal parts of the pump which is caused by
metal to metal contact will be prevented.
Adjustment Of Low Idle And High Idle
Illustration 49
Stanadyne Fuel Injection Pump.
(1) Low idle adjustment screw
(2) High idle adjustment screw
Work carefully around an engine that is running. Engine

parts that are hot, or parts that are moving, can cause
personal injury.
Illustration 48
Lucas Fuel Injection Pump.
(1) Low idle adjustment screw

(2) High idle adjustment screw
1.
Low Idle Adjustment

Run the engine until the normal operating temperature
is reached. Check the rpm at low idle. Use the
adjustment screw (1) in order to adjust the low idle.
Loosen the locknut and turn the screw clockwise in
order to increase the rpm. Turn the adjustment screw
counterclockwise in order to decrease the rpm.
NOTE: The correct rpm for low idle is given in the

following publications: Technical Marketing
Information (TMI) and Fuel Setting And Related
Information Fiche.
2.
High Idle Adjustment

a. High Idle Adjustment On Type 1 Engines and 9RM
Engines.

engines, please refer to the Systems Operation,
Testing and Adjusting Module, "Engine Design"
for more information.
6-61
TM 5-3895-382-24
The adjustment for high idle must be made only under
conditions with no load on the engine. The high idle
rpm is found on the data plate on the side of the fuel
injection pump.
Table 10
5P-4150
5P-7448
6V-2170
8S-2245
8S-2270
1U-8857
6V-6068
Run the engine until the normal operating

temperature is reached. Then check the maximum
high idle. Use the high idle adjustment screw (2) in
order to adjust the high idle. Loosen the locknut.
Turn the screw in a clockwise direction in order to
increase the rpm.
Turn the screw in a
counterclockwise direction in order to decrease the
rpm. When the correct rpm is reached, tighten the
locknut Then, seal the screw.
Tools Needed
Tester Group
Adapter
Tube Assembly
Cleaning Tool Group
Fuel Collector
Extension
SAE J-967 Calibration
Fluid
1
1
1
1
1
1
1
Perform the following procedure in order to identify the fuel

injector nozzles which do not operate correctly:
b. Tamper Prevention High Idle On Type 2 Engines and

7BJ Engines.
engines, please refer to the Systems Operation,
Testing and Adjusting Module, "Engine Design"
High idle has been preset at the factory. The setting
of the high idle of these engines should not be
adjusted. Adjusting the high idle setting can void the
following items: fuel injection pump warranty, engine
warranty and emissions standards. A seal is installed
on the high idle screw (2) in order to help prevent
tampering. Adjustment of the high idle should be
made only by personnel that have the correct training.
Illustration 50
Fuel injector nozzles and lines.
Run the engine until normal operating temperature is

reached. Check the maximum high idle. High idle
must be checked under conditions with no load on the
engine. The high idle rpm is listed on the data plate
which is located on the side of the fuel injection pump.
(5) Nuts for the fuel injection lines
NOTE: The correct rpm for low idle is given in the

following publications: Technical Marketing
Information (TMI) and Fuel Setting And Related
Information Fiche.
1.
Run the engine at low idle.
2.
Loosen the nut of the fuel injection line (5) at each fuel
injector nozzle. Listen for the low idle to decrease or
become rough at each cylinder.
3.
The fuel injector nozzle has a defect when the nut of the
fuel injection line (5) is loosened and the following items
do not occur idle decreases and rough idle. Remove
the fuel injector nozzle for additional testing.
Fuel Injector Nozzle Tests

NOTE: If leakage at the nut of the fuel line occurs, make
sure that the fuel line and the nut are correctly
aligned with the inlet connection of the fuel
injector nozzle. Do not tighten the nuts on the
high pressure fuel lines more than the
recommended torque. If the nut is tightened
more, the fuel line may be restricted or the
threads of the fuel injector nozzle and the nut may
be damaged.
Fuel Injector Nozzle Tests On Type I

Engines and 9RM Engines
and Adjusting Module, "Engine Design for more
information.
6-62
TM 5-3895-382-24
Cleaning Of Fuel Injector Nozzles
NOTE: Use extra care not to break a wire of the brass

wire brush in an orifice (18) or passage in the fuel
injector nozzle. Removal of a broken wire is very
difficult. Removal of a broken wire may damage
the fuel injector nozzle.
Before a fuel injector nozzle is tested, remove any loose

carbon from the tip of the fuel injector nozzle.
1.
Fasten the fuel injector nozzle in a holder or a vise with

brass jaws. Release the pressure on the nozzle holder
spring by loosening the adjusting screw. Remove the
nozzle cap nut and the nozzle with the correct size of
wrench.
4.
Clean the orifices (19) in the nozzle tip with a cleaning

wire. If the size is not known, carefully try different sizes
of wires in order to find the correct wire. Insert the wire
into the orifice. Slowly rotate the wire in order to clean
the orifice.
NOTE: Extra care must be used in handling the valve

needle (16) in order to prevent scratches or burrs
on the needle. Scratches and burrs could cause
leakage through the valve and spray distortion.
Pressure Test And Adjustment
Make sure that you wear eye protection at all times during
testing. When fuel injection nozzles are tested, test fluids
travel through the orifices of the nozzle tip with high
pressure. Under this amount of pressure, the test fluid
can pierce the skin and cause serious injury to the
operator. Always keep the tip of the fuel injection nozzle
pointed away from the operator and into the fuel collector
and extension.
Illustration 51
(8) Fuel inlet
(9) Cap nut
(10) Fuel return
(11) Pressure adjusting screw
(12) Spring for pressure adjusting screw
(13) Body
(14) Spindle for spring
(15) Retaining nut for fuel injector nozzle
(16) Valve needle
(17) Nozzle
(18) Seat washer
(19) Orifices
2.
3.
Illustration 52
5P-4150 Nozzle Testing Group.
Remove the valve needle (16) from the nozzle body.

Use the Brass Wire Brush in the 8S-2245 Cleaning Tool
Group in order to remove any carbon that may be on the
body (13).
(1) 5P-7448 Adapter

(3) 6V-2170 Tube Assembly
(4) 1U-8857 Extension
(6) 8S-2270 Fuel Collector
(7) 8T-5313 Filter
Clean the seat of the valve needle (16) and the fuel
reservoir with a Scraper. The Scraper is in the 8S-2245
Cleaning Tool Group.
6-63
TM 5-3895-382-24
Back Leakage Test
NOTICE
Do not use dirty test fluids when you test fuel injection
nozzles. Also, do not test fuel injection nozzles unless
you have the correct service tools. The use of dirty test
fluids and the use of incorrect service tools will result in
damage to fuel injection nozzles.
1.
1.
Position the fuel injector nozzle so that the fuel spray is

directed into the 1U-8857 Extension (4) and the
8S-2270 Fuel Collector (6).
Refer to Illustration 52 in order to connect the fuel

injector nozzle (2) to the tooling.
2.
Pump the pressure to about 1030 kPa (150 psi) less

than the opening pressure of the fuel injector nozzle.
Refer to Specifications, "Fuel Injection Nozzles" for the
correct setting of the opening pressure. Release the
handle. Note the time that is required for the pressure
to decrease to approximately 0 kPa (0 psi). If the fuel
injector nozzle is not defective, the time will not be less
than 5 seconds or more than 45 seconds.
3.
When the test in Step 2 is done, look for any leakage

from the pressure faces of the holder and the retaining
nut of the fuel injector nozzle. If leaks are visible, make
sure that the components are tightened to the correct
torque. If leakage continues to occur, unscrew the
retaining nut from the body. Inspect the threaded
surfaces for foreign particles and damage. If the
threaded surfaces are clean and the threaded surfaces
are undamaged, test the fuel injector nozzle again by
using Steps 1 and 2.
4.
If the pressure decreases to 0 kPa (0 psi) in less than 5

seconds, too much fuel leaks around the valve needle.
The valve needle or the fuel injector nozzle must be
replaced in order to correct the problem.
The spray from the fuel injector nozzle must be directed

into the 1U-8857 Extension (4) and the 8S-2270 Fuel
Collector (6).
Use clean 6V-6068 Calibration Fluid when the fuel
injector nozzles are tested. The calibration fluid is
equivalent to SAE J-967 (ISO 4113) oil.
2.
Close the gauge protector valve. Close the shutoff

valve. Open the pump isolator valve. In order to flush
the fuel injector nozzle, operate the nozzle tester for 10
to 15 strokes by using a rate of approximately 60
strokes per minute.
3.
Open the gauge protector valve. Slowly increase the

pressure until the valve in the fuel injector nozzle opens.
Note the highest pressure Indication on the gauge
before the pointer decreases to 0 kPa (0 psi). This
highest pressure indication is the opening pressure of
the fuel injector nozzle. The opening pressure is
defined when the valve needle (16) is lifted from the
valve seat.
Refer to the table in Specifications, "Fuel Injection
Nozzles" for correct pressure settings. If the opening
pressure is not within the range of the setting which is
listed in the table, the opening pressure of the fuel
injector nozzle must be adjusted.
4.
Loosen the cap nut (9). Turn the pressure adjusting

screw (11) clockwise in order to increase the pressure.
Turn the pressure adjusting screw counterclockwise in
order to decrease the pressure.
5.
Tighten the cap nut (9). Check the opening pressure

again on the nozzle tester. If the pressure is correct,
remove the fuel injector nozzle from the nozzle tester.

Fuel Injector Nozzle And Seat Test

1.

2.
NOTE: Before the fuel injector nozzle is removed from

the tester, be sure that the gauge protector valve
is closed in order to prevent damage to the
pressure gauge.
6-64
Pump the pressure of the nozzle tester to approximately

1030 kPa (150 psi) below the opening pressure of the
fuel injector nozzle. A drop of fuel should not form on
the tip of the fuel injector nozzle in order for a sufficient
quantity to drip from the tip for at least ten seconds. A
light dampness is acceptable. If the results of the tests
are not acceptable, clean the fuel injector nozzle.
Replace the fuel injector nozzle if fuel leakage occurs
after cleaning the fuel injector nozzle.
TM 5-3895-382-24
Test The Spray Pattern
Installation Of A Fuel Injector Nozzle
testing. When fuel injection nozzles am tested, test fluids
and extension.
Illustration 54
Components for installation of a fuel injector nozzle.
The pressure adjustment must be correct before testing the

spray pattern.
(20) Camp
(21) Spacer
{22) Dust seal
(23) Body
(24) Seat washer
1.
NOTE: If a seat washer remains in the recess of the

cylinder head for the fuel injector nozzle, the
protrusion of the fuel injector nozzle into the
cylinder will be incorrect. Also, if the seat washer
is damaged, the protrusion of the fuel injector
nozzle into the cylinder will be incorrect.
Illustration 53
Correct spray pattern for a fuel injector nozzle.
1.

2.

2.
Close the gauge protector valve and the shutoff valve.

Open the pump isolator valve.
3.
Quickly pump the nozzle tester and look at the spray

pattern when the fluid begins to flow through the orifices
(18) of the fuel injector nozzle.
When a fuel injector nozzle is removed from the cylinder

head, replace the seat washer (24) and the dust seal
(22).
The dust seal (22) is positioned under the spacer (21)

and the clamp (20). The dust seal is positioned on the
face of the cylinder head.
Fuel Injector Nozzle Tests On Type 2

Engines and 7BJ Engines
information.
The spray, which flows from all of the orifices, must

have the same pattern. The fuel injector nozzle is
defective if there is a difference in the vertical patterns
or a difference in the horizontal patterns. Refer to the
correct spray pattern in Illustration 53.
Perform the following procedures in order to determine if a fuel

injector nozzle does not work correctly.
NOTE: Be sure that the gauge protector valve is closed

before the fuel injector nozzle is removed from the
nozzle tester. Closing the valve will prevent
damage to the pressure gauge.
6-65
TM 5-3895-382-24
Table 11
Tools Needed
5P-4150
5P-7448
6V-2170
8S-2245
8S-2270
1U-8857
6V-6068
Tester Group
Adapter
Tube Assembly
Cleaning Tool Group
Fuel Collector
Extension
SAE J-967 Calibration
Fluid
1
1
1
1
1
1
1
Illustration 56
Fuel injector nozzles and lines.
(1) Nut for the fuel supply line
(2) Banjo bolt
(7) Fuel return line
1.
Run the engine at low idle.
2.
Loosen the nut for the fuel supply line (1) at each fuel
injector nozzle. Listen for the low idle to decrease or
become rough at each cylinder.
3.
The fuel injector nozzle is defective when the fuel supply

line (1) is loosened and the following events occur:
The engine rpm does not decrease.

The engine does not idle roughly.
Remove the fuel injector nozzle for additional testing.
NOTE: If leakage occurs at the nut for the fuel supply line
(1), make sure that the fuel supply line (6) and the
nut for the fuel supply line (1) are correctly
aligned with the inlet connection of the fuel
injector nozzle (1). Do not tighten the nut for the
fuel supply line (1) on the high pressure fuel line
more than the recommended torque. If the nut is
tightened more, the fuel line may become
restricted or the threads of the fuel injector nozzle
and the nut may be damaged.
Illustration 55
(1) Connection for the nut (not shown) of the fuel supply line
(2) Threaded hole for the banjo bolt of the fuel return line
(3) Nut of the fuel injector nozzle
(4) Wire clip
(5) Seat washer
Cleaning Of Fuel Injector Nozzles

Before a fuel injector nozzle is tested, remove any loose
carbon from the tip of the fuel injector nozzle. Do not use
abrasive material or a wire brush in order to clean the nozzle.
The fuel injector nozzle is not a serviceable part.
Disassembling or adjusting the nozzle will violate the standards
of emissions.
6-66
TM 5-3895-382-24
NOTE: Extra care should be used in handling the fuel
injector nozzle in order to prevent damage to the
nozzle tip. A scratch or a burr could cause needle
leakage or spray distortion. Keep dirt from the
orifices in the nozzle tip which could damage
engine components or cause spray distortion.
1.
Connect the fuel injector nozzle (9) to the tooling that is

shown in Illustration 57.
The spray from the fuel injector nozzle must be directed
into the 1U-8857 Extension (11) and the 8S-2270 Fuel
Collector (12).
Pressure Test
Refer to the table in Specifications, "Fuel Injector

Nozzles" for the correct pressure settings. If the
opening pressure is not within the range of the setting
which is given in the table, the fuel injector nozzle must
be replaced.
and extension.
Use clean 6V-6068 Calibration Fluid when the fuel

injector nozzles are tested. The calibration fluid is
equivalent to SAE J-967 (ISO 4113) oil.
2.
Close the gauge protector valve. Close the shutoff

valve. Open the pump isolator valve. In order to flush
the fuel injector nozzle, operate the nozzle tester for 10
to 15 strokes at a rate of approximately 60 strokes per
minute.
3.
Open the gauge protector valve. Slowly increase the

pressure until the valve in the fuel injector nozzle opens.
Note the highest pressure indication on the dial indicator
before the pointer moves to 0 kPa (0 psi). This highest
pressure indication is the opening pressure of the fuel
injector nozzle. The opening pressure is defined when
the valve needle (16) is lifted from the valve seat.
Refer to the table in Specifications, "Fuel Injection
Nozzles" for correct pressure settings. If the opening
pressure is not within the range of the setting that is
given in the table, the fuel injector nozzle must be
replaced.
Back Leakage Test

1.
Illustration 57
5P-4150 Nozzle Testing Group.
Connect the fuel injector nozzle (9) to the tooling. Refer

to Illustration 57 for more information.
Position the fuel injector nozzle so that the direction of
the fuel spray is into the 1U-8857 Extension (11) and
the 8S-2270 Fuel Collector (12).
(8) 5P-7448 Adapter

(10) 6V-2170 Tube
(11) 1U-8857 Extension
(12) 8S-2270 Fuel Collector
(13) 8T-5313 Filter
2.
NOTICE
Do not use dirty test fluids when you test fuel injection
nozzles. Also, do not test fuel injection nozzles unless
you have the correct service tools. The use of dirty test
fluids and the use of incorrect service tools will result In
damage to fuel injection nozzles.
Pump the pressure to about 1030 kPa (150 psi) below

the opening pressure of the fuel injector nozzle. Refer
to Specifications, "Fuel Injection Nozzles" for the correct
setting of the opening pressure. Release the handle.
When the pressure begins to decrease, note the time
that is required for the pressure to decrease to
approximately 0 kPa (0 psi). If the fuel injector nozzle is
not defective, the time will not be less than 5 seconds or
more than 45 seconds.
If the time that is required for the pressure to decrease
to 0 kPa (0 psi) is less than 5 seconds, too much fuel is
leaking around the valve needle. Replace the fuel
injector nozzle.
6-67
TM 5-3895-382-24
3.
Look for any leakage from the pressure faces of the

holder and the retaining nut of the fuel injector nozzle. If
leakage is visible, make sure that the components are
tightened to the correct torque.
If leakage continues to occur, unscrew the retaining nut
from the body. Inspect the threaded surfaces for foreign
particles and damage. If the faces are clean and
undamaged, test the fuel injector nozzle. Repeat Steps
1 and 2.
Illustration 58
Correct spray pattern for fuel injector nozzles.
Fuel Injector Nozzle and Seat Test

1.

1.
Position the fuel injector nozzle so that the direction of

the fuel spray is into the 1U-8857 Extension (11) and
the 8S-2270 Fuel Collector (12).
2.

Position the fuel injector nozzle so that direction of the
fuel spray is into the 1U-8857 Extension (11) and
Pump the pressure of the nozzle tester to approximately

1030 kPa (150 psi) below the opening pressure of the
fuel injector nozzle. Fuel should not collect on the tip of
the fuel injector nozzle in a sufficient quantity in order to
drip from the tip for at least ten seconds. A light
dampness is acceptable.
2.
Close the gauge protector valve and the shutoff valve.

Open the pump isolator valve.
3.
Quickly pump the nozzle tester and look at the spray

pattern when the fluid begins to flow through the orifices
of the fuel injector nozzle.
If the results of the tests are not acceptable, replace the

fuel injector nozzle.
The spray, which flows from all of the orifices, must

have the same pattern. The fuel injector nozzle is
defective if there is a difference in the vertical patterns
or a difference in the horizontal patterns. Refer to the
correct spray pattern in Illustration 58.
Test The Spray Pattern
NOTE: Be sure that the gauge protector valve is closed

before the fuel injector nozzle is removed from the
nozzle tester. Closing the valve will prevent
damage to the pressure gauge.
and extension.
Installation Of Fuel Injector Nozzles

1.
The pressure adjustment must be correct before testing the

spray pattern.
When a fuel injector nozzle is removed from the cylinder

head, replace the seat washer (5). Refer to Illustration
55 for more information.
NOTE: If a seat washer remains in the recess of the

cylinder head for the fuel injector nozzle, the
protrusion of the fuel injector nozzle into the
cylinder will be incorrect. Also, if the seat washer
is damaged, the protrusion of the fuel injector
nozzle into the cylinder will be incorrect.
2.
6-68
Place a 2 mm (0.1 inch) bead of 4C-5591 Anti-Seize

Compound on the first two threads of the fuel injector
nozzle below the nut (3). Refer to Illustration 55 for
more information.
TM 5-3895-382-24
NOTE: Do not rotate the fuel injector nozzle after the fuel
injector nozzle has been tightened to the specified
torque. Rotating the fuel injector nozzle will
cause a broken seal of the antiseize compound
between the threads. A seal which is broken may
allow leakage of combustion gas through the
threads.
Cold Start Advance Unit
Some of the Lucas, Bosch, and Stanadyne fuel injection
pumps have a cold start advance unit. The cold star advance
unit holds the timing of the fuel injection pump in an advance
position when the engine is cold.
NOTICE
It is Important that the electrical connections to the sender
unit are connected correctly. If the cold start advance unit
fails to operate correctly, engine damage may result
because the engine timing will be fully advanced for
normal engine operation.
Illustration 59
Lucas DP200 fuel injection pump.
The cold start advance unit is on the rear of the timing case on
the left side of the engine.
(1) Engine stop solenoid

(2) 3 Amp wire
(3) Sending unit
(4) 3 Amp wire
(5) 6 Amp wire
(7) Cold start advance unit
(8) Start switch
The cold start advance unit on the Lucas and the Bosch fuel
injection pumps operate in a similar manner. As the engine
begins to reach normal operating temperature, the cold star
advance unit energizes. By energizing, the fuel Injection pump
timing is retarded to the correct timing for normal operation.
The cold star advance unit on the Stanadyne fuel injection
pump operates differently. As the engine begins to reach
normal operating temperature, the cold start advance unit will
de-energize. By de-energizing, the fuel injection pump timing
is retarded to the correct timing for normal operation.
NOTICE
Damage to the engine will occur if the engine is load
tested at more than 80 percent of full load with the cold
start advance unit disconnected.
Illustration 60
Bosch fuel injection pump.
(2) 3 Amp wire
(4) Sending unit
(5) 3 Amp wire
(6) Cold start advance unit
(7) 6 Amp wire
(8) Start switch
6-69
TM 5-3895-382-24
Illustration 62
(A) Exhaust valves
(B) Inlet valves
Illustration 61
(2) 3 Amp wire
(3) 6 Amp wire
(5) Cold star advance unit
(6) 3 Amp wire
(7) Sending unit
(8) Start switch
Illustration 63
Air Inlet And Exhaust System
(A) Exhaust valves

(B) Inlet valves
SMCS Code: 1050
Valve Lash
Valve Lash Setting
Accidental engine starting can cause injury or death to
personnel.
The temperature of the engine does not change the valve lash
setting.
To prevent accidental engine starting, turn the ignition

switch to the OFF position, place a do not operate tag at
the ignition switch location and disconnect and tape the
electrical connection to the stop solenoid that is located
on the fuel injection pump.
Valve Lash Setting

Inlet valve .......................................0.20 mm (0.008 inch)
Exhaust valve .................................0.45 mm (0.018 inch)
Valve Lash Adjustment
If the valve lash requires adjustment several times in a short
period of time, excessive wear exists in a different par of the
engine. Repair the problem in order to prevent more damage
to the engine.
6-70
TM 5-3895-382-24
Not enough valve lash can be the cause of rapid wear of the
camshaft and valve lifters. Not enough valve lash can indicate
that the seats for the valves are defective.
Perform the following procedure in order to adjust the valve

lash:
1.
Set the top center position for number 1 piston on the

compression stroke. Before adjustments are made,
lightly tap each rocker arm at the top of the adjustment
screw. Use a soft mallet to ensure that the lifter seats
against the camshaft's base circle.
2.
Measure the valve lash for the inlet and exhaust valves
on cylinder 1. If necessary, make an adjustment to the
valve lash on the inlet and the exhaust valves for
number 1 cylinder.
Valves become defective due to the following causes:
Fuel injector nozzles that operate incorrectly.
Excessive dirt and oil are present on the filter for the
inlet air.
Incorrect fuel settings on the fuel injection pump.
The load capacity of the engine Is frequently exceeded.

a. Loosen the valve adjustment locknut that is on the
adjustment screw (1).
Too much valve lash can cause broken valve stems, springs,
and spring retainers. Too much valve lash can be an
indication of the following problems:
worn camshaft and valve lifter
worn rocker arms
bent pushrods
broken socket on the upper end of a pushrod
loose adjustment screw for the valve lash
b. Place the appropriate feeler gauge (2) between the

rocker arm and the valve. Turn the adjustment screw
(1) while the valve adjustment locknut is being held
from turning. Adjust the valve lash until the correct
specification is achieved.
c. After each adjustment, tighten the valve adjustment
locknut while the valve adjustment screw (1) is being
held from turning.
3.
If the camshaft and valve lifters show rapid wear, look for fuel
in the lubrication oil or dirty lubrication oil as a possible cause.
Turn the crankshaft for 180 degrees in the direction of

the normal engine rotation. Measure the valve lash of
the inlet valve and the exhaust valve of number 3
cylinder. If necessary, make an adjustment to the inlet
valve and the exhaust valve on number 3 cylinder.
The valve lash is measured between the top of the valve stem
and the rocker arm lever.

NOTE: Number 1 cylinder is at the front of the engine.

held from turning.
4.

cylinder. If necessary, make an adjustment of the valve
lash on number 4 cylinder.
Illustration 64
Setting The Valve Lash.
(1) Adjustment screw
(2) Feeler gauge
6-71
TM 5-3895-382-24

held from turning.
5.

cylinder. If necessary, make an adjustment of the valve
lash on number 2 cylinder.
Illustration 65
Cylinder Head On The 8-6691 Cylinder Head Stand Set.

6.
Put the cylinder head on the 8S-6691 Cylinder Head

Stand Set (A).
7.
Test the cylinder head for leaks at a pressure of

200 kPa (29 psi).

held from turning.
Cylinder Head
Inspect The Cylinder Head
Table 12
Illustration 66
Measure The Cylinder Head For Flatness.
Tools Needed
8S-6691
Cylinder Head Stand Set
(A) Side to side

(B) End to end
(C) Diagonal
1.
Remove the cylinder head from the engine.
2.
Remove the water temperature regulator housing.
3.
Remove the valve springs and valves.
4.
Clean the cylinder head thoroughly. Make sure that the

contact surfaces of the cylinder head and the cylinder
block are clean, smooth and flat.
5.
Inspect the bottom surface of the cylinder head for

pitting, corrosion, and cracks. Inspect the area around
the valve seat insets and the holes for the fuel injector
nozzles.
6-72
TM 5-3895-382-24
Resurfacing The Cylinder Head
The cylinder head face can be resurfaced by removing metal
from the face if the following conditions exist.
Illustration 67
Diagonal.
The cylinder head

specifications.
The cylinder head face is damaged by pitting, corrosion,

or wear.
The thickness of the cylinder head must not be less than

102.48 mm (4.035 inch) after the cylinder head has
been machined.
face
is
not
flat within
the
If the cylinder head is resurfaced, the recesses for the valve

seat inserts must be machined to the dimensions which are
given in Specifications, "Cylinder Head Valves". The valve
seat inserts must be ground on the side which is inserted into
the cylinder head. Grinding this surface will ensure that no
protrusion exists above the bottom face of the cylinder head.
Grind the outer edge of the cylinder head side of the valve sea
insert to a chamfer of 0.90 to 1.30 mm (0.035 to 0.051 inch) at
30 degrees to the vertical.
(1) Straight edge

(2) Feeler gauge
Valve Tests
Timing Of Valves
Illustration 68
Side To Side.
(1) Straight edge
(2) Feeler gauge
8.
Measure the cylinder head for flatness. Measure the

flatness with a straight edge (1) and with a feeler gauge
(2).
Measure the cylinder block from one end to the opposite

end (B).
Measure the cylinder block from one side to the

opposite side (A).
Measure the cylinder block from one corner to the

opposite comer (C).
Refer to Specifications,
requirements of flatness.
"Cylinder
Head"
for
1.
Remove the rocker cover and the coolant pump.
2.
Set the piston of number 1 cylinder to top center on the

compression stroke. Refer to the Testing and Adjusting,
"Setting The Top Center Compression Position For No.
1 Piston". Use the Systems Operation, Testing and
Adjusting, "Set The Top Center Position By Reverse Pin
Timing" procedure or the Systems Operation, Testing
and Adjusting, "Set The Top Center Position By The
Alternate Method" procedure in order to set the top
center position.
3.
Remove the front rocker arm and the inlet valve spring
of the number 1 cylinder.
NOTE: In order to aid in the checking of the valve timing,

the valve lash is increased. By loosening the
tension on the Number 1 inlet valve, a more
accurate determination of the valve lash is
allowed if the mark on the crankshaft pulley or the
damper is within 2.5 degrees of the pointer
indicator. Refer to Step 4.
the
6-73
TM 5-3895-382-24
4.
Fasten a temporary pointer to the timing case cover.

The tip of the temporary pointer should be near the
outer edge of the crankshaft pulley or the damper.
Make a temporary mark on the crankshaft pulley or the
damper which aligns with the temporary pointer.
Valve Depth Check
5.
Remove the timing pin.
8T-0455
6.
When the engine is viewed from the front, rotate the

crankshaft in a clockwise direction.
Rotate the
crankshaft until the inlet valve of the rear cylinder is fully
open.
7.
Set the valve lash of the number 1 inlet valve to 1.50

mm (0.059 inch).
8.

crankshaft in a clockwise direction until the pushrod of
the inlet valve for number 1 cylinder begins to tighten.
In this position, make sure that the mark on the
crankshaft pulley or the damper is within : 2.5 degrees
of the temporary pointer indicator.
Table 14
Tools Needed
Liner Projection Tool Group
NOTE: Use the following formula in order to calculate the

measurement which is equal to 2.5 degrees on the
pulley or damper:
Table 13.
Illustration 69
8T-0455 Liner Projection Tool Group.
Formula For Calculating The Measurement

on The Pulley or The Damper
(C X P)/360 = M
C is the circumference of the pulley or the damper.
P is equal to 2.5 degrees.
M is the measurement which is equal to 2.5 degrees on the pulley
or the damper.
9.
(1) 1P-2403 Dial indicator

(2) 1P-2402 Gauge body
(3) 1P-5507 Gauge block
Use the 8T-0455 Liner Projection Tool Group in order to check

the depths of the inlet valve and the exhaust valve below the
face of the cylinder head.
1.
If the timing is more than 2.5 degrees out of position, the

timing gears are not in correct alignment.
Use the gauge block (3) in order to set the dial indicator
(1) to zero.
One tooth on the camshaft gear is equivalent to 23 mm

(0.91 inch) at the circumference of a pulley of 203 mm
(7.99 inch) diameter. If a large damper is installed, one
tooth on the camshaft gear is equivalent to the following
measurements:
35 mm (1.38 inch) at the circumference of a damper of

310 mm (12.20 inch) diameter
37 mm (1.46 inch) at the circumference of a damper of

327 mm (12.87 inch) diameter
10.

crankshaft in a clockwise direction until the inlet valve of
the rear cylinder is fully open. Refer to Specifications,
"Cylinder Head Valves" for the correct valve lash.
Illustration 70
Valve Depth.
6-74
TM 5-3895-382-24
2.
Measure the depth of the inlet valve and the exhaust

valve below the cylinder head face. Use the gauge
body (2) and the dial indicator (1) in order to measure
the depth.
Refer to Specifications, "Cylinder Head Valve for the
minimum, the maximum, and the service wear limits for
the valve depth below the cylinder head face. The
minimum and the maximum limits are dimensions for a
new engine.
4.
Move the valve in a radial direction away from the dial

indicator. Make sure that the valve moves away from
the dial indicator as far as possible. Position the contact
point of the dial indicator on the edge of the valve head.
Set the position of the needle of the dial indicator to
zero.
5.
Move the valve in a radial direction toward the dial

indicator as far as possible. Note the distance of
movement which is indicated on the dial indicator. If the
distance is greater than the maximum clearance of the
valve in the valve guide, replace the valve guide. The
maximum clearance is given in Specifications, "Cylinder
Head Valves".
Service wear occurs on an engine which has been in

operation. If the valve depth below the cylinder head
face on a used engine exceeds the specification for
service wear, the following Items must be replaced:
Replacing Valve Guides and Valve Inserts
valves
valve inserts
Table 15
Tools Needed
If the valve depth below the cylinder head face on a
used engine exceeds the specification for service wear,
the cylinder head may also need to be replaced.
157-3720
Valve Seat Cuter and

Guide Reamer
NOTE: The valve seat cutter of the 157-3720 Valve Seat

Cutter and Guide Reamer has two cutting sides.
One side is for cutting the valve seat in the valve
insert for naturally aspirated engines which have
46 degree valve seats. The other side of the
cutter is for cutting the valve seat in the valve
insert for turbocharged engines which have 31
degree valve seats.
Testing The Valve Guides

Perform this test in order to determine if a valve guide should
be replaced.
When new valve guides are installed, new valves and new
valve seat inserts must be installed. Valve guides and valve
seat inserts are supplied as a partially finished part. The
unfinished valve guides and unfinished valve seat inserts are
installed in the cylinder head. Then, the valve guides and
valve inserts are cut and reamed in one operation with special
tooling. This procedure ensures the concentricity of the valve
seat to the valve guide in order to create a seal that is gas tight
NOTE: All lubricant must be removed from the outside of
the inlet and exhaust valve guides before the
valve seal is installed.
Illustration 71
Measure The Radial Movement Of The Valve In The Valve Guide.
Perform the following procedure in order to correctly adjust

new valve guides and valve insets:
(1) Valve guide

(2) Radial movement o the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) When the valve head is lifted, the edge of the valve head is the
following value: 15.0 mm (0.60 inch)
1.
Place a new valve in the valve guide.
2.
Place a dial indicator with a magnetic base on the face

of the cylinder head.
3.
Lift the edge of the valve head to a distance of 15.0 mm

(0.60 inch).
1.
Remove the original valve guide and the original valve

seat insert. Install a new valve guide and a new valve
seat insert. Refer to the Disassembly and Assembly
manual for removal and installation procedures for valve
guides and valve inserts.
NOTE: Do not cut the valve seat before the valve guide is
installed.
6-75
TM 5-3895-382-24
2.
Machine the recess in the cylinder head for the valve

seat insert. Refer to the dimensions that are given in
the Specifications manual. Use the bore of the new
valve guide as a guide.
Remove all debris. Thoroughly clean the recess for the
valve seat insert.
3.
Ensure that the valve seat insert does not protrude

above the bottom face of the cylinder head. If the valve
seat insert protrudes above the bottom face of the
cylinder head, the back of the valve seat insert must be
machined. Refer to the Specifications manual for
dimensions of the valve seat insert.
4.
Press the valve seat insert into the recess of the

cylinder head for the valve sea insert. Use a hydraulic
press or a driver in order to install the valve seat insert.
Use the bore of the new valve guide as a guide. Refer
to the Disassembly and Assembly manual for additional
information regarding tools. Ensure that the bottom of
the valve seat insert fully contacts the bottom of the
recess in the cylinder head.
5.
Illustration 72
The wastegate is mounted on the turbocharger.
(1) Dial indicator
(2) Clip
(3) Pin
(4) Actuator rod
(5) Locknut
(6) Actuator
(7) Line for the boost sensor
Cut the valve seat with the valve seat cuter. Refer to
the Specifications manual for the correct angles and
dimensions for the valve seats and depth of the valve
head. Ensure that the depth of the valve head below
the face of the cylinder head is within the tolerance.
1.
Disconnect the line for the boost sensor (7) at the

actuator (6). Connect an air supply to the actuator. The
pressure of the air supply must not exceed 207 kPa
(30 psi). The pressure of the air supply must be
measured by a gauge which is capable of measuring
pressures to the nearest 0.7 kPa (0.1 psi). The
pressure of the air supply must be capable of
adjustment to the nearest 0.7 kPa (0.1 psi).
2.
Place a magnetic base on the turbocharger. Position

the contact of the dial indicator (1) on the end of the
actuator rod (4). Set the pointer of the dial indicator to
zero.
3.
Slowly increase the air pressure. Determine the air

pressure which is necessary in order to move the
actuator rod. The actuator rod should move a distance
of the following value: 1.00 mm (0.039 inch).
Testing The Wastegate

If the valve of the wastegate does not operate at the correct
pressure, the performance of the engine will be adversely
affected. If the valve opens at a pressure that is too low, the
following items will occur: black exhaust smoke and loss of
power at lower engine rpm. If the valve opens at a pressure
that is too high, pressures in the engine cylinders will be too
high. Cylinder pressures that are too high will cause the
following items to occur failure of the cylinder head gasket and
damage to the bearings and the pistons.
Purge the air pressure. Ensure that the needle of the

dial indicator moves to zero when the pressure from the
air supply is purged in order to repeat the test.
Repeat this step one or more times in order to ensure
that an accurate air pressure is obtained for opening the
valve of the wastegate. Compare the opening pressure
of the valve of the wastegate in the following table with
the measured pressure.
6-76
TM 5-3895-382-24
Table 16
Number That Is
Stamped
On The Turbocharger
2674A081"
2674A084
2674A089"
2674A092"
"2674A093"
"2674A094"
2674A095"
2674A096
2674A097"
2674A098"
2674A099"
"2674A306
2674A307"
2674A311"
2674A315
"2674A316"
Lubrication System
SMCS Code: 1300
Opening Pressure
Of The Valve For
The Wastegate
88 4 kPa (12.8 0.6 psi)
124 5 kPa (18.0 0.7 psi)
150 5 kPa (21.8 0.7 psi)
150 5 kPa (21.8 0.7 psi)
110 5 kPa (16.0 0.7 psi)
105 5 kPa (15.0 0.7 psi)
145 5 kPa (21.0 0.7 psi)
150 5 kPa (21.8 0.7 psi)
138 5 kPa (20.0 0.7 psi)
96 5 kPa (13.9 0.7 psi)
107 5 kPa (15.5 0.7 psi)
138 5 kPa (20.0 0.7 psi)
150 5 kPa (21.8 0.7 psi)
145 5 kPa (21.0 0.7 psi)
150 5 kPa (21.8 0.7 psi)
96 5 kPa (13.9 0.7 psi)
4.
If the operation of the valve of the wastegate is not

correct, the actuator rod (4) requires adjustment.
Remove the dial indicator from the end of the actuator
rod.
5.
Keep the air pressure applied to the actuator (6).

Release the locknut on the actuator rod (4). Remove
the clip (2). Remove the actuator rod from the pin (3).
The pin is on the arm of the valve of the wastegate.
6.
If the air pressure was too low, rotate the actuator rod
(4) in the direction which reduces the length of the
actuator rod. If the air pressure was too high, rotate the
actuator rod in the direction which increases the length
of the actuator rod. Rotate the length of the rod in
increments of one-half turn.
Fluid Spillage Containment

Care must be taken in order to ensure that fluids am contained
during performance of inspection, maintenance, testing,
adjusting and repair. Collect all fluids with suitable containers
before opening any compartment or disassembling any
component that contains fluids. For tools and supplies that are
suitable for collecting fluids and containing fluids, refer to the
Tools And Shop Products Guide, NENG2500. Also refer to
your local regulations and requirements.
Inspect The Oil Pump
If any pa of the oil pump is worn enough in order to affect the
performance of the oil pump, the oil pump must be replaced.
Perform the following procedures in order to inspect the oil
pump.
Refer to Specifications, "Engine Oil Pump" for
clearances and torques.
Illustration 73
Cover of the oil pump.
(1) Bolts for the cover
NOTE: Use only the end of the threaded rod in order to

make adjustments.
Pushing or pulling the
actuator rod could change the calibration of the
actuator. Changing the calibration could increase
the wastegate boost which could damage the
engine.
7.
Place the pin (3) through the actuator rod (4) and
through the arm of the wastegate valve. Install the clip
(2). Tighten the locknut (5). Release the air pressure.
8.
Repeat Step 2 through Step 7 until the operation of the

wastegate is correct.
6-77
1.
Remove the oil pump from the engine. Remove the

cover of the oil pump.
2.
Remove the outer rotor. Clean all of the parts. Look for
cracks in the metal or other damage.
TM 5-3895-382-24
6.
Clean the top face of the oil pump and the bottom face
of the cover. Install the cover on the oil pump. Install
the oil pump on the engine.
Engine Oil Cooler

Inspection of a Plate Type Engine Oil Cooler
Hot oil and hot components can cause personal injury. Do

not allow hot oil or hot components to contact the skin.
Illustration 74
Measure the clearance of the outer rotor to the body.
3.
Install the outer rotor. Measure the clearance of the

outer rotor to the body.
Illustration 75
Measure the clearance of the inner rotor the outer rotor.
4.
Measure the clearance of the inner rotor to the outer

rotor.
Illustration 76
Measure the end play of the rotor.
5.
Measure the end play of the rotor with a straight edge

and a feeler gauge.
6-78
TM 5-3895-382-24
Illustration 77
(1) Cover plate
(2) Three-piece O-ring
(3) Cooling plate
(4) O-rings for connector of oil hose
(5) Nuts on stud for flange

(6) Nuts and bolts for cover plate
(7) Two-piece flange for connector of oil hose
Perform the following procedure in order to inspect the engine

oil cooler:
1.
Place a container under the oil cooler in order to collect

any engine oil or coolant that drains from the oil cooler.
Remove one of the oil hoses. Do not remove both of
the oil hoses at the same time in order to ensure that
cooling plate (3) remains fastened to cover plate (1)
when assembly (9) is removed.
Before removing the second oil hose, install two piece
flange (7) and the nuts on the studs for flange (5)
without the oil hose.
2.
Remove the nuts and bolts for cover plate (6). Remove
assembly (9). Remove O-rings (4).
6-79
(8) Stud
(9) Cover plate with cooling plate assembly
(10) Gasket
3.
Thoroughly clean the flange face of the cover plate and

the cylinder block. If a sealant was used in order to
create the gasket, thoroughly remove the sealant from
the surfaces of the cylinder block and cover plate (9).
When assembly (9) is reassembled, use new paper
gasket (10).
4.
Place assembly (9) on a clean work surface. Remove

four nuts (5) that retain the two-piece flanges for the oil
hoses. Remove cover plate (1) from four studs of
cooling plate (3).
5.
Remove the three-piece O-tings (2). When the oil

cooler is reassembled, these O-tings must be replaced
with new O-tings.
TM 5-3895-382-24
Problems Of The Lubrication System
Table 17
Personal injury can result from air pressure.
Tools Needed
Personal injury can result without following proper

procedure. When using pressure air, wear a protective
face shield and protective clothing.
4C-4890
Inspect the cooling plate (3) for cracks and dents.

Replace the cooling plate if cracks or dents exist.
If necessary, clean the outside of the cooling plate and
clean the inside of the cooling plate. Use a solvent that
is not corrosive on copper. Ensure that no restrictions
for the flow of lubricating oil exist in the cooling plate.
If the studs (8) were removed from the cylinder block,

clean the threads. Place Loctite 270 on the threads of
the stud which are threaded into the cylinder block.
8.
Place a new gasket (10) on the studs (8). Do not use

any sealant on the gasket. Place the assembly (9) on
the cylinder block.
Clean the seats for the three-piece O-rings (2). Install

new O-rings for the hose connections.
Low oil pressure
High oil pressure
Excessive wear of components
1.
Inspect the rear main bearing for leakage through the

seal.
2.
Inspect each end of the oil pan for leakage through the
seals. Inspect the oil pan for leakage through the
gasket.
3.
Inspect the lubrication system for leakage at all

connections.
4.
Inspect the cylinder head for leakage through the

gasket.
Leakage of Oil In The Cylinder Head
NOTE: Do not remove the two-piece flanges (7) and nuts

(5) from the studs before one of the oil hoses is
installed on the cover plate. When the oil hoses
are installed, this placement of the flanges and
nuts will help to ensure that the cooling plate is
held in the correct position on the cover plate.
Leakage of oil in the cylinder head can be the cause of blue

smoke. There are four possible causes of leakage of oil into
the cylinder head:
Oil leakage between worn valve bores, valve guides,

and valve stems.
Piston rings are worn or damaged.
Ensure that the cooling system of the engine is filled to

the correct level. Operate the engine.
Piston rings are incorrectly installed.
Check for oil or coolant leakage.
The viscosity of the oil is incorrect.
Install the oil hoses on the cover plate. Tighten the nuts
for the flange (5) to a torque of 22Nom (16 lb-ft).
10.
Excessive oil consumption
Leakage of Oil Through Seals And Gaskets
Tighten the nuts and bolts for the cover plate (6) to a
torque of 22 Nom (16 lb-ft).
9.
Excessive Oil Consumption
Dry the cooling plate with low pressure air. Flush the
inside of the cooling plate with clean lubricating oil.
7.
The following problems are the most common problems in the

lubrication system:
Maximum air pressure at the nozzle must be less than 205

kPa (30 psi) for cleaning purposes.
6.
Hydraulic Test Group
Oil with a low viscosity can be caused by water

contamination, fuel contamination, or chemical
breakdown of the oil. The chemical breakdown can be
caused by these conditions:
6-80
An engine that continually overheats
Dirt
Other contaminants
TM 5-3895-382-24
Dirt and other contaminants are agents that create a low pH in
the oil.
Excessive Component Wear

Premature component wear can be caused by the following
conditions:
Oil with a viscosity which is too low or contamination of the oil

by particulate materials increases the wear on all engine parts.
Particulate materials are in the engine oil which causes

abrasion of moving parts.
A restricted passage in the engine for the lubricating oil

prevents the oil from lubricating a moving part or cooling
the part.
Low oil pressure prevents an adequate flow of oil to the

component.
Low Oil Pressure

The following conditions will cause low oil pressure:
The oil level is low in the crankcase.
A restriction exists on the oil pump screen.
Connections in the oil lines are leaking.
The connecting rod or the main bearings are worn.
The rotors in the oil pump are worn.
Lubricating oil should be changed at the times which are

specified in Operation And Maintenance, "Maintenance Interval
Schedule". The type of lubricating oil is specified in Operation
And Maintenance, "Lubricant Specifications".
The oil pressure relief valve is operating incorrectly.
Cooling System
A worn oil pressure relief valve can allow oil to leak through the
valve which lowers the oil pressure. Refer to Specifications,
"Engine Oil Bypass Valve" for the correct operating pressure
and other information.
SMCS Code: 1350
When an engine that is turbocharged runs at the normal

temperature for operation and at high idle, the oil pressure
must be a minimum of 280 kPa (41 psi). A lower pressure is
normal at low idle.
The pressure type cooling system can operate safely at

a higher temperature than the boiling point of water at a
range of atmospheric pressures.
The pressure type cooling system prevents cavitation in

the water pump.
This engine has a pressure type cooling system. A pressure

type cooling system gives two advantages:
4C-4890 Hydraulic Test Group can be used in order to test the

pressure of the lubrication system.
Cavitation is the sudden generation of low pressure bubbles in

liquids by mechanical forces. The generation of an air or
steam pocket is much more difficult in a pressure type cooling
system.
High Oil Pressure

High oil pressure can be caused by the following conditions:
The spring for the oil pressure relief valve is installed

incorrectly.
The plunger for the oil pressure relief valve becomes

jammed in the closed position.
Excessive sludge exists in the oil which makes the

viscosity of the oil too high.
Regular inspections of the cooling system should be made in

order to identify problems before damage can occur. Visually
inspect the cooling system before tests are made with the test
equipment.
Visual Inspection Of The Cooling System
6-81
1.
Check the coolant level in the cooling system.
2.
Look for leaks in the system.
3.
Inspect the radiator for bent fins and other restriction to

the flow of air through the radiator.
4.
Inspect the drive belt for the fan.
5.
Inspect the blades of the fan for damage.
6.
Look for air or combustion gas in the cooling system.
TM 5-3895-382-24
7.
Inspect the radiator cap for damage.

surface must be dean.
The sealing
8.
Look for large amounts of dirt in the radiator core. Look

for large amounts of dirt on the engine.
Test Tools For The Cooling System

Table 18
9.
Part Number
4C-6500
8T-2700
Shrouds that are loose or missing cause poor air flow

for cooling.
Testing The Cooling System

9U-7400
9s-8140
Remember that temperature and pressure work together. Both

the temperature and the pressure must be checked when a
problem with the cooling system exists. The pressure of the
cooling system will have an effect on the temperature of the
cooling system. Review Illustration 78 in order to determine
the following effects on the boiling point of water:
pressure
height above sea level
Required Tools
Part Name
Digital Thermometer Group
Blowby/Air Flow Indicator
Group
Multitach
Pressurizing Pump
Quantity
1
1
1
1
Illustration 79
4C-6500 Digital Thermometer Group.
The 4C-6500 Digital Thermometer Group is used in the

diagnosis of problems that cause overheating or overcooling in
the engine. This tool can be used to check the temperature in
several areas of the cooling system. The testing procedure is
in Tool Operating Manual, NEHS0554.
Illustration 78
Cooling system pressure at specific altitudes and boiling points of
water.
Illustration 80
8T-2700 Blowby/Air Flow Indicator Group.
The 8T-2700 Blowby/Air Flow Indicator Group is used to check

the air flow through the radiator core.
The operating
instructions are included with the tooling.
6-82
TM 5-3895-382-24
Illustration 82
Illustration 81
9U-7400 Multitach.
9S-8140 Pressurizing Pump.

(1) Release valve
(2) Adapter
(3) Hose
The 9U-7400 Multitach is used to measure the fan rpm. The

testing procedure is in Tool Operating Manual, NEHS0605.
The 9S-8140 Pressurizing Pump pressurizes the cooling

system in order to test for leaks.
Adding The Antifreeze

Do not add pure antifreeze to the cooling system in order to
adjust the concentration of antifreeze. The pure antifreeze
increases the concentration of antifreeze in the cooling system.
The increased concentration increases the concentration of
dissolved solids and undissolved chemical inhibitors in the
cooling system.
Add an antifreeze and water mixture in the concentration which
provides the desired freeze protection. Use the following chart
in order to determine the correct concentration of antifreeze in
water to use.
Table 19
Illustration 83
Pressure cap that is mounted on the radiator.
Antifreeze Concentration For Freeze Protection

Temperature
-15C (5F)
-23C (-9F)
-37C (-35F)
-51C (-60F)
Concentration
30% antifreeze
and 70% water
40% antifreeze
and 60% water
50% antifreeze
and 50% water
60% antifreeze
and 40% water
(4) Sealing surface between the pressure cap and the radiator.
Use the following procedures to inspect the pressure cap and
test the pressure cap:
Pressurized system: Hot coolant can cause serious bum.

To open cap, stop engine, wait until radiator is cool. Then
loosen cap slowly to relieve the pressure.
Testing The Pressure Cap

One cause for a pressure loss in the cooling system can be a
defective seal on the radiator pressure cap.
6-83
1.
When the engine has cooled, loosen the pressure cap

to the first stop. Remove the pressure cap when the
pressure is released from the cooling system.
2.
Inspect the pressure cap carefully. Look for damage to

the seal. Look for damage to the surface that seals.
Remove any debris on the cap, the seal, or the sealing
surface.
TM 5-3895-382-24
3.
Put the pressure cap on the 9S-8140 Pressurizing

Pump.
4.
Observe the exact pressure when the pressure cap

opens.
5.
7.
Testing The Water Temperature

Regulator
Compare the pressure to the pressure that is given in

Specifications, "Pressure Cap". If the pressure cap
opens at a pressure beyond the range that is given in
Specifications, "Pressure Cap", the pressure cap is
defective. Replace a defective pressure cap.
1.
Remove the water temperature regulator from the

engine.
2.
Hang the water temperature regulator in a pan of water.

Put a thermometer in the water.
Put the water
temperature regulator completely under water. Do not
allow the water temperature regulator to be in contact
with the pan.
3.
Heat the water in a container. Stir the water in order to

keep all of the water at the same temperature.
4.
Replace the water temperature regulator if the water

temperature regulator does not open at the
temperatures that are given in Specifications, "Water
Temperature Regulator".
Testing The Radiator And Cooling

System For Leaks
Use the following procedure to test the radiator and the cooling
system for leaks.
Pressurized system: Hot coolant can cause serious burn.

To open cap, stop engine, wait until radiator is cool. Then
loosen cap slowly to relieve the pressure.
1.
If any leakage exists on the inside of the cooling system,

identify the location of the leakage. Repair the source of
the leak in the cooling system.
Engine And Cooling System Heat

Problems
When the engine has cooled, loosen the pressure cap

to the first stop. Allow the pressure to release from the
cooling system. Then remove the pressure cap.
2.
Make sure that the coolant covered the top of the

radiator core.
NOTE: Use a coolant recovery system in order to collect

any coolant which drains from the coolant
system.
3.
Put the 9S-8140 Pressurizing Pump on the radiator.
1.
4.
Use the pressurizing pump to increase the pressure to

an amount of 20 kPa (3 psi) more than the operating
pressure of the pressure cap. This operating pressure
is given in Specifications, "Pressure Cap".
5.
Inspect the radiator for leakage.
6.
Inspect all connections and hoses of the cooling system

for leaks.
b. Hot coolant is released from the coolant system but

not through the pressure cap during normal operation
of the engine. Hot coolant can also be released when
the engine is stopped.
The radiator and the cooling system do not have

leakage If all of the following conditions exist:
c. Coolant must be added frequently to the cooling

system. The coolant is not released through the
pressure cap or through an outside leak.
You do not see any leakage after five minutes.
The dial indicator remains constant beyond five minutes.
The reading on the dial indicator decreases, and you do

not observe any outside leaks.
The following conditions indicate that a heat problem

exists:
a. Hot coolant is released through the pressure cap
during the normal operation of the engine. Hot
coolant can also be released when the engine is
stopped.
2.
If any of the conditions in Step 1 exist, perform the

following procedures:
a. Run the engine at medium idle, which is
approximately 1200 rpm, for three minutes after the
high idle shuts off. Running the engine at medium
idle will allow the engine to cool before the engine is
stopped.
6-84
TM 5-3895-382-24
3.
Perform the following procedures in order to determine if

the pressure cap is damaged or if a leak exists in the
cooling system:
Cooling System Conditioner
a. Perform the "Visual Inspection Of The Cooling

System" procedures.
Supplemental cooling system additive contains alkali. To

prevent personal injury, do not drink, avoid contact with
the skin and eyes.
b. Perform the "Testing The Pressure Cap" procedures.
NOTICE
All water is corrosive at engine operating temperature.
The cooling system should be protected with a 3% to 6%
concentration of cooling system conditioner at all times.
c. Perform the "Testing The Radiator And Cooling

System For Leaks" procedures.
d. Check the tension of all belts on the engine. Refer to
the Testing And Adjusting, "Belt Tension Chart" for
more information.
4.
Caterpillar does not recommend the use of cooling system

solutions that are intended to stop leaks.
If the coolant does not flow through the radiator and

through other components of the cooling system,
perform the following procedures:
a. Perform the "Testing
Regulator" procedures.
The
Water
Use of these products may result in excessive internal

deposits that could reduce the engine's heat transfer
characteristics.
Temperature
Caterpillar Cooling System Conditioner can be used with an
antifreeze or without an antifreeze of ethylene glycol base in
the coolant.
b. Clean the radiator and other components with hot

water or steam at low pressure. Detergent in the
water may also be used. Compressed air may be
used to remove materials from the cooling system.
Identify the cause of the restriction before you choose
the method for cleaning.
When the conditioner is added to the coolant, the cooling

system must be flushed and the cooling system must be
cleaned. Refer to Operation and Maintenance, "Cooling
System Specifications" for additional information.
c. Straighten any fins of the radiator if the fins are bent.

5.
Check the high idle of the engine. The engine may

overheat if the high idle rpm is set too high.
6.
Timing of the engine which is incorrect may also cause

overheating of the engine. Late timing creates more
heat in the engine. Early timing creates less heat in the
engine.
NOTE: If the timing of the engine is too early, the exhaust

valves may be burned and damage to the exhaust
manifold may occur.
6-85
TM 5-3895-382-24
Belt Tension Chart
SMCS Code: 1357
Table 20
Belt Tension Chart

Belt
Size
3/8
1/2
5V
11/16
3/4
15/16
8K
6PK
Gauge Reading
Belt Width
Belt Tension
Belt Tension
Initial (1)
Used (2)
10.72 mm (0.422 Inch)
445 22 N (100 5 lb)
400 22 N (90 5 lb)
13.89 mm (0.547 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
15.88 mm (0.626 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 Ib)
17.48 mm (0.688 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
19.05 mm (0.750 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 lb)
23.83 mm (0.983 Inch)
534 22 N (120 5 lb)
400 44 N (90 10 Ib)
27.92 mm (1.099 Inch)
800 22 N (180 5 lb)
489 44 N (110 10 lb)
20.94 mm (0.824 Inch)
667 22 N (150 5 lb)
467 44 N (105 10 lb)
Measure the tension of the belt that is farthest from the engine.
Borroughs
Gauge Numbers
Old Gauge
New Gauge
Number
Number
BT-33-95
BT-33-97
BT-33-95
BT-33-97
BT-33-72
BT-33-72C
BT-33-72
BT-33-72C
BT-33-72
BT-33-72C
BT-33-72
BT-33-77
-----BT-33-109
-----BT-33-109
(1) Belt Tension "Initial" is used for a new belt.

(2) Belt Tension 'Used" is for a belt with over 30 minutes of operation at the rated speed.
Basic Block
SMCS Code: 1200
Cylinder Liner Projection
Table 21
Tools Needed
8T-0455
Linear Projection Tool Group
Illustration 84
8T-0455 Liner Projection Tool Group.
6-86
TM 5-3895-382-24
1.
Use the 8T-0455 Liner Projection Tool Group in order to

measure the flange projection of the cylinder liner. Use
the gauge block (3) in order to zero the dial indicator (1).
Before the performance of the compression test, make sure

that the following conditions exist:
Illustration 85
Measure the liner projection.
The battery is in good condition.
The battery is fully charged.
The starting motor operates correctly.
The valve lash is set correctly.
All fuel injector nozzles are removed.
The fuel supply is disconnected.
1.
Install a gauge for measuring the cylinder compression

in the hole for a fuel injector nozzle.
2.
Operate the starting motor in order to turn the engine.

Record the maximum pressure which is indicated on the
compression gauge.
3.
Repeat Steps 1 and 2 for all cylinders.
(1) 1P-2403 Dial Indicator

2.
Position the gauge body (2) and the dial indicator (1) in
order to measure the flange projection in four locations
around the cylinder liner. Do not measure the projection
from the flame ring, if equipped.
Inspection Of The Cylinder Liner

The condition of a cylinder liner is determined by the following
criteria:
The four measurements should not vary more than 0.03

mm (0.001 inch) from each other.
The average
projection between adjacent cylinders must not vary
more than 0.03 mm (0.001 inch).
The extent and the location of any polished areas that

are on the bore of the cylinder liner is a condition. If the
bore of the cylinder liner is polished, an engine can have
oil consumption that is high with very little wear on the
bore. Observe the area that is near the top of the bore
of the cylinder liner. However, the area is just below the
ring of carbon. The thrust from the top piston ring is the
maximum in this area.
The wear that is on the bore of the cylinder liner is a

condition. Refer to the Specifications manual for the
dimensions of a cylinder liner.
Damage to the cylinder liner such as cracks and deep

scratches is a condition.
Refer to Specifications, "Cylinder Block for the

tolerance of the flange projection that is above and
below the face of the cylinder block.
Cylinder Compression Test
The cylinder compression test should only be used in order to
compare the cylinders of an engine. If one or more cylinders
vary by more than 350 kPa (51 psi), several tests should be
conducted. The tests will determine if an adjustment is
required or if replacement of components is required. Perform
the following tests If one or more cylinders vary by more than
350 kPa (51 psi):
If the conditions that follow exist, the cylinder liner does not
need to be replaced:
Measure the height of the piston above the cylinder

block.
Measure the bore of the cylinder liner.
Check the surface finish of the cylinder liner.
Measure the piston rings for wear or damage.
Perform the valve tests that are described in the

Systems Operation. Testing and Adjusting manual.
The honed finish can be clearly seen on the area of the

cylinder liner.
The engine performance and the oil consum ption are

acceptable.
If the cylinder liner requires replacement, refer to the

Disassembly and Assembly manual for the procedures for
removal and installation of the cylinder liner.
6-87
TM 5-3895-382-24
A new cylinder liner is partially finished. Personnel with the
correct training are required in order to finish a new cylinder
liner. Special equipment and tools are also required. Refer to
the Specifications manual for additional information.
NOTE: If a new cylinder liner is installed, new piston
rings must be installed.
Height Of The Piston Above The Cylinder Block
If the height of the piston above the cylinder block is not within
the tolerance that is given in Specifications, "Piston and
Rings", the piston and the bearing for the piston pin must be
replaced. If any of the following components are replaced or
remachined, the piston height above the cylinder block must be
measured:
crankshaft
cylinder head
connecting rod
bearing for the piston pin
piston
Illustration 86 8T-0455
Liner Projection Tool Group.
The correct piston height must be maintained in order to

ensure that the engine conforms to the standards for
emissions.
NOTE: The top of the piston should not be machined. If
the original piston is installed, be sure that the
original piston is assembled to the correct
connecting rod and installed in the original
cylinder.
Six grades of length of connecting rods determine the piston
height above the cylinder block. The grade of length of a
connecting rod is identified by a letter or a color. The letter or
the color is marked on the side of the connecting rod. Refer to
"Inspection Of Connecting Rods" for specifications of the
connecting rods.
1.
Use the 8T-0455 Liner Projection Tool Group in order to

measure the piston height above the cylinder block.
Use the gauge block (3) to zero the dial indicator (1) on
the face of the cylinder block.
2.
Position the gauge block (3) on the cylinder block.

Rotate the crankshaft until the piston is at the
approximate top center. Ensure that the flame ring of
the cylinder liner does not interfere with the gauge block
or the dial indicator.
Illustration 87
Measurement of the piston height.
6-88
TM 5-3895-382-24
3.
Position the gauge body (2) and dial indicator (1) in

order to measure the piston height above the cylinder
block. Slowly rotate the crankshaft in order to determine
when the piston is at the highest position. Record this
dimension. Compare this dimension with the dimension
that is given in Specifications, "Pistons and Rings".
In order to ensure that the piston height above the cylinder

block is correct, six grades of length of connecting rods are
used. The grade of length is identified by a letter or a color
which is marked on the side of the connecting rod. The
longest grade is marked with the letter "F". The shortest grade
is marked with the letter "L". The difference in length between
each grade of connecting rods is the following value: 0.046 mm
(0.0018 inch).
Inspection Of Connecting Rods

These procedures determine the following characteristics of
the connecting rod:
The grade of length of a connecting rod is determined in the

factory by machining an eccentric hole in a semi-finished
piston pin bushing.
Therefore, the grade of length is
determined by the position of the center of the hole in the
piston pin bearing. There is a hole that is in the connecting rod
for the piston pin bearing. The grade of length is not
determined by the position of the hole that is in the connecting
rod for the piston pin bearing.
the length of the connecting rod

the distortion of the connecting rod
the parallel alignment of the bores of the connecting rod
NOTE: If the crankshaft or the cylinder block are

replaced, the piston height for all cylinders must
be measured.
The grade of length of the
connecting rods may need to be changed in order
to obtain the correct piston height.
If the connecting rod must be replaced, a new connecting rod

assembly must be purchased and installed. Refer to Table 22
A new piston pin bearing is installed in the new connecting rod
at the factory. The bore of the piston pin bearing is reamed to
the correct eccentricity.
If the grade of length must be changed, one of the following

actions must be taken:
New connecting rod assemblies that are the correct

grade of length must be installed. Refer to "Length Of A
Connecting Rod".
Piston Pin Bearings

NOTE: This procedure requires personnel with the
correct training and the use of specialized
equipment for machining.
New piston pin bearings must be bored after installation

in the original connecting rods. Refer to "Piston Pin
Bearings".
If the piston pin bearing requires replacement but the original

connecting rod is not replaced, the following procedures must
be performed:
NOTE: When the piston pin is installed, always install

new retaining rings on each end of the piston pin.
If the piston pin cannot be removed by hand, heat
the piston to a temperature of 45 5 C
(113 9 F) in order to aid the removal of the
piston pin. Heating the piston to this temperature
may also aid the installation of the piston pin.
There is a recess on the face of the connecting
rod. The recess is for the piston pin. The recess
must always face the same side as the bore for
the journal bearing.
1.
Determine the grade of length of the connecting rod.

Use one of the following characteristics:
The mark
The color
Measuring the length
NOTE: The length of the connecting rod is measured

when the following items are completed: Remove
the bearing for the crankshaft journal. Install the
original piston pin bearing in the connecting rod.
Refer to "Measure The Length Of A Connecting
Rod".
Length Of A Connecting Rod

CRL is the length of the connecting rod. Refer to Table 22 for
each grade of length of connecting rod.
2.
6-89
Ensure that the connecting rod is aligned parallel and

that the connecting rod is not distorted. Refer to
"Distortion Of A Connecting Rod" in this service manual.
TM 5-3895-382-24
3.
Remove the piston pin bearing from the connecting rod.

Install a new bearing in the connecting rod. The new
bearing is partially finished. The new bearing must be
bored off-center to the correct diameter. This off-center
position is determined by the grade of length of the
connecting rod. Refer to Table 22. The correct
diameter of the bore in the piston pin bearing is given in
the Specifications, "Connecting Rod" manual.
Table 22
Surface finish of the bored hole in the piston pin

bearing .....................................Ra 0.8 micrometers
4.
Machine the ends of the piston pin to the correct length.

Remove any sharp edges. Refer to Specifications,
"Connecting Rod".
5.
If the grade of length of the connecting rod is changed,

the letter that is stamped on the connecting rod must be
removed. Etch a letter that is for the new grade of
length on the side of the connecting rod.
Color
"F
Red
165.728 to
165.761 mm
(6.5247 to
(6.5265 inch)
"G"
Orange
165.682 to
165.715 mm
(6.5229 to
(6.5247 inch)
"H"
White
165.637 to
165.670 mm
(6.211 to
(6.5229 inch)
J"
Green
165.591 to
165.624 mm
(6.5193 to
6.5211 inch)
K"
Purple
165.545 to
165.578 mm
(6.5175 to
6.5193 inch)
"L
Blue
165.499 to
165.532 mm
(6.5157 to
6.5175 inch)
NOTE: Do not stamp a new letter on the connecting rod.

The force of stamping may damage the
connecting rod.
Table 22 references the following information: grade of
length of the connecting rod and lengths of the
connecting rods.
Length Of The
Connecting
Rod (CRL)
Grade of
Length
Measure The Length Of A Connecting Rod

If the mark or the color of the grade of length cannot be
observed on the connecting rod, perform the following
procedure:
Illustration 88
Measure the length of the connecting rod.
(1) Measuring pins
(2) Connecting rod
(CRL) Connecting Rod Length
6-90
TM 5-3895-382-24
1.
Refer to Illustration 88. Use the following tools in order

to measure the length of the connecting rod:
If the piston pin bearing is not removed, the limit "L" is

the following value: 0.06 mm ( 0.0024 inch).
appropriate gauges for measuring distance

measuring pins (1)
L is equal to 219.08 0.03 mm (8.625 0.001 inch).
2.
Be sure that the measuring pins (1) are parallel. "CRL"

is measured when the bearing for the crankshaft journal
is removed and the original piston pin bearing is
installed.
Measure "CRL". Compare the "CRL" that is measured
to the "CRL" that is given in Table 22. The grade of
length of the connecting rod is determined by the "CRL".
Refer to Table 22 for the correct grade of length.
3.
Inspect the piston pin bearing and the piston pin for
wear.
4.
Measure the clearance of the piston pin in the piston pin

bearing. Refer to Specifications, "Connecting Rod" for
dimensions.
Crankshaft Seals
Installing The Crankshaft Rear Seal on Type 1 Engines and
9RM Engines
Distortion Of A Connecting Rod

1.
Use the following tools in order to measure the

distances for the connecting rod (2) which are specified
in Illustration 89:
appropriate gauges for measuring distance
measuring pins (1)

and Adjusting, "Engine Design" for more
information.
Table 23
Tools Needed
9U-6205
Rear Seal Installer Group
8T-5096
Dial Indicator Group
The crankshaft rear seal has a dust lip that protrudes from the
rear face of the seal. The dust lip can be easily damaged if a
standard seal driver is used for installation. The 9U-6205 Rear
Seal Installer Group will help prevent damage to the dust lip.
NOTE
Illustration 89
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and the
crankshaft journal bearing is shown in Illustration 89.
2.
Measure the connecting rod for distortion and parallel

alignment between the bores.
The bores for the crankshaft bearing and the bearing for
the piston pin must be square and parallel with each
other within the required limits. If the piston pin bearing
is removed, the limit "L" is the following value:
0.25 mm ( 0.010 inch).
The limits are measured at a distance of 127 mm (5.0
inch) from each side of the connecting rod.
6-91
The crankshaft rear seal is easily damaged.

Extreme care should be used when you install the
crankshaft rear seal. Damage across the lip of the
seal, which can be visually observed, will cause
leakage of oil through the seal.
TM 5-3895-382-24
Illustration 90
Crankshaft rear seal.
Illustration 91
Sealing area on the crankshaft for the rear seal.
(A) 2.3 mm (0.09 inch)

(B) 4.6 mm (0.18 inch)
(C) 6.9 mm (0.27 inch)
1.
The seal is at position (A) on new engines. Position (A)

is 2.3 mm (0.09 inch) from the face of the rear housing.
2.
If the oil leaks through the seal which is located at

position (A), use the rear seal installer in order to move
the seal to position (B). Position (B) is 4.6 mm
(0.18 inch) from the rear housing face.
3.
4.
If all three seal positions have been used and the seal
leaks, the sealing area of the crankshaft flange can be
reground. The minimum diameter of the crankshaft
flange at the sealing area is 133.17 mm (5.243 inch).
The crankshaft flange requires a diameter that is
unmachined for a distance of 4.78 mm (0.188 inch) from
the rear end of the crankshaft.
Installing the Crankshaft Rear Seal on Type 2

Engines and 7BJ Engines
If oil leaks through the seal which is located at position

(B), use the rear seal installer in order to move the seal
to position (C). Position (C) is 6.9 mm (0.27 inch) from
the rear housing face.

information.
Table 24
Tools Needed
9U-6205
Rear Seal Installer Group
8T-5096
The crankshaft rear seal has a dust lip that protrudes from the
rear face of the seal. The dust lip can be easily damaged if a
standard seal driver is used for installation. The 9U-6205 Rear
Seal Installer Group will help prevent damage to the dust lip.
NOTE: The crankshaft rear seal is easily damaged.
Extreme care should be used when you install the
crankshaft rear seal. Damage across the lip of the
seal, which can be visually observed, will cause
leakage of oil through the seal.
6-92
TM 5-3895-382-24
Illustration 92
Crankshaft rear seal.
Illustration 93
Sealing area on the crankshaft for the rear seal.
(1) 0 mm (0 inch)
(2) 4.6 mm (0.18 inch)
(3) 6.9 mm (0.27 inch)
4.
If all three seal positions have been used and the seal
leaks, the sealing area of the crankshaft flange can be
reground. The minimum diameter of the crankshaft
flange at the sealing area is 133.17 mm (5.243 inch).
The crankshaft flange requires a diameter that is
unmachined for a distance of 4.78 mm (0.188 inch) from
the rear end of the crankshaft.
Three positions are allowed for installing the rear seal in the oil
seal housing.
Use a press and the rear seal installer in order to install the
seal at the correct depth. The rear seal installer hat two sides.
Use the correct side of the rear seal installer in order to press
the seal to the correct depth.
1.
The seal is at position (1) on new engines.
2.
If oil leaks through the seal at position (1), use the rear
seal installer in order to move the seal to position (2).
Position (2) is 4.6 mm (0.18 inch) from the rear housing
face.
Installing the Crankshaft Front Seal on Type 1 and

9RM Engines and Type 2 and 7BJ Engines
information.
NOTE: If the crankshaft flange is worn at position (2), use

the modified seal driver to install the seal at
position (3). If the crankshaft flange is not worn,
first install the new seal at position (2). If the oil
leaks through the seal at position (2), move the
seal to position (3).
3.
Table 25
Tools Needed
If the oil leaks through the seal at position (2), use the
rear seal installer in order to move the seal to position
(3). Position (3) is 6.9 mm (0.27 inch) from the rear
housing face.
Position (3) can be used with a new seal if the following
conditions exit:
If oil leaks through the seal at position (3), install a new

seal or grind the crankshaft flange.
A wet clutch is not used.

The crankshaft is new.
The crankshaft palm area has been corrected.
Make sure that the seal is installed square in the
housing.
6-93
1U-7600
Slide Hammer Puller
9U-6210
Front Seal Installer
TM 5-3895-382-24
3.
Clean the oil seal housing. Inspect the new front oil seal
and the oil seal housing for damage. If a scratch across
the lip of the oil seal can be observed, do not use the
seal.
4.
Place clean engine oil on the outer circumference of the

oil seal. Place the oil seal into the oil seal housing so
that face of the oil seal is even with the face of the front
oil seal housing. Ensure that the lip of the oil seal with
the spring is toward the timing case cover. Ensure that
the oil seal is square to the bore of the oil seal housing.
Illustration 94
Installation of the crankshaft front seal and wear sleeve.
(2) Front oil seal
(3) Hub of crankshaft pulley
(4) Wear sleeve
(5) Face of front oil seal housing
(6) Depth of front oil seal
The front oil seal (2) is normally installed to a depth of

7.00 0.25 mm (0.276 0.010 inch)(A) from the face of the
front oil seal housing (5). If wear occurs on the hub of the
crankshaft pulley (3), leakage of oil can occur. If there is a
leak, the front oil seal (2) can be installed to a depth of 9.3 mm
(0.37 inch) from the face of the front oil seal housing.
Illustration 95
9U-6210 Front Seal Installer.
(6) The side of the adapter is stamped '9.3 mm".
(7) Hole in threaded bar
(8) Threaded bar
(9) Nut
(10) Pressure plate
(11) Fastener plate
(12) Sleeve
(13) Adapter
If a wear sleeve (4) is installed, the front oil seal is installed to a

depth of 9.30 mm (0.366 inch) from the face of the front oil seal
housing. When a wear sleeve is installed, a new front oil seal
must be installed. When a wear sleeve is purchased, detailed
procedures and a special tool are provided with the wear
sleeve for the installation. When the wear sleeve is installed,
the flange does not require removal.
5.
Perform the following procedure in order to install a front oil

seal:
1.
Remove the following components: fan, drive belts and

crankshaft pulley.
2.
Use the 1U-7600 Slide Hammer Puller to remove the

front oil seal. Refer to the Disassembly and Assembly
module.
Use the 9U-6210 Front Seal Installer to install the new

front oil seal and the wear sleeve. Place the fastener
plate (11) on the front of the crankshaft. Place the
adapter (13) on the face of the oil seal housing. Ensure
that the correct side of the adapter is used for the
desired depth of the oil seal. The "9.3 mm" side of the
adapter (6) is shown in Illustration 95.
Assemble the pressure plate (10) and the sleeve (12) on
the threaded bar (8). Place this assembly in position on
the adapter (13). Tighten the threaded bar (8) on the
stud of the fastener plate (11).
6-94
TM 5-3895-382-24
6.
7.
Place a rod through the hole in the threaded bar (8) in

order to prevent movement of the bar when the nut (9)
is tightened. Tighten the nut in order to push the oil seal
into the housing to the desired depth.
Flywheel And Flywheel Housing

Heat the ring gear immediately prior to installation. Do not
heat the ring gear to a temperature that is greater than 250C
(482F). Install the ring gear so that the chamfer on the gear
teeth is next to the starter motor pinion when the flywheel is
installed.
Remove the 9U-6210 Front Seal Installer. Lightly

lubricate the area of the crankshaft pulley that contacts
the oil seal with clean engine oil. Install the crankshaft
pulley.
Flywheel Housing Checks
Thrust Washers For The Center

Main Bearing
Table 26
Tools Needed
8T-5096
Face Runout Check
Illustration 96
(1) Thrust washer for the center man bearing.
The axial movement of the crankshaft is controlled by thrust

washers (1). The thrust washers are installed on both sides of
the center main bearing.
The clearance between the thrust washer and the crankshaft
can be measured with a feeler gauge.
Illustration 97
Face runout check.
Place a dial indicator on one end of the crankshaft in order to

measure the end play of the crankshaft.
The maximum permissible end play is 0.51 mm (0.020 inch). If
the end play is greater than the maximum, oversize washers
can be installed. The oversize washers can be installed on
one or both sides of the center main bearing. The oversize
washers will reduce the end play in order to be within the
maximum permissible end play.
6-95
1.
Position the magnetic base of the dial indicator group on

the crankshaft flange. Position the contact of the dial
indicator on the face of the flywheel housing.
2.
Force the crankshaft to the rear in order to remove the

clearance for the main bearing.
TM 5-3895-382-24
Table 27
Bore Of The
Housing Flange
362 mm (14.25 inch)
410 mm (16.14 inch)
448 mm (17.64 inch)
511 mm (20.12 inch)
584 mm (22.99 inch)
648 mm (25.51 inch)
787 mm (30.98 inch)
Maximum Permissible
Face Runout
0.23 mm (0.009 inch)
0.25 mm (0.010 inch)
0.28 mm (0.011 inch)
0.30 mm (0.012 inch)
0.36 mm (0.014 inch)
0.41 mm (0.016 inch)
0.48 mm (0.019 inch)
Bore Runout Check
Illustration 98
Locations for measuring the face runout of the flywheel housing.
(A) Bottom
(B) Right Side
(C) Top
(D) Left side
3.
Set the dial indicator to 0.0 mm (0.00 inch) at location

(A). Turn the crankshaft in order to measure the face
runout at locations (B), (C), and (D).
4.
Maximum face runout.

information.
Illustration 99
Bore runout check.
a. Type 1 and 9RM Engines

Calculate the difference between the lowest
measurement and the highest measurement of the
four locations. This difference must not be greater
than 0.20 mm (0.008 inch). This dimension is the
maximum permissible face runout of the flywheel
housing.
b. Type 2 and 7BJ Engines
than the limit that is given in the following table. This
difference is the maximum permissible face runout of
the flywheel housing.
6-96
TM 5-3895-382-24
Flywheel Checks
Face Runout Check
Illustration 100
Locations for measuring the bore runout of the flywheel housing.
(1) Bottom
(2) Right side
(3) Top
(4) Left side
1.
2.
3.
4.
Illustration 101
Tooling setup for measuring the face runout of the flywheel.
Fasten the magnetic base of the dial Indicator group to

the crankshaft flange. Adjust the contact of the dial
indicator in order to touch the bore of the flywheel
housing at location (1). Set the pointer of the dial
indicator to 0.0 mm (0.00 inch).
1.
Push the crankshaft to the rear in order to remove the

main bearing clearance before the measurement is
taken at each location.
Install the dial indicator in Illustration 101, as shown.

Push the crankshaft to the rear in order to remove the
main bearing clearance before the measurement is
taken at each location. Set the pointer of the dial
2.
Turn the crankshaft. Record the dial indicator reading at

locations (2), (3), and (4).
Turn the flywheel. Read the dial indicator for every 90

degrees.
3.
Alignment error.

measurement and the highest measurement of the four
locations. This difference must not be greater than 0.30
mm (0.012 inch). This dimension is the maximum
permissible distance for the bore runout of the flywheel
housing.

information.
a. Type 1 and 9RM Engines
than 0.20 mm (0.008 inch). This dimension is the
maximum permissible distance for the face runout of
the flywheel.
6-97
TM 5-3895-382-24
b. Type 2 and 7BJ Engines
Electrical System

than 0.03 mm (0.001 inch) for every 25 mm (1.0 inch)
of the radius of the flywheel. The radius of the
flywheel is measured from the axis of the crankshaft
to the contact point of the dial indicator.
SMCS Code: 1400

Test Tools For The Electrical
System
Most of the tests of the electrical system can be done on the
engine. if the test shows a defect in a component, remove the
component for more testing.
Outside Diameter Check

Before the electrical system is tested, the following conditions
should exist:
NOTE: The flywheel housing may require removal in

order to perform this runout check.
The wiring insulation must be in good condition.
The wire and cable connections must be clean and tight.
The battery must be fully charged.

Table 28
Tools Needed
4C-4911
8T-0900
6V-7070
Battery Load Tester

Ammeter
Digital Multimeter
4C-4911 Battery Load Tester
Illustration 102
Tooling setup for measuring the outside diameter runout of the
flywheel.
1.
Mount the magnetic base of the dial indicator group to

the flywheel housing or the engine block Position the
contact of the dial indicator on the top of the flywheel in
Illustration 102, as shown. Set the pointer of the dial
2.
Turn the flywheel. Read the dial indicator for every 90

degrees.
3.

measurement and the highest measurement of the four
locations. This difference must not be greater than 0.30
mm (0.012 inch). This dimension is the maximum
permissible distance for the outside diameter runout of
the flywheel.
Illustration 103
4C-4911 Battery Load Tester.
6-98
1
1
1
TM 5-3895-382-24
The 4C-4911 Battery Load Tester is a portable unit. The
battery load tester can be used to load test all 6 volt, 8 volt and
12 volt batteries.
A trigger switch that can be locked in the ON or OFF position is

used to turn on the ammeter When the trigger is released, the
last current reading remains on the display for five seconds.
Retaining the reading allows accurate measurements to be
taken in areas with limited access when the digital display is
not visible to the operator.
The battery load tester has two heavy-duty cables. The cables
can be easily fastened to the battery terminals.
A knob on the top of the battery load tester adjusts the current
from the battery to a maximum of 100 amperes. The tester is
cooled by an internal fan that is automatically activated when a
load is applied.
Power for the ammeter is produced by batteries which are

located inside the handle.
Refer to Special Instruction, SEHS8420
instructions for the 8T-0900 Ammeter.
The battery load tester has an LCD in order to display the

voltage and the amperage.
for
operating
6V-7070 Digital Multimeter
Refer to the Tool Operating Manual, SEHS9249 for operating

instructions for the 4C-4911 Battery Load Tester.
Illustration 105
6V-7070 Digital Multimeter.
8T-0900 Ammeter
The 6V-7070 Digital Multimeter is a portable instrument.

The digital multimeter has seven functions and 29 ranges. A
digital display indicates the measurement.
The digital
multimeter measures resistance in ohms. This capability
permits continuity checks for fast circuit inspection. The digital
multimeter can also be used for troubleshooting small
capacitors.
Illustration 104
8T0900 Ammeter.
The 8T-0900 Ammeter is a portable instrument for measuring

electrical current. The ammeter measures the electrical
current without interrupting the circuit or damaging the
insulation on the conductors.
The ammeter has a digital display of 1 to 1200 amperes for
indicating the current. If a 6V-6014 Cable is connected
between the ammeter and the digital multimeter, current
readings of less than 1 ampere can be displayed on the
multimeter.
A lever is used to open the jaws of the ammeter in order to
place the jaws on an electrical conductor. The current is
measured when the jaws surround the electrical conductor.
The diameter of the electrical conductor cannot exceed 19 mm
(0.75 inch).
6-99
TM 5-3895-382-24
Battery
Personal injury can result from battery fumes or

explosion.
Batteries give off flammable fumes that can explode.
Electrolyte is an acid and can cause personal injury if it
contacts the skin or eyes.
Prevent sparks near the batteries. Sparks could cause
vapors to explode. Do not allow jumper cable ends to
contact each other or the engine. Improper jumper cable
connections can cause an explosion.
Always wear protective glasses when working with
batteries.
The battery circuit is an electrical load on the charging unit.
The load is variable because of the condition of the charge in
the battery. The alternator may be damaged if both of the
following conditions occur:
The alternator is in operation.
The circuit between the battery and the alternator is

broken.
The damage can occur when the load on the battery is lost.
The lost load on the battery causes a sudden increase in the
voltage. This high voltage can damage the charging unit, the
regulator, and other electrical components.
The 4C-4911 Battery Load Tester is used to load test a battery
that does not hold a charge.
Refer to the Tool Operating Manual, SEHS9249 for instructions
on the use of the 4C-4911 Battery Load Tester. Refer to
Special Instruction, SEHS7633 for the correct procedures and
specifications for testing batteries.
6-100
TM 5-3895-382-24
Starting Motor
Illustration 106
Starting circuit for 12 volt system. (typical example)
(1) Test point
(2) Test point
(3) Test point
(4) Test point
(5) Test point
(X) Hold-in coil
(W) Pull-in coil
Start switches have a capacity of 5 to 20 amperes. The coil of

a start relay draws about 1 ampere between test points (1) and
(2). The switch contacts of the start relay for the staring motor
are rated between 100 and 300 amperes. The start relay can
easily switch the load of 5 to 50 amperes for the staring motor
solenoid.
Procedures For Diagnosis Of The

Starting Motor
The procedures for diagnosing the staring motor are intended
to help the serviceman determine if a starting motor needs to
be replaced or repaired. The procedures are not intended to
cover all possible problems and conditions. The procedures
serve only as a guide. The most common 12 volt circuit is
shown in Illustration 106.
The staring motor solenoid is a switch with a capacity of about

1000 amperes. The staring motor solenoid has two functions:
General Information
All electrical starting systems have four elements:
Ignition switch
Start relay
Starting motor solenoid
Starting motor
The pinion gear is engaged with the ring gear of the

flywheel.
The starting motor is rotated.
The starting motor solenoid has two coils. Pull-in coil (W)
draws about 40 amperes. Hold-in coil (X) requires about 5
amperes.
6-101
TM 5-3895-382-24
When the start relay closes, coils (W) and (X) receive power.
Battery voltage is applied to test point (3), which is the start
terminal (S). Terminal "G" of the coil (X) is permanently
grounded to the ground post or the housing of the starting
motor. Grounding for the test point (4) of the pull-in coil (W) is
momentary.
This ground takes place through the DC
resistance of the starting motor.
Table 30
Maximum Acceptable Voltage Drop In The
Staring
Circuit
12 Volt
24 Volt
System
System
Battery post "-' to
0.7 volts
1.4 volts
the starting motor
terminal "-
Drop across the
0.5 volts
1.0 volts
disconnect switch
Battery post +"
0.5 volts
1.0 volts
to this terminal of
the starting motor
solenoid +"
Solenoid terminal
0.4 volts
0.8 volts
"Bat to the solenoid
terminal Mtr
When the magnetic force increases in both coils, the pinion

gear moves toward the ring gear of the flywheel. Then, the
solenoid contacts close in order to provide power to the
starting motor. When the solenoid contacts close, the ground
is temporarily removed from the pull-In coil (W). Battery
voltage is supplied on both ends of the pull-in coil while the
starting motor cranks. During this period, the pull-in coil is out
of the circuit.
Cranking of the engine continues until current to the solenoid is
stopped by releasing the ignition switch.
Power which is available during cranking varies according to
the temperature and condition of the batteries. The following
chart shows the voltages which are expected from a battery at
the various temperature ranges.
Voltage drops that are greater than the amounts in Table 30

are caused most often by the following conditions:
Table 29
Typical Voltage Of Electrical System During
Cranking At Various Ambient Temperatures
Temperature
12 Volt
24 Volt
System
System
6 to 8 volts
12 to 16 volts
-23 to -7 C
(-10 to 20 F)
7 to 9 volts
14 to 18 volts
-7 to 10 C
(20 to 50 F)
8 to 10 volts
16 to 24 volts
10 to 27 C
(50 to 80 F)
Loose connections
Corroded connections
Defective switch contacts
Diagnosis Procedure
NOTICE
If equipped with electric start, do not crank the engine for
more than 30 seconds. Allow the starter to cool for two
minutes before cranking again.
Never turn. the disconnect switch off while the engine is
running. Serious damage to the electrical system can
result.
If the starting motor does not crank or cranks slow, perform the
following procedure:
The following table shows the maximum acceptable loss of

voltage in the battery circuit. The battery circuit supplies high
current to the starting motor. The values in the table are for
engines which have service of 2000 hours or more.
1.
Measure the voltage of the battery at the battery posts

with the multimeter when you are cranking the engine or
attempting to crank the engine. Measure the voltage
across the battery posts. Do not measure the voltage
across the cable post clamps.
2.
Battery voltage
a. If the voltage is equal or greater than the voltage in
Table 29, then go to Step 3.
6-102
TM 5-3895-382-24
b. The battery voltage is less than the voltage in
Table 29.
b. The starting motor voltage is less than the voltage

specified in Table 29.
Refer to Special Instruction, SEHS7633 in order to

test the battery.
The voltage drop between the battery and the starting

motor is too great. Go to Step 6.
A low charge in a battery can be caused by several

conditions.
Deterioration of the battery

A shorted starting motor
A defective alternator
Loose drive belts
Current leakage in another par of the electrical system
3.
Measure the current that is between the positive battery

post and the starting motor solenoid. Use the 8T-0900
Ammeter. Refer to the Specifications, "Starting Motor"
for the maximum current that is allowed for no load
conditions.
The voltage at the battery post is within 2 volts of the

lowest value in the applicable temperature range of
Table 29.
The large starting motor cables get hot.
Measure the voltage drops in the cranking circuits with

the multimeter. Compare the results with the voltage
drops which are allowed in Table 30.
7.
Voltage drops in the cranking circuits.

a. Voltage drops are equal to the voltage drops that are
given in Table 30 or the voltage drops are less than
the voltage drops that are given in Table 30. Go to
Step 8 in order to check the engine.
b. The voltage drops are greater than the voltage drops
that are given in Table 30. The defective component
should be repaired or replaced.
8.
NOTE: If the following conditions exist, do not perform

the test in Step 3 because the starting motor has a
problem.
6.
Rotate the crankshaft by hand in order to ensure that

the crankshaft is not stuck. Check the oil viscosity and
any external loads that could affect the engine rotation.
a. If the crankshaft is stuck or difficult to turn, repair the
engine.
b. If the engine is not difficult to turn, go to Step 10.
9.
The current and the voltages the are specified in the
Specifications module are measured at a temperature of
27C (80F).
When the temperature is below
27C (80F), the voltage will be lower through the
starting motor.
When the temperature is below
27C (80F), the current through the starting motor will
be higher. If the current is too great, a problem exists in
the starting motor. Repair the problem or replace the
starting motor.
4.
Use the multimeter in order to measure the voltage of

the starting motor. Measure the voltage from test point
(4) to test point (5) when you are cranking or attempting
to crank the engine.
5.
Voltage across test points (4) and (5).
Attempt to crank the starting motor.

a. The starting motor cranks slowly.
Remove the starting motor for repair or replacement.
b. The starting motor does not crank.
Check for the blocked engagement of the pinion gear
and flywheel ring gear.
NOTE: Blocked engagement and open solenoid contacts

will give the same electrical symptoms.
a. If the voltage is equal to the voltage that is given in

Table 29 or if the voltage is greater than the voltage
that is given in Table 29, then the battery and the
starting motor cable that goes to the starting motor
are within specifications. Go to Step 8.
6-103
TM 5-3895-382-24
3.
Start Relay Tests

If the engine does not start, perform these tests in order to find
any fault of the start relay.
Table 31
If the test light turns on for either test, the star relay
must be replaced.
Tools Needed
6V-7070
8S-4627
Digital Multimeter
Test Light
If the resistance is correct, disconnect the "C1" and "C2"

terminals. Use the 8S-4627 Test Light between the
"C1" and "C2" terminals. The test light should not turn
on. Then, move the probe of the test light from the "C2"
terminal to the "C4" terminal. The test light should not
turn on.
1
1
4.
If the start relay is not defective, refer to

Troubleshooting for other tests of the starting system.
9G-4368 Relay
069-5466 Relay
Illustration 107
9G-4368 Relay.
Illustration 108
069-5466 Relay.
The following test is with battery current:

The following test is performed with battery current:
1.
2.
Put the multimeter on the 200 ohm scale. Turn the

ignition switch to the ON position.
Put the multimeter leads on the "C1" and "C2" terminals.
The resistance across the leads (1) should be zero
ohms.
1.
Put the multimeter on the 200 ohm scale. Turn the

ignition switch for the engine to the ON position.
2.
Put the multimeter leads on the terminals "4" and "7".

Put the multimeter leads on the terminals "6" and "9".
If the resistance is not zero, the start relay must be

replaced.
The resistance must be zero ohms across both sets of

terminals.
The following test is with no battery current:

1.
2.
If the resistance is not zero, the start relay must be

replaced.
Disconnect the wires from the "W1" and "W2" terminals

of the start relay.
The following test is with no battery current.
Put the multimeter leads on each "W1 " and "W2"

terminal. The resistance across the leads (2) should
measure 15 1 ohms.
1.
If the resistance is not correct, replace the start relay.
6-104
Disconnect the wires from the "A" and "B" terminals of

the start relay.
TM 5-3895-382-24
2.
Put the multimeter leads on terminals "A" and "B".
Before the charging system is tested on the engine, the

charging system and the battery must be inspected. Use the
following inspection procedures:
The resistance should be between 30 and 34 ohms If

the resistance is not correct, replace the start relay.
3.
If the resistance is correct, disconnect terminals "4" "7",

"6" and "9".
4.
Put the leads of the 8S-4627 Test Light between

terminals "4" and "7". The test light should not turn on.
Put the leads of the test light on terminals "6" and "9".
The test light should not turn on.
1.
The battery must be charged to at least 75% of rated

power output. The specific gravity of the solution in the
battery should be 1.225. The battery should be held
firmly in place. The battery holder must not put too
much stress on the battery.
2.
The cables between the battery, the starter, and the

ground of the engine must be the correct size. Wires
and cables must be free of corrosion. The wires and the
cables should have cable support clamps in order to
prevent stress on the battery connections.
3.
The leads, the junctions, the switches, and the panel

instruments which relate to the charging system must
operate correctly.
4.
The alternator and the drive components for the

alternator must operate correctly.
If the test light turns on, the start relay must be replaced.
5.
If the start relay is not defective, refer to

Troubleshooting for other tests of the starting system.
Charging System
The condition of the charge in the battery at each regular
inspection will indicate if the charging system operates
correctly. A problem exists when the battery is constantly in a
condition of low charge. A problem also exists if more than
one ounce of water must be added to a cell in the battery
during the following periods:
Alternators
Table 32
One week
Each 100 hours of operation
Tools Needed
6V-7070
8T-0900
Testing the charging system is preferable when the following

conditions exist:
When a component is replaced or repaired, the charging

system should be tested. This test will verify that the charging
system is operating correctly.
1
1
1.
Put the positive lead "+" of the multimeter on the "Bat"

terminal of the alternator. Put the negative " lead on the
ground terminal or on the frame of the alternator. Put
the ammeter around the positive output wire of the
alternator.
2.
Turn off all electrical accessories. Turn off the fuel to

the engine. Crank the engine for 30 seconds. Wait for
two minutes in order to cool the starting motor. If the
electrical system appears to operate correctly, crank the
engine again for 30 seconds.
The alternator is mounted on the engine.

The voltage regulator is mounted on the engine.
The wiring and electrical components which are used in
the test are a permanent par of the electrical system.
Bench testing can be done on the alternator and the voltage

regulator.
This testing will determine if the individual
component is defective.
Digital Multimeter
Ammeter
NOTE: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging
test. If the battery has a low charge, do not
perform this step. Jump start the engine or
charge the battery before starting the engine.
Refer to Specifications, "Alternator and Regulator for additional

information.
6-105
3.
Start the engine and run at full throttle.
4.
Check the output current of the alternator. The initial

charging current should be equal to the minimum full
load current or the initial charging current should be
greater than the minimum full load current. Refer to
Specifications, "Alternator and Regulator for the correct
minimum full load current at different rpm.
TM 5-3895-382-24
Table 33
Fault Conditions And Possible Causes
Current At Start-up
The Voltage Is Below the

Specification After 10
Minutes.
The Voltage Is Within The

Minutes.
Less than the

specifications
Replace the alternator.

Check the circuit of the
ignition switch.
Turn on all accessories. If

the voltage decreases below
the specifications, replace
the alternator.
Decreases after matching

specifications
The alternator and the

battery match the
specifications. Turn on
all accessories in order to
verify that the voltage stays
within specifications.
The current consistently

exceeds the specifications.
In order to test the battery,

follow the procedures that
are in the Tool Operation
Manual, SEHS7633. Test the
alternator again.
The alternator operates

within the specifications. In
order to test the battery,
follow the procedures that
are in the Tool Operation
Manual, SEHS7633.

Inspect the battery for
damage.
5.
After approximately ten minutes of operating the engine

at full throttle, the output voltage of the alternator should
be 14.0 0.5 volts for a 12 volt system. After
approximately ten minutes of operating the engine at full
throttle, the output voltage of the alternator should be
28.0 1 volts for a 24 volt system. Refer to the Fault
Conditions And Possible Causes in Table 33.
The Voltage Is Within The

Minutes.
current to decrease to 10 amperes depends on the

following conditions:
The battery charge

The ambient temperature
The rpm of the engine
Refer to the Fault Conditions and Possible Causes in Table 33.

6.
After ten minutes of engine operation, the charging

current should decrease to approximately 10 amperes.
The actual length of time for the charging
6-106
TM 5-3895-382-24
ALPHABETICAL INDEX
A
Air Inlet And Exhaust System ................................................... 6-70

Cylinder Head......................................................................... 6-72
Testing The Wastegate ......................................................... 6-76
Valve Lash .............................................................................. 6-70
Valve Tests ............................................................................. 6-73
Fuel System ................................................................................ 6-49

Adjustm ent Of Low Idle And High Idle ............................... 6-61
Cold Start Advance Unit........................................................ 6-69
Fuel Injector Nozzle Tests ................................................... 6-62
Pressure Test For The Fuel Transfer Pump ..................... 6-50
Remove Air From The Fuel System.................................... 6-58
Type 1 Engines and 9RM Engines ................................. 6-55
Setting The Top Center Compression Position
For No. 1 Piston ................................................................ 6-52
Tests For The Air Inlet Heater ............................................. 6-49
Timing Of The Fuel Injection Pump .................................... 6-56

Cylinder Head And Valves .................................................... 6-20
Turbocharger ......................................................................... 6-19
B
Basic Block ................................................................................. 6-86
Crankshaft Seals ................................................................... 6-91
Cylinder Compression Test ................................................. 6-87
Cylinder Liner Projection....................................................... 6-86
Flywheel And Flywheel Housing.......................................... 6-95
Height Of The Piston Above
The Cylinder Block............................................................. 6-88
Inspection Of Connecting Rods ........................................... 6-89
Inspection Of The Cylinder Liner .................................... 6-87
Thrust Washers For The Center Main Bearing................. 6-95
Fuel System ................................................................................ 6-10

Air Inlet Heater ....................................................................... 6-17
Fuel Injection Pump............................................................... 6-13
Fuel Injector Nozzles For Type 1
Engines and 9RM................................................................... 6-12
Engines and 7BJ ................................................................... 6-12
Belt Tension Chart .................................................................... 6-86

Engine Oil Cooler .................................................................. 6-78
Fluid Spillage Containment .................................................. 6-77
Inspect The Oil Pump............................................................ 6-77
Problems Of The Lubrication System ................................. 6-80
Cooing System ........................................................................... 6-81

Cooling System Conditioner ................................................ 6-85
Engine And Cooling Sys tem Heat Problems .................... 6-84
Testing The Cooling System ................................................ 6-82
Visual Inspection Of The Cooling System .......................... 6-81
Cooling System .......................................................................... 6-23
S
Systems Operation Section .........................................................6-4

Alternators ............................................................................6-105
Battery ...................................................................................6-100
Charging System ..................................................................6-105
Start Relay Tests .................................................................6-103
Starting Motor .......................................................................6-101
Test Tools For The Electrical System................................. 6-98
Table of Contents .........................................................................6-3

Alternator ................................................................................ 6-24
Circuit Breakers ..................................................................... 6-25
Starting Motor ......................................................................... 6-24
Engine Design ...............................................................................6-4
Testing and Adjusting ................................................................ 6-49

Testing and Adjusting Section ................................................. 6-26
Troubleshooting Fuel Injector Nozzles
On A Nozzle Tester............................................................ 6-27
Troubleshooting Problems.................................................... 6-40
Troubleshooting The Engine................................................ 6-39
Troubleshooting The Fuel Injector Nozzles
On The Engine ................................................................... 6-26
Troubleshooting The Turbocharger ................................... 6-28
6-107/(6-108 blank)
TM 5-3895-382-24
SENR6241-06
February 1999
CHAPTER 7
Disassembly and
Assembly
Machines
7BJ1-Up (Engine)
5HK1-Up (Engine)
9RM1-Up (Engine)
NOTES:
This chapter contains Disassembly and Assembly instructions. Additional information may be found in:
Discard all locking-type fasteners (i.e. lock washers, lock nuts, locking tab washers, etc.) when removed. Replace all
7-1
TM 5-3895-382-24
Most accidents involving product operation, maintenance and repair a caused by failure to observe basic safety rules or precautions.

Attention! Become Alert! Your Safety Is Involved.
Operations that may cause product damage are identified by "NOTICE labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might Involve a potential hazard. The warnings in this
publication and on the product a therefore not all Inclusive. If a tool, procedure, work method or operating technique not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also
ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures
you choose.
The specifications, torques, pressures, measurements, adjustments, illustrations, and other Items can change at any time. These
Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available,
seethe Service Manual Contents Microfiche, REG1139F.
7-2
TM 5-3895-382-24
Water Pump - Disassemble
(Type 1 Engines and 9RM Engines) .............................. 7-41
Water Pump - Assemble
Water Pump - Install ................................................................. 7-44
Water Temperature Regulator Remove and Install............................................................ 7-44
Water Outlet Manifold - Remove ............................................ 7-46
Water Outlet Manifold - Install ................................................. 7-47
Flywheel- Remove ..................................................................... 7-47
Flywheel - Install ........................................................................ 7-48
Crankshaft Rear Seal - Remove ............................................. 7-49
Crankshaft Rear Seal - Install ................................................. 7-50
Flywheel Housing - Remove and Install ................................ 7-51
Crankshaft Pulley - Remove and Install ................................ 7-52
Crankshaft Front Seal - Remove ............................................. 7-53
Crankshaft Front Seal - Install ................................................ 7-54
Front Cover - Remove ............................................................... 7-54
Front Cover - Install .................................................................. 7-55
Gear Group (Front) - Remove ................................................. 7-56
Gear Group (Front) - Install ..................................................... 7-57
Housing (Front) - Remove ........................................................ 7-58
Housing (Front) - Install ............................................................ 7-58
Valve Mechanism Cover- Remove and Install ..................... 7-59
Rocker Shaft and Pushrod - Remove .................................... 7-61
Rocker Shaft - Disassemble .................................................... 7-61
Rocker Shaft - Assemble ......................................................... 7-62
Rocker Shaft and Pushrod - Install ........................................ 7-63
Cylinder Head - Remove .......................................................... 7-64
Cylinder Head - Install .............................................................. 7-65
Lifter Group - Remove and Install .......................................... 7-66
Camshaft - Remove and Install .............................................. 7-67
Camshaft Gear- Remove and Install ..................................... 7-68
Camshaft Bearings- Remove and Install ............................... 7-70
Engine Oil Pan - Remove and Install ..................................... 7-71
Cylinder Liner - Remove .......................................................... 7-72
Cylinder Liner - Install ............................................................... 7-73
Piston Cooling Jets - Remove and Install ............................. 7-74
Pistons and Connecting Rods - Remove .............................. 7-75
Pistons and Connecting Rods - Disassemble ...................... 7-75
Pistons and Connecting Rods - Assemble ............................ 7-76
Pistons and Connecting Rods - Install ................................... 7-77
Connecting Rod Bearings- Remove ....................................... 7-78
Connecting Rod Bearings- Install ........................................... 7-80
Crankshaft Main Bearings - Remove ..................................... 7-81
Crankshaft Main Bearings - Install ......................................... 7-82
Crankshaft - Remove ................................................................ 7-83
Crankshaft - Install .................................................................... 7-84
Crankshaft Gear - Remove and Install .................................. 7-87
Bearing Clearance - Check ..................................................... 7-88
V-Belts- Remove and Install .................................................... 7-89
Fan - Remove and Install ......................................................... 7-89
Fan Drive - Remove .................................................................. 7-90
Fan Drive- Install ....................................................................... 7-90
Alternator- Remove and Install ............................................... 7-90
Electric Starting Motor - Remove and Install ........................ 7-91
Dipstick - Remove and Install .................................................. 7-93
Relief Valve - Disassemble & Assemble ............................... 7-93
Table of Contents
Disassembly and Assembly
Section
Engine Design ..............................................................................7-4
Fuel Filter Base - Remove and Install ......................................7-5
Fuel Transfer Pump - Remove ...................................................7-7
Fuel Transfer Pump - Disassemble ...........................................7-8
Fuel Transfer Pump - Assemble ................................................7-8
Fuel Transfer Pump - Install .......................................................7-9
Fuel Injection Lines - Remove and Install ............................. 7-10
Fuel Injection Nozzles - Remove
Fuel Injection Nozzles - Install
Fuel Injection Nozzles- Remove
(Type 2 Engines and 7BJ Engines) ............................... 7-13
Fuel Injection Nozzles- Install
Fuel Injection Pump - Remove
Fuel Injection Pump - Install
(Type 2 Engines and 7BJ Engines)................................ 7-17
Turbocharger - Remove ........................................................... 7-21
Turbocharger - Disassemble ................................................... 7-22
Turbocharger - Assemble ........................................................ 7-23
Turbocharger - Install ............................................................... 7-24
Exhaust Manifold - Remove and Install
Air Inlet Manifold - Remove
Air Inlet Manifold - Install
Inlet and Exhaust Valve Springs Remove and Install ........................................................... 7-30
Inlet and Exhaust Valves Remove and Install ........................................................... 7-31
Inlet and Exhaust Valve Guides Remove and Install ........................................................... 7-33
Inlet and Exhaust Valve Seat Inserts Remove and Install ........................................................... 7-34
Engine Oil Filter Base - Remove ............................................ 7-35
Engine Oil Filter Base - Disassemble .................................... 7-36
Engine Oil Filter Base - Assemble .......................................... 7-36
Engine Oil Filter Base - Install ................................................. 7-37
Engine Oil Relief Valve - Remove and Install ....................... 7-37
Engine Oil Pump - Remove ..................................................... 7-38
Engine Oil Pump - Install ......................................................... 7-39
Water Pump - Remove ............................................................. 7-40
Index Section
Index............................................................................................. 7-94
7-3
TM 5-3895-382-24
crankshaft rotates in the following direction: ............... Clockwise

Section
When the camshaft is viewed from the front of the engine, the
camshaft rotates in the following direction: ................. Clockwise
Engine Design
SMCS Code: 1000

Illustration 1
(A) Exhaust valves
(B) Inlet valves
Illustration 2

(A) Exhaust valves

(B) Inlet vales

The second method does not require the removal of the valve
cover. Refer to the inlet manifold and the exhaust manifold.
Type 1 engines have two exhaust ports in a row and two inlet
ports that are in a row.
The second method does not require the removal of the valve
cover. Refer to the inlet manifold and the exhaust manifold.
Type 2 engines alternate the exhaust ports and the inlet ports.

Stroke.................................................................127 mm (5.00 inch)
Capacity ..................................................................4 liters (243 in 3)
Stroke ................................................................127 mm (5.00 inch)
Compression Ratio ....................................................................16:1
Capacity ..................................................................4 liters (243 in 3)
Firing Order.......................................................................... 1, 3, 4, 2
Valve Lash
Firing Order .......................................................................... 1,3, 4, 2

Exhaust valve ...........................................0.45 mm (.018 inch)
7-4
TM 5-3895-382-24
Valve Lash
Exhaust valve ...........................................0.45 mm (.018 inch)
When the crankshaft is viewed from the front of the
engine, the crankshaft rotates In the following
When the camshaft is viewed from the front of the
engine, the camshaft rotates in the following
Illustration 3
Typical example.
Fuel Filter Base - Remove and Install
1.
Disconnect two fuel lines (1) at the fuel injection pump.
2.
Cap the lines or plug the lines immediately.
SMCS Code: 1262-010

Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
adjusting and repair of the product. Be prepared to collect
the fluid with suitable containers before opening any
compartment or disassembling any component containing
fluids.
Illustration 4
Typical example.
3.
4.
Disconnect fuel return line (2).

Refer to Special Publication, NENG2500, "Caterpillar Tools

and Shop Products Guide" for tools and supplies suitable
to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates
Illustration 5
Typical example.
7-5
TM 5-3895-382-24
5.
Disconnect two fuel lines (3).
Installation Procedure
6.
NOTICE
component life.
Illustration 6
Typical example.
7.
Remove three bolts (4) that hold two fuel lines (3) on the
rear of the engine.
Illustration 8
Typical example.
1.
Install fuel filter base (6) on the engine.
2.
Install two bolts (5).
NOTE: If the fuel filter was removed, use the following

steps to install the fuel filter:
a. Replace the seal on fuel filter base (6).
b. Insert fuel filter (9) in fuel filter base (6).
c. Install collar (8). Turn the collar in the clockwise
direction in order to lock fuel filter (9) in place.
Illustration 7
Typical example.
8.
Remove two bolts (5).
9.
Remove fuel filter base (6).
d. Install the bayonet type lock ring, the O-ring, and the
top plate in fuel filter (9). Install cap (7).
NOTE: Use the following steps in order to remove fuel

filter (9). The fuel filter assembly has a bayonet
type lock ring that allows the fuel filter to drain
into the canister for easy removal.
a. Remove cap (7). Remove the top plate, the O-ring,
and the bayonet type lock ring from fuel filter (9). This
will allow fuel to flow into the canister of the fuel filter.
b. Turn collar (8) in the counterclockwise direction in
order to remove fuel filter (9).
Illustration 9
Typical example.
c. Pull fuel filter (9) from fuel filter base (6).
7-6
TM 5-3895-382-24
3.
Install three bolts (4) that hold the fuel lines to the rear
of the engine.
Fuel Transfer Pump - Remove

SMCS Code: 1256-011
Removal Procedure
NOTICE
Contaminants may
component life.
rapid
wear and shortened
NOTICE
fluids.
Illustration 10
Typical example.
4.
cause
Connect two fuel lines (3).

mandates.
Illustration 11
5.
Connect fuel return line (2).
Illustration 13
Typical example.
Disconnect two fuel lines (1).

immediately.
Plug all openings
2.
Remove four bolts (3).
3.
Remove fuel pump (2) and the gasket.
NOTE: If the fuel transfer pump is difficult to remove,

rotate the crankshaft until the rocker arm of the
fuel transfer pump is not under pressure.
Illustration 12
Typical example.
6.
1.
Connect two fuel lines (1) at the fuel injection pump.
7-7
TM 5-3895-382-24
1.
Place an identification mark on each half of the fuel

transfer pump for the assembly procedure.
2.
Remove the screw that holds cover (1).
3.
Remove cover (1) and the gasket.
4.
Remove gauze (2).
5.
Remove the screws that hold the two halves of the fuel
transfer pump together.
6.
Rotate diaphragm assembly (5) at 90 degrees in order

to remove the pull rod from link arm (8).
7.
Remove diaphragm assembly (5).

component life.
8.
Remove stem seal (6), spring seat washer (7), and

diaphragm spring (12) from the pull rod.
NOTICE
during performance of Inspection, maintenance, testing,
fluids.
NOTE: Diaphragm assembly (5) and the pull rod are not
serviced parts.
9.
Use a suitable lever in order to remove valves (4). The

valves are peened in. NOTE: Some of the peened
metal may need to be removed in order to remove
valves (4).

10.
Hold rocker lever (11) in a vise and hit the body of the
fuel transfer pump with a soft hammer in order to
release retainers (10). This will allow you to remove link
arm (8).
Fuel Transfer Pump Disassemble

SMCS Code: 1256-015
Disassembly Procedure
Start By:
a. Remove the fuel transfer pump.
Refer to
Disassembly and Assembly, "Fuel Transfer Pump Remove".
NOTICE

mandates.
NOTICE
Do not damage the face on the body of the fuel transfer
pump.
11.
Remove the following items: rocker lever (11), pin (9),

link arm (8), and the return spring.
Fuel Transfer Pump - Assemble

SMCS Code: 1256-016
Assembly Procedure
NOTICE
component life.
Illustration 14
7-8
TM 5-3895-382-24
1.
Inspect the components of the fuel transfer pump for

damage. Replace the components, if necessary.
2.
Clean all of the components before assembly.
Install seat washers (3).
4.
Push valves (4) into position.
Place diaphragm assembly (5) over the lower half of the

body of the fuel transfer pump. Ensure that the blade of
the pull rod is aligned with the slot of link arm (8).
11.
Press lightly on diaphragm assembly (5) until the notch

in the pull rod is in the slot of link arm (8). Rotate
diaphragm assembly (5) at 90 degrees in either
direction. This will engage the pull rod in the slot of link
arm (8).
12.
Push rocker lever (11) toward the body of the fuel

transfer pump. Push rocker lever (11) until diaphragm
assembly (5) is level with the flange on the body of the
fuel transfer pump.
13.
Install the top half of the body of the fuel transfer pump
and align the marks on the flanges. Keep pressure on
rocker lever (11). Install spring washers and the
screws. Tighten the screws evenly.
14.
Install gauze (2).
15.
Install the gasket and cover (1).
NOTE: Refer to the Testing and Adjusting, "Fuel Transfer

Pump Pressure Test" for the correct procedure.
Illustration 15
3.
10.
End By:
a. Install the fuel transfer pump. Refer to Disassembly
and Assembly, "Fuel Transfer Pump -Install".
NOTE: It is possible for the valves to be installed

incorrectly. Refer to Illustration 15 for the correct
installation.
Fuel Transfer Pump - Install

SMCS Code: 1256-012
5.
When valves (4) are installed, peen the edge of the

valve housing evenly in six places. This will keep valves
(4) in position.
6.
Install rocker lever (11), pin (9), and link arm (8) into the
bottom half of the fuel transfer pump.
7.
Install the return spring and ensure that the ends of the
spring are installed correctly.
8.
Using a soft hammer and a suitable adapter install two

retainers (10) into the grooves. Ensure that retainers
(10) fasten the pin. Peen the open ends of the grooves
in order to fasten the retainers in position.
9.
Install the diaphragm spring (12) under diaphragm

assembly (5). Place spring seat washer (7) and stem
seal (6) on the pull rod.
NOTICE
component life.
NOTICE
Ensure that the small diameter at the top of the seal is on
the road section of the pull rod.
7-9
TM 5-3895-382-24
Fuel Injection Lines - Remove and Install
NOTICE
fluids.
SMCS Code: 1252-010

Removal Procedure
Start By:

a. Remove the fuel filter base. Refer to Disassembly

and Assembly, "Fuel Filer Base - Remove and Install".
NOTICE

mandates.

component life.
NOTICE
fluids.
Illustration 16
Typical example.
1.
Inspect the condition of the gasket. Replace the gasket,

if necessary.
2.
Ensure that the rocker arm for the fuel transfer pump is
not under pressure.
3.
Install the gasket and fuel transfer pump (2). If fuel

transfer pump (2) is difficult to install, rotate the
crankshaft.
4.
Install two lock plates (4).
5.
Install four bolts (3). Tighten the bolts to a torque of

22 Nm (16 lb-ft).
6.
Connect two fuel lines (1).
7.
Loosen the vent screw on the top of the fuel filter and
operate the priming lever on the fuel transfer pump in
order to remove the air from the fuel system. When only
fuel comes out of the vent screw, tighten the vent screw.
8.

mandates.
Illustration 17
Start the engine and check the fuel system for fuel leaks
And for air leaks.
7-10
1.
Disconnect four fuel injection lines (1) from the fuel

injection nozzles.
2.
Cap all openings or plug all openings immediately.
TM 5-3895-382-24
3.
Disconnect four fuel injection lines (1) from the fuel

injection pump.
4.
Plug all openings immediately.
End By:
a. Install the fuel filter base. Refer to Disassembly and
Assembly, "Fuel Filter Base - Remove and Install.
NOTE: Secure fittings (4) with a wrench when you

remove fuel injection lines (1) at the fuel injection
pump.
5.
Remove four fuel injection lines (1) from the engine.
6.
Remove four bolts (2) and eight washers.
7.
Remove fuel return line (3).

(Type 1 Engines and 9RM
Engines)
SMCS Code: 1254-011
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to Disassembly
and Assembly, "Fuel Injection Lines - Remove and
Install".
NOTICE

Engines, refer to the Disassembly and Assembly,
"Engine Design" topic.

component life.
NOTICE
Contaminants may
component life.
cause
rapid
wear and shortened
NOTICE
fluids.
Illustration 18
1.
Install fuel return line (3).
2.
Install four bolts (2) and eight new washers.
3.
Install four fuel injection lines (1).
4.
Connect four fuel injection lines (1) at the fuel injection

pump.

mandates.
NOTE: Secure fittings (4) with a wrench when you

conned fuel injection line (1) at the fuel injection
pump.
5.
Connect four fuel injection lines (1) to the fuel injection

nozzles. Tighten the fuel injection lines to a torque of
18 Nm (13 lb-ft).
7-11
TM 5-3895-382-24
NOTICE
component life.
NOTICE
fluids.
Illustration 19
1.
Remove two bolts (1) and clamp (2) from the cylinder
head.
2.
Remove clamp (2).
Refer to Special Publication, NENG2500, Caterpillar Tools

and Shop Products Guide for tools and supplies suitable
mandates.
Illustration 20
3.
Remove fuel injection nozzle (3) and the seat washer

that is on the end of fuel injection nozzle (3).
4.
Remove dust seal (5) and spacer (4).
Illustration 21

Engines)
SMCS Code: 1254-012
7-12
1.
Install dust seal (5) and spacer (4).
2.
Install the seat washer on the end of fuel injection

nozzle (3).
3.
Install fuel injection nozzle (3) into the cylinder head.
TM 5-3895-382-24
NOTICE
fluids.
mandates.
Illustration 22
4.
Install clamp (2) and bolts (1). Tighten bolts (1) to a

torque of 12 Nm (9 lb-f4).
End By:
a. Install the fuel Injection lines. Refer to Disassembly
Install".
Fuel Injection Nozzles- Remove

(Type 2 Engines and 7BJ
Engines)
SMCS Code: 1254-011
Removal Procedure
Start By:
Illustration 23
a. Remove the fuel injection lines. Refer to Disassembly

Install".
1.
Remove bolts (1) from the fuel injection nozzles.
2.
Remove tube assembly (2) from the fuel injection

nozzles.
NOTICE
component life.
Illustration 24
7-13
TM 5-3895-382-24
Illustration 25
3.
Loosen threaded nut (5) on fuel injection nozzle (3).
4.
Remove fuel injection nozzle (3) from the engine.
5.
Ensure that seat washer (4) is removed from the bore of

the fuel injection nozzle.
Illustration 26

(Type 2 Engines and 7BJ
Engines)
SMCS Code: 1254-012
Illustration 27

1.
Thoroughly clean the threads on threaded nut (5) and

the cylinder head.
2.
Ensure that wire clip (6) is in position on fuel injection

nozzle (3).
NOTICE

located in the cylinder head. If the original sea
washer is not removed, the projection of the fuel
injection nozzle will be incorrect when a new seat
washer is installed. Do not reuse seat washer (4).

component life.
7-14
3.
Install a new seat washer (4) into the recess in the

cylinder head.
4.
Put a 2 mm (.08 inch) bead of 4C-5591 Anti-Seize

Compound on the first two threads of threaded nut (5).
5.
Put fuel injection nozzle (3) into position in the cylinder

head. Make sure that the detent ball in the fuel injection
nozzle is aligned correctly with ball detent (X) in the
cylinder head.
6.
Carefully tighten threaded nut (5) to a torque of 30 Nm

(22 lb-ft). Remove any excess Anti-Seize Compound
from fuel injection nozzle (3).
TM 5-3895-382-24
NOTE: Do not rotate the fuel injection nozzle after
installation. The seal which is made by the antiseize compound may break. A broken seal may
allow leakage pat the seat of the fuel injection
nozzle.
Start By:
a. Remove the water pump. Refer to Disassembly and
Assembly, "Water Pump - Remove".
b. Remove the fuel injection lines. Refer to Disassembly
Install".
engines, refer to the Disassembly and Assembly,
NOTICE
component life.
NOTICE
fluids.
Illustration 28
7.
Put tube assembly (2) in position on the fuel injection

nozzles.
8.
Install bolts (1) that hold tube assembly (2) in position.

End By:
a. Install the fuel injection lines. Refer to Disassembly
Install".

mandates.

Engines)
SMCS Code: 1251-011
Removal Procedure
Table 1
Required Tools
Tool
A
B
C
Part
Number
173-9774
9U-6198
8S-2264
8S-4712
Part Description
(1)
Bolt Remove
Crankshaft Turning Tool
Puller Group
Bolt
Qty
1
1
1
2
Illustration 29
NOTE: Some engines may have four tamper proof bolts

(1). Use Tool (A) in order to remove the tamper
proof bolts.
(1) The bolt remover is required in order to remove the tamper Proof
bolts on the ass cover r the fuel pump.
7-15
TM 5-3895-382-24
2.
Remove cover (2).
Illustration 30
3.
Illustration 33
Remove nut (3) and the lockwasher.
7.
Disconnect hose (7) from the fuel injection pump.
8.
Remove three nuts (6) that hold fuel injection pump (5)
in position.
9.
Remove fuel injection pump (5) and the gasket.
NOTE: Ensure that you do not lose the key when the fuel
injection pump is removed.
Also notice the
position of marks (4) in order to ensure proper
alignment of fuel Injection pump (5) during
installation.
Fuel Injection Pump - Install (Type 1 Engines and

9RM Engines)
Illustration 31
4.
SMCS Code: 1251-012
Use Tool (B) to rotate the crankshaft until keyway (X) is

at 30 degrees from the vertical centerline.
Table 2
Required Tools
Tool
A
(1)
Part
Number
173-9774
Part Description
Bolt Remover
(1)
Qty
1
The bolt remover is required in order to install the

tamper proof bolts on the access cover for the fuel
injection pump.

Illustration 32
5.
Install Tool (C).
6.
Disengage the gear from the fuel injection pump.
NOTICE
component life.
7-16
TM 5-3895-382-24
1.
Inspect the condition of the gasket for the fuel injection

pump. Replace the gasket, if necessary.
Illustration 36
8.
NOTE: Some engines have four tamper proof bolts (1).

Use Tool (A) in order to install the four bolts.
Illustration 34
2.
Install cover (2) and four bolts (1).
9.
Install the gasket and fuel injection pump (5).
NOTE: Align marks (4) that are on fuel injection pump (5)
and the timing gear cover.
Set the timing of the fuel injection pump. Refer to the

Testing and Adjusting Module for the correct procedure.
End By:
and Assembly, "Fuel Injection Lines - Install".
3.
Install the key.
4.
Install three nuts (6) that hold fuel injection pump (5) in
position.
5.
Connect hose (7) to fuel injection pump (5).
6.
Engage the gear with the fuel injection pump.
b. Install the water pump. Refer to Disassembly and

Assembly, "Water Pump - Install".
Fuel Injection Pump - Remove (Type 2 Engines and

7BJ Engines)
SMCS Code: 1251-011
Removal Procedure
Table 3
Required Tools
Tool
A
Illustration 35
7.
Install the lockwasher and nut (3).
7-17
Part
Number
150-3992
150-3993
Part Description
Timing Pin(1)
Timing Pin(2)
Qty
1
1
(2)
Required to install Bosch fuel injection pumps.
(3)
Required to install Lucas and Stanadyne fuel injection

pumps.
TM 5-3895-382-24
Start By:
b. Remove the fuel injection lines. Refer to Disassembly
Install".
c. Disconnect any wires to fuel injection pump.
NOTICE
component life.
NOTICE
fluids.
Illustration 38
Typical example
NOTE: Do not remove hub nut (4) from the shaft of the
fuel injection pump. The hub of the fuel injection
pump is installed in the correct position from the
factory in order to ensure proper timing. If hub
nut (4) is removed and the hub is removed, the
hub will need to be accurately installed on the
shaft of the fuel injection pump.
Special
equipment is available at your Caterpillar Dealer
for this procedure.

mandates.
1.
NOTE: Do not release torx screws (5). If the torx screws

are released and the timing plate is moved, the
timing position that is set at the factory will be
lost. If the torx screws are released, the number 1
cylinder must be set to the top center position on
the compression stroke before the torx screws
are tightened.
Ensure that the number 1 cylinder is at the top center

position on the compression stroke. Refer to the
Testing and Adjusting, "Fuel System" topic for additional
information.
2.
Slowly rotate the crankshaft until hole (6) in the timing

gear and hole (7) in the hub are in alignment with hole
(8) in the fuel injection pump body.
NOTE: The location of Tool (A) for Bosch fuel injection

pumps will be located toward the top of the fuel
injection pump. The location of Tool (A) for Lucas
and Stanadyne fuel injection pumps will be
located toward the bottom of the fuel injection
pump.
3.
Illustration 37
Typical example
7-18
Install Tool (A) through hole (6) in the timing gear and
hole (7) in the hub. Push Tool (A) into position in hole
(8) in the fuel injection pump body. If Tool (A) can be
fully seated, the fuel injection pump timing is correct.
No resistance should be felt when the timing pin is
inserted into hole (8) of the fuel injection pump body.
TM 5-3895-382-24
4.
Remove four bolts (1). Timing gear (2) should be free

from the fuel injection pump shaft.
Fuel Injection Pump- Install (Type 2 Engines and 7BJ

Engines)
SMCS Code: 1251-012
Table 4
Required Tools
Tool
A
Illustration 39
Typical example
5.
Remove three nuts (9) and fuel Injection pump (10) from
the engine.
Part
Number
150-3992
150-3993
Part Description
(1)
Timing Pin
Timing Pin(2)
Qty
1
1
(1)
The timing pin is required to install Bosch fuel injection

pumps.
(2)
Timing pin is required to install Lucas and Stanadyne

fuel injection pumps.

NOTICE
component life.
Illustration 40
Typical example
6.
Remove O-ring seal (11) from fuel injection pump (10).
Illustration 41
7-19
1.
Check the condition of O-ring seal (1) from fuel injection

pump (2). If the seal is worn or damaged, use a new
par for replacement.
2.
Lightly lubricate O-ring seal (1) with clean engine oil.

Install O-ring seal (1) on fuel injection pump (2).
TM 5-3895-382-24
NOTICE
The number 1 cylinder must be at the top center position
on the compression stroke before the fuel injection pump
is installed. If the crankshaft needs to be rotated, the fuel
injection pump must be mounted temporarily or the loose
gear could cause damage to the front housing.
Illustration 44
Illustration 42
3.
Put fuel injection pump (2) in position on the engine.

Ensure that the timing gear is aligned with the hub of
fuel injection pump (2). Install three nuts (3) and tighten
the nuts to a torque of 28 Nm (21 Ib-ft).
4.
Position gear (5) on the shaft of the fuel injection pump.
5.
Put the timing gear plate in position and install four bolts
(4). Tighten the four bolts finger tight.
NOTE: The fuel injection pump gear will only fit in one
position. Install the gear with the letters "C" and
"M" facing away from the engine.
NOTE: The location of Tool (A) for Bosch fuel injection
pumps will be located toward the top of the fuel
injection pump. The location of Tool (A) for Lucas
and Stanadyne fuel injection pumps will be
located toward the bottom of the fuel injection
pump.
6.
Illustration 43
Install Tool (A) through hole (6) in the timing gear and
hole (7) in the hub. Push Tool (A) into position in hole
(8) in the fuel injection pump body. If Tool (A) can be
fully seated, the fuel injection pump timing is correct.
No resistance should be felt when the timing pin is
inserted into hole (8) of the fuel injection pump body.
NOTICE
The fuel injection pump may be supplied with the fuel
injection pump shaft in the locked position. The drive
shaft of the fuel injection pump must not be rotated
without the spacer in position under the locking screw.
Damage to the drive shaft of the fuel injection pump will
result.
7-20
TM 5-3895-382-24
7.
When the timing plate is installed, rotate gear (5) by

hand in a counterclockwise direction in order to remove
the backlash between gear (5) and the idler gear. Do
not rotate the crankshaft or the fuel injection pump shaft.
Tighten bolts (4) to a torque of 28 Nm (21 lb-ft).
8.
Remove Tool (A) from the fuel injection pump gear
End By:
Install".
Illustration 45
Typical example

c. Connect wires to injector pump.
Turbocharger - Remove
SMCS Code: 1052-011
Removal Procedure
NOTICE
Contaminants may
component life.
cause
rapid
1.
Loosen two clamps (1).
2.
Slide hose (2) away from turbocharger (3).
3.
Remove two bolts (4) and the gasket.
4.
Disconnect oil return line (6) from the cylinder block and
remove the gasket.
5.
Remove nuts (5).
wear and shortened
NOTICE
fluids.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
mandates.
Illustration 46
Typical example
7-21
6.
Remove three bolts (7).
7.
Remove turbocharger (3) and the gaskets.
8.
TM 5-3895-382-24
4.
Turbocharger - Disassemble
Remove hose assembly (3) and the gasket.
SMCS Code: 1052-015

Start By:
a. Remove the turbocharger. Refer to Disassembly and
Assembly, "Turbocharger - Remove".
NOTICE
component life.
Illustration 48
Typical example
NOTICE
fluids.
5.
Remove six bolts (4).
6.
Remove three clamps (5).
7.
Separate compressor housing (6) from cartridge (7).

mandates.
1.
Place an index mark on all of the components for the

assembly procedure.
Illustration 49
Typical example
Illustration 47
Typical example
2.
Remove elbow (1) and the O-ring seal.
3.

Illustration 50
Typical example
7-22
8.
9.
Remove three clamps (9).
10.
Separate cartridge (7) from turbine housing (10).
TM 5-3895-382-24
Turbocharger - Assemble
SMCS Code: 1052-016
Assembly Procedure
NOTICE
component life.
1.
Inspect the condition of the gaskets.

gaskets, if necessary.
Replace the
Illustration 53
Typical example
5.
Assemble compressor housing (6) and cartridge (7).
6.
Install three clamps (5).
7.
Apply 5P-3931 Anti-Seize Compound to six bolts (4).

Tighten the bolts to a torque of 15 4 Nm (113 Ib-ft).
Illustration 51
Typical example
Illustration 54
Typical example
Illustration 52
Typical example
2.
Assemble cartridge (7) and turbine housing (10).
3.
Install three clamps (9).
4.
Apply 5P-3931 Anti-Seize Compound to six bolts (8).

Tighten the bolts to a torque of 19 1 Nm (141 Ib-ft).
8.
Install hose assembly (3) and the gasket.
9.
10.
Install elbow (1) and the O-ring seals.
End By:
a. Install the turbocharger. Refer to Disassembly and
Assembly, "Turbocharger - Install".
7-23
TM 5-3895-382-24
Turbocharger - Install
SMCS Code: 1052-012
NOTICE
component life.
1.
Inspect the condition of all gaskets.

Replace the
Illustration 56
Typical example
4.
Apply 5P-3931 Anti-Seize Compound to nuts (5).

Tighten the nuts to a torque of 55 5 Nm (40 4 Ib-ft).
5.
Install the gasket and oil return line (6).
6.
7.
Slide hose (2) onto the turbocharger (3).
8.
Tighten two clamps (1).
Exhaust Manifold - Remove and Install (Type 1

Engines and 9RM Engines) SMCS Code: 1059-010
Removal Procedure
Start By:
Illustration 55
Typical example
2.
Install turbocharger (3) and the gaskets.
3.
Install three bolts (7).

NOTICE
component lie.
7-24
TM 5-3895-382-24
Exhaust Manifold - Remove and Install (Type 2
Engines and 7BJ Engines)
SMCS Code: 1059-010
Removal Procedure
Start By:
b. Remove the air inlet manifold. Refer to Disassembly
and Assembly, "Air Inlet Manifold Remove and
Install".
Illustration 57
Typical example
1.
Remove exhaust manifold nuts (1).
2.
Remove exhaust manifold (2) and the gasket.

NOTICE
NOTICE
Contaminants may cause rapid wear ant shortened

component life.

component life.
Illustration 59
Typical example
Illustration 58
Typical example
1.

if necessary.
2.
Install the gasket and exhaust manifold (2).
3.
Install exhaust manifold nuts (1). Tighten the plated

nuts to a torque of 44 Nm (32 Ib-ft). Tighten the nuts
that are not plated to a torque of 50 Nm (37 Ib-ft).
End By:
a. Install the turbocharger. Refer to Disassembly and
7-25
TM 5-3895-382-24
Illustration 60
1.
2.
Remove exhaust manifold nuts (1) in reverse order of

the numbered sequence.
Illustration 62
Typical example
Remove exhaust manifold (2) from the engine.

1.
Inspect the condition of the gaskets. If the gaskets are

damaged, use new parts for replacement. Install
exhaust manifold gaskets (3) on the cylinder head.
Illustration 61
Typical example
3.
Remove two exhaust manifold gaskets (3) from the

engine.
Illustration 63
Typical example
NOTICE
component life.
Illustration 64
NOTICE
Damage to the exhaust manifold can occur if the exhaust
manifold is not aligned and tightened correctly.
7-26
TM 5-3895-382-24
2.
Install exhaust manifold (2) on the cylinder head.
3.
Install exhaust manifold nuts (1). Tighten the exhaust

manifold nuts in the numerical sequence to a torque of
33 Nm (24 b-ft).
End By:
a. Install the air inlet manifold. Refer to Disassembly
and Assembly, "Air Inlet Manifold - Remove and
Install".
b. Install the turbocharger. Refer to Disassembly and
Illustration 65
Typical example
Air Inlet Manifold - Remove (Type 1 Engines and

9RM Engines)
SMCS Code: 1058-011
Removal Procedure
NOTICE
component life.
Illustration 66
Typical example
NOTICE
fluids.
mandates.
7-27
1.
Disconnect electrical connector (5) for the air inlet

heater.
2.
Disconnect fuel line (6) to the air inlet heater.
3.
Remove two bolts (7) that hold the bracket for fuel line
(6) in position.
4.
Loosen two hose damps (8) and slide hose (9) toward
the turbocharger.
5.
Remove four bolts (3) in order to remove elbow (2) and

gasket (4).
6.
Disconnect boost pressure hose (10).
7.
Remove bolts (12) that hold the turbocharger support to

air inlet manifold (14).
8.
Remove bolts (13) that hold air inlet manifold (14) to the
cylinder head.
9.
Remove air inlet manifold (14) and gaskets (11).
10.
Remove seal (1).
TM 5-3895-382-24
Air Inlet Manifold - Install (Type 1 Engines and 9RM
Engines)
2.
Install seal (1) on the engine.
3.
Position gaskets (11) and air inlet manifold (14) on the

engine.
SMCS Code: 1058-012
NOTE: Ensure that the front gaskets and the rear gaskets
are installed with the notch at the top left side.
The center gasket can be installed in either
direction.
4.
Install bolts (13).
NOTICE
5.
Position the turbocharger support on air inlet manifold

(14) and install bolts (12).

component life.
6.
Connect boost pressure hose (10).
7.
Install gasket (4) and elbow (2) with four bolts (3).
8.
Slide hose (9) in position and tighten hose clamps (8).
9.
Place the bracket for fuel line (6) in position and install
two bolts (7).
10.
Connect fuel line (6) to the air inlet heater.
11.
Connect electrical connector (5) for the air inlet heater.
1.
Inspect the gaskets for wear or damage. If the gaskets

am worn or damaged, use new parts for replacement.
Air Inlet Manifold - Remove (Type 2 Engines and 7BJ

Engines)
SMCS Code: 1058-011
Removal Procedure
Illustration 67
Typical example

NOTICE
component life.
Illustration 68
Typical example
7-28
TM 5-3895-382-24
NOTICE
fluids.
4.
Remove bolts (5) that fasten air inlet manifold (6) to the
engine.
5.
Remove air inlet manifold (6).

SMCS Code: 1058-012

mandates.

Air Inlet Manifold - Install (Type 2 Engines and 7BJ

Engines)
NOTICE
component life.
1.
Inspect the gaskets for wear or damage. If the gaskets

are worn or damaged, use new parts for replacement
Illustration 69
Typical example
1.
Disconnect tube (1) from the air inlet heater.
2.
Loosen hose clamps (3) and slide the hose toward the
turbocharger.
3.
Remove four bolts (2) and remove elbow (4) from the air
inlet manifold.
Illustration 71
Typical example
2.
Illustration 70
Typical example
7-29
Install the gasket and air inlet manifold (6) with bolts (5).
Tighten bolts (5) to a torque of 33 Nm (24 lb-ft).
TM 5-3895-382-24
1.
Ensure that the piston is at the top center position.
NOTE: If the rocker arm assembly has been removed,

use the following procedure in order to find the
top center position.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
a. Install Tool (A).
b. Compress the valve springs in order to open the
valve.
Illustration 72
Typical example
c. Turn the crankshaft until the piston touches the valve.
3.
Put the gasket and elbow (4) in position on the air inlet
manifold.
4.
Install four bolts (2).
5.
Slide the hose into position and tighten hose damps (3).
6.
Connect tube (1) to the air inlet heater.
d. Continue to turn the crankshaft and release the

pressure of Tool (A) until the piston is at the top
center position.
Inlet and Exhaust Valve Springs - Remove and Install

SMCS Code: 1108-010
Removal Procedure
Table 5
Required Tools
Tool
A
Part
Number
9U-6195
Part Description
Valve Spring Compressor
Illustration 73
Qty
1
Start By:
a. Remove the rocker shaft. Refer to Disassembly and
Assembly, "Rocker Shaft and Pushrod - Remove".
2.
Install Tool (A).
3.
Compress valve springs (1).

keepers (2).
Remove two valve
NOTICE
Ensure that the valve spring is compressed squarely or
damage to the valve stem may occur.
NOTICE
4.
component life.
NOTE: Before you begin the removal of the valve
springs, refer to the Testing and Adjusting
Module, "Valve Depth Check' for appropriate
information on the valve springs.
7-30
Release the pressure on Tool (A). Remove valve spring

retainer (3) and valve springs (1).
TM 5-3895-382-24
NOTE: If you are replacing all of the valve springs, the
procedure can be done on two cylinders at the
same time. The procedure can be done on
cylinder 1 and cylinder 4, or on cylinder 2 and
cylinder 3.
4.
Install two valve keepers (2).
5.
Release the pressure slowly on Tool (A). Remove Tool

(A).
NOTE: If you are replacing all of the valve springs the

procedure can be done on two cylinders at the
same time. The procedure can be done on
cylinder 1 and cylinder 4, or on cylinder 2 and
cylinder 3.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
End By:
Table 6
a. Install the rocker shaft. Refer to Disassembly and

Assembly, "Rocker Shaft and Pushrod - Install.
Required Tools
Tool
A
Part
Number
9U-6195
Part Description
Qty
Inlet and Exhaust Valves - Remove and Install
SMCS Code: 1105-010
NOTICE
Removal Procedure
Table 7

component life.
1.
Required Tools
Part
Number
9U-6195
Tool
Place the new valve springs into position.
NOTE: Ensure that the closed damper coils are toward

the cylinder head if double valve springs are
used.
Part Description
Qty
1
Start By:
a. Remove the cylinder head assembly.
Refer to
Disassembly and Assembly, "Cylinder Head Remove".
NOTICE
component life.
Illustration 74
2.
Install valve spring retainer (3).
3.
Install Tool (A). Compress valve springs (1).
NOTICE
Ensure that the valve spring is compressed squarely or
damage to the valve stem may occur.
7-31
1.
Clean the bottom face of the cylinder head. Use a dial

indicator to check the depth of the valves below the face
of the cylinder head before the valve springs are
removed. Refer to the Specifications Module for the
correct dimensions.
2.
Place an index mark on the heads of the inlet valves

and the exhaust valves for installation
TM 5-3895-382-24
8.
Remove seals (5).
9.
Remove valve spring seat washers (6).
10.
Remove inlet valves (7) and exhaust valves (7).
Table 8
Required Tools
Tool
A
Part
Number
9U-6195
Part Description
Qty
1
NOTICE
component life.
Illustration 75
3.
Use Tool (A) to compress inner springs (3) and outer

springs (4).
NOTE: Some engines may have only a single inlet valve

spring and a single exhaust valve spring.
4.
Remove two valve keepers (1).
The valve keepers can be thrown from the valve when the
valve spring compressor is released. Ensure that the
valve keepers are properly installed on the valve stem. To
help prevent personal injury, keep away from the front of
the valve keepers and valve springs during the installation
of the valves.
5.
Slowly release the pressure on Tool (A) and remove

Tool (A).
6.
Remove valve spring retainers (2).
7.
Remove inner springs (3) and outer springs (4).
Illustration 76
1.
7-32
Lubricate the stems of inlet valves (7) and the stems of

exhaust valves (7) with clean engine oil.
TM 5-3895-382-24
2.
Install inlet valves (7) and exhaust valves (7) in the

respective positions.
3.
Install valve spring seat washers (6).
4.
Install new seals (5).
5.
Install inner springs (3) and outer springs (4).
Inlet and Exhaust Valve Guides - Remove and Install

SMCS Code: 1104-010
Removal Procedure
Table 9
Required Tools
NOTE: Install inner springs (3) and outer springs (4) on

the valve spring sea washers with the damper
coils toward the cylinder head. This is done with
double valve springs. If single valve springs are
used, the springs can be installed in either way.
6.
Tool
A
Part Description
Qty
Valve Guide Driver
Start By:
Install valve spring retainers (2).
a. Remove the inlet valves and the exhaust valves.

Refer to Disassembly and Assembly, "Inlet and
Exhaust Valves - Remove and Install".
NOTICE
The valve keepers can be thrown from the valve when the
valve spring compressor is released. Ensure that the
valve keepers am properly installed on the valve stem. To
help prevent personal injury, keep away from the front of
the valve keepers and valve springs during the installation
of the valves.
7.
Part
Number
1U-9136

component life.
Use Tool (A) to compress inner springs (3) and outer

springs (4).
NOTE: Some engines may have only a single inlet valve

spring and a single exhaust valve spring.
8.
Install two valve keepers (1).
9.
Slowly release the pressure on Tool (A) and remove

Tool (A). Strike the top of the valves with a soft hammer
in order to ensure that the valve keepers are properly
installed.
NOTE: Refer to the Specifications Module, "Cylinder

Head Valves" for more information on inlet valves
and exhaust valves.
10.
Illustration 77
Use a dial indicator to check the depth of the new valves

below the cylinder head. If the depth of the new valves
is below the correct depth, the valve seat inserts must
be replaced. Refer to Disassembly and Assembly, "Inlet
and Exhaust Valve Seat Insets - Remove and Install".
End By:
a. Install the cylinder head assembly.
Refer to
Disassembly and Assembly, "Cylinder Head - Install".
7-33
1.
Use Tool (A) in order to remove the valve guides from

the cylinder head assembly.
2.
Repeat the procedure for the remaining valve guides.
TM 5-3895-382-24
Inlet and Exhaust Valve Seat Inserts - Remove and

Install
Table 10
SMCS Code: 1103-010

Required Tools
Tool
A
Part
Number
1U-9169
9U-6220
Part Description
Valve Guide Driver
Stop Collar
Removal Procedure
Qty
Table 11
1
1
Required Tools
NOTICE
Tool

component life.
Part
Number
9U-6396
9U-6397
9S-3095
Part Description
Qty
Insert Valve Seat Extractor

Exhaust Valve Seat
Extractor
Channel
1
1
1
Start By:
a. Remove the inlet valves and the exhaust valves.
Refer to Disassembly and Assembly, "Inlet and
Exhaust Valves - Remove and Install".
NOTICE
component life.
Illustration 78
1.
Position the valve guide. Carefully tap the valve guide

in order to start the installation. Use Tool (A) and Tool
(B) to seat the valve guide in the cylinder head
assembly.
2.
Check the protrusion of the inlet valve guide. The inlet

valve guide should protrude 15.10 mm (.595 inch)
above the cylinder head assembly.
3.
Repeat the procedure for the remaining valve guides.

Illustration 79
End By:
a. Install the inlet valves and the exhaust valves. Refer
to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install.
7-34
TM 5-3895-382-24
1.
Use the appropriate parts of Tool (A) in order to install

the valve seat insert into the cylinder head assembly.
2.
Repeat the procedure for the remaining valve seat

insets.
NOTE: Refer to the Specifications Module for more

information on the valve seat inserts.
End By:
a. Install the inlet valves and the exhaust valves. Refer
to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
Engine Oil Filter Base - Remove
Illustration 80
1.
Use Tool (A) with appropriate extractor (2) and channel

(3) in order to remove valve seat inserts (1).
2.
Remove valve seat inserts (1) from the cylinder head.
3.
Repeat the procedure for the remaining valve seat

inserts.
SMCS Code: 1306-011

Removal Procedure
NOTICE
component life.
Table 12
NOTICE
fluids.
Required Tools
Tool
A
Part
Number
9U-6183
9U-6184
9U-6185
Part Description
Valve Seat Driver
Valve Seat Driver
Valve Seat Driver
Qty
1
1
1
NOTICE


component life.

mandates.
Illustration 81
7-35
TM 5-3895-382-24
NOTICE
fluids.
mandates.
Illustration 82
Typical example
1.
Loosen two hose clamps (1) and disconnect the hoses.
2.
3.
Remove nut (3) that holds the hose clamp and move the
hose clamp.
4.
Remove engine oil filter base (4) from the engine block.
Engine Oil Filter Base - Disassemble

SMCS Code: 1306-015
Illustration 83
Typical example
Start By:
a. Remove the engine oil filter base.
Refer to
Disassembly and Assembly, "Engine Oil Filter Base Remove".
NOTICE
1.
Remove engine oil filter (1) from engine oil filter base
(2).
2.
Remove cap (3) from engine oil cooler (4) (if equipped).
3.
Remove engine oil cooler (4) from engine oil filter base
(2), if necessary.
Engine Oil Filter Base - Assemble

component life.
SMCS Code: 1306-016

Assembly Procedure
NOTICE
component life.
7-36
TM 5-3895-382-24
Illustration 85
Typical example
Illustration 84
Typical example
1.
Install engine oil cooler (4) on engine oil filter base (2)
(if equipped).
2.
Place cap (3) on engine oil cooler (4).
3.
Install engine oil filter (1) on engine oil filter base (2).
End By:
1.
Install engine oil filter base (4) on the engine block.
2.
Place the hose clamp in position and install nut (3).
3.
Install three bolts (2).
4.
Connect two hoses and tighten two hose clamps (1).
Engine Oil Relief Valve - Remove and Install
a. Install the engine oil filter base. Refer to Disassembly

and Assembly, "Engine Oil Filter Base - Install".
SMCS Code: 1315-010

Removal Procedure
Engine Oil Filter Base - Install
Start By:
SMCS Code: 1306-012
a. Remove the engine oil pan. Refer to Disassembly

and Assembly, "Engine Oil Pan - Remove".
NOTICE
NOTICE

component life.

component life.
7-37
TM 5-3895-382-24
End By:
a. Install the engine oil pan. Refer to Disassembly and
Assembly, "Engine Oil Pan - Install".
Engine Oil Pump - Remove

SMCS Code: 1304-011
Removal Procedure
Table 13
Required Tools
Tool
Illustration 86
1.
2.
Remove bolt (3).
3.
Remove engine oil relief valve (4) and the gasket.
4.
Disconnect oil tube (2) and remove the O-rings.
Part
Number
1P-1855
Part Description
Retaining Ring Pliers
Qty
1
Start By:
a. Remove the front housing. Refer to Disassembly and
Assembly, "Housing (Front) - Remove".
NOTE: The engine oil pump is mounted on the No. 1
crankshaft main bearing cap. The engine oil
pump can be removed without removing the front
housing if the No. 1 crankshaft main bearing cap
is removed. Use a 9U-6282 Torque Extension in
order to remove the No. 1 crankshaft main
bearing cap.
The engine oil pump is then
removed from the No. 1 crankshaft main bearing
cap.
NOTICE
component life.
NOTICE
component life.
NOTICE
fluids.
Illustration 87
1.
Connect oil tube (2) and install new O-rings.
2.

if necessary.
3.
Install engine oil relief valve (4) and the gasket.
4.
Install bolt (3).
5.

mandates.
7-38
TM 5-3895-382-24
Illustration 88
Illustration 90
1.
7.
2.
Remove bolt (2).
8.
Remove engine oil pump (7).
3.
Remove the strainer, suction pipe (3), and the gasket.
Engine Oil Pump - Install
4.
Remove the engine oil relief valve.

Refer to
Disassembly and Assembly, "Engine Oil Relief Valve Remove".
SMCS Code: 1304-012

Table 14
Required Tools
Tool
A
Part
Number
1P-1855
Part Description
Qty
1
NOTICE
component life.
NOTICE
If any of the pads on the engine oil pump are worn or
damaged, the entire pump must be replaced.
Illustration 89
5.
Use Tool (A) to remove retaining ring (4).
6.
Remove idler gear (5). Inspect the shaft of the idler

gear for wear or damage. Use a suitable press to
remove the shaft for the idler gear from the main
bearing cap.
NOTE: If the No. 1 crankshaft main bearing cap was

removed, install the No.
1 crankshaft main
bearing cap with the engine oil pump. Tighten the
bolts for the No. 1 crankshaft main bearing cap to
a torque of 265 N m (195 Ib-ft).
1.
7-39
If the shaft for the idler gear on the engine oil pump was
removed, remove the excess Loctite 603. Apply a new
layer of Loctite 603 to the bore in the main bearing cad
and install the shaft.
TM 5-3895-382-24
Illustration 91
2.
Fill engine oil pump (7) with clean engine oil. Install
engine oil pump (7) on the engine.
3.
Install three bolts (6). Tighten the bolts to a torque of 22

Nm (16 Ib-ft).
Illustration 93
7.
Install the strainer, suction pipe (3), and the gasket.
8.
Install bolt (2). Tighten the bolt to a torque of 22 Nm

(16 lb-ft).
9.
Install two bolts (1). Tighten the bolts to a torque of 22

Nm (16 Ib-ft).
End By:
a. Install the front housing. Refer to Disassembly and
Assembly, "Housing (Front) - Install".
Water Pump - Remove

SMCS Code: 1361-011
Removal Procedure
NOTICE
Illustration 92
4.
Install idler gear (5).
5.
Use Tool (A) to install retaining ring (4).

component life.
NOTE: After you install the engine oil pump and the idler
gear, ensure that there is a minimum of 0.08 mm
(.003 inch) backlash between the gear on the
engine oil pump and the idler gear.
6.
Install the engine oil relief valve. Refer to Disassembly

and Assembly, "Engine Oil Relief Valve - Install".
7-40
TM 5-3895-382-24
Water Pump - Disassemble (Type 1 Engines and
9RM Engines)
NOTICE
fluids.
SMCS Code: 1361-015

Table 15

Required Tools
Tool

mandates.
A
1.
Drain the coolant from the cooling system into a suitable

container for storage or disposal.
Part
Number
6V-3009
5H-9976
9S-9152
7X-0290
Part Description
Crossbar
Screw
Bearing Pull
Bolt
Qty
1
1
1
2
Start By:
Assembly "Water Pump - Remove".
NOTICE
component life.
NOTICE
fluids.
Illustration 94
Typical example
2.
Remove eight bolts (1) and two nuts (2).
3.
Tap water pump (3) with a soft hammer in order to

loosen water pump (3).
4.

Remove water pump (3) and the gasket.

mandates.
7-41
TM 5-3895-382-24
Illustration 95
1.

gasket.
Illustration 98
Remove cover (2) and the
4.
Use a suitable lever in order to remove seal (5).
Illustration 99
Illustration 96
5.
2.
Remove O-ring seal (3).
Use a suitable press in order to remove shaft (6), seal

(7), and impeller (8) from housing (9).
NOTE: The water pump for Type 2 Engines and 7BJ

Engines is not serviceable.
Contact your
Caterpillar
dealer
for
more
replacement
information.
Water Pump - Assemble (Type 1 Engines and 9RM

Engines)
SMCS Code: 1361-016
Assembly Procedure
Illustration 97
3.
Install Tool (A). Remove gear (4).
7-42
TM 5-3895-382-24
NOTICE
component life.
NOTE: The water pump for Type 2 Engines and 7BJ
Engines is not serviceable.
Contact your
Caterpillar
dealer
for
more
replacement
information.
1.
Clean the inside of the pump body. Ensure that the

bearing bore and the counterbore for the water seal are
particularly clean.
2.
Apply 4C-9507 Retaining Compound to the outer

surface of the bearing. Keep the compound away from
the ends of the bearing.
Illustration 101
NOTICE
Ensure that the water seal is not contaminated by oil or
grease. Hold the seal only by the edge of the flange. Do
not damage the ring of green sealant that is applied to the
body of the water seal behind the flange.
7.
Hold water seal (5) by the edge of the flange. Push the
seal onto shaft (6) until the seal is against the chamfer
of the counterbore. Only apply force to the outer flange
of the seal.
NOTE: Ensure that the wide end of the seal is toward the
bearing and that the seal is square with the
counterbore.
8.
Continue to apply force and hold water seal (5) for ten
seconds. This ensures that the water seal will remain in
place.
9.
Hold the water pump with the gear end of the shaft on a
suitable support. Use a flat bar in order to press
impeller (8) onto shaft (6) to a depth of 8.30 0.20 mm
(.320 .010 inch). After installation, ensure that the
impeller will turn freely.
Illustration 100
3.
Support the gear end of the water pump body.
4.
Place the bearing and shaft (6) square in the pump

body. Ensure that the shortest end of shaft (6) is in
housing (9).
5.
Use a suitable press and a suitable adapter that will

apply force to the bearing. The adapter should not
apply force to the shaft. Press the bearing onto the
shaft until the end of the bearing is level with the bottom
of the counterbore for the water seal.
NOTE: Apply 4C-9507 Retaining Compound to impeller

(8) if the original impeller is used. Remove excess
compound after assembly.
NOTE: Remove the excess compound from the end of

the bearing.
6.
Install seal (7).
7-43
TM 5-3895-382-24
Water Pump - Install
SMCS Code: 1361-012
NOTICE
component life.
1.
Inspect the condition of the gasket.

Replace the
Illustration 102
10. Lubricate oil seal (3) with clean engine oil. Install oil
seal (3) with the flat surface toward the bearing.
Press oil seal (3) into the body with a suitable adapter
until the rear of the seal is level with the end of the
pump.
11. Continue to apply force and hold oil seal (3) in
position for ten seconds. This ensures that the seal
will remain in place.
12. Press gear (4) onto shaft (6) to a depth of 1.60 1.00
mm (.015 .005 inch).
NOTE: Apply 4C-9507 Retaining Compound to gear (4) if
the original gear is used.
Remove excess
compound after assembly.
Illustration 104
Typical example
2.
Install the gasket and water pump (3).
3.
Install eight bolts (1) and two nuts (2).
NOTE: Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual for the correct procedure.
Water Temperature Regulator - Remove and Install

SMCS Code: 1355-010
Removal Procedure
NOTICE
Illustration 103
13.
Install a new gasket and cover (2) on the pump body.
14.
Install six bolts (1). Tighten the bolts to a torque of 9

Nm (80 lb-in).

component life.
End By:
a. Install the water pump. Refer to Disassembly and
Assembly, Water Pump - Install"
7-44
TM 5-3895-382-24
NOTICE
fluids.
mandates.
1.

2.
Remove upper radiator hose.
Illustration 106
Typical example of Type 1 and 9RM engines
5.
Remove water temperature regulator (4) and the gasket

from water temperature regulator housing (5).
NOTE: Type 1 and 9RM engines may have two water

temperature regulators for some engine ratings.
Type 2 and 7BJ engines will have one water
temperature regulator for all engine ratings.
NOTE: Refer to the Testing and Adjusting Module for the
correct procedure on testing the water
temperature regulator.
NOTICE
component life.
Illustration 105
Typical example of Type and 9RM engines
1.

3.

if necessary.
Remove six bolts (1) that hold cover (2) and bracket (3)
in position.
NOTE: Type 2 engines and 7BJ engines have four

mounting bolts (1) that hold cover (2) in position.
4.
Remove bracket (3) and cover (2) from the water

temperature regulator housing.
Illustration 107
Typical example of Type 1 and 9RM engine
7-45
TM 5-3895-382-24
NOTICE
fluids.
NOTE: Type 1 and 9RM engines may have two water

temperature regulators for some engine ratings.
Type 2 and 7BJ engines will have one water
temperature regulator for all engine ratings.
2.

Install water temperature regulator (4) and the gasket

into housing (5).

mandates.
1.

Illustration 108
Typical example of Type 1 and 9RM engines.
3.
Install bracket (3) and cover (2) on the water

temperature regulator housing.
4.
Install six bolts (1) that fasten cover (2) and bracket (3)
to the water temperature regulator housing.
Illustration 109
Typical example.
NOTE: Type 2 engines and 7BJ engines have four

mounting bolts (1) for the cover.
5.
2.
Remove clamp (1) for the boost line.
3.
Loosen clamp (2) and disconnect hose (3).
Install the upper radiator hose and fill the radiator to the
correct level with coolant.
NOTE: Refer to the Operation and Maintenance Manual

for the correct procedure.
Water Outlet Manifold - Remove

SMCS Code: 1362-011
Removal Procedure
NOTICE
Illustration 110
Typical example.

component life.
7-46
4.
Remove all bolts (4) that hold water outlet manifold (5)
in position.
5.
Remove water outlet manifold (5) and the gasket.
TM 5-3895-382-24
Water Outlet Manifold - Install
4.
Connect hose (3) and tighten clamp (2).
SMCS Code: 1362-012
5.
Install clamp (1) for the boost line.
6.
Install the upper radiator hose and fill the cooling system
with coolant to the correct level. Refer to the Operation
and Maintenance Manual for the correct procedure.
NOTICE
Flywheel - Remove
component life.
SMCS Code: 1156-011

Removal Procedure
Table 16
Required Tools
Tool
A
Part
Number
FT-0120
Part Description
Lifting Bracket
Qty
1
NOTICE
component life.
Illustration 111
Typical example.
1.

if necessary.
2.
Put water outlet manifold (5) and the gasket in position

on the engine.
3.
Install bolts (4) that secure water outlet manifold (5) to

the engine.
Illustration 113
1.
Illustration 112
Typical example.
7-47
Install Tool (A) and a suitable lifting device on flywheel

(1).
TM 5-3895-382-24
Illustration 116
Illustration 114
2.
6.
Remove four bolts (3) and bearing housing (4).
NOTE: The bearing housing must be removed in order to

allow clearance for the removal of the flywheel
bolts.
3.
Use a hammer and a punch in order to remove ring gear

(5) from flywheel (1).
Flywheel - Install
SMCS Code: 1156-012
Remove six bolts (2) and the washers.

Table 17
Required Tools
Tool
A
Part
Number
FT-0120
Part Description
Lifting Bracket
Qty
1
Illustration 115
4.
Remove flywheel (1) and the ring gear. The weight of

flywheel (1) and the ring gear is 53 kg (120 lbs).
5.
If removal of the ring gear is necessary, place an index

mark on the chamfer of the ring gear for the installation
process.
Illustration 117
1.
If ring gear (5) was removed, heat ring gear (5) to a

temperature of 250 C (480 F).
2.
Install ring gear (5) on flywheel (1).
NOTE: Ensure that the chamfer of the ring gear is in the

correct position on the flywheel.
7-48
TM 5-3895-382-24
Crankshaft Rear Seal - Remove

SMCS Code: 1161-011
Removal Procedure
Start By:
a. Remove the flywheel housing. Refer to Disassembly
and Assembly, "Flywheel Housing - Remove and
Install".
NOTICE
Illustration 118
3.

component life.
Install Tool (A) and a suitable lifting device on flywheel

(1) and position flywheel (1) and the ring gear in the
flywheel housing. The weight of flywheel (1) is 53 kg
(120 lb).
NOTICE
adjusting and repair of the machine. Be prepared to
collect the fluid with suitable containers before opening
any compartment or disassembling any component
containing fluids.
mandates.
Illustration 119
4.
Install six bolts (2) and the washers. Tighten the bolts to
a torque of 105 Nm (77 lb-ft).
5.
Install bearing housing (4) and four bolts (3).
6.
Refer to the Specifications Module for additional

information on the installation of the flywheel and the
ring gear.
Illustration 120
7-49
1.
Remove ten bolts (1).
2.
Remove two socket head bolts (2).
3.
Remove the crankshaft rear seal, the gasket, and

housing (3) from the dowels in the cylinder block.
TM 5-3895-382-24
Crankshaft Rear Seal - Install

SMCS Code: 1161-012
Table 18
Required Tools
Tool
A
Part
Number
9U-6205
1P-0510
Part Description
Rear Seal Installer
Driver Group
Qty
1
1
Illustration 122
NOTICE
component life.
1.

if necessary.
2.
Clean the areas of the parts that will contact each other.
4.
Lubricate the components with clean engine oil. Install

Tool (A) onto the crankshaft flange.
5.
Position the new gasket on the dowels in the cylinder

block.
Illustration 123
6.
Place housing (3) and the crankshaft rear seal over Tool
(A).
7.
Position housing (3) on the dowels in the cylinder block.
8.
Remove Tool (A).
9.
Install two socket head bolts (2).
10.
Install ten bolts (1). Tighten all of the bolts to a torque of

22 Nm (16 lb-ft).
Illustration 121
3.
Use Tool (A) and a suitable press to install the

crankshaft rear seal into the housing.
End By:
a. Install the flywheel housing. Refer to Disassembly
and Assembly, "Flywheel Housing -Remove and
Install".
7-50
TM 5-3895-382-24
Flywheel Housing - Remove and Install

SMCS Code: 1157-010
Removal Procedure
Table 19
Required Tools
Part
Number
6V-2156
Tool
A
Part Description
Link Bracket
Qty
2
Start By:
Illustration 124
a. Remove the electric starting motor.

Refer to
Disassembly and Assembly, "Electric Starting Motor Remove and Install".
2.
Remove two bolts (1) on the top of flywheel housing (2).
b. Remove the flywheel. Refer to Disassembly and

Assembly, "Flywheel - Remove".
NOTICE
component life.
NOTICE
containing fluids.
Illustration 125

mandates.
1.
Support the engine with blocks or a suitable lifting

device on a flat level surface.
3.
Attach Tool (A) and support the flywheel housing.
4.
5.
If necessary, hit flywheel housing (2) with a soft hammer

in order to remove flywheel housing (2). The weight of
flywheel housing (2) is 32 kg (70 lb).
Table 20
Required Tools
Tool
A
1.
7-51
Part
Number
6V-2156
Part Description
Link Bracket
Qty
2
Clean the rear face of the cylinder block and the face of
the flywheel housing. Inspect the felt seal on the rear
flange of the engine oil pan. Replace the felt seal, if
necessary. Inspect the dowels for damage. Replace
the dowels, if necessary.
TM 5-3895-382-24
End By:
a. Install the flywheel.
Refer to Disassembly and
Assembly, "Flywheel - Install".
b. Install the electric starting motor.
Refer to
Disassembly and Assembly, "Electric Starting Motor Remove and Install".
Crankshaft Pulley - Remove and Install

SMCS Code: 1205-010
Removal Procedure
Illustration 126
2.
Start By:
Use Tool (A) to position flywheel housing (2) on the

dowels that are on the cylinder block.
a. Remove the V-Belts. Refer to Disassembly and

Assembly, "V-Belts - Remove and Install".
Illustration 127
3.
Illustration 128
Typical example.
Install six bolts (3).
NOTE: The bolts for the flywheel housing have the

following torque:
a. The M10 bolts in a cast iron flywheel housing have a
torque of 44 Nm (33 lb-ft).
Remove three bolts (2) and washer (3).
2.
Remove crankshaft pulley (1).
NOTE: Some engines have a water immersion seal that is

placed on the front cover. The seal has a flexible
lip on the front. The plastic mandrel that is
supplied with the seal must be installed in the
seal when the crankshaft pulley is removed. This
will ensure that the lip maintains the correct
shape.
b. The M12 bolts in a cast iron flywheel housing with a

stamp 8.8 have a torque of 75 Nm (55 lb-ft).
c. The M12 bolts in a cast iron flywheel housing with a
stamp 10.9 have a torque of 115 Nm (85 lb-ft).
d. The M10 bolts in an aluminum flywheel housing have
a torque of 70 Nm (52 lb-ft).
4.
1.
7-52
TM 5-3895-382-24
NOTICE

component life.
NOTICE
containing fluids.
mandates.
Illustration 129
Typical example.
1.
Remove the plastic mandrel, if necessary.
2.
Install crankshaft pulley (1).
3.
Lubricate bolts with clean engine oil.
4.
Install washer (3) and three bolts (2). Tighten the bolts
to a torque of 115 Nm (85 lb-ft).
End By:
a. Install the V-Belts.
Assembly, "V-Belts - Remove and Install".
Illustration 130
Typical example.
Crankshaft Front Seal - Remove

1.
Use Tool (A) to drill three evenly spaced holes in

crankshaft front seal (1).
2.
Place Tool (B) in the holes in order to remove

crankshaft front seal (1). Use Tool (B) in each of the
three holes to evenly remove the crankshaft front seal.
SMCS Code: 1160-011

Removal Procedure
Table 21
NOTE: Do not damage the flange of the crankshaft during

the removal process for the crankshaft front seal.
Required Tools
Tool
A
B
Part
Number
1U-8145
1U-7600
Part Description
Drill Bit
Slide Hammer Puller
Qty
NOTICE
Ensure that the main lip is used in order to remove the
crankshaft front seal. Do not damage the edge of the
housing for the crankshaft front seal.
1
1
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly
and Assembly, "Crankshaft Pulley - Remove and
Install".
7-53
TM 5-3895-382-24
Crankshaft Front Seal - Install

SMCS Code: 1160-012
Table 22
Required Tools
Tool
A
Part
Number
9U-6210
Part Description
Qty
1
NOTICE
Illustration 132

component life.
1.
Clean the housing for the crankshaft front seal and

inspect the housing for damage.
2.
Lubricate the crankshaft front seal with clean engine oil.
4.
Use Tool (A) to install crankshaft front oil seal (1).
5.
Apply clean engine oil on the area of the crankshaft

pulley that will be in contact with crankshaft front seal
(1).
End By:
a. Install the crankshaft pulley. Refer to Disassembly
and Assembly, "Crankshaft Pulley -Remove and
Install".
Front Cover - Remove

SMCS Code: 1166-011
Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly
and Assembly, "Crankshaft Pulley - Remove and
Install".
Illustration 131
3.
b. Remove the water pump. Refer to Disassembly and

Place crankshaft front oil seal (1) into the housing.
c. Remove the alternator. Refer to Disassembly and

Assembly, "Alternator - Remove and Install"
NOTICE
Ensure that the lip of the crankshaft front seal that is
spring loaded is facing toward the inside of the front
housing and that it is square with the bore of the housing
for the crankshaft front seal.
7-54
TM 5-3895-382-24
Illustration 133
Illustration 134
1.
Remove seventeen bolts (1) and two nuts (3).
3.
Install a new gasket and front cover (2).
2.
Remove front cover (2) and the gasket.
4.
Install two bolts (1) in order to hold the gasket and the
cover in place.
Front Cover - Install

SMCS Code: 1166-012
Table 23
Required Tools
Tool
A
B
Part
Number
9U-6210
9U-6200
Part Description
Qty
1
1
NOTICE
Keep all pads clean from contaminants.
Illustration 135

component life.
5.
1.
Clean all surfaces of the front housing and clean the

front cover thoroughly.
2.
Use Tool (A) to install crankshaft front oil seal, if

necessary.
Refer to Disassembly and Assembly,
"Crankshaft Front Seal - Install".
NOTICE
The location of the front cover is critical. If the front cover
is not centered, the backlash between the fuel injection
pump gear and the water pump gear could be affected.
This could result in damage to the fuel injection pump.
6.
Use Tool (B) and the bolts for the crankshaft pulley in
order to center the front cover.
Install the remaining bolts (1) and the two nuts (3).
Tighten the nuts and the bolts to a torque of 22 Nm (16
lb-ft).
End By:
a. Install the alternator. Refer to Disassembly and
Assembly, "Alternator - Remove and Install".
7-55
TM 5-3895-382-24
c. Install the crankshaft pulley.
Refer to
Disassembly and Assembly, "Crankshaft Pulley Remove and Install".
Gear Group (Front) - Remove
SMCS Code: 1206-011
Removal Procedure
Table 24
Required Tools
Part
Number
8S-2264
Tool
A
Part Description
Puller Group
Qty
Illustration 137
Start By:
a. Remove the front cover. Refer to Disassembly and
Assembly, "Front Cover - Remove".
4.
Remove bushing (4) from idler gear (2), if necessary.
5.
Remove the bushing with a suitable puller. If the

bushing cannot be removed with a puller, grind the face
off of one bushing. The remainder of the bushing can
then be removed with a press.
NOTICE
component life.
1.
Align the timing marks on the crankshaft gear, the

camshaft gear, and the idler gear.
Illustration 138
Illustration 136
2.
Remove three bolts (1) from idler gear (2).
3.
Remove idler near (2) and retainer plate (3).
7-56
6.
Remove idler gear hub (5).
7.
Remove nut (6) and the spring washer from fuel

injection pump gear (8).
8.
Remove four bolts (7) from fuel injection pump gear (8).
9.
Use Tool (A) to remove fuel injection pump gear (8).
TM 5-3895-382-24
Gear Group (Front) - Install
6.
Machine the bores for clearance on idler gear hub (5).

The bore should have a clearance of 0.07 0.03 mm
(.003 .001 inch) on idler gear hub (5). The bore can
have a diameter of 50.79 0.01 mm (1.999 .001 inch).
7.
Machine the front faces of the bushings for the end play
of idler gear (2). The gear and the bushings can have a
thickness of 30.15 0.01 mm (1.187 .001 inch).
SMCS Code: 1206-012

NOTICE
component life.
Illustration 141
8.
Illustration 139
Install idler gear (2) and retainer plate (3) on the engine.
1.
Install fuel injection pump gear (8) on the engine.
NOTE: Ensure that the timing marks on the camshaft

gear, the crankshaft gear, and the idler gear are
aligned.
2.
Install four bolts (7) on fuel injection pump gear (8).
9.
Install three bolts (1) on idler gear (2).
3.
Install nut (6) and the spring washer on fuel injection

pump gear (8). Tighten the nut to a torque of 44 Nm
(32 lb-ft).
10.
Check the end play of idler gear (2). Idler gear (2) can
have end play of 0.15 0.05 mm (.006 .002 inch).
4.
Install idler gear hub (5) on the engine.
11.
Check the backlash between the camshaft gear and

idler gear (2). The gears must have a minimum
backlash of 0.08 mm (.003 inch).
End By:
a. Install the front cover. Refer to Disassembly and
Assembly, "Front Cover - Install".
Illustration 140
5.
Use a suitable press to Install new bushings (4) into

idler gear (2).
7-57
TM 5-3895-382-24
Housing (Front) - Remove

SMCS Code: 1151-011
Removal Procedure
Start By:
a. Remove the front gear group. Refer to Disassembly
and Assembly, "Gear Group (Front) - Remove".
b. Remove the camshaft gear. Refer to Disassembly
and Assembly, "Camshaft Gear - Remove and
Install".
Illustration 143
NOTICE
2.

component life.
Remove eight bolts (3) that hold the oil pan to the
bottom of front housing (2).
3.
Remove front housing (2) and the gasket.
NOTICE
fluids.
NOTE: Ensure that the hub for the idler gear does not
fall. Also ensure that the thrust washer for the
camshaft is not lost.
4.
Remove the crankshaft front oil seal from front housing

(2), if necessary.
Housing (Front) - Install

SMCS Code: 1151-012


mandates.
NOTICE
component life.
1.
Install a new crankshaft front oil seal, if necessary.
2.

if necessary.
NOTE: Ensure that the gasket for the engine oil pan is
not damaged. Replace the gasket, if necessary.
Also ensure that the thrust washer for the
camshaft is in the correct position.
3.
Illustration 142
1.
Remove all bolts (1) that fasten the front housing to the
cylinder block.
7-58
Apply 4C-9502 Gasket Sealant to the bottom portion of

the gasket.
TM 5-3895-382-24
Valve Mechanism Cover - Remove and Install

SMCS Code: 1107-010
Removal Procedure
NOTICE
component life.
NOTICE
fluids.
Illustration 144
4.
Install the gasket and front housing (2). Cut the gasket
to the correct length, if necessary.
5.
Install eight bolts (3) that hold the engine oil pan to the
bottom of the front housing.

mandates.
NOTE: The engines are equipped with either an
aluminum valve cover or with a composite valve
cover. The aluminum valve cover has a seal that
fits between the valve cover and the inlet
manifold. The composite valve cover has a seal
that is permanently fixed to the side of the valve
cover.
Illustration 145
6.
Install all bolts (1) that fasten the front housing to the
cylinder block and to the oil pan. Tighten the M8 bolts
to a torque of 22 Nm (16 lb-ft). Tighten the M10 bolts
to a torque of 44 Nm (33 lb-ft).
NOTE: Ensure that the bottom of the front housing is

aligned with the bottom of the cylinder block.
End By:
a. Install the camshaft gear. Refer to Disassembly and
Assembly, "Camshaft Gear - Remove and Install.
Illustration 146
Typical example.
b. Install the front gear group. Refer to Disassembly and

Assembly, "Gear Group (Front) - Install".
7-59
TM 5-3895-382-24
Illustration 147
Aluminum valve cover.
Illustration 149
Typical example.
Illustration 148
Composite valve cover.
1.
Loosen hose clamp (1).
2.
Disconnect breather hose (2).
3.
Remove three nuts (3), steel washers (6), and sealing

washers (8).
Illustration 150
Aluminum vale cover.
NOTE: When you remove nuts (3), ensure that the nuts
on the rocker arm bracket are not loosened.
NOTE: Current production engines have an additional
shim washer (7).
4.
Remove valve cover (4), gasket (10), and seal (5).
5.
Remove seal (9) for the oil filler cap.
Illustration 151
Composite valve cover.
NOTE: The engines are equipped with either an
aluminum valve cover or with a composite valve
cover. The aluminum valve cover has a seal that
fits between the valve cover and the inlet
manifold. The composite valve cover has a seal
that is permanently fixed to the side of the valve
cover.
1.
Inspect the condition of the gaskets and the seals.

Replace the gaskets and the seals, if necessary.
2.
Install seal (9) for the oil filler cap, if necessary.
3.
Apply 8T-9022 Silicone Gasket to gasket (10).
NOTE: Ensure that the flat face of the gasket is toward

the valve cover.
7-60
TM 5-3895-382-24
4.
Install gasket (10), seal (5), and valve cover (4).
5.
Lubricate three nuts (3) with clean engine oil.
6.
Install three nuts (3), steel washers (6), and sealing

washers (8).
1.
Remove three nuts (1) and bolt (2). Begin with the end
brackets and move toward the center.
2.
Remove rocker shaft assembly (3).
3.
Remove the oil seal from the oil supply passage in the
cylinder head.
NOTE: When you install three nuts (3) without shim

washers (7), tighten the nuts to a torque of 20 N
m
(15 lb-ft). Do not overtighten the nuts.
NOTE: When you install three nuts (3) with shim washers
(7), tighten the nuts to a torque of 30 N
m (22 lbft). Do not overtighten the nuts.
7.
Connect breather hose (2).
8.
Tighten hose clamp (1).
Rocker Shaft and Pushrod - Remove

SMCS Code: 1102-011; 1208-011
Illustration 153
Removal Procedure Start By:

4.
a. Remove the valve mechanism cover.

Refer to
Disassembly and Assembly, "Valve Mechanism Cover
- Remove and Install".
Remove eight pushrods (4). Place an identification

mark on the pushrods for installation.
Rocker Shaft - Disassemble
NOTICE
SMCS Code: 1123-015


component life.
Table 25
Required Tools
Tool
A
Part
Number
1P-0510
Part Description
Driver Group
Qty
1
Start By:
a. Remove the rocker shaft assembly.
Refer to
Disassembly and Assembly, "Rocker Shaft and
Pushrod - Remove".
Illustration 152
NOTE: It is not necessary to remove the oil supply tube

in order to remove the rocker shaft assembly and
the pushrods.
7-61
TM 5-3895-382-24
Rocker Shaft - Assemble
SMCS Code: 1102-016
Assembly Procedure
1.
Lubricate all of the components with clean engine oil.
Illustration 154
1.
Use a screwdriver or a similar tool to remove retaining

ring (1) from both ends of the rocker shaft assembly.
Illustration 156
(1) Retaining ring
(2) Washer on the end of the rocker shaft
(3) Rocker arm assembly
(4) Shaft bracket
(5) Spring on the rocker shaft
(6) Washer
(7) Rocker shaft
(8) Bolt
(9) Connection for the oil supply
(10) Rocker arm bushing
2.
Illustration 155
(1) Retaining ring
(2) Washer on the end of the rocker shaft
(3) Rocker arm assembly
(4) Shaft bracket
(5) Spring on the rocker shaft
(6) Washer
(7) Rocker shaft
(8) Bolt
(9) Connection for the oil supply
(10) Rocker arm bushing
2.
NOTE: Ensure that the bolt and the connection are

correctly positioned on the rocker shaft.
NOTE: Ensure that all of the oil holes in the rocker shaft
and in the rocker arms are not plugged before you
begin the assembly procedure.
3.
Install bushing (10) in rocker arm (3) with a suitable

press. Ream the bushing to a clearance of 0.06 0.03
mm (.0024 .0012 inch), if necessary.
4.
Install each of the components in the correct order onto

rocker shaft (7). See Illustration 156.
Remove the rocker arms and the shaft brackets from

the rocker shaft assembly.
NOTE: Place an identification mark on each of the

components for installation.
3.
Check the clearance between rocker arm (3) and rocker

shaft (7). Replace bushing (10) if the clearance is larger
than 0.13 mm (.005 inch). Use Tool (A) and a suitable
press in order to remove bushing (10) for rocker arm (3),
if necessary.
4.
Remove bracket (4) for rocker shaft (7).
5.
Remove springs (5), washers (6), bolt (8), and

connection (9) for the oil supply from rocker shaft (7).
Install connection (9) for the oil supply and bolt (8) on
rocker shaft (7).
7-62
TM 5-3895-382-24
2.
Install a new oil seal in the oil supply hole in the cylinder
head.
Illustration 157
5.
Install retaining ring (1).

Illustration 159
End By:
3.
a. Install the rocker shaft assembly.

Refer to
Pushrod - Install".
Put rocker shaft assembly (3) in position on the cylinder

head. Make sure that the connection for the oil supply
is installed correctly into the oil seal.
NOTE: Ensure that the adjustment screws are properly

seated in the ends of pushrods (4).
Rocker Shaft and Pushrod - Install

SMCS Code: 1102-012; 1208-012
NOTE: It may be necessary to loosen the adjustment

screws on each rocker arm. This will help prevent
a bent valve or a bent pushrod during the
installation of the rocker shaft.
NOTICE
4.
Lubricate three nuts (1) and bolt (2) with clean engine
oil.

component life.
5.
Install three nuts (1) and bolt (2).
6.
Alternately tighten the nuts and the bolt. Start from the
center and work toward the outside. Tighten the nuts
and bolt on an aluminum bracket to a torque of 40 Nm
(30 lb-ft). Tighten the nuts and bolt on a cast iron or a
steel bracket to a torque of 75 Nm (55 lb-ft).
7.
Adjust the inlet valve lash to 0.20 mm (.008 inch) and

adjust the exhaust valve lash to 0.45 mm (.018 inch).
Refer to the Testing and Adjusting, "Air Inlet and
Exhaust System" topic for more information on adjusting
the valve lash.
End By:
a. Install the valve mechanism cover.
Refer to
Disassembly and Assembly, "Valve Mechanism Cover
- Remove and Install".
Illustration 158
1.
Install eight pushrods (4).
NOTE: Ensure that the pushrods are installed in the

original location and that the pushrods are seated
in the valve lifters correctly.
7-63
TM 5-3895-382-24
Cylinder Head - Remove

SMCS Code: 1100-011
Removal Procedure
Start By:
a. Remove the fuel injection nozzles.
Refer to
Disassembly and Assembly, "Fuel Injection Nozzles Remove".
Illustration 161
b. Remove the air inlet manifold. Refer to Disassembly

and Assembly, "Air Inlet Manifold - Remove".
1.
c. Remove the exhaust manifold. Refer to Disassembly

and Assembly, "Exhaust Manifold - Remove and
Install".
Gradually loosen 22 cylinder head bolts (1) in the

reverse order that is shown above. This will help
prevent distortion of the cylinder head.
d. Remove the water outlet manifold.

Refer to
Disassembly and Assembly, "Water Outlet Manifold Remove".
e. Remove the rocker shaft assembly and the pushrods.
Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrod - Remove".
Illustration 162
Typical example.
2.
Attach a suitable lifting device to cylinder head (2).

Carefully lift cylinder head (2) off the engine block. The
weight of the cylinder head is 41 kg (90 lb).
NOTICE
Place the cylinder head on a surface that will not scratch
the face of the cylinder head.
Illustration 160
Typical example.
7-64
TM 5-3895-382-24
2.
Place cylinder head gasket (3) on dowels (4) on top of

the cylinder block. The cylinder head gasket (3) is
stamped "FRONT TOP". Do not use any sealant or
compound on the cylinder head gasket.
3.
Install Tool (A) in positions 15 and 20 in the cylinder

block. Refer to Illustration 167.
Illustration 163
3.
Remove cylinder head gasket (3).
4.
Note the location of dowels (4) on each end of the

cylinder block. Dowels (4) hold cylinder head gasket (3)
in place while cylinder head (2) is installed.
Illustration 165
Typical example.
Cylinder Head - Install

SMCS Code: 1100-012
4.
Attach a suitable lifting device to cylinder head (2).
5.
Place cylinder head (2) on the cylinder block. Ensure

that the cylinder head is positioned on dowels (4) and
that cylinder head gasket (3) is positioned correctly.
6.
Remove Tool (A).
Table 26
Required Tools
Tool
A
B
1.
Part
Number
9U-6238
8T-3052
Part Description
Guide Bolt
Degree Wheel
Qty
2
1
Thoroughly clean the top of the cylinder block and the

bottom of the cylinder head. Ensure that there is no
debris in the cylinder bores.
Illustration 166
Typical example.
7.
Illustration 164
7-65
Lubricate cylinder head bolts (1) with dean engine oil.
TM 5-3895-382-24
e. Install the fuel injection nozzles.
Refer to
Disassembly and Assembly, "Fuel Injection Nozzles Install".
Lifter Group - Remove and Install

SMCS Code: 1209-010
Removal Procedure
Table 27
Illustration 167
8.
Required Tools
Part
Number
1U-7262
Gradually tighten all of the bolts (1 through 22) in a

numerical sequence to a torque of 110 Nm (80 lb-ft).
Tool
9.
Tighten all of the bolts (1 through 22) again in a

numerical sequence to a torque of 110 Nm (80 lb-ft).
Start By:
10.
Place an index mark on the bolts and use Tool (B) in

order to further tighten the bolts.
Part Description
Telescoping Magnet
Qty
1
a. Remove the camshaft. Refer to Disassembly and

Assembly, "Camshaft -Remove and Install".
a. Turn the short bolts that are marked with an "S" for an
additional 150 degrees (2.5 flats).
NOTICE
b. Turn the medium length bolts that are marked with an

"M" for an additional 180 degrees (3.0 flat).

component life.
c. Turn the long bolts that are marked with an "L" for an
additional 210 degrees (3.5 flats).
NOTE: Refer to the Testing and Adjusting Module,
"Cylinder Compression" for the correct procedure
to test the cylinder head.
End By:
a. Install the rocker shaft and the pushrods. Refer to
Pushrod - Install".
b. Install the water outlet manifold.
Refer to
Disassembly and Assembly, "Water Outlet Manifold Install".
Illustration 168
1.
c. Install the exhaust manifold. Refer to Disassembly

and Assembly, "Exhaust Manifold - Remove and
Install".
Use Tool (A) to remove lifters (1).
NOTE: Ensure that the lifters are marked with the

appropriate cylinder number for installation
purposes.
d. Install the air inlet manifold. Refer to Disassembly

and Assembly, "Air Inlet Manifold - Install.
7-66
TM 5-3895-382-24
d. Remove the camshaft gear. Refer to Disassembly

and Assembly, "Camshaft Gear - Remove and
Install".
Table 28
NOTICE
Required Tools
Part
Number
1U-762
Tool
A
Part Description
Telescoping Magnet
Qty
component life.
NOTICE
NOTICE
fluids.

component life.

mandates.
1. Turn the engine upside-down so the valve lifters are
held in a position away from the camshaft.
Illustration 169
1.
Use Tool (A) to install lifters (1).
NOTE: Ensure that the lifters are seated correctly and

that the lifters are in the correct cylinders.
Camshaft - Remove and Install

SMCS Code: 1210-010
Removal Procedure
Illustration 170
Start By:
2. Remove thrust washer (1). Make a note of the

location of the hollow dowel (X) for installation
purposes.
a. Remove the rocker shaft and the pushrods. Refer to

Pushrods - Remove".
b. Remove the fuel transfer pump.
Refer to
Disassembly and Assembly, "Fuel Transfer Pump Remove".
c. Remove the front housing. Refer to Disassembly and
7-67
TM 5-3895-382-24
Illustration 173
Illustration 171
2.
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed.
3.
Put thrust washer (1) in position. Make sure that thrust

washer (1) is aligned with hollow dowel (X).
End By:
Carefully remove camshaft (2) from the engine.
a. Install the camshaft gear. Refer to Disassembly and

Assembly, "Camshaft Gear - Remove and Install".
b. Install the front housing. Refer to Disassembly and

Assembly, "Housing (Front) - Install".
NOTICE
c. Install the fuel transfer pump. Refer to Disassembly

and Assembly, "Fuel Transfer Pump - Install".

component life.
d. Install the rocker shaft and the pushrods. Refer to

Pushrods - Install".
Camshaft Gear - Remove and Install

SMCS Code: 1210-010-GE
Removal Procedure
Table 29
Required Tools
Tool
Illustration 172
A
NOTICE
Do not damage the lobes or the bearings when the
camshaft is removed.
NOTE: Ensure that camshaft (2) is clean.
Lubricate
camshaft (2) with clean engine oil prior to
installation.
1.
Carefully install camshaft (2) in the engine.
7-68
Part
Number
1U-6671
4S-4712
1P-0510
Part Description
Puller Group
Bolt
Driver Group
Qty
1
2
1
TM 5-3895-382-24
Start By:
a. Remove the fan.
Assembly, "Fan - Remove and Install".
b. Remove the front cover. Refer to Disassembly and
Assembly, "Front Cover - Remove".
Illustration 176
3.
Install Tool (A) and remove the camshaft gear.
NOTE: Do not lose the key from the camshaft gear.

4.
Illustration 174
1.
Inspect the camshaft gear for wear and damage.

Replace the gear, if necessary.
Rotate the crankshaft until the timing marks on the

crankshaft gear, the camshaft gear, and the fuel
injection pump gear are aligned.
NOTE: The timing marks on the Idler gear may not be

aligned. This is caused by the difference in the
speed of the rotation of the idler gear.
Illustration 177
1.
NOTE: When you install the camshaft gear, ensure that

the teeth that have the timing marks are facing
toward the front. Also, ensure that the key is
aligned properly in the keyway. If necessary, tap
the gear with a soft hammer in order to seat the
key in the keyway.
Illustration 175
2.
Install camshaft gear (2).
Remove bolt (1) and the washer on camshaft gear (2).
2.
If necessary, remove the idler gear in order to align the

gear teeth correctly.
3.
Install bolt (1). Tighten the bolt to a torque of 78 Nm

(58 lb-ft).
NOTE: Ensure that the timing marks on the camshaft

gear, the crankshaft gear, and the fuel injection
pump gear are aligned.
7-69
TM 5-3895-382-24
4.
If a new camshaft gear is used, check the backlash of

the camshaft gear. The minimum backlash for a new
gear is 0.08 mm (.003 inch).
End By:
b. Install the fan. Refer to Disassembly and Assembly,
"Fan - Remove and Install".
Camshaft Bearings - Remove and Install

SMCS Code: 1211-010
Illustration 179
Removal Procedure
1. Use Tool (A). Apply 4C-5591 Anti-Seize Compound

to the threads of Tool (A).
Table 30
Required Tools
Tool
Part
Number
8S-2241
8H-0684
Part Description
Camshaft Bearing Tool
Group
Ratchet Wrench
2. Remove camshaft bearings (1) from the cylinder

block.
Qty
Table 31
Start By:
Required Tools
Tool
a. Remove the camshaft. Refer to Disassembly and

Assembly, "Camshaft - Remove and Install".
NOTICE
Part
Number
8S-2241
8H-0684
Part Description
Camshaft Bearing Tool
Group
Ratchet Wrench
Qty
1
1
NOTICE

component life.

component life.
Illustration 178
Illustration 180
7-70
TM 5-3895-382-24
Illustration 182
Typical example.
Illustration 181
1.
Use Tool (A) in order to install the camshaft bearings in

the cylinder block.
2.
Install camshaft bearings (1) in the cylinder block.
End By:
a. Install the camshaft. Refer to Disassembly and
Assembly, "Camshaft - Remove and Install".
1.
Remove oil pan drain plug (2) and the O-ring seal.
Drain the engine oil into a suitable container for storage
or disposal.
2.
Remove twenty bolts (1).
3.
Remove engine oil pan (3) and gasket (4).
NOTICE
Engine Oil Pan - Remove and Install

SMCS Code: 1302-010

component life.
Removal Procedure
1.
NOTICE
Clean all surfaces thoroughly. Inspect the condition of

the gasket. Replace the gasket, if necessary.

component life.
NOTICE
fluids.
Illustration 183
Typical example.

mandates.
7-71
2.
Install gasket (4) and engine oil pan (3).
3.
Install twenty bolts (1). Tighten the bolts to a torque of

22 Nm (16 lb-ft).
4.
Install the O-ring seal and oil pan drain plug (2). Tighten
the drain plug to a torque of 34 Nm (25 lb-ft).
TM 5-3895-382-24
5.
Fill the engine oil pan to the correct level that is

indicated on the engine oil level gauge.
NOTE: Before you proceed with the removal of the

cylinder liner, check the cylinder liners for wear or
for damage. Check the inner diameter of each
cylinder liner at the top, the middle, and the
bottom. Check the inner diameter at two places
that are 180 degrees away from each other. The
maximum wear for the cylinder liners is 0.25 mm
(.010 inch).
NOTE: Refer to the Operation and Maintenance Manual

Cylinder Liner - Remove

SMCS Code: 1216-011
NOTE: An engine may have a high rate of oil

consumption if the surface of the cylinder liners
are glazed. Glaze can be removed from the
cylinder liners by honing the bore of the cylinder
liner.
Removal Procedure
Table 32
Required Tools
Tool
Part
Number
1A-1460
2J-3507
5F-7347
5H-1504
5P-8245
6V-2183
8H-0684
9U-6234
9U-6281
Part Description
Bolt
Full Nut
Head
Hard Washer
Washer
Screw
Ratchet Wrench
Puller Plate
Leg
1.
Qty
3
1
1
1
1
1
1
1
1
Rotate the crankshaft in order to gain access to the

cylinder liner.
Place a protective cover on the
crankshaft in order to prevent damage.
Start By:
a. Remove the cylinder head. Refer to Disassembly and
Assembly, "Cylinder Head - Remove".
b. Remove the pistons and connecting rods. Refer to
Disassembly and Assembly, "Pistons and Connecting
Rods - Remove".
Illustration 184
c. Remove the piston cooling jets. Refer to Disassembly

and Assembly, "Piston Cooling Jets - Remove".
NOTICE
component life.
7-72
2.
Install Tool (A) that is shown above.
3.
Remove cylinder liner (1).
TM 5-3895-382-24
Cylinder Liner - Install
3.
Use Tool (A) to install cylinder liner (1).
SMCS Code: 1216-012
4.
Press cylinder liner (1) into the cylinder block within 50.0
mm (2.00 inch) of the top of the cylinder block.
5.
Apply 6V-1541 Quick Cure Primer to the exposed area

of cylinder liner (1). Also apply 9S-3265 Compound to
the exposed area of cylinder liner (1).
Table 33
Required Tools
Tool
Part
Number
1A-1460
2J-3507
5F-7347
5H-1504
5P-8245
6V-2183
8H-0684
9U-6235
1U-9895
8T-0455
Part Description
Bolt
Full Nut
Head
Hard Washer
Washer
Screw
Ratchet Wrench
Puller Plate
Cross Block
Liner Projection Tool
Group
Qty
3
1
1
1
1
1
1
1
1
1
Illustration 186
NOTICE
6.
Use Tool (B) and Tool (A) for the final installation of
cylinder liner (1). Cylinder liner (1) is a press fit to a
distance of 0.03 mm (.001 inch) from the top of the
cylinder block.
7.
Wipe off any excess 9S-3265 Compound.
8.
Use Tool (B) to check that cylinder liner (1) is 0.10 mm

(.004 inch) above the cylinder block or below the
cylinder block.
9.
Immediately after you install a new cylinder liner, follow

the recommendations below:

component life.
1.
2.
Clean the cylinder block bore with 8T-9011 Component

Cleaner before you install the cylinder liner.
Apply clean engine oil to the cylinder block bore. Do not
apply the clean engine oil to the top 50.0 mm (2.00 inch)
of the cylinder block bore.
a. Do not operate the engine at full load.

b. Do not operate the engine at high speed.
c. Do not allow the engine to run at low idle for an
extended period of time.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, "Piston Cooling Jets - Install".
b. Install the pistons and connecting rods. Refer to
Disassembly and Assembly, "Piston and Connecting
Rods - Install".
Illustration 185
c. Install the cylinder head. Refer to Disassembly and

Assembly, "Cylinder Head - Install".
7-73
TM 5-3895-382-24
NOTE: Check that the ball moves freely against the
pressure of the valve of the piston cooling jet and
check that the tube of the piston cooling jet is not
damaged.
Piston Cooling Jets - Remove and Install

SMCS Code: 1331-010
Removal Procedure
3.
Start By:
Ensure that you know that a hollow dowel (3) is used to

locate the piston cooling jet.

and Assembly, "Engine Oil Pan - Remove and Install".
NOTICE
NOTICE

component life.

component life.
NOTICE
fluids.
mandates.
Illustration 188
1.
Install four piston cooling jets (2).
NOTE: Ensure that piston cooling jet (2) is properly

located on hollow dowel (3).
2.
Install four nuts (1). Tighten the nuts to a torque of 27

Nm (20 lb-ft).
End By:
a. Install the engine oil pan. Refer to Disassembly and
Assembly, "Engine Oil Pan - Remove and Install".
Illustration 187
1.
Remove four nuts (1).
2.
Remove four piston cooling jets (2).
NOTE: The engine crankshaft may be rotated in order to

access all of the piston cooling jets.
7-74
TM 5-3895-382-24
4.
Pistons and Connecting Rods - Remove
Remove connecting rod caps (2) and the connecting rod

bearings. Keep connecting rod caps (2) and the
connecting rod bearings together for installation.
SMCS Code: 1225-011

Removal Procedure
Table 34
Required Tools
Part
Number
8S-2269
Tool
A
Part Description
Ridge Reamer
Qty
1
Start By:
a. Remove the cylinder head. Refer to Disassembly and
b. Remove the engine oil pump. Refer to Disassembly
and Assembly, "Engine Oil Pump - Remove".
Illustration 190
c. Remove the piston cooling jets. Refer to Disassembly

and Assembly, "Piston Cooling Jets - Remove and
Install".
5.
Push pistons (3) and the connecting rods out of the top
of cylinder block (4).
Pistons and Connecting Rods - Disassemble
NOTICE
SMCS Code: 1225-015

component life.
Table 35
1.
Use Tool (A) to remove the liner wear ridge from the
inner surface of the cylinder liner.
Required Tools
Tool
2.
Position the two pistons that are being removed at the

bottom center position.
A
B
Part
Number
1U-6683
1P-1857
Part Description
Ring Expander
Qty
1
1
Start By:
a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, "Piston
and Connecting Rods - Remove".
NOTICE
component life.
Illustration 189
3.
Remove nuts (1) and the bolts.
7-75
TM 5-3895-382-24
Illustration 193
Typical example.
Illustration 191
Typical example.
1.
5.
Use Tool (A) to remove three piston rings (1) from

piston (2).
Use a suitable press and a suitable adapter to remove

piston pin bushing (9) from connecting rod (6).
Pistons and Connecting Rods - Assemble

SMCS Code: 1225-016
Assembly Procedure
Table 36
Required Tools
Tool
A
B
Illustration 192
Typical example.
2.
Use Tool (B) to remove two retaining rings (3).
3.
Remove piston pin (4).
Part Description
Ring Expander
Qty
1
1
NOTICE
component life.
NOTE: If the piston pin cannot be removed by hand, heat

the piston to a temperature of 45 5 C
(113 9 F).
4.
Part
Number
1U-6683
1P-1857
Remove bearing (5) from connecting rod (6).
7-76
TM 5-3895-382-24
7.
Use Tool (A) to install piston rings (1) on piston (2) with
the following steps.
a. Install the oil control piston ring in the groove

that is lowest on the piston. The latch pin must
be inside the ends of the spring.
NOTE: Ensure that the latch pin is 180 degrees from the
piston ring gap.
b. Install the cast iron piston ring with the tapered

face into the second groove on the piston. The
stamp "TOP" must be toward the top of the
piston.
Illustration 194
Typical example.
1.
Ream piston pin bushing (7) in order to obtain a

clearance of 0.0085 0.0055 mm (.0003 .0002 inch)
between the piston pin and the piston pin bushing.
2.
Lubricate all components with clean engine oil.
3.
Use a suitable press and a suitable adapter to install

piston pin bushing (7) into connecting rod (6).
NOTE: Cast iron piston rings that are new have a red
mark which must be on the left of the piston ring
gap when the piston ring is installed.
c. Position the piston ring gaps at 120 degrees

away from each other.
d. Install the piston ring with the barrel face and the
molybdenum insert into the top groove on the
piston. The top piston ring has a wedge shape.
The stamp "TOP" must be toward the top of the
piston.
NOTE: Ensure that the oil hole is aligned with the oil hole
at the top of the connecting rod.
NOTE: Top piston rings that are new have a green mark
which must be on the left of the ring gap when the
ring is installed.
End By:
a. Install the pistons and the connecting rods.

Refer to Disassembly and Assembly, "Piston
and Connecting Rods - Install".
Pistons and Connecting Rods - Install
SMCS Code: 1225-012
Illustration 195
Typical example.
4.
Install bearing (5) in connecting rod (6).
5.
Install piston pin (4).
Table 37
Required Tools
NOTE: If the piston pin cannot be installed by hand, heat

the piston to a temperature of 45 5 C (113 9 F).
6.
Part
Number
1U-6684
8T-0455
Tool
Use Tool (B) to install two retaining rings (3).
7-77
Part Description
Qty
Piston Ring Compressor

Liner Projection Tool
Group
1
1
TM 5-3895-382-24
NOTICE
component life.
1.
Thoroughly clean all of the components.
2.
Lubricate the piston and the cylinder liner with clean

engine oil.
3.
Rotate the crankshaft until the connecting rod journal is

at the bottom center. Lubricate the connecting rod
journal with clean engine oil.
4.
Install the upper connecting rod bearing cap in the

connecting rod. Ensure that the location tab is correctly
installed in the connecting rod.
5.
Lubricate the bearing for the upper connecting rod

journal with clean engine oil.
Illustration 197
6.
11.
Install connecting rod cap (2) with bolts (1) and the nuts.
Tighten the connecting rod cap bolts and the nuts to a
torque of 125 Nm (92 Ib-ft).
NOTE: If the connecting rod cap is held in position with

only a bolt, tighten the bolt to a torque of 155 N
m
(114 Ib-ft).
Align the piston rings on the piston so that the distance

between the gaps is 120 degrees.
12.
Rotate the crankshaft in order to ensure that there is no

binding.
13.
Refer to the Testing and Adjusting Module, "Basic

Block" for the correct procedure on checking the height
of the piston above the cylinder block.
End By:
a. Install the piston cooling jets. Refer to Disassembly
and Assembly, "Piston Cooling Jets - Remove and
Install".
b. Install the engine oil pump. Refer to Disassembly and
Assembly, "Engine Oil Pump - Remove".
Illustration 196
7.
c. Install the cylinder head. Refer to Disassembly and

Install Tool (A) on the piston.
NOTE: Ensure that Tool (A) is installed correctly and that

the piston can easily slide out of the tool.
Connecting Rod Bearings - Remove

SMCS Code: 1219-011
NOTE: The arrow or the "FRONT" mark that is on the top

of the piston must be toward the front of the
engine.
Removal Procedure
Start By:
8.
Push the piston and the connecting rod assembly into

the cylinder liner and onto the connecting rod journal.
9.
Install the lower connecting rod bearing in the

connecting rod cap. Ensure that the location tab is
correctly installed in the connecting rod cap.
10.
Lubricate the lower connecting rod bearing with clean

engine oil.

and Assembly, "Engine Oil Pan - Remove and Install".
7-78
TM 5-3895-382-24
NOTICE
component life.
NOTICE
during performance of Inspection, maintenance, testing,
fluids.
Illustration 199
Type A connecting rod.

mandates.
Illustration 200
Type B connecting rod.
NOTE: There are two types of connecting rods that may

be used in the engine. Type A connecting rods
have serrated mating faces on the connecting rod
and the connecting rod cap. Type A connecting
rods are held together with a through bolt and a
nut. Type B connecting rods have an alignment
pin in the connecting rod cap. Type B connecting
rods are held together with a bolt that is threaded
into the connecting rod.
Illustration 198
Typical example.
1.
Remove bolt (2) and two bolts (1) that hold the oil
pressure relief valve in position.
2.
Remove the oil pressure relief valve in order to gain

access to the connecting rods.
3.
Remove two bolts (4) and bolt (3).

strainer.
Remove the oil
4.
Remove the oil strainer in order to gain access to the

connecting rods.
5.
In order to remove the connecting rod caps, turn the

crankshaft in a clockwise direction until the piston is at
the bottom center position.
7-79
6.
If you have Type A connecting rods, remove two nuts

(9) and two bolts (10). If you have Type B connecting
rods, remove two bolts (11).
7.
Remove connecting rod cap (8) from the connecting

rod.
8.
Remove lower connecting rod bearing (5). Keep the

connecting rod bearings together with the respective
connecting rod caps for installation purposes.
TM 5-3895-382-24
9.
Carefully push the connecting rod into the cylinder liner

in order to remove upper connecting rod bearing (6).
The connecting rod may need to be rotated in order to
prevent contact with the piston cooing jet. Remove
upper connecting rod bearing (6).
10.
Repeat Steps 5 through 9 for the remaining connecting

rod bearings.
NOTE: There are two types of connecting rods that may

be used in the engine. Type A connecting rods
have serrated mating faces on the connecting rod
and the connecting rod cap. Type A connecting
rods are held together with a through bolt and a
nut. Type B connecting rods have an alignment
pin in the connecting rod cap. Type B connecting
rods are held together with a bolt that is threaded
Connecting Rod Bearings - Install

1.
Clean the bearing surface of connecting rod (7) and

connecting rod cap (8).
2.
Clean upper connecting rod bearing (6) and lubricate

the bearing face wit clean engine oil.
NOTICE
3.
Clean lower connecting rod bearing (5) and lubricate the

bearing face with clean engine oil.
SMCS Code: 1219-012

component life.
NOTE: Align the tabs on the connecting rod bearings

with the tab grooves in the connecting rod.
Illustration 201
Type A connecting rod.
4.
Install upper connecting rod bearing (6) in connecting

rod (7).
5.
Pull the connecting rod into position against the

crankshaft. The connecting rod may need to be rotated
in order to prevent contact with the piston cooling jet.
6.
Install lower connecting rod bearing (5) in connecting

rod cap (8).
7.
Install bearing cap (8) in position on connecting rod (7).

Ensure that the identification numbers are stamped on
the same side.
8.
If you have Type A connecting rods, install two bolts

(10) and two nuts (9). If you have Type B connecting
rods, install two bolts (11).
9.
Repeat Steps 1 through 8 for the rem aining connecting

rod bearings.
Illustration 202
Type B connecting rod.
Illustration 203
7-80
TM 5-3895-382-24
10.
Put the oil strainer in position on the engine and install

bolts (4) and bolt ().
11.
Put the oil pressure relief valve in position on the engine

and install two bolts (1) and bolt (2).
2.
Make sure that the main bearing cap is marked for the
location and direction for installation.
The main
bearings and the main bearing caps must be installed in
the same location.
End By:
a. Install the engine oil pan. Refer to Disassembly

and Assembly, "Engine Oil Pan - Remove and
Install".
Crankshaft Main Bearings - Remove
SMCS Code: 1203-011
Removal Procedure
Table 38
Illustration 204
Required Tools
Tool
A
Part
Number
9U-6282
Part Description
Torque Wrench Extension
3.
Remove two bolts (1) and main bearing cap (2).
Qty
1
Start By:
a. Remove the engine oil relief valve and the strainer
assembly. Refer to Disassembly and Assembly,
"Engine Oil Relief Valve - Remove and Install".
NOTICE
component life.
Illustration 205
NOTE: Remove the following components from the

engine in order to remove the rear main bearing
with the crankshaft in position: flywheel, flywheel
housing, rear oil seal housing and bridge
assembly.
4.
Remove lower main bearing (3) from main bearing cap

(2). Keep the respective main bearing and the main
bearing cap together for proper installation.
NOTE: Tool (A) must be used in order to remove the front

main bearing cap with the front housing and the
engine oil pump in place. If Tool (A) is not
available, removal of the front cover and the
engine oil pump will be necessary. The engine oil
pump is attached to the front main bearing cap.
Removal of the bolts is not possible with a socket.
Refer to Disassembly and Assembly, "Engine Oil
Pump -Remove".
1.
Remove all necessary components in order to gain

access to the specific main bearing cap.
Illustration 206
7-81
TM 5-3895-382-24
5.
Push upper main beating (4) from the opposite side of

the beating tab with a suitable tool. Carefully rotate the
crankshaft while you push on the beating. Remove
upper main bearing (4) from the cylinder block. Keep
the upper beating halves together in order to ensure
proper installation.
6.
Repeat Steps 1 through 5 for the remaining main

beatings.
NOTICE
Only the upper half of the main bearing has lubrication
holes. Make sure the upper half of the main bearing is
installed correctly in the cylinder block to ensure proper
lubrication.
2.
Slide upper main beating (4) into position between the

crankshaft journal and the cylinder block.
Crankshaft Main Bearings - Install

SMCS Code: 1203-012
Table 39
Required Tools
Tool
(1)
A
B
Part
Number
9U-6282
8T-5096
Part Description
Qty
Torque Wrench Extension

Dial Indicator
1
1
Illustration 208
(1)
Tool (A) must be used in order to install the front main

bearing cap with the front housing and the engine oil
pump in place.
3.
NOTICE
NOTE: Ensure that the lower halves of the main beatings

are installed so that the beating tabs fit into the
notch in the main bearing caps.

component life.
4.
Illustration 207
1.
Clean main beating cap (2) and lower main beating (3).
Lubricate the beating surface of lower main beating (3)
with clean engine oil.
Install lower main beating (3) in main bearing cap (2).
Illustration 209
Clean upper main beating (4) and lubricate the beating

surface with clean engine oil.
5.
NOTE: Ensure that the upper halves of the main beatings

are installed so that the beating tabs fit into the
notch in the cylinder block.
Make sure that the beating tabs on both halves of the

main bearings are located on the same side. Install
main beating caps (2).
6.
Lubricate the threads of bolts (1) with clean engine oil.
7.
Install bolts (1) and tighten the bolts to a torque of 250

Nm (185 Ib-ft). Use Tool (A) to tighten the bolts for the
front main bearing cap.
7-82
TM 5-3895-382-24
8.
Repeat Steps 1 through 7 for the remaining main

bearings.
c. Remove the front housing. Refer to Disassembly and

9.
Rotate the crankshaft in order to ensure that the

crankshaft turns freely.
d. Remove the flywheel housing. Refer to Disassembly

Install".
e. Remove the housing for the crankshaft rear seal.
Refer to Disassembly and Assembly, "Crankshaft
Rear Seal - Remove".
NOTICE
component life.
Illustration 210
Typical example.
10.
Check the crankshaft end play. Use a prybar to move

the crankshaft toward the rear of the engine. Install
Tool (B) and zero the dial indicator.
Move the
crankshaft with the prybar toward the front of the
engine.
Measure the crankshaft end play.
The
maximum permissible crankshaft end play is 0.51 mm
(.020 inch).
NOTE: If the crankshaft was not removed for the rear

main bearing removal, the following components
must be installed: bridge assembly, rear oil seal
housing, flywheel housing and flywheel.
Illustration 211
End By:
1.
Remove two socket head bolts (1).
2.
Remove bridge (2).
a. Install the engine oil relief valve and the strainer

assembly. Refer to Disassembly and Assembly,
"Engine Oil Relief Valve - Remove and Install".
Crankshaft - Remove
SMCS Code: 1202-011
Removal Procedure
Start By:
a. Remove the fuel injection pump.
Refer to
Disassembly and Assembly, "Fuel Injection Pump Remove".
Illustration 212
b. Remove the engine oil pump. Refer to Disassembly

and Assembly, "Engine Oil Pump - Remove".
7-83
TM 5-3895-382-24
NOTE: Inspect the main bearing caps and the connecting
rod caps for the proper identification mark. The
identification marks should give the location and
the direction of the bearings in the engine.
3.
Remove ten main bearing cap bolts (3).
4.
Remove five main bearing caps (4).
5.
Remove the lower main bearings and the lower thrust

washers. Keep the lower main bearings with the
respective main bearing cap.
Illustration 214
10.
Attach lifting straps and a suitable lifting device to

crankshaft (7).
11.
Lift crankshaft (7) out of the cylinder block. The weight

of the crankshaft is 29 kg (65 Ib). Do not scratch any of
the finished surfaces on the crankshaft.
Illustration 213
NOTE: The connecting rod caps can be held on the

connecting rod with two bolts and two nuts. The
connecting rod caps can also be held on the
connecting rod with two bolts that are threaded
6.
Remove eight nuts (5).
7.
Remove four connecting rod caps (6).
8.
Remove the bearings from connecting rod caps (6).

Keep the connecting rod bearings with the respective
connecting rod cap.
Illustration 215
12.
Remove upper main bearings (8) and upper thrust

washers (9).
Crankshaft - Install
NOTICE
Do not allow the connecting rods to strike the piston
cooling jets. Damage or misalignment may occur.
SMCS Code: 1202-012

9.
Push the piston assemblies into the cylinder bores.

NOTICE
component life.
1.
7-84
Ensure that all of the lubrication passages are clean and

free of debris.
TM 5-3895-382-24
2.
Clean the seat for the main bearing in the cylinder block
and clean the upper main bearings.
7.
Clean the lower thrust washers and lubricate the lower

thrust washers. Place the lower thrust washers in the
cylinder block.
Illustration 216
Illustration 218
3.
Install upper main bearings (8) with the location tabs in

the correct position in the cylinder block. Lubricate
upper main bearings (8) with clean engine oil.
8.
Ensure that the dowels for main bearing caps (4) are in
the correct position in the main bearing caps or in the
cylinder block. Install main bearing caps (4) in the
position that is marked during the removal process. All
of the location tabs on the main bearings should be on
the same side. The serial number that is stamped on
the main bearing cap should match the number that is
stamped on the bottom face of the cylinder block.
NOTE: The connecting rod caps can be held on the

connecting rod with two bolts and two nuts. The
connecting rod caps can also be held on the
connecting rod with two bolts that are threaded
9.
Install bolts (3) in the main bearing caps. Tighten the

bolts to a torque of 265 40 Nm (196 30 lb-ft).
Illustration 217
4.
Ensure that the main bearing journals of crankshaft (7)

are clean. Attach lifting straps and a suitable lifting
device in order to position the crankshaft in the cylinder
block.
5.
Clean upper thrust washers and lubricate upper thrust

washers (9). Place upper thrust washers (9) in the
cylinder block on both sides of the center main bearing.
NOTICE
Ensure that the slotted sides of the thrust washers are
toward the crankshaft.
6.
Illustration 219
Clean the lower main bearings. Install the lower main

bearings in the main bearing caps with the location tabs
in the correct position. Lubricate the lower main bearing
caps with clean engine oil.
10.
7-85
Install connecting rod caps (6) and connecting rod cap

bolts (5). Tighten the bolts to a torque of 155 Nm
(115 lb-ft).
TM 5-3895-382-24
b. Install bridge (2) and the rubber seals, if equipped.
The rubber seals will sit higher than the bridge when
the seals are correctly installed. Use a straight edge
to line up the bridge with the face of the cylinder
block. Tighten socket head bolts (1) to a torque of 16
Nm (12 Ib-ft). Tighten the bolts evenly.
c. When the bridge is positioned and the socket head
bolts have been tightened, inject 8T-9013 Silicone
Sealant in the grooves that are at each end of the
bridge. The grooves must be completely filled.
d. When the gasket for the oil pan is removed, damage
may occur to the existing seal in the grooves of the
bridge. If the seal is damaged, apply a sufficient
amount of 8T-9013 Silicone Sealant in order to fill the
grooves.
Illustration 220
NOTE: Most of the current engines have setscrews that

fasten the oil pan to the bridge. The threads of
the setscrews have a sealant that is applied by the
manufacturer. When the setscrews are installed,
ensure that the threads of the socket head bolts
and the bridge are clean. Also apply 9S-3263
Thread Lock Compound to the threads of the
setscrews. Follow the same process when studs
are used instead of the setscrews.
End By:
a. Install the housing for the crankshaft rear seal. Refer
to Disassembly and Assembly, "Crankshaft- Install".
b. Install the flywheel housing. Refer to Disassembly
Install".
Illustration 221
c. Install the oil pump. Refer to Disassembly and

Assembly, "Engine Oil Pump - Install".
d. Install the fuel injection pump. Refer to Disassembly
and Assembly, "Fuel Injection Pump - Install".
Illustration 222
11.
Clean the bridge and the face of the cylinder block.

Apply a thin bead of 8T-9013 Silicone Sealant on the
corners of the seat for the bridge. Also apply the
sealant around the thread holes in the seat for the
bridge. Use the following steps when you apply
8T-9013 Silicone Sealant to the cylinder block and the
bridge.
a. Apply a 3.0 mm (.12 inch) bead of 8T-9013 Silicone
Sealant along the corner of the top Recess in the
cylinder block.
7-86
TM 5-3895-382-24
NOTE: Be careful not to nick or scratch the bearing
journal surface of the crankshaft.
Crankshaft Gear- Remove and Install

SMCS Code: 1204-010-GE
Removal Procedure
Start By:
a. Remove the fan.
Assembly, "Fan -Remove and Install".
b. Remove the front cover. Refer to Disassembly and
Assembly, "Front Cover -Remove".
NOTE: Rotate the crankshaft until the timing marks on
the crankshaft gear, the camshaft gear, and the
idler gear are aligned.
Illustration 225
Typical example.
1.
Heat crankshaft gear (4) in an oven to 180 C (356 "F).
2.
Install crankshaft gear (4) on crankshaft (5) with the

timing marks toward the front.
Illustration 223
Typical example.
1.
Remove three bolts (1) in idler gear (2).
2.
Remove idler gear (2) and spacer (3).

Illustration 226
Typical example.
3.
Install spacer (3) and idler gear (2).
4.
Install three bolts (1) on idler gear (2). Tighten the bolts
to a torque of 44 Nm (32 Ib-ft).
NOTE: Ensure that the timing marks on the crankshaft

gear, the camshaft gear, and the idler gear are
aligned.
5.
Illustration 224
Typical example.
Refer to Disassembly and Assembly, "Gear Group

(Front) - Install" for the correct alignment of the idler
gear.
End By:
3.
Use a suitable puller to remove crankshaft gear (4) from

crankshaft (5).

NOTE: Do not use a flame on the crankshaft gear for

removal purposes.
b. Install the fan. Refer to Disassembly and Assembly,

Fan - Remove and Install.
7-87
TM 5-3895-382-24
c. The crankshaft must be free of oil at the contact
points of Tool (A).
Bearing Clearance - Check

SMCS Code: 1203-535; 1219-535
d. Put a piece of Tool (A) on the crown of the bearing

that is in the cap. Do not allow Tool (A) to extend
over the edge of the bearing.
Measurement Procedure
Table 40
Qty
e. Use the correct torque-turn specifications in order to

install the bearing cap. Do not use an impact wrench.
Be careful not to dislodge the bearing when the cap is
installed.
f. Do not turn the crankshaft when Tool (A) is installed.
Required Tools
Tool
A
Part
Number
-
Part Description
Plastigage
NOTICE
component life.
NOTE: Caterpillar does not recommend the checking of

the actual bearing clearances particularly on
small engines. This is because of the possibility
of obtaining inaccurate results and the possibility
of damaging the bearing or the journal surfaces.
Each Caterpillar engine bearing is quality checked
for specific wall thickness.
Illustration 227
Typical example.
NOTE: The measurements should be within specifications

and the correct bearings should be used. If the
crankshaft journals and the bores for the block
and the rods were measured during disassembly,
no further checks are necessary. However, if the
technician still wants to measure the bearing
clearances, Tool (A) is an acceptable method.
Tool (A) is less accurate on journals with small
diameters if clearances are less than 0.10 mm
(.004 inch).
g. Carefully remove the cap, but do not remove Tool (A).

Measure the width of Tool (A) while Tool (A) is in the
bearing cap or on the crankshaft journal. Refer to
Illustration 227.
h. Remove all of Tool (A) before you install the bearing
cap.
NOTE: When Tool (A) is used, the readings can
sometimes be unclear For example, all parts of
Tool (A) are not the same width. Measure the
major width in order to ensure that the parts are
within the specification range.
NOTICE
Lead wire, shim stock or a dial bore gauge can damage
the bearing surfaces.
1.
The technician must be very careful to use Tool (A)

correctly. The following points must be remembered:
a. Ensure that the backs of the bearings and the bores
am clean and dry.
b. Ensure that the bearing locking tabs am properly
seated in the tab grooves.
7-88
TM 5-3895-382-24
NOTE: Refer to the Specifications Module, "Belt Tension
Chart" for the correct belt tension.
V-Belts - Remove and Install

SMCS Code: 1357-010
NOTE: If the V-belt cannot be checked with a gauge,

press on the V-belt at the center of the longest
free length in order to check the deflection. Under
a moderate amount of pressure, the V-belt should
have a deflection of 10.0 mm (.40 inch).
Removal Procedure
3.
Install fan guard (1).
Fan - Remove & Install

SMCS Code: 1356-010
Removal Procedure
Illustration 228
Typical example.
1.
Remove fan guard (1).
2.
Loosen three bolts (2) and slide alternator (3) toward the
engine.
3.
Maneuver V-belts (4) around the fan and remove the

belts.
NOTE: Never replace one V-belt. Always replace two Vbelts, if equipped.
Illustration 230
1.
Remove four bolts (1).
2.
Remove fan (2).
3.
Remove extension (3) that is behind the fan.
4.
Remove the fan pulley, if necessary.
Illustration 229
Typical example.
1.
Install V-belts (4) behind the fan and on the pulleys.
2.
Slide alternator (3) away from the engine. Tighten three

bolts (2).
Illustration 231
7-89
TM 5-3895-382-24
1.
Inspect the condition of the fan pulley. Replace the fan

pulley, if necessary.
2.
Install extension (3) behind the fan.
3.
Install fan (2).
4.
Install four bolts (1). Tighten the bolts to a torque of 22

N.m (16 lb-ft).
Fan Drive - Remove

SMCS Code: 1359-011
Removal Procedure
Illustration 233
Start By:
a. Remove the fan.
Assembly, "Fan - Remove and Install".
1.
Install the fan drive.
2.
Use Tool (A) to install fan drive housing (1).
3.
Install the four bolts. Tighten the bolts to a torque of 44

N.m (32 Ib-ft).
End By:
a. Install the fan. Refer to Disassembly and Assembly,
"Fan -Remove and Install".
Alternator -Remove & Install

SMCS Code: 1405-010
Removal Procedure
1.
Illustration 232
1.
Remove the four bolts for fan drive housing (1).
2.
Remove the fan drive.
Place an index mark on all of the electrical wires that

are connected to the alternator.
Disconnect the
electrical wires from the alternator.
Fan Drive - Install

SMCS Code: 1359-012
Table 41
Required Tools
Tool
A
Part
Number
1P-0510
Part Description
Driver Group
Qty
Illustration 234
Typical example.
7-90
TM 5-3895-382-24
Illustration 235
Typical example.
Illustration 237
Typical example.
2.
Loosen two nuts (1).
1.
Put alternator (3) in position on the engine.
3.
Loosen bolt (4) and slide alternator (3) toward the

engine. Remove V-belt (5) from the engine.
2.
Install two bolts (2) with the washers and nuts (1).
Tighten nuts (1) finger tight. Install bolt (4) and the
washer. Do not tighten bolt (4) at this time.
4.
Remove bolt (4) and the washer from alternator (3).

3.
5.
Remove two nuts (1) with the washers and bolts (2).
6.
Remove alternator (3) from the engine.
Put V-belt (5) in position on the engine. Adjust the

tension on V-belt (5) by moving alternator (3) away from
the engine. Tighten bolt (4) after the proper belt tension
is made. For additional information on adjusting the Vbelt, refer to the Operation and Maintenance Manual,
"Alternator and Fan Belts -Inspect/Adjust/Replace".
4.
Tighten nuts (1) in order to secure alternator (3) in

position on the engine.
Electric Starting Motor - Remove

and Install
SMCS Code: 1453-010
Removal Procedure
1.
Illustration 236
Typical example.
7-91
Place an identification mark on all electrical wires that

are connected to the starting motor. Disconnect the
electrical wires from the starting motor.
TM 5-3895-382-24
NOTE: Ensure that the washer is installed according to
the index mark that was made during the removal
process.
Illustration 238
2.
Remove three nuts (1).
3.
Remove electric starting motor (2).
Illustration 241
Illustration 239
4.
Remove washer (3).
NOTE: Place an index mark on the washer for installation

purposes.
Illustration 240
1.
Install washer (3).
7-92
2.
Install electric starting motor (2).
3.
Install three nuts (1).
TM 5-3895-382-24
Dipstick Assembly
Relief Valve
Remove & Install Dipstick

Assembly 1326-010
Disassemble & Assemble Relief

Valve 1304-017
1P-1857
Tools Needed
Retainer Ring Pliers
A
1
Start By:
a. remove oil pressure relief valve
1.
Loosen nut (1).
2.
Pull dipstick assembly (2) out of the oil pan.
3.
Disassemble the dipstick assembly by removing gauge

(3) and seal (5) from tube assembly (4).
NOTE: For installation of the dipstick assembly, reverse

the removal steps.
7-93
1.
Apply pressure to the end plate.

remove retaining ring (5).
2.
Remove end plate (4).
3.
Remove spring (3).
4.
Remove plunger (2) from body (1).
Use Tool (A) to
TM 5-3895-382-24
ALPHABETICAL INDEX
A
Crankshaft Gear - Remove and Install .................................. 7-86

Installation Procedure............................................................ 7-87
Removal Procedure............................................................... 7-87

(Type 1 Engines and 9RM Engines) ...................................... 7-28
Crankshaft Main Bearings - Install ......................................... 7-82


(Type 2 Engines and 7BJ Engines) ....................................... 7-29
Crankshaft Main Bearings - Remove ..................................... 7-81

Removal Procedure .............................................................. 7-81

Crankshaft Pulley - Remove and Install ................................ 7-52


Crankshaft Rear Seal - Install.................................................. 7-50

Crankshaft Rear Seal - Remove .............................................. 7-49
Alternator- Remove and Install ............................................... 7-90

Cylinder Head - Install .............................................................. 7-65

Installation Procedure ........................................................... 7-65
B
Cylinder Head - Remove........................................................... 7-64

Measurement Procedure ...................................................... 7-88
Cylinder Liner - Install................................................................ 7-73

C
Camshaft - Remove and Install .............................................. 7-67
Cylinder Liner - Remove .......................................................... 7-72

D
Camshaft Bearings - Remove and Install ............................. 7-70

Dipstick Assembly ..................................................................... 7-93

Remove and Install Dipstick ................................................ 7-93
Camshaft Gear- Remove and Install ..................................... 7-68

Disassembly and Assembly Section .........................................7-4
Connecting Rod Bearings - Install .......................................... 7-80

Electric Starting Motor - Remove and Install ........................ 7-91

Connecting Rod Bearings - Remove ...................................... 7-78

Engine Design ...............................................................................7-4

Crankshaft- Install ..................................................................... 7-84

Engine Oil Filter Base - Assemble........................................... 7-36

Assembly Procedure ............................................................. 7-36
Crankshaft - Remove................................................................. 7-83

Engine Oil Filter Base - Disassemble ..................................... 7-36

Disassembly Procedure........................................................ 7-36
Crankshaft Front Seal - Install ................................................ 7-54

Engine Oil Filter Base - Install ................................................. 7-37

Crankshaft Front Seal - Remove ............................................. 7-53

Engine Oil Filter Base - Remove ............................................. 7-35

7-94
TM 5-3895-382-24
Engine Oil Pan - Remove and Install ..................................... 7-71

Removal Procedure ............................................................... 7-11
Engine Oil Pump - Install .......................................................... 7-39


Engine Oil Pump - Remove ...................................................... 7-38


Engine Oil Relief Valve - Remove and Install........................ 7-37

(Type 1 Engines and 9RM Engines)....................................... 7-24
Installation Procedure........................................................ 7-25
Removal Procedure........................................................... 7-24


Installation Procedure........................................................ 7-26
Removal Procedure........................................................... 7-25


Fan - Remove and Install ......................................................... 7-89

Fuel Transfer Pump - Assemble ................................................7-8

Assembly Procedure ...............................................................7-8
Fan Drive - Install ...................................................................... 7-90

Fuel Transfer Pump - Disassemble ...........................................7-8

Disassembly Procedure...........................................................7-8
Fan Drive - Remove................................................................... 7-90

Fuel Transfer Pump - Install........................................................7-9

Installation Procedure...............................................................7-9
Flywheel - Install ........................................................................ 7-48

Fuel Transfer Pump - Remove ...................................................7-7

Removal Procedure..................................................................7-7
Flywheel - Remove ................................................................... 7-47

Flywheel Housing - Remove and Install ................................ 7-51

Gear Group (Front) - Install ..................................................... 7-57

Front Cover - Install .................................................................. 7-55

Gear Group (Front) - Remove ................................................. 7-56

Front Cover - Remove ............................................................... 7-54

Fuel Filter Base - Remove and Install ......................................7-5

Installation Procedure...............................................................7-6
Housing (Front) - Install ............................................................ 7-58

Fuel Injection Lines - Remove and Install ............................. 7-10

Housing (Front) - Remove ....................................................... 7-58



Inlet and Exhaust Valve Guides Remove and Install ................................................................... 7-33
Important Safety Information ......................................................7-2
7-95
TM 5-3895-382-24
Inlet and Exhaust Valve Seat Inserts Remove and Install.................................................................... 7-34
T
Table of Contents .........................................................................7-3
Turbocharger- Assemble ......................................................... 7-23
Assembly Procedure ............................................................ 7-23
Inlet and Exhaust Valve Springs Remove and Install.................................................................... 7-30

Turbocharger- Disassemble .................................................... 7-22

Inlet and Exhaust Valves - Remove and Install ................... 7-31

Removal Procedure .......................................................................
Turbocharger- Install ................................................................ 7-24

Turbocharger- Remove ............................................................. 7-21
L
Lifter Group - Remove and Install .......................................... 7-66
V-Belts - Remove and Install.................................................... 7-89

Piston Cooling Jets - Remove and Install ............................. 7-74

Valve Mechanism Cover - Remove and Install .................... 7-59

Pistons and Connecting Rods - Assemble ........................... 7-76

W
Water Outlet Manifold - Install ................................................. 7-47
Pistons and Connecting Rods - Disassemble ...................... 7-75

Water Outlet Manifold - Remove ............................................ 7-46

Pistons and Connecting Rods - Install ................................... 7-77

Water Pump - Assemble

Assembly Procedure ............................................................ 7-42
Pistons and Connecting Rods - Remove .............................. 7-75

R
Water Pump - Disassemble

Relief Valve ................................................................................. 7-93

Disassemble and Assemble Relief Valve .......................... 7-93
Water Pump - Install ................................................................. 7-44

Rocker Shaft - Assemble.......................................................... 7-62

Water Pump - Remove ............................................................. 7-40

Rocker Shaft - Disassemble..................................................... 7-61

Water Temperature Regulator Remove and Install ................................................................... 7-44

Rocker Shaft and Pushrod - Install ........................................ 7-63

Rocker Shaft and Pushrod - Remove .................................... 7-61
7-96
TM 5-3895-382-24
KEN2604
April 1994
CHAPTER 8
Disassembly &
Assembly
3054 Engine Supplement For Vibratory
Compactors
ENGINE:
5HK8000-UP
NOTES:
8-1
TM 5-3895-382-24
Do not operate or perform any lubrication, maintenance or repair on this product until you have read and understood the
The hazards are identified by the "Safety Alert Symbol and followed by a "Signal Word" such as "WARNING" as shown below.

Attention Become Alert! Your Safety is Involved.
the product are therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and other. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
8-2
TM 5-3895-382-24
Index
Alternator .......................................................................................8-6
Disassemble & Assemble Alternator .................................8-6
Starter..............................................................................................8-4
Disassemble & Assemble Starter ......................................8-4
Disconnect batteries before performances of any service

work.
8-3
TM 5-3895-382-24
Starter
Disassemble & Assemble Starter
Start By:
a. remove starting motor.
1.
Remove nut (1), washer (2) and connector (3).
2.
Remove nut (4) and starting motor cover (5).
3.
Remove nut (6), washer (7) and connector (3).
4.
Remove nut (8) and washer (9).
5.
Remove bolt (10), washer (11), starting motor terminal

(12), insulator (13) and insulator (14).
8-4
6.
Remove lever housing plug (15) and gasket (16).
7.
Remove three bolts (17) and washers (18).
8.
Pull back on solenoid assembly (19) and remove nut

(20) and solenoid.
9.
Remove six bolts (21) and housing assembly (22).
TM 5-3895-382-24
10.
Matchmark housing assemblies.
11.
Remove five bolts (23), housing assembly (24), and

starter motor drive assembly (25).
12.
Matchmark housing assemblies.
13.
Remove two bolts (26) and housing assembly (27).
14.
Remove armature assembly (28).
15.
Remove roll pin (29) and lift plate assembly (30).
16.
Remove eight shoe pole screws (31), four shoe poles

(32), insulator (33), and starting motor coil (34).
17.
Remove retaining ring (35).
18.
Remove spring retainer (36), spring (37), boot (38),

spring retainer (39), and washer (40).
NOTE: To assemble starting motor, reverse disassembly

steps.
End By:
a. Install starting motor.
s8-5
TM 5-3895-382-24
Alternator
3.
Remove the pulley nut, washer and pulley (4), fan (5),
and the key from the rotor shaft.
4.
Mark the front and rear frame assemblies for proper

assembly. Remove four screws (6) (one has a nut on it
on the back of the alternator).
5.
Separate the front frame and rotor assembly from the

rear frame and stator assembly. Watch for the wave
washer at the back of the rear frame to fall out.
6.
Remove four screws (7) and rotor (8) from the front
frame.
7.
Remove spacer (10) and front bearing (11), with a

suitable puller. Remove bearing cover (9) from the
rotor.
Disassemble & Assemble

Alternator
Start By:
a. remove alternator.
1.
Remove the two screws and regulator (1).
2.
Disconnect capacitor lead (2) from the back of the

alternator. Remove the screw and capacitor (3).
8-6
TM 5-3895-382-24
8.
11.
Remove rear bearing (12) with a suitable puller.
Unsolder the four stator leads and separate rectifier (18)

from stator (19).
NOTE: To assemble the

disassembly steps.
End By:
a. install alternator.
9.
Remove terminal nuts (13), (14), (15) and (16).

Remove all of the washers and insulators.
10.
Remove two screws (17). Remove the stator and

rectifier assembly from the rear frame. Remove the
remaining insulators from the terminal studs.
8-7/(8-8 blank)
alternator,
reverse
the
TM 5-3895-382-24
KENR2644-01
October 1998
CHAPTER 9
Disassembly &
Assembly
3054 Engine Supplement for
CP-433C & CS-433C
Vibratory Compactors
CP-433C:
2JM1-UP
1ZN1-UP
4JZI-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
ENGINE:
5HK1-UP
NOTES:
9-1
TM 5-3895-382-24
The hazards are identified by the Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as shown below.
The meaning of this safety alert symbol is s follows:

Operations that may cause product damage are identified by "NOTICE labels on the product and in this publication.
the product a therefore not al inclusive. If a tool, procedure, work method or operating technique not specifically recommended by
Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be
9-2
TM 5-3895-382-24
Index
Air Cleaner ....................................................................................9-4
Alternator .......................................................................................9-5
Engine (CS-433C & CP-433C) ............................................... 9-12
Engine Enclosure..........................................................................9-9
Fuel Filter .......................................................................................9-7
Fuel Filter, Disassemble And Assemble ..................................9-8
Fuel Lift Pump................................................................................9-8
Hydraulic Oil Cooler .................................................................. 9-11
Muffler .............................................................................................9-6
Oil Filter, Oil Filter Base & Oil Cooler ........................................9-9
Radiator ...................................................................................... 9-10
Secondary Fuel Filter ...................................................................9-7
Secondary Fuel Filter, Disassemble
and Assemble............................................................................9-8
Starter..............................................................................................9-5
Water Separator............................................................................9-6
Water Separator, Disassemble And Assemble ........................9-7
Disconnect batteries before performance of any service

work.
9-3
TM 5-3895-382-24
Disassembly & Assembly
Air Cleaner
Remove & Install Air Cleaner
1051-010
1.
2.
3.
Remove primary element (6) from the air cleaner

housing.
4.
Remove secondary element (9) from air cleaner housing

(1).
5.
Loosen hose clamp (7), and remove hood (8) from the
air cleaner housing.
6.
Remove four nuts and bolts (10), and remove air

cleaner housing (1) from the hydraulic oil tank.
Loosen hose clamp (2), and remove hose (3) from air
cleaner housing (1).
Unfasten two clamps (4), and remove cover (5) from the
air cleaner housing. Remove the O-ring seal from the
cover. Check the O-ring seal for damage or wear and
NOTE: For installation of the air cleaner, reverse the

removal steps.
9-4
TM 5-3895-382-24
Starter
Alternator
Remove & Install Starter

1518-010
Remove & Install Alternator

1405-010
1.
Open the engine access door on the left side of the

machine.
1.
Open the engine access door on the left side of the

machine.
2.
Turn the disconnect switch to the OFF position.
2.
Turn the disconnect switch to the OFF position.
3.
Mark or identify all electrical wires for installation

purposes. Slide the rubber cover down two electrical
wires (5). Remove the nut, and disconnect the two
electrical wires from starter (1).
3.

purposes. Disconnect electrical wires (3) and (5) from
alternator (2).
4.
4.
Remove plastic plug (2), and disconnect electrical wire

(4) from the starter.
Loosen bolt (1). Remove bolt (6). Rotate pulley guard

(4) out of the way. Rotate the alternator toward the
engine, and remove two V-belts (7) from the alternator
pulley.
5.
Remove three bolts (3), and remove starter (1) from the
engine.
5.
Remove bolt (1), and remove alternator (2) and pulley

guard (4) from the engine.
NOTE: For installation of the starter, reverse the removal

steps.
NOTE: If the alternator pulley was removed, tighten the

alternator pulley nut to a torque of 65 to 74 N
m
(48 to 55 lb-ft).
NOTE: When installing the alternator, the alternator
pulley must be aligned with the crankshaft pulley
within 2.4 mm (0.09 In).
NOTE: For installation of the alternator, reverse the
removal steps.
9-5
TM 5-3895-382-24
Muffler
Water Separator
Remove & Install Muffler

1062-010
Remove & Install Water Separator

1263-010
1.
1.
Open the engine access door on the right side of the

machine.
2.
Turn the drain valve on the bottom of the water

separator counterclockwise to open. Drain the water
and sediment into a suitable container. Close the drain
valve.
3.
Disconnect tube assembly (1) and hos e assembly (4)

from water separator (3). Cap and plug immediately.
4.
Remove two bolts (2), and remove water separator (3)

from the engine.
Open the engine access doors on both sides of the

machine.
NOTE: For installation of the water separator, reverse the

removal steps.
2.
Loosen the bolt, and remove clamp (1) and the exhaust
pipe from muffler (2).
3.
Remove two nuts and bolts (3) that fasten the muffler to
the bracket.
4.
Loosen bolt (4), and remove the clamp and muffler (2)
from the engine.
NOTE: For installation of the muffler, reverse the removal

steps.
9-6
TM 5-3895-382-24
Disassemble & Assemble Water
Separator 1263-017
5.
Remove ring (9) and element (8) from filter base (4).
6.
Remove seal (7) from the filter base. Check the seal for
wear or damage, and replace if necessary.
7.
Remove nut (1) and cap (2) from the filter base.
Remove seal (3) from the cap. Check the seal for wear
or damage, and replace if necessary.
8.
Remove plug (6) from filter base (4). Remove washer

(5) from the plug. Check the washer for wear or
damage, and replace if necessary.
Start By:
a. remove water separator
NOTE: For assembly of the water separator, reverse the

disassembly steps.
End By:
a. install water separator
Fuel Filter
Remove & Install Fuel Filter
1261-010
1.
Remove valve (17) from bowl (13). Remove washer

(16) from the valve. Check the washer for wear or
2.
Loosen head (11), and remove bowl (13) from element

(8).
3.
Remove bolt (15) from bowl (13). Remove seal (14)

from the bolt. Check the seal for wear or damage, and
4.
Remove bowl (13) from head (11). Remove seals (10)

and (12) from the head. Check the seals for wear or
9-7
1.

machine.
2.
Turn the drain valve on the bottom of the fuel filter

counterclockwise to open. Drain the fuel, water and
sediment into a suitable container. Close the drain
valve.
3.
Disconnect hose assembly (4) from fuel filter (3). Plug

and cap immediately.
4.
Disconnect five fuel lines (1) from the fuel filter. Cap
and plug immediately.
TM 5-3895-382-24
5.
Remove two bolts (2), and remove fuel filter (3) from the
bracket.
2.
Remove seal (6) from the filter base. Check the seal for
wear or damage, and replace if necessary.
NOTE: For installation of the fuel filter, reverse the

removal steps.
3.
Remove nut (1), cap (2) and plug (4) from the filter
base. Remove seal (3) from the cap. Check the seal
for wear or damage, and replace if necessary.
Disassemble & Assemble Fuel Filter

1261-017
NOTE: For assembly of the fuel filter, reverse the

disassembly steps.
Start By:
End By:
a. remove fuel filter
a. install fuel filter
Fuel Lift Pump

Remove & Install Fuel Lift Pump
1258-010
1.
Disconnect fuel lines (1) and (3) from fuel lift pump (2).
Cap and plug immediately.
2.
Remove four bolts (4). Remove fuel lift pump (2) and
the gasket from the engine. When installing the fuel lift
pump, tighten four bolts (4) to a torque of 2 2 N
m
(16 lb-ft).
NOTE: If the fuel lift pump is difficult to remove, rotate

the crankshaft until the camshaft eccentric, which
operates the fuel lift pump, is in a position which
will free the lever on the fuel lift pump.
NOTE: When installing the fuel lift pump, make sure the
camshaft eccentric is in the minimum lift position
before the fuel lift pump is installed. Clean the
face of the fuel lift pump and the cylinder block
before installing the fuel lift pump.
NOTE: For installation of the fuel lift pump, reverse the
removal steps.
1.
Remove ring (8) and element (7) from filter base (5).
9-8
TM 5-3895-382-24
NOTE: After the fuel lift pump has been installed it may
be necessary to prime the fuel system. Refer to
the Operation & Maintenance Manual for the
correct procedure.
Engine Enclosure
Remove & Install Engine Enclosure
7263-010
Oil Filter, Oil Filter Base & Oil

Cooler
Remove & Install Oil Filter,
Oil Filter Base & Oil Cooler
1306,1318 & 1378-010
1.
Loosen the two clamps that fasten oil lines (4) to oil
cooler (7).
2.
Disconnect electrical connector (1) for the engine oil

pressure switch.
3.
Remove three bolts (2) and nut (3), and remove oil filter
(5), oil filter base (6) and oil cooler (7) as a unit from the
engine and oil lines (4). Cap and plug immediately.
1.
Loosen the hose clamp, and remove hood (1) from the
air cleaner housing.
2.
Loosen the bolt, and remove exhaust pipe (2) and the
clamp from the muffler.
3.
Remove the eight bolts, and remove top panel (3) from
the machine.
4.
Remove two bolts (4) that fasten backup alarm (5) to the
cowling. Mark the two electrical wires for assembly
purposes, and disconnect them from the backup alarm.
5.
For assembly purposes, mark the two electrical wires on

two rear lights (6). Disconnect the two electrical wires
from each of the rear lights.
6.
Remove the cable ties that fasten electrical harness (7)

to the cowling, and move the electrical harness out of
the way.
NOTE: For Installation of the oil filter, oil filter base and
oil cooler, reverse the removal steps.
9-9
TM 5-3895-382-24
7.
Attach lifting straps and a hoist to engine enclosure (8)

as shown. The engine enclosure consists of the left and
right doors, the cowling and the radiator grill. Remove
eight bolts (9) that fasten the engine enclosure to the
frame, and remove the engine enclosure. The weight of
the engine enclosure is 128 kg (282 lb).
3.
Loosen the hose clamp, and remove hose (1) from the
bottom of the radiator.
4.
Loosen the hos e clamp, and remove hose (2) from the
top of radiator (3).
5.
Attach Tooling (A) and a hoist to radiator (3) as shown.

Remove eight bolts (4) that fasten the radiator to the
hydraulic oil cooler, and remove the radiator. The
weight of the radiator is 35 kg (77 lb).
Radiator
Remove & Install Radiator
1353-010
6V-2156
Tools Needed
Line Brackets
A
2
Start By:
a. remove engine enclosure
At operating temperature, the engine cooling system is

hot and under pressure. Steam can cause personal injury.
Check the coolant level only after the machine has
stopped and the fill cap and radiator are cool enough to
touch with the bare hand. Remove the fill cap slowly to
relieve pressure. Cooling system conditioner contains
kakali. Avoid contact with skin and eyes to prevent
personal injury.
1.
Release the pressure in the cooling system by slowly

loosening the fill cap on the radiator.
2.

container. The capacity of the cooling system is
11 liters (2.9 U.S. gal).
9-10
TM 5-3895-382-24
NOTE: After the radiator has been installed, fill the
cooling system with coolant to the correct level.
See the Operation & Maintenance Manual for the
correct procedure.
NOTE: For installation of the radiator, reverse the
removal steps.
End By:
a. install engine enclosure
Hydraulic Oil Cooler

Remove & Install Hydraulic Oil
Cooler 1374-010
6V-2156
Tools Needed
Line Brackets
2.
Disconnect hose assemblies (1) and (2) from hydraulic

oil cooler (3). Cap and plug immediately.
3.
Remove the two bolts that fasten plate (6) to shroud (5)
and the hydraulic oil cooler. Move the bracket and two
hoses out of the way.
4.
Remove the four bolts and one half of fan guard (4). It
is necessary to remove one half of the fan guard to gain
access to bolts (7).
5.
Remove two bolts (7), the washers and rubber mounts

that fasten hydraulic oil cooler (3) to the mount
assembly.
A
2
Start By:
a. remove radiator
At operating temperature, the hydraulic oil tank is hot and

under pressure. Hot oil can cause burns. Remove the fill
cap on the hydraulic oil tank only when the engine is
stopped and the fill cap is cool enough to touch with your
bare hand.
1.
Drain the hydraulic oil from the hydraulic oil tank.

The capacity of the hydraulic oil tank is 72 liters
(19 U.S. gal).
9-11
TM 5-3895-382-24
6.
1.
Drain the hydraulic oil from the hydraulic oil tank.

The capacity of the hydraulic oil tank is 72 liters
(19 U.S. gal).
2.
Remove the two nuts and bolts that fasten muffler (1) to
the engine.
3.
Loosen bolt (3), and remove the clamp and muffler (2)
from the engine.
4.
Loosen the two hose clamps, and remove hose (2) from
the turbocharger and air cleaner housing.
5.
Mark or Identify all electrical wires for installation

purposes. Slide the rubber down two electrical wires
(6). Remove the nut, and disconnect the two electrical
wires from the starter.
6.
Remove the plastic plug, and disconnect electrical wire

(4) from the starter.
7.
Remove the bolt that fastens ground strap (5) to the

flywheel housing.
8.
Disconnect hose assembly (7) from the primary fuel

filter. Cap and plug immediately. Remove the bolt and
clip that fastens hose assembly (7) to the flywheel
housing.
Attach Tooling (A) and a hoist to hydraulic oil cooler (3)

as shown. Remove six remaining bolts (8), and remove
the hydraulic oil cooler from the shroud. The weight of
the hydraulic oil cooler is 34 kg (75 lbs).
NOTE: After the hydraulic oil cooler has been installed,

fill the hydraulic oil tank to the correct level. See
correct procedure.
NOTE: For installation of the hydraulic oil cooler, reverse
the removal steps.
End By:
a. install radiator
Engine (CS-433C & CP-433C)

Remove & Install Engine
1000-010
Star By:
a. remove engine enclosure
b. * tilt operators platform
* This procedure is in the CS-431C, CP-433C & CS-433C
Machine Systems Disassembly & Assembly module, Form No.
KENR2643.

stopped, and the fill cap is cool enough to touch with your
bare hand.
9-12
TM 5-3895-382-24
NOTE: Refer to Paragraph 2-2 for Cold Starting Aid

Replacement on military models. Military models
do not have electric engine starting aids.
9.
10.
11.
Disconnect electrical wire (8) from the engine starting

aid. Remove the four cable ties that faster the electrical
wire to the engine.

purposes. Disconnect electrical wires (9) from the
alternator.
Remove the cable tie that fastens electrical harness (10)
to the engine.
9-13
12.
Disconnect electrical connector (12) from the hydraulic

oil temperature switch.
13.
Disconnect electrical connector (16) from the engine

coolant temperature switch.
14.
Disconnect electrical connector (17) from the engine oil

pressure switch.
15.
Disconnect electrical connector (18) from the engine oil

pressure switch.
16.

purposes. Disconnect two electrical wires (13) from the
fuel pump solenoid.
17.
Remove all of the cable ties that fasten electrical

harness (10) to the engine. Move the electrical harness
out of the way.
18.
Disconnect throttle cable (14) from the engine. Loosen

jam nut (15), and remove throttle cable (14) from the
bracket.
19.
Disconnect hose assembly (11) from the secondary fuel

filter. Plug and cap immediately.
TM 5-3895-382-24
20.
Disconnect hose assemblies (19) from steering pump

(20). Disconnect hose assembly (21) from the hydraulic
oil tank. Cap and plug immediately.
23.
Disconnect hose assemblies (26) and (27) from

vibratory pump (25). Cap and plug immediately.
21.
Disconnect hose assemblies (22) and (23) from the

hydraulic oil cooler. Cap and plug immediately.
24.
Disconnect hose assemblies (29) and (30) from

vibratory pump (25). Cap and plug immediately.
22.
Remove the two bolts that fasten plate (24) to the

shroud and hydraulic oil cooler. Move the bracket and
two hoses out of the way.
25.

purposes. Disconnect the two electrical wires from
neutral start switch (31). Remove the cable ties that
fasten the wiring harness to the pumps.
26.
Remove the cotter pin and pin that fastens control cable
(33) to plate (28).
27.
Loosen jam nut (32), and remove control cable (33)

from the bracket. Move the control cable out of the way.
9-14
TM 5-3895-382-24
28.
29.
30.
Disconnect the hose assemblies from elbows (40). Cap

and plug immediately. The hose assemblies connect
front propel pump (43) to the front propel motor.
31.

rear propel pump (45) to the rear propel motor.
32.

and plug immediately. The hose assembles connect
rear propel pump (45) to the flushing manifold.
33.

front propel pump (43) to the flushing manifold.
Disconnect hose assembly (35) from vibratory pump

(25). Cap and plug immediately.
34.
Put identification marks on electrical connectors (34) for

installation purposes. Remove the screw from each
electrical connector (34), and remove the electrical
connectors from the control valve on the vibratory pump.
Disconnect the hose assemblies from elbows (38) and

(42). Cap and plug immediately. The hose assemblies
connect front propel pump (43) to the propel interlock
valve.
35.

connect rear propel pump (45) to the propel interlock
valve.
36.
Disconnect the hose assembly from elbow (41) on rear

propel pump (43). Cap and plug immediately.
NOTE: The low charge pressure switch is now located

next to the charge oil filter.
Left Side Engine and Pumps
Right Side of Engine and Pumps
NOTE: For photographic purposes, the above two photos

were taken with the pumps and engine removed
from the machine.
9-15
TM 5-3895-382-24
37.
Remove four bolts (48), and remove air cleaner housing

(47) from the hydraulic oil tank.
38.
Attach a hoist to engine (49) as shown. Remove four

nuts and bolts (50) that hold the engine to the frame of
the machine.
39.
Make sure all necessary hose assemblies and electrical

wires have been disconnected. Carefully remove the
engine, radiator, hydraulic oil cooler and pumps as a
unit from the machine. The weight of the engine,
radiator, hydraulic oil cooler and pumps as a unit is
726 kg (1600 lbs).
NOTE: For installation of the engine, reverse the removal

steps.
NOTE: After the engine has been installed, fill the cooling
system with coolant to the correct level. Fill the
hydraulic oil tank to the correct level. See the
Operation & Maintenance Manual for the correct
filling procedures.
9-16
TM 5-3895-382-24
KERNR2645-02
October 1998
CHAPTER 10
Specifications
CP-433C & CS-433C
Propel System
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
This chapter contains specifications that may be helpful in performing maintenance found in Chapter 11.
10-1
TM 5-3895-382-24

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word' such as "WARNING" as shown below.

Operations that may cause product damage am identified by NOTICE labels on the product and in this publication.
the product a therefore not all inclusive. If a tool, procedure, work method or operating technique not specifically recommended by
The information, specifications, and illustrations in this publication am on the basis of information available at the time It was written.
When replacement parts are required for this product

Caterpillar
recommends
using
Caterpillar
replacement parts or parts with equivalent
specifications, including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature
failures, product damage, personal injury or death.
10-2
TM 5-3895-382-24
Index
Specifications
Axle Group.................................................................................10-13
Axle Propel Motor ...................................................................... 10-8
Charge Filter ............................................................................10-11
Brake Interlock Valve ...............................................................10-12
Drum Drive ................................................................................. 10-7
Drum Propel Motor .................................................................... 10-7
Final Drive .................................................................................10-10
Flushing Valve...........................................................................10-11
Gear Reducer ............................................................................. 10-7
Parking Brake And Speed Shift Valve...................................10-10
Propel Pump ............................................................................... 10-4
Pump Servo ........................................................................ 10-6
Pump Mounting Group ............................................................. 10-6
Thermal Bypass Valve ............................................................10-12
When the words "use again" are in the description, the
specification given can be used to determine if a part can be
used again. If the par is equal to or within the specification
given, use the part again.
When the word "permissible" is in the description, the
specification given is the "maximum or minimum" tolerance
permitted before adjustment, repair and/or new parts are
needed.
A comparison can be made between the measurements of a
worn part and the specifications of a new part to find the
amount of wear. A part that is worn can be returned to service
if an estimate of the remainder of its service life is good. If a
short service life is expected, replace the part.
REFERENCE: See CP-433C & CS-433C Propulsion System,
Form No. KENR2646 for Systems Operation, Testing And
Adjusting.
10-3
TM 5-3895-382-24
Specifications
Tandem Propel Pump
Rotation is counterclockwise or clockwise by viewing from the

output shaft end.
Output per section .......................... 56.3 liter/min (14.6 U.S gpm)

at a pressure of ...................................6900 kPa (1000 psi)
with pump at .......................................................... 1250 rpm
with engine at ........................................................ 1250 rpm
Type of pump: Piston, tandem
NOTE: Torques for cover end pump are the same as the
torques for shaft end pump.
For bench test, use SAE 10W oil at 65C (150F).

Pump displacement (each section) ........................ 45.92 cm 3/rev
(2.80 in3/rev)
NOTE: Shaft end section drives front drum, cover end

section drives rear wheels.
Test at full speed:

Output per section ......................113.7 liter/min (29.6 U.S. gpm)
at a pressure of .....................................2050 kPa (300 psi)
with pump at........................................................... 2350 rpm
Output per section ......................112.5 liter/min (29.3 U.S. gpm)
at a pressure of....................................6900 kPa (1000 psi)
with pump at .......................................................... 2350 rpm
Test at half speed:
Output per section ........................56.8 liter/min (14.8 U.S. gpm)
at a pressure of .....................................2050 kPa (300 psi)
with pump at .......................................................... 1250 rpm
10-4
(1)
Tighten seven screws to a

torque of ........................................................ 81 to 100 Nm
(60 to 74 lb-ft)
(2)
Tighten two plugs to a torque of ....................27 to 4 Nm

(20 to 30 lb-ft)
(3)
Tighten two nuts to a torque .........................18 to 24 Nm

(13 to 18 lb-ft)
TM 5-3895-382-24
(4)
Tighten 10 screws to a torque of .................14 to 17 Nm

(10.5 to 12.5 lb-ft)
(5)
Tighten two plugs to a torque of ............. 136 to 163 Nm

(100 to 120 lb-ft)
(6)
Tighten bypass to a torque of

(do not overtighten) ........................................10 to 14 Nm
(7 to 10 lb-ft)
10-5
TM 5-3895-382-24
Pump Mounting Group
Pump Servo
(7)
Tighten nut to a torque of ..............................18 to 24 Nm

(13 to 18 lb-ft)
(8)
Tighten locknut to a torque of .......................24 to 37 Nm

(18 to 27 lb-ft)
NOTE: Tighten nut while maintaining location of inside

nut.
(9)
Charge relief valve pressure setting ................. 2825 kPa

(410 psi)
(10)
Main relief valve pressure setting

for CP-433C & CS-433C ..................................29 900 kPa
(4350 psi)
(1)
NOTE: The tandem pump must have pump pressure

synchronization of within 1380 kPa (200 psi).
Tighten bolt to a torque of .......................61 Nm (45 lb-ft)
Pump hub mounting dimension (A) .......................63.0 1.0 mm

2.5 0.04 in
10-6
TM 5-3895-382-24
Drum Propel Motor
Drum Drive
Type of Motor: Piston (variable displacement)

Rotation is counterclockwise or clockwise by viewing from the
output shaft end.
Motor displacement (maximum) ............................... 46.0 cm 3/rev
(2.80 in3/rev)
(1)
Motor displacement (minimum) ................................ 22.5 cm 3/rev

(1.37 in3/rev)
Tighten ten nuts to a torque of ....................680 60 Nm

(503 44 lb-ft)
Gear Reducer
Loop flushing valve setting of 1378 kPa (200 psi) at 2.5 gpm.
(A)
Maximum displacement screw setting ................20.6 mm

(.81 in)
(B)
Minimum displacement screw setting .................17.5 mm

(.69 in)
Output torque capacity .................................................18 000 Nm

(13 320 lb-ft)
10-7
TM 5-3895-382-24
Axle Propel Motor
Type of drive motor .................................................................piston

(variable displacement)
Rotation .........................................clockwise or counterclockwise
Maximum displacement ......................46.0 cm 3/rev (2.80 in3/rev)
Minimum displacement ........................24.6 cm 3/rev (1.50 in3/rev)
Case pressure ...................................................... 170 kPa (25 psi)
Maximum case pressure ..................................... 520 kPa (75 psi)
Loop flushing valve setting of 1378 kPa (200 psi) at 2.5 gpm
10-8
TM 5-3895-382-24
(1)
Torque for five bolts ........................................14 to 16 Nm

(10 to 12 lb-ft)
(2)
Torque for six bolts ...................................... 81 to 101 Nm

(60 to 74 lb-ft)
(3)
Torque for one bolt .........................................44 to 64 Nm

(32 to 47 lb-ft)
10-9
TM 5-3895-382-24
Final Drive
Parking Brake and Speed Shift

Valve
(1)
Torque for 16 nuts ................................................. 530 Nm

(390 lb-ft)
(2)
Torque for two nuts ............................................... 135 Nm

(100 lb-ft)
(1)
NOTE: Using a soft hammer, rap the wheel hub, retighten

the nut. Repeat this procedure until the nut will
not advance with the application of 135 N
m
(100 lb-ft) of torque.
Check valve cracking pressure setting ............. 1240 kPa

(180 psi)
Check valve flow capacity..................................53 liter/min
(14 U.S. gpm)
(2)
Torque to install valves into block ...............45 to 55 Nm

(35 to 40 lb-ft)
(3)
Tighten nuts to a torque of ..........................0.5 to 0.7 Nm

(4 to 6 lb-in)
(4)
Solenoid coil voltage ................................................24 VDC

Solenoid coil resistance .....................................31.4 ohms
NOTE: After assembly of new bearings (3), loosen nut

to relieve preload to zero torque. Tighten nut.
Check rolling torque. Torque for rotation of
wheelhub .................................. 4 to 7 N
m (3 to 5 lb-ft)
NOTE: After assembly of old bearings (3), loosen nut
to relieve preload to zero torque. Tighten nut.
Check rolling torque. Torque for rotation of
wheel hub .................2.0 to 3.4 N
m (1.5 to 2.50 lb-ft)
(3)
Torque for 32 bolts ...................................... 90 to 120 Nm

(65 to 90 lb-ft)
10-10
TM 5-3895-382-24
Flushing Valve
Charge Filter
(1)
Bypass valve opens at a pressure

differential of.....................................................345 35 kPa
(50 5 psi)
(1)
Open centered three position shuttle valve
(2)
Visual Bypass Indicator shows red at a

pressure differential of ...................................172 34 kPa
(25 5 psi)
(2)
Charge relief valve:

Pressure setting ........................................ 1725 140 kPa
(250 20 psi)
(3)
Tighten filter to a torque of ............................44 3.5 Nm

(32.6 2.6 lb-ft)
(3)
Torque to install valve into block ............................60 Nm

(45 lb-ft)
NOTE: The alternative torque for the filter is 3/4 turn past
contact.
10-11
TM 5-3895-382-24
Brake Interlock Valve
Thermal Bypass Valve
(1)
Tighten nut to a torque of .................................. 7 to 8 Nm

(5 to 6 lb-ft)
(2)
Tighten nut to a torque of ..............................45 to 54 Nm

(35 to 40 lb-ft)
Opening temperature .................................................71C (160F)

Relief valve setting ............................................... 345 kPa (50 psi)
10-12
TM 5-3895-382-24
Axle Group
(1)
Tighten 16 lug nuts torque of ............................... 530 Nm

(390 lb-ft)
(2)
Apply sealer between case and cage and between

cage and carrier.
10-13/(10-14 blank)
TM 5-3895-382-24
KENR2646-03
October 1998
CHAPTER 11
Systems Operation
Testing & Adjusting
CP-433C & CS-433C
Propel System
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
This chapter contains Systems Operation, Testing & Adjusting instructions. Additional information may be found in:
Chapter 10, Specifications, Propulsions System
11-1
TM 5-3895-382-24
Safety precautions and warnings am provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury
The hazards are identified by the 'Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING" as shown below.


Caterpillar
recommends
using
Caterpillar
specifications Including, but not limited to, physical
Failures to heed this warning can lead to premature
11-2
TM 5-3895-382-24
Index
System Operations
Brake Efficiency Check ..........................................................11-48
Axle Assembly..........................................................................11-19
Carrier ...................................................................................11-21
End Reduction Case............................................................11-20
No-Spin Differential .............................................................11-22
Wheel Planetaries ................................................................11-25
Main Relief Valve Pressure Test

Forward Drive .......................................................................11-39
Reverse Drive ......................................................................11-40
Manual Displacement Control
Neutral Adjustment .................................................................11-42
Axle Propel Motor ....................................................................11-14

Motor Flush Valve.................................................................11-16
No-Spin Differential Operation Test .....................................11-47
Charge Filter ............................................................................11-16
Propel Control Linkage Adjustment ......................................11-42
Drum Propel Motor ..................................................................11-11

Propel Motor Case Leakage Test

Axle Propel Motor ................................................................11-49
Drum Propel Motor ..............................................................11-49
Flushing Valve Charge

Relief Valve Pressure Test ....................................................11-38
Propel Motor Flushing Valve Test Procedure .....................11-50
Parking Brake And Speed Shift Control Valve ...................11-18
Propel Pump Synchronization ...............................................11-45
Propel Brake Interlock (Electrical Schematic) ....................11-26
Servo Pressure Check ...........................................................11-41
Propel Brake Interlock Valve ..................................................11-17
Swashplate Neutral Adjustment Procedure ........................11-43

Axle Propel Pump ...............................................................11-43
Drum Propel Pump .............................................................11-44
Propel Pump in Neutral Position............................................11-28

Propel Pump in Forward Position
Forward, Low Speed With Parking Brake Off..................11-30
Reverse, High Speed With Parking Brake Off.................11-32
System Tests And Adjustments ............................................11-37

Pressure Test Tools ............................................................11-38
Pump Efficiency Check ......................................................11-37
Travel Speed Test ...............................................................11-37
Propel Pumps ............................................................................. 11-8

High Pressure And Charge Relief Valves ......................... 11-9
Pump Servo Valves ............................................................11-10
Thermal Bypass Valve Operational Test .............................11-46

Troubleshooting........................................................................11-34
Checks During Operation ...................................................11-35
Visual Checks .......................................................................11-34
Propel System Introduction ...................................................... 11-4

Thermal Bypass Valve Group ................................................11-17
REFERENCE: For Specifications with illustrations, refer to the

Specifications for the CP-433C and CS-433C Propel System,
Form No. KENR2645. If the Specifications in Form No.
KENR2645 are not the same as listed in the Systems
Operation and the Testing And Adjusting, look at the print date
on the front cover of each book. Use the Specifications listed
in the book with the latest date.
11-3
TM 5-3895-382-24
Systems Operation
Propel System
Introduction
(1) Flushing valve. (2) Line from charge filter. (3) Tandem propel pumps. (4) Axle propel motor. (5) Drum drive motor. (6) Brake for axle moor (f
equipped). (7) Unfiltered charge oil. (8) Parking brake and speed shift valves. (9) Thermal bypass valve. (10) Hydraulic oil tank. (11) Brake interlock
valve. (12) Line from charge filter relief. (13) Hydraulic oil cooler.
The propel system is a closed loop, hydrostatic system. The

main components of the system are: tandem propel pump (3),
axle propel motor (4), drum drive motor (5), parking brake and
speed shift valves (8), hydraulic oil tank (10) and oil cooler
(13).
11-4
TM 5-3895-382-24
Charge oil for the propel system is supplied by the steering
system. The steering system sends filtered charge oil to
pumps (3). Flow from the pumps is controlled by the propel
control lever on the operator console. A control cable connects
the lever to the front pump. A linkage rod connects the front
pump to the rear pump. The operator uses the propel lever to
control direction and speed of the machine. The pumps supply
oil to drum and axle drive motors (4) and (5). Case drain oil
from the motors flows through thermal bypass valve (9). Oil in
the bypass valve flows either to oil cooler (13) or back to
hydraulic oil tank (10).
The speed shift control valve sends charge oil to the drive
motors to change the motor displacement for high and low
speeds. The parking brake valve controls the flow of charge oil
to the brake in the drum drive motor.
Left Side Of Drum.
(5) Drum drive motor.
Drum drive motor (5) is located on the left side of the drum.
The motor is a variable displacement, bi-directional piston type
motor. When the machine propels it receives high pressure oil
from the front section (pump closest to the flywheel) of the
tandem propel pump. It transmits the torque through a
planetary gear reduction gearbox to the drum. Isolation
mounts are used to isolate drum vibration internal gearbox and
yoke.
Below Operator Platform.

(3) Tandem propel pumps.
Propel pumps (3) are located under the operator platform. The
propel pumps are variable-displacement piston pumps that
provide minimum pressure to the system when the machine is
not moving.
Rear Axle.
(4) Axle propel motor.
Axle propel motor (4) is located on the rear of the axle. The
motor is a variable-displacement, bi-directional and piston-type
motor. When the machine propels, the motor receives highpressure oil from the rear section of the tandem pump. The
motor transmits the torque through the axle assembly to the
rear wheels.
11-5
TM 5-3895-382-24
Under Hydraulic Oil Tank.

(9) Thermal bypass valve.
Rear of Operator Platform (right side).

(8) Parking brake and speed shift valves.
Thermal bypass valve (9) is located under the hydraulic oil tank
behind the operator platform.
Parking brake and speed shift valves (8) are located under the
operators platform.
The valve directs return oil flow from the drive motors to
hydraulic oil cooler (13) and/or to hydraulic oil tank (10). The
cracking temperature is 56C (160F).
The parking brake valve is a solenoid operated, two position

valve that controls the operation of the brake in the drum drive
motor.
The speed shift control valve is a solenoid operated, two
position valve that controls the operation of the speed shi
mechanism in the drum drive and the axle motors.
Rear Of Engine.
(13) Hydraulic oil cooler.
Hydraulic oil cooler (13) is located at the rear of the engine.

The cooler is air cooled by the engine fan. The hot oil is
cooled and then exits the outlet port (on the left side when
facing the front of the machine) to the hydraulic oil tank.
Under Operator Platform.

(6) Brake interlock valve.
Brake interlock valve (6) is located under the operators

platform. This valve connects the two ends of the servo
together to prevent the pump from developing hydraulic flow
whenever the propel lever is moved off of neutral and the
parking brake applied. When the parking brake is released the
coil for valve (6) is energized. This blocks oil connecting the
servos allowing the servo to develop a differential pressure and
allow the pump to develop hydraulic oil flow.
11-6
TM 5-3895-382-24
Front Of Hydraulic Oil Tank.
Right Side Under Platform.
(1) Flushing Valve.
(16) Charge filter.
Flushing valve (1) is located on the front side of the hydraulic

tank. The valve has seven test ports for measuring pressures
of the propel, vibratory and charge systems and the scheduled
oil sampling test.
Charge filter (16) is located on the right side of the machine

under the platform. This is a 13 micron filter, that has a
manual indicator for bypass. If the filter becomes plugged, a
pressure drop is created. When the pressure drop reaches
350 kPa (50 psi), the filter bypass valve opens and oil flows
through the valve to the spring loaded check valve. The check
valve is part of parking brake and speed shift valve (8). When
the pressure reaches 1220 kPa (175 psi) in the passage
between the bypass and check valves, the check valve opens
and oil flows to the thermal bypass valve and on to the oil
cooler if needed. At the same time, if the charge pressure
drops below 1220 kPa (175 psi) after the filter, then a warning
light and horn will sound off. The check valve prevents the
brake pressure from dropping below 1550 kPa (225 psi).
NOTE: A pressure drop of 172 kPa (25 psi) across the
filter shows red on the visual bypass indicator
which means the hydraulic oil filter should be
changed.
Control console.
(14) Speed selector switch. (15) Propel lever.
The operator controls the propel system using speed selector

switch (14) and propel lever (15). When the operator moves
the switch from Low Range to High range, solenoid on parking
brake and speed shift valve (8) sends the unfiltered charge oil
to rear axle and drum drive motor displacement port. This
changes the motor displacement from maximum displacement
to minimum displacement resulting in higher speed operation.
With the switch in the Low Range position, the displacement
ports for the two motors are open to case drain. The biased
motor is maximum displacement. By moving the propel lever
forward or backward, the operator sets the displacement of the
propel pump. This determines the direction and speed of the
machine.
11-7
TM 5-3895-382-24
Propel Pumps
Propel Pumps.
(1) Swashplate. (2) Barrel assembly. (3) Port plate. (4) Pistons. (5) Housing. (6) Shaft. (7) Bearing sleeve. (8) Link pin. (9) Rotating group (10)
Spring. (11) Servo control spool. (12) Control sleeve. (13) Servo piston.
When the engine is running, shaft (6) and barrel assembly (2)
are rotating. There are seven pistons (4) in the barrel
assembly. Port plate (3) and swashplate (1) are fastened to or
held by housing (5) and do not rotate. Spring (10) keeps a
force on the barrel assembly to make a high pressure seal
between the barrel assembly and the port plate. When the
barrel assembly is rotating, each piston (4) follows the angle of
the swashplate. If the swashplate angle is at zero, the pistons
do not move in and out of the barrel assembly, and there is no
oil flow. Charge oil from the steering system maintains oil
pressure in the propel pump to keep the barrel assembly full of
oil. The charge oil is also used to fill the closed loop system
with oil. This pressure provides the service braking for the
system.
The position of the swashplate is controlled by servo control

spool (11) and servo piston (13). Movement of the propel
control lever moves the servo control spool. The spool routes
charge oil to activate and adjust the servo piston. As the
swashplate moves, it controls the movement of link pin (8)
which allows bearing sleeve (7) to cover the port on control
sleeve (12). This controls the amount of stroke for the pump.
The servo piston controls the direction and amount of
swashplate angle.
Oil flows from the propel pump to the propel motor and back to
the pump through the inlet and outlet ports. The position of the
swashplate determines the direction of flow and which of the
two loop lines is the high pressure line.
11-8
TM 5-3895-382-24
High Pressure and Charge Relief Valves
Servo Piston Assembly.

(1) High pressure relief valves. (2) Charge relief valve.
High Pressure Relief Valve
Charge Relief Valve
High pressure relief valves (1) protect the propel pressure

system. The check part of each valve directs make-up charge
oil to the rotating group to be used in the closed-loop system.
The relief part of each valve protects the system during
operation. If system differential pressure exceeds 29 900 kPa
(4337 psi), high-pressure oil flows through the relief valve to
the low-pressure side of the pump. Each propel pump has two
relief valves, one for FORWARD drive and one for REVERSE
drive. High pressure oil from the pump acts on both the inlet
ends of the high pressure valve spools and the opposite end of
the check valve. As loop pressure becomes larger than charge
oil pressure, the check valve shifts and seats to stop the flow
between the loop and the charge circuit.
The propel pumps have a charge relief valve. Charge oil

enters the pump through the charge circuit oil line. Charge
relief vale (2) is located in the pump housing. When the
charge relief valve opens, excess oil goes to the hydraulic oil
tank. The charge relief valve is NON -ADJUSTABLE. Charge
pressure is maintained by relief vale in the flushing valve. The
poppet and charge relief valve in the flushing valve determine
the system pressure. The orifice in poppet maintains 1.5 gpm
of flushing/cooling flow out of pumps. If for some reason
pressure exceeds 2825 kPa (410 psi), then relief valve opens,
otherwise it is closed and charge pressure is maintained at
1725 kPa (250 psi) at the flushing valve.
11-9
TM 5-3895-382-24
Pump Servo Valves

(1) Lever. (2) Piston. (3) Swashplate neutral adjusting screw.
(4) Cavity. (5) Cavity.
The pump swashplate is moved by the servo piston assembly.

The servo piston is a double-acting piston that is a part of the
propel pump. The swashplate is connected to the center of the
piton with lever (1).
The control valve is manual displacement controlled. The
valve controls the flow of charge oil to the servo piston
assembly.
When the propel lever is in the NEUTRAL position, the control
valve is spring centered. Charge oil is blocked by the valve
spool and both ends of the servo piston assembly are vented
to the hydraulic oil tank. Piston (2) is held in the center
position by adjusting screw (3) and a spring. The pump
swashplate will remain at zero angle and there is no oil flow
from the pump.
When the propel lever is in the FORWARD or REVERSE
position, the control valve is shifted. The oil shifts the servo to
put the pump on stroke. The manual displacement control
spool has a return spring located externally of the pump.
11-10
TM 5-3895-382-24
Drum Propel Motor
Components Of Dram Propel Motor.

(1) Port plate. (2) Piston. (3) Retainer ring. (4) Output shaft. (5) Cylinder block. (6) Spring. (7) Servo piston assembly. (8) Swashplate.
The drum propel motor is a bi-directional, variable

displacement piston motor. The motor uses a two position
servo control to provide two travel speeds.
Cylinder block (5) is splined to output shaft (4). The end of

cylinder (5) and port plate (1) are high pressure, metal-tometal, seal surfaces. Retaining ring (3) is in a groove in the
bore of the cylinder. The force of spring (6) between retainer
ring (3) and the retainer holds the cylinder tight against port
plate (1) and holds the port plate against the motor housing.
Spring pressure also holds the slipper end of pistons (2)
against swashplate (8). There are seven pistons in the motor.
The hydraulic oil in the main circuit of the propel system flows
in a continuous closed loop from the propel pump. The
direction of the hydraulic oil flow in the circuit, and direction the
motor turns, is determined by the direction the pump
swashplate is tilted from the neutral position (FORWARD or
REVERSE operation). The speed of the motor, in each of two
positions, is determined by the volume of hydraulic oil supplied
by the pump.
The swashplate is connected by a pin to servo piston assembly

(7) and does not rotate. The two-position servo piston
assembly controls swashplate angle. This motor operates
either at maximum displacement (low speed) or at minimum
displacement (high speed).
11-11
TM 5-3895-382-24
Charge pressure on the low pressure side of the closed circuit
loop is routed through the motor flush valve to the motor case.
Oil from the motor flush valve enters the motor case through
case drain outlet (12). Oil circulated through the motor case
serves to cool and flush the motor.
Drum Motor Servo Control.

(7) Servo piston assembly. (8) Swashplate. (15) Spring. (16) Pin.
(17) Servo pressure port. (18) End cap.
The motor uses servo piston assembly (7) to change the

operating angle of swashplate (8). The assembly is controlled
by the pump charge pressure through the speed shift control
valve. The speed shift switch is located on the main console.
The piston is connected to the swashplate by pin (16). Servo
pressure port (17) is located in end cap (18). When the speed
shift switch is in the HIGH position, the control valve opens.
Change oil pressure at the servo pressure port acts on the
piston and overcomes the force of spring (15). The piston
moves and causes the swashplate to rotate. In this position
the swashplate is at the minimum angle. At minimum angle,
the motor pistons have minimum stroke (displacement) and
can produce high speeds.
Drum Propel.
(11) Brake line. (12) Case drain outlet. (13) Closed circuit loop line.
(14) Closed circuit loop line.
High pressure oil enters the motor through closed circuit loop
line (13). Oil flows through port plate (1) to piston (2) in
cylinder block (5). The force of the oil pushes the piston
against swashplate (8). The piston reacts by trying to reach
maximum outward stroke. Since the swashplate is at an angle,
the piston starts to move along the swashplate. This
movement causes the cylinder and output shaft (4) to rotate.
When the switch is in the LOW position, the control valve

closes and oil pressure to the servo pressure port is open to
tank. Spring (15) pushes piston servo assembly (7) and
causes swashplate (8) to rotate. The spring holds the piston
and swashplate at the maximum angle. At maximum angle,
the motor pistons have maximum stroke (displacement) and
can produce low speeds.
As the cylinder and output shaft continue to rotate, the piston

moves around the angled swashplate and piston stroke starts
to decrease. Oil is forced through the opposite side of port
plate (1) to low pressure closed circuit loop line (14).
NOTE: Closed circuit loop line (14) is called a low
pressure loop line, and dosed circuit loop line (13)
is called a high pressure loop line in this example.
Moving the pump swashplate overcenter in the
opposite direction causes a change in the
direction of flow in the pump and motor closed
circuit loop (FORWARD or REVERSE operation).
Closed circuit loop line (14) becomes high
pressure and closed circuit loop line (13)
becomes low pressure. A change in the direction
of flow in the closed loop circuit causes a change
in motor direction of rotation.
11-12
TM 5-3895-382-24
Motor Flush Valve
Motor Flush Valve.

(A) Closed loop circuit port. (B) Closed loop circuit port.
(C) Flush port.
Drum Propel Motor.

(1) Relief valve. (2) Crossover shuttle check valve.
The motor flush valve is located in the drum motor of the

propel closed loop circuit. Lines (A) -(A) and (B) -(B) represent
both sides of the closed loop circuit. The direction of tilt of the
pump swashplate, either FORWARD or REVERSE operation,
determines direction of flow in the loop. Direction of flow in the
loop determines whether a line is high pressure or low
pressure.
Pilot pressure on the high pressure side shifts spring centered
crossover shuffle check valve (2). The low pressure side
opens to relief valve (1). The relief valve in the flushing valve
is set at 1724 kPa (200 psi). Because the relief valve is set at
a lower pressure, charge pressure oil crosses the relief valve.
Oil flows through flush port (C) to the motor case. This oil
cools and flushes the motor and pump.
11-13
TM 5-3895-382-24
Axle Propel Motor
Components Of Axle Propel Motor.

(1) Cylinder block. (2) Pin. (3) Piston. (4) Servo piston assembly. (5) Port plate. (6) Retainer ring. (7) Spring. (8) Retainer. (9) Swashplate
(10) Output shaft.
The axle propel motor is a bi-directional, variable displacement

piston motor. The motor uses a two position servo control to
provide two travel speeds.
Cylinder block (1) is splined to output shaft (10). The end of

cylinder (1) and port plate (5) are high pressure, metal-tometal, seal surfaces. Retaining ring (6) is in a groove in the
bore of cylinder (1). Retainer (8) is against the ends of pins
(2). The force of spring (7), between retaining ring (6) and
retainer (8), holds the cylinder tight against port plate (5) and
holds the port plate against the motor housing. Spring
pressure also holds the slipper end of pistons (3) against
swashplate (9). There are seven pistons in the motor.
The hydraulic oil in the main circuit of the propel system flows
in a continuous closed loop from the propel pump. The
direction of the hydraulic oil flow in the circuit, and direction the
motor turns, is determined by the direction the pump
swashplate is tilted from the neutral position (FORWARD or
REVERSE operation). The speed of the motor, in each of two
positions, is determined by the volume of hydraulic oil supplied
by the pump.
Swashplate (9) is connected by a pin to servo piston assembly

(4) and does not rotate. The two-position servo piston
assembly controls swashplate angle. This motor operates
either at maximum displacement (low speed) or at minimum
displacement (high speed).
11-14
TM 5-3895-382-24
Axle Motor Servo Control.

(4) Servo piston assembly. (9) Swashplate. (15) Spring. (16) Pin.
(17) Servo pressure port. (18) End cap.
Axle Propel.
(11) Case drain outlet (12) Closed circuit loop line. (13) Closed circuit
loop line. (14) Servo pressure port.
The motor uses servo piston assembly (4) to change the

operating angle of swashplate (9). The assembly is controlled
by the pump charge pressure through the speed shift control
valve. The speed shift switch is located on the main console.
High pressure oil enters the motor through closed circuit loop
line (12). Oil flows through port plate (5) to piston (3) in
cylinder block (1). The force of the oil pushes the piston
against swashplate (9). The piston reacts by trying to reach
maximum outward stroke. Since the swashplate is at an angle,
the piston will start to move along the swashplate. This
movement causes the cylinder, and output shaft (10), to rotate.
The piston is connected to the swashplate by pin (16). Servo

pressure port (17) is located in end cap (18). When the speed
shift switch is in the HIGH position, the control valve opens.
Charge oil pressure at the servo pressure port acts on the
piston and overcomes the force of spring (15). The piston
moves and causes the swashplate to rotate. In this position
the swashplate is at the minimum angle. At minimum angle,
the motor pistons have minimum stroke (displacement) and
can produce high speeds.
As the cylinder and output shaft continue to rotate, the piston

moves around the angled swashplate and piston stroke starts
to decrease. Oil is forced through the opposite side of port
plate (5) to low pressure closed circuit loop line (13).
NOTE: Closed circuit loop line (13) is called a low
pressure loop line, and closed circuit loop line
(12) is called a high pressure loop line. Moving
the pump swashplate over-center in the opposite
direction causes a change in the direction of flow
in the pump and motor closed circuit loop
(FORWARD or REVERSE operation).
Closed
circuit loop line (13) becomes high pressure and
closed circuit loop line (12) becomes low
pressure. A change in the direction of flow in the
closed loop circuit will cause a change in motor
direction of rotation.
When the switch is in the LOW position, the control valve

closes and oil pressure to the servo pressure pod is open to
tank. Spring (15) pushes piston assembly (4) and causes
swashplate (9) to rotate. The spring holds the piston and
swashplate at the maximum angle. At maximum angle, the
motor pistons have maximum stroke (displacement) and can
produce low speeds.
Charge pressure on the low pressure side of the closed circuit

loop is routed through the motor flush valve to the motor case.
Oil from the motor flush valve enters the motor case through
the drain line. Oil circulated through the motor case serves to
cool and flush the motor.
11-15
TM 5-3895-382-24
Charge Filter
Motor Flush Valve
Motor Flush Valve.

(A) Closed loop circuit port. (B) Closed loop circuit port.
(C) Flush port.
Charge Filter.
(1) Inlet port. (2) Outlet port. (3) Element.
Before being used in the two propel loops, charge oil passes
through the charge filter. During normal operation, charge oil
comes from the steering pump, enters the filter at inlet port (1),
and passes through the element (3). The element traps any
debris that is in the oil. Oil then exits the filter through outlet
port (2), and is routed to the propel pumps.
If the element becomes clogged with debris, the restriction to
the flow of oil causes a pressure increase outside the element.
If the pressure differential across the element reaches 350 kPa
(50 psi), the pressure of the oil causes the bypass valve to
shift. Charge oil passes directly through the bypass valve and
exits the filter through the outlet port to the thermal bypass
valve.
Axle Propel Motor.
(1) Relief valve. (2) Crossover shuttle check valve.
The filter has a manual indicator to show the oil is taking the
bypass route and an audible alarm sounds at 1205 kPa (175
psi) for low charge pressure.
The motor flush valve is located in the axle motor of the propel
closed loop circuit. Lines (A) -(A) and (B) -(B) represent both
sides of the closed loop circuit. The direction of tilt of the pump
swashplate, either FORWARD or REVERSE operation,
determines direction of flow in the loop. Direction of flow in the
loop determines whether a line is high pressure or low
pressure.
Correct maintenance must be used to make sure that the filter

element does not become clogged, stopping the flow of clean
oil to the propel system.
Pilot pressure on the high pressure side shifts spring centered

crossover shuttle check valve (2). The low pressure side
opens to relief valve (1). The relief valve is set at 1724 kPa
(200 psi). The charge relief valve in the flushing vale is set at
1724 kPa (200 psi). Because the relief valve is set at a lower
pressure, charge pressure oil crosses the relief valve. Oil
flows through flush port (C) to the motor case. This oil cools
and flushes the motor and pump.
11-16
TM 5-3895-382-24
Propel Brake Interlock Valve
Thermal Bypass Valve Group
Propel Brake Interlock Valve.

(1) Propel brake interlock vale.
Propel brake interlock valve (1) prevents the operator from

propelling the machine while the parking brake is applied. The
valve prevents the pump swashplate from moving out of
neutral when the parking brake is applied.
Thermal Bypass Valve Group.

(1) Cooler port. (2) Thermostat. (3) Inlet port. (4) Passage.
The bypass valve group directs returning hydraulic oil flow from
the drive motors to either the hydraulic oil cooler or tank.
When the temperature of the hydraulic oil reaches 71 C
(160F), thermostat (2) begins to open and the hydraulic oil
has a split flow to the oil cooler and tank. When the hydraulic
oil temperature to inlet (3) is over 85C (185F), the thermostat
fully opens and the hydraulic oil goes through cooler port (1) to
the oil cooler. When the return oil pressure, in the bypass
valve group, reaches 345 kPa (50 psi) bypass relief valve will
open and allow the return oil to go directly to the hydraulic oil
tank.
The valve has a solenoid on one end to move the valve spool.
When the parking brake button is in the RELEASE or OFF
position, the valve spool shifts to block the lines between the
servo pistons. Charge oil can now be directed by the servo
valve to one end of the servo piston to move the swashplate
from neutral.
When the parking brake is in the ON position, the valve spool
connects both sides of the servo piston. This equalizes the
pressure between both servo pistons and prevents the servos
from moving. The oil from the servo piston is open to case
drain and goes back through the control valve.
11-17
TM 5-3895-382-24
Speed Shift Control Valve
Parking Brake and Speed Shift

Control Valve
Speed shift control valve (6) is a solenoid operated, two

position valve that controls the operation of the speed shift
mechanism in the drum and axle propel motors.
When speed selection switch (1) is in the LOW speed position,
speed shift solenoid (4) is not energized. The control vale in
this position allows oil from the shift valves and the motors to
go to the thermal bypass valve. The motors are now in the
maximum displacement position (LOW speed).
When the speed selection switch is in the HIGH speed
position, speed shift solenoid (4) is energized. The speed shift
control valve in this position allows unfiltered charge oil from
the steering pump to go to the shift valves in the motors. The
motors are now in the minimum displacement position (HIGH
speed).
Operator Console.
(1) Sped selection switch. (2) Parking brake button.
Parking Brake And Speed Shift Control Valve.

(3) Parking brake solenoid. (4) Speed shift solenoid. (5) Parking
brake valve. (6) Speed shift control valve.
Parking Brake Valve

Parking brake valve (5) is a solenoid operated, two position
valve that controls the operation of the brake in the drum drive
motor.
When parking brake button (2) is pushed in (parking brake
applied), parking brake solenoid (3) is not energized. The
valve in this position allows the oil from the brake release
piston to drain through the thermal bypass valve and on to the
tank and the brake springs will apply the parking brake.
When the button is pulled out (parking brake released), parking
brake solenoid (3) is energized. The parking brake valve in
this position allows unfiltered charge oil to go to the piston of
the brake and will release the parking brake.
11-18
TM 5-3895-382-24
Axle Assembly
Axle Assembly.
(1) Wheel planetades. (2) Carrier. (3) Wheel planetaries. (4) End reduction case.
The axle assembly receives power from the axle propel motor.
Axle components provide speed reductions and torque
increases, then transmit power to the rear wheels to drive the
machine.
End reduction case (4) receives power from the motor. The
case provides a speed reduction and torque increase, and
sends this power to carrier (2).
The carrier provides the second speed reduction and torque
increase. The carrier contains a no-spin differential and sends
power through the no-spin differential to the wheel planetaries
(1) and (3).
The wheels are attached to the end assemblies. The end
assemblies provide the final speed reduction and torque
increase, driving the wheels and propelling the machine.
The following sections provide additional information on the
end reduction case, carrier, no-spin differential, and wheel
planetaries.
11-19
TM 5-3895-382-24
End Reduction Case
End Reduction Case.

(1) Case. (2) Input gear. (3) Cover. (4) Output gear.
The end reduction case provides a mechanical connection

between the axle propel motor and the carrier. The case also
provides a gear reduction, so the output rpm is less than the
input rpm from the motor.
The motor is mounted to cover (3). The splined output shaft of
the motor meshes with the internal splines of input gear (2).
The teeth of the input gear mesh with the teeth of output gear
(4). Case (1) is mounted directly to the carrier. Output gear
(4) has internal splines which provide the connection to the
carrier pinion shaft.
When the motor is operating, input gear (2) transfers power to
output gear (4). The output gear is larger than the input gear,
providing a reduction in output rpm to the carrier.
11-20
TM 5-3895-382-24
Carrier
Carrier.
(1) Ring gear. (2) Case. (3) Pinion shaft. (4) No-spin differential.
The carrier receives power from the end reduction case, and
provides a speed reduction and a torque increase. The carrier
transfers this power through no-spin differential (4) to the end
assemblies.
Power from the end reduction case turns pinion shaft (3). The
shaft causes ring gear (1) to rotate at a slower speed than the
shaft. The ring gear causes the attached case and differential
to rotate at the same speed as the ring gear. The differential
provides power to the two assemblies.
Pinion shaft (3) is connected by splines to the output gear in

end reduction case. The beveled teeth of the pinion shaft are
engaged with ring gear (1). Ring gear is secured to case (2).
The no-spin differential assembly is held inside the case by the
spider par of the differential.
11-21
TM 5-3895-382-24
No-Spin Differential
No-Spin Differential (Left Side Disassembled).

(1) Side gear. (2) Driven clutch. (3) Spring. (4) Holdout ring. (9)
Spring retainer. (11) Center cam. (12) Snap ring. (13) Spider.
The differential is the same on one side of the spider as it is on

the other side. The differential has two springs (3) and (6), two
side gears (1) and (8), two driven clutches (2) and (7), two
holdout rings (4) and (5), one center cam (11), one snap ring
(12), and one spider (13).
No-Spin Differential (Assembled).

(1) Side gear. (2) Driven clutch. (3) Spring. (4) Holdout ring. (5)
Holdout ring. (6) Spring. (7) Driven clutch. (8) Side gear. (9) Spring
retainer. (10) Spring retainer. (11) Center cam. (12) Snap ring. (13)
Spider.
Spider (13) is fastened to the carrier case and turns at the

speed of the ring gear. The spider has clutch teeth on both
sides. Spider also has one long tooth called the spider key
(15). Center cam (11 ) fits inside the spider and is held in
position by snap ring (12). Cam is turned by the spider key
which fits inside notch (14).
The no-spin differential allows the axle to send different

torques to each rear wheel. When the speeds of the wheels
are the same, the no-spin differential can send the same
amount of torque to each wheel. When the speeds of the
wheels are different (when the machine is turning) the no-spin
differential sends the torque to the wheel that turns sower, If
one wheel loses traction on ice or mud, both wheels turn at the
same speed, but the spinning wheel will have less torque.
11-22
TM 5-3895-382-24
Driven clutches (2) and (7) are identical. Each clutch has a
cam (17) which is part of the clutch. The tooth on the cam
engage with the teeth of center cam (11). The teeth of the
driven clutch engage with the clutch teeth on spider (13).
The holdout ring (4) sits in the driven clutch, in the groove
between the teeth of the driven clutch and the teeth of the cam.
The teeth of the holdout ring engage with the notches in the
center cam. Notch (16) in the holdout ring engages with spider
key (15). The spider key controls the movement of the holdout
ring in relation to the spider. There is no connection between
the holdout ring and the driven clutch except friction.
Springs (3) and (6) fit between the side gears and spring
retainers (9) and (10). The outside splines of the spring
retainers are connected to the inside splines of the driven
clutches. The force of the springs holds the driven clutches
against spider (13) and the side gears against the differential
case.
The outside splines of side gears (1) and (8) are connected to
the inside splines of driven clutches (2) and (7). The inside
splines of the side gears are connected to the axle shafts of
the wheel end assemblies.
Spider and Center Cam.

(11) Center cam. (13) Spider. (14) Notch In center cam.
(15) Spider key.
Clutch and Holdout Ring.

(2) Driven clutch. (4) Holdout ring. (16) Notch In holdout ring.
(17) Cam.
11-23
TM 5-3895-382-24
Operation of No-Spin Differential
Operation While Turning
Straight Operation.
(1) Side gear. (2) Driven clutch. (7) Driven clutch. (8) Side gear.
(13) Spider. (18) Teeth of the spider. (19) Teeth of the driven
clutches.
Operation While Turning.
(1) Side gear. (2) Driven clutch. (7) Driven clutch. (8) Side gear.
(13) Spider.
When the machine drives straight forward (or backward) on

solid ground, both wheels provide tractive effort in moving the
machine. Teeth (18) on both sides of the spider (13) are fully
engaged with teeth (19) of driven clutches (2) and (7). The
teeth of cams (17) engage with teeth of center cam (11).
When the machine enters into a turn, the travel of the outside
wheel is further than the travel of the inside wheel. The
traction of the road forces the outside wheel to turn faster than
the speed of the ring gear. This movement of one wheel
turning faster than the other wheel starts the "clutch action" of
the no-spin differential.
In this fully engaged condition, spider (13) turns both driven

clutches and side gears at the same speed as the ring gear.
The two side gears provide power to the axle shafts of the
wheel end assembles.
The faster wheel causes side gear (1), and driven clutch (2) to
turn faster than the ring gear. The teeth of center cam (11)
work like ramps and the teeth of cam (17) move up the teeth of
the center cam.
This action causes the driven clutch to become disengaged
with the spider. The driven clutch pulls holdout ring (4) out of
the grooves in the center cam. The friction between the
holdout ring and driven clutch turns the holdout ring until notch
(16) in the holdout ring engages with spider key (15).
11-24
TM 5-3895-382-24
The holdout ring is now turned by the spider key at the speed
of the ring gear. The tooth of the holdout ring is in a position
so they can not engage the notches in the center cam. The
driven clutch and cam moves around the holdout ring at a
speed faster than the ring gear. The holdout ring keeps the
driven clutch and cam from engaging with the center cam and
spider. The driven clutch, cam, drive axle, and wheel now turn
freely.
Wheel Planetaries
On the opposite side of the spider, driven clutch (7) and side
gear (8) are fully engaged with the spider. The teeth of the
spider send the drive force to this engaged driven clutch and
side gear. This provides the driving force of the machine to the
inside wheel.
When the turn is finished, the speed of the disengaged wheel
slows to nearly the speed of the ring gear. The resistance of
the ground to the wheel causes the torque on this wheel to be
in a small reverse direction. This causes the driven clutch and
cam to turn in a direction opposite the direction of the ring
gear.
Wheel planetaries.
(1) Spider. (2) Ring gear. (3) Hub assembly. (4) Planet pins.
(5) Planet spur gear. (6) Sun gear.
The friction between the holdout ring and the driven clutch
causes the holdout ring to move in a direction opposite the
direction of the ring gear. The notch in the holdout ring moves
away from the spider key. When the teeth of the holdout ring
are in a position to engage the notches in the center cam, the
force of the spring pushes the driven clutch and cam to the
inside. The driven clutch pushes the holdout ring.
The wheel planetaries are a reduction of the spur gearing built

into the wheel hubs. The spur teeth of sun gear (6), which
floats, mesh with teeth of planet spur gears (5). The planet
spur gears rotate on planet pins (4) which are mounted in
spider (1). The planet spur gear teeth in turn mesh with teeth
of the floating ring gear (2).
Power is transmitted by the carrier to the axle shafts and the
sun gear of the planetary reduction, through the revolving
planet gears, and into the spider which drives wheel hub
assembly (3).
The holdout ring now engages the center cam and is turned at
the speed of the ring gear. The teeth of cam (17) now engage
the center cam and the teeth of the drive clutch engage the
spider. At this time, both wheels are turned at the same
speed.
11-25
TM 5-3895-382-24
Propel Brake Interlock
(Electrical Schematic)
Propel Brake Interlock Electrical Schematic.

(1) Start relay. (2) Main relay. (3) Parking brake fuse. (4) Wire to starter. (5) Neutral start relay #2 (NSR2). (6) Neutral start relay #1 (NSR1). (7)
Brake relay #1 (BR1). (8) Brake relay #2 (B2). (9) Parking brake switch. (10) Wire to diode and alternator indicator lamp. (11) Parking brake solenoid.
(12) Wire to engine shutdown solenoid. (13) Wire to key start fuse. (14) Front propel pump neutralizer valve. (15) Rear propel pump neutralizer valve.
(16) Neutral start switch. (17) Key start switch.
11-26
TM 5-3895-382-24
The propel brake interlock performs two functions. It prevents
the operator from propelling the machine while the parking
brake is applied and it also provides for controlled propelling
when the parking button is released.
If an operator would try to release the parking brake with the

propel control lever in the forward or reverse position, the
machine would not move. With the propel control lever not in
the neutral position, neutral start relay #2 (NSR2)(5) is not
energized. Electrical power is sent from neutral star relay #2
(NSR2)(5) to brake relay #2 (BR2)(8). Due to the electrical
logic of brake relay #2 (BR2)(8), this would continue to supply
the coils of brake relay #1 (BR1)(7) and brake relay #2
(BR2)(8) with electrical power even if parking brake switch (9)
is released. This prevents electrical power from being supplied
to parking brake solenoid (11), front propel pump neutralizer
valve (14) and rear propel pump neutralizer valve (15). This
provides a latching mechanism and prevents an operator from
propelling the machine until the propel control lever is brought
back to the neutral position. With the propel control lever in the
neutral position, the latching mechanism is eliminated and the
operator is allowed to operate and propel the machine.
The main components of the propel brake interlock are:

parking brake fuse (3), neutral start relay #2 (NSR2)(5), neutral
start relay #1 (NSR1)(6), brake relay #1 (BR1)(7), brake relay
#2 (BR2)(8), parking brake switch (9), parking brake solenoid
(11), front propel pump neutralizer valve (14), rear propel pump
neutralizer valve (15) and neutral start switch (16).
Parking brake solenoid (11), front propel pump neutralizer
valve (14) and rear propel pump neutralizer valve (15) receive
electrical power from brake relay #2 (BR2)(8). This allows
parking brake solenoid (11) to move the two-position brake
valve, sending non-filtered charge pressure oil to the parking
brake in the front propel motor. In order for this to be
accomplished, the following three conditions must be met:
First, key start switch (17) must be in the ON position. This
provides electrical power to parking brake switch (9) from main
relay (2) and parking brake fuse (3).
Second, the propel control lever must be in the neutral
position. With the propel control lever in this position, neutral
start relay #2 NSR2 (5) is energized, breaking continuity from
neutral start relay #2 (NSR2)(5) to brake relay #2 (BR2)(8).
Third, parking brake switch (9) must be released. When this is
done and with the propel control lever in the neutral position,
electrical power to the brake relay #1 (BR1)(7) and brake relay
#2 (BR2)(8) is interrupted and electrical power is supplied to
parking brake solenoid (11), front propel pump neutralizer vale
(14) and rear propel pump neutralizer vale (15).
This in turn allows both propel pumps to go on stroke when the
propel control lever is moved forward or reversed and allows
unfiltered charge pressure oil to flow to the parking brake in the
front propel motor. The charge pressure works against the
applied spring pressure, releasing the parking brake.
11-27
TM 5-3895-382-24
Propel System in Neutral Position
(1) Flushing valve. (2) Charge relief valve. (3) Line from charge filter. (4) Tandem propel pump. (5) Axle propel motor. (6) Servo control valves. (7)
Drum drive motor. (8) Brake interlock valve. (9) Unfiltered charge oil. (10) Parking brake and speed shift valve. (11) Thermal bypass valve. (12)
Hydraulic oil tank. (13) Line from charge filter relief. (14) Hydraulic oil cooler.
When the engine is running, tandem propel pump (4) and the
steering pump are rotating. The steering pump provides the
charge oil for the propel system. The maximum charge oil
pressure in neutral Is controlled by charge relief valve (2) in
flushing valve (1). The charge oil is used as make-up oil for
propel pump and motor leakage, cooling for the pump and
motors, to move the pump swashplates, to release the parking
brake and to shift motor displacement for high and low speeds.
Servo control valves (6) are connected to each other by a

linkage rod. Both control valves always move together. The
front pump supplies oil for drum drive motor (7) and the rear
pump supplies oil to axle propel motor (5).
11-28
TM 5-3895-382-24
With the propel lever (on operators console) in the NEUTRAL
position, the control valves are in the NEUTRAL position. The
spring-loaded servo-pistons hold the swashplates in the
center/neutral positions when the parking brake is ON.
Although the rotating groups are turned by the pump drive, no
high-pressure oil output is generated. With no pressure to
either side of the swashplate there is no oil flow from the
pumps.
With the parking brake button pushed in (applied), the parking
brake valve is not energized. The springs in the brake apply
the parking brake.
Charge oil opens the charge relief valve, flows through the
pump case, and exits the pump through the case drain outlet.
11-29
TM 5-3895-382-24
Forward, Low Speed With Parking Brake Off
Hydraulic oil tank. (13) Line from charge filter relief. (14) Hydraulic oil cooler. (15) Axle motor flushing valve. (16) Drum motor flushing valve.
When the parking brake button is pulled out (released), the

parking brake and interlock valves (8) are energized. The
parking brake valve shifts to the right. Charge oil goes to the
parking brake and moves the piston against the spring force
and releases the parking brake. The interlock valve shift to the
left when energized. The passage for each side of the pump
control piston is now separated and the swashplate will move
when oil is directed to one side.
When the operator moves the propel lever to the FORWARD

position, servo control valves (6) shift from the neutral position.
Filtered charge oil enters the pump at line (3). Charge oil flows
through the control valves to the servo-pistons, causing the
swashplates to rotate.
11-30
TM 5-3895-382-24
Swashplate angle is determined by how far the propel lever is
moved off center. Due to normal operating force changes, the
swashplates tend to drift from the set position. Drift is sensed
by the feedback linkage connecting the swashplates to the
control valves. This activates the control valves, supplying
pressure to the servo-pistons and maintaining the swashplates
in the set position.
As soon as the swashplates are tilted, the rotating groups
receive the charge oil. The high pressure oil in closed circuit
loop lines goes to each propel motor. The low pressure oil in
closed circuit loop lines leaves each motor and returns to the
pumps, or goes to tank through shuttle valves.
The high pressure oil closes the check valve on the high
pressure side of the closed circuit loop. The low pressure
check valve opens to allow oil from charge circuit oil to enter
low pressure closed circuit loop. This compensates for internal
leakage within the different circuit components.
The high pressure oil in the closed circuit loop moves the
shuttle valve spool inside motor flushing valves (15) and (16).
Hot low pressure oil flows from the flushing valves to the relief
motor shuttle valves. This allows fresh charge oil to enter the
low pressure side of the loop through the pump checks.
The high pressure relief valves protects the system from
sudden high pressure spikes. When the differential pressure is
above the high pressure relief valves setting, the valves route
the oil to the low pressure loop.
Oil from the case of the axle pump goes to the case of the
drum pump, and to hydraulic oil tank (12). Oil from the case of
drum drive motor and axle motor goes to thermal bypass valve
(11).
When the speed selector switch on the operator console is in
the LOW speed position, the speed shift control valve is not
energized. In this position the shift spool in each propel motor
is open to drain.
Each motor is at maximum (large)
displacement (low speed).
11-31
TM 5-3895-382-24
Reverse, High Speed With Parking Brake Off
Hydraulic oil tank. (13) Line from charge filter relief. (14) Hydraulic oil cooler. (15) Axle motor flushing valve. (16) Drum motor flushing valve
When the parking brake button is pulled out (released), parking

brake and interlock valves (8) are energized. The parking
brake valve shifts to the right. Charge oil goes to the parking
brake and moves the piston against the spring force and
releases the parking brake. The interlock valve shift to the left
when energized. The passage for each side of the pump
control piston is now separated and the swashplate will move
when oil is directed to one side.
When the operator moves the propel lever to the REVERSE

position, servo control valves (6) shift from the neutral position.
Filtered charge oil enters the pump at line (3). Charge oil flows
through the control valves to the servo-pistons, causing the
swashplates to rotate.
Swashplate angle is determined by how far the propel lever is
moved off center. Due to normal operating force changes, the
swashplates tend to drift from the set position. Drift is sensed
by the feedback linkage connecting the swashplates to the
control valves. This activates the control valves, supplying
pressure to the servo-pistons and maintaining the swashplates
in the set position.
11-32
TM 5-3895-382-24
As soon as the swashplates are tilted, the rotating groups
receive the charge oil. The high pressure oil in closed circuit
loop lines goes to each propel motor. The low pressure oil in
closed circuit loop lines leaves each motor and returns to the
pumps, or goes to tank through shuffle valves.
The high pressure oil closes the check valve on the high
pressure side of the closed circuit loop. The low pressure
check valve opens to allow oil from charge circuit oil to enter
low pressure closed circuit loop. This compensates for internal
leakage within the different circuit components.
The high pressure oil in the closed circuit loop moves the
shuttle valve spool inside motor flushing valves (15) and (16).
Hot low pressure oil flows from the flushing valves to the relief
motor shuttle valves. This allows fresh charge oil to enter the
low pressure side of the loop through the pump checks.
The high pressure relief valves protect the system from sudden
high pressure spikes. When the differential pressure is above
the high pressure relief valves setting, the valves route the oil
to the low pressure loop.
Oil from the case of the axle pump goes to the case of the
drum pump, and to hydraulic oil tank (12). Oil from the case of
drum drive motor and axle motor goes to thermal bypass valve
(11).
When the speed selector switch on the operator console is in
the HIGH speed position, the speed shift control valve is
energized. The valve spool moves to the right. In this position
the speed shift spool in each propel motor is supplied with
charge oil. Each motor is in minimum (small) displacement
(high speed).
11-33
TM 5-3895-382-24
Visual Checks
Troubleshooting
A visual inspection of the propel system and its components is

the first step when a diagnosis of a problem is made. Then
check the operation of the machine. Finally, check the system
with instruments. Stop the engine. To remove the tank filler
cap, slowly turn the filler cap until it is loose. Let the tank
pressure lower before the filler cap is removed. Make the
following inspections.
During a diagnosis of the hydraulic system, remember that

correct oil flow and pressure are necessary for correct
operation. The output of the pump (oil flow) increases with an
increase in engine speed (rpm) and decreases when engine
speed (rpm) is decreased.
Oil pressure is caused by
resistance to the flow of oil.
The 4C-4892 ORFS Fittings Group can be used to make the
pressure tests of the propel system. Before any tests are
made, visually inspect the complete hydraulic system for
leakage of oil and for parts that have damage. For some of the
tests a magnet, thermometer and a measuring rule (either for
inches or millimeters) are usable tools.
When any test is made of the system, the hydraulic oil must be
at the normal temperature for operation.
1.
Measure the oil level of the hydraulic tank.
2.
Look for air in the oil that is in the hydraulic tank. Do

this immediately after the machine is stopped. Use a
clear bottle or container to get a sample of the oil. Look
for air bubbles in the oil that is in the bottle.
Do not check for leaks with your hands. Pin hole (very
small) leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks.
Sudden movement of the machine or release of oil under

pressure can cause injury to persons on or near the
machine. To prevent possible injury, do the procedure
that follows before testing and adjusting the propel
system:
3.
Inspect all oil lines and connections for damage or

leaks. Look for oil on the ground under the machine.
4.
1.
Move the machine to a smooth horizontal location.

Move away from working machines and personnel.
Remove the hydraulic filter elements and look for

particles removed from the oil by the filter elements. A
magnet will separate ferrous particles from nonferrous
particles (port plates, O-ring seals, etc.).
2.
Permit only one operator on the machine. Keep all

other personnel either away from the machine or in view
of the operator.
a. Bronze-colored particles give an indication of pump or

motor port plate failure.
3.
Activate the parking brake.
b. Shiny steel particles give an indication of pump or

motor piston failure or motor cam deterioration.
4.
Stop the engine.
5.
Move the steering wheel to all positions to release any

pressure in the hydraulic system.
6.
Carefully loosen the filler cap on the hydraulic tank to

release any pressure in the tank.
7.
Make sure all hydraulic pressure is released before any

fitting, hose or component is loosened, tightened,
removed or adjusted.
8.
The pressure in the system has now been released and

lines or components can be removed.
c. Rubber particles give an indication of a seal or hose

failure.
d. Aluminum particles give an indication of steering
pump group failure.
Whenever foreign particles such as rubber or metal are found,
all the components of the propel, vibration, brake and steering
circuits must be flushed through. Each loop line circuit must be
independently filtered. Do not use parts that have been
damaged.
11-34
TM 5-3895-382-24
Checks During Operation
Problem: Propel system operates in forward speeds only.
The checks during operation can be used to find leakage in the

system. They can also be used to find a bad valve, pump or
motor. Travel speed can be used to check the condition of the
propel motors and the pump.
Probable Cause:
Drive the machine backwards and forwards several times.

Operate the propel controls in all speed ranges.
1.
Watch the drive drum and wheels. Starting and

stopping operations should be progressive. Drum and
wheel rotation should be smooth and regular at all
times.
2.
Check for noise from the pump and drive motors.
3.
Check for the sound of the relief valves opening. The

opening pressures of the relief valves are given in the
relief valve pressure tests located in the Testing And
Adjusting section of this module.
1.
Failure of the pump servo piston.
2.
Failure of the pump servo valve.
3.
Failure of the rocker arm section of the pump

swashplate assembly.
4.
Main relief valve damaged or incorrectly adjusted in the

reverse line of loop circuit.
5.
Propel shuttle valve spool is stuck in one position.
Problem: Propel system operates in reverse speeds only.
4.
Probable Cause:
After selecting the travel speed of the compactor, the

forward and reverse motion should be identical.
1.
Failure of the pump servo piston.
2.
Failure of the pump servo valve.
3.

4.
Main relief valve damaged or incorrectly adjusted in the

forward line of loop circuit.
Propel shuttle valve spool is stuck in one position.
Problem: Propel system engages very slowly when

making a shift.
Probable Cause to Low Charge Pressure:
1.
Low charge pressure.
5.
2.
Low oil level in the hydraulic tank.
Problem: Propel system does not disengage (zero oil flow)

when propel control lever is returned to neutral.
3.
Plugged filter element.
4.
Inadequate flow from steering pump.
5.
Plugged stroking orifices in the propel pumps.
6.
Plugged orifice out of brake shift valve.
Probable Cause:
1.
Failure of the propel pump servo piston.
2.
Failure of the propel pump servo valve.
3.

4.
Incorrect neutral adjustment of the swashplate.
5.
Incorrect linkage rod adjustment between drum and axle

pump controls.
6.
Incorrect neutral adjustment of the manual displacement

control lever.
Problem: Propel system engages very suddenly when

making a shift.
Probable Cause:
1.
Stroking orifices missing from propel pumps.
2.
Broken or weak propel pump servo valve springs.
11-35
TM 5-3895-382-24
Problem: Parking brake does not release when parking
brake button is pulled up.
Problem: External oil leaks from drum or axle propel

motors.
Probable Cause:
Probable Cause:
1.
Failure of the parking brake button.
1.
Motor case pressure is too high.
2.
Worn or damaged piston seal in the brake group.
2.
Restriction in the oil return line to hydraulic tank.
3.
Failure of the parking brake valve.
3.
Faulty thermal bypass valve.
4.
Fault in the electric circuit.
4.
5.
Failure of neutral start switch.
Seals damaged due to pressure peaks, use of

unapproved hydraulic oil which is not compatible with
the seal material or incorrect tightening torque values.
6.
Failure of neutral start relay.
Problem: Propel system oil overheats.
7.
Failure of brake relay.
Probable Cause:
8.
Steering pump relief valve damaged or incorrectly

adjusted.
1.
Incorrect type of oil used in the hydraulic circuit.
2.
The oil cooler is internally restricted.
9.
Failure of the steering pump.

3.
The oil cooler is externally restricted.
4.
Excessive internal leakage in circuit which causes low

charge line pressure.
5.
Thermal bypass valve is not shifting to allow hot oil to

flow through the oil cooler.
6.
Operating pressures exceeding relief pressures due to

mechanical problems.
Problem: Parking brake does not engage when the parking

brake button is pushed down.
Probable Cause:
1.
Failure of the parking brake button.
2.
Failure of brake relay.
3.
Worn brake discs.
4.
Failure of the parking brake valve.
5.
Fault in the electric circuit.
Problem: Main relief valve pressures are not correct.

Probable Cause:
1.
2.
The shuttle or relief valves in the flushing valve stuck.
3.
Internal damage to front gear reducer or rear propel

motor.
4.
Damage to end reduction case, carrier, or wheel

assemblies.
5.
Damage to drum support assembly on vibratory side of

drum.
Problem: Noisy drum drive motor.

Probable Cause:
1.
If the motor gives off a regular humming noise, the shaft

bearings are bad.
2.
If there is excessive vibration, the retaining bolts are

loose.
3.
If the motor gives off noise (banging sounds), the

charge pressure from the steering pump is too low.
11-36
TM 5-3895-382-24
If the test bench cannot be run at 6900 kPa (1000 psi) and at
full pump rpm, run the pump shaft at 1000 rpm. Measure the
pump flow at 2100 kPa (300 psi) and at 6900 kPa (1000 psi).
Use these values in the top part of Formula II. For the bottom
part of the formula, run the pump shaft at 2000 rpm. Measure
the pump flow at 2100 kPa (300 psi).
System Tests and Adjustments

Pump Efficiency Check
For any pump test at a given rpm, the pump flow at 2100 kPa
(300 psi) will be larger than the pump flow at 6900 kPa
(1000 psi). The difference between the pump flow of the two
operating pressures is the flow loss.
Formula II:
Method of finding flow loss:

Pump flow at 300 psi ................................... 57.5 gpm (liter/min) *
Pump flow at 1000 psi ................................-52.0 gpm (liter/min) *
Flow loss .......................................................... 5.5 gpm (liter/min) *
Travel Speed Test
Flow loss when expressed as a percent of pump flow is used

as a measure of pump performance.
NOTE: The machine must be in high speed range for this

test.
Example of finding percent of flow loss:
The oil in the system must be SAE 10W hydraulic oil. The oil
temperature must be at 38C (100F) to get correct results. All
speed tests are made with the engine rpm at maximum rpm.
gpm flow loss

Pump flow @ 300 psi
or
*5.5
*57.5
X 100 =
X 100 =
gpm @ 300 psi -gpm @ 1000 psi

gpm @ 300 psi @ 2000 rpm
Percent of
flow loss
NOTE: The machine must be at top speed through the

entire timing trap.
If the percent of flow loss is more than 10%, pump

performance is not good enough.
Travel speeds that are the same as those that follow are an
indication that the circuit operation is normal. The relief valves
for both charge pump and main line closed circuit must be
tested to be sure that the opening pressure of each is correct.
* The numbers in the examples are for illustration and are not
values for any specific pump or pump condition.
See
Specifications for pump flow of a new pump at 2100 kPa
(300 psi) and 6900 kPa (1000 psi).
Maximum travel time ....................................................10 seconds
Machine Test
Minimum travel speed:

Forward motion .......................................11 km/h (600 ft/min)
Reverse motion ......................................11 km/h (600 ft/min)
Install a Flow Meter. For Formula I, measure pump flow at

2100 kPa (300 psi) and at 6900 kPa (1000 psi) with the engine
at high idle rpm.
Times for forward and reverse through the 30.5 m

(100 ft) timing trap must match within one second.
Formula I:
X 100=
Percent of
flow loss
Time the machine in forward and reverse through a

30.5 m (100 ft) timing trap. The vibration system must be off.
9.5%
gpm @ 300 psi -gpm @ 1000 psi

gpm @ 100 psi
X 100 =
If the travel speed is not correct, check the following:
Percent of
flow loss
Bench Test
If the test bench can be run at 6900 kPa (1000 psi) and at full
pump rpm, find the percent of flow loss using Formula I.
11-37
1.
Pump efficiency.
2.
Setting of the charge system relief valve.
3.
Setting of the main line closed circuit relief valves.
4.
Make sure the machine is in high speed range.
5.
Make sure the linkage rod between the drum and axle
pumps is adjusted correctly.
6.
Check axle propel motor

displacement adjustment.
for
correct
minimum
TM 5-3895-382-24
Pressure Test Tools
2.
Engage the parking brake. Put the propel control lever

in the STOP position. Start and run the engine at high
idle until the hydraulic oil temperature reaches 38C
(100F). Engine rpm should be 2350 50 rpm.
3.
With the propel system in neutral and the vibratory

system off, record the pressure on the gauge connected
to the test port. The charge relief valve setting should
be 1725 69 kPa (250 10 psi).
4.
Charge pressure is determined by pump speed

(steering output), internal leakage of the closed loops,
orifices in the charge reliefs (one vibratory and one
propel) and open centered flushing valve. If the orifices
are ok, the valve must be adjusted. Stop the engine
and proceed to Step 5. If the charge relief valve
pressure is correct, remove all tooling and connect all
hoses.
5.
Install a tachometer on the engine to measure engine

speed. Check to be sure the hydraulic oil temperature
reaches 38C (100F).
6.
Loosen locknut (4). Use an allen wrench to turn

adjustment screw (3) clockwise to increase the pressure
or counterclockwise to decrease the pressure. After the
relief valve pressure is adjusted correctly, use an allen
wrench to hold the adjustment screw and tighten the
locknut to a torque of 16 Nm (12 lb-ft).
7.
Verify the charge relief valve pressure. When the

pressure is correct, remove the pressure gauge from the
test port.
Tools Needed
4C-4892
Fittings Group
Use the above fittings group for all of the pressure tests that
follow. In some procedures, more than one of the same
pressure gauge is required. It may be necessary to use two
pressure gauge kits.
Flushing Valve Charge Relief Valve Pressure Test
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
NOTE: The procedure described in this test will measure

charge pressure when the propel control lever is
in the STOP position and the vibration system is
off.
This charge pressure is measured and
recorded at the flushing valve.
Flushing valve
(1) Charge pressure test port (2) Charge relief valve. (3) Adjustment
screw. (4) Locknut.
1.
Connect a 0 to 4000 kPa (580 psi) pressure gauge to

charge pressure test port (1) on the flushing valve.
11-38
TM 5-3895-382-24
Forward Drive
Tools Needed
4C-4892
Fittings Group
NOTE: Do not run the machine against the brake for

more than five seconds.
Refer to the WARNING

Troubleshooting.
on
the
first
page
of
Flushing Valve Pressure Test

(2) Drum forward test port. (3) Axle forward test port.
NOTE: Do the Propel Charge Relief Valve Pressure Test

before doing the main relief valve test.
1.
Make sure that the parking brake is applied. Make sure

the propel control lever is in neutral.
3.
Connect two 60 000 kPa (9000 psi) pressure gauges

from the 4C4892 ORFS Fittings Group to test ports (2)
and (3).
4.
Start the engine and run at high idle.
5.
Move the speed selection switch to the HIGH speed

position.
6.
Release the parking brake.
7.
Slowly move the propel control lever in the forward

direction. Look at the pressure gauge on test port (2)
and record the relief valve pressure of the drum pump in
forward direction. Look at the pressure gauge on test
port (3) and record the relief valve pressure of the axle
pump in forward direction. The relief valve pressure of
both the pumps should be 29 900 kPa (4337 psi).
8.
If the relief valve pressures are not correct, check the

following: low charge pressure, shuttle or relief valves in
the flushing valve stuck, internal damage to front gear
reducer or rear propel motor, damage to end reduction
case, carrier, or wheel assemblies, damage to drum
support assembly on vibratory side of drum or swap
cartridges with each other to check if one is stuck open.
If cartridge is bad it will need to be replaced. Move the
control lever back to neutral. Stop the engine.
9.
Remove the relief valve and install a new valve. Tighten

to a torque of 136 to 163 Nm (100 to 120 lb-ft).
10.
Repeat Steps 4, 5, 6, and 7 to recheck the pressure

reading.
11.
When the correct relief valve pressure is obtained, move

the control lever to the NEUTRAL position. Stop the
engine.
12.
Remove the pressure gauges from test ports (2) and

(3). Reconnect the brake wire connector.
Parking Brake Valve

(1) Brake wire connector.
2.
Disconnect brake wire connector (1). This allows the

parking brake to stay applied during the test.
11-39
TM 5-3895-382-24
Reverse Drive
Tools Needed
4C-4892
Fittings Group


Troubleshooting.
on
the
first
page
of
NOTE: Do the Propel Charge Relief Valve Pressure Test

before doing the main relief valve test.
Flushing Valve Pressure Test

(4) Axle reverse test port. (5) Drum reverse test port.
1.
3.
Make sure that the parking brake is applied. Make sure

the propel control lever is in neutral.
4.
5.
6.
7.
8.
Parking Brake Valve

2.
Disconnect brake wire connector (1). This allows the

9.
10.
11.
12.
11-40
Connect two 60 000 kPa (9000 psi) pressure gauges

from the 4C4892 ORFS Fittings Group to test ports (4)
and (5).
Start the engine and run at high idle.
position.
Release the parking brake.
Slowly move the propel control lever in the forward
direction. Look at the pressure gauge on test port (5)
and record the relief valve pressure of the drum pump in
reverse direction. Look at the pressure gauge on test
port (4) and record the relief valve pressure of the axle
pump in reverse direction. The relief valve pressure of
both the pumps should be 31 715 to 35 163 kPa
(4600 to 5100 psi).
If the relief valve pressures are not correct, check the
following: low charge pressure, shuttle or relief valves in
the flushing valve stuck, internal damage to front gear
reducer or rear propel motor, damage to end reduction
case, carrier, or wheel assemblies, damage to drum
support assembly on vibratory side of drum or swap
cartridges with each other to check if one is stuck open.
If cartridge is bad it will need to be replaced. Move the
control lever back to neutral. Stop the engine.
Remove the relief valve and install a new valve. Tighten
to a torque of 136 to 163 Nm (100 to 120 lb-ft).
Repeat Steps 4, 5, 6, and 7 to recheck the pressure
reading.
When the correct relief valve pressure is obtained, move
the control lever to the NEUTRAL position. Stop the
engine.
Remove the pressure gauges from test ports (4) and
(5). Reconnect the brake wire connector.
TM 5-3895-382-24
NOTE: If the differential pressure does not increase,
check the following:
Servo Pressure Check
a. Charge pressure inadequate to fully stroke the pump.

Troubleshooting.
on
the
first
page
of
b. Servo pressure leakage (past the servo piston).

6.
Front Propulsion Pump

(1) Front propel pump. (2) Servo pos.
1.
After stopping the machine, apply the parking brake.
2.
Remove and plug the two hoses from servo ports (2)
that connect to the brake interlock valve. Install two
4000 kPa (580 psi) gauges in the servo ports.
3.
Start the machine and operate at high idle. Release the

parking brake.
4.
Observe the pressure on both gauges with the control

lever in neutral. The differential pressure between the
two gauges should be within 69 kPa (10 psi) of each
other.
NOTE: If the differential pressured is greater than 69 kPa

(10 psi), proceed to the procedure "Manual
Displacement Control Neutral Adjustment".
5.
Gradually move the control lever forward.

The
differential pressure between gauges installed in servo
port (2) should increase in proportion to output system
pressure. As an example, you have an output system
pressure of 6890 kPa (1000 psi) requiring a differential
pressure of 482 kPa (70 psi) or an output system
pressure of 60 000 kPa (5000 psi) will require a
differential pressure of 1240 kPa (180 psi). The position
of the control lever determines the swashplate angle.
11-41
Remove the pressure gauges from servo ports (2) and

install the hoses back to the brake interlock valve.
TM 5-3895-382-24
Propel Control Linkage Adjustment
Manual Displacement Control Neutral Adjustment
Make reference to WARNING on first page of Testing and

Adjusting.
Machine can lurch in either direction if the machine is not

properly raised off the ground and supported (wheels and
drum off the ground completely) during the adjustment.
Personal injury or death can result. Be sure the area is
clear of all personnel and equipment while testing and
adjusting.
Tools Needed
8S-7640
8S-7611
8S-7615
8S-8048
Stand
Tube
Pin
Saddle
A
4
4
4
4
Propel Control Linkage Adjustment

(1) Bracket. (2) Bolts. (3) Propel cable.
1.
Place propel control lever at operator console in the

NEUTRAL position.
2.
Loosen two bolts (2) in bracket (1) that propel cable (3)
is attached to on the axle pump.
3.
Move the bracket till the ball of the neutral start switch is
engaged in 1.5 mm (.06 in). Adjustment of the tie rod is
required so both pumps remain in neutral. Tighten the
two bolts.
4.
Start the engine. Move the propel handle forward and

when machine starts moving, shut the key switch off.
Now try starting the engine again. If adjustment is
properly made, the machine should not start until the
handle is returned to the neutral position.
5.
The operation works the same with the propel handle in

the reverse direction.
NOTE: Place machine on jack stands, supporting the
machine at four points, one stand supporting
each side of the frame at the rear of the machine,
and one jack stand supporting each side of the
yoke at the front of the machine. Use tooling (A)
to support both the rear and the yoke of the
machine.
11-42
TM 5-3895-382-24
Swashplate Neutral Adjustment Procedure
Axle Propel Pump
Make reference
Troubleshooting.
1.
to
WARNING
on
first
page
of
Make sure the parking brake is applied, and the propel

control lever is in the STOP position.
MDC Neutral Adjustment

(1) External control linkage. (2) Servo gauge ports.
NOTE: For photographic purposes the pump is shown

out of machine.
NOTE: Ensure the engine is set to low idle before
starting.
1.
Remove external control linkage (1) from the control

handle. Install a 0 to 2065 kPa (0 to 300 psi) gauge in
the servo gauge port (2) of the propel pump. There is a
second servo port on the opposite side of the pump.
2.
Loosen the washer head screw to allow the neutral

bracket to move, but not freely.
Flushing valve
(1) Test port far axle pump (forward direction). (2) Test port for drum
pump (forward direction). (3) Test port for axle pump (reverse
direction). (4) Test port for drum pump (reverse direction).
3.
Start the engine and slowly accelerate to normal

operating rpm.
2.
4.
Insert a Phillips screwdriver into the 1/4 inch clearance

hole and engage the slot of the neutral adjust bracket.
Slowly rotate the bracket, using the Phillips screwdriver,
until the pressure is equal on both servo gauges.
5.
Then, slowly rotate the bracket until one of the servo

gauges starts to increase in pressure. Mark the position
of the bracket.
6.
Now, slowly rotate the bracket in the opposite direction

until the other servo gauge begins to increase in
pressure. Mark the position of the bracket.
7.
Rotate the bracket to a position between the two marks,

and hold while torquing the washer head screw to 11 to
15 Nm (95 to 132 lb-in).
8.
Connect four 60 000 kPa (8700 psi) pressure gauges to

test ports (1), (2), (3) and (4).
Axle Pump
(5) Adjustment screw. (6) Servo control lines.
NOTE: This procedure should be performed with the

machine off the ground (raise drum and wheels
off the ground).
Stop the engine. Remove the gauges and install the

gauge port plugs. Install and adjust, if necessary, the
external control linkage.
11-43
TM 5-3895-382-24
NOTE: For photographic purposes the pump shown is
out of machine.
3.
4.
5.
6.
7.
Disconnect servo control lines (6) from the axle pump.

Plug and cap the hoses. Install a 3445 kPa (500 psi)
minimum pressure and 9.52 mm (.375 in) or greater I.D.
hose between the two ports where the servo control
lines were connected.
Start and run the engine at low idle.
Look at the 60 000 kPa (8700 psi) pressure gauges.
Both readings, for the axle pump, should be the same
and should be approximately the same as the charge
pressure.
If it is necessary to adjust the neutral position of the
servo piston, remove the protective cap. Loosen the
locknut and turn adjustment screw (5) to get the same
pressure reading on each gauge.
Stop the engine. Remove the 60 000 kPa (8700 psi)
pressure gauges and replace them with 4000 kPa (580
psi) pressure gauges or Tetra gauges.
NOTE: Using a lower pressure gauge may damage the

gauge.
8.
9.
10.
11.
12.
13.
Start and run the engine at high idle. Engine rpm

should be 2350 50 rpm.
Turn the adjustment screw until both pressure gauge
readings are the same. Then, turn the adjustment
screw clockwise until one of the pressure readings
starts to increase. Note the position of the adjustment
screw.
Now turn the adjustment screw counterclockwise until
the reading on the other pressure gauge begins to
increase. Note the position of the adjustment screw.
Turn the adjustment screw clockwise one-half the
distance to the first adjustment screw position.
Hold the adjustment screw and tighten the locknut to a
torque of 18 to 24 Nm (13 to 18 lb-ft). Install the
protective cap.
Stop the engine. Remove the pressure gauges from the
test ports.
Install the servo control oil lines on the axle pump.
Drum Propel Pump

NOTE: Do the same procedure for the swashplate neutral
adjustment of the drum propel pump as above
using the drum pump test ports and servos.
11-44
TM 5-3895-382-24
Propel Pump Synchronization
Axle Propel Motor

(5) Maximum displacement screw.
Flushing Valve
(1) Test port for axle pump (forward direction). (2) Test port for dram
pump (forward direction). (3) Test port for axle pump (reverse
direction). (4) Test port for drum pump (reverse direction).
NOTE: The engine has been removed for photographic

purposes.
6.

Troubleshooting.
on
the
first
page
of
7.
NOTE: This test must be performed outside in an area

clear of obstacles and personnel.
1.
8.
Conned four 0 to 60 000 kPa (0 to 8700 psi) gauges to

test ports (1), (2), (3) and (4) on the flushing valve.
Mark the gauges to correspond with the test ports they
are connected to. Use lines with enough length so the
gauges can be read from the driver seat.
9.
If axle and drum readings differ by more than 1378 kPa

(200 psi) in low range adjust axle motor maximum
displacement screw (5).
position.
Move the propel control lever forward to full speed.
Record the reading of the gauges connected to test
ports (1) and (2).
Move the propel control lever in reverse to full speed.
ports (3) and (4).
NOTE: Drum and axle pumps should come on stroke at

the same time in both forward and reverse
directions. If not, adjust by turning the length of
the external linkage rod (7) between the pumps. If
adjustment is required, neutral start switch must
be rechecked.
2.
3.
4.
5.
Start and run the engine at high idle until the hydraulic
oil temperature reaches 38C (100F). Engine rpm
Move the speed selection switch to the LOW speed
position.
Move the propel control lever forward to full speed.
ports (1) and (2).
Move the propel control lever in reverse to full speed.
ports (3) and (4).
Axle Propel Motor

(6) Minimum displacement screw.
NOTE: The engine has been removed for photographic

purposes.
10.
11-45
If axle and drum readings differ by more than 1378 kPa

(200 psi) in high range adjust axle motor minimum
displacement screw (6).
TM 5-3895-382-24
Thermal Bypass Valve Operational Test

Install a flow meter in the outlet line of the oil cooler. When oil
temperature is above 71C (160F) the flow should increase
approximately 4 gpm while the machine is moving. The total
flow should be a minimum of 10 gpm to a maximum of 13 gpm.
Propel Pumps
(7) External linkage rod.

out of machine.
11.
If adjustment of the axle minimum and maximum

displacement screws does not bring the pressures
within 1378 kPa (200 psi), then the pump and motor
efficiencies should be checked.
12.
If one of the gauges shows 0 for that direction of travel,

the propel pump is not going on stroke or a mechanical
problem exists with that propel pump.
13.
When the pressure difference between the four test

ports is less than 1378 kPa (200 psi), remove the
pressure gauges from the test ports.
11-46
TM 5-3895-382-24
NOTICE
Do not operate the machine if both wheels of the NO-SPIN
differential are not driving.
No-Spin Differential Operation Test

1.
2.
3.
4.
5.
6.
7.
8.
9.
With the engine not running, raise the axle until the
wheels are not contacting the ground surface. Place a
blocking stand under the axle to block the wheels off the
surface.
With the help of an assistant on the opposite side, start
the test by rotating both wheels in a forward direction as
far as possible. Both wheels should stop after rotating a
short distance.
While the assistant holds the right wheel locked forward
against the stop, rotate the left wheel in a backward
direction. Listen for an indexing or clicking sound. (The
right wheel must be held firmly against the stop or the
left wheel will not disengage freely.) Grasp the left wheel
to stop its rotation. Then, move it slightly forward
(toward the stop). The NO-SPIN differential should lock
up.
Rotate both wheels in a backward direction as far as
possible. Both wheels should stop after rotating a short
distance.
While the assistant holds the right wheel locked against
the stop in the backward direction, rotate the left wheel
in a forward direction. Listen for an indexing or clicking
sound. (The right wheel must be held firmly against the
stop or the left wheel will not disengage freely.) Grasp
the left wheel to stop its rotation. Then, move it slightly
backward (toward the stop). The NO-SPIN differential
should lock up.
Repeat Steps 2, 3, 4, and 5, with the left wheel blocked
against the stop and rotating the right wheel both in
forward and reverse.
The steps are completed successfully if the rotated
wheels disengage easily by hand, they rotate freely and
evenly, and a faint indexing or clicking sound is heard.
The NO-SPIN differential is installed correctly and is
functioning correctly.
If either wheel does not rotate freely in either direction, a
check of the NO-SPIN differential should be made.
Check to see that both wheels of the NO-SPIN
differential are driving. Make this test under load, so
that engine torque is applied through the NO-SPIN
differential with the wheels on the ground. One way to
achieve this load is to drive up to a solid obstruction (on
loose dirt or gravel, if possible) and attempt to spin both
wheels together. Perform this test in forward and
reverse.
10.
11-47
On a flat surface, with good traction, drive the machine

in a tight circle in forward and reverse to be sure that the
outside wheel is free to overrun (the outside tire does
not scuff). A clicking or indexing sound may be heard.
The sound of gear re-engagement may also be heard
upon completion of the turn. This is normal.
TM 5-3895-382-24
4.
Brake Efficiency Check

Troubleshooting.
on
the
first
page
of
NOTE: The rear wheels must not spin during this test. If
wheel spin is a problem, move to a location with
better soil density.
NOTE: Do the Main Relief Valve Pressure Test before

doing the brake efficiency check.
Parking Brake Valve

1.
Disconnect wire connector (1). This will allow the

Test Ports (2)

Test port for axle pump (forward direction). (3) Test port for drum
pump (forward direction).
2.
Connect a 60 000 kPa (8700 psi) pressure gauge from

the 4C4892 ORFS Fittings Group to test ports (2) and
(3).
3.
Start and run the engine at high idle until the hydraulic
oil temperature reaches 38C (100F). Engine rpm
Release the parking brake. Slowly move the propel

control lever fully forward until the pressure gauge
readings exceed 25 000 kPa (3600 psi) or the drum
begins to turn.
11-48
5.
As soon as the drum starts to turn, note the pressure

gauge readings. The pressure must not be less than
25 000 kPa (3600 psi).
6.
If the pressure is less than 25 000 kPa (3600 psi), it is

an indication that the brake discs are worn and need to
be replaced.
7.
Connect the wire connector for the brake.
TM 5-3895-382-24
5.

Drum Propel Motor

Troubleshooting.
on
the
first
page
6.
of
Axle Propel Motor
Tools Needed
4C-6500
4C-8689
Temperature Probe
Flow Meter
With the machine stationary read the amount of oil

going through the flow meter. If there is more than 4
liter/min (1 U.S. gpm) of leakage, the motor has too
much internal leakage and must be repaired or
replaced. While moving the flushing valve sends 2 gpm
of additional oil.
Remove all test tooling and connect the oil line back to
the motor.
1
1
Troubleshooting.
NOTE: Install 4C6500 temperature probe into the

hydraulic tank. Operate the machine until the oil
temperature reaches 38C (100 F).
on
the
first
page
of
Tools Needed
1.
Stop the machine. Apply the parking brake.
4C-6500
4C-8689
Temperature Probe
Flow Meter
1
1
NOTE: Install 4C6500 temperature probe into the

hydraulic tank. Operate the machine until the oil
temperature reaches 38C (100F).
1.
Stop the machine. Apply the parking brake.
Drum Propel Motor

(1) Drum propel motor. (2) Oil drain line.
2.
3.
4.
Disconnect oil drain line (2) from drum propel motor (1).
Connect a short length of hose to the fitting that line (2)
was connected to. Connect the other end of the hose to
the inlet of the flow meter. Connect the drain line to the
outlet end of the flow meter.
Start and run the machine at low idle for several minutes
then run at high idle until the hydraulic oil temperature
reaches 38C (100F) again. Engine rpm should be
2350 50 rpm.
Axle Propel Motor

(1) Axle propel motor. (2) Oil drain line.
2.
3.
11-49
Disconnect oil drain line (2) from axle propel motor (1).
Connect a short length of hose to the fitting that line (2)
was connected to. Connect the other end of the hose to
the inlet of the flow meter. Connect the drain line to the
outlet end of the flow meter.
TM 5-3895-382-24
4.
5.
6.
Start and run the machine at low idle for several minutes
then run at high idle until the hydraulic oil temperature
reaches 38C (100F) again. Engine rpm should be
2350 50 rpm.
Read the amount of oil going through the flow meter. If
there are more than 4 liters/min (1 U.S. gpm) of
leakage, the motor has too much internal leakage and
must be repaired or replaced. While propelling, the
flushing valve sends 2 .5 gpm of additional oil.
Remove all test tooling and connect the oil line back to
the motor.
Propel Motor Flushing Valve Test Procedure

3.
Tools Needed
4C-6500
4C-4892
6V-7830
Temperature Probe
Fittings Group
Tetra Gauge
QTY
TOOL
1
1
1
A
B
C
Remove the side access panels, and disconnect the

brake solenoid connector (1). This allows the parking
brake to stay applied during the test.

NOTE: Perform the propel charge relief valve pressure

test and the main relief valve pressure test, in this
module, before doing this test.
1.
2.
4.
Install two test fittings (2) in drum propel motor flushing

valve (3).
5.
Install two test fittings (4) in axle propel motor flushing

valve (5).
Install Tool (A) into the hydraulic oil tank. Operate the
machine until the oil temperature reaches 38C (100F).
Stop the machine. Make sure the parking brake is
applied and the propel control lever is in neutral. Block
the rear wheels.
11-50
TM 5-3895-382-24
6.

Tooling (B) to drum forward test port (6) on cooling and
test valve (7).
12.

Tooling (B) to drum reverse test port (9) on the cooling
and test valve (7).
7.
8.
Connect Tool (C) to forward flushing valve test port (8).

position.
Start the engine and run at high idle, with the propel
lever in NEUTRAL, until the pressure on Tool (C) has
stabilized. Record the pressure.
13.
14.
Connect Tool (C) to reverse flushing valve test port (10).

position.
Start the engine and run at high idle, with the propel
lever in NEUTRAL, until the pressure on Tool (C) has
9.
15.
NOTICE
Do not move the propel lever in REVERSE or damage to
the gauge will result.
NOTICE
Do not move the propel lever in FORWARD or damage to
10.
16.
11.
Slowly move the propel lever in the FORWARD

direction until the pressure gauge connected at test port
(6) reads 10 335 kPa (1500 psi). Look at the flushing
valve test port gauge and record the pressure.
Subtract the pressure recorded in step 10, from the
pressure recorded in step 9, to determine the difference.
The difference should be 310 138 kPa (45 20 psi).
17.
11-51
Slowly move the propel lever in the REVERSE direction

until the pressure gauge connected at test port (9) reads
10 335 kPa (1500 psi). Look a the flushing valve test
port gauge and record the pressure.
pressure recorded in step 15, to determine the
difference. The difference should be 310 138 kPa
(45 20 psi).
TM 5-3895-382-24
18.

Tooling (B) to axle forward test port (11) on the cooling
and test valve (7).
24.

Tooling (B) to drum reverse test port (13) on the cooling
and test valve (7).
19.
Connect Tool (C) to forward flushing valve test port (12)

on the axle motor.
position.
Start the engine and run at high idle, propel lever in
NEUTRAL, until the pressure on Tool (C) has stabilized.
Record the pressure.
25.
26.
Connect Tool (C) to reverse flushing valve test port (14).

position.
Start the engine and run at high idle, propel lever in
NEUTRAL until the pressure on the gauge has
20.
21.
27.
NOTICE
Do not move the propel lever in REVERSE or damage to
NOTICE
Do not move the propel lever in FORWARD or damage to
22.
28.
23.
Slowly move the propel lever in the FORWARD

direction until the pressure gauge connected at test port
(11) reads 10 335 kPa (1500 psi). Look at the flushing
valve test port gauge and record the pressure.
(45 20 psi).
29.
30.
11-52
Slowly move the propel lever in the REVERSE direction

until the pressure gauge connected at test port (13)
reads 10 335 kPa (1500 psi). Look at the flushing valve
test port gauge and record the pressure.
(45 20 psi).
If the measurements are out of tolerance, replace the
pressure adjustment cartridge.
TM 5-3895-382-24
KENR2647-02
October 1998
CHAPTER 12
Specifications
CP-433C & CS-433C
Vibratory System
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
This chapter contains specifications that may be helpful in performing maintenance found in Chapter 13.
12-1
TM 5-3895-382-24
Most Accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions.

The information, specifications, and illustrations in this publication are on the basis of information available at the time. It was written.
When replacement parts am required for this product

Caterpillar recommends using Caterpillar replacement
parts or parts with equivalent specifications including, but
not limited to, physical dimensions, type, strength and
material.
Failure to heed this warning can lead to premature failures,
product damage, personal injury or death.
12-2
TM 5-3895-382-24
Index
Specifications
Drum Assembly........................................................................12-12
Gearbox ....................................................................................12-10
Vibratory Cooling Valve ............................................................ 12-9
Vibratory Motor............................................................................ 12-8
Vibratory Motor............................................................................ 12-8
Vibratory Pump........................................................................... 12-4
Pump Servo............................................................................. 12-5
Electrical Displacement Control (EDC) .............................. 12-5
Vibratory Pump .......................................................................... 12-6
Electrical Displacement Control (EDC) .............................. 12-7
Servo Piston ........................................................................... 12-7
Vibratory Magnetic Sensor ...................................................... 12-9
Introduction
used again. If the par is equal to or within the specification
needed.
REFERENCE: CP-433C & CS-433C Vibration System, Form
No. KENR2648 for Systems Operation, Testing and Adjusting.
12-3
TM 5-3895-382-24
Coil (inside PCP cover)

Maximum continuos voltage:
High amplitude coil ............................................... 6.8 Vdc
Low amplitude coil ............................................... 6.1 Vdc
Current in neutral .......................................................469 ma
Current at full stroke .............................................. 13018 ma
Specifications
Pump Servo
Resistance at 24C (76F):

High amplitude coil ..........................................19.5 ohms
Low amplitude ..................................................15.5 ohms
(5) Tighten neutral adjust screw locknut
to torque of ........................................................2.8 to 3.4 Nm
(25 to 30 lb-in)
(1) Tighten locknut to a torque of .............................24 to 37 Nm

(18 to 27 lb-ft)
(2) Tighten ten bolts to a torque of ..........................14 to 18 Nm
(10 to 13 lb-ft)
(3) Tighten locknut to a torque of .............................18 to 24 Nm
(13 to 18 lb-ft)
Electrical Displacement Control (EDC)
(4) Pressure Control Pilot (PCP)

NOTE: The PCP cover is filled with silicone oil.
12-4
TM 5-3895-382-24
Test At Half Speed
Vibratory Pump
(9XL229-Up,
3WZ158-Up,
2JM579-Up,
3TM706-Up,
5BZ119-Up,
6EN127-Up,
1ZN121-Up, 1FS1-Up, 1XZ1-Up)
Output ..........................................44.6 liter/min (11.6 U.S. gpm)

At a pressure of ........................................2050 kPa (300 psi)
With pump at ............................................................. 1100 rpm
With engine at ........................................................... 1100 rpm
4JZ122-Up,
2TN118-Up,

At a pressure of ......................................6900 kPa (1000 psi)
With pump at ............................................................. 1100 rpm
(1) Tighten ten bolts to a torque of .................... 15 to 17.5 Nm
(11 to 13 lb-ft)
(2) Tighten seven bolts to a torque of ............... 15 to 17.5 Nm
(11 to 13 lb-ft)
(3) Tighten seven bolts to a torque of ...................36 to 43 Nm
(26 to 32 lb-ft)
(4) High pressure relief settings .................................25 000 kPa
(3625 psi)
Tighten plugs to a torque of ..............................40 to 95 Nm
(30 to 70 lb-ft)
(5) Charge relief valve setting ...................................... 2800 kPa
(410 psi)
Rotation is counterclockwise when seen from drive end.

Type of pump: piston
For bench test use SAE 10W oil at 65C (150F)
Displacement ............................................................... 41.0 cm 3/rev
(2.5 in3/rev)
Test At Full Speed
At a pressure of ........................................2050 kPa (300 psi)
With pump at ............................................................. 2200 rpm
Output ............................................. 88.4 liter/min (23 U.S. gpm)
At a pressure of ......................................6900 kPa (1000 psi)
With pump at ............................................................. 2200 rpm
With engine at............................................................ 2200 rpm
12-5
TM 5-3895-382-24
Electrical Displacement Control (EDC) /Servo Piston
(6)
Electrical Displacement Control (EDC) Unit.
(7)
Tighten EDC neutral adjustment locknut

to a torque of ...................................................14 to 24 Nm
(10 to 18 lb-ft)
(8)
Tighten servo piston neutral adjustment locknut

to a torque of ...................................................28 to 51 Nm
(21 to 36 lb-ft)
(9)
Servo control piston.
(10)
Tighten servo gage test port

to torque of ......................................................27 to 47 Nm
(20 to 25 lb-ft)
(11)
Tighten feedback linkage pivot screw

to torque of ........................................................8 to 15 Nm
(6 to 11 lb-ft)
(12)
Tighten control spool bore plug

to torque of ......................................................41 to 94 Nm
(30 to 70 lb-ft)
(13)
Pressure Control Pilot (PCP) valve.
12-6
TM 5-3895-382-24
Vibratory Motor
Vibratory Motor
(9XL1-228, 3WZ1-157, 2JM1-578, 4JZ1-121, 3TM1-705,

5BZ1-118, 6EN1-126, 1ZN1-120, 2TN1-117)
(9XL229-Up,
3WZ158-Up,
2JM579-Up,
3TM706-Up,
5BZ119-Up,
6EN127-Up,
4JZ122-Up,
2TN118-Up,
Type of motor: gear

NOTE: Rotation can be clockwise or counterclockwise.
Rotation depends on the direction of oil flow in
the closed circuit loop line.
Type of motor: piston
(1) Tighten four bolts to a torque of .............................. 270 Nm

(200 lb-ft)
NOTE: Rotation can be clockwise or counterclockwise.

Rotation depends on the direction of oil flow in
the closed circuit loop line.
NOTE: Normal operating range for the

vibratory system ..............................1400 to 1800 vpm
Fixed displacement .................................35 cm 3/rev (2.14 in3/rev)

(1) Tighten four bolts to a torque of .......................47 to 61 Nm
(35 to 45 lb-ft)
NOTE: Normal operating range for the vibratory
system.................................................1400 to 1800 vpm
12-7
TM 5-3895-382-24
Vibratory Magnetic Sensor (If Equipped)
Flushing Valve
(1) Clearance between magnetic sensor and gear

tooth ..............................................................1.57 mm (.062 in)
(1) Charge relief valve:

Pressure setting ..................................... 1725 140 kPa
(250 20 psi)
Torque to install valve into block ........................60 Nm
(45 lb-ft)
(2) Resistance ........................................................265 30 ohms
(2) Shuttle valve:

Torque to install valve into block ................................90 Nm
(65 lb-ft)
12-8
TM 5-3895-382-24
Gearbox
Gearbox
(1) Seal. (2) Boot. (3) Bearing cone. (4) Bearing cone. (5) Washer. (6) Lock tanged washer. (7) Locknut. (8) Spindle. (9) Hub. (10) Bolts. (11)
Shoulder bolts.
12-9
TM 5-3895-382-24
Tightening Procedure For Gearbox Spanner Nut
5.
Recheck the rolling torque. The final reading should be

1.7 to 4.5 Nm (15 to 40 lb-in) greater than the value
measure in Step (1).
6.
A final rolling torque of 5 to 7 Nm (45 to 65 lb-in) should

result in a bearing preload of .025 to 0.51 mm
(.0010 to .0020 in).
7.
If the lockwasher tang does not line up with the locknut

slot, tighten the locknut to line up the tang and bend into
the locknut slot.
Tighten eight bolts (10) to a torque of .....................20 to 25 Nm

(15 to 20 lb-ft)
NOTE: Four shoulder bolts (11) are equally spaced.
Tighten four shoulder bolts (11)
to torque of ..................................................................20 to 25 Nm
(15 to 20 lb-ft)
Measuring Rolling Torque

(A) Torque wrench. (B) Direction of pull. (C) Viewed standing here.
1.
Install seal (1), boot (2), and bearing cone (3) in hub (9).
Install spindle (8) into hub (9). Hold the spindle
stationary and use a torque wrench as illustrated above
to determine the rolling torque created by the seal and
boot. A typical rolling torque is 3.4 Nm (30 lb-in).
NOTE: Bearing cones (3) and (4) should be clean and

wiped dry of any lubricating oil. Bearing cones
which have oil present will affect rolling torque
readings.
2.
Heat shaft bearing cone (4) in an oven to 135C

(275F). Press in the shaft bearing cone until the rolling
torque increases 1.7 to 4.5 Nm (15 to 40 lb-in) greater
than the value measure in Step (1).
NOTE: It will be necessary to continually rotate the

housing to seat the bearing cone in order to
obtain a correct rolling resistance.
3.
Apply 9S3263 Thread Lock to the threads of the locknut.

Install washer (5), lock tanged washer (6) and locknut
(7).
4.
Tighten the locknut with a torque wrench to 306 Nm

(225 lb-ft). Rotate hub (9) to seat the bearing.
12-10
TM 5-3895-382-24
Drum Assembly
(1)
(2)
Turn the setscrew to adjust the length of the vibratory

shaft to 29.4 mm (1.16 in) from the gearbox housing
face. (Note: This allows a 3.2 mm (.13 in) gap
between the shafts.)
(3)
Use 6V4876 Molykote Lubricant on splines as required.
(4)
Apply 9S3263 Thread Lock to the bolt threads.
Apply lubricant to the shaft spines.
12-11/(12-12 blank)
TM 5-3895-382-24
KENR2648-03
October 1998
CHAPTER 13
Systems Operation
Testing & Adjusting
CP-433C & CS-433C

Vibratory System
CP-433C:
2JM1-UP
1ZN1-UP
4J21-UP
CS-433C:
3TM1-UP
2TN1-UP
SBZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
This chapter contains Systems Operation, Testing & Adjusting instructions.
Chapter 12, Specifications, Vibratory System
13-1
TM 5-3895-382-24


Caterpillar
recommends
using
Caterpillar
specifications including, but not limited to, physical
Failure to heed this warning can lead to premature
13-2
TM 5-3895-382-24
Troubleshooting .......................................................................13-29
Checks During Operation ..................................................13-29
Visual Checks .......................................................................13-29
Index
Systems Operation
VPM Measurement Tests ......................................................13-38

Vibratory Amplitude Valve Coil Resistance Procedure
(Fixed Frequency) ...................................................................13-44
Circuit Functions ......................................................................13-20

Vibratory System - OFF ......................................................13-20
Vibratory System ON - HI AMPLITUDE ...........................13-22
Vibratory System ON - LOW AMPLITUDE.......................13-23
Vibratory Amplitude Valve Test

(Fixed Frequency) ...................................................................13-43
Electrical Circuit (Variable Frequency) .................................13-29
Vibratory Frequency Test (Fixed Frequency) .....................13-35
Introduction ................................................................................ 13-4
Vibratory Frequency Test (Variable Frequency) .................13-36
Pump Electrical Displacement Control (EDC) ....................13-26
Vibratory Motor Case Leakage Test ....................................13-34
Variable Frequency System (If Equipped) ..........................13-25

Vibratory Drum Assembly. ....................................................13-18
Vibratory Pump Charge Relief Valve Pressure

Test ............................................................................................13-35
Vibratory Flushing Valve ........................................................13-15
Vibratory Tachometer Calibration .........................................13-40
Vibratory Motor .........................................................................13-17
REFERENCE: For Specifications with illustrations, refer to the

Specifications for the CP-433C & CS-433C Vibratory System,
Form No.
KENR2647.
If the Specifications in Form
No. KENR2647 are not the same as listed in the Systems
Operation and the Testing and Adjusting, look at the print date
on the front cover of each book. Use the Specifications listed
in the book with the latest date.
Vibratory Motor .........................................................................13-17

Vibratory Pump .......................................................................... 13-6
Servo Piston Assembly ......................................................... 13-9
Vibratory Pump ........................................................................13-11
Servo Piston Assembly .......................................................13-14
Electronic Displacement Control (EDC) ..........................13-14

Electrical Displacement Control Coil Resistance
Procedure ..................................................................................13-45
Machines With Variable Frequency
EDC Neutral Adjustment ....................................................13-46
EDC Neutral Adjustment ....................................................13-47
Magnetic Sensor Adjustment ................................................13-39
Magnetic Sensor Resistance ................................................13-38
Magnetic Sensor Voltage Test ..............................................13-38
Main Relief Valve Pressure Test ..........................................13-40
High Amplitude ....................................................................13-40
Low Amplitude .....................................................................13-41
Pump Efficiency Check ..........................................................13-31
System Tests And Adjustments ............................................13-31
13-3
TM 5-3895-382-24
Systems Operation
Introduction
Vibratory System Schematic.

(1) Vibratory motor. (2) Vibratory flushing manifold. (3) Vibratory pump. (4) Hydraulic oil cooler. (5) Charge pressure line from the brakeshift valve.
(6) Hydraulic oil tank.
The vibratory system hydraulics let the operator control the

vibratory action of the drum. The drum is made to vibrate by
the rotation of an eccentric weight shaft inside the drum. The
weight shaft is coupled to vibratory motor (1), which rotates the
weight shaft rapidly, causing the drum to vibrate.
The operator controls the direction of system oil flow (high or

low amplitude), determining the rotational direction of the
eccentric weight shaft. The construction of the weight shaft
causes the drum to vibrate in high-amplitude when the shaft is
rotated in clockwise direction, and in low-amplitude when
rotated in the counterclockwise direction.
Vibratory motor (1) is a par of a closed-loop hydraulic system,

powered by vibratory pump (3). The vibratory pump is
mounted to the back of the tandem propel pumps. The
vibratory pump is a variable-displacement piston pump which
provides minimum pressure to the system when the vibratory
system is not operating. When not operating, the pressure of
the oil in the system will be 1655 to 2140 kPa (250 to 310 psi).
If equipped with the variable frequency option, the operator

also can vary the quantity of system oil flow, determining the
frequency (in vibrations per minute) of the drum. Normal
operating range while propelling for the vibratory system is
approximately 1400 to 1800 vpm.
The operator controls the vibratory system operation, using the

vibratory control switch on the operators console. By moving
this switch, the operator controls the flow of oil through the
vibratory system.
13-4
TM 5-3895-382-24
Vibrato System Component Location.

(2) Vibratory flushing manifold. (3) Vibratory pump. (4) Hydraulic oil cooler. (6) Hydraulic oil tank.
A portion of the hot oil in the closed-loop system is continually

routed through flushing manifold (2). The manifold ports this
hot oil through the oil cooler and then to the hydraulic oil tank.
This permits fresh oil to enter the system regularly, keeping the
components from over-heating. The flushing manifold has
seven test ports which are used to check hydraulic pressure of
the machine systems. Two of the test ports are used for
checking the high/low amplitude pressure settings of the
vibratory system.
13-5
TM 5-3895-382-24
Vibratory Pump
(9XL1-228, 3WZ1-157, 2JM1-578, 4JZ1-121, 3TM1705, 5BZ1-118, 6EN1-126, 1ZN1-120, 2TN1-117)
Vibrato Pump.
(1) Vibratory pump. (2) Servo piston assembly. (3) Pump control
valve.
The amount and direction of oil flow from vibratory pump (1) to
the vibratory motor is controlled by servo piston assembly (2)
and pump control valve (3).
13-6
TM 5-3895-382-24
Vibratory Pump (Swashplate at zero angle) (Typical Example).

(4) Drive Shaft. (5) Piston. (6) Port plate. (7) Swashplate. (8) Cylinder. (9) Housing.
When the engine is running, drive shaft (4) and cylinder (8) are
rotating. There are seven pistons (5) in the cylinder. Port plate
(6) and swashplate (7) are fastened to or held by housing (9)
and do not rotate. When the cylinder is rotating, each of the
pistons follows the angle of the swashplate. If the swashplate
angle is zero, the pistons do not move in and out of the
cylinder and there is no oil flow. Charge oil from the charge
filter maintains oil pressure in the pump to keep the vibratory
circuit full of oil and to lubricate the pump components.
13-7
TM 5-3895-382-24
Vibratory Pump (Swashplate at maximum angle)(Typical Example).

(6) Port plate. (8) Cylinder. (9) Housing. (10) Splines. (11) Spring. (12) Closed circuit loop line port. (13) Retaining ring. (14) Retainer. (15) Closed
circuit loop line port.
When the swashplate is moved to the maximum angle, the

pistons move in and out of the cylinder at the maximum stroke.
As the piston moves out of the cylinder, oil from the low
pressure loop line is supplied behind it. When the piston
moves back into the cylinder the oil that is pushed ahead of the
piston goes through port plate (6) and into closed circuit loop
line port (12).
Port plate (6) and the end of cylinder (8) are high pressure,
metal to metal, seal surfaces and are precision machined parts
that must be protected from damage. Retainer (14) is against
the edge of splines (10). Retaining ring (13) is in a groove in
the bore of the cylinder. The force of spring (11) between the
retainer and retaining ring (13) holds the cylinder tight against
the port plate and the port plate against housing (9).
NOTE: Closed circuit loop line port (12) is shown as a

high pressure loop line, and closed circuit loop
line port (15) is shown as a low pressure loop line
in the illustration. Moving the swashplate overcenter in the opposite direction causes a change
in the direction of flow. Closed circuit loop line
port (12) becomes low pressure and closed circuit
loop line port (15) becomes high pressure.
The swashplate has a pin attached that is moved by the servo

piston assembly. The servo piston assembly controls both the
direction and amount of swashplate angle.
13-8
TM 5-3895-382-24
Charge oil enters the vibratory pump through charge oil inlet
(17). The charge pressure entering the vibratory pump is
controlled by the charge relief valve in the vibratory flushing
valve. The charge relief valve (18) located inside the vibratory
pump is used to prevent damage to the pump. An orifice in the
vibratory pump charge relief valve (18) allows approximately
1.5 gallons per minute of oil to flow through the pump case for
cooling. If the charge pressure entering the pump reaches
2869 kPa (415 psi), charge relief valve (18)
opens to allow more oil to flow through case drain oil line (22)
to the hydraulic tank.
The maximum working pressure for each dosed circuit loop
line is limited to 18 980 kPa (2755 psi) above charge pressure
by high pressure relief valves (16) and (19). Check valves (21)
are built into the high pressure relief valves. The primary
purpose of the check valves is to keep closed circuit loop lines
(12) and (15) full of oil, to make up for internal leakage and
protect the charge system from high pressure oil when the
vibratory system is in operation.
Vibratory Pump.
(12) Closed circuit loop line port. (15) Closed circuit loop lines port.
(16) High pressure relief valve (High amplitude). (17) Charge oil inlet.
Servo Piston Assembly
Vibrato Pump.
(18) Charge relief valve.
amplitude).
(19) High pressure relief valve (Low
The vibratory pump contains charge relief valve (18) and high
pressure relief valves (16) and (19), one for the high amplitude
side of the closed loop circuit and one for the low amplitude
side of the closed loop circuit. Both the charge relief valve and
high pressure relief valves are of the direct acting type.

(1) Lever. (2) Piston. (3) Adjustment screw. (4) Cavity. (5) Cavity.
The pump swashplate is moved by the servo piston assembly.

The servo piston is a double-acting piston that is a par of the
vibratory pump. The swashplate is connected to the center of
the piston with lever (1).
The electrical displacement control is a solenoid operated,
three position valve that has two coils.
The electrical
displacement control sends the flow of charge oil to the servo
piston assembly. Orifices are installed in the passage that
connect the electrical displacement control to the servo piston
assembly. The orifices are used to control the rate at which
the servo piston assembly stokes and destrokes.
Vibratory Pump Schematic.

(12) Closed circuit loop line port. (15) Closed circuit loop line port
(16) High pressure relief valve (High amplitude). (17) Charge oil inlet.
(18) Charge relief valve. (19) High pressure relief valve (Low
amplitude). (21) Check valves. (22) Case drain oil line.
13-9
TM 5-3895-382-24
When the vibratory control switch is in the OFF position, the
high amplitude and low amplitude solenoid coils are not
energized. Charge oil is blocked by the valve spool inside the
valve body and both ends of the servo piston assembly are
vented to the hydraulic oil tank through the electrical
displacement control. Piston (2) is held in the centered
position by adjusting screw (3) and a spring inside the servo
piston. The vibratory pump swashplate will remain at zero
angle and there is no oil flow from the vibratory pump.
When the vibratory control switch is depressed to the ON
position and the vibratory selector switch is at the HIGH
amplitude position, the high amplitude solenoid coil is
energized. The valve spool inside the valve body moves
against the force of the centering spring and allows charge oil
pressure to flow to cavity (4) of the servo piston assembly.
Cavity (5) is connected to the hydraulic oil tank through the
vibratory amplitude valve. Piston (2) is moved opposite cavity
(4) against the servo piston internal stop. This will move the
swashplate to the maximum angle for HIGH amplitude.
When the vibratory control switch is depressed to the ON
position and the vibratory selector switch is at the LOW
amplitude position, the low amplitude solenoid coil is
energized. The valve spool inside the valve body moves
against the force of the centering spring in the opposite
direction and allows charge oil pressure to flow to cavity (5) of
the servo piston assembly. Cavity (4) is connected to the
hydraulic oil tank through the vibratory amplitude valve. Piston
(2) is moved opposite cavity (5) against the servo piston
internal stop. This will move the swashplate to the maximum
angle for LOW amplitude.
13-10
TM 5-3895-382-24
Vibratory Pump
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up,
3TM706-Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up,
Vibratory Pump.
(1) Servo piston assembly. (2) Displacement control unit.
(3) Vibratory pump.
The amount and direction of oil flow from vibratory pump (3) is
controlled by servo piston assembly (1)
and displacement control unit (2).
NOTE: The vibratory pump shown is equipped with
Electrical Displacement Control (EDC) used on
machines with variable frequency vibratory
systems.
]13-11
TM 5-3895-382-24
Vibratory Pump.
(4) Driveshaft. (5) Swashplate. (6) Servo piston neutral adjustment screw. (7) Barrel assembly. (8) Charge oil inlet. (9) Passage (charge oil).
(10) Closed circuit loop line ports. (11) Pot plates. (12) Spring. (13) Pistons.
When the engine is running, driveshaft (4) and barrel assembly

(7) are rotating. There are nine pistons (13) in barrel assembly
(7). Spring (12) keeps a force on barrel assembly (7) to make
a high pressure seal between barrel assembly (7) and port
plate (11). When barrel assembly (7) is rotating, each piston
(13) follows the angle of swashplate (5). If swashplate (5)
angle is at zero, the pistons do not move in and out of barrel
assembly (7) and there is no oil flow. Charge oil from charge
filter maintains oil pressure in the hydraulic pump to keep
barrel assembly (7) full of oil, lubricate the pump components
and to make up for the normal, internal loss of oil due to
leakage.
The position of swashplate (5) is controlled by the EDC, and

servo piston (6). When the EDC receives an electrical signal
from the vibratory control switch, it causes a servo valve inside
the EDC assembly to move. The servo valve routes charge oil
to activate and adjust servo piston (6). Servo piston (6)
controls the direction and amount of swashplate (5) angle.
Oil flows from the pump to the eccentric weight motor and back
to the pump through closed circuit loop line ports (10). The
position of swashplate (5) determines the direction and rate of
flow.
13-12
TM 5-3895-382-24
Vibratory Pump.
Vibratory Pump Schematic.
(14) Closed circuit loop line port. (15) Case drain oil line.
(16) Closed circuit loop line port.
(14) Closed circuit loop line poet. (15) Case drain oil line.
(16) Closed circuit loop line port. (17) Charge oil inlet. (18) High
pressure relief valve (Low amplitude). (19) High pressure relief valve
(High amplitude)(20) Charge relief valve. (21) Check valves.
Charge oil enters the vibratory pump through charge oil inlet
(17). The charge pressure entering the vibratory pump is
controlled by the charge relief valve in the vibratory flushing
valve. The charge relief valve (20) located inside the vibratory
pump is used to prevent damage to the pump. If the charge
pressure entering the pump reaches 2800 kPa (410 psi),
charge relief valve (20) opens to allow more oil to flow through
case drain oil line (15) to the hydraulic tank.
The maximum working pressure for each closed circuit loop
line is limited to 25 000 kPa (3625 psi) above charge pressure
by high pressure relief valves (18) and (19). Check valves (21)
are built into the high pressure relief valves. The primary
purpose of the check valves is to keep closed circuit loop lines
(14) and (16) full of oil, to make up for internal leakage and
protect the charge system from high pressure oil when the
vibratory system is in operation.
Vibratory Pump.
(17) Charge oil inlet. (18) High pressure relief valve (Low amplitude).
(19) High pressure relief valve (High amplitude). (20) Charge relief
valve (underside do pump).
The vibratory pump contains charge relief valve (10) and high
pressure relief valves (18), one for the high amplitude side of
the closed loop circuit and one for the low amplitude side of the
closed loop circuit. Both the charge relief valve (19) and high
pressure relief valves (18) are of the direct acting type.
13-13
TM 5-3895-382-24
Servo Piston Assembly/Electrical Displacement Control (EDC)
EDC.
(1) Electrical Displacement Control (EDC). (2) Sensing piston. (3) Spring. (4) EDC neutral adjustment. (5) Servo piston neutral adjustment.
(6) Servo control piston. (7) Feedback linkage. (8) Displacement control spool. (9) Control oil passages. (10) Pressure control pilot (PCP) valve.
(11) Manual EDC override.
Electrical displacement control (1) is mounted on the hydraulic

pump.
As sensing piston (2) moves to the left as shown, displacement

control spool (8) is moved to the right.
The pump control consists of three sections: EDC (1),

displacement control spool (8), and servo control piston (6).
EDC (1) is a two-stage electrohydraulic control. uses feedback
linkage (7) and control oil (9) from the steering system pump to
set up a closed swashplate control circuit. EDC (1) receives
electrical input from the flow analyzer flow control dial at
pressure control pilot (PCP) valve (10).
This opens a path for control oil (9) to servo control piston (6).
As servo control piston (6) tilts the swashplate, feedback
linkage (7) moves sensing piston (2) through spring (3)
connection back towards neutral to maintain the swashplate
angle set by PCP (10).
EDC (1) maintains the position of the swashplate in proportion
to the electrical input. Servo control piston (6) has feedback
linkage (7), which moves the displacement control spool (8) in
the proper relation to the input signal and the position of the
swashplate. Any swashplate position error is sensed by the
feedback linkage (7), and displacement control spool (8)
corrects the error.
EDC (1), uses an electrohydraulic pressure control pilot to

control differential pilot pressure. PCP (10) converts an
electrical input signal to a hydraulic input signal to operate
spring (3) centered sensing piston (2). Sensing piston (2) is
mechanically linked with the displacement control spool (8)
through feedback linkage (7). As sensing piston (2) moves,
displacement control spool (8) is moved. This opens a path for
control oil (9) to move servo control piston (6). Servo control
piston (6) tilts the swashplate, varying the pump's
displacement.
13-14
TM 5-3895-382-24
Flushing Valve
Shuffle Valve.
(4) Spring. (5) Port to loop line. (6) Port to charge relief valve and oil
cooler. (7) Port to loop line. (8) Port to loop line. (9) Port to loop line.
(10) Spool.
Vibratory Flushing Valve Manifold.

(1) Axle forward pressure test port. (2) Drum forward pressure test
pot. (3) Shuttle valve. (4) Vibratory loop high amplitude test port. (5)
Charge pressure test port. (6) Axle reverse pressure test port. (7)
Drum reverse pressure test port. (8) Charge relief valve. (9) Vibratory
loop low amplitude test port. (10) Hydraulic oil test port (SOS).
The shuttle valve allows oil from the vibratory system to go to

the oil cooler. When oil from the high pressure side of the
vibratory system loop is at ports (7) and (9), shuttle spool (10)
moves all the way to the opposite end of the valve body. Oil
from the low pressure side of the vibratory system loop goes
through port (8), around spool (10), and through port (6) to the
charge relief valve. The oil then goes to the oil cooler.
The vibratory flushing valve manifold contains seven test ports,

shuttle valve (3) and charge relief valve (8).
When oil from the high pressure side of the vibratory system
loop is at ports (5) and (8), shuttle spool (10) moves all the way
to the opposite end of the valve body. Oil from the low
pressure side of the vibratory system loop goes through port
(9), around spool (10), and through port (6) to the charge relief
valve. The oil then goes to the oil cooler.
The shuttle valve always allows oil from the low pressure side
of the vibratory loop to go to the oil cooler When the vibratory
system is off, the shuttle valve is open centered and allows oil
from both sides of the loop to go to the oil cooler.
13-15
TM 5-3895-382-24
Charge Relief Valve.

(11) Adjustment screw. (12) Spring. (13) Port to oil cooler. (14) Port
to propel and vibratory flushing valve. (15) Piston.
The charge relief valve maintains charge oil pressure while the
machine is in operation. Low pressure loop oil from the propel
cooling valve and vibratory flushing valve put pressure on port
(14). When the pressure on the end of piston (15) is greater
than the force of spring (12), piston (15) moves and allows oil
to go through port (13) to the oil cooler. Screw (11) is used to
adjust the valve pressure setting.
13-16
TM 5-3895-382-24
Vibratory Motor
Vibratory Motor
(9XL1-228, 3WZ1-157, 2JM1-578, 4JZ1-121, 3TM1-705,

5BZ1-118, 6EN1-126, 1ZN1-120, 2TN1-117)
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up,

3TM706-Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up,
Components Of Vibratory Motor.

(1) Output shaft. (2) Driven gear. (3) End cap.
Components Of Vibratory Motor.
The vibratory motor is a fixed displacement hydraulic motor.

Oil flows to and from the motor through hoses attached to end
cap (3).
(1) End cap. (2) Port plate. (3) Cylinder block. (4) Piston. (5) Shaft.
(6) Housing. (7) Swashplate.
The vibratory motor is a fixed displacement hydraulic motor.

Oil flows to the motor and from the motor through hoses
attached to the end cap (1).
High pressure oil from the pump enters the motor through the
end cap. The oil then rotates the drive gear assembly (not
shown in illustration). The drive gear assembly rotates driven
gear assembly (2) and transmits the power generated through
output shaft (1).
High pressure oil from the pump enters the motor through the
end cap (1). The oil will pass through the port plate (2) and the
oil will act on the piston (4).
Cooling and lubricating the internal moving parts of the motor

is done with normal internal leakage oil.
Piston (4) is one of nine pistons in the assembly of the cylinder

block (3).
After driving the vibratory motor, the oil flows from motor into
the low pressure loop line.
As the pistons react to the high pressure oil, the cylinder block
(3) and the pistons (4) rotate as an assembly. The cylinder
block (3) is splined to the shaft (5). Rotating torque is
transferred to the shaft (5). The displacement of the motor is
controlled by the nonadjustable swashplate control angle (7).
The nonadjustable swashplate control angle is machined into
motor housing (6).
13-17
TM 5-3895-382-24
Vibratory Drum Assembly
Vibrator Drum Assembly.

(1) Eccentric weight. (2) Eccentric weight. (3) Drive shaft. (4) Coupling. (5) Vibratory motor.
Vibratory action for the machine occurs at the drum assembly.

Drive shaft (3) is connected to vibratory motor (5) with coupling
(4).
When the operator turns the vibratory system ON, the vibratory
motor causes drive shaft (3), eccentric weights (1) and (2) and
coupling (4) to rotate. The rotation of the eccentric weight
creates the desired vibratory action of the drum assembly.
13-18
TM 5-3895-382-24
Eccentric Weight Cross Section (High Amplitude).

(6) Steel shot.
Eccentric weight (1) and (2) are loaded with steel shot (6).
When the vibratory selection switch is placed in the high
amplitude mode, the eccentric weight rotates in one direction.
The steel shot is captured in one side of the weight
compartment as shown above.
The weight of the steel shot in this position increases the
natural eccentricity of the weight. This causes the drum
assembly to vibrate in the high amplitude mode.
Eccentric Weight Cross Section (Low Amplitude).

(6) Steel shot.
When the vibratory selection switch is placed in the low

amplitude mode, the eccentric weight rotates in the opposite
direction. This causes steel shot (6) to be captured in the
opposite side of the weight compartment as shown above.
The weight of the steel shot in this position offsets the natural
eccentricity of the weight. This causes the drum assembly to
vibrate in the low amplitude mode.
13-9
TM 5-3895-382-24
Circuit Functions
Vibratory System - OFF
Vibratory System Circuit Diagram - OFF.

(1) Vibratory motor. (2) Vibratory flushing relief valve. (3) Oil line from propel cooling valve. (4) Closed circuit loop line. (5) Check valve. (6) Servo
piston assembly. (7) Charge relief valve. (8) Oil line from hydraulic oil filter. (9) Vibratory pump. (10) Vibratory flushing valve. (11) Closed circuit loop
line. (12) Check valve. (13) Hydraulic oil tank. (14) Vibratory amplitude valve.
Return oil from the steering system supplies the charge oil
(make-up oil) for the vibratory system. Charge oil is supplied
to the hydraulic oil filter before entering the vibratory system
through oil line (8).
When the vibratory control switch on top of the propel control

lever or the vibratory selection switch is placed in the OFF
position, electric circuit to vibratory control solenoid valve (14)
is isolated. The vibratory amplitude valve is held in center
position (null position) by the two centering springs. The
vibratory amplitude valve blocks charge oil from flowing
through servo piston assembly (6), and the vibratory pump
swashplate is at zero angle (neutral position). In this position
there is no flow of oil from vibratory pump (9) to vibratory motor
(1).
13-20
TM 5-3895-382-24
When the vibratory system or propel system are not in use the
charge pressure of charge relief valve (7) is measured at the
vibratory flushing valve. Refer to the Testing and Adjusting
section for the pressure values. The case drain oil from the
vibratory pump and motor cases goes to hydraulic oil tank (13).
Excess charge oil that passes through the propel pumps goes
to vibratory flushing valve (10) and the oil cooler before
returning to the hydraulic oil tank.
Charge oil enters into closed circuit loop lines (4) and (11)
through check valves (5) and (12). Because the charge
pressure in both closed circuit loop lines is equal, the shuttle
valve spool inside vibratory flushing valve (10) is held in center
position and oil flow from both sides of loop flow to oil cooler.
When the propel system is in operation, hot low pressure oil
flows from the propel cooling valve to the oil cooler. When
measured at the vibratory flushing valve, relief valve (2) limits
the charge pressure for the vibratory system and propel
system to 1725 345 kPa (250 20 psi) at 38C (100F)
minimum.
13-21
TM 5-3895-382-24
Vibratory System ON -HI AMPLITUDE
Vibratory System Circuit Diagram - ON - HIGH AMPLITUDE.

(1) Vibratory motor. (2) Flushing relief valve. (3) Oil line from propel cooling valve. (4) Closed circuit loop line. (5) Check valve. (6) Servo piston
assembly. (7) Charge relief valve. (8) Oil line from hydraulic oil filter (9) Vibratory pump. (10) Vibratory flushing valve. (11) Closed circuit loop line.
(13) Hydraulic oil tank. (14) Vibratory amplitude valve. (15) High pressure relief valve.
Vibratory servo valve (14) receives an electrical input when the

vibratory control switch is in the ON position and the vibratory
selection switch is moved to the HIGH AMPLITUDE position.
The electrical input causes the vibratory amplitude valve to
move from centered position to the straight through position.
This allows charge oil from oil line (8) to pass across the relief
valve to servo piston assembly (6), moving the swashplate to
from vibratory pump (9) flows into closed maximum angle for
high amplitude. The vibratory selector switch controls the
direction of swashplate angle by sending current to one of the
vibratory servo valve coils.
High pressure oil delivered from vibratory pump (9) flows into
closed circuit loop line (4). The high pressure oil drives
vibratory motor (1). Low pressure oil from the vibratory motor
flows back to the vibratory pump through closed circuit loop
line (11).
When the vibratory system is being operated, the return loop
pressure is limited to 1725 140 kPa (250 20 psi) by flushing
relief valve (2). High pressure oil in closed circuit loop line (4)
moves the shuttle valve spool inside vibratory flushing valve
(10) from centered position to allow hot, low pressure oil in
closed circuit loop line (11) to flow through vibratory flushing
valve (10) and the hydraulic oil cooler before entering the
hydraulic oil tank. Fresh charge oil enters low pressure closed
circuit loop line (11) through check valve (5), compensating for
oil loss through the vibratory flushing valve and internal
leakage.
Oil which passes from the closed circuit into the vibratory pump
is returned to the hydraulic oil tank.
13-22
TM 5-3895-382-24
Vibratory System ON -LOW AMPLITUDE
Vibratory System Circuit Diagram - ON - LOW AMPLITUDE.

(1) Vibratory motor. (2) Flushing relief valve. (3) Oil line from propel cooling valve. (4) Closed circuit loop line. (6) Servo piston assembly. (8) Oil line
from hydraulic oil filter. (9) Vibratory pump. (10) Vibratory flushing valve. (11) Closed circuit loop line. (12) Check valve. (13) Hydraulic oil tank. (14)
Vibratory amplitude valve. (16) High pressure relief valve.
Vibratory servo valve (14) receives an electrical input when the

vibratory control switch is in the ON position and the vibratory
selection switch is moved to the LOW AMPLITUDE position.
The electrical input causes the vibratory amplitude valve to
move from centered position and allows charge oil from oil line
(8) to pass across the relief valve to servo piston assembly (6),
moving the swashplate to maximum angle for low amplitude.
The vibratory selector switch controls the direction of
swashplate angle by sending current to one of the vibratory
pump servo valve coils.
High pressure oil delivered from vibratory pump (9) flows into
closed circuit loop line (11). The high pressure oil drives
vibratory motor (1). Low pressure oil from the vibratory motor
flows back to the vibratory pump through closed circuit loop
line (4).
13-23
TM 5-3895-382-24
For early pumps, the maximum working pressure for closed
circuit loop line (4) is limited to 18 982 kPa (2755 psi) above
return loop pressure by high pressure relief valve (16). For late
pumps, the maximum working pressure for dosed circuit loop
line (4) is limited to 25 000 kPa (3625 psi) above return loop
pressure by high pressure relief valve (16). When the circuit
pressure increases to the high pressure relief valve setting, oil
passes from the closed circuit loop line into the charge circuit.
The oil then returns to hydraulic oil tank (13) or into the low
pressure side of the loop to prevent cavitation of the pump.
When the vibratory system is being operated, the return loop
pressure is limited to 1725 345 kPa (250 20 psi) by cooling
relief valve (2). High pressure oil in closed circuit loop line (11)
moves the shuttle valve spool inside vibratory flushing valve
(10) from centered position and hot, low pressure oil in closed
circuit loop line (4) flows through vibratory flushing valve (10).
The oil flows through cooling relief valve (2) and the hydraulic
oil cooler before entering the hydraulic oil tank. Fresh charge
oil enters low pressure closed circuit loop line (4) through
check valve (12), compensating for oil loss through the
vibratory flushing valve and internal leakage.
Oil which passes from the dosed circuit into the vibratory pump
and motor cases is returned to the hydraulic oil tank.
13-24
TM 5-3895-382-24
Variable Frequency System
(If Equipped)
Vibratory Schematic Variable Frequency).

(1) Vibratory motor. (2) Cooling relief valve. (3) Oil line from propel cooling valve. (4) Closed circuit loop line. (5) Check valve. (6) Servo piston
assembly. (7) Charge relief valve. (8) Oil line from hydraulic oil filter. (9) Vibratory pump. (10) Vibratory flushing valve. (11) Closed circuit loop line.
(12) Check valve. (13) Hydraulic oil tank. (14) Electrical Displacement Control valve (EDC).
The variable frequency vibratory circuit is an option. The

vibratory circuit, flushing circuit and motor are the same as
used in the fixed frequency. The control of the pump is
different.
The frequency (VPM) of the weight is variable between 14001800 vpm. The variable output of pump (9) is controlled by
electrical displacement control valve (EDC)(14).
In the fixed displacement system, the pump output remains the

same. The direction of flow changes in closed loop circuit
passages (4) and (11), to increase or decrease the vibratory
weight amplitude. Vibrations Per Minute (VPM) is fixed.
In the variable frequency system, the output (flow) of the pump
is variable. The high/low amplitude control switch is the same.
13-25
TM 5-3895-382-24
Pump Electrical
Displacement Control (EDC)
Pressure Control Pilot (PCP) Valve.

(8) Pole piece. (9) Centering springs. (10) Armature. (11) Pole piece.
(12) Magnet. (13) Magnet. (14) Pivot point. (15) Flapper. (16)
Nozzle. (17) Nozzle. (18) Oil supply port. (19) Orifice. (20) Office.
(21) Control port 1. (22) Oil return port. (23) Control port 2.
PCP (1) valve is the first stage of the electrical displacement

control (EDC) unit. The hydraulic portion of the PCP valve is a
closed loop that uses internal hydraulic feedback from the
pump swashplate piston. The PCP electrical section receives
a direct current (DC) input in its torque motor stage. The
torque motor stage of the PCP consists of armature (10),
mounted on the torsion pivot (14) and suspended in a
magnetic field air gap. Magnets (12) and (13) are permanent
magnets of parallel polarity constructed to form a magnetic
bridge.
Electrical Displacement Control (EDC).
When the EDC is at null, the armature is centered in the air

gap. The two factors that allow the armature to remain in the
centered position are the equal magnetic forces of the
opposing magnets and centering springs (9). While the
armature is centered, flapper (15) is centered between nozzles
(16) and (17). Upstream from the nozzles are orifices (19) and
(20). In between each orifice and nozzle is a control port.
(1) Pressure control plot (PCP) valve. (2) Manual override lever. (3)
Rotary valve. (4) Null adjust screw and locknut (5) Rotary valve cam.
(6) Actuator spool. (7) Modulation spring.
The EDC is a two-stage electrohydraulic control unit. It uses

mechanical feedback and ported control oil to set up a closed
loop swashplate control circuit. The EDC receives electrical
input from the vibratory control rheostat and the vibratory
control switch.
In the null position, charge oil from the charge pump enters oil
supply port (18) and passes through the two orifices. Because
the flapper is centered between the two nozzles there is no
pressure difference, so an equal amount of the oil flows
through the nozzles, past the flapper and out oil return port
(22).
The vibratory selector switch controls the direction of

swashplate angle by sending a current to one of the two coils
inside the EDC. One coil controls the direction of swashplate
angle when the vibratory selector switch is positioned for high
amplitude.
The second coil controls the direction of
swashplate angle when the vibratory selector switch is
positioned for low amplitude. The vibratory control rheostat
controls the amount of swashplate angle by controlling the
amount of current sent to the coils.
As current is increased in one direction the end of the armature

becomes polarized either north or south. The armature then
moves towards the opposing magnetic field. The amount of
movement is dependent upon the amount of amperage of the
control current introduced to polo pieces (A1 and (11).
13-26
TM 5-3895-382-24
When current is applied to cause the armature to move
towards magnet (13) a torque shift occurs at pivot (14). That
torque shift causes the flapper to move closer to nozzle (16).
As the flapper moves closer to the nozzle, the pressure rises
between nozzle (16) and orifice (20). This pressure increase
causes the oil to flow through control port 1 (21).
Initially, due to step input from the control current, the flapper
closes off the nozzle sending all oil through the control port
causing the pump to go to full stroke. As the oil pressure rises
in the passageway between the nozzle and the orifice, it
moves the flapper back toward the null position. When the
torque output of the torque motor stage and the pressure
feedback are equal, the pilot control system is then equalized.
When the pilot control system is equalized, the flapper is in the
position to maintain the desired speed setting. The control oil
pressure in passage (21) is then proportional to the control
current plus the control oil pressure in the passage (23).
The second stage of the EDC routes the control oil pressure
from passage (21) to one end of actuator spool (6). When the
control oil pressure reaches 85 kPa (12 psi) it overcomes
modulation spring (7) and shifts the actuator spool. When the
spool shifts it moves rotary valve cam (5), which rotates rotary
valve (3). The rotation of the rotary valve opens a port and
allows charge oil to pass to the servo piston. Oil acting upon
the servo piston causes it to shift and rotate the swashplate on
its axis.
A valve sleeve that is concentric with the rotary valve is
attached to the swashplate. When the rotary valve rotates and
opens a port the swashplate turns. The valve sleeve turns with
the swashplate and closes off the port, shutting off the supply
of control oil. Because the sleeve valve moves with the
swashplate, the swashplate is able to follow the rotational input
of the rotary valve.
The modulator spring tension setting is designed to give a
specific actuator spool deadband width and is not adjustable.
Null adjust screw and locknut (4) moves the fixed deadband in
relation to its alignment to the rotary valve control port opening.
Manual override lever (2) on the PCP allows the pump to be
controlled manually instead of electrically.
The manual
override lever actuates the PCP flapper valve.
13-27
TM 5-3895-382-24
Electrical Circuit
(Variable Frequency)
Electrical Circuit (Variable Frequency).

(1) Fuse. (2) Propel speed switch. (3) Amplitude control switch. (4) Low amplitude rheostat (5) Electronic displacement control valve (EDC). (6)
Control switch. (7) Frequency control rheostat (8) High amplitude rheostat.
13-28
TM 5-3895-382-24
The major components of the vibratory electrical circuit are:
fuse (1), propel speed switch (2), amplitude control switch (3),
low amplitude rheostat (4), electronic displacement control
valve (EDC)(5), control switch (6), frequency control rheostat
(7), high amplitude rheostat (8).
Control switch (6), located on the propel lever, turns the

vibratory system on and off. Switch (3), located on the
operator control console, selects vibratory amplitude.
Frequency control rheostat (7) is located on the operator
control console and controls the VPM of the weights.
The electrical circuit controls the drum vibratory hydraulic

system by varying the amperage flow to the EDC. The
variable circuit turns the vibratory system on and off, controls
the vibratory amplitude and controls the vibrations per minute
(VPM) of the eccentric weights.
A vibratory lockout circuit can be installed as an option. The

optional vibratory lockout circuit prevents the operator from
running the vibratory system when the machine is in high
speed range.
13-29
TM 5-3895-382-24
Visual Checks
Troubleshooting
A visual inspection of the vibratory system and its components

is the first step when a diagnosis of a problem is made. Then
check the operation of the machine. Finally, check the
vibratory system with gauges.
Perform the following
inspections.
During a diagnosis of the hydraulic system, remember that

correct oil flow and pressure are necessary for correct
operation. The output of the pump (oil flow)
increases with an increase in engine speed (rpm) and
decreases when engine speed (rpm) is decreased. Oil
pressure is caused by resistance to the flow of oil.
Do not check for leaks with your hands. Pin hole (very
small) leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks.
The 4C-4892 ORFS Fittings Group can be used to make

pressure tests on the vibratory system. Before any tests are
leakage of oil and for parts that are damaged. For some of the
tests a magnet and a mm (in) measuring rule are usable tools.
When any test is made of the vibratory system, the hydraulic
oil must be at the normal temperature for operation (38C
[100F]).
1.
Check the oil level of the hydraulic oil tank.
2.
Look for air in the oil that is in the hydraulic oil tank. Do
Sudden movement of the machine or release of oil under

pressure can cause injury to persons on or near the
machine. To prevent possible injury, do the procedure
that follows before testing and adjusting the vibratory
system.
3.
Check all oil lines, hoses and connections for leaks and
damage. Look for oil on the ground under the machine.
4.
Remove and check the hydraulic filter element for

foreign materials.
1.

a. Bronze-colored particles give an indication of pump

port plate failure.
2.

of the operator.
b. Shiny steel particles give an indication of pump or

motor piston failure or motor cam deterioration.
3.
4.
Stop the engine.
5.
Move the hydraulic control lever to all positions to

release any pressure in the hydraulic system.
6.
Carefully loosen the filler cap on the hydraulic oil tank.
7.

c. Rubber particles give an indication of a seal or hose

failure.
d. Aluminum particles give an indication of steering
pump failure.
Checks During Operation
With the engine running, operate the machine in each direction
and from low to high speed. Make note of all noises that are
not normal and find their sources. If the operation is not
correct, refer to the list of problems and probable causes.
The checks during operation can be used to find leakage in the
system. They can also be used to find a bad valve, pump or
motor. Vibratory frequency can be used to check the condition
of the vibratory motor and the Pump.
13-30
TM 5-3895-382-24
Prior to checking the vibratory system, drive the machine
backwards and forwards several times operating the propel
controls in all speed ranges. While the machine is being driven
backwards and forwards, check the condition of the rubber
blocks. The blocks act as an isolator between vibrating and
non-vibrating parts of the machine.
Problem: Harsh engagement of vibratory.

Probable Cause:
1.
Charge circuit relief valve is set too high.
Problem: Slow vibratory stopping.

Check for the sound of the relief valves opening. The opening
pressures of the relief valves are given in Relief Valve
Pressure Tests in Testing And Adjusting.
Probable Cause:
1.
Relief valve pressure set too low.
2.
Main relief valve does not close correctly on the return

side of the closed loop circuit.
Problem: Low charge pressure.

Probable Cause:
1.
Low oil level in hydraulic oil tank.
2.
Restricted hydraulic filter element.
3.
Failure of the steering pump.
4.
Charge relief valve adjustment not correct.
5.
Failure of the servo control assembly.
6.
Failure of the vibratory control solenoid valve.
7.
Main relief valve setting is not correct or valve does not

close.
8.
Pump port plate wear causing excessive leakage from

the high pressure line into the pump housing.
Problem: Compactor will not reach maximum vibratory

frequency.
Probable Cause:
1.
Drum oil level is too high.
2.
Engine high idle is not correctly adjusted.
3.
Frequency gauge (if equipped) is defective or not

correctly adjusted.
4.
5.
Incorrect internal stops in servo.
6.
Vibratory system pressure higher than main relief valve

pressure.
Problem: Vibratory does not work in high or low

amplitude.
7.
Excessive pump/motor internal leakage.
Probable Cause:
8.
Failure of the O-rings for the servo piston assembly.
1.
9.
Incorrect voltage at the EDC on machines equipped with

variable frequency.
2.
Failure of the vibratory pump.

10.
Failure of the EDC.
3.
Faulty vibratory control switch on the console.

11.
EDC neutral setting incorrect.
4.
Faulty vibratory selector switch on the console.
5.
Electrical problem with EDC (If Equipped) or the wiring

to the EDC.
Problem: Variation in maximum frequency readings

between high and low amplitude.
Probable Cause:
Problem: Periodic loss of vibratory in high or low

amplitude.
1.
Incorrect neutral adjustment of the pump servo control

assembly.
2.
Mechanical failure of the pump servo control assembly.
3.
Main relief valve setting is not correct or valve does not

close correctly on one side of the loop line.
4.
Failure of the pump swashplate assembly.
Probable Cause:
1.
Faulty vibratory control switch.
2.
Faulty vibratory selector switch.
3.
Loose connection in the electric circuit wiring.
13-31
TM 5-3895-382-24
Problem: Noisy vibratory mechanism.
Method of finding flow loss:
Probable Cause:
1.
Low oil level in the drum.
Pump flow at 100 psi ................................... 57.5 gpm (liter/min) *

Pump flow at 1000 psi ................................-52.0 gpm (liter/min) *
Flow loss .......................................................... 5.5 gpm (liter/min) *
2.
Failure of the vibratory drive shaft or components

leading up to the vibratory drive shaft.

3.
Loose retaining bolts for the vibratory motor.
Problem: Hydraulic circuit oil overheats.
gpm flow loss

Percent of
X 100 =
flow loss
Pump flow @ 100 psi
Probable Cause:
1.
Incorrect type of oil used in the hydraulic system.

or
*5.5
*57.5
X 100 = 9.5%
2.
Hydraulic oil cooler is restricted.
3.
Excessive internal leakage in the closed loop circuit.
4.
5.
Cooling relief valve pressure setting higher than pump

charge relief valve pressure setting.
* The numbers in the examples are for illustration and are not
values for any specific pump or pump condition.
See
Specifications for pump flow of a new pump at 690 kPa (100
psi) and 6900 kPa (1000 psi).
6.
Failure of vibratory shaft bearings which causes

extended periods of time over the vibratory pump high
pressure reliefs.
Machine Test

Install a Flow Meter. For Formula I, measure pump flow at 690

kPa (100 psi) and at 6900 kPa (1000 psi) with the engine at
high idle rpm.
Problem: Maximum VPM is too high.

Probable Cause:
1.
Faulty VPM gauge.
2.
Engine RPM is too high.
3.
Incorrect internal displacement stops were supplied.
Formula I
gpm @ 100 psi - gpm @ 1000 psi
gpm @ 100 psi
X 100 =
Percent of
flow loss
Bench Test
If the bench test can be run at 6900 kPa (1000 psi) and at full
System Tests and Adjustments

If the bench test cannot be run at 6900 kPa (1000 psi) and at
Use these values in the top part of Formula II. For the bottom
(100 psi) will be larger than the pump flow at 6900 kPa (1000
psi). The difference between the pump flow of the two
Formula II
gpm @ 100 psi @ 2000 rpm
13-32
X 100 =
Percent of
flow loss
TM 5-3895-382-24
2.
Install a 3445 kPa (500 psi) minimum pressure hose

and needle valve between servo port (3) and the
opposite servo port, on other side. This will cross port
the servo and remove the effects of any control
pressure on the servo piston.
3.
Start and slowly accelerate the engine to full throttle.

Operate the vibratory system in both high and low
amplitudes several times and then stop the vibratory
system.
4.
With the servo cross-port line installed and the needle

valve open, note the system pressure gauge readings
with engine running at low idle. The difference in the
system pressure gauge readings is the offset pressure.
(9XL1-228, 3WZ1-157, 2JM1-578, 4JZ1-121, 3TM1-705,

5BZ1-118, 6EN1-126, 1ZN1-120, 2TN1-117)
Tools Needed
Tetra Gauges
6V-7830
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
NOTE: Tests should be performed on tires or loose dirt.

Tires are recommended.
Never operate the
vibratory system when the machine is on
concrete.
NOTE: To achieve finer gauge resolution, lower pressure

gauges will be required. 60 000 kPa (8700 psi)
pressure gauges are used at the beginning to
prevent gauge damage.
NOTE: Make sure the parking brake is applied, and the

propel control lever is in neutral.
Flushing Manifold.
5.
If the offset pressure is not zero, loosen the servo

locknut with an 11/16 hex wrench. Turn the adjustment
screw with a 3/16 internal hex wrench to decrease the
highest system pressure to half of the offset pressure.
6.
Close the needle valve (disconnect the servo cross port

line/plug the servo ports). Operate the vibratory system
in both high and low amplitudes several times. Return
the pump to neutral (non-vibratory) and open the needle
valve (reinstall the cross-port line) this will allow the
servo spring to locate the swashplate in the neutral
position.
7.
Install the low pressure gauges and note the system

pressure gauge readings. If the offset pressure is not
zero, repeat Steps 5 through 8.
8.
Once the swashplate neutral has been found, hold the

servo adjustment screw from turning and torque the
servo locknut to 18 to 24 Nm (13 to 18 lb-ft).
9.
Stop the engine. Remove the pressure gauges.
(1) Test port for vibratory (low amplitude) pressure. (2) Test port for
vibratory (high amplitude) pressure. (3) Servo Port.
1.
Connect two 60 000 kPa (8700 psi) pressure gauges to

test ports (1) and (2).
13-33
TM 5-3895-382-24
1.
Connect two 60 000 kPa (8700 psi) pressure gauges to

test ports (1) and (2).
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up, 3TM706Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up, 1ZN121-Up, 1FS1Up, 1XZ1-Up)
2.
Remove plugs from servo ports (3) and (4). Install a

3445 kPa (500 psi) minimum pressure hose between
servo port (3) and servo port (4). This will cross port the
servo and remove the effects of any control pressure on
the servo piston.
3.
Start and slowly accelerate the engine to full throttle.

Operate the vibratory system in both high and low
amplitudes several times and then stop the vibratory
system.
4.
With the servo cross-port line installed, note the system

pressure gauge readings with engine running at low
idle. The difference in the system pressure gauge
readings is the offset pressure.
Tools Needed
Tetra Gauges
6V-7830
Make reference
Troubleshooting.
to
WARNING
on
first
page
of

Never operate the
concrete.
NOTE: To achieve finer gauge resolution, lower pressure

gauges will be required. 60 000 kPa (8700 psi)
pressure gauges are used at the beginning to
prevent gauge damage.
NOTE: Make sure the parking brake is applied, and the

propel control lever is in neutral.
Flushing Manifold.
5.
If the offset pressure is not zero, loosen the pump

neutral adjustment locknut with a 17 mm hex wrench.
Turn the pump neutral adjustment screw (5) with a 7
mm hex wrench until the system pressure gauge
readings are equal.
6.
Turn the pump neutral adjustment screw (5) clockwise

until one of the gauges registers an increase in system
pressure. Note the position of the pump neutral
7.
Turn the pump neutral adjustment screw (5)

counterclockwise until the other gauge registers an
increase in system pressure. Note the position of the
pump neutral adjustment screw (5).
8.
Turn the pump neutral adjustment screw (5) to a

position halfway between the positions noted above.
The system pressure gauges should indicate equal
pressures.
9.
Once the swashplate neutral has been found, hold the

servo adjustment screw from turning and torque the
pump neutral adjustment locknut to 28 to 51 Nm (21 to
37 lb-ft).
10.
Stop the engine. Remove the pressure gauges and

servo cross port line. Reinstall the plugs in the servo
pods (3) and (4).
(1) Test port for vibratory high amplitude) pressure. (2) Test port for
vibratory (low amplitude) pressure. (3) Servo port.
Vibratory Pump.
(4) Servo port. (5) Pump neutral adjustment.
13-34
TM 5-3895-382-24
Vibratory Motor Case Leakage Test
Make reference
Troubleshooting.
to
WARNING
on
first
page
of

Never operate the
concrete.
2.
Disconnect hose (2) from vibratory motor (1) and cap

the line. Connect a hose to the fittings from which hose
(2) was removed. Put the other end of the hose in a 19
liter (5 U.S. Gallons) container.
3.
Move the vibratory selector switch to the HIGH

AMPLITUDE position.
4.
Start and run the engine at high idle.
5.
Depress the vibratory control switch to the ON position

to start the vibratory system. At the same time the
switch is depressed, move the hose to a second 19 liter
(5 U.S. Gallons) container. At the end of one minute,
move the hoses back to the first, container.
6.
Depress the vibratory control switch to the OFF position

to stop the vibratory system. Stop the engine.
7.
Measure the amount of oil in the second container. If

there are more than 4 liters (1 U.S. Gallon), the vibratory
motor has too much internal leakage and must be
repaired or replaced.
8.
Remove the temporary case drain line and cap from

hose (2). Reinstall hose (2) to vibratory motor (1).
NOTE: The oil temperature must be a minimum of 38 C

(100 F) to obtain accurate results.
1.
Make sure the parking brake is applied and the propel

control lever is in the NEUTRAL position. Make sure
the vibratory control switch on the propel control lever is
in the OFF position.
Vibratory Motor (Early).

(1) Vibrator motor. (2) Case drain hose to hydraulic tank.
Vibrato Motor (Later).

(1) Vibrator motor. (2) Case drain hose to hydraulic tank.
13-35
TM 5-3895-382-24
valve in the pump. The thickness should be 11.4 mm
(.45 in). Check that the orifice is not plugged. The
charge relief valve normally should not be adjusted. If
the shim thickness is correct, adjust the charge relief
valve in the flushing manifold. Loosen locknut (4) and
turn adjustment screw (3). After proper adjustment is
made tighten the locknut.
Flushing Valve Charge Relief Valve Pressure Test
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
NOTE: The procedure described in this test will measure

charge pressure when the propel control lever is
in the NEUTRAL position and the vibratory
system is off. This charge pressure is measured
and recorded at the cooling manifold.
5.
Once the charge relief valve pressure is correct, remove

all tooling.
Vibratory Frequency Test (Variable Frequency)
Make reference
Troubleshooting.
133-9905
133-0963
4C-6500
to
WARNING
on
Tools Needed
Frequency Meter
Drum Vibration Tachometer
Temperature Probe
Flushing Manifold.
(1) Charge pressure test port. (2) Charge relief valve. (3) Adjustment
screw. (4) Locknut.
1.
Connect a 0 to 4000 kPa (580 psi) pressure gauge to

charge pressure test port (1) on the flushing manifold.
2.
Engage the parking brake. Put the propel control lever

in the NEUTRAL position. Start and run the engine at
high idle until the hydraulic oil temperature reaches
38C (100F). Engine rpm should be 2350 50 rpm.
3.
With the propel system in neutral and the vibratory

system OFF, record the pressure on the gauge
connected to the test port. The charge relief valve
setting should be 1725 138 kPa (250 10 psi).
4.
Charge pressure is determined by the steering pump

output, the internal leakage of the closed loop circuit,
the charge relief valves in each pump (one vibratory and
two propel) and open centered shuttle and charge relief
valves in the flushing manifold. If the charge pressure is
not correct, check the shim thickness of the charge relief
Side View of Operator Console.

(1) Vibrations per minute control dial.
13-36
first
page
of
1
1
1
TM 5-3895-382-24
Never operate the
concrete.
NOTE: The hydraulic oil temperature should be at least
38 C (100 F). The vibratory system should not
be run longer than five minutes with the drum
stationary. If testing time longer than five minutes
is required, the drum should be periodically
rotated to lubricate the eccentric weight shaft
bearings.
1.
Stop the machine and apply the parking brake.
2.
Start and run the engine at high idle (2350 50 rpm).
3.
Place the vibratory amplitude selector switch in HIGH

AMPLITUDE position. Rotate vibrations per minute
(vpm) control dial (1) to the full clockwise position.
4.
Depress the vibration control switch to start the vibratory

system. Read the vibrations per minute (vpm) from the
optional gauge or from either vibratory tachometer. The
maximum frequency for high amplitude should be 1875
75 vpm.
5.
Turn the vibrations per minute control dial (1) to the full
counterclockwise position. Read the vpm from the
optional vpm gauge or from either vibratory tachometer.
The minimum frequency for high amplitude is 1400 50
vpm. To adjust the minimum frequency, loosen the
locknut for high amplitude rheostat (3) and turn the
screw to obtain the correct minimum frequency. When
the minimum frequency is correct, tighten the locknut.
6.
Depress the vibratory control switch to stop the vibratory

system.
7.
Move the vibratory amplitude selector switch to the

LOW AMPLITUDE position. Rotate the vibrations per
minute (vpm) to the full clockwise position.
8.
Depress vibratory control switch to start the vibratory

system. Read the vibrations per minute (vpm) from
optional vpm gauge or read either vibratory tachometer.
The maximum vpm for low amplitude is 1875 75 vpm.
NOTE: The maximum frequency values for HIGH and

LOW amplitude should be within 50 vpm of each
other.
NOTE: If the frequency is not correct, refer to the
troubleshooting guide.
NOTE: If the frequency is not correct, refer to the

troubleshooting guide.
Fuse Compartment (View A-A).

(2) Low amplitude rheostat. (3) High amplitude rheostat.
13-37
9.
Turn vibrations per minute control dial (1) to the full

counterclockwise position. Read the vpm from the
optional vpm gauge or from either vibratory tachometer.
The minimum frequency for low amplitude is 1400 50
vpm. To adjust the minimum frequency, loosen the
locknut for low amplitude rheostat (2) and turn the screw
to obtain the correct minimum frequency. When the
minimum frequency is correct, tighten the locknut.
10.
Depress the vibratory control switch to stop the vibratory

system.
TM 5-3895-382-24
VPM Measurement Tests
Magnetic Sensor Resistance
If the hand held meter is correct and the vpm meter does not
accurately indicate system frequency, check the following
procedures to determine the cause, and repair.
Magnetic Sensor Voltage Test
Magnetic Sensor.
(1) Terminals. (2) Wires. (3) Case.
Magnetic Sensor.
1.
Disconnect two electrical wires (2) from magnetic

sensor.
2.
Touch the leads of an ohmmeter to terminals (1).

Resistance should be 265 30 ohms. If not, replace
the magnetic sensor.
3.
Set the ohmmeter on its highest setting.
4.
Attach one ohmmeter lead to one of the magnetic

sensor terminals (1). Touch the other ohmmeter lead to
the magnetic sensor case (3).
5.
Electrical resistance should be infinite. If the ohmmeter

gives any reading, the magnetic sensor should be
replaced.
6.
Repeat Steps 4 and 5 for the other terminal (1) of the

magnetic sensor.
(1) Terminals. (2) Wires. (3) Case.
1.
Disconnect two electrical wires (2) from magnetic

sensor.
2.
Set a voltmeter on lowest AC setting. Attach voltmeter

leads to magnetic sensor terminals (1).
3.
Start engine and run at full throttle.
4.
Move vibratory control switch to the low-amplitude

position.
5.
There should be a reading on the voltmeter as the

magnetic sensor picks up pulses from the sprocket as
the drive shaft rotates.
6.
If no reading is obtained, the magnetic sensor may be

out of adjustment, or may need to be replaced.
7.
Shut engine OFF.
13-38
TM 5-3895-382-24
Magnetic Sensor Adjustment
Vibratory Tachometer Calibration
Vibratory Tachometer.
(1) VPM meter. (2) Calibration screw.
Magnetic Sensor Installation.

(1) Sprocket. (2) Magnetic sensor. (3) Locknut. (4) Drive shaft.
REFERENCE: For complete information on removing items

listed in step 1, see Remove Drum Support (Vibratory Side) in
Vibratory Drum Disassembly and Assembly module, Form No.
KEBR2361.
1.
Remove vibratory motor, drum support cover, and

splined coupling from vibratory end of drum.
2.
Check the sprocket (1). It must be positioned directly

under the magnetic sensor (2), and must be securely
attached to the drive shaft (4).
3.
Using a feeler gauge, check the gap between magnetic

sensor and tip of sprocket tooth. Gap should be 1.57
mm (.062 in).
4.
Adjust gap, if necessary, by loosening locknut (3) and

turning magnetic sensor in or out until correct gap is
obtained.
5.
Retighten locknut (3).
6.
Install splined coupling, drum support cover, and

vibratory motor to vibratory end of drum.
13-39
1.
Compare frequency of the vibratory system on the

gauge to that of hand held Vibratory Tachometer 1330963.
2.
Large dial (1) should be set on #8.
3.
Small calibration screw (2) can be used to calibrate the

gauge. A 2.0 mm (5/64 in) allen wrench should be used
to adjust the small calibration screw. An access hole is
available on the bottom side of the console.
TM 5-3895-382-24
High Amplitude
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
3.
Move vibratory selector switch (3) to the HIGH

AMPLITUDE position.
4.

5.
Look at the gauge and depress vibratory control switch

(2) to the ON position to start the vibratory system.
Engine rpm
NOTE: This main relief pressure should be checked while

running the vibratory system. For this reason, it
is recommended that the drum be placed on tires
to simulate an uncompacted soil condition. The
hydraulic oil temperature should be 38 C (100 F).
NOTE: The force needed to overcome the inertia of the

weights will cause the pressure in the vibratory
system to momentarily reach the high amplitude
relief valve setting. Observe the gauge when
starting the vibratory system and record the
highest reading.
1.
6.

control lever is in the NEUTRAL position.
Vibratory Pump
Vibratory Flushing Valve.
(4) High amplitude relief valve.
(1) High amplitude test port.
2.
The high amplitude relief valve setting should be 29 000

to 33 100 kPa (4200 to 4800 psi).
7.
Connect a 60 000 kPa (8700 psi) pressure gauge to test

port (1).
Control Panel.
(2) Vibratory control switch. (3) Vibratory selector switch.
13-40
If the high amplitude relief valve setting is not correct,

high amplitude relief valve (4) must be replaced.
TM 5-3895-382-24
8.
When a new high amplitude relief valve is installed,

check the pressure setting again. If it is correct, stop
the engine and remove all tooling.
Low Amplitude
NOTE: If continued high pressure operation is seen, a

problem may exist with the vibratory drive
mechanism.
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
NOTE: This main relief pressure should be checked while

running the vibratory system. For this reason, it
is recommended that the drum be placed on tires
to simulate an uncompacted soil condition. The
hydraulic oil temperature should be 38 C (100 F).
1.

control lever is in the STOP position.
Vibratory Flushing Valve.

(1) Low amplitude test port.
2.
Connect a 60 000 kPa (8700 psi) pressure gauge to test

port (1).
Control Panel.
(2) Vibratory control switch. (3) Vibratory selector switch.
3.
13-41
Move vibratory selector switch (3) to the LOW

AMPLITUDE position.
TM 5-3895-382-24
4.

Engine rpm
5.
Look at the gauge and depress vibratory control switch

(2) to the ON position to start the vibratory system.
8.
NOTE: The force needed to overcome the inertia of the

weights will cause the pressure in the vibratory
system to momentarily reach to the low amplitude
relief valve setting. Observe the gauge when
starting the vibratory system.
The highest
reading on the gauge is the low amplitude relief
valve setting.
6.
For early pumps, the low amplitude relief valve setting

should be 21 360 to 25 500 kPa (3100 to 3700 psi). For
later pumps, the high amplitude relief valve setting
should be 29 000 to 33 100 kPa (4200 to 4800 psi).
Vibratory Pump (Early).

(4) Low amplitude relief valve.
Vibratory Pump (Later).

(4) High amplitude relief valve.
7.
If the low amplitude relief valve setting is not correct, low

amplitude relief valve (4) must be replaced.
13-42
When a new low amplitude relief valve is installed,

check the pressure setting again. If it is correct, stop
the engine and remove all tooling.
TM 5-3895-382-24
5.
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up, 3TM706Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up, 1ZN121-Up, 1FS1Up, 1XZ1-Up)
Loosen the locknut (5) on EDC control neutral

adjustment screw (4) with a 17 mm hex wrench. Turn
the EDC control neutral adjustment screw (4) with a 5
mm internal hex wrench until both gauge readings are
the same.
6.
Turn the EDC control neutral adjustment screw (4)

clockwise until one of the pressure gauge readings
starts to increase. Note the position of the EDC control
neutral adjustment screw (4).
Make reference
Troubleshooting.
7.
Now turn EDC control neutral adjustment screw (4)

counterclockwise until the reading on the other pressure
gauge begins to increase. Note the position of the EDC
control neutral adjustment screw (4). Turn the EDC
control neutral adjustment screw (4) one-half the
distance to the first screw setting.
8.
Hold EDC control neutral adjustment screw (4) and

tighten locknut (5) to a torque of 14 to 24 Nm (10 to 18
lb-ft).
9.
Stop the engine. Remove the gauges and install servo

port plugs (2) and (3). Connect wire harness for
electrical displacement control (EDC) (1).
Machines with Variable Frequency

Electrical Displacement Control (EDC) Neutral Adjustment
to
WARNING
on
first
page
of
NOTE: Tests should be performed on tires or loose noncompacted soil. Rubber tires are recommended.
Never operate the vibratory system when the
machine is on concrete.
1.

control lever is in the neutral position.
NOTE: The swashplate neutral adjustment procedure

should be performed prior to doing the electrical
displacement control neutral adjustment. The
swashplate neutral adjustment will affect the
gauge readings.
Vibratory Pump.
(1) Wire harness for electrical displacement control (EDC). (2) Servo
port. (3) Servo port. (4) EDC control neutral adjustment screw. (5)
Locknut

out of the machine.
2.
Disconnect wire harness for electrical displacement

control (EDC) (1).
3.
Remove servo port plugs (2) and (3). Install 6V-3965

Quick Disconnects. Install a 600 kPa (1000 psi) gauge
to each Quick Disconnect.
4.
Start and run the engine at low idle rpm.
13-43/(13-44 blank)
TM 5-3895-382-24
KENR2639-02
October 1998
CHAPTER 14
Specifications
Systems Operation
Testing & Adjusting
CP-433C & CS-433C

Steering System
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES :
Additional Information may be found in:
14-1
TM 5-3895-382-24

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
The information, specifications, and Illustrations in this publication are on the basis of information available at the time it was written.
When replacement parts are required for this product,

parts or parts with equivalent specifications, including, but
material.
14-2
TM 5-3895-382-24
Index
Specifications
Steering Pivot Clearance Adjustments ................................14-17

Horizontal Steering Pivot Clearance ................................14-18
Oscillation Bearing Clearance ...........................................14-29
Vertical Steering Pivot Clearance .....................................14-18
Index ............................................................................................ 14-3

Introduction ................................................................................ 14-3
Steer Pump Priority Flow Test ..............................................14-16
Steering Column Group ........................................................... 14-5
System Pressure Check ........................................................14-15
Steering Control Unit ................................................................ 14-5
Operation Checks ...............................................................14-13
Pump Efficiency Check ......................................................14-15
Visual Checks ......................................................................14-13
Cylinders ..................................................................................... 14-4

Pivot And Oscillation Assembly ............................................... 14-6
Pump ........................................................................................... 14-4
Introduction
used again. If the part is equal to or within the specification
Systems Operation
Introduction ................................................................................ 14-7
Priority Valve Operation .........................................................14-10
No Flow .................................................................................14-10
No Steering Load ................................................................14-10
With Steering and Load ......................................................14-11
Steering Relief .....................................................................14-11

needed.
Steering Control Unit Operation ...........................................14-12

Oil Flow .................................................................................14-12
Pump ........................................................................................... 14-9
System Schematic .................................................................... 14-7
14-3
TM 5-3895-382-24
Pump
Cylinders
Rotation is clockwise when seen from drive end.

Type of pump .............................................................................Gear
(1) Put hydraulic oil on rod end threads.

Torque for piston nut .........................................820 28 Nm
(590 20 lb-ft)
Displacement ...............................................................28.5 cm3/rev

(1.74 in3/rev)
(2) Rod diameter (new) ..................................38.090 .013 mm

(1.4995 .0005 in)
Relief valve setting ........................................................13 000 kPa

(1885 psi)
(3) Head bore (new) ........................................38.200 .025 mm

(1.5040 0010 in)
Tighten four bolts to a torque of ..................................18 4 Nm

(13 3 lb-ft)
(4) Cylinder bore (new) ..................................76.162 .038 mm

(2.9985 .0015 in)
14-4
TM 5-3895-382-24
(2) Pin and the groove of the drive shaft must be aligned with
the root of the rotor.
Steering Control Unit (SCU)
Tighten bolts in sequence shown to an initial

torque of..................................................................................17 Nm
(150 lb-in)
Tighten bolts in sequence shown to a final

torque of ..........................................................................28 3 Nm
(250 25 lb-in)
If the steering control unit drive is not timed correctly, the

machine can turn in the opposite direction as the steering
wheel. To prevent personal injury, loss of life and/or
property damage, make sure the drive is timed correctly.
Steering Column Group
(1) Torque for steering wheel nut ..........................41 to 54 Nm

(30 to 40 lb-ft)
(2) Torque for steering control unit
mounting bolts .......................................................23 4 Nm
(17 3 lb-ft)
(1) Torque for setscrew (not shown) on

end of housing .......................................................11 1 Nm
(100 10 lb-in)
14-5
TM 5-3895-382-24
Steering Pivot and Oscillation Assembly
(1) Upper pivot pin vertical end-play ......................0.2 - 0.8 mm

(.008 -.030 in.)
(5) Pivot pin diameter ....................................... 88.90 0.04 mm

(3.500 .002 in)
Pivot Shims
(6) Steering pivot frame bore

diameter ........................................................ 76.14 0.04 mm
(2.998 .002 in)
NOTE: Install thickest shims first:

0.6 mm (.024 in)
1.2 mm (.047 in)
1.9 mm (.075 in)
Oscillation axial end-play ...................................... 0.05 - 0.25 mm

(.002 - .010 in) endplay.
(2) Pivot housing bore diameter ................120.615 0.019 mm

(4.7486 .0007 in)
(7) Oscillation shims:

0.25 mm (.010 in)
0.80 mm (.030 in)
1.20 mm (.047 in)
1.60 mm (.059 in)
3.00 mm (.105 in)
(3) Oscillation pin diameter ..................................63.519 0.006

2.5007 .0001
(4) Pivot plate bore diameter .........................99.985 .018 mm
(3.9364 .0007 in)
14-6
TM 5-3895-382-24
Systems Operation
Steering System Schematic.

(1) Steering cylinders. (2) Steering control unit (SCU). (3) Steering pump. (4) Strainer. (5) Hydraulic oil tank. (6) Relief valve. (7) Charge oil line to
propulsion and vibration systems.
Introduction
The main components of the steering system are steering
cylinders (1), steering control unit (2), steering pump (3) and
hydraulic oil tank (5).
14-7
TM 5-3895-382-24
View Of Area Under Console.
View Of Left Side Of Machine.

(5) Hydraulic oil tank.
(2) Steering control unit.
Hydraulic oil tank (5) is located behind the operators platform.

A strainer is located in the hydraulic oil tank. The hydraulic oil
passes through the strainer and out to the steering, propulsion,
and vibration systems.
The oil flows from steering pump (3) to steering control unit (2).
The steering control unit is located at the bottom of the steering
column just under the steering console. The steering control
unit is open center and non-load sensing.
Right Side Engine Compartment.
View Of Area Under Operator Platform.
(3) Steering pump.
(1) Steering cylinder.
Steering pump (3) pulls oil from hydraulic tank (5). The
steering pump is located on the left side of the engine. It is
mounted to the front engine housing.
When the steering wheel is turned, two double acting steering

cylinders (1) receive oil from steering control unit (2) so that the
compactor can make the desired turn. When the steering
wheel is not being turned, oil goes through the steering pump
to maintain pressure at the steering control unit. There is a
small amount of oil required to make up for losses through the
bleed orifice in the steering pump. With the steering control
unit in the spring centered position, no oil is ported to the steer
cylinders.
14-8
TM 5-3895-382-24
Steering Pump
Pump
Steering Pump.
(1) Flow divider spool. (2) Pilot relief valve. (3) Priority flow divider and pilot relief valve body. (4) Pump housing. (5) Driving pump gear. (6) Mounting
flange. (7) Helical gear. (8) Driven pump gear.
The steering pump supplies priority oil flow to the steering

circuit. It also supplies charge oil for propel and vibratory
circuits. It also supplies oil for the blade leveling option if
equipped. The priority flow divider valve divides the oil flow
between the steering circuit and the charge/leveling blade
circuit. The steering circuit has priority, and the return flow
from the steering circuit goes to the charge circuit.
The steering pump is a fixed displacement gear pump driven

off of the front engine housing. The output from the pump will
vary with the RPM of engine. Priority flow divider and pilot
relief valve body (3) is mounted to pump housing (4). Priority
valve spool (1) divides the flow of oil from the pump into a
constant priority flow and a variable secondary flow. Pilot relief
valve (2) limits the steering pressure relief.
14-9
TM 5-3895-382-24
No Steering Load
Priority Valve Operation

Machine Off (no flow)
Priority Flow Divider Valve Body Cross Section.
Priority Flow Divider Valve Body Cross Section.
(16) Spring. (11) Control orifice. (14) Steering circuit port. (17) Flow
passage. (18) Flow passage. (19) Charge circuit port. (20) Passage.
(1) Priority valve spool. (9) Orifice. (10) Pressure passage. (11)
Control orifice. (12) Damping orifice. (13) Passage. (14) Steering
circuit port. (15) Passage.
Pressure acting on both ends of priority spool (1) creates a

force which moves priority spool (1) to the left compressing
spring (16).
When the machine starts up, oil from the steering pump enters
the valve body through pressure passage (10). The oil flows
into the center of priority spool (1), passage (15). It then flows
through control orifice (11) into passage (13) and onto the
steering circuit through steering circuit port (14).
As oil flow increases in pressure port (10), the pressure drop

across control orifice (11) increases until enough force is
generated to move priority spool (1) to the left as shown.
Some oil flow can now pass through passage (20) to the
charge/blade circuit through charge circuit port (19).
The oil in passage (15) senses pressure on both ends of

priority spool (1). Oil pressure is sensed through damping
orifice (12) on the right hand end and through control orifice
(11) on the left hand end.
As oil flow into the valve increases more, oil flow through
control orifice (11) attempts to increase. This increases the
pressure drop across control orifice (11). Priority spool (1)
moves farther to the left. As priority spool (1) moves to the left,
flow passage (17) decreases and flow passage (18) increases
in size. When flow passage (17) decreases, oil flow to the
steer circuit decreases. When flow passage (18) increases, oil
flow to the charge/blade circuit increases.
14-10
TM 5-3895-382-24
With Steering and Load
Steering Relief
With Steer and Load.

(1) Priority spool. (11) Control orifice. (17) Flow Passage. (20) Steer
relief passage.
(10) Pressure passage. (18) Flow passage.
When the steering is operated during a load on the charge

circuit the priority function of the valve is operated. Inlet
pressure in pressure passage (10) increases. High inlet
pressure forces more oil flow to the charge circuit and
decreases flow to the steering circuit. The force on both ends
of priority spool (1) becomes unbalanced. Priority spool (1)
moves to the right as shown. Flow passage (18) decreases,
flow to charge circuit decreases and priority flow to steering is
restored.
A similar condition exists if a load at the charge inlet creates

high pressure. When the inlet pressure is high on the charge
relief side of the valve, priority spool (1) moves to allow more
flow to the charge circuit. The pressure drop increases across
control orifice (11) and moves priority spool (1) to the left as
shown.
The priority flow is metered at flow passage (17). Control
orifice (11) is designed to maintain a constant flow to the
steering circuit. During operation, priority spool (1) will
oscillate.
The location of priority spool (1), as shown, is also the position
during system relief. Steering relief pressure is limited to
13 000 kpa (1885 psi). Relief oil exits the valve through relief
passage (21).
14-11
TM 5-3895-382-24
The steering wheel is connected to spool (6) by shaft assembly
and splines. When the steering wheel is turned, spool (6) turns
a small amount until centering springs (7) are compressed.
Then, sleeve (11) starts to turn. As long as the steering wheel
is turned, the spool and sleeve both turn as a unit, but they turn
a few degrees apart.
When the spool and sleeve are a few degrees apart, oil
passages are opened between them. This allows oil to flow
from inlet port (3) through passages in body (12) to the
metering section.
Cross Section Of Steering Control Unit.

(1) Outlet port. (2) Check valve (not shown). (3) Inlet port. (4) Internal
pump gear. (5) External pump gear. (6) Spool. (7) Centering springs.
(8) Cross pin. (9) Left turn port. (10) Right turn port. (11) Sleeve.
(12) Body. (13) Drive. (A) Control section. (B) Metering section.
The steering control unit is spring centered (no turn), non-load

sensing type.
Pump Gears In Metering Section.
The steering control unit has two main sections. They are
control section (A) and metering section (B). The two sections
are connected inside the unit, both hydraulically and
mechanically. These two sections work together to send oil to
the steering cylinders.
(4) Internal pump gear. (5) External pump gear. (8) Cross pin. (13)
Dive.
When the steering wheel is turned, cross pin (8) turns with
sleeve (11) and causes drive (13) to turn also. The drive
causes a rotation of internal pump gear (4) inside external
pump gear (5). This rotation of the gear sends a controlled
(metered) flow of pilot oil back through body (12). This oil
flows to right or left turn ports (9) or (10) and then to the
steering cylinders. The right or left turn port that is not used for
pressure oil to the steering cylinders, is used for return oil from
the other ends of the steering cylinders.
Oil goes through inlet port (3) into control section (A). When
the steering wheel is turned, the control section sends oil to
metering section (B). Metered oil from section (B) is directed
by control section (A) to either left turn port (9) or right turn port
(10).
Metering section (B) is a small hydraulic pump. It produces a
specific amount (metered) of oil flow. This metered oil is then
directed by control section (A) to the steering cylinders.
If the steering wheel rotation is stopped, centering springs (7)

move sleeve (11) back in alignment with spool (6). This closes
the passages between the metering section and control
section. The steering control unit is then in the neutral
position.
The direction and the speed of a turn are controlled by the

steering control unit. As the steering wheel is turned faster,
there is an increase in the flow of oil from the steering control
unit to the steering cylinders. This increased flow causes the
cylinders to move farther and faster, which turns the machine
faster.
When the engine is off, the steering control unit can be

manually operated. The metering section works as a pump.
Return oil from the steering cylinders is not returned to the
hydraulic oil filter. The suction of the metering section opens
check valve (2) and let return oil from the steering cylinders go
to the inlet side of the metering section. During power
operation, supply pressure keeps the check valve closed.
Oil Flow
Oil flows through inlet port (3). When the steering wheel is
stationary (NEUTRAL), the oil is stopped by spool (6). The oil
cannot flow through the steering control unit to the steering
cylinders until the steering wheel is turned.
14-12
TM 5-3895-382-24
NOTE: During certain performance tests it will be
necessary to release the parking brake to help
drum movement when turns are required.

Troubleshooting
Troubleshooting can be difficult. A list of possible problems
and probable causes is on the pages that follow.
This list of problems and probable causes will only give an
indication of where a problem can be and what repairs are
needed. Normally, more or other repair work is needed
beyond the recommendations on the list. Remember that a
problem is not necessarily caused only by one part, but by the
relation of one part with other parts. This list cannot give all
possible problems and probable causes. The serviceman
must find the problem and its source, then make the necessary
repairs.
7.

A visual inspection of the steering system and its components

is the first step when a diagnosis of a problem is made. Stop
the engine, make the following inspections.
When any test is made of the steering hydraulic system, the

hydraulic oil must be at the normal temperature for operation.
1.
Measure the oil level.
2.
Look for air in the oil that is in the hydraulic tank. Do

3.
Remove the hydraulic filter element and look for

particles removed from the oil by the filter element.
4.
Check all oil lines and connections for damage.
Operation Check
Sudden movement of the machine or pressure oil release

can cause injury to persons on or near the machine. To
prevent possible injury, do the procedure that follows
before testing and adjusting the steering hydraulic
system.
2.

Visual Checks
The 4C4892 ORFS Fittings Group can be used to make

pressure tests of the steering system. Before any tests are
leakage of oil and for parts that are damaged. For some of the
tests a magnet and a mm (in) measuring rule will be needed.
1.
6.
Operation checks of the steering system can be used for a

diagnosis of poor performance and to find the source of oil
leakage inside the hydraulic system.
Problem: Steering pump makes noise and the steering
cylinder rods do not move smoothly.

Stop the engine.
Probable Cause:

of the operator.
1.
Air in the steering hydraulic circuit.
2.
The steering pump is worn.
3.

3.
Loose oil line connection on the inlet side of the steering

pump.
4.

4.
Low oil level in the hydraulic oil tank.
5.
5.
Viscosity of the hydraulic oil is wrong.
14-13
TM 5-3895-382-24
Problem: Too much force is needed to turn the steering
wheel.
Problem: Machine turns too slow in one direction.

Probable Cause:
Probable Cause:
1.
1.
Relief valve is open.
2.
3.
Steering pump oil pressure is too low, caused by a worn

steering pump.
4.
Steering control unit covers are too tight.
5.
Steering control unit is defective.
6.
Hydraulic oil is cold.
7.
Alignment of steering column is not correct.
Restriction in steering control unit.
Problem: The steering control unit does not return to

center position correctly.
Probable Cause:
1.
Steering control unit covers are too tight.
2.
Alignment of the steering column is not correct.
3.
Valve spool in the steering control unit has a restriction.
Problem: Temperature of hydraulic oil is too hot.

Probable Cause:
Problem: Machine does not turn when steering wheel is
turned.
1.
Viscosity of the hydraulic oil is wrong.
Probable Cause:
2.
Air is mixed with the hydraulic oil.
1.
3.
Steering system relief valve has a defect.
2.
Air in the hydraulic system.
4.
There is a restriction in the one of the steering system

lines or components.
3.
Dirt in the hydraulic system.
4.
Steering pump operation is not correct.
5.
Frame articulation is locked because the lock pin is in

position.
Problem: Steering wheel turns without the operator

turning it.
Probable Cause:
1.
Foreign material causes the sleeve valves in steering

control unit to stick.
2.
Centering springs are broken or damaged in the

steering control unit.
3.
Timing of the steering control unit drive is not correct.

The drive must be timed as follows.
Problem: Machine turns too slow in both directions.

Probable Cause:
1.
Not enough oil flow from steering pump.
2.
Steering pump suction line is restricted.
3.
Steering control unit operation is not correct.
4.
Seal leakage in the steering cylinders.
5.
Priority valve spool inside steering pump does not allow

enough oil to go to the steering control unit.

property damage, make sure the drive is timed as follows.
14-14
TM 5-3895-382-24
*Numbers in examples are for illustration and are not values for
any specific pump or pump condition. See Specifications for
pump flow of a new pump at 690 kPa (100 psi) and 6900 kPa
(1000 psi).
Steering Control Unit Drive Timing
If the test bench can be run at 6900 kPa (1000 psi) and at full
If the test bench cannot be run at 6900 kPa (1000 psi) and at
Use these values in the top par of Formula II. For the bottom
Formula 2:
gpm @ 100 psi @ 2000 rpm
Steering Control Unit Dive Timing.

(1) Cross pin. (2) Rotor tooth used for alignment. (3) Rotor. (4)
Stator.
X 100 =
Percent of
flow loss
System Pressure Check
Cross pin (1) must align with the bottom of rotor tooth (2).
Make reference
Troubleshooting.
(100 psi) will be larger than the pump flow at 6900 kPa (1000
psi). The difference between the pump flow of the two
to
on
Tools Needed
ORFS Fittings Group
4C4892
Method for finding flow loss:
WARNING
Pump flow at 100 psi .................................... 57.5 gpm (liter/min)*

Pump flow at 1000 psi ................................. -52.0 gpm (liter/min)*
Flow loss ............................................................5.5 gpm (liter/min)*
gpm flow loss
Pump flow @ 100 psi
or
*5.5
*57.5
X 100 =
Percent of
flow loss
X 100 = 9.5%
Frame Lock Pin Installed.

(1) Lock pin. (2) Yoke.
1. Apply the parking brake.
14-15
first
page
of
TM 5-3895-382-24
2.
Install frame lock pin (1) in the hole provided in

articulation yoke (2).
3.
Connect the 0 to 25 000 kPa (0 to 3600 psi) pressure

gauge from the fittings group, to pressure tap (1). This
pressure gauge will measure the steering relief valve
pressure setting.
4.
Steering Pump.
1. Priority flow line. 2. Charge circuit line (secondary flow).
3.
Install the flowmeters in lines (1) and (2). Line (1)

supplies priority oil flow to the steering circuit. Line (2)
supplies secondary oil flow to the charge circuit.
4.
Start and run the engine at 2350 RPM (high idle).
Steering Pump.
Priority
(Steer)
(1) Pressure tap.
5.
Turn the steering wheel to the left until the steering relief
valve opens. Record the reading on the gauge. The relief
valve pressure should be 13 500 500 kPa (1960 75 psi).
5.
Steer Pump Priority Flow Test
Make reference
Troubleshooting.
4C4892
to
WARNING
Tools Needed
Flowmeter
Steer Pump Flow 2350 RPM (gpm)

Secondary
Service
Total
(Charge)
Limit
11
17
15
Measure the flow rate in lines (1) and (2). Add the
measurements together to obtain total flow. Refer to
chart above.
NOTE: The flows in lines (1) and (2) can be measured

separately with one flowmeter. The resulting
flows can then be added together to obtain total
flow.
on
first
page
of
1.
Apply the parking brake.
2.
Install the frame lock pin in the hole provided in the

articulation yoke.
14-16
TM 5-3895-382-24
Steering Pivot Clearance Adjustments
Steering Pot.
1. Bushings. 2. Upper pivot pin. 3. Pivot bearings. 4. Oscillation bearings. 5. Shim. 6. Pivot housing plate. 7. Lower pivot pin
8T5096
Tools Needed
Dial Indicator Test Group
Clearance Checks
NOTE: After installation of the front yoke assembly, the
clearance between the vertical bushings and
vertical pins must be checked. Use the following
procedure:
14-17
TM 5-3895-382-24
Vertical Steering Pivot Clearance
Horizontal Steer Pivot Clearance
1.
Put the machine on a hard level surface.

engine, and apply the secondary brake.
Stop the
2.
Attach the base of 8T5096 Dial Indicator to the top of

the steer pivot housing as shown. Set the dial indicator
actuator on the top of the rear frame.
3.
Set the dial indicator to zero.
4.
Place a hydraulic jack under the rear frame at the pivot

assembly.
Steering Pivot Area

Dial Indicator position.
Check the horizontal steer pivot clearance as follows:

1.

engine, and apply the parking brake.
2.
Disconnect the wire from the brake solenoid on top of

the brake/shift valve.
3.
Attach the base of 8T5098 Dial Indicator or equivalent to

the top of the steer pivot housing. Set the dial indicator
actuator against the front face of the rear frame.
4.
5.
Release the parking brake on the operator control

console. (Parking brake stays engaged when the
solenoid wire is disconnected in step 2.)
6.
7.
Propel the machine in the forward direction against the

parking brake. Observe the indicator reading.
8.
Propel the machine in the reverse direction against the

parking brake. Observe the indicator reading sweep.
(Movement of the indicator needle from the position in
the forward direction to the position of the needle in the
reverse direction. Total indicator travel is the indicator
sweep.)
9.
With the new bearings, bushings and pins the total

movement recorded should be .10 to .76 mm (.004 to
.030 in). On a used machine the total movement should
not exceed 1.27 mm (.050 in).
Steering Pivot Area

Dial indicator position.
5.
Raise the hydraulic jack and record the reading on the

dial indicator.
NOTE: When adjusting vertical clearance, top spacer (3)

is the only pivot point location to be shimmed.
6.
7.
With new bearings and shims installed, total movement

should be .13 to 1.14 mm (.005 to .045 in) on a used
machine; total vertical movement should not exceed
1.91 mm (.075 in). If the movement is too much, the
clearance can be reduced by adding spacers at the
vertical pin joints. If the movement is too small, the
clearance can be increased by removing spacers at the
vertical pin joint.
If the proper clearance cannot be obtained with the
spacers, the steer pivot housing should be
disassembled. Bushings or any other worn components
should be replaced.
14-18
Stop the
TM 5-3895-382-24
10.
If the movement is too much, the steer pivot housing

should be disassembled. Bushings, bearings and any
other worn components should be replaced.
Oscillation Bearing Clearance
NOTE: When removing or adding shims behind the plate,

remove or add equal amounts at the top and
bottom of the plate.
8.
Check the oscillation bearing clearance as follows:

NOTE: During assembly, it is recommended that this
clearance measurement be made prior to
installing the drum into the yoke.
1.

engine, and apply the secondary brake.
Stop the
NOTE: Inadequate bearing lubrication may result if zero

endplay or a preload condition is present.
9.
Steering Pivot Area

Dial Indicator position.
2.

the brake/shift valve.
3.
Attach the base of 8T5098 Dial Indicator to the front

face of the steer pivot bearing plate. Set the dial
indicator actuator against the front face of the oscillation
shaft. Set the dial indicator to zero.
4.

console. (Parking brake will stay engaged when the
solenoid wire is disconnected in step 2).
5.
6.

parking brake. Observe the Indicator reading.
7.

(Movement of the Indicator needle from the position in
sweep.)
Total movement should be .05 to .25 mm (.002 to .010

in) on a new assembly. The maximum reading for a
used assembly should be .51 mm (.020 in). If the
movement is too much, reduce clearance by removing
shims from behind the plate. If the clearance is too
small, add shims to increase the clearance.
14-19/(14-20 blank)

removal or addition of shims, the oscillation assembly
should be disassembled. Bushings and any other worn
components should be replaced.
TM 5-3895-382-24
KENR2718-02
October 1998
CHAPTER 15
Specifications
Systems Operation
Testing & Adjusting
CP-433C & CS-433C

Leveling Blade System
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
15-1
TM 5-3895-382-24


material.
15-2
TM 5-3895-382-24
Index
Specifications
Leveling Blade Control Valve .................................................. 15-4
Leveling Blade Cylinder ........................................................... 15-4
Systems Operation
Introduction ................................................................................. 15-5
Leveling Blade Control Valve .................................................. 15-6
FLOAT Position........................................................................15-10
HOLD Position ............................................................................ 15-7
LOWER Position ........................................................................ 15-9
RAISE Position .......................................................................... 15-8
Leveling Blade Cylinder Leakage Test ................................15-13
Leveling Blade System Pressure Check..............................15-12
Performance Tests ..........................................................15-11
Visual Checks ..................................................................15-11
15-3
TM 5-3895-382-24
Specifications
Leveling Blade Control Valve
(1) Relief valve setting .....................................10 330 345 kPa

(1500 50 psi)
Leveling Blade Cylinder
(2) Apply Loctite #271 to threads of retainer
(3) Torque for four bolts ..........................................12 to 15 Nm

(9 to 11 lb-ft)
(4) Torque for two bolts ...........................................12 to 15 Nm

(9 to 11 lb-ft)
(1) Put hydraulic oil on rod end threads. Torque for

piston nut................................................... 309 Nm (227 lb-ft)
(2) Rod diameter (new) ..................................38.105 .030 mm
(1.5002 .0012 in)
(3) Sleeve I. D. (new) ....................................38.250 .0250 mm
(1.5060 .0010 in)
(4) Cylinder bore (new) ..................................76.200 .076 mm
(3.0000 .0030 in)
15-4
TM 5-3895-382-24
Systems Operation
Introduction
Blade Control Lever.

(5) Blade Control lever
Leveling Blade System Schematic.
(1) Leveling blade control valve. (2) Oil line to secondary brake valve.
(3) Oil line from steering priority valve. (4) Leveling blade cylinder.
Control valve (1) is located under the operator's platform. Oil

flows from the steering priority valve to control valve (1). The
control valve is a four position valve, controlled by blade
control lever (5). Control valve (1) sends oil to and from the
blade cylinder, allowing the blade to RAISE, HOLD, LOWER or
FLOAT.
The leveling blade system is a mechanically controlled,

hydraulically operated system. The main components of the
leveling blade system are control valve (1), cylinder (4) and the
leveling blade.
Hydraulic oil for the leveling blade system comes from the
excess flow outlet of the steering priority valve.
Leveling Blade Cylinder.

(4) Leveling blade cylinder. (6) Leveling blade.
Leveling blade (6) is attached to the machine at the drum yoke.

The blade is raised or lowered by retracting or extending
cylinder (4). The maximum depth of cut with the leveling blade
is 76.2 mm (3 in).
Leveling Blade Control Valve.

(1) Leveling blade control valve.
15-5
TM 5-3895-382-24
Leveling Blade Control Valve.

(1) Detent ball and spring. (2) Centering spring. (3) Passage to piston end of cylinder. (4) Outlet passage. (5) Passage to head end of cylinder. (6)
Spool. (7) Valve body. (8) Inlet passage. (9) Relief valve.
The control valve is a four-way, four-position, open center

directional valve. The control valve allows oil to flow to the
blade cylinder as directed by the blade control lever.
Relief valve (9) is located in the valve body (7). The relief
valve is screw adjustable to limit maximum pressure to
10 330 345 kPa (1500 50 psi).
The operator sets the position of the control valve by moving

the blade control lever at the operators console. The four
positions are RAISE, HOLD, LOWER and FLOAT.
Oil from the steering priority valve enters valve body (7) at inlet
passage (8). Passages (3) and (5) are connected to the blade
cylinder. Return oil flows through outlet passage (4) to the
hydraulic oil filter and second brake valve.
Spool (6) is held in the HOLD position by centering spring (2).

The control valve contains detent ball and spring (1) which
holds spool (6) in place when the control valve is set in the
FLOAT position.
15-6
TM 5-3895-382-24
HOLD Position
Leveling Blade Control Valve - HOLD Position.

(2) Centering spring. (3) Passage to rd end of cylinder. (4) Outlet passage. (5) Passage to head end of cylinder. (6) Spool. (8) Inlet passage (9) Relief
valve.
In the HOLD position, spool (6) stops the pressure oil in

passage (8) from going into passages (3) and (5). The oil in
passage (3) to the rod end of the cylinder and passage (5) to
the head end of the cylinder is blocked. This holds the blade in
position.
Centering spring (2) holds spool (6) in this position. Pressure
oil from inlet passage (8) flows across the spool to outlet
passage (4).
15-7
TM 5-3895-382-24
RAISE Position
Leveling Blade Control Valve - RAISE Position.

(2) Centering spring. (3) Passage to rod end of cylinder. (4) Outlet passage. (5) Passage t head end of cylinder. (6) Spool. (8) Inlet passage (10)
Passage.
When spool (6) is shifted from the HOLD position to the RAISE
position, the spool is moved to the right. Pressure oil is
allowed to flow from inlet passage (8) to cylinder rod end
passage (3) through internal passage (10). This results in the
blade raising.
With spool (6) in the RAISE position, cylinder head end
passage (5) is open to outlet passage (4).
Centering spring (2) is compressed in this position. When the
blade control lever is released, centering spring (2) returns to
normal position. This pulls the blade control lever back into the
HOLD position.
15-8
TM 5-3895-382-24
LOWER Position
Leveling Blade Control Valve - LOWER Position.

(2) Centering spring. (3) Passage to piston end of cylinder. (4) Outlet passage. (5) Passage to head end of cylinder. (6) Spool. (8) Inlet passage. (11)
Passage.
When spool (6) is shifted from the HOLD position to the

LOWER position, the spool is moved to the left. Pressure oil is
allowed to flow from inlet passage (8) to cylinder head end
passage (5) through internal passage (11). This results in the
blade lowering.
With spool (6) in the LOWER position, cylinder rod end
passage (3) is open to outlet passage (4).
Centering spring (2) is compressed in this position. When the
blade control lever is released, centering spring (2) returns to
normal position. This pulls the blade control lever back into the
HOLD position.
15-9
TM 5-3895-382-24
FLOAT Position
Leveling Blade Control Valve - Float Position.

(1) Detent ball and spring. (2) Centering spring. (3) Passage to rod end of cylinder. (4) Outlet passage. (5) Passage to head end of cylinder. (6)
Spool. (8) Inlet passage. (10) Passage. (11) Passage. (12) Detent sleeve.
When spool (6) is shifted from the HOLD position to the

FLOAT position the spool is moved all the way to the left.
Centering spring (2) is fully compressed, and detent bails and
springs (1) are located in the groove of detent sleeve (12).
Centering spring (2) does not have enough force to pull the
detent balls past the groove in the detent sleeve. Spool (6) will
be held in the FLOAT position until the operator moves the
blade control lever out of the FLOAT position.
With the control valve in the FLOAT position, spool (2) blocks
pressure oil in inlet passage (8) and internal passages (10) and
(11). Cylinder rod end passage (3) and cylinder head end
passage (5) are open to outlet passage (4). Since the cylinder
rod and head ends are open to tank, the blade will follow the
shape of the ground.
15-10
TM 5-3895-382-24
7.

Troubleshooting can be difficult. A list of possible problems

and probable causes is on the pages that follow.
8.

This list of problems and probable causes will only give an

indication of where a problem can be and what repairs am
needed. Normally, more or other repair work is needed
beyond the recommendations on the list. Remember that a
problem is not necessarily caused only by one part, but by the
relation of one part with other parts. This list cannot give all
possible problems and probable causes. The serviceman
must find the problem and its source, then make the necessary
repairs.
Visual Checks

Troubleshooting
A visual inspection of the leveling blade system and its

components is the first step when a diagnosis of a problem is
made. Stop the engine, make the following inspections.
The 4C4890 Fittings Group can be used to make pressure

tests of the leveling blade system. Before any tests are made,
visually inspect the complete hydraulic system for leakage of
oil and for parts that are damaged. For some of the tests a
magnet and a mm (in) measuring rule will be needed.
When any test is made of the leveling blade hydraulic system,
the hydraulic oil must be at the normal temperature for
operation.
1.
Measure the oil level.
2.
Look for air in the oil that is in the tank. Do this

immediately after the machine is stopped. Use a clear
bottle or container to get a sample of the oil. Look for
air bubbles in the oil that is in the bottle.
3.
Remove the hydraulic filter element and look for

particles removed from the oil by the filter element.
4.
Check all oil lines and connections for damage.
Performance Tests
Performance tests of the leveling blade system can be used for
a diagnosis of poor performance and to find the source of oil
leakage inside the hydraulic system.
Sudden movement of the machine or pressure oil release

can cause injury to persons on or near the machine. To
prevent possible injury, do the procedure that follows
before testing and adjusting the leveling blade hydraulic
system.
Problem: Steering pump makes noise and the blade

cylinder rod does not move smoothly.
Probable Cause:
1. Move the machine to a smooth horizontal location. Move

away from working machines and personnel. Stop the
engine.
Air in the leveling blade hydraulic circuit.
The steering pump is worn.
2. Permit only one operator on the machine. Keep all other

personnel either away from the machine or in view of
the operator.
The steering priority valve is worn.
Loose oil line connection on the inlet side of the steering

pump.
Low oil level in the tank.
Viscosity of the oil is wrong.
Blockage at suction strainer.
3.
4.

5.

6.
Problem: Temperature of oil is too hot.

Probable Cause:
15-11
Low oil level in the tank.
Viscosity of the oil is wrong.
Air is mixed with the oil.
Steering priority valve

incorrectly adjusted.
relief
valve
damaged
or
TM 5-3895-382-24
Blade control valve relief valve damaged or incorrectly

adjusted.
A restriction in the one of the leveling blade system lines

or components.
2.
Disconnect pressure line (2) from inlet port (4) of blade

control valve (1). Install a tee and the 0 to 25000 kPa
(0 to 3600 psi) pressure gauge from the fittings group in
inlet port (4). Connect line (2) to the tee. This gauge
will measure the blade control valve relief valve
pressure setting.
Problem: Blade position drifts when control lever is in

HOLD position.
3.
Start and run the engine at 2200 rpm.
Probable Cause:
4.
Pull the blade control lever back to the RAISE position.

Keep the blade control lever in the RAISE position after
the blade is completely raised. Read the pressure on
the gauge.
The relief valve pressure should be
10 330 345 kPa (1500 50 psi).
5.
If the relief valve pressure is not correct, it must be

adjusted. Stop the engine.
6.
Remove nut (3) from relief valve (5). Loosen the

locknut, and turn the adjustment screw clockwise to
increase the pressure setting or counterclockwise to
decrease the pressure setting.
7.
Check the relief valve pressure setting again. If it is

correct, tighten the locknut and install nut (3).
8.
Remove the pressure gauge and tee from inlet port (4)
and pressure line (2). Reconnect pressure line (2) to
inlet port (4). Install the side panel.
Blade control valve body and spool are worn.
Blade control valve centering spring is damaged.
Seal leakage in the blade cylinder.
Leveling Blade System

Pressure Check
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
Tools Needed
4C4892
Fittings Group
Blade Control Valve.

(1) Blade control valve. (2) Pressure line. (3) Nut. (4) Inlet port.
(5) Relief Valve.
1.
Remove the side panel from the right side of the

operator's compartment.
15-12
TM 5-3895-382-24
Leakage Test
Make reference
Troubleshooting.
to
WARNING
on
first
page
of
Leveling Blade Cylinder.

(1) Hose. (2) Cylinder rod end port. (3) Leveling blade cylinder.
1.
Start the engine. Push the blade control lever forward

to lower the blade completely. Shut off the engine.
2.
Disconnect hose (1) from rod end port (2) of blade

cylinder (3).
3.
Install a plug into the end of hose (1).
4.
Position a 5 liter (1 U.S. gal) graduated container under

port (2). Start and run the engine at 2200 rpm.
5.
Push the blade control lever forward to the LOWER

position. If the oil leakage from port (2) is in excess of
0.5 liters/min (0.13 U.S. gpm) internal cylinder leakage
is too much, and the blade cylinder should be repaired
or replaced.
6.
Shut off the engine. Remove the plug from the end of
hose (1), and connect the hose to port (2).
15-13/(15-14 blank)
TM 5-3895-382-24
KENR2643-01
October 1998
CHAPTER 16
Disassembly &
Assembly
CP-433C & CS-433C

Machine Systems
CP-433C:
2JM1-UP
1ZN1-UP
4JZ1-UP
CS-433C:
3TM1-UP
2TN1-UP
5BZ1-UP
1FS1-UP
1XZ1-UP
NOTES:
locking type fasteners with new ones.
16-1
TM 5-3895-382-24


material.
16-2
TM 5-3895-382-24
Propel & Vibratory Pumps
(CS-433C & CP-433C) ...........................................................16-73
Remove & Install Propel & Vibratory Pumps ..............16-73
Disassemble and Assemble Vibratory Pump
5070-017 ...........................................................................16-76
Pump Drive................................................................................16-81
Remove & Install Pump Drive .......................................16-81
Rear Reduction Case Assembly .........................................16-105
Remove And Install Rear Reduction
Case Assembly ..............................................................16-105
ROPS (Roll-Over Protective Structure) ................................16-10
Remove & Install ROPS (Roll-Over Protective
Structure) ..........................................................................16-10
Steering Control Unit (SCU) ..................................................16-15
Remove & Install Steering Control
Unit (SCU) ........................................................................16-15
Disassemble & Assemble Steering Control
Unit (SCU).........................................................................16-15
Steering Cylinder .....................................................................16-11
Remove & Install Steering Cylinder ..............................16-11
Disassemble And Assemble Steering
Cylinder..............................................................................16-12
Steering Pivot Lock .................................................................16-10
Separation & Connection Of Steering
Pivot Lock .........................................................................16-10
Steering Pump..........................................................................16-13
Remove & Install Steering Pump...................................16-13
Disassemble & Assemble Steering Pump ..................16-16
Steering Wheel & Steering Column .....................................16-21
Remove & Install Steering Wheel &
Steering Column ..............................................................16-21
Thermal Bypass Valve ............................................................16-68
Remove & Install Thermal Bypass Valve ....................16-68
Vibratory Flushing Valve ........................................................16-65
Remove & Install Vibratory Flushing Valve .................16-65
Vibratory Motor .........................................................................16-52
Remove & Install Vibratory Motor .................................16-52
Disassemble & Assemble Vibratory Motor ..................16-52
Wheel And Tire Assemblies ..................................................16-83
Remove & Install Wheels & Tire Assemblies .............16-83
Remove & Install Wheel End Assemblies ...................16-84
Yoke & Steer Pivot ..................................................................16-47
Remove & Install Yoke & Steer Pivot ...........................16-47
Index
Assembly & Installation Of Conventional
Duo-Cone Seals ........................................................................ 16-4
Axle ..........................................................................................16-100
Remove & Install Axle ...................................................16-100
Disassemble & Assemble Axle ....................................16-101
Axle Propel Motor ....................................................................16-90
Remove & Install Axle Propel Motor..............................16-90
Disassemble Axle Propel Motor ....................................16-91
Assemble Axle Propel Motor .........................................16-95
Blade ........................................................................................16-107
Remove & Install Blade.................................................16-107
Blade Cylinder .......................................................................16-107
Remove & Install Blade Cylinder ................................16-107
Disassemble & Assemble Blade Cylinder .................16-108
Brake Interlock Valve ..............................................................16-71
Remove & Install Brake Interlock Valve .......................16-71
Disassemble & Assemble Brake Interlock
Valve ...................................................................................16-72
Brake/Shift Valve .....................................................................16-69
Remove & Install Brake/Shift Valve ..............................16-69
Disassemble & Assemble Brake/Shift Valve. ............16-70
Bumper & Front Scraper ........................................................16-22
Remove & Install Bumper & Front ................................16-22
Drum Assembly .......................................................................16-23
Remove & Install Drum Assembly ................................16-23
Disassemble Drum Assembly........................................16-42
Assemble Drum Assembly .............................................16-44
Drum Gear Reducer ...............................................................16-26
Remove & Install Drum Gear Reducer ........................16-26
Disassemble Drum Gear Reducer ................................16-28
Assemble Drum Gear Reducer .....................................16-32
Drum Propel Motor ..................................................................16-56
Remove & Install Drum Propel Motor....................................16-56
Disassemble And Assemble Drum
Propel Motor......................................................................16-57
Drum Support Housing ...........................................................16-37
Remove & Install Drum Support Housing ...........................16-37
Disassemble & Assemble Drum Support
Housing .............................................................................16-39
Hydraulic Oil Filter ...................................................................16-82
Remove & Install Hydraulic Oil Filter ...........................16-82
Hydraulic Oil Tank ...................................................................16-66
Remove & Install Hydraulic Oil Tank ...........................16-66
Hydraulic System Pressure Release ...................................16-11
Leveling Blade Control Valve ..............................................16-109
Remove & Install Leveling Blade
Control Valve ..................................................................16-109
Disassemble & Assemble Leveling Blade
Control Valve ..................................................................16-110
Operators Platform ..................................................................... 16-7
Tilt & Lower Operators Platform ..................................... 16-7
Remove & Install Operators Platform ............................ 16-8
Disconnect batteries before performance of any service

work.
16-3
TM 5-3895-382-24
Disassembly & Assembly
Assembly & Installation of
Conventional Duo-Cone Seals
Assembly and Installation of
Conventional Duo-Cone Seals
7561-016, 012
Introduction
NOTE: Conventional Duo-Cone seals am used in the
drum support housings and the drum gear
reducer.
This introduction gives the
Conventional Duo-Cone Seals.
procedure
for
(6) Seal Ring Face. (7) Seal Ring Ramp. (8) Seal Ring Retaining Ring
Lip. (9) Installation Tool.
installing
1.
It is most important that correct assembly and installation

procedures are followed when Duo-Cone Seals are used.
Many Duo-Cone Seal failures are the direct result of one or
more mistakes made during assembly or installation of the seal
components.
Remove any oil film, dust or other foreign matter from

rubber toric rings (2) and from ramps (4) and (7) and lips
(3) and (8) of both seal rings (1) and housings (5). Use
Isopropyl alcohol and dean cloth or paper towels for
wiping.
NOTICE
Never permit oil to get on the toric rings or ramps before
both seal rings are put together in their final assembled
position (Step 10).
(1) Seal. (2) Rubber Toric Ring. (3) Housing Reining Lip. (4) Housing
Ramp. (5) Seal Ring Housing.
16-4
TM 5-3895-382-24
Avoid prolonged skin contact with Isopropyl alcohol.

Avoid breathing the vapors in enclosed areas without
adequate ventilation and do not smoke. Do not use near
open flame or welding operations or other heated surfaces
exceeding 482 C (900 F).
3.
Put installation tool (9) onto seal ring (1) with toric ring
(2). Lower the rings into a container with Isopropyl
alcohol until all surfaces of toric ring (2) are wet.
NOTICE
Do not use Stanisol or any other liquid that leaves an oil
film or does not evaporate quickly.
2.
Put toric ring (2) on seal ring (1), at the bottom of seal
ramp (7) and against retaining lip (8).
4.
NOTICE
Make sure that toric ring (2) is straight on seal ring (1) and
not twisted. Be careful when you work on the rubber toric
ring. Nicks, cuts and scratches can cause leaks.
16-5
With all surfaces of toric ring (2) wet, use installation tool
(9) to position seal ring (1) and toric ring (2) squarely
against housing (5) as shown. Use sudden and even
pressure to pop (push) toric ring (2) under retaining lip
(3) of housing (5).
TM 5-3895-382-24
NOTE: Toric rings (2) must never slip on the ramps of
either seal rings (1) or seal ring housings (5). To
prevent slippage, wait a minimum of two minutes
to let the Isopropyl alcohol evaporate before
further assembly. Once correctly in place, the
toric ring must roll on the ramps only.
5.
Check assembled height (A) in at least four places, 90

apart. The difference in height around the ring must not
be more than 1 mm (.04 in).
6.
If small adjustments are necessary, do not push directly

on seal ring (1); use installation tool (9).
7.
Toric ring (2) can twist if it is not wet all around during
installation or if there are burrs or fins on retaining lip (3)
of housing (5).
8.
NOTICE
Misalignment, twists and bulges of the toric will cause
Duo-Cone Seal failures. If correct installation is not
obvious, remove seal from housing and repeat Steps 3
thru 6.
16-6
Wipe seal faces (6) of seal rings (1) clean. Use a lint
free cloth or paper towel. No particles of any kind are
permissible on the sealing surfaces. Even a small piece
from a paper towel can hold the seal faces apart and
cause leakage.
TM 5-3895-382-24
Operators Platform
Tilt & Lower Operators Platform
7352-084
8S-9906
9.
10.
A
1
Put a thin film of clean oil on the seal faces. Use an

applicator, a disposable tissue or a clean finger to
distribute the oil evenly. Be careful not to get any oil on
the rubber toric rings.
1.
Remove bolts and nuts (1) from storage locations (X).

Install bolts (1) at the pivot as shown.
2.
Remove bolts (2).
3.
Remove bolts and nuts (3) from the operators platform.
Make sure both housings (5) are in correct alignment

and are concentric. Move the parts slowly and carefully
toward each other.
NOTICE
Do not slam seals together. High impact can scratch or
break the seal components.
11.
Tools Needed
Rachet Puller
Once in place, fasten all parts tightly.
16-7
TM 5-3895-382-24
Remove & Install Operators Platform 7352-010
4.
Use a suitable chain to attach Tool (A) to ROPS (4).
5.
Attach Tool (A) to the lifting hook on operator's platform

(5) as shown.
1.
Tilt the operators platform. Refer to the topic "Tilt &

Lower Operators Platform" in this module.
2.
Remove the ROPS (if equipped). Refer to the topic

"Remove & Install ROPS (Roll-Over Protective
Structure) in this module.
3.
Turn the battery disconnect switch to the OFF position.
4.
Disconnect four electrical connectors (1).
5.
Disconnect hose assemblies (2) from the fittings on

each of the two steering cylinders. Cap and plug
immediately.
6.
(5) to plate (3) on the propel pump.
7.
Loosen jam nut (4), and remove control cable (5) from
the bracket. Move the control cable out of the way.
NOTE: If the machine is not equipped with a ROPS, use a

lifting strap and hoist to tilt the operators platform
in place of Tool (A).
6.
Use Tool (A) to tilt the operators platform as shown.

Install bolts and nuts (2)(which were removed during
Step 2) to hold operators platform (5) in the tilted
position.
NOTE: To lower the operators platform, reverse the tilt

steps.
16-8
TM 5-3895-382-24
12.
Lower operators platform (11) as shown. Refer to the

topic Tilt & Lower Operators Platform" in this module.
Remove two bolts and nuts (12) from the pivot points.
NOTE: When removing the operators platform make sure

all hose assemblies, cables and electrical
connectors are free.
13.
Attach a hoist and lifting straps to operators platform

(11) as shown. Remove the operators platform from the
machine. The weight of the operators platform is
318 kg (700 lb).
NOTE: For installation of the operators platform, reverse

the removal steps.
8.
Disconnect hose assembly (6) from the brake/shift

valve. Cap and plug immediately.
9.
Disconnect hose assembly (10) from the steering pump.

10.
Remove the bolt, and remove hose assemblies (6) and

(10) from clamp (7).
11.
Disconnect throttle cable (8) from the engine. Loosen

jam nut (9), and remove throttle cable (8) from the
bracket. Move the throttle cable out of the way.
16-9
TM 5-3895-382-24
ROPS (Roll-Over Protective Structure)
Steering Pivot Lock
Remove & Install ROPS (Roll-Over Protective Structure)

7323-010
Separation & Connection of Steering

Pivot Lock 7506-029
No clearance for a person in this area when turning

vehicle. When machine is to be lifted, transported on
another vehicle or service work being performed near the
center of the machine, connect steering pivot lock
between front and rear frames to keep machine in a
straight ahead position.
Before operation or when
operating, be sure steering pivot lock, located near the
lower center of the machine, is disconnected and pinned
in the storage position.
1.
Disconnect electrical connector (3).
2.
Attach a hoist to ROPS (Roll-Over Protective Structure

(1) as shown.
3.
Remove twelve nuts and bolts (2) that fasten the ROPS
to the frame of the machine. Remove ROPS (1). The
weight of the ROPS is 160 kg (352 lb).
NOTE: For installation of the ROPS (Roll-Over Protective

Structure), reverse the removal steps.
Steering Pivot Lock Pin in Storage Position.
Steering Pivot Lock Pin in Locked Position.
16-10
1.
Put steer pivot group (3) in alignment with main frame

group (4).
2.
Remove pin (2), and move lock pin (1) from the storage
position to the locked position.
TM 5-3895-382-24
3.
Install pin (2).

bare hand.
NOTE: The following steps are for separation of the

steering pivot lock.
4.
Remove pin (2).
5.
Lift lock pin (1), and install pin (2) to hold the lock pin in
the storage position.
1.
Release the pressure in the hydraulic system.
2.
Disconnect hose assemblies (2) from steering cylinder

(3). Cap and plug immediately.
3.
Disconnect grease line (1) from the end of the steering

cylinder.
4.
Remove two bolts (4) and the lock nuts that hold
steering cylinder (3) in position, and remove the steering
cylinder and any spacers from the machine.
Hydraulic System Pressure Release

1.

Stop the engine.
2.

of the operator.
3.
Move all hydraulic controls to all positions to release any

4.

5.
6.
During certain performance tests it will be necessary to

release the parking brake to help drum movement when
turns are required.
7.

8.

Steering Cylinder
Remove & Install Steering Cylinder 4303-010
NOTE: Position the machine on a level surface.
Start By:
a. connect steering pivot lock
b. tilt operators platform
NOTE: For installation of the steering cylinder, reverse

the removal steps.
NOTE: The removal and installation procedure for the

right hand and left hand steering cylinders is the
same.
NOTE: After installing the steering cylinder, lubricate the

bolts and fill the hydraulic oil tank to the correct
level. See the Operation & Maintenance Manual
for the correct lubricating and filling procedures.
16-11
TM 5-3895-382-24
Disassemble & Assemble Steering
Cylinder 4303-017
Start By:
a. remove steering cylinder
1.
Remove two bolts (11), and slide cover (14) and rod
assembly (10) partially out of cylinder assembly (12).
2.
Push head (5) into the cylinder assembly and remove

lockwire ring (8).
3.
Remove head (5) and rod assembly (10) from cylinder

assembly (12).
4.
Remove nut (1), piston (2) and head (5) from rod
assembly (10). Remove O-ring seal (13) from the rod
assembly. Check the O-ring seal for damage or wear
and replace if necessary. During assembly, tighten nut
(1) to a torque of 820 28 N
m (590 20 lb-ft).
5.
6.
Remove O-ring seal (6) and back-up ring (7) from the
outside of head (5). Remove lip-type seal (9), and seal
(15) from inside head (5). Check the back-up rings,
O-ring seals and lip-type seal for damage or wear and
NOTE: During assembly of the steering cylinder, put a

thin coat of clean oil on the O-ring seals, back-up
rings and lip-type seal.
NOTE: For assembly of the steering cylinder, reverse the
disassembly steps.
End By:
Remove wear ring (3) and O-ring seal (4) from piston
(2). Check the wear ring and O-ring seal for damage or
wear and replace if necessary.
a. install steering cylinder
16-12
TM 5-3895-382-24
Steering Pump
Remove & Install Steering Pump 4306-010

bare hand.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
system
2.
Drain the hydraulic oil from the hydraulic oil tank into a
suitable container. The capacity of the hydraulic oil tank
is 72 liters (19 U.S. gal).
3.

machine.
4.
Disconnect hose assemblies (1) and (5) from steering

pump (4). Cap and plug immediately.
5.
Remove bolt (2) and five bolts (3), and remove steering
pump (4) and the gasket from the engine.
NOTE: For installation of the steering pump, reverse the

removal steps.
NOTE: After the steering pump has been installed, fill the
cooling system with coolant to the correct level.
Fill the hydraulic oil tank to the correct level. See
correct filling procedures.
16-13
TM 5-3895-382-24
Disassemble & Assemble Steering
Pump 4306-017
Start By:
a. remove steering pump
1.
2.
3.
Remove nut (22), and remove gear (20) and woodruff

key (21) from drive gear (11). When assembling the
steering pump tighten nut (22) to a torque of
50 to 54 N
m (37 to 40 lb-ft).
Remove four bolts (14), and remove end cap (6) from
housing (10).
Remove plug (1), spring (4) and priority valve (5) from
end cap (6). Remove O-ring seal (3) from plug (1).
Check the O-ring seal for damage or wear and replace if
necessary.
6.
Remove backup seals (8) and seals (18) from both

sides of housing (10).
7.
Remove drive gear (11), driven gear (19) and bushings

(9) and (12) from housing (10).
8.
Remove O-ring seals (7) and (13) from each side of the
housing. Check the O-ring seals for damage or wear
and replace if necessary.
9.
If necessary, remove the two dowels from each side of

housing (10).
4.
Remove flange (15) from housing (10) and drive gear

(11).
NOTE: For assembly of the steering pump, reverse the

disassembly steps.
5.
Remove retaining ring (17), and remove lip-type seal

(16) from flange (15). Check the lip-type seal for
damage or wear and replace if necessary.
End By:
a. install steering pump
16-14
TM 5-3895-382-24
6.
Remove & Install Steering Control
Unit (SCU) 4312-010
While holding steering control unit (9), remove four bolts

(10) that fasten the steering control unit and steering
column (8) to the column. Remove the steering control
unit from the splines on the steering column.
NOTE: For installation of the steering control unit (SCU),

revere the removal steps.
Disassemble & Assemble Steering Control
Unit(SCU) 4312-017
Start By:
a. remove steering control unit (SCU)
1.
Turn the battery disconnect switch to the OFF position

and release hydraulic system pressure (16-11).
2.
Remove two bolts (2), and remove cover (1) from

console (3).
3.
Remove four bolts (6), and remove cover (5) from the
column.
4.
Remove three bolts (4) that fasten console (3) to the

column, and move the console out of the way.
5.
1.
Be sure the outside of the steering control unit is

thoroughly clean and free of dirt and debris prior to
disassembly. Make alignment marks on the valve body
to aid in proper assembly.
2.
Remove seven cap screws (1).
3.
Remove end cap (2).
4.
Remove seal (3) from end cap (2). Check the seal for
Put identification marks on four hoses (7) for installation

purposes. Disconnect four hoses (7) from steering
control unit (9). Cap and plug immediately.
16-15
TM 5-3895-382-24
5.
Place the steering control unit (SCU) on end so internal

components will not fall out.
6.
Remove geroter housing (4). Lift the housing straight

up.
(2) End cap. (3) Seal. (4) Geroter housing. (5) Sea.
(6) Geroter. (7) Spacer. (8) Drive (9) Spacer plate.
9.
Components of the geroter assembly shown in above

photo.
NOTE: Geroter housing (4) and geroter (6) are not

serviced separately.
7.
8.
Remove seal (5) from geroter housing (4). Check the

seal for damage or wear and replace if necessary.
Remove geroter (6), spacer (7), drive (8) (not shown)

and spacer plate (9) as a unit.
16-16
10.
Remove O-ring seal (10). Check the O-ring seal for

11.
Remove spool and sleeve assembly (11) from control

housing (12).
TM 5-3895-382-24
12.
Remove back-up ring (13), O-ring seal (14), O-ring seat

(15)(not shown), two bearing races (16) and needle
thrust bearing (17) from spool and sleeve assembly
(11).
14.
Remove pin (18) from spool and sleeve assembly

(11)(slip fit).
15.
Separate control spool (19) and control sleeve (20).
16.
Remove centering spring kit (21) from control spool

(19).
(11) Spool and sleeve assembly. (13) Back-up ring.

(14) O-ring. (15) O-ring seat. (16) Bearing races.
(17) Needle thrust bearing.
13.

photo.
NOTE: Spring kit (21) has six centering springs.
16-17
TM 5-3895-382-24
(13) Back-up ring. (14) O-ring seal. (15) O-ring seat.

(16) Bearing races. (17) Needle thrust bearing. (18) Pin.
(19) Control spool. (20) Control sleeve. (21) Centering spring kit.
17.

photo.
18.
Remove retaining ring (22) and gland bushing (23) from

the control housing.
19.
Disassemble gland bushing (23). Remove dust seal

(24) from seal gland bushing (25). Turn the seal gland
bushing over and remove quad ring seal (26).
16-18
20.
Remove set screw (27) from control housing (12).
21.
Install a 1/8" - 24 machine screw into the end of check

ball seat (28). Remove the check ball seat with pliers.
TM 5-3895-382-24
26.
NOTICE
When spool and sleeve assembly (11) is installed In the
control housing, be sure it is not tilted out of position. The
assembly should be pushed gently Into place with a slight
rotating action, keeping pin (18) nearly horizontal. The
spool and sleeve assembly should be installed until it is
flush with the meter end of the housing (side with fourteen
holes in the end). Be sure the spool and sleeve assembly
turns freely in the center housing.
NOTICE
O-ring seals (31) and (32) are different sizes. Note the
location of the O-ring seals on the check ball seat prior to
removal. Do not mix during assembly.
22.
Remove check ball (29) and check ball retainer (30)

from the control housing. Remove O-ring seals (31) and
(32) from check ball seat (28). Inspect the O-ring seals
for damage or wear and replace if necessary.
27.
Put the center housing in a vertical position. Install two

bearing races (16) and needle thrust bearing (17).
28.
Assemble gland bushing (23). Install dust seal (24) in

seal gland bushing (25) with the flat or smooth side of
the seal facing the bushing. Turn the seal gland
bushing over Install quad ring seal (26) in the seal gland
bushing. Smooth the seal in place with your finger. Do
not use a seal that falls freely into the pocket in the
bushing.
29.
Install gland bushing (23) over the control spool with a

twisting motion. Use a soft faced hammer to seat the
gland bushing against bearing race (16).
Install
retaining ring (22). Be sure the retaining ring is properly
seated.
30.
Put the steering control unit (SCU) in a vertical position

with the steering column end facing down. Install O-ring
seal (10) in control housing (12).
31.
Install spacer plate (9). Be sure the holes in the spacer

plate align with the tapped holes in the control housing.
Put pin (18) in a horizontal position in the control
housing. Install drive (8). Be sure the slot in drive (8)
engages with pin (18).
NOTE: The following steps are for assembly of the

steering control unit (SCU).
NOTICE
Be sure all parts of the steering control unit (SCU) are
clean and free of dirt and debris. Do not use a cloth or
paper towel to dry parts. Lint or other material can get
into the hydraulic system and cause damage to
components. Replace any parts that have scratches or
burrs that could result in leakage.
23.
24.
25.
Put a thin coat of clean hydraulic oil on control spool

(19) and control housing sleeve (20). Install the control
spool in the control housing sleeve. The spool should
turn freely in the sleeve. Put the spring slots in each
component in alignment. Some spool and sleeve sets
may have alignment marks on them. In this case, align
the marks. Install centering spring kit (21). Be sure the
springs are centered. Install pin (18) that holds control
spool (19) and control housing sleeve (20) together.
The pin should be flush on each side of the sleeve after
installation.
Install check ball retainer (30) in control housing (12).

Be sure the retainer is straight and not tilted in the bore.
Install check ball (29).
Put a thin coat of 1U-6396 Assembly Compound on Oring seals (31) and (32) and check ball seat (28). Install
the O-ring seals in their original location on the check
ball seat. Using a 1/8" -24 machine screw, install the
check ball seat in the center housing.
Install set screw (27) and tighten to a torque of 11 N
m
(100 lb-in). After installation, the set screw should be
slightly below the outside surface of the center housing.
16-19
TM 5-3895-382-24
35.

property damage, make sure the drive is timed as follows.
End By:
a. install steering control unit (SCU)
NOTICE
The steering control unit (SCU) must be timed. This
requires obtaining the correct relationship between pin
(18), geroter (6) and geroter housing (4). One end of pin
(18) will point to the largest clearance between the geroter
and geroter housing. The other end of the pin points to
the least clearance. Pin (18) cannot be seen after drive (8)
s installed, so it will be necessary to make a mark on the
gear end of the drive for proper alignment.
32.
Install O-ring seal (5) in geroter housing (4). Install

geroter (6) in geroter housing (4). Put the geroter in
position on the spacer plate. Align the star valleys.
There should be a parallel relationship of the
components. Align all the cap screw holes without
disengaging the geroter from the drive.
33.
Install spacer (7) in the geroter housing.
34.
Install O-ring seal (3) in end cap (2). Install the end cap
in its original position on the geroter housing. Be sure
the cap screw holes in the end cap are in alignment.
Install seven cap screws (1). Tighten the cap screws in

the sequence shown to an initial torque of 17 N
m (150
lb-in). Tighten the cap screws in the sequence shown
to a final torque of 28 3 N
m (250 25 lb-in).
16-20
TM 5-3895-382-24
Steering Wheel & Steering
Column
Remove & Install Steering Wheel &
Steering Column 4309-010
1.
Turn the battery disconnect switch to the OFF position.
2.
Remove three screws (1), and remove cover (2) from

the steering wheel.
3.
Remove nut (3) and the washer, and remove steering

wheel (4) from the steering column. During installation,
tighten nut (3) to a torque of 41 to 54 N
m (30 to 40 lbft).
4.
Remove two bolts (6), and remove cover (5) from

console (7).
5.
Remove four bolts (10), and remove cover (9) from the
column.
6.
Remove three bolts (8) that fasten console (7) to the

column, and move the console out of the way.
7.
While holding steering control unit (12), remove four

bolts (13) that fasten the steering control unit and
steering column (11) to the column. Remove the
steering control unit from the splines on the steering
column. Remove the steering column from the column.
NOTE: For installation of the steering wheel and steering

column, reverse the removal steps.
16-21
TM 5-3895-382-24
Bumper & Front Scraper
2.
Remove six bolts and nuts (2), and remove shims (3),
bumper (1) and the front scraper from yoke (4). The
weight of the bumper and front scraper is 130 kg (286
lb).
3.
Remove four bolts and nuts (5), and remove four

adjustment bars (6) and scraper (7) from bumper (1).
4.
Remove four bolts and nuts (8), and remove scraper (7)
from adjustment bars (6).
Remove & Install Bumper & Front

Scraper 7156, 6607-010
NOTE: For installation of the bumper and front scraper,

reverse the removal steps.
NOTE: After the bumper and front scraper have been
installed, adjust the clearance, dimension (X),
between the scraper and drum. Loosen four bolts
and nuts (8). Obtain a clearance, dimension (X),
of 13 2 mm (0.51 0.08 in) between scraper (7)
and drum (9). Tighten four bolts and nuts (8).
1.
Attach lifting straps and a hoist to bumper (1) as shown.
NOTE: When removing the bumper, note the thickness

and number of shims (3) on each side of the yoke.
When installing the bumper, install the shims in
their original location.
16-22
TM 5-3895-382-24
Drum Assembly
Remove & Install Drum Assembly
6605-010
Star By:
a. connect steering pivot lock
1.
Remove the bumper and front scraper. Refer to the

topic "Remove & Install Bumper & Front Scraper" in this
module.
6.
Remove clamp (5) that fastens hose assembly (4) to the

support.
7.
Remove the bolt and clamp that fastens wiring harness

(6) to cover (7).
8.
Remove the bolt and cover (7) from the drum support
housing.
9.
Move the cover back, and put identification marks on

the two wires for vibratory sensor (8). Disconnect the
two wires from the vibratory sensor.

bare hand.
2.
Release the pressure in the hydraulic system (page 1611).
3.
is 72 liter (19 U.S. gal).
4.
To prevent movement of the machine, put wooden

blocks in front of and behind each rear wheel.
5.
Disconnect hose assembles (1), (3) and (4) from

vibratory motor (2). Cap and plug immediately.
16-23
TM 5-3895-382-24
10.
Remove the two bolts and plate (9).
11.
Remove the two bolts and clamp (10). Move the three
hose assemblies and electrical harness out of the way.
12.
Disconnect five hose assemblies (11) from drum propel

motor (12). Plug and cap immediately.
13.
Remove the two bolts and plate (13).
14.
Remove the two bolts and clamp (14). Move the five
hose assemblies out of the way.
15.
Attach a suitable hoist to both sides of drum assembly

(17) as shown. Raise the drum assembly approximately
12.7 mm (0.50 in). Install a suitable stand (15) under
each side of yoke (16) as shown.
16.
Use the suitable hoist to support the drum assembly.
NOTE: When removing the drum assembly, note the

thickness and number of the shims on each side
of the yoke. When installing the drum assembly,
install the shims in their original location.
17.
16-24
Remove six bolts (18) that fasten drum assembly (17) to

the left (propel) side of yoke (16). Remove any shims
that may be between the mounting plate and the yoke.
TM 5-3895-382-24
18.
19.
Remove 16 bolts (19) that fasten drum assembly (17) to

the right (vibratory) side of yoke (16). Remove any
shims that may be between the rubber mounts and the
yoke.
NOTE: For installation of the drum assembly, reverse the

removal steps.
NOTE: After the drum assembly has been installed, fill
the hydraulic oil tank to the correct level. See the
filling procedures.
Use the suitable hoist to remove drum assembly (17)

from the yoke. The weight of a smooth drum assembly
is 2100 kg (4620 lb). The weight of a padded drum
assembly is 2500 kg (5500 lb).
End By:
a. separate steering pivot lock
20.
Note that the notch at location (X) on mounting plate

(20) is toward the rear of the yoke as shown. When
installing drum assembly (17) make sure the mounting
plate is positioned correctly.
21.
Note that rubber mounts (21) and mounting plate are

not symmetrical. When installing drum assembly (17)
make sure that the rubber mounts and mounting plate
(22) are positioned correctly.
16-25
TM 5-3895-382-24
Drum Gear Reducer
(CS-433C & CP-433C)
Remove & Install Drum Gear Reducer
(CS-433C & CP-433C) 5655-010
Start By:
a. remove drum assembly
1.
Position wooden blocks on both sides of the drum

assembly.
2.
Drain the oil from the drum gear reducer into a suitable
container. The capacity of the drum gear reducer is 2.4
liters (0.62 U.S. gal).
3.
Remove two bolts (1), and remove drum propel motor

(2) from the drum gear reducer.
4.
Attach a hoist and lifting strap to drum gear reducer (6)

as shown.
5.
Remove 24 bolts (4), and remove drive plate (3),

mounting plate (5) and drum gear reducer (6) as a unit
from drum assembly (7). The weight of the drive plate,
mounting plate and drum gear reducer as a unit is 160
kg (352 lb).
16-26
6.
Position drive plate (3), mounting plate (5) and drum

gear reducer (6) as shown.
7.
Remove ten nuts (8), and use two persons to remove

drive plate (3) from drum gear reducer (6). The weight
of the drive plate is 36 kg (80 lb). When installing the
drive plate on the drum gear reducer tighten ten nuts (8)
to a torque of 680 60 N
m (500 45 lb-ft).
8.
Remove fitting (9) from drum gear reducer (6).
9.
Remove 17 bolts (10), and use two persons to remove

mounting plate (5) from drum gear reducer (6). The
weight of the mounting plate is 27 kg (60 lb). The
weight of the drum gear reducer is 95 kg (210 lb).
TM 5-3895-382-24
10.
Remove the four bolts that fasten each of the rubber

mounts (12) to plates (11). Remove the six rubber
mounts from the plates.
11.
Remove the two bolts that fasten each of the three

plates (11) to drum assembly (7). Remove the three
plates from the drum assembly.
NOTE: For installation of the drum gear reducer, reverse

the removal steps.
NOTE: After the drum gear reducer has been installed, fill
the drum gear reducer with oil to the correct level.
See the Operation & Maintenance Manual for the
correct procedure.
End By:
a. install drum assembly
16-27
TM 5-3895-382-24
Disassemble Drum Gear Reducer
(CS-433C & CP-433C) 5655-015
126-6608
Tools Needed
Spanner Socket
A
1
Start By:
a. remove drum gear reducer (CS-433C & CP-433C)
1.
Remove 20 bolts (9), and remove cover (1) and O-ring

seal (11) from ring gear (12). Check the O-ring seal for
wear or damage and replace if necessary.
4.
Remove sun gear (6) from the second stage carrier.
5.
Remove second stage carrier (10) from ring gear (12).
2.
Remove thrust washer (2), sun gear (3) and bearing

thrust washer (4) from the first stage carrier. Thrust
washer (2) and bearing thrust washer (4) may have
stuck to the cover when it was removed.
6.
Remove ring gear (12), O-ring seal (13) and two dowel
pins (7) from housing (8). Check the O-ring seal for
3.
Remove first stage carrier (5) from the ring gear.
16-28
TM 5-3895-382-24
8.
7.
Use the following procedure to disassemble second

stage carrier (10).
a. Remove retaining ring (23) which holds planet gear
(20) and roller bearing assembly (21) on carrier (25).
Use the following procedure to disassemble first stage

carrier (5).
b. Remove planet gear (20) and roller bearing assembly

(21) from the carrier.
a. Locate pin (17) that holds bearing shaft (18) in carrier

(19).
c. Remove roller bearing assembly (21) from planet gear

(20).
b. Drive pin (17) into bearing shaft (18) until it bottoms.

Make sure the pin has bottomed or damage to the
carrier could occur when the bearing shaft is
removed.
d. Repeat steps (a) through (c) to remove the remaining

two planet gears and roller bearing assemblies from
carrier (25).
c. Remove bearing shaft (18) from carrier (19). Remove

pin (17) from bearing shaft (18).
e. Remove retaining ring (24), and remove sun gear (22)

from carrier (25).
d. Slide planet gear (16) and four thrust washers (14)

from carrier (19).
e. Remove 19 needle bearings (15) from the inside of
planet gear (16).
f. Repeat steps (a) through (e) for each of the two
remaining planet gears.
16-29
TM 5-3895-382-24
9.
Remove five retaining rings (29) from spindle (32).

Remove gear (30) and roller bearings (31) from each of
the five spindle sections.
14.
Remove bearing cone (27) from spindle (32).
15.
Remove duo-cone seals (28) and (34) from the spindle.
10.
Remove thrust spacer (36) and coupling (37) from

inside housing (8). Remove external retaining ring (33)
and internal retaining ring (35) from the coupling.
16.
Turn the spindle over.
11.
Use Tool (A) to remove bearing nut (38) from the

spindle.
12.
Turn the housing and spindle over. Use a soft hammer

to tap on the flange of housing (8). Separate housing
(8) and bearing cone (39) from spindle (32).
13.
If necessary, remove bearing cups (26) and (40) from

housing (8).
16-30
TM 5-3895-382-24
17.
Install and tighten 11 M5 X 0.8 X 20 mm sockethead

screws (47) in thrust plate (45) to compress nine springs
(44) and relieve the spring pressure on retaining ring
(46).
18.
Remove retaining ring (46) from spindle (32).
19.
Remove piston (43) from the spindle.
20.
Remove back-up ring (51) and O-ring seal (52) from

spindle (32). Remove back-up ring (42) and O-ring seal
(41) from the spindle.
21.
Remove six plates (49), seven discs (50) and end plate
(48) from spindle (32).
22.
Slowly and evenly loosen and remove 11 sockethead

screws (47) to relieve the spring pressure on thrust plate
(45). Remove the thrust plate and nine springs (44)
from piston (43).
16-31
TM 5-3895-382-24
Assemble Drum Gear Reducer
(CS-433C & CP-433C) 5655-016
126-608
6Y-6339
Tools Needed
Spanner Socket
Duo-Cone Seal Installation Tool
A
1
1.
Install nine springs (44) in piston (43). Position thrust

plate (45) on the piston. Install and evenly tighten 11
M5 X 0.8 X 20 mm sockethead screws (47).
2.
Position spindle (32) with the large opening facing

upward. Install end plate (48). six plates (49) and
seven discs (50) inside spindle (32). Make sure the
discs and plates are alternated in the correct sequence.
3.
Install back-up ring (51) in the lower groove in the inside

wall of spindle (32). Install O-ring seal (52) above backup ring (51).
4.
Install O-ring seal (41) in the upper groove in the inside

wall of spindle (32). Install back-up ring (42) above Oring seal (41).
B
1
5.
16-32
Apply a light coating of clean grease on the O-ring seals

and backup rings.
TM 5-3895-382-24
6.
Install piston (43) in spindle (32), and install retaining

ring (46). Do not remove sockethead screws (47) at this
time.
7.
Turn the spindle over.
16-33
8.
Install bearing nut (38) on spindle (32). Use Tool (A) to

tighten the bearing nut to a torque of 200 N
m (150 lbft). Mark both the bearing nut and spindle with a
reference line to indicate the minimum final position of
the bearing nut. Remove bearing nut (38).
9.
Use Tool (B) to install duo-cone seal (34) on spindle

(32). Refer to the topic "Assembly & Installation of
Conventional Duo-Cone Seals" in this module for the
correct procedure.
10.
Install bearing cups (26) and (40) in housing (8).
11.
Install bearing cone (27) into bearing cup (26).
12.
Use Tool (B) to install duo-cone seal (28) in housing (B).

Refer to the topic "Assembly & Installation of
Conventional Duo-Cone Seals" in this module for the
correct procedure.
TM 5-3895-382-24
NOTE: Make sure the duo-cone seal components are not
pinched or displaced when the housing is
installed.
13.
Install housing (8) over spindle (32) with the largest

inside diameter facing downward.
14.
Install bearing cone (39) on spindle (32).
15.
Install bearing nut (38) on spindle (32). Use Tool (A) to

tighten the bearing nut to a minimum torque of 825 N
m
(600 lb-ft). Make sure that the bearing nut is at or past
the reference line marked in step 8.
16.
Using a hammer and punch, stake bearing nut (38) in

one place.
17.
Install external retaining ring (33) in the groove on the

outside of coupling (37). Install internal retaining ring
(35) in the groove located near the middle of the inside
of the coupling.
18.
23.
Apply a light coating of clean grease on thrust spacer

(36). Install thrust spacer (36) on spindle (32).
a. Install sun gear (22) in carrier (25), and install

retaining ring (24).
NOTE: Gears (30) are a matched set. If one of the gears

needs replacing, all must be replaced. If the gear
or roller bearing needs to be replaced, both must
be replaced, as the assembly of the components
is permanent. Each new roller bearing has a
retainer around it for easier installation into the
gear.
19.
20.
Use the following procedure to assemble second stage

carrier (10).
b. Apply a light coating of clean oil on planet gear (20)

and roller bearing assembly (21).
NOTE: Roller bearing assembly (21) consists of two
internal retaining rings, needle bearings and an
inner race carrier. A new roller bearing assembly
comes packaged with a retainer to keep the
needle bearings in place for easier installation.
Apply a light coating of clean oil on five gears (30) and

roller bearings (31).
c. Install one of the internal retaining rings from the roller

bearing assembly into planet gear (20).
Center roller bearing (31) and the retainer on the end of

gear (30) with the large chamfer on its inside diameter
and push the roller bearing through the retainer into the
gear until it snaps into the groove of the gear.
d. Use the retainer to install roller bearing assembly (21)

in planet gear (20). The retainer should slide off
during assembly.
21.
Install each of the five roller bearings and gears (30) on

spindle (32).
e. Install the other internal retaining ring from the roller

bearing assembly into planet gear (20).
22.
Install five retaining rings (29) on the spindle to hold

each of the roller bearings and gears in place.
f. Install the roller bearing assembly and planet gear

(20) on carrier (25). Install retaining ring (23) to hold
the planet gear in place.
g. Repeat steps (c) through (f) for the two remaining
planet gears.
16-34
TM 5-3895-382-24
24.
Use the following procedure to assemble first stage

carrier (5).
a. Apply a light coating of clean grease on planet gear
(16). Line the inside of the planet gear with 19 needle
bearings (15).
b. Stand carrier (19) on its side. Insert bearing shaft
(18) approximately 12.7 mm (.5 in) into the carrier.
Be sure to insert the end of the bearing shaft without
a pin hole into the side of the carrier with a pin hole.
The chamfered pin hole in the bearing shaft should
face upward.
c. Apply a light coating of clean grease on two thrust
washers (14). Place the thrust washers on the end of
the bearing shaft which has been inserted into the
carrier.
d. Place planet gear (16) with needle bearings (15) on
the bearing shaft.
e. Apply a light coating of clean grease on two remaining
thrust washers (14). Position the thrust washers
between the planet gear and the carrier, and slide the
bearing shaft through the thrust washers and carrier.
f. Align the pin holes in the carrier and bearing shaft.
Install the smaller end of pin (17) into the aligned
holes until the top of the pin is approximately 2.5 mm
(.1 in) below the surface of the carrier.
g. Repeat steps (a) through (f) for the remaining two
planet gears (16).
16-35
TM 5-3895-382-24
25.
Apply a light coating of clean grease on O-ring seal (13).

Place the O-ring seal around the rim of housing (8).
35.
Remove 11 M5 X 0.8 X 20 mm sockethead screws (47)

that were installed in the brake assembly during step 1.
26.
Install two dowel pins (7) in the dowel pin holes in

housing (8).
End By:
27.
Position ring gear (12) on housing (8), aligning the

dowel pin holes in the ring gear with dowel pins (7).
28.
Position second stage carrier (10) in ring gear (12).
29.
Apply a light coating of clean oil on sun gear (6). Install

the sun gear in second sage carrier (10).
30.
Position first stage carrier (5) on sun gear (6).
31.
Apply a light coating of clean oil on sun gear (3).

Position sun gear (3) in first stage carrier (5).
32.
Apply a light coating of clean grease on thrust washers

(2) and (4). Position the thrust washers on the inside of
cover (1).
33.
Apply a light coating of clean grease on O-ring seal (11).

Place the O-ring seal around the underside of cover (1).
34.
Position cover (1) on ring gear (12), and install 20 bolts.

Tighten the bolts to a torque of 48 to 60 N
m (35 to 45
lb-ft).
a. install drum gear reducer (CS-433C & CP-433C)
16-36
TM 5-3895-382-24
(CP-433C & CS-433C R.H. Side)
Remove & Install Drum Support
Housing CP-433C & CS-433C R.H. Side)
5656-010
6V-2156
Tools Needed
Link Bracket
A
1
Star By:
1.
2.
4.
Remove coupling (5) from shaft assembly (6).
5.
Loosen the lock nut, and turn vibratory sensor (7)

counterclockwise three turns. Remove shaft assembly
(6) from the drum support housing.
Drain the oil from the drum support housing into a

suitable container. The capacity of the drum support
housing is 1.9 liters (0.5 U.S. gal).
Remove two bolts (1), and remove vibratory motor (2)

from the vibratory gear box. When installing, apply 9S3263 Thread Lock on the threads of two bolts (1).
NOTE: Apply 6V-4876 Molykote Paste Lubricant on the

splines at both ends of shaft assembly (6) before
installation.
NOTE: After installing shaft assembly, measure the
length of shaft assembly (6) and adjust as
required. For the proper procedure refer to the
topic "Drum Assembly" in the Specifications
module for the vibration system, Form No.
KENR2647.
3.
NOTE: When the length of the shaft assembly is correct,

make sure the sprocket on the shaft assembly is
centered beneath vibratory sensor (7). When the
sprocket is centered, turn vibratory sensor (7) in
(clockwise) until it touches the tips of the
sprocket teeth. Then back the vibratory sensor
out approximately one turn. This will provide a
clearance (gap) of 1.6 mm (0.06 in) between the
sprocket teeth and the vibratory sensor.
Remove 12 bolts (3), and remove cover (4) and the Oring seal from the vibratory gearbox. Check the O-ring
When installing, apply 9S-3263 Thread Lock on the
threads of 12 bolts (3).
16-37
TM 5-3895-382-24
6.
8.
Remove eight bolts (16), and remove drum support

housing (13) and plate (12) as a unit from the drum
assembly. The weight of the drum support housing and
plate as a unit is approximately 130 kg (286 lb). When
installing, apply 9S-3263 Thread Lock on the threads of
eight bolts (16).
9.
Lower the drum support housing and plate (12) to a

level surface. While supporting the drum support
housing and plate, remove four bolts (17) and support
(18) from both sides of the plate. The weight of each
support is 30 kg (66 lb).
10.
Use the following steps to disassemble shaft assembly
(6).
Remove the 16 bolts and four rubber mounts (14) from

supports (10).
11.
a. Remove two bolts (10) from sprocket (8) and bushing

(11). During the final assembly procedure, apply
9S-3263 Thread Lock on the threads of two bolts
(10).
To prevent dirt from getting inside the drum support

housing, install the 12 bolts and cover (4) on drum
support housing (13). Position drum support housing
(13) and plate (12) on cover (4).
12.
Remove ten nuts and bolts (15) and Tool (A). Remove
plate (12) from drum support housing (13). The weight
of the plate is 22kg (48 lb). The weight of the drum
support housing is 73 kg (160 lb).
13.
Remove rubber gasket (19) from the bearing housing on

the drum assembly. Check the rubber gasket for wear
or damage and replace if necessary.
b. Install two bolts (10) in the two threaded holes,

location (X), of bushing (11).
c. Tighten two bolts (10), and remove sprocket (8) and
bushing (11) from shaft (9).
NOTE: For installation of the drum support housing,

revere the removal steps.
End By:
NOTE: After the drum support housing has been
installed, fill the housing with oil to the correct
7.
Remove one of the bolts that fastens drum support

housing (13) and plate (12) together. Attach a suitable
lifting bracket and Tool (A) as shown.
16-38
TM 5-3895-382-24
Disassemble & Assemble Drum
Support Housing (CP-433C &
CS-433C R.H. Side) 5656-017
9U-6237
1P-0510
Tools Needed
Spanner Wench
Driver Group
A
1
B
1
Start By:
a. remove drum support housing
1.
Make sure the outside of the drum support housing is

clean and free of dirt and debris.
2.
Put alignment marks on the housing and cover to aid in

the assembly steps.
3.
Install the drum support housing on a suitable stand or

move to a clean flat area for disassembly. The weight
of the drum support housing is 73 kg (160 lb).
4.
Remove twelve bolts (1).
6.
For the drum support housing, on the right hand side

(CS-431C, CP-433C & CS-433C), remove O-ring (3).
Check the O-ring seal for wear or damage. Replace if
necessary. For the drum support housing on the left
hand side (CS-431C only) uses 9T-9014 Silicone
Sealant to seal the cover to the housing.
7.
Bend tab on washer (5) away from corresponding slot in

nut (4).
8.
Use Tool (A) to remove retaining nut (4).
NOTE: Every third bolt in the pattern has a lock washer

and is slightly longer than the other bolts. Mark
or identify for later installation.
5.
Remove cover (2).
NOTE: During assembly, 9S-6232 Thread Lock was used

on nut (4).
To remove the nut, it may be
necessary to slightly heat nut (4).
16-39
TM 5-3895-382-24
9.
Remove tab washer (5).
10.
Remove flat washer (6).
11.
Position the housing a press and support with blocks as

shown. Use Tool (B) and a press to remove bearing
and shaft assembly (7) from housing (8).
12.
Use two people to lift housing (8) from bearing and shaft
assembly (7). The weight of the housing is 36 kg (80
lb).
16-40
13.
Remove seal (9) from housing (8).
14.
Remove bearing assembly (10) from housing (8).
15.
Remove two bearing races (11) from housing (8).
TM 5-3895-382-24
22.
Place a bolt into the housing to rotate the housing with a

torque wrench. Use a torque wrench capable of inchlbs to determine the rolling torque created. A typical
rolling torque value is 3.4 N
m (30 lb-in).
23.
Heat bearing (10) to 135 C (275 F). Press in bearing

assembly (10) until the rolling torque increases 1.7 to
4.5 N
m (15 to 40 lb-in) greater than the value
measured in Step 22.
NOTE: It will be necessary to continually rotate the

housing to seat the bearing assembly in order to
obtain a correct rolling resistance.
16.
If necessary, remove bearing assembly (12) and seal

(13) from shaft assembly (7).
NOTE: Seal (13) will be damaged and will require

replacement if removed.
Install two bearing races (11) into housing (8) with a

press or a hammer and a brass drift.
18.
Install bearing assembly (12) into housing (8) with the

hub flange upright.
NOTE: The bearing assembly should be clean and wiped

dry of any lubricating oil. Bearing assemblies
which have oil present will affect rolling torque
readings.
Apply grease to seal (9) and install seal into housing (8).
20.
Press shaft assembly (7) into seal (9) and bearing

assembly (12).
21.
Turn the housing 180 and secure shaft assembly so it

will not move during the next procedure.
25.
Install tab washer (5).
26.
Use Tool (A) to install retaining nut (4).
27.
Use Tool (A) and tighten retaining nut (4) to a torque of

306 N
m (225 lb-ft).
28.
Recheck the rolling torque. The final reading should be

1.7 to 4.5 N
m (15 to 40 lb-in) greater than the value
observed in Step 22.
NOTE: A final rolling torque of 5 to 7 N

m (45 to 65 lb-in)
should result in a bearing preload of .0254 to
.0508 mm (.001 to .002 in).
29.
NOTE: Apply a light lubricating oil to the lip of seal (13)

and press into housing (8) with a press.
19.
Install flat washer (6).
NOTE: Apply 9S-3263 Thread Lock to the threads of nut

(4).
NOTE: The following steps are for the assembly of the

drum support housing.
17.
24.
Bend tab washer (5) up into slot on retaining nut (4).
NOTE: If the tang does not line up, tighten nut (4) until
the tang can be bent into the slot.
30.
Release shaft assembly and remove bolt used for

checking rolling torque.
31.
For the drum support housing on the right hand side

(CS-431C, CP-433C & CS-433C), install O-ring (3). For
the drum support housing on the left hand side (CS431C only), apply a 3.2 mm (.125 in) continuous bead
of 8T-9014 Silicone Sealant on the mounting surface of
the housing where the cover fastens.
32.
Position cover (2) in its original location.
33.
Install twelve bolts (1). Place longer bolts and washers

in their original locations.
End By:
a. install drum support housing
16-41
TM 5-3895-382-24
Disassemble Drum Assembly
6605-015
6V-2157
FT-2434
FT-2433
Tools Needed
Line Bracket
Shaft Support Assembly
Bearing Removal Block
A
2
1
1
Start By:
a. remove drum gear reducer
(CS-433C & CP-433C)
b. remove drum support housing
1.
3.
Attach a suitable lifting bracket and Tooling (A) to right

bearing housing (2) as shown. The weight of the
bearing housing is 110 kg (242 lb).
4.
Use a suitable pry bar (4) and wooden block to support

weight shaft (5).
5.
Remove eight nuts (3), and remove right bearing

housing (2) from the drum assembly. Move the right
bearing housing away from the drum assembly, and
position wooden blocks (6) under weight shaft (5) as
shown.
6.
Lower the weight shaft onto wooden blocks (6), and

remove pry bar (4) and right bearing housing (2).
Drain the oil from the drum assembly into a suitable

container. The capacity of the drum assembly is
51 liters (13.5 U.S. gal).
Right (Vibratory) Side of Drum Assembly
2.
Remove retaining ring (1), and remove the five rubber

mounts and washer from the weight shaft.
16-42
TM 5-3895-382-24
7.
Use a lifting strap and hoist to support Tool (B). Install

Tool (B) on weight shaft (5) as shown.
8.
Use one person to hold the end of Tool (B) that si

opposite the weight shaft. If necessary, use another
person to pull weight shaft (5) from the left bearing
housing as shown.
9.
Remove the weight shaft from the drum assembly. The

weight of the weight shaft is 105 kg (231 lb).
Left Side of Dam Assembly

(CS-433C Drum Assembly shown)
10.
Attach a hoist, suitable lifting bracket and Tooling (A) to

left bearing housing (8) as shown. The weight of the left
bearing housing is 110 kg (242 lb).
11.
Remove eight nuts (7), and remove left bearing housing

(8) from the drum assembly.
12.
Remove O-ring seal (9) from the left and right bearing
housings. Check the O-ring seal for damage or wear
13.
Perform the following procedure to determine if new

bearings (12) should be installed in the left and right
bearing housings.
a. Remove four bolts (10), and retainer (11) from the left
and right bearing housings. Rotate the inner race of
the bearing by hand.
The race should rotate
smoothly. Check the bearing for damage.
16-43
TM 5-3895-382-24
15.
Position the bearing housing in a press as shown. Use

the press and Tool (C) to remove bearing (12) from the
bearing housings.
Assemble Drum Assembly 6605-016
6V-2157
FT-2434
8T-5096
A
2
1
1
NOTE: Clean the drum reservoir, all internal parts and

bearing housings thoroughly before assembly of
the drum assembly.
b. To check the clearance between the bearing roller

and the outer race, stand the bearing housing up
vertically. Hold bearing (12) in position with one hand
and using feeler gauge (13) with the other, side the
feeler gauge between the bearing roller and the outer
race at the "12 o'clock" position. Do not rotate the
bearing rollers over the top of the feeler gauge as this
will give a false reading. The clearance between the
bearing rollers and the outer race should be .102 to
.152 mm (.004 to .006 in).
14.
Tools Needed
Line Bracket
Shaft Support Assembly
If it is necessary to remove bearings (12) from bearing

housings (2) and (8), insert Tool (C) through bearing
(12) as shown.
1.
If is necessary to install new bearings into bearing

housings (2) and (8), heat the bearing housings to a
maximum temperature of 82 C (180 F) as shown.
2.
Install bearing (12) in each of the bearing housings.

The bearings should drop into position.
NOTE: Install the bearings with the bearing nomenclature

facing up.
16-44
TM 5-3895-382-24
3.
4.
Position retainer (11) on the left and right bearing

housings. Apply 9S-3263 Thread Lock on the threads
of bolts (10). Install four bolts (10) that fasten the
retainer to each of the bearing housings. Tighten the
bolts to a torque of 48 10 N
m (35 7 lb-ft).
Apply 6V-4876 Molycoat Paste Lubricant on the

contact surfaces of weight shaft (5) and the bearing
inside the left bearing housing.
7.
Use a lifting strap and hoist to support Tool (B). Using

one person to hold the end of Tool (B), install weight
shaft (5) in the left bearing housing. Make sure the
correct end of weight shaft (5) is installed in the left
bearing housing. If necessary, use another person to
push weight shaft (5) into the left bearing housing as
shown.
8.
Position wooden blocks under weight shaft (5) as

shown. Remove Tool (B) from the weight shaft.
Install O-ring seal (9) on each of the bearing housings.
NOTE: Before installing the bearing housings, make sure

the oil reservoirs have been thoroughly steam
cleaned and tack cloth used during the final
cleaning.
5.
6.
Use a hoist, suitable lifting bracket and Tooling (A) to

position left bearing housing (8) on the drum assembly,
and install eight nuts (7).
16-45
TM 5-3895-382-24
9.
Use a hoist, suitable lifting bracket and Tooling (A) to

position right bearing housing (2) as shown.
14.
Install the washer, the five rubber mounts and retainer

(1) in the weight shaft.
10.
Install a suitable pry bar (4) through right bearing

housing (2) and into the end of weight shaft (5). Use
wooden blocks and pry bar (4) to support the weight
shaft.
15.
Use Tooling (C) to check the weight shaft end play. The
end play must be 4.0 2.0 mm (0.16 0.08 in). If the
end play is not correct, disassemble and assemble the
drum assembly again. Verify that the drum assembly
was assembled correctly.
11.
Remove wooden blocks (6) from under the weight shaft.

NOTE: The drum assembly must be flushed before oil is
added.
Refer to the topic "Drum Flushing
Procedure" in Special Instruction, SEHS9880.
NOTE: Fill the drum assembly with oil to the correct
for the correct filling procedure.
End By:
a. Install drum gear reducer

(CS-433C & CP-433C)
b. Install drum support housing
12.
Apply 6V-4876 Molycoat Paste Lubricant on the

contact surfaces of weight shaft (5) and the bearing
inside the right bearing housing.
13.
Position right bearing housing (2) on the drum

assembly, and install eight nuts (3). Tighten the nuts to
a torque of 375 48 N
m (275 35 lb-ft). Remove pry
bar (4) and Tooling (A).
16-46
TM 5-3895-382-24
Yoke & Steer Pivot

Remove & Install Yoke & Steer Pivot 6604-010
8T-5096
Tools Needed
A
1
Start By:

NOTE: Before removing the drum assembly, determine if
the components in the steer pivot need to be
replaced. Perform the following procedures to
check the steer pivot clearances.
6.
Total vertical movement should not exceed 1.91 mm

(.075 in). If the movement is too much, the clearance
can be reduced by adding spacers at the vertical pin
joints, locations (X). If the movement is too small, the
clearance can be increased by removing spacers at the
vertical pin joints.
7.

spacers, the steer pivot housing should be
disassembled. Bushings or any other worn components
should be replaced. With new bearings and shims
installed, total movement should be .13 to 1.14 mm
(.005 to .045 in) on a used machine.
Vertical Steer Pivot Clearance

1.

Stop the
Horizontal Steer Pivot Clearance

Check the horizontal steer pivot clearance as follows:
2.
Attach the base of Tool (A) to the top of the steer pivot
housing as shown. Set the dial indicator actuator on the
top of the rear frame.
3.
4.
Place a hydraulic jack under the rear frame at the steer

pivot assembly.
5.
Raise the hydraulic jack and record the reading on the

dial indicator.
1.

2.

the brake/shift valve. Refer to Step 3 in the topic
"Brake/Shift Valve" in this module.
3.
Attach the base of Tool (A) to the top of the steer pivot
housing. Set the dial indicator actuator against the front
face of the rear frame.
4.
16-47
Stop the
TM 5-3895-382-24
5.

console (parking brake stays engaged when the
6.
7.

8.

sweep.)
9.
On a used machine the total movement should not

exceed 1.27 mm (.050 in).
10.
If the movement is too much, the steer pivot housing

should be disassembled. Bushings, bearings and any
other worn components should be replaced. With new
bearings, bushings and pins the total movement
recorded should be .10 to .76 mm (.004 to .030 in).
6.

7.

sweep.)
NOTE: When removing or adding shims behind the plate,

remove or add equal amounts at the top and
bottom of the plate.
8.
NOTE: Inadequate bearing lubrication may result if zero

end play or a preload condition is present.
9.
Oscillation Bearing Clearance

Check the oscillation bearing clearance as follows:
1.
2.

The maximum reading for a used assembly should be

.51 mm (.020 in). If the movement is too much, reduce
clearance by removing shims from behind the plate. If
the clearance is too small, add shims to increase the
clearance.

removal or addition of shims, the oscillation assembly
should be disassembled. Bushings and any other worn
components should be replaced. Total movement
should be .05 to .25 mm (.002 to .010 in) on a new
assembly.
Stop the
Remove & Install Yoke & Steer Pivot

the brake/shift valve. Refer to Step 3 in the topic
"Brake/Shift Valve" in this module.
NOTE: The bumper should be installed between the yoke

side plates to prevent the yoke from deflecting
when it is removed.
3.
Attach the base of Tool (A) to the front face of the steer
pivot bearing plate. Set the dial indicator actuator
against the front face of the oscillation shaft. Set the
dial indicator to zero.
4.

console (parking brake will stay engaged when the
5.
1.
16-48
Use lifting straps and a hoist to position bumper (2)

between yoke (1) as shown. Position the shims
between the bumper and yoke, and install the six bolts
that hold the bumper in place. The weight of the
bumper is 130 kg (286 lb).
TM 5-3895-382-24
2.
3.
Use a hoist to raise yoke (1), and position wooden

blocks under both sides of the machine frame as shown.
Remove support stands (4) from each side of the yoke.
Lower the frame of the machine onto the wooden
blocks.
To prevent the yoke from rotating, position support

stand (4) under the right side of yoke (1).
16-49
4.
Attach a hoist to yoke (1) as shown.
5.
Remove two bolts (5), and install two 8C-8290 (M24 X

3.0 X 150 mm) bolts (6). Remove the remaining six
bolts (5) and the shims (top and bottom) from behind
plate (7). For assembly purposes, note the quantity and
location of the shims. Move plate (7) away from the
yoke. Attach a hoist to plate (7). Remove two bolts (6),
and remove plate (7). The weight of the plate is 35 kg
(77 lb).
6.
Use the hoist to remove yoke (1) from the steer pivot.
The weight of the yoke (with bumper) is 650 kg
(1430 lb).
TM 5-3895-382-24
7.
If necessary, use a press to remove the spherical

bearing from plate (7).
10.
Remove nuts and bolts (11) and the spacers that fasten
the steering cylinders to steer pivot (9).
11.
Position a suitable floor jack under steer pivot (9) as

shown.
12.
Remove nuts and bolts (12) that hold the pins in place.
13.
Remove pins (13) and the shims, and remove steer

pivot (9) from the machine frame. For assembly
purposes, note the quantity and location of the shims.
The weight of the steer pivot is 160 kg (352 lb).
14.
If necessary, remove the four spring bushings from the

machine frame.
NOTE: When installing the spherical bearing in plate (7)

the grease holes must be positioned vertically.
8.
If necessary, remove spherical bearings (8) from yoke

(1).
9.
Remove steer lock pin (10) from steer pivot (9).
16-50
TM 5-3895-382-24
15.
If necessary, remove two bearings (14) from steer pivot

(9).
16.
If necessary, remove two bearings (15) from the steer

pivot.
17.
If necessary, remove spherical bearing (16) from the

steer pivot.
NOTE: When installing spherical bearing (16) in steer

pivot (9) the grease holes must be positioned
vertically.
NOTE: For installation of the yoke and steer pivot,
End By:

NOTE: After the drum assembly has been installed,
perform the vertical steer pivot clearance,
horizontal steer pivot clearance and oscillation
bearing clearance procedures.
16-51
TM 5-3895-382-24
Vibratory Motor
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up, 3TM706Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up, 1ZN121Up, 1FS1Up, 1XZ1-Up)
Remove & Install Vibratory Motor 5651-010

cap on the hydraulic oil tank only when the engine Is
bare hand.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
2.
NOTE: For photographic purposes the yoke is removed

from the machine.
system
4.
Remove two bolts (4), and remove vibratory motor (3)

and O-ring seal from the drum support housing. Check
the O-ring seal for damage or wear and replace if
necessary.
NOTE: For installation of the vibratory motor, reverse the

removal steps.
NOTE: After the vibratory motor has been installed, fill
filling procedure.
Disassemble & Assemble Vibratory Motor 5651-017

Start By:
a. remove vibratory motor
3.
1.
Be sure the outside of the vibratory motor is thoroughly

clean prior to disassembly.
2.
Remove four bolts (1) and end cap (2).
Disconnect hose assemblies (1) and (2) from vibratory

motor (3). Cap and plug immediately.
16-52
TM 5-3895-382-24
3.
Put identification marks on nine pistons (9) as to their

location in the slipper guide (10) and cylinder block (11).
6.
Remove retainer guide (12), four pins (13), and retainer

(14).
Remove valve plate (3), gasket (4), needle bearing (5),

and locating pin (6). Needle bearing (5) is press fit in
end cap (2).
NOTICE
During removal of the rotary group (8) from housing (7),
do not let the components fall apart.
The piston
assemblies (9) should be installed in their original bores in
the slipper guide (10) and cylinder block (11).
4.
5.
There is spring force against washer (15). When retaining

ring (16) is removed, the spring force will be released. To
prevent possible personal injury, removal of the internal
components in cylinder block (11) should be performed in
a press in order to retain spring (17) and washer (15).
Lay housing (7) on side and remove rotating group (8).
7.
16-53
Put cylinder block (11) in a press. Install a suitable drive

plate of the same size as the washer (15). Put a slight
compression on the washer (15) with the press.
Remove the retaining ring (16) and slowly release the
spring compression.
TM 5-3895-382-24
NOTE: All motor components must be cleaned and
inspected before assembly. If any components
are worn beyond recommended limits they must
be replaced. Lubricate all moving parts with clean
oil during assembly. Assemble motor with all new
seals.
8.
Remove notched washer (15), spring (17) and washer

(18).
9.
Remove swash plate (19).
10.
Remove retaining ring (21), seal (22), retaining ring (23)

and remove shaft (24).
11.
12.
Install retaining ring (27), bearing (26) and retaining ring

(25). Install shaft (24). Install retaining ring (23), seal
(22) and retaining ring (21).
13.
Install swash plate (19).
Remove retaining ring (25), bearing (26) and retaining

ring (27). Bearing (26) is press fit on shaft (24).
NOTE: The notched washer (15) is located between
spring (17) and retaining ring (16).

vibratory motor.
14.
16-54
Instill washer (18), spring (17) and notched washer (15).
TM 5-3895-382-24
15.
16.
17.
Put cylinder block (11) in a press. Install a suitable drive

plate on notched washer (15) and compress spring (17)
until retaining ring (16) can be installed.
18.
Lay housing (7) on side and install rotary group (8).
19.
Using a press, install needle bearing (5). Install locating

pin (6), gasket (4), and valve plate (3).
20.
Position end cap (2) on motor and install four bolts (1).
Tighten four bolts (1) to a torque of 47 to 61 N m
(35 to 45 lb-ft)
Install retainer (14), three pins (13) and retainer guide

(12).
Install the nine pistons (9) according to their original

location in the slipper guide (10) and cylinder block (11).
Move the slipper guide (10) from side to side to ensure
the piston assemblies (9) move freely in the cylinder
block (11).
16-55
TM 5-3895-382-24
Drum Propel Motor

(CS-433C & CP-433C)
Remove & Install Drum Propel Motor
(CS-433C & CP-433C) 4351-010

bare hand.
5.
Remove two bolts (3), and use two persons to remove

drum propel motor (2) from the drum gear reducer. The
weight of the drum propel motor is 30 kg (66 lb).
6.
Remove the O-ring seal from the drum propel motor.

necessary.
Drain the oil from the drum gear reducer into a suitable
container. The capacity of the drum gear reducer is 2.4
liters (0.62 U.S. gal).
NOTE: For installation of the drum propel motor, reverse

the removal steps.
1.
Release the
(page 16-11).
2.
3.
4.
pressure
in
the
hydraulic
system
NOTE: After the drum propel motor has been installed,

fill the drum gear reducer and hydraulic oil tank
with oil to the correct levels. See the Operation &
Maintenance Manual for the correct procedures.
Disconnect four hose assemblies (1) from drum propel

motor (2). Cap and plug immediately.
16-56
TM 5-3895-382-24
Disassemble & Assemble Drum

Propel Motor (CS-433C & CP-433C)
4351-010
2P-8312
Tools Needed
Pliers
A
1
Start By:
a. remove drum propel motor
1.
Remove caps and fittings (1) from housing (2).
There is spring pressure when servo cover (5) is removed.

Use longer bolts (3) as described to release the spring
tension and prevent possible personal injury.
16-57
2.
Remove two bolts (3) that am opposite each other.

Install two M6 X 2.0 X 50 mm bolts. Remove the
remaining two bolts (3). Slowly and evenly, remove the
two longer bolts to release the spring tension.
3.
Remove servo cover (5), spring (7), stop (12) and spring
(8) from housing (2). Remove O-ring seal (10) from the
servo cover. Check the O-ring seal for damage or wear
4.
Remove four bolts (4), and remove servo cover (6) and
spring (9) from housing (2). Remove O-ring seal (11)
from the servo cover. Check the O-ring seal for damage
or wear and replace if necessary. If necessary, loosen
the nut, and remove servo stop (13) from servo cover
(6).
TM 5-3895-382-24
5.
Remove retaining ring (15), and remove lip seal (14)

from the front cover.
8.
Remove retaining ring (20), and remove shaft (21) and

the bearing from front cover (17).
6.
Remove eight bolts (16), and remove front cover (17)

from the housing.
9.
Remove retaining ring (23), and remove bearing (22)

from shaft (21).
7.
Remove two journal bearings (18) from dowels (19) and

front cover (17).
10.
Remove swashplate (24) from the housing.
16-58
TM 5-3895-382-24
11.
Use Tool (A) to remove cylinder block assembly (25)

from housing (2).
12.
Remove seven pistons (26) and slipper guide (27) from

cylinder block (28).
14.
Remove pin retainer (30) and three pins (31) from the
cylinder block.

15.
13.
Put cylinder block (28) in a press. Install a suitable

piece of square steel stock against washer (32). Put
slight compression on washer (32) with the press.
Remove retaining ring (34), and slowly release the
spring compression.
NOTICE
Washers (32) and (35) are different in size.
Put
identification marks on the washers so they can be
installed in their original location in the cylinder block.
Remove retainer guide (29) from the cylinder bock.
16.
16-59
Remove washer (32), spring (33) and washer (35) from

the cylinder block.
TM 5-3895-382-24
NOTICE
Servo pistons (41) and (42) are different. Put identification
marks on the servo pistons so they can be installed in
their original location in the housing.
20.
Remove servo pistons (41) and (42) from housing (2).
21.
Remove hollow piston (44) from each of the servo

pistons. If necessary, remove slipper (43) from each of
the hollow pistons.
22.
Remove seal rings (45) from each of the servo pistons.
NOTICE
During removal, do not damage valve plate (36).
17.
Put an identification mark on valve plate (36) as to its

location in housing (2) and locating pin (38). Remove
valve plate (36) from the housing. If necessary, remove
locating pin (38).
18.
Remove two dowels (37) and gasket (39) from housing

(2). Remove any of the gasket material from front cover
(17).
19.
Remove needle bearing (40) from the housing.
16-60
TM 5-3895-382-24
23.
Remove charge relief plug (48), spring (47) and poppet

(46) from housing (2). Remove the O-ring seal and any
shims from the charge relief plug. Check the O-ring
24.
Remove plugs (49), springs (51), spring guides (52) and

valve spool (50) from housing (2). Remove the O-ring
seals from plugs (49). Check the 0-ring seals for
26.
Install the O-ring seals on plugs (49). Install valve spool

(50), spring guides (52), springs (51) and plugs (49) in
housing (2).
27.
Install the O-ring seal and any shims on charge relief

plug (48). Install poppet (46) spring (47) and charge
relief plug (48) in housing (2).
28.
Install slipper (43) on each of the hollow pistons. Install

hollow piston (44) in each of the servo pistons. Install
seal rings (45) on each of the servo pistons.

drum propel motor.
25.
Be sure all parts of the drum propel motor are clean and
free of dirt and debris prior to assembly.
NOTICE
Most of the components in the drum propel motor have
critical, machined surfaces.
Do not damage these
surfaces during assembly of the drum propel motor.
Protect all exposed surfaces, openings and ports from
damage and foreign material. Lubricate all machined
surfaces with clean hydraulic oil prior to assembly.
16-61
TM 5-3895-382-24
29.
Install servo pistons (41) and (42) in housing (2). If

necessary, compress the seal rings when installing the
servo pistons.
30.
Install needle bearing (40) in the housing. Install the

needle bearing until it makes contact with the
counterbore in the housing and with the printed number
on the bearing facing up.
31.
32.
Install washer (35), spring (33) and washer (32) in the

cylinder block. Put the cylinder block in a press Install a
suitable piece of square steel stock against washer (32).
Using a press, compress spring (33), and install
retaining ring (34).
Slowly release the spring
compression.
NOTE: Position pin retainer (30) at the top of the cylinder

block splines.
33.
Install three pins (31) and pin retainer (30) in the

cylinder block.
34.
Install retainer guide (29) on the cylinder block.
Install locating pin (38) in housing (2). Install valve plate

(36) in its original position in the housing. Make sure
the valve plate is engaged with the locating pin.
16-62
TM 5-3895-382-24
35.
Install seven pistons (26) in slipper guide (27). Install

the slipper guide and the pistons in cylinder block (28).
39.
Install bearing (22) on shaft (21), and install retaining

ring (23).
36.
Use Tool (A) to install cylinder block assembly (25) in

the housing.
40.
Install shaft (21) and the bearing in front cover (17), and
install retaining ring (20).
37.
Install swashplate (24) in the housing as shown.
41.
38.
Install two dowels (37) in the housing.

gasket (39) on the housing.
Install two dowels (19) in front cover (17). Apply a light

film of 5P-0960 Multi-Purpose Grease to the inner
faces of each journal bearing to hold them in position.
Install two journal bearings (18) on the front cover and
dowels.
Install new
16-63
TM 5-3895-382-24
42.
43.
Position front cover (17) on the gas ket and housing (2),
and install eight bolts (16).
Put clean grease on the inside diameter of lip seal (14).

Install the seal in front cover (17), and install retaining
ring (15).
16-64
44.
Install O-ring seal (11) and servo stop (13) in servo

cover (6). Position spring (9) and servo cover (6) on
housing (2), and install four bolts (4).
45.
Install O-ring seal (10) in servo cover (5). Position

spring (8), stop (12), spring (7) and servo cover (5) on
the housing, and install two longer bolts (3). Install two
original bolts (3). Remove the two longer bolts, and
install the two remaining original bolts.
TM 5-3895-382-24
Vibratory Flushing Valve

Remove & Install Vibratory Flushing Valve 5619-010
Start By:
a. tilt operators platform
46.

under pressure. Hot oil can cause burns Remove the fill
stopped, and the fill cap is coo enough to touch with your
bare hand.
Install caps and fittings (1) in housing (2).
End By:
a. install drum propel motor
16-65
1.
Release the pressure in the hydraulic system (page

16-11).
2.
3.
Disconnect seven hose assemblies (3) from vibratory

flushing valve (1). Cap and plug immediately.
4.
Remove two bolts (2), and remove the vibratory flushing

valve from the hydraulic oil tank.
TM 5-3895-382-24
Hydraulic Oil Tank

Remove & Install Hydraulic Oil Tank 5056-010
Start By:
5.

under pressure. Hot oil can cause burns Remove the fill
stopped, and the fill cap is coo enough to touch with your
bare hand.
If necessary, remove shuttle valve (4) and charge relief

valve (5) from vibratory flushing valve (1). Check the Oring seals and back-up rings on the shuttle valve for
wear or damage and replace if necessary. Check the
O-ring seals on the charge relief valve for wear or
damage and replace if necessary.
NOTE: When installing shuttle valve (4) in vibratory

flushing valve (1), tighten the shuttle valve to a
torque of 90 N
m (65 lb-ft). When installing
charge relief valve (5) in the vibratory flushing
valve, tighten the charge relief valve to a torque of
60 N
m (45 lb-ft).
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
sys tem
2.
3.
Remove two bolts (2), and move vibratory flushing valve

(1) away from the hydraulic oil tank.
NOTE: For installation of the vibratory flushing valve,

NOTE: After the vibratory flushing valve has been
installed, fill the hydraulic oil tank to the correct
NOTE: After installing the vibratory flushing valve and
filling the hydraulic oil tank, perform the
Test. Refer to the topic in CP-433C & CS-433C
Vibratory System Systems Operation & Testing
And Adjusting Service Manual, Form No.
KENR2648.
16-66
TM 5-3895-382-24
4.
Mark hose assemblies (3) and (4) for assembly

purposes. Disconnect hose assemblies (3) and (4) from
the hydraulic oil tank. Cap and plug immediately.
5.
Remove bolts (5) that fasten thermal bypass valve (6) to

the bottom of the hydraulic oil tank. When installing,
apply 9S-3263 Thread Lock on the threads of bolts (5).
6.
Disconnect hose assembly (7) from the bottom of the

hydraulic oil tank. Cap and plug immediately.
16-67
7.
Remove four bolts (8) that fasten air cleaner (9) to the
hydraulic oil tank.
8.
Disconnect electrical connector (10) for the hydraulic oil

temperature switch.
9.
Disconnect hose assembly (11) from the hydraulic oil

tank. Cap and plug immediately.
10.
Remove cap (13) from hydraulic oil tank (12).
11.
Remove sight gauge (14) from the hydraulic oil tank.
12.
Remove four bolts (16) and two straps (12) that fasten
the hydraulic oil tank to the frame.
TM 5-3895-382-24

Remove & Install Thermal Bypass Valve 5074-010
Start By:
13.

bare hand.
Attach lifting straps and a suitable lifting bracket to

hydraulic oil tank (12) as shown. Remove the hydraulic
oil tank from the machine. The weight of the hydraulic
oil tank is 70 kg (154 lb).
NOTE: For installation of the hydraulic oil tank, reverse

the removal steps.
1.
Release the
(page 16-11).
2.
3.
Remove two bolts (2), and move vibratory flushing valve

(1) away from the hydraulic oil tank.
NOTE: After the hydraulic oil tank has been installed, fill
filling procedure.
16-68
pressure
in
the
hydraulic
system
TM 5-3895-382-24
Brake/Shift Valve
Remove & Install Brake/Shift Valve 4282-010
Start By:
4.

bare hand.
Mark hose assemblies (3) and (4) for assembly

purposes. Disconnect hose assembles (3) and (4) from
the hydraulic oil tank. Cap and plug immediately.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
system
2.
5.
Disconnect fitting (5) and two hose assemblies (8) from

thermal bypass valve (7).
6.
Remove two bolts (6), and remove thermal bypass valve

(7) from the bottom of the hydraulic oil tank. When
installing, apply 9S-3263 Thread Lock on the threads
of two bolts (6).
3.
NOTE: For installation of the thermal bypass valve,

Disconnect two electrical connectors (1) for the

brake/shift valve.
4.
Disconnect fitting (3) and hose assembly (4) from

brake/shift valve (2). Cap and plug immediately.
NOTE: After the thermal bypass valve has been installed,

fill the hydraulic oil tank to the correct level. See
correct filling procedure.
16-69
TM 5-3895-382-24
Disassemble & Assemble Brake/Shift Valve 4282-017

Start By:
a. remove brake/shift valve
5.
Disconnect fitting (5) and hose assembly (7) from

brake/shift valve (2).
6.
Remove three bolts (6) that fasten the brake/shift valve

to the frame.
7.
1.
Bend the tabs down on lock (5). Remove nut (1) from
shift coil (4) and nut (2) from brake coil (3). Remove the
lock from the coils. Remove brake coil (3) and shift coil
(4). When installing nuts (1) and (2), tighten the nuts to
a torque of 5.5 to 8.0 N
m (48 to 70 lb-in).
2.
Remove brake valve cartridge (6), shift valve cartridge

(7) and check valve (8) from manifold (9). When
installing brake valve cartridge (6) and shift valve
cartridge (7), tighten the valve cartridges to a torque of
45 to 54 N
m (35 to 40 lb-ft).
Move the brake/shift valve to gain access to fitting (8)

and hose assembly (9). Disconnect the fitting and hose
assembly from the brake/shift valve. Cap and plug
immediately. Remove the brake/shift valve from the
machine.
NOTE: For installation of the brake/shift valve, reverse

the removal steps.
NOTE: After the brake/shift valve has been installed, fill
filling procedure.
16-70
TM 5-3895-382-24

Remove & Install Brake Interlock Valve 4265-010
3.
4.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
system
2.
Remove the access panel from under the left side of the
operators platform.
3.
Disconnect electrical connector (4) for brake interlock

valve (2).
4.
Disconnect four hose assemblies (3) from the brake

interlock valve. Cap and plug immediately.
5.
Rem ove two bolts (1), and remove brake interlock valve
(2) from the machine.
Remove back-up ring (10) and O-ring seals (11) from

check valve (8). Check the back-up ring and O-ring
seals for wear or damage and replace if necessary.
Remove O-ring seals (12) and back-up rings (13) from

the brake valve cartridge and the shift valve cartridge.
Check the O-ring seals and back-up rings for wear or
damage and replace if necessary.
NOTE: For installation of the brake interlock valve,

NOTE: For assembly of the brake/shift valve, reverse the

disassembly steps.
End By:
a. install brake/shift valve
16-71
TM 5-3895-382-24
Disassemble & Assemble Brake Interlock Valve

4265-017
Start By:
a. remove brake interlock valve
1.
Remove nut (1), and remove coil (2) from valve

cartridge (3). During assembly, tighten nut (1) to a
torque of 7 to 8 N
m (5 to 6 lb-ft).
2.
Remove valve cartridge (3) from valve body (4). During

assembly, tighten valve cartridge (3) to a torque of 45 to
54 N
m (35 to 40 lb-ft).
NOTE: For assembly of the brake interlock valve, reverse

the disassembly steps.
End By:
a. install brake interlock valve
16-72
TM 5-3895-382-24
Propel & Vibratory Pumps (CS-433C & CP-433C)

Remove & Install Propel & Vibratory
(CS-433C & CP-433C) 5070 & 5652-010
Pumps
Start By:

bare hand.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
2.
Vibratory and Propel Pumps (Early).
system
Vibratory and Propel Pumps (Later).
3.

4.

5.

purposes. Disconnect the two electrical wires from
neutral start switch (7). Remove the cable ties that
fasten the wiring harness to the pumps.
6.
(9) to plate (4).
7.
Loosen jam nut (8), and remove control cable (9) from
the bracket. Move the control cable out of the way.
Vibrator and Propel Pumps (Early).
16-73
TM 5-3895-382-24
8.
Disconnect hose assembly (11) from vibratory pump (1).

9.
Disconnect the electrical connector for electrical

connectors (10) from the main wiring harness.
11.

axle propel pump (22) to the axle propel motor.
12.

axle propel pump (22) to the vibratory flushing valve.
13.

and plug immediately. The hose assembles connect
drum propel pump (20) to the vibratory flushing valve.
14.

connect drum propel pump (20) to the brake interlock
valve.
15.
Disconnect the hose assembles from elbows (15) and

connect axle propel pump (22) to the brake interlock
valve.
16.
Disconnect the hose assembly from elbow (18) on drum

propel pump (20). Cap and plug immediately.
NOTE: The low charge pressure switch is now located

next to the charge oil filter.
17.
Left Side of Engine and Pumps.
Right Side of Engine and Pumps.
NOTE: For photographic purposes, the above two photos

were taken with the pumps and engine removed
from the machine.
10.

drum propel pump (20) to the drum propel motor.
16-74
Disconnect the hose assembly from fitting (16). Cap

and plug immediately. The hose assembly connects
axle propel pump (22) to the hydraulic oil tank.
TM 5-3895-382-24
18.
Remove nut and bolt (24) that fastens the pumps to the
pump support.
20.
Remove two bolts (25), and remove the vibratory pump,

the axle propel pump and the drum propel pump as a
unit from the pump drive. The weight of the vibratory
pump, axle propel pump and drum propel pump as a
unit is 100 kg (220 lb).
21.
Remove two nuts and bolts (27), and separate vibratory

pump (1) from axle propel pump (22).
Remove the two nuts, and remove linkage rod (26) from
drum propel pump (20) and axle propel pump (22).
23.
Remove two bolts (28), and separate drum propel pump

(20) from axle propel pump (22).
24.
Loosen bolt (29), and remove hub (30) from the shaft of
the drum propel pump.
NOTE: When installing hub (30) on the shaft of the drum

propel pump, the dimension from the face of the
hub to the end of the shaft must be 8.0 1.5 mm
(0.31 0.06 in). After the correct dimension has
been obtained, tighten bolt (29) to a torque of 61
N
m (45 lb-ft).
Attach a suitable lifting bracket and lifting strap to axle

propel pump (22) as shown.
19.
22.
NOTE: For installation of the propel and vibratory pumps,

NOTE: After the propel and vibratory pumps have been
installed, fill the hydraulic oil tank to the correct
16-75
TM 5-3895-382-24
Disassemble and Assemble Vibratory Pump 5070017
(9XL229-Up, 3WZ158-Up, 2JM579-Up, 4JZ122-Up, 3TM706Up, 5BZ119-Up, 6EN127-Up, 2TN118-Up, 1ZN121-Up, 1FS1Up, 1XZ1-Up)(Vibratory Pump Only)
Start By:
a. Remove the propel or vibratory pump.

NOTE: The propel pumps are similar to the vibratory
pump.
The following procedure shows the
disassembly and assembly of the vibratory pump.
For specific differences in the pumps, refer to
TM 5-3895-382-24
3.
Remove relief valves (4) and springs (5).
1.
Remove seven screws (1) and control valve (2) with the
gasket. Check the gasket for wear or damage and
replace, if necessary.
4.
Remove seven screws (6) and cover (7) with the gasket.
Inspect the gasket for wear or damage and replace, if
necessary.
2.
Remove two plugs (3). Check the seal on the plugs for
5.
Remove two screws (8) and remove cover (9) with the
16-76
TM 5-3895-382-24
6.
Remove charge relief plug (10).
9.
Remove spring (14) and spool (15).
10.
11.
Remove seven screws (17) and cover (18) with the

NOTE: After removing any plug, check the seals for wear
or damage and replace, if necessary.
7.
Remove charge relief poppet (11) and spring (12).
NOTE: There are shims between the plug and the spring.
8.
Remove plug (13).
16-77
TM 5-3895-382-24
12.
Remove two O-rings (19) and locating pins (20).
16.
Remove seal (24) from cover (23). Check the seal for
wear or damage and replace, if necessary.
13.
Use a hammer and soft punch to remove shaft

assembly (21) from the housing.
17.
18.
Use a suitable puller to remove bearing (26).
19.
Remove six screws (27) and cover (28) with the gasket.
Check the gasket for wear or damage and replace. if
necessary.
14.
15.
Remove O-ring (22). Inspect the O-ring for wear or

damage and replace, if necessary.
Remove seal cover (23).
16-78
TM 5-3895-382-24
20.
Use a suitable puller to remove bearing (29). Check the

bearing for wear or damage and replace if necessary.
23.
21.
Remove cylinder block assembly (30) from the pump

housing.
(31) Pistons. (32) Retainer. (33) Retainer guide. (35) Pin

guide. (34) Pins.
22.
Remove pistons (31), retaining ring (32) and retainer

guide (33).
24.
Remove three pins (34) and pin guide (35).
Cylinder Block Components.
16-79
Remove swashplate (36), port plate (37) and locating

pin (38).
TM 5-3895-382-24
25.
Remove control link (39).
30.
Remove nut (46) and turn cover (45) to remove the

cover from servo piston (47).
31.
Check O-rings (48) and backup rings on the servo

piston for wear or damage and replace, if necessary.
NOTE: To reassemble the propel vibratory system

hydraulic pump, reverse the disassembly steps.
End By:
a. Install the propel or vibratory hydraulic pump.
26.
Remove screw (40).
27.
Remove feedback link (41) and neutral link (42).
28.
Remove neutral adjust screw (43).
29.
Remove five screws (44) and cover (45) with gasket.

Check the gasket for wear or damage and replace, if
necessary.
NOTE: The servo piston will come out attached to cover

(45) by the setscrew.
16-80
TM 5-3895-382-24
Pump Drive
Remove & Install Pump Drive
3108-010
Start By:
a. remove propel and vibratory pumps

NOTE: In the following procedure, the engine was
removed for better photo illustration of the pump
drive. The engine does not have to be removed in
order to service the pump drive.
3.
Remove eight bolts (4), and remove flange (5) from the
flywheel. When installing flange (5) apply 9S-3263
Thread Lock on the threads of bolts (4).
NOTE: For installation of the pump drive, revere the

removal steps.
End By:
a. install propel and vibratory pumps 16-81
1.
Remove four bolts (2) and support (3).
2.
Remove the remaining eight bolts, and remove adapter

(1) from the flywheel housing.
16-81
TM 5-3895-382-24
Hydraulic Oil Filter
Remove & Install Hydraulic Oil Filter 5068-010

bare hand.
1.
2.
Release the
(page 16-11).
pressure
in
the
hydraulic
system
5.
Remove two screws (5), and remove bypass indicator

(7) from the hydraulic oil filter base. During assembly,
apply 9S-3263 Thread Lock on the threads of the two
screws. Tighten the two screws to a torque of 1.7 N
m
(15 lb-in). Do not over tighten the screws.
6.
Remove filter (6) from hydraulic oil filter base (4). When
installing the filter on the hydraulic oil filter base, tighten
the filter to 3/4 turn past contact.
Remove the access panel from under the right side of

the operators platform.
NOTE: For installation of the hydraulic oil filter, reverse

the removal steps.
3.
Disconnect hose assemblies (2) and (3) from hydraulic

oil filter base (4). Cap and plug immediately.
4.
Remove four bolts (1), and remove hydraulic oil filter

base (4) from the frame.
16-82
TM 5-3895-382-24
Wheels & Tire Assemblies
Remove & Install Wheels & Tire
Assemblies 4202-010
8S-7640
8S-7611
8S-7615
8S-8048
Tools Needed
Stand
Tube
Pin
Saddle
A
2
2
2
2
NOTE: The procedure that follows is for either or both

wheel and tire assemblies.
1.
Engage the parking brake. Place wooden wedges in

front of and behind the drum assembly.
3.
Remove eight lug nuts (2). Use two persons to remove

wheel and tire assembly (1). The weight of the wheel
and tire assembly is 100 kg (220 lb). When installing
the wheel and tire assembly, tighten the lug nuts to a
torque of 530 70 N
m (390 52 lb-ft).
4.
Check the condition of the wheel studs. If the studs are

damaged, use new pans for replacement.
NOTE: For installation of the wheel and tire assemblies

NOTE: The shipping weight of the Roller with pad-foot

shell kit is 18,252 lbs (8279 kgs).
2.
Raise the rear of the machine until the tires are just off
the floor. Install tooling (A) under the rear frame of the
machine as shown.
16-83
TM 5-3895-382-24
Remove & Install Wheel End Assemblies
(CS-433C & CP-433C) 4051-010
5P-9736
6V-2157
5S-4087
Tools Needed
Link Bracket
Link Bracket
Socket
A
1
1
1
Start By:
a. remove wheel and tire assemblies

NOTE: In the following procedure, the axle assembly was
removed for better photo illustration of the wheel
end assemblies. The axle assembly does not
have to be removed from the machine in order to
service the wheel end assemblies.
1.
2.
3.
Install three forcing screws (3) of the appropriate size in

the planetary spider assembly as shown. Tighten the
screws evenly to separate the planetary spider
assembly from the wheel hub assembly, but do not
entirely remove the planetary spider assembly.
4.
Remove the top forcing screw from the planetary spider

assembly. Fasten Tool (A) and a hoist to planetary
spider assembly (2) as shown. Completely separate the
planetary spider assembly from the wheel hub assembly
with the forcing screws. Weight of the planetary spider
assembly is 19 kg (42 lb).
Rotate the wheel end assembly so the fill/drain plug is at

the bottom. Drain the oil from the wheel end assembly.
The capacity of the wheel end assembly is 1.4 liters
(.34 U.S. gal).
Put an alignment mark on the planetary spider assembly

and the wheel hub assembly for assembly purposes.
Remove sixteen bolts (1) that hold planetary spider
assembly (2) to the wheel hub assembly.
16-84
TM 5-3895-382-24
5.
Disassemble the planetary spider assembly as follows:
7.
Remove axle shaft (12) and ring gear (13) from the
wheel hub assembly.
8.
Remove pin (14). Remove bearing adjusting nut (15)

with Tool (C).
9.
Fasten tool (B) and a hoist to wheel hub assembly (16)

as shown. Remove the wheel hub assembly from the
carrier. It may be necessary to use a soft faced
hammer to free the wheel hub assembly from the
carrier. Weight of the wheel hub assembly is 54 kg
(120 lb).
a. If necessary, remove thrust button (4) from the

planetary spider assembly with a press.
b. Remove snap ring (5), washer (6) and planetary
gear (7). Remove the other two planetary gears
the same way. Discard the snap rings, and use
new parts for replacement.
c. Remove three set screws (9).

Remove
planetary shaft (8) with a press as shown.
Remove the other two planetary shafts the same
way.
6.
Remove snap ring (10) from the end of the axle shaft,
and discard it. Use new parts for replacement. Remove
sun gear (11) from the end of the axle shaft.
16-85
TM 5-3895-382-24
11.
Remove bearing cone (18), two bearing cups (19) and

the inner bearing cone from the hub.
NOTE: The following steps are for the installation of the

wheel end assemblies.
10.
12.
Be sure all parts of the wheel end assembly are dean

and free of dirt and debris prior to assembly. Lubricate
the bearing cup and cone sets with clean oil. Inspect
the threads on the end of the carrier. If the threads are
damaged, the bearing adjusting nut cannot be tightened
properly.
13.
Press two bearing cups (19) in the hub. Place the inner
bearing cone in the inner bearing cup in the hub.
14.
Put a light coat of oil on seal (17). Install the seal in the
hub, on top of the inner bearing cone. Be sure the lip of
the seal is facing in toward the hub.
Remove seal (17) from the hub. Discard the seal, and
use new parts for replacement.
NOTICE
Keep the bearing cup and cone sets together. This will
help ensure that these parts am reassembled in their
original locations.
NOTICE
Do not damage seal (17) when the wheel hub assembly is
installed on the axle assembly.
16-86
15.
Fasten Tool (B) and a hoist to wheel hub assembly (16),

and put it in position on the carrier.
16.
Install the outer bearing cone in the wheel hub

assembly. Be sure the bearing cone is seated in the
outer bearing cup.
TM 5-3895-382-24
17.
Install bearing adjusting nut (15). Tighten the nut with

Tool (C) to a torque of 135 N m (100 lb-ft), while
rotating the wheel hub assembly in both directions. Rap
the wheel hub assembly with a soft faced hammer; then
re-tighten the nut again to a torque of 135 N
m (100 lbft). Repeat this procedure until the nut will not advance
with the application of 135 N
m (100 lb-ft) of torque.
18.
Loosen the bearing adjusting nut to relieve the preload

on the bearings. The torque on the bearing adjusting
nut should be zero.
19.
Determine the wheel hub assembly rolling torque. This

torque value must be obtained while the hub is being
rotated at a steady rate (not starting torque). Use a flat
bar with a welded nut in the center, attached to the face
of the hub. Use a torque wrench to turn the hub. Note
the rolling torque.
20.
An alternate method for determining wheel hub

assembly rolling torque is to wind a cord around the hub
barrel. Attach a spring scale to the cord, and pull it
straight out at a steady rate. Torque in units of lb-ft. =
(Ib. pull X inches of hub barrel radius) divided by 12.
21.
Tighten bearing adjusting nut (15), and recheck the hub

rolling torque. The increase in rolling torque from Step
19 to Step 20 should be 4 to 7 N
m (3 to 5 lb-ft) if new
beatings are used. If the beatings are reused, the
torque increase should be 2.0 to 3.4 N
m (1.50 to 2.50
Ib-ft).
22.
Install pin (14) in the adjusting nut.
26.
Assemble the planetary spider assembly as follows:
a. Check the condition of the bores in planetary

gears (7). If the bores are rough or worn, use
new parts for replacement.
b. Install planetary shafts (8) in the spider with a
press. Install set screws (9). Put a thin coat of
oil in the bores of planetary gears (7). Install the
planetary gears on the planetary shafts. Install
washers (6) and new snap rings (5) to hold the
gears.
27.
Install thrust button (4) in the spider.
28.
Be sure the mounting flange on the planetary spider

assembly and the mounting face on the wheel hub
assembly are clean and free of dir. Put a bead of 8T9022 General Purpose Adhesive Sealant on the face
of the wheel hub assembly. Be sure the adhesive
sealant goes around the inner edge of all fastener holes
to ensure complete sealing.
29.
Fasten Tool (A) and a hoist to planetary spider

assembly (2). Put the planetary spider assembly in
position on the wheel hub assembly, aligning the gear
teeth of the planetary gears with the teeth on the sun
gear and ring gear. Align the match marks on the
planetary spider assembly and the wheel hub assembly.
30.
Install sixteen bolts (1) that hold the planetary spider

assembly to the wheel hub assembly. Tighten the bolts
to a torque of 90 to 125 N
m (65 to 90 lb-ft).
31.
Fill the wheel end assembly with oil to the correct level.
See, "Planetary" in the Operation & Maintenance
Manual.
End By:
a. Install wheel and tire assemblies
23.
Press ring gear (13) into place on the carrier. Pin (14)
must line up with hole (20) on the back side of the ring
gear.
24.
Install axle shaft (12) into the axle assembly. The

splines on the end of the axle shaft must engage with
the internal splines in the differential.
25.
Install sun gear (11) and a new snap ring (10) to hold it
in position.
16-87
TM 5-3895-382-24
Axle Propel Motor
Remove & Install Axle Propel Motor 5058-010
At operating temperature, the oil in the hydraulic oil tank

and in the hydraulic system is hot and under pressure.
Hot oil can cause burns. Prior to disconnecting any
hydraulic lines, release the pressure in the hydraulic
system. Stop the engine. Move the hydraulic control
levers to all positions to release the pressure in the
hydraulic system. Release the pressure in the hydraulic
oil tank. Remove the fill cap on the hydraulic oil tank only
when it is cool enough to touch with your bare hand.
Remove the fill cap slowly to release the pressure in the
hydraulic oil tank.
4.
Disconnect hose assemblies (2) and (5) from axle

propel motor (3). Cap and plug immediately.
5.
Remove two bolts (4), and use two persons to remove

axle propel motor (3) from the rear reduction case
assembly. The weight of the axle propel motor is 23 kg
(51 lb).
1.
Release the pressure in the hydraulic system (16-11).
2.

machine.
NOTE: For installation of the axle propel motor, reverse

the removal steps.
3.
Disconnect hose assembly (1) from the axle propel

motor. Cap and plug immediately.
NOTE: After the axle propel motor has been installed, fill
filling procedure.
16-88
TM 5-3895-382-24
Disassemble Axle Propel Motor
5058-015
1P-1862
1P-3075
1P-1860
2P-8312
Tools Needed
Pliers
Puller Group
Pliers
Pliers
A
1
1
1
1
Start By:
a. remove axle propel motor

1.
Thoroughly clean the outside of the hydraulic propel

motor prior to disassembling it.
2.
Put an alignment mark across the housing and front

cover for assembly purposes.
3.
NOTE: Up-type seal (4) will be damaged during removal

from the front cover.
Remove seven screws (1) that hold the front cover to

the housing. Remove front cover (2) and the shaft as a
unit. Remove the gasket from the housing. At this time,
the hydraulic oil can be drained from the housing.
16-89
4.
Use Tool (A) to remove snap ring (3). Use Tool (B) to
remove lip-type seal (4) from the front cover.
5.
Use Tool (A) to remove snap ring (5). Remove the

bearing and shaft (6) from the front cover as a unit. It
may be necessary to use a press to remove the shaft
and bearing from the front cover.
TM 5-3895-382-24
NOTE: There is a snap ring on each side of bearing (8).

6.
7.
Use Tool (C) to remove upper and lower snap rings (7)
from shaft (6). Using a press, remove shaft (6) from
bearing (8).
Put identification marks on two journal bearings (10) as

to their location in the front cover. Remove the two
journal bearings from the front cover. Remove two
spring pins (9) from the front cover.
16-90
8.
Remove five bolts (12) and cover (14) from the housing.
Remove the gasket from under the cover.
9.
Remove five bolts (11) and cover (13) from the housing.
Remove gasket (17) from under the cover.
10.
Remove spring (15) and stop (16) from the servo piston.
TM 5-3895-382-24
13.
Use Tool (D) to remove cylinder block assembly (21)

from housing (22).
14.
Remove seven pistons (23) and slipper guide (24) from

cylinder block (25).
15.
Remove retainer guide (26) from the cylinder block.
NOTICE
Do not turn the main housing upside down to remove the
swashplate from the housing. Numerous parts in the
housing, which are finely polished, can be scratched or
gouged.
11.
Remove sleeve bearing (18) and swashplate (19) from

the housing.
NOTICE
Sleeve bearing (18) must be reinstalled in its original
position on swashplate (19).
12.
Note the position of sleeve bearing (18) on the

swashplate prior to removal. Remove sleeve bearing
(18) and pin (20) from swashplate (19).
16-91
TM 5-3895-382-24
16.
Remove pin retainer (27) and three pins (28) from the
cylinder block.
19.
Put an identification mark on valve plate (34) as to its

location in the housing and locating pin (33). Remove
valve plate (34) from the housing.
20.
If necessary, remove locating pin (33) from the housing.
NOTE: Needle bearing (35) will be damaged when it is

removed from the housing.
21.
Remove needle bearing (35) from the housing.

17.
Put cylinder block (25) in a press. Install a suitable

piece of square steel stock against washer (30). Put
slight compression on washer (30) with the press.
Remove retaining ring (29), and slowly release the
spring compression.
NOTICE
The inside shape of servo piston (36) is different at each
end. Note the way the servo piston is installed in the main
housing so it can be reinstalled in its original position.
22.
NOTICE
Washers (30) and (32) are different in size.
Put
identification marks on the washers so they can be
installed in their original location in the cylinder block.
18.
Remove washer (30), spring (31) and washer (32) from

the cylinder block.
16-92
Remove servo piston (36) from housing (22).
TM 5-3895-382-24
Assemble Axle Propel Motor
5058-016
1P-1862
1P-1860
2P-8312
23.
Tools Needed
Pliers
Pliers
Pliers
A
1
1
1
1.
Be sure all parts of the axle propel motor are clean and
free of dirt and debris prior to assembly.
2.
Install spring guides (40) and (42) on valve spool (39).

Install the valve spool in housing (22).
3.
Install the O-ring seal on both plugs (41). Install both

springs (44) and both plugs (41) in the housing.
4.
Install the O-ring seal on plug (46). Install the shims in

the plug. Install poppet (43), spring (45) and plug (46) in
the housing.
Remove bearing rings (37) from the inner grooves of the

servo piston. Remove piston rings (38) and the two Oring seals from the outer grooves of the servo piston.
Check the bearing rings, the piston rings and the O-ring
seals for damage or wear and replace if necessary.
24.
Remove plug (46), spring (45) and poppet (43) from the
housing. Remove the shims and the O-ring seal from
plug (46). Check the O-ring seal for damage or wear
25.
Remove plug (41) and spring (44) from both sides of the
housing. Remove the O-ring seal from each plug (41).
necessary.
26.
Remove spring guide (40), valve spool (39) and spring

guide (42) from the housing.
16-93
TM 5-3895-382-24
NOTE: When installing needle bearing (35) in the

housing, the printed (numbered) end of the
bearing cage must be visible (toward the inside of
the housing).
5.
Install bearing rings (37) in the grooves of servo piston

(38). Install the two O-ring seals in the outer grooves of
the servo piston. Install one piston ring (38) over the Oring seal.
6.
Put clean oil on the bearing rings and piston ring.

Carefully slide servo piston (36) into the servo bore of
housing (22) as shown.
NOTICE
Do not slide the servo piston through the housing any
farther than necessary to install the second piston ring on
the servo piston. Sharp edges on the servo bore, inside
the pump housing, can damage the first piston ring. Do
not damage the bearing ring when sliding the servo piston
back into the pump housing.
7.
Slide the servo piston through the housing until the

piston ring groove (without a piston ring) is just exposed.
Install the remaining piston ring (38) in the groove of the
servo piston. Put clean oil on the piston ring and slide
the servo piston back into the housing.
16-94
8.
Install needle bearing (35) in housing (22). Install the

needle bearing until it protrudes 2.0 to 2.5 mm (0.08 to
0.10 in) above the inside surface of the housing.
9.
Install locating pin (33) in the housing. Install the

locating pin until it protrudes 4.19 to 4.70 mm (0.165 to
0.185 in) above the inside surface of the housing.
10.
Install valve plate (34) in the housing. The bronze side

of the valve plate must be visible inside the housing.
The notch on the valve plate must engage locating pin
(33).
TM 5-3895-382-24
11.
Install washer (32), spring (31) and washer (30) in

cylinder block (25). Put the cylinder block in a press.
Install a suitable piece of square steel stock against
washer (30). Using the press, compress spring (31),
and install retaining ring (29). Slowly release the spring
compression.
14.
Install seven pistons (23) in slipper guide (24). Install

the slipper guide and the pistons in cylinder block (25).
15.
Use Tool (D) to install cylinder block assembly (21) in

housing (22).
16.
Install pin (20) in swashplate (19). Install sleeve bearing

(18) on pin (20). The notched side of the sleeve bearing
must be facing the convex portion of the swashplate.
NOTE: Position pin retainer (27) at the top of the cylinder

block splines.
12.
13.
Install three pins (28) and pin retainer (27) in the

cylinder block.
Install retainer guide (26) on the cylinder block.
16-95
TM 5-3895-382-24
17.
Put clean hydraulic oil on the slipper face of each piston.

Install sleeve bearing (18) and swashplate (19) in the
housing. Be sure the swashplate is seated on each
piston, and the sleeve bearing is engaged in the groove
in servo piston (36). It may be necessary to move the
servo piston to allow the sleeve bearing to engage
properly.
18.
Install spring (15) and stop (16) in servo piston (36).
19.
Install a new gasket (17), cover (13) and five bolts (11).
Install a new gasket, cover (14) and five bolts (12).
Tighten the bolts to a torque of 13.6 to 17.6 N
m (10 to
13 lb-ft).
16-96
20.
Install two spring pins (9) in front cover (22). Spring

pins (9) must protrude 1.65 to 2.03 mm (0.065 to 0.080
in) above the journal bearing surfaces of the front cover.
21.
Install two journal bearings (10) on the front cover and

spring pins (9). The ends of spring pins (9) must not
protrude beyond the surface of the journal bearings after
they are installed.
22.
Install lower snap ring (7) in the lower most groove on

shaft (6). Using a press, install shaft (6) into bearing (8).
Install the shaft until the bearing makes contact with the
snap ring.
23.
Use Tool (C) to install upper snap ring (7) on shaft (6).
TM 5-3895-382-24
29.
If any hydraulic fittings were removed from the axle

propel motor, reinstall them in their original locations.
End By:
a.
24.
Install bearing (8) and shaft (6) as a unit in front cover

(2). Use Tool (A) to install snap ring (5).
25.
Position a new gasket on the pump housing, and lower

the shaft and front cover (2) into position. Carefully
align the shaft splines with the cylinder block splines.
Continue to lower the shaft and front cover into position
while aligning front cover with the swashplate and the
end of the shaft with the beating in the pump housing.
When the shaft and front cover are properly installed,
the spring inside the cylinder block will hold the front
cover away from the pump housing and gasket a
maximum distance of 3 mm (0.125 in).
26.
Install seven twelve point bolts (1) that fasten the front
cover to the pump housing. Tighten the 3/8'-16 X 1.25
in twelve point bolt to a torque of 53 to 64 N
m (39 to
47 lb-ft). Tighten the remaining six 7/16'-14 X 1.00 in
twelve point bolts to a torque of 81 to 100 N
m (60 to
74 lb-ft).
27.
Put clean hydraulic oil on the lip-type seal (4). Slide the
lip-type seal over the shaft, and install the lip-type seal
in the front cover.
28.
Use Tool (A) to install snap ring (3).
16-97
Install axle propel motor
TM 5-3895-382-24
Axle (CS-433C & CP-433C)
Remove & Install Axle
(CS-433C & CP-433C) 3278-010
Start By:
a. remove wheel and tire assemblies
At operating temperature, the oil in the hydraulic oil tank

and in the hydraulic system is hot and under pressure.
Hot oil can cause burns. Prior to disconnecting any
hydraulic lines, release the pressure in the hydraulic
system. Stop the engine. Move the hydraulic control
levers to all positions to release the pressure in the
hydraulic system. Release the pressure in the hydraulic
oil tank. Remove the fill cap on the hydraulic oil tank only
when it is cool enough to touch with your bare hand.
Remove the fill cap slowly to release the pressure in the
hydraulic oil tank.
4.
Disconnect hose assemblies (2) and (3) from axle

propel motor (4). Cap and plug immediately.
NOTE: The axle, reduction case assembly and axle

propel motor are removed as a unit in the
following steps.
1.
2.
3.
Release the
(page 16-11).
pressure
in
the
hydraulic
5.
Fasten axle assembly (5) to a suitable floor jack as

shown. Install wood blocks under the mounting bracket
of the axle so the unit can not tip.
6.
Remove four bolts (6), the washers and nuts that hold
the axle (5) to the frame of the machine.
7.
Remove axle (5) from under the machine. Weight of the

axle is 476 kg (1050 lb).
system

machine.
Disconnect hose assembly (1) from the axle propel
motor. Cap and plug immediately.
NOTE: For installation of the axle, reverse the removal

steps.
NOTE: After the axle has been installed, fill the hydraulic
oil tank to the correct level. See the Operation &
Maintenance Manual for the correct filling
procedure.
End By:
a. install wheel and tire assemblies.
16-98
TM 5-3895-382-24
Disassemble & Assemble Axle
(CS-433C & CP-433C) 3278-017
6V-2157
1P-0513
Tools Needed
Link Bracket
Plate
A
2
B
1
Start By:
a. remove axle (CS-433C & CP-433C)

NOTE: In the following steps, the axle was disassembled
and assembled in a vertical position, on an engine
roll-over stand. Although it is not necessary, use
of the engine roll-over stand makes the
disassembly and assembly procedure easier.
1.
Remove the rear reduction case assembly from the

axle. See, "Remove And Install Rear Reduction Case
Assembly" in this module.
2.
Put the axle in a vertical position with the carrier cover

up as shown. Fasten Tooling (A) and a hoist to the
wheel end assembly as shown. Remove eleven bolts
(1), the washers and nuts that hold the carrier cover to
the carrier housing. Slowly remove the carrier cover
from the carrier housing so the differential does not
come out with the carrier cover. Weight of the wheel
end assembly and carrier cover is 221 kg (487 lb).
3.
Remove and discard the gasket from between the

carrier housing and the carrier cover. Use new parts for
replacement.
16-99
4.
Fasten a hoist to ring gear and differential assembly (2)

as shown. Remove the ring gear and differential
assembly from the carrier housing. Weight of the ring
gear and differential assembly is 35 kg (78 lb).
5.
Remove pinion shaft and bearing cage (3) from the

carrier housing by hand. It may be necessary to pry
between the bearing cage and carrier housing to
remove the unit.
6.
Remove thrust block (4) and the pin from the carrier
cover.
TM 5-3895-382-24
7.
8.
Remove bearing cup (5) from the carrier housing.

Remove the other bearing cup from the carrier cover.
If necessary, remove six studs (6) from the carrier

housing.
NOTE: Steps 9 through 13 are for the disassembly of the

pinion shaft assembly.
9.
Remove washer (10), outer bearing cone (9) and

bearing cage (8) from pinion shaft (7).
16-100
10.
Remove two bearing cups (11) from bearing cage (8).
11.
Remove the snap ring that retains bearing (12) on the

end of the pinion shaft.
12.
Remove pinion bearing spacer (14) from the pinion

shaft.
13.
Remove inner bearing cone (13) and bearing (12) from

pinion shaft (7) with a press.
TM 5-3895-382-24
NOTE: Steps 14 through 22 are for the disassembly of

the differential.
17.
14.
Put an alignment mark on the case and cover assembly

of the differential for assembly purposes.
The
components must be reinstalled in their original
positions.
NOTE: The No-Spin differential is serviced as a unit.

However, it can be disassembled for cleaning
purposes.
15.
Loosen, but do not remove eight bolts (15) that hold the
case to the cover.
16.
Remove cover (16) from the No-Spin differential.

Remove bearing cone (17) from the cover.
18.
Remove side gear (18), spring retainer (19) and spring

(20).
19.
Remove two drive clutch assemblies (21) and spider

assembly (22). Separate the drive clutch assemblies
and the spider assembly.
Put the differential in a press as shown. Install Tooling

(B) on the end of the differential as shown. Apply
pressure on the differential so it can not move in the
press. Remove eight bolts (15) and the washers that
hold the case and cover together. Slowly release the
pressure on the differential until all the spring force
under cover (16) is released.
16-101
TM 5-3895-382-24
28.
Inspect the splines on the side gears. Remove any

burrs or small chips. Check the walls for fractures.
29.
Check the way each side gear fits on the mating axle
shaft (part of the wheel end assembly). Be sure the
splines do not bind.
30.
Check the spring load of two springs (20) as follows:
a. Place one spring in a spring tester.

b. Compress the spring to its operating height of
15.7 mm (.62 in).
20.
c. The force of the compressed spring must be 290

31 N (65 7 lb).
Remove spring (20), spring retainer (19) and side gear

(18) from the other side of the differential.
d. Repeat Steps a through c for the other spring. If

either spring load is not correct, both springs
must be replaced.
21.
Remove twelve bolts (25), the washers and nuts that

hold ring gear (26) to case (23). Separate the ring gear
from the case.
22.
Remove bearing cone (24) from the case.

axle.
23.
Be sure all parts of the No-Spin differential are

thoroughly clean.
24.
Inspect the splines on the drive clutch assemblies.

Remove any burrs or small chips.
25.
Check the holdout rings (inside driven clutch

assemblies) for fractures and chipping or excessive
wear of the teeth.
26.
Check the teeth on the spider and center cam (inside

spider assembly) for chips or wear.
27.
Be sure the center cam moves freely inside the spider

assembly.
16-102
31.
Check cover (16) and case (23) for wear or score

marks. If the parts are worn or scored, use new parts
for replacement.
32.
Check the ring gear and pinion shaft for wear. The ring
gear and pinion shaft are a matched set. If either part is
worn, a replacement of both parts must be made.
TM 5-3895-382-24
36.
Install one spring retainer (19) over side gear (18) with
the retaining lip facing up. The spring retainer should
seat against the shoulder of the side gear.
37.
Install one spring (20) over the splined end of the side
gear. The small diameter end of the spring should be
against the spring retainer.
38.
Position spider assembly (22) over one drive clutch

assembly (21). Be sure long tooth (28) on the spider
assembly is positioned over slot (27) in the holdout ring
of drive clutch assembly (21).
39.
Position the remaining drive clutch assembly (21) over

the spider assembly. Again, be sure slot in the holdout
ring of the drive clutch assembly is positioned over the
long tooth on the spider assembly.
40.
Compress one of the drive clutch assemblies over the

side gear splines a few times. Be sure the spring does
not bind and the coils do not overlap. Check to be sure
that there is good contact between the end coil of the
spring and the spring retainer when the drive clutch
assembly and the side gear splines are fully meshed.
NOTE: Steps 33 through 45 are for the assembly of the

differential.
Hot water can cause burns. To prevent possible personal

injury, wear protective gloves when handling the hot ring
gear in Step 33.
33.
Install bearing cone (24) on case (23). Heat ring gear

(26) in water to a temperature of 71 to 82C (160 to
180F). The ring gear should remain in the water for 10
to 15 minutes so it will be thoroughly heated. Put ring
gear (26) in position on case (23). If the ring gear does
not easily fit on case (23), repeat the heating procedure.
Install twelve bolts (25), the washers and nuts that hold
the ring gear in position. Install bolts (25) with the bolt
heads against the gear. The ring gear must be flush
with the differential assembly flange after installation.
Check the installation with a .075 mm (.0030 in) feeler
gauge.
34.
Set the case and ring gear on a bench with the bearing
end down and the inner case facing upward.
35.
Place the ground hub of one side gear (18) into the bore
of the case. Be sure the side gear rotates freely in the
case.
16-103
TM 5-3895-382-24
41.
Install the remaining spring retainer (19) over the splines

of the remaining side gear (18). Be sure the retaining lip
is facing up, and the spring retainer seats against the
side gear shoulder. Install the remaining spring (20)
over the side gear splines and against the retaining lip.
The small diameter of the spring must be against the
spring retainer.
51
If studs (6) were removed from the carrier housing,

reinstall them.
52.
Install bearing cup (5) in the carrier housing. Install the

other bearing cup in the carrier cover.
53.
Install thrust block (4) and the pin in the carrier cover.
42.
Install side gear (18), spring retainer (19) and spring

(20) over the other driven clutch assembly of the NoSpin differential. Be sure the side gear is facing up.
54.
43.
Compress the side gear over the driven clutch assembly

of the No-Spin differential a few times. Be sure the
spring does not bind and coils do not overlap. Check to
be sure that there is good contact between the end coils
of the spring and the spring retainer when the driven
clutch assembly and side gear splines are fully meshed.
Put a 3.2 mm (.125 in) continuous bead of 8T-9022

General Purpose Adhesive Sealant on the face of the
carrier housing at the location for the pinion shaft
assembly. The sealant should go around the inner
edges of all fastener holes to ensure complete sealing.
Install pinion shaft and bearing cage assembly (3) in the
carrier housing. Use a soft faced hammer to seat the
assembly in the housing.
55.
Fasten a hoist to ring gear and differential assembly (2).

Install the ring gear and differential assembly in the
carrier housing. Be sure that the ring gear engages with
the pinion shaft properly. If the components do not
mesh easily, remove the ring gear and differential
assembly, and check for obstructions.
44.
Install bearing cone (17) on cover (16). Install cover

(16) over the side gear. Be sure the side gear splines
are completely meshed with the driven clutch assembly
splines.
45.
Put the differential in a press as shown in photo above

Step 16. Install tool (B) on the end of the differential as
shown. Compress the differential. Be sure the splines
mesh and the alignment marks made on the case and
cover during disassembly line up with each other.
Install eight bolts (15) and the washers that hold the unit
together.
NOTE: If the wheel end assemblies have not been

removed, and the axles are present, ensure that
the ring gear and differential assembly meshes
with the spline of the axle.
56.
Put a new gasket on the carrier housing. Fasten tool

(A) and a hoist to the wheel end assembly and carrier
cover. Slowly lower the unit into position on the carrier
housing. Be sure the splines on the axle engage
properly with the ring gear and differential assembly.
Install eleven bolts (1), the washer and nuts that hold
the unit together.
57.
Install the rear reduction case assembly. See, "Remove

And Install Rear Reduction Case Assembly" in this
module.
NOTE: Steps 46 through 50 are for the assembly of the

pinion shaft assembly.
46.
Install inner bearing cone (13) and bearing (12) on the

pinion shaft with a press.
47.
Install the snap ring which retains bearing (12) on the

end of the pinion shaft.
48.
Install bearing spacer (14) on the pinion shaft.

spacer can be installed in either direction.
49.
Install two bearing cups (11) in bearing cage (8).
50.
Put clean oil on inner bearing cone (13). Install bearing

cage (8) on the pinion shaft. Be sure the bearing cage
is seated on the inner bearing cone. Put clean oil on
outer bearing cone (9), and install it on the pinion shaft.
Be sure the bearing cone is seated in the bearing cage.
Install washer (10) on the pinion shaft.
The
End By:
a. install axle (CS-433C & CP-433C)
16-104
TM 5-3895-382-24
Rear Reduction Case Assembly
(CS-433C & CP-433C)
Remove And Install Rear Reduction Case Assembly
(CS-433C & CP-433C) 3260 & 3265-010
Start By
a. remove axle (CS-433C & CP-433C)
6.
Remove snap ring (5) from the reduction case cover,

and discard it. Use new parts for replacement.
1.
Remove axle propel motor (1) from the reduction case

assembly.
2.
Put an alignment mark across the reduction case and

the carrier for assembly purposes.
3.
Remove the drain plug from the rear reduction case

assembly, and drain the oil. The capacity of the rear
reduction case assembly is .95 liters (.250 U.S. gal).
7.
Bend lock washer (6) off of outer nut (7). Remove the
outer nut and lock washer.
4.
Remove two dowels (2) from the reduction case with a

hammer and a punch.
8.
Remove four bolts (8) and input shaft cap (9) from the
reduction case.
5.
Remove fifteen bolts (3), the washers and the nuts that
hold reduction case cover (4) in position. Remove the
cover.
16-105
TM 5-3895-382-24
9.
Using a soft faced hammer, remove the bearings and

input gear (10) from the reduction case as a unit.
NOTE: Bearing cage (17) and bearing (18) may remain in

the reduction case after it is removed from the
carrier.
10.
Remove inner nut (11), the washer and reduction drive

gear (12) from the pinion shaft.
14.
Remove bearing cage (17) and bearing (18) from the

reduction case.
NOTE: The following steps are for the installation of the

rear reduction case assembly.
11.
15.
Be sure all parts of the rear reduction case assembly

are clean and free of dirt and debris prior to installation.
16.
If required, install bearing (18) and bearing cage (17) in

the carrier.
17.
Put a 3.2 mm (.125 in) continuous bead of 8T-9022

General Purpose Adhesive Sealant on the mounting
flange of input shaft cap (9). Install the input shaft cap
and the four bolts and washers which hold it to the
reduction case.
18.
Install two bearings (13) on input gear (10).
Remove two bearings (13) from input gear (10).
12.
Remove reduction gear key (14) from the pinion shaft.
13.
Remove six nuts (15) and the washers that hold

reduction case (16) to the carrier.
Remove the
reduction case from the carrier.
16-106
TM 5-3895-382-24
Blade
Blade Cylinder
Remove & Install Blade 6151-010
Remove & Install Blade Cylinder

5102-010

bare hand.
1.
1.
Release the
(page 16-11).
pressure
in
the
hydraulic
system
2.
Disconnect hose assembles (1) from blade cylinder (2).

3.
Remove nut and bolt (3). Repeat for the opposite end
of the cylinder. Remove the cylinder.
Park the machine on a solid, level surface. Lower the

blade (1).
2.
Remove nut and bolt (2).
3.
Attach a hoist. Remove two nuts and two bolts (3) from
both sides of the machine. Drive out bushings.
4.
Using a hoist, lift the blade away from the machine. The
weight of the blade is approximately 380 kg (840 lb).
NOTE: For installation of the blade, reverse the removal

steps.
NOTE: For installation of the blade cylinder, reverse the

removal steps.
NOTE: After installing the blade cylinder, fill the
hydraulic oil tank to the correct level. See the
Operation and Maintenance Manual for the correct
filling procedures.
16-107
TM 5-3895-382-24
Disassemble & Assemble Blade
Cylinder 5102-017
Start By:
a. remove blade cylinder.
1.
Remove two bolts (13), and slide cover (14) and rod
assembly (9) partially out of cylinder assembly (16).
2.
Push head (5) into the cylinder assembly and remove

lockwire ring (8).
3.
Remove head (5) and rod assembly (9) from cylinder

assembly (16).
4.
Remove nut (1), piston (2) and head (5) from rod
assembly (9). Remove O-ring seal (15) from the rod
assembly. Check the O-ring seal for damage or wear
and replace if necessary. During assembly, tighten nut
(1) to a torque of 309 Nom (227 lb-ft).
6.
Remove O-ring seal (6) and back-up ring (7) from the
outside of head (5). Remove lip-type seal (10), O-ring
seal (12) and back-up ring (11) from inside head (5).
Check the back-up rings, O-ring seals and lip-type seal
for damage or wear and replace if necessary.
NOTE: During assembly of the blade cylinder, put a thin

coat of clean oil on the O-ring seals, back-up
rings and lip-type seal.
NOTE: For assembly of the blade cylinder, reverse the
disassembly steps.
End By:
5.
Remove wear ring (4) and O-ring seal (3) from piston
(2). Check the wear ring and O-ring seal for damage or
wear and replace if necessary.
a. Install blade cylinder.
16-108
TM 5-3895-382-24
Remove & Install Leveling Blade Control
Valve 5051-010
At operating temperature, the hydraulic oil tank Is hot and

bare hand.
1.
Start the machine and lower the leveling blade to the

ground. Engage the parking brake and connect steering
pivot lock.
2.
Release the
(page 16-11).
3.
Mark or identify all hydraulic hoses for installation

purposes.
4.
Disconnect four hose assemblies (4) from leveling blade

control valve. Cap and plug immediately.
5.
Remove two bolts (5). Loosen cable adjust locknut (1).

Slide collar (2) back. Detach cable from cable retainer
(not shown).
6.
Remove three bolts (3)(not shown) and leveling blade

control valve.
pressure
in
the
hydraulic
system
NOTE: For installation of the leveling blade control valve,

NOTE: After installing the leveling blade control valve, fill
Operation and Maintenance Manual for the correct
filling procedures.
16-109
TM 5-3895-382-24
Disassemble & Assemble Leveling Blade

Control Valve 5051-017
Start By
a. remove leveling blade control valve
1.
Thoroughly clean the outside of the leveling blade

control valve prior to disassembly to prevent
contamination of the valve.
8.
2.
Remove all fittings and the O-ring seals from the valve
body. Check O-ring seals for wear or damage. Replace
as required.
End By:
3.
Remove two screws (1), retainer plate (2), retainer (21),

and seal (20). Remove spool assembly (19).
4.
Remove relief valve (3). Check O-rings (4) for damage

or wear. Replace as required.
5.
Remove plug (5), O-ring (6), spring (7), and poppet (8).
Check O-ring (6) for damage or wear. Replace as
required.
6.
Remove four screws (12), end cap (11), detent

assembly (13), washer (14), spring (10), collar (15),
spacer (9), spacer (16), retainer (17), and seal (18).
7.
Be sure all internal parts of the leveling blade control

valve are clean. Coat all parts with clean hydraulic oil.
After installing the leveling blade control valve, adjust

the "Relief valve setting".
See the "Testing and
Adjusting Manual".
a. install leveling blade control valve
NOTE: For assembly of the leveling blade control valve.

reverse the disassembly step.
16-110
TM 5-3895-382-24
APPENDIX A
REFERENCES
A-1. SCOPE
This appendix lists forms, field manuals, technical manuals, and other publications either referenced in this manual or which apply to
the operation and maintenance of the Roller. Web sites which may be useful are also included in this appendix.
A-2. DEPARTMENT OF THE ARMY PAMPHLETS
Consolidated Index of Army Publications and Blank Forms .............................................................................................................DA Pam 25-30
Using Unit Supply System (Manual Procedures) ............................................................................................................................DA Pam 710-2-1
The Army Maintenance Management System (TAMMS) .............................................................................................................DA Pam 738-750
A-3. FORMS
Recommended Changes to Publications and Blank Forms ............................................................................................................. DA Form 2028
Recommended Changes to Equipment Technical Publications ..................................................................................................DA Form 2028-2
Organizational Control Record for Equipment .................................................................................................................................... DA Form 2401
Equipment Inspection and Maintenance Worksheet ......................................................................................................................... DA Form 2404
Equipment Inspection and Maintenance Worksheet (Electronic) .................................................................................................DA Form 5988E
Maintenance Request ............................................................................................................................................................................. DA Form 2407
Preventive Maintenance Schedule and Record ................................................................................................................................... DD Form 314
Product Quality Deficiency Report (NSN 7540-00-105-0078) .......................................................................................................................SF 368
A-4. FIELD MANUALS
NBC Contamination Avoidance ..........................................................................................................................................................................FM 3-3
NBC Protection ......................................................................................................................................................................................................FM 3-4
NBC Decontamination...........................................................................................................................................................................................FM 3-5
NBC Handbook ......................................................................................................................................................................................................FM 3-7
Camouflage ..........................................................................................................................................................................................................FM 20-3
Operation and Maintenance of Ordnance Materiel in Extreme Cold Weather (0 to -65F) ................................................................ FM 9-207
Recovery and Battlefield Damage Assessment and Repair ....................................................................................................................FM 9-43-2
Soldier's Manual for First Aid .......................................................................................................................................................................... FM 21-11
Basic Cold Weather Manual ........................................................................................................................................................................... FM 31-70
Northern Operations ........................................................................................................................................................................................ FM 31-71
Army Motor Transport Units and Operators ................................................................................................................................................ FM 55-30
Desert Operations (How to Fight) .....................................................................................................................................................................FM 90-3
Operational Symbols ....................................................................................................................................................................................FM 101-5-1
Manual for Wheel Vehicle Driver .................................................................................................................................................................FM 21-305
A-5. SUPPLY BULLETIN
Storage Serviceability Standard - Tracked Vehicles, Wheeled Vehicles, and Component Parts...................................................SB 740-98-1
A-1
TM 5-3895-382-24
A-6. TECHNICAL BULLETINS
Equipment Improvement Report and Maintenance Digest
(US Army Tank-Automotive Command) Tank-Automotive Equipment ....................................................................... TB 43-001-39-Series
Color, Marking, and Camouflage Painting of Military Vehicles,
Construction Equipment, and Materiels Handling Equipment....................................................................................................... TB 43-0209
Maintenance in the Desert .......................................................................................................................................................................... TB 43-0239
Use of Antifreeze and Cleaning Compounds in Engine Cooling Systems .......................................................................................... TB 750-651
Inspection, Use and Tightening of Metal Fasteners Used on Tank-Automotive Equipment ........................................................... TB 43-0218
A-7. TECHNICAL MANUALS
Chemical, Biological, and Radiological (CBR) Decontamination ............................................................................................................. TM 3-220
Inspection, Care, and Maintenance of Antifriction Bearings ..................................................................................................................... TM 9-214
Care and Use of Hand Tools and Measuring Tools ................................................................................................................................... TM 9-243
Materials Used for Cleaning, Preserving, Abrading, and Cementing
Ordnance Materiel and Related Items Including Chemicals ............................................................................................................. TM 9-247
STE/ICE-R.....................................................................................................................................................................................TM 9-4910-571-12&P
Tool Outfit Hydraulic System Test and Repair Unit (HYSTRU) ................................................................................................ TM 9-4940-468-13
Operator, Unit, Direct Support, and General Support Maintenance
Manual for Lead Storage Batteries ........................................................................................................................................ TM 9-6140-200-14
Operator's Unit, Direct Support, and General Support Maintenance Manual for
Care, Maintenance, Repair, and Inspection of Pneumatic Tires and Inner Tubes ........................................................ TM 9-2610-200-24
Preparing Hazardous Materials for Military Air Shipments ......................................................................................................................TM 38-250
Principals of Automotive Vehicles ...............................................................................................................................................................TM 9-8000
Painting Instructions for Field Use ............................................................................................................................................................TM 43-0139
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use .................................................................... TM 750-244-6
A-8. OTHER PUBLICATIONS
Army Logistics Readiness and Sustainability ..........................................................................................................................................AR 700-138
Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items ................................................................CTA 50-970
Abbreviations and Acronyms ...............................................................................................................................................................ASME Y14.38M
A-9. WEB SITES
Military Traffic Management Command (MTMC) ................................................................................................................http://www.tea.army.mil
Logistical Support Activity (LOGSA) ..................................................................................................................................http://www.logsa.army.mil
US Army Tank-Automotive and Armaments Command (TACOM) ............................................................................ http://www.tacom.army.mil
A-2
TM 5-3895-382-24
APPENDIX B
MAINTENANCE ALLOCATION CHART (MAC)
Section I. INTRODUCTION
B-1. THE ARMY MAINTENANCE SYSTEM MAC
a. This introduction (Section I) provides a general explanation of all maintenance and repair functions authorized at various
maintenance levels under The Army Maintenance Management System (TAMMS) concept.
b. The Maintenance Allocation Chart (MAC) in Section II designates overall authority and responsibility for the performance of
maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or
component will be consistent with the capacities and capabilities of the designated maintenance levels, which are shown on the MAC in
column (4) as:
Unit- Includes two subcolumns, C (operator/crew) and O (unit) maintenance.
Direct Support- Includes an F subcolumn.
General Support- Includes an H subcolumn.
Depot- Includes a D subcolumn.
c. Section III lists the tools and test equipment (both special tools and common tool sets) required for each maintenance function
as referenced from Section II.
d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.
B-2. MAINTENANCE FUNCTIONS
Maintenance functions are limited to and defined as follows:
a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with
established standards through examination (e.g., by sight, sound, or feel).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and
comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes
decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.
d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating
characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
B-1
TM 5-3895-382-24
B-2. MAINTENANCE FUNCTIONS (CONT)
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and
diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard
of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.
g. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions.
Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner
to allow the proper functioning of an equipment or system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized by the
MAC and the assigned maintenance level is shown as the third position code of the SMR code.
i. Repair. The application of maintenance services 1 including fault location/troubleshooting2, removal/installation and
disassembly/assembly3 procedures, and maintenance actions 4 to identify troubles and restore serviceability to an item by correcting
specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system.
j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational
condition as required by maintenance standards in appropriate technical publications (i.e. DMWR). Overhaul is normally the highest
degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition
in accordance with original manufacturing standards. Rebuild is the highest degree of material maintenance applied to Army
equipment. The rebuild operation includes the act of returning to zero those age measurements (e.g. hours/miles) considered in
classifying Army equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION
a. Column (1), System. Column 1 lists the major systems by which all components and assemblies of the vehicle are divided.
This division reflects the overall arrangement of the Commercial Off The Shelf (COTS) manuals for the vehicle.
b. Column (2), Component/Assembly. Column 2 contains the item names of components, assemblies, subassemblies, and
modules for which maintenance is authorized.
c. Column (3), Maintenance Function. Column lists functions to be performed on the item listed in Column 2. (For detailed
explanation of these functions, see paragraph B-2.)
Services - Inspect, test, service, adjust, align, calibrate, and or replace.
Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault
within a system or unit under test (UUT).
Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded Item to the level of its least component,
that is assigned an SMR code for the level of maintenance under consideration (i.e. identified as maintenance significant).
Actions - Welding, grinding, riveting, straightening, facing, machining, and/or resurfacing.
B-2
TM 5-3895-382-24
d. Column (4), Maintenance Level. Column 4 specifies each level of maintenance authorized to perform each function listed in
Column 3, by indicating work time required (expressed as manhours in whole hours or decimals) in the appropriate subcolumn. This
work-time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the
number or complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work-time
figures are shown for each level. The work-time figure represents the average time required to restore an item (assembly,
subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time
includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality
assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the
maintenance allocation chart. The symbol designations for the various maintenance levels are as follows:
C.............................................................................................
O.............................................................................................
F .............................................................................................
L .............................................................................................
H.............................................................................................
D.............................................................................................
Operator or crew maintenance

Unit maintenance
Direct support maintenance
Specialized Repair Activity (SRA) 5
General Support maintenance
Depot maintenance
e. Column (5), Tools and Equipment Ref Code. Column 5 specifies, by code, those common tool sets (not individual tools),
common TMDE, and special tools, special TMDE, and special support equipment required to perform the designated function. Codes
are keyed to tools and test equipment in Section III.
f. Column (6), Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the
remarks contained in Section IV.
B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III
a. Column (1), Tool or Test Equipment Code. The tool and test equipment reference code correlates with a code used in the
MAC, Section II, column 5.
b. Column (2), Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.
c. Column (3), Nomenclature. Name or identification of the tool or test equipment.
d. Column (4), National Stock Number. The National Stock Number of the tool or test equipment.
e. Column (5), Tool Number. The manufacturer's part number, model number, or type number.
B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV
a. Column (1), Remarks Code. The code recorded in column 6, Section II.
b. Column (2), Remarks. This column lists information pertinent to the maintenance function being performed as indicated in
the MAC, Section II.
This maintenance level Is not included in Section II column (4) of the Maintenance Allocation Chart. Functions to this level of maintenance are
identified by a work-time figure in the 'H" column of Section II column (4), and an associated reference code is used In the remarks column (6).
This code is keyed to Section IV, Remarks, and the SRA complete repair application is explained there.
B-3
TM 5-3895-382-24
Section II. MAINTENANCE ALLOCATION CHART
FOR
CS-433C SELF-PROPELLED VIBRATORY ROLLER
(1)
(2)
Group
Number
(3)
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
Maintenance
Component/Assembly
Function
(5)
(6)
Depot
Tools and
Equipment
Remarks
Ref Code
Code
Engine
Air Cleaner Assembly
Replace
0.5
1, 9
Air Cleaner Support
Replace
1.0
1, 3
Air Filter Element
Inspect
0.1
Service
0.1
Air Inlet Heater

Alternator
Replace
0.2
Test
0.3
1, 3
Replace
0.4
1, 3
Test
1.1
Replace
Alternator V-Belts
Inspect
1, 7
0.6
0.1
1, 9
0.1
Adjust
0.5
1,3, 12
Replace
0.5
1, 3, 12
Alternator Bracket
Replace
0.8
Camshaft Assembly &
Replace
4.0
1,7
Camshaft Bearing
Replace
19.5
1, 7
Camshaft Gear
Replace
17
1, 7
Cold Starting Aid Start
Replace
Connecting Rod
Replace
1, 9
Tappets
1.0
1, 9
3.0
1, 7
Bearings
Crankshaft
Replace
20.0
1, 7
Crankshaft Gear
Replace
1.5
1,7
Replace
14.5
1, 7
14.0
1, 7
(On Engine)
Crankshaft Main
Replace
Bearing
Crankshaft Oil Seals
Replace
5.0
1, 7, 16, 17
Crankshaft Pulley
Replace
2.5
Crankshaft Thrust
Replace
13.5
1, 7
Cylinder Block
Replace
20.0
1, 7
Cylinder Head
Replace
1, 7
Washers
4.0
Repair
1, 7
6.0
B-4
1, 7
TM 5-3895-382-24
(1)
(2)
Group
(3)
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
Maintenance
Number
Component/Assembly
Function
Cylinder Liners
Replace
Dipstick Assembly
Replace
Engine Assembly,
Inspect
19.7
0.2
(5)
(6)
Depot
Tools and
Equipment
Remarks
Ref Code
Code
1, 7
1, 3
0.1
Turbo, Diesel, 3054T

Test
0.5
Service
1.5
Adjust Valves
Replace
1.0
1, 3
2.0
1, 3
12.0
1, 7
Repair
Engine Oil Sampling
5, 6
40.0
1, 7
Replace
0.3
1, 3
Engine Enclosure
Replace
2.2
1, 3
Exhaust Manifold
Replace
1.0
1, 9
Fan
Replace
1.0
1, 9
Fan Drive Housing
Replace
1.0
1, 3
Flywheel Housing
Replace
13.5
Flywheel & Ring Gear
Inspect
1.5
Replace
12.5
1, 7,19
13.5
1, 7, 19
Valve
Flywheel Ring Gear
Replace
Front Engine Support
Replace
Fuel Filter
Service
1, 7, 19
1, 7
1.0
1, 9
Replace
0.5
1, 3
Fuel Injection Lines
Replace
1.3
1, 3
Fuel Injector Nozzles
Test
0.5
1, 7
Replace
1.0
1, 7
Repair
1.0
Fuel Injection Pump
0.1
Test
Replace
6.0
Repair
Fuel Transfer Pump
Fuel Injection Pump

Gear
1, 7
7.5
1, 7
1, 7
Test
1.0
1, 9
Replace
1.0
1, 9
Repair
1.0
1, 7
Replace
1.7
1, 7
16.2
1, 7
Timing
Gear Case
Off)
Replace
(Timing
Gear Case
On)
B-5
1, 7
B
TM 5-3895-382-24
(1)
(2)
Group
Number
(3)
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
Maintenance
Component/Assembly
Function
3.5
(5)
(6)
Depot
Tools and
Equipment
Remarks
Ref Code
Code
Hydraulic Oil Cooler
Replace
Idler Gear & Hub
Replace
15.2
1, 3
1, 7
Inlet Manifold
Replace
1.0
1, 7
Lifting Bracket
Replace
Muffler
Inspect
0.5
0.1
Replace
1.5
1, 9
Oil Filter Element
Replace
0.5
1, 3
Oil Filter, Oil Filter
Replace
1.0
1, 9
Repair
1.0
1, 3
Oil Pan
Replace
1.5
Oil Pump
Replace
2.0
1, 7
Inspect
0.5
1, 7
Replace
2.0
1, 7
Replace
1.5
1, 7
Base, & Cooler
Oil Strainer & Suction
1, 3
Pipe
Oil Pressure Relief
Valve
Repair
1.8
1, 7
Piston Cooling Jets
Replace
1.9
1, 7
Pistons & Connecting
Replace
8.0
1, 7
10.0
17
Rod Assembly
Repair
Precleaner
Replace
Radiator
Inspect
0.2
Test
0.5
Service
0.8
Replace
1.0
1, 3
Repair
Radiator Hoses
0.1
Inspect
4.0
1, 7
0.1
Replace
0.8
1, 3
Rear Engine Support
Replace
1.0
1, 9
ROPS (Roll-over
Inspect
0.1
Protective Structure)
Replace
Rocker Shaft Assembly
1.5
Replace
1.5
1, 7
Repair
2.5
1, 7
Test
1.5
1, 7
& Push Rods

Starter
B-6
TM 5-3895-382-24
(1)
(2)
Group
(3)
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
Maintenance
Number
Component/Assembly
Starter Relay
Function
(5)
(6)
Depot
Tools and
Equipment
Remarks
Ref Code
Code
Replace
1.0
1, 9
Replace
0.5
Test
0.5
1, 3
Timing Gear Housing
Replace
13.5
Timing Gear Housing
Replace
0.5
1, 7
1, 7, 15
Cover
Turbocharger
Test
1.2
1, 9
Replace
1.0
1, 9
Repair
Valves, Engine
2.0
Replace
Repair
1, 7
5.0
1, 7
5.0
1, 7
Valve Guides, Engine
Replace
14.0
1, 9
Valve Seat Inserts,
Replace
12.2
1, 9
Valve Springs, Engine
Replace
11.0
1, 9
Valve Cover
Replace
Water Separator
Service
Engine
Water Pump
1.0
1, 9
Service
0.3
1, 3
Replace
0.3
1, 3
Repair
0.3
1, 3
Replace
0.5
0.1
Repair
Water Temperature
1, 3
1.0
1, 7
Test
1.5
1, 3
Replace
1.0
1, 3
Replace
1.5
1, 3
Regulator
(Thermostat)
Water Temperature
Regulator Housing
Systems
Axle
Test
1.5
1, 8
Replace
3.5
1, 8
9.5
1, 7
Repair
Axle Propel Motor
Test
1.5
Replace
1.6
Repair
Backup Alarm Override
1, 3
1, 3
4.0
Replace
0.5
Switch
B-7
1, 7
1, 3
TM 5-3895-382-24
(1)
(2)
Group
Number
(3)
Maintenance
Component/Assembly
Batteries & Cables
Function
Inspect
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
C
O
F
H
Depot
D
(5)
(6)
Tools and
Equipment
Remarks
Ref Code
0.1
Replace
0.5
1, 3
Brake Assemblies
Replace
Test
1.5
1, 3
Replace
1.5
1, 3
12.0
Repair
Brake Shift Valve
2.5
Replace
1.5
Repair
Bumper & Front
Code
P
1, 7
1, 7
1, 3
2.5
Replace
2.0
1, 3
Replace
2.0
1, 3
Replace
2.0
1, 3
Replace
0.2
1, 9
Replace
16.0
Scraper (Smooth
Drum)
Bumper & Front
Scraper (Pad-foot
Drum)
Bumper & Front
Scraper (Universal)
Decontamination Kit
Mounting Bracket
Drum Assembly
1, 3, 4, 11,
20, 21
Drum Gear Reducer
Repair
5.0
1, 3
Replace
7.0
1, 3
Repair
Drum Propel Motor
5.0
Replace
1.0
Repair
Drum Support Housing,
1, 3, 18
1, 3
4.0
1, 7
Replace
9.0
1, 7, 20, 21
Replace
9.0
1, 7, 20, 21
Left
Drum Support Hous ing,
Right
Duo-cone Seals
Replace
Handrail
Replace
Hydraulic Oil Filter
Inspect
Hydraulic Oil Sampling
1.5
0.3
1, 7, 18
1, 3
0.1
Replace
0.5
1, 3
Replace
0.3
1, 3
Replace
4.0
1, 3
Inspect
0.2
1, 3
Replace
2.0
1, 3, 11
Repair
3.0
1, 3
Repair
3.0
1, 3
Valve
Hydraulic Oil Tank
Leveling Blade
Service
1.0
B-8
P
P
TM 5-3895-382-24
(1)
(2)
Group
Number
(3)
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
Maintenance
Component/Assembly
Leveling Blade Control
Function
(5)
(6)
Depot
Tools and
Equipment
Remarks
Ref Code
Code
Test
1.5
1, 3
Test
0.5
1, 3
Manual Brake Release
Replace
0.8
1, 3
Replace
0.8
1, 3
NATO Receptacle
Replace
0.4
1, 3
NATO Receptacle
Replace
0.8
1, 3
Service
0.5
Valve
Hand Pump
Needle Valve
Cables
Operator Platform
Replace
1,3
4.0
1.8
1, 7
Pad-foot Shell Kit
Replace
1, 3, 4, 11
Propel & Vibratory
Test
1.5
1, 7
Adjust
0.5
1, 7
Replace
1.0
1, 7
Repair
4.0
1, 7
Pumps
Propel Control Linkage Adjust
0.5
Pump Drive
Replace
Rifle Mounting Bracket
Replace
Rear Reduction Case
Replace
1, 3
4.0
0.2
1, 3
1, 9
7.0
1, 7
Assembly
Seat Assembly Replace
Replace
0.5
1, 3
Seat Suspension Repair
Replace
1.5
1, 3, 13
Steering Control Unit
Replace
1.5
1, 7
2.0
1, 7
(SCU)
Repair
Steering Cylinder
Replace
1.5
1, 3
Repair
1.5
1, 3
1, 3
Steering Pivot Lock
Service
Steering Pump
Test
1.5
Replace
2.0
Steering Wheel &
0.2
P
1, 3
Repair
2.5
1, 7
Replace
1.0
1, 7
Column
Stowage Box
Replace
0.4
1, 9
Test
1.5
1, 3
Replace
1.5
1, 3
B-9
TM 5-3895-382-24
(1)
(2)
Group
Number
(3)
Maintenance
Component/Assembly
Vibratory Flushing
Function
(4)
MAINTENANCE LEVEL
Direct
General
Unit
Support Support
C
O
F
H
Depot
D
(5)
(6)
Tools and
Equipment
Remarks
Ref Code
Code
Test
1.5
1, 7
Replace
1.5
1, 7
Motor
Vibratory Tachometer
Adjust
0.5
1, 3
VPM Sensor
Test
0.5
1, 3
Adjust
1.5
1, 3
Test
1.5
1, 3
Replace
1.0
1, 3
Vibratory Motor
Repair
Wheel & Tire
3.0
Inspect
0.2
Service
0.5
1, 7
P
Assemblies
P
Replace
0.5
Repair
0.5
Wheel End Assemblies
Replace
Yoke & Steer Pivot
Service
1, 3
1, 3
2.5
1, 7
0.1
Adjust
10.0
1, 3
Replace
10.0
1, 7
B-10
TM 5-3895-382-24
Section III. TOOLS AND TEST EQUIPMENT

FOR
Tool or Test
Equipment
Maintenance
Reference Code
Level
Nomenclature
1
O, F, H
Tool Kit, General Mechanics:
Automotive
(SC 5180-90-N26)
2
O
Shop Equipment,
Organizational Repair, Light,
Truck Mounted
(SC 4940-95-B03)
3
O
Shop Equipment, Automotive
Maintenance and Repair: OM
Common No. 1, Less Power
(SC 4910-95-A74)
4
O
Shop Equipment, Automotive
Maintenance and Repair:
OM Supplemental No. 1,
Less Power
(SC 4910-95-A73)
5
O
Simplified Test Equipment for
Internal Combustion
Engines Reprogrammable
(STE/ICE-R)
TM 9-4910-571-12&P
6
O, F
Shop Equipment, Contact
Maintenance, Truck
Mounted
(SC 4940-95-B04)
7
F, H
Shop Equipment General
Purpose Repair, Semitrailer
Mounted
(SC 4940-95-CL-B02)
8
F, H
Tool Outfit Hydraulic Systems
Test and Repair (HSTRU)
(SC 4940-95-CL-B07)
9
O
National Stock
Number
5180-00-177-7033
Tool Number
W33004
4940-00-294-9516
T13152
4910-00-754-0654
W32593
4910-00-754-0653
W32867
4910-01-222-6589
A56243
4940-00-294-9518
T10138
4940-00-287-4894
T10549
4940-10-036-5784
T30377
5120-00-640-6364
(Included in T13152)
10
Wrench, Torque (0-300 lb-in)
5120-00-776-1841
11
5120-01-113-9564
12
Gauge, Belt Tension
6635-01-093-3710
BT-33-73F
13
Attachment, Screwdriver
5120-01-367-3539
FTX55
14
Ratchet Puller
5120-01-275-2286
8S9906
15
Installer Group
2815-01-437-0477
9U6200
16
Installer, Rear Seal
2815-01-435-7172
9U6205
17
Adapter
5120-01-437-0474
9U6210
18
Seal, Installation
5120-01-470-4620
6Y6339
19
Bracket, Lifting
5340-01-336-2459
FT0120
20
Block, Bearing Removal
FT2433
21
Support Assembly
FT2434
B-11
Change 1
TM 5-3895-382-24
Section IV. REMARKS

FOR
(1)
Remarks
Code
(2)
Remarks
Limited repair by replacement of external seals and clamp only.
SRA or Dealer for repair.
Limited repair by replacement of cartridge only.
Service consists of tilting and lowering operator platform. Stowage box must be
removed prior to tilting platform.
Preventive Maintenance Checks and Services (PMCS).
B-12
TM 5-3895-382-24
Section V. FABRICATED TOOLS
a. FT0120 Lifting Bracket
This bracket is used to remove flywheels on 5.4 inch Bore Caterpillar engines.
Figure B-1. Lifting Bracket, FT0120

b. FT2433 Block, Bearing Removal
This block makes removal of bearings from housings simpler and easier.
Figure B-2. Block Bearing Removal

Overall Dimensions:
MM
Length ....................................................................................102
Width ........................................................................................51
Width .......................................................................................25
IN.
4.0
2.0
1.0
B-13
TM 5-3895-382-24
c. FT2434 Support Assembly
One end is used to remove vibration weights; the other end to remove roller bearing cage.
Figure B-3. Support Assembly, Shaft

MM
Length ........................................................................................................................ 2900
Inside diameter (large end) .................................................................................... 80.02
Inside diameter (small end) ................................................................................... 74.50
Outside diameter (small end) ................................................................................ 79.95
B-14
IN.
114.000
3.150
2.930
3.148
TM 5-3895-382-24
APPENDIX C
SCHEMATICS
C-1. SCOPE
This appendix provides schematic diagrams of the electrical and hydraulic systems of the Roller. A chart containing symbols and their
definitions is provided for each schematic.
C2. GENERAL
Refer to Figure C-1 (Sheets 1 through 9) for the electrical system and Figure C-2 (Sheets 1 through 5) for the hydraulic system.
ELECTRICAL SCHEMATIC
THIS ORGANIZATIONAL RELATIONSHIP OF SCHEMATICS IS

PROVIDED FOR REFERENCE
(Figure
(Figure
(Figure
(Figure
(Figure
(Figure
(Figure
(Figure
(Figure
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
C-1
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
Sheet
1
2
3
4
5
6
7
8
9
of
of
of
of
of
of
of
of
of
9)
9)
9)
9)
9)
9)
9)
9)
9)
Figure C-1. Electrical Schematic (Sheet 1 of 9)
C-1
TM 5-3895-382-24
C-2
TM 5-3895-382-24
C-3
TM 5-3895-382-24
C-4
TM 5-3895-382-24
C-5
TM 5-3895-382-24
C-6
TM 5-3895-382-24
C-7
TM 5-3895-382-24
HARNESS AND WIRE ELECTRICAL SCHEMATIC SYMBOLS
ELECTRICAL SCHEMATIC SYMBOLS AND DEFINITIONS
FUSE -A component in an electrical circuit that will open the circuit if too much current flows through it.
REED SWITCH -A switch whose contacts a controlled by a magnet. A magnet closes the contacts of a
normally open reed switch; It opens the contacts of a normally closed reed switch.
SENDER -A component that is used with a temperature or pressure gauge. The sender measures the
temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or
pressure.
RELAY (Magnetic Switch) -A relay is an electrical component that is activated by electricity It has a coil that
makes an electromagnet when current flows through it. The electromagnet can open or close the switch
part of the relay.
CIRCUIT BREAKER (C/B) -A component in an electrical circuit that will open the circuit if too much current
flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit
again.
SOLENOID -A solenoid is an electrical component that is activated by electricity. It has a coil that makes an
electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece
of metal that can do work.
C-8
TM 5-3895-382-24
ELECTRICAL SCHEMATIC SYMBOLS AND DEFINITIONS
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease
in that condition.
Normally closed switch that will open with an Increase of a specific condition.
Normally closed switch that is open due to an applied condition, and will open again with a specific decrease
in that condition.
The circle indicates that the component has screw terminals and a wire can be disconnected from it.
No circle indicates that the wire cannot be disconnected from the component.
This indicates that the component has a wire connected to it that is connected to ground.
This indicates that the component does not have a wire connected to ground. It is grounded by being
fastened to the machine.
C-9
TM 5-3895-382-24
HYDRAULIC SCHEMATIC
(Figure C-2 Sheet 1 of 7)

THIS ORGANIZATIONAL RELATIONSHIP OF SCHEMATICS IS

PROVIDED FOR REFERENCE
Figure C-2. Hydraulic Schematic (Sheet 1 of 7)
C-10
TM 5-3895-382-24
C-11
TM 5-3895-382-24
C-12
TM 5-3895-382-24
C-13
TM 5-3895-382-24
HYDRAULIC SCHEMATIC SYMBOLS
CYLINDERS
HYDRAULIC PUMPS
C-14
TM 5-3895-382-24
VALVES
MOTORS
DIRECTIONAL CONTROL VALVES
VALVE SPOOL CENTERS
C-15
TM 5-3895-382-24
PRESSURE CONTROL VALVES
VALVE ACTUATORS
C-16
TM 5-3895-382-24
ALPHABETICAL INDEX
A
Axle Planetaries
Check Oil Level ...................................................................... 1-65
Change Gear Lubricant......................................................... 1-85
Additive, Supplemental Coolant............................................... 1-28

Additives, Cooling System ........................................................ 1-23
Axle Propel Motor.....................................................................16-88

Assemble ............................................................................16-103
Disassemble .........................................................................16-89
Remove & Install..................................................................16-88
Specifications .......................................................................... 10-8
Air Cleaner Elements, Cleaning............................................... 1-52

Air Cleaner Elements, Remove and Install............................ 1-52
Air Cleaner, Remove & Install ....................................................9-4
Axle Propel Motor System Operation ...................................11-14

Motor Flush Valve ................................................................11-16
Air Cleaner Service Indicator, Check...................................... 1-51

Cylinder Head And Valves .................................................... 6-20
Turbocharger .......................................................................... 6-19
B
Back-up Alarm Override Switch
Removal & Installation..............................................................2-2
Air Inlet And Exhaust System ................................................... 6-70

Cylinder Head......................................................................... 6-72
Testing The Wastegate ......................................................... 6-76
Valve Lash............................................................................... 6-70
Valve Tests ............................................................................. 6-73
Back-up Alarm, Check operation............................................. 1-58
Air Inlet Manifold - Removal

Type 1 Engines and 9RM Engines ...................................... 7-27
Basic Block.....................................................................................6-8
Crankshaft Seals .................................................................... 6-91
Cylinder Compression Test.................................................. 6-87
Cylinder Liner Projection....................................................... 6-86
Flywheel And Flywheel Housing.......................................... 6-95
Height Of The Piston Above
The Cylinder Block ............................................................ 6-88
Inspection Of Connecting Rods ........................................... 6-89
Inspection Of The Cylinder Liner..................................... 6-87
Thrust Washers For The Center Main Bearing ................ 6-95
Alternator and Regulator........................................................... 5-41
Batteries, Clean/Check Electrolyte Level ............................... 1-76
Alternator
Disassemble & Assemble........................................................8-6
Remove & Install ......................................................................9-5
Battery or Battery cable Replacement ................................... 1-76
Air Inlet Manifold Installation Type 1 Engines and 9RM Engines,..................................... 7-28

Measurement Procedure ...................................................... 7-88
Alternator
Belts, Inspect/Adjust. ................................................................. 1-75

Belt Tension Chart ............................................................ 5-40,6-86
Antifreeze/Coolant, Conventional............................................ 1-27

Blade ........................................................................................16-107
Remove & Install Blade.....................................................16-107
Axle.............................................................................................16-98
Disassemble & Assemble...................................................16-99
Remove & Install ..................................................................16-98
Blade Cylinder ........................................................................16-107

Remove & Install Blade Cylinder.....................................16-107
Disassemble & Assemble Blade Cylinder......................16-108
Axle Assembly System Operation.........................................11-19

Carrier....................................................................................11-21
End Reduction Case............................................................11-20
No-Spin Differential..............................................................11-22
Wheel Planetaries ................................................................11-25
Blade Cylinder Pivot Points, Lubricate Fittings ..................... 1-62

Blade Pivot Pins, Lubricate Fittings ........................................ 1-62
Axle Differential
Check Oil Level ...................................................................... 1-65
Brake Efficiency Check ...........................................................11-48

Brake Interlock Valve (Solenoid Valve) ................................16-71
Remove & Install..................................................................16-71
Specifications ........................................................................10-12
Axle Gear Reducer

Check Oil Level ...................................................................... 1-64
Axle Group.................................................................................10-13
Index-1
TM 5-3895-382-24
Brake/Shift Valve ......................................................................16-69
Remove & Install Brake/Shift Valve ...................................16-69
Disassemble & Assemble Brake/Shift Valve....................16-70
Crankcase Oil, Fill...................................................................... 1-74

Crankshaft
Installation ............................................................................... 7-84
Removal................................................................................... 7-83
Breather, Hydraulic Tank, W ash............................................. 1-81

Bumper & Front Scraper.........................................................16-22
Remove & Install Bumper & Front.....................................16-22
Crankshaft Front Seal

Installation ............................................................................... 7-54
Removal................................................................................... 7-53
Bypass Valve (Thermal)..........................................................16-70

Operation...............................................................................11-17
Operational Test...................................................................11-46
Remove & Install..................................................................16-70
Specifications ........................................................................10-12
Crankshaft Gear
Installation ............................................................................... 7-87
Removal................................................................................... 7-87
Camshaft .................................................................................... 5-22
Crankshaft Main Bearings

Camshaft - Remove and Install ............................................... 7-67

Removal Procedure.............................................................. 7- 67
Crankshaft Pulley
Installation ............................................................................... 7-53
Removal................................................................................... 7-52
Camshaft Bearings - Remove and Install .............................. 7-70

Crankshaft Rear Seal

Installation ............................................................................... 7-50
Removal................................................................................... 7-49
Camshaft Gear - Remove and Install ..................................... 7-68

Cutting Edges, Check for Wear ...................................... 1-49,1-82
Cylinder Block Specifications ................................................... 5-27

Cylinder Block......................................................................... 5-27
Piston Cooling Jets (If Equipped)........................................ 5-28
Charge Filter
Specifications ........................................................................10-11
System Operation ................................................................11-16
Cylinder Head Specifications ................................................... 5-16

Circuit Breaker/Fuses ................................................................ 1-45
Cylinder Head
Installation ............................................................................... 7-65
Removal................................................................................... 7-64
Cold Starting Aid Replacement...................................................2-3

Cold Weather Lubricants .......................................................... 1-36
Commercial Oil........................................................................... 1-40
Cylinder Head Valves Specifications ...................................... 5-12

Connecting Rod.......................................................................... 5-31

Cylinder Liner
Installation ............................................................................... 7-73
Removal................................................................................... 7-72
Connecting Rod Bearings

Installation ............................................................................... 7-80
Removal................................................................................... 7-78
D
Decontamination Kit Bracket Replacement..............................2-7
Diesel Engine Oil,
Caterpillar................................................................................ 1-36
Commercial............................................................................. 1-37
Coolant Level, Check ................................................................ 1-55

Coolant Recommendations ...................................................... 1-24
Coolant/Antifreeze, Long Life ................................................... 1-25
Dipstick Assembly...................................................................... 7-93

Remove and Install................................................................ 7-93
Cooling Specifications ............................................................... 1-23

Cooling System Maintenance, Conventional......................... 1-31
Drum Assembly........................................................................16-23
Assemble Drum Assembly..................................................16-44
Disassemble Drum Assembly............................................16-42
Remove & Install Drum Assembly.....................................16-23
Specifications .......................................................................12-12
Cooling System .......................................................................... 6-81

Additives .................................................................................. 1-23
Clean/Flush............................................................................. 1-90
Cooling System Conditioner................................................. 6-85
Engine And Cooling System Heat Problems ..................... 6-84
Testing The Cooling System ................................................ 6-82
Visual Inspection Of The Cooling System .......................... 6-81
Drum Drive .................................................................................. 10-7
Index-2
TM 5-3895-382-24
Drum Gear Reducer
Assemble...............................................................................16-32
Check Oil Level ...................................................................... 1-64
Disassemble .........................................................................16-28
Remove & Install..................................................................16-26
Engine Lubricant Viscosity........................................................ 1-38

Engine, Remove & Install ......................................................... 9-12
Engine Oil, Change.................................................................... 1-72
Engine Oil and Filter(s),
Change. ................................................................................... 1-72
Replace.................................................................................... 1-73
Drum Interchange (Smooth/Pad Foot) ......................................2-8

Drum Propel Motor..................................................................... 10-7
Engine Oil Filter Base

Assembly................................................................................. 7-36
Disassembly............................................................................ 7-36
Install ........................................................................................ 7-37
Remove.................................................................................... 7-35
Specifications .......................................................................... 5-23
Drum Propel Motor...................................................................16-56

Disassemble And Assemble Drum
Propel Motor..........................................................................16-57
Remove & Install Drum Propel Motor................................16-56
System Operation ................................................................11-11
Engine Oil Pan

Installation ............................................................................... 7-71
Removal................................................................................... 7-71
Specifications .......................................................................... 5-25
Drum Scrapers,
Adjust ....................................................................................... 1-47
Replace.................................................................................... 1-48
Drum Support Housing (Vibratory Gearbox Group)
Check Oil Level ...................................................................... 1-66
Remove & Install ..................................................................16-37
Engine Oil Pressure................................................................... 5-25

Engine Oil Pump
Install ........................................................................................ 7-39
Remove.................................................................................... 7-38
Specifications .......................................................................... 5-24
Duo-Cone Seals,
Assembly & Installation Of Conventional........................... 16-4
Engine Oil Relief Valve

Installation ............................................................................... 7-38
Removal................................................................................... 7-37
Disassembly and Assembly.................................................. 7-93
Specifications .......................................................................... 5-23
E
Electric Starting Motor
Engine Oil Sampling.................................................................. 2-20

Electrical Circuit (Variable Frequency) .................................13-29
Engine Oil Sampling Valve Replacement.............................. 2-22
Alternators .............................................................................6-105
Battery....................................................................................6-100
Charging System ..................................................................6-105
Start Relay Tests..................................................................6-103
Starting Motor........................................................................6-101
Test Tools For The Electrical System................................. 6-98
Exhaust Manifold Specifications .............................................. 5-21

Type 2 Engines and 78J Engines ........................................ 5-21
Exhaust Manifold (Type 1 Engines and 9RM Engines)
Electric Starting Motor ............................................................... 5-42

12 Volt Starting Motor ............................................................ 5-42
24 Volt Starting Motor ............................................................ 5-43
Start Relays ............................................................................ 5-44
Exhaust Manifold (Type 2 Engines and 7BJ Engines)

Engine Valve Lash, Check/Adjust............................................1-70

Alternator ................................................................................. 6-24
Circuit Breakers ...................................................................... 6-25
Starting Motor.......................................................................... 6-24
Extender, Long Life Coolant/Antifreeze .................................. 1-25
F
Engine Crankcase Oil, Check Level ....................................... 1-53
Fan
Installation ............................................................................... 7-89
Removal................................................................................... 7-89
Engine Design ...............................................................5-4, 6-4, 7-4

Type 1 Engines and 9RM Engines .........................5-4, 6-4, 7-4
Type 2 Engines and 7BJ Engines ..........................5-4, 6-5, 7-4
Fan Drive
Installation ............................................................................... 7-90
Removal................................................................................... 7-90
Specifications .......................................................................... 5-40
Engine Enclosure, Remove & Install .........................................9-9
Index-3
TM 5-3895-382-24
Filter, Engine Oil,
Change .................................................................................... 1-72
Replace.................................................................................... 1-73
Filter, Fuel,
Replace ................................................................................... 1-77
Filter, Hydraulic Oil,
Change .................................................................................... 1-83
Final Drive (Wheel End Assembly)
Remove & Install................................................................16-100
Specifications ........................................................................10-10
Flushing Valve...........................................................................10-11
Flushing Valve Charge
Relief Valve Pressure Test.................................................11-38
Flywheel and Flywheel Housing Runout................................ 5-37
Flywheel Housing Runout..................................................... 5-38
Flywheel Runout..................................................................... 5-38
Flywheel
Install .................................................................................................
Remove.................................................................................... 7-47
Flywheel Housing
Installation ............................................................................... 7-51
Removal................................................................................... 7-51
Front Cover
Installation ............................................................................... 7-55
Removal................................................................................... 7-54
Fuel Filter
Remove & Install.......................................................................9-7
Replace (Element) ................................................................. 1-77
Fuel Filter
Installation ..................................................................................7-6
Removal......................................................................................7-5
Fuel Injection Lines
Installation ............................................................................... 7-11
Removal................................................................................... 7-10
Fuel Injection Nozzles Specifications ........................................5-8
Fuel Injection Nozzles (Type 1 Engines and 9RM
Engines)
Installation ............................................................................... 7-12
Removal................................................................................... 7-11
Fuel Injection Nozzles (Type 2 Engines and 7BJ
Engines)
Installation ............................................................................... 7-14
Removal................................................................................... 7 - 1 3
Fuel Injection Pump Specifications ............................................5-5
Type 2 Engines and 7BJ Engines ..........................................5-7
Fuel Injection Pump (Type 1 Engines and 9RM
Engines
Index-4
Installation ............................................................................... 7-16

Removal................................................................................... 7-15
Fuel Injection Pump (Type 2 Engines and 7BJ Engines
Installation ............................................................................... 7-19
Removal................................................................................... 7-17
Fuel Lift Pump,
Clean Strainer and Sediment Chamber ............................ 1-77
Remove & Install.......................................................................9-8
Fuel Specifications ..................................................................... 1-32
Fuel Sulfur Level ........................................................................ 1-37
Fuel System Testing & Adjustment......................................... 6-49
Adjustment Of Low Idle And High Idle................................ 6-61
Fuel Injector Nozzle Tests .................................................... 6-62
Pressure Test For The Fuel Transfer Pump...................... 6-50
Remove Air From The Fuel System.................................... 6-58
Setting The Top Center Compression Position
For No. 1 Piston .................................................................... 6-52
Tests For The Air Inlet Heater.................................................. 6-49
Timing Of The Fuel Injection Pump......................................... 6-56
Fuel System Specifications ...................................................... 6-10
Air Inlet Heater........................................................................ 6-17
Fuel Injection Pump............................................................... 6-13
Engines and 9RM................................................................... 6-12
Engines and 7BJ.................................................................... 6-12
Priming..................................................................................... 1-79
Fuel System Troubleshooting .................................................. 6-26
Troubleshooting Fuel Injector Nozzles
On A Nozzle Tester................................................................ 6-27
Troubleshooting Problems.................................................... 6-40
Troubleshooting The Engine................................................ 6-39
Troubleshooting The Fuel Injector Nozzles
On The Engine ....................................................................... 6-26
Troubleshooting The Turbocharger .................................... 6-28
Fuel Tank Cap and Fill Screen, Clean.................................... 1-80
Fuel Tank, Check Level ............................................................ 1-56
Fuel Transfer Pump
Assembly....................................................................................7-8
Disassembly...............................................................................7-8
Installation ..................................................................................7-9
Removal......................................................................................7-7
Specifications .......................................................................... 5-11
Fuel Transfer Pump
Install ...........................................................................................7-9
Remove.......................................................................................7-7
TM 5-3895-382-24
Fuel/Water Separator
Drain......................................................................................... 1-57
Replace Element.................................................................... 1-78
Indicators and Gauges, Test for Proper Function................. 1-57
Inlet and Exhaust Valve Guides Remove and Install ................................................................ 7-33
Inspection, Walk-Around........................................................... 1-50
Gear Group (Front)

Installation ............................................................................... 7-57
Specifications .......................................................................... 5-36
Installation Procedure................................................................ 7-34

Inlet and Exhaust Valve Seat Inserts Remove and Install................................................................ 7-34
Gear Oil........................................................................................ 1-41

Gear Reducer ............................................................................. 10-7

Gearbox.....................................................................................12-10
Inlet and Exhaust Valve Springs Remove and Install................................................................ 7-30
Glycol............................................................................................ 1-24
Ground Engaging Tool Bits, Torques for................................ 1-21

Handrail Replacement (Type III) .............................................. 2-24
Inlet and Exhaust Valves - Remove and Install .................... 7-31
Horn, Check Operation............................................................. 1-58

Housing (Front)
Specifications .......................................................................... 5-36
L
Lifter Group
Installation ................................................................................7-67
Removal................................................................................... 7-66
Hydraulic Hoses, Check Condition.......................................... 1-60
Leveling Blade
Control Valve Cylinder Specifications ................................. 15-4
Cylinder Leakage Test........................................................15-13
Cylinder Specifications .......................................................... 15-4
Introduction ............................................................................. 15-5
Replacement/Repair.............................................................. 2-29
System Pressure Check .....................................................15-12
Hydraulic Oil................................................................................ 1-40

Hydraulic Oil Cooler................................................................... 9-11
Hydraulic Oil Filter, Change ..................................................... 1-83
Hydraulic Oil Level, Check ....................................................... 1-55
Leveling Blade Control Valve ................................................... 15-6

FLOAT Position....................................................................15-10
HOLD Position ........................................................................ 15-7
LOWER Position .................................................................... 15-9
RAISE Position....................................................................... 15-8
Remove Install ....................................................................16-109
Disassemble & Assemble.................................................16-110
Hydraulic Oil Sampling ............................................................. 2-25

Hydraulic Oil Sampling Valve Replacement.......................... 2-27
Hydraulic Oil System Charge Oil Pressure
Indicator, Check .................................................................... 1-54
Hydraulic Oil, Change ............................................................... 1-83
Leveling Blade Troubleshooting ............................................15-11

Performance Tests ...............................................................15-11
Visual Checks ......................................................................15-11
Hydraulic Oil Filter....................................................................16-82

Remove & Install Hydraulic Oil Filter ................................16-82
Light Switch, Check Operation................................................. 1-59
Hydraulic Oil Tank....................................................................16-66

Remove & Install Hydraulic Oil Tank ................................16-66
Long Life Coolant/Antifreeze .................................................... 1-25

Hydraulic System Pressure Release ...................................16-11
Long Life Coolant/Antifreeze Extender................................... 1-25
Hydraulic Tank Breather, W ash.............................................. 1-81
Lubricant Viscosities and Refill Capacities ............................ 1-42
Lubricants, Cold Weather ......................................................... 1-36
Important Safety Information ...............................................5-2, 7-2
Index-5
TM 5-3895-382-24
Engine Oil Cooler................................................................... 6-78
Fluid Spillage Containment................................................... 6-77
Inspect The Oil Pump............................................................ 6-77
Problems Of The Lubrication System ................................. 6-80
Oil, Engine
Check Level ............................................................................ 1-53
Change .................................................................................... 1-72
Fill ............................................................................................ 1-74
Oil Additives, Aftermarket......................................................... 1-39

Oil, Commercial .......................................................................... 1-40
Magnetic Sensor
Adjustment............................................................................13-39
Resistance.............................................................................13-38
Voltage Test..........................................................................13-38
Oil Filter, Oil Filter Base & Oil Cooler,

Remove & Install.......................................................................9-9
Main Relief Valve Pressure Test...........................................13-40

High Amplitude .....................................................................13-40
Low Amplitude......................................................................13-41
Oil, Gear....................................................................................... 1-41

Oil, Hydraulic
Specifications .......................................................................... 1-40
Change ................................................................................... 1-83
Check Level ............................................................................ 1-55

Forward Drive .......................................................................11-39
Reverse Drive .......................................................................11-40
Maintenance Intervals (Commercial Practice) ...................... 1-43
When Required....................................................................... 1-45
Initial 250 Service Hours
or First 3 Months Operation.................................................. 1-68
Every 10 Service Hours or Daily.......................................... 1-50
Every 100 Service Hours or Monthly................................... 1-64
Every 1000 Service Hours or I Year.................................... 1-83
Every 2000 Service Hours or 1 Year................................... 1-89
Every 50 Service Hours or Weekly...................................... 1-61
Every 500 Service Hours or 3 Months................................ 1-82
Oil, Re-Refined Base Stock...................................................... 1-39
Maintenance Records (Commercial Practice)....................... 1-92

Hand Pump Replacement..................................................... 2-44
Needle Valve Replacement.................................................. 2-47
Pad- foot Shell Installation/Removal....................................... 2-50
Manual Displacement Control

Neutral Adjustment .............................................................11-42
Metric Fasteners, Torques for.................................................. 1-21
Piston Cooling Jets - Remove and Install .............................. 7-74

Oil, Synthetic Base Stock.......................................................... 1-39

Operators Platform ..................................................................... 16-7
Tilt & Lower ............................................................................. 16-7
Remove & Install.................................................................... 16-8
Adjust ....................................................................................... 1-48
Oscillating Pins, Lubricate Fittings .......................................... 1-61
Parking Brake And Speed Shift Control Valve ....................11-18
Metering Pump Group (Steering Control Unit)

Operation...............................................................................14-12
Oil Flow..................................................................................14-12
Metering Pump Group (Steering Control Unit)
Specifications .......................................................................... 14-5
Pistons and Connecting Rods - Assemble ........................... 7-76

Muffler
Specifications .......................................................................... 5-22
Remove & Install.......................................................................9-6
Piston and Rings Specification ................................................ 5-33

Type Engines and 9RM Engines ......................................... 5-33
NATO Receptacle Cables Replacement................................ 2-39
Platform Tilting (Operators), Adjust......................................... 1-48
NATO Receptacle Replacement.............................................. 2-35
Priming Fuel System ................................................................. 1-79
Neutral Start Switch, Check Operation................................... 1-59

No-Spin Differential Operation Test......................................11-47
Index-6
TM 5-3895-382-24
Priority Valve Operation ..........................................................14-10
No Flow..................................................................................14-10
No Steering Load .................................................................14-10
With Steering and Load.......................................................14-11
Steering Relief......................................................................14-11
Remove and Install Rear Reduction

Case Assembly...................................................................16-105
Re-Refined Base Stock Oil....................................................... 1-39
Relief Valve.................................................................................. 7-93
Disassemble and Assemble................................................. 7-93
Propel & Vibratory Pumps ......................................................16-73

Remove & Install..................................................................16-73
5070-01..................................................................................16-76
Rifle Mounting Bracket Replacement..................................... 2-57

ROPS (Roll-Over Protective Structure).................................16-10
Remove & Install ROPS (Roll-Over
Protective Structure) ............................................................16-10
Propel Brake Interlock (Electrical Schematic) ....................11-26

Propel Brake Interlock Valve ..................................................11-17
Rocker Shaft
Assembly................................................................................. 7-62
Disassembly............................................................................ 7-61
Propel Control Linkage Adjustment.......................................11-42

Axle Propel Motor.................................................................11-49
Drum Propel Motor...............................................................11-49
Rocker Shaft and Pushrod

Installation ............................................................................... 7-63
Removal................................................................................... 7-61
Propel Motor Flushing Valve Test Procedure......................11-50

Rollover Protective Structure (ROPS), Inspect ..................... 1-91
Propel Pump ............................................................................... 10-4
Pump Servo............................................................................. 10-6
Propel Pump in Neutral Position............................................11-28
Scheduled Oil Sampling (SOS) .................................. 1-35,1-71

Forward, Low Speed With Parking Brake Off..................11-30
Reverse, High Speed With Parking Brake Off.................11-32
Scrapers,
Adjust ....................................................................................... 1-47
Replace.................................................................................... 1-48
Propel Pump Synchronization................................................11-45
Seat Assembly Replacement................................................... 2-58
Propel Pumps ............................................................................. 11-8

High Pressure And Charge Relief Valves .......................... 11-9
Pump Servo Valves .............................................................11-10
Seat Belt, Inspect for Wear or Damage.................................. 1-51
Propel System Introduction ...................................................... 11-4
Servo Pressure Check ............................................................11-41
Propel System Tests And Adjustments ................................11-37

Pressure Test Tools .............................................................11-38
Pump Efficiency Check .......................................................11-37
Travel Speed Test................................................................11-37
Solenoid Valve (Brake Interlock Valve).................................16-73

Remove & Install..................................................................16-73
Specifications ........................................................................10-12
Propel System Troubleshooting ............................................11-34

Visual Checks .......................................................................11-34
Standard Fasteners, Torques for............................................. 1-21
Seat Suspension Repair ........................................................... 2-59
Standard Hose Clamps Worm Drive

Band Type, Torques for ........................................................... 1-21
Pump Drive ...............................................................................16-81

Remove & Install Pump Drive ............................................16-81
Starter
Disassemble & Assemble .......................................................8-4
Remove & Install.......................................................................9-5
Pump (Vibratory) Efficiency Check........................................13-31

Pump Electrical Displacement Control (EDC).....................13-26
Steering Wheel & Steering Column

Remove & Install..................................................................16-21
Pump Mounting Group.............................................................. 10-6
Steer Pivot, Adjust...................................................................... 1-88
R
Steering Column Group ............................................................ 14-5
Radiator Core, Clean................................................................. 1-45
(Metering Pump Group) ..........................................................16-15
Radiator, Remove & Install....................................................... 9-10

Rear Reduction Case Assembly
(CS-433C & CP-433C)..........................................................16-105
Index-7
TM 5-3895-382-24
Remove & Install..................................................................16-15
Operation...............................................................................14-12
Oil Flow..................................................................................14-12
Specifications .......................................................................... 14-5
Steering Cylinder Ends, Lubricate Fittings ............................ 1-63
Thermal Bypass Valve.............................................................16-68

Operation...............................................................................11-17
Operational Test...................................................................11-46
Remove & Install..................................................................16-68
Specifications ........................................................................10-12
Steering Cylinders
Tires, Check Pressure............................................................... 1-46
Steering Cylinder......................................................................16-11
Disassemble And Assemble...............................................16-12
Remove & Install..................................................................16-11
Specifications .......................................................................... 14-4
Torque Specification .................................................................. 1-21

Torques
for Ground Engaging Tool Bits ............................................ 1-21
for Metric Fasteners ............................................................... 1-21
for Standard Fasteners ......................................................... 1-21
for Standard Hose Clamps
Worm Drive Band Type ........................................................ 1-21
Steering Pins ............................................................................... 1-61

Steering Pivot, Adjust................................................................ 1-88
Steering Pump..........................................................................16-13
Remove & Install Steering Pump.......................................16-13
Specifications .......................................................................... 14-4
Total Base Number.................................................................... 1-37

Turbocharger
Disassembly Procedure ........................................................ 7-22
Specifications .......................................................................... 5-20
Steering System
Introduction ............................................................................. 14-7
Schematic................................................................................ 14-7
Steering Pivot Clearance Adjustments .................................14-17
Horizontal Steering Pivot Clearance ................................14-18
Oscillation Bearing Clearance............................................14-29
Vertical Steering Pivot Clearance......................................14-18
V
VPM Measurement Tests .......................................................13-38
Steering Pivot Lock..................................................................16-10

Separation & Connection Of Steering
Pivot Lock ..............................................................................16-10
Variable Frequency System (If Equipped)...........................13-25

V-Belts
Installation ............................................................................... 7-89
Removal................................................................................... 7-89
Steer Pump Priority Flow Test...............................................14-16

Steering System Pressure Check .........................................14-15
Valve Lash, Engine, Check/Adjust................................. 1-70,1-89
Steering System Troubleshooting.........................................14-14

Operation Checks ................................................................14-13
Pump Efficiency Check .......................................................14-15
Visual Checks .......................................................................14-13
Valve Mechanism Cover ........................................................... 5-12
Stowage Box Replacement...................................................... 2-72
Valve Mechanism Cover

Installation ............................................................................... 7-60
Removal................................................................................... 7-59
Sulfur Level, Fuel ....................................................................... 1-37
Valve Rocker Arms and Lifters ................................................ 5-12
Swashplate Neutral Adjustment Procedure .........................13-32
Vibratory Amplitude Valve Coil Resistance Procedure

(Fixed Frequency) ....................................................................13-44
Swashplate Neutral Adjustment Procedure .........................11-43

Axle Propel Pump................................................................11-43
Drum Propel Pump ..............................................................11-44
Vibratory Amplitude Valve Test

(Fixed Frequency) ....................................................................13-43
Synthetic Base Stock Oil........................................................... 1-39
Vibratory & Propel Pumps

Remove & Install Propel & Vibratory Pumps ...................16-75
5070-017 ...............................................................................16-78
Systems Operation Section .........................................................6-4
Vibratory Bearing, Change Lubricant...................................... 1-87

Vibratory Cooling Valve ............................................................. 12-9
Index-8
TM 5-3895-382-24
Vibratory Circuit Functions .....................................................13-20
Vibratory System - OFF.......................................................13-20
Vibratory System ON - HI AMPLITUDE............................13-22
Vibratory System ON - LOW AMPLITUDE.......................13-23
Vibratory Drum Assembly.......................................................13-18
Vibratory Flushing Valve .........................................................13-15
Index-9
TM 5-3895-382-24
Vibratory Flushing Valve .........................................................16-65
Remove & Install Vibratory Flushing Valve ......................16-65
Water Temperature Regulator ................................................ 5-25

Pressure Cap .......................................................................... 5-26
Vibratory Frequency Test (Fixed Frequency) ......................13-35

Vibratory Frequency Test (Variable Frequency) .................13-36
Water Temperature Regulator Installation ............................................................................... 7-45

Removal................................................................................... 7-44
Vibratory Gearbox Group (Drum Support Housing),

Change Gear Lubricant............................................................. 1-86
Wheel And Tire Assemblies ...................................................16-83

Remove & Install..................................................................16-83
Vibratory Magnetic Sensor ....................................................... 12-9
Wheel End Assemblies (Final Drive)

Remove & Install..................................................................16-84
Specifications ........................................................................10-10
Vibratory Motor..........................................................................16-52
Remove & Install..................................................................16-52
Specifications .......................................................................... 12-8
Testing & Adjustment..........................................................13-17
Vibratory Motor Case Leakage Test.....................................13-34
Wheel Nuts, Tighten.................................................................. 1-46
Y
Yoke & Steer Pivot
Remove & Install..................................................................16-47
Vibratory Pump Servo................................................................ 12-5

Electrical Displacement Control (EDC)............................... 12-5
Vibratory Pump........................................................................... 12-6
Electrical Displacement Control (EDC)............................... 12-7
Servo Piston............................................................................ 12-7
Specifications .......................................................................... 12-4
Test.............................................................................................13-35
Vibratory System
Tests And Adjustments .......................................................13-31
Troubleshooting....................................................................13-29
Visual Checks .......................................................................13-29
Vibratory Tachometer Calibration..........................................13-40
Viscosity, Engine Lubricant...................................................... 1-38
W
Water............................................................................................ 1-23
Water Separator
Replace Element.................................................................... 1-78
Drain......................................................................................... 1-57
Water Outlet Manifold
Installation ............................................................................... 7-47
Removal................................................................................... 7-46
Water Pump Specifications ...................................................... 5-26
Water Pump (Type 1 Engines and 9RM Engines)
Assembly................................................................................. 7-42
Disassembly............................................................................ 7-41
Installation ............................................................................... 7-44
Removal................................................................................... 7-40
Water Separator,
Remove & Install.......................................................................9-6
Index-10
TM 5-3895-382-24
By Order of the Secretary of the Army:
Official:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
9920204
DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 256547 TM 5-3895-382-24.
PUBLICATION NUMBER
PUBLICATION DATE
TM 3-4230-209-10
TEAR ALONG PERFORATED LINE
BE EXACTPINPOINT WHERE IT IS
PAGE
NO.
PARAGRAPH
1-3
1-6
3-1
3-3
3-18
3-10
FIGURE
NO.
TABLE
NO.
IN THIS SPACE, TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:
Tank unit illustration shows suction hose

item #3 as two hoses coupled together. Reason: suction hose is now one hose.
Text refers to cleaning solvent item 7, App. D
in Expendable Supplies Section. Reason:
Should be item 10, App. D.
Blender hose illustration is not accurate as
shown. Reason: Blender hose should show
quick-disconnect couplings at both ends.
PRINTED NAME, GRADE OR TITLE, AND TELEPHONE NUMBER
SSG. TED RYBA 671-3681
DA
FORM
1 JUL 79
2028-2
PUBLICATION TITLE
Decontaminating Apparatus
Power Driven, Skid-Mounted: 500-Gallon, M12A1
PREVIOUS EDITIONS
ARE OBSOLETE.
SIGN HERE:
SSG Ted Ryba
P.S. IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION, MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FILL IN YOUR
UNITS ADDRESS
FOLD BACK
OFFICIAL BUSINESS
NOTE:
Apply Stamp
Commander
ATTN: AMSTA-AC-NML
PUBLICATION NUMBER
PUBLICATION DATE
TM 5-3895-382-24
BE EXACTPINPOINT WHERE IT IS
PARAGRAPH
FIGURE
NO.
TABLE
NO.
IN THIS SPACE, TELL WHAT IS WRONG

AND WHAT SHOULD BE DONE ABOUT IT:
PAGE
NO.
PUBLICATION TITLE
Roller, Vibratory, Self-propelled, Types I & III,

Caterpillar Model CS-433C
PRINTED NAME, GRADE OR TITLE, AND TELEPHONE NUMBER
DA
FORM
1 JUL 79
2028-2
PREVIOUS EDITIONS
ARE OBSOLETE.
SIGN HERE:
P.S. IF YOUR OUTFIT WANTS TO KNOW ABOUT YOUR

RECOMMENDATION, MAKE A CARBON COPY OF THIS
AND GIVE IT TO YOUR HEADQUARTERS.
REVERSE OF DA FORM 2028-2
FOLD BACK
OFFICIAL BUSINESS
Commander
ATTN: AMSTA-AC-NML
FILL IN YOUR
UNITS ADDRESS
THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE
SQUARE 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
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
WEIGHTS
CUBIC MEASURE
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
1 Cu Centimeter=1000 Cu Millimeters=0.06 Cu Inches

1 Cu Meter=1,000,000 Cu Centimeters=35.31 Cu Feet
LIQUID MEASURE
1 Milliliter=0.001 Liters=0.0338 Fluid Ounces

1 Liter=1000 Milliliters=33.82 Fluid Ounces
TEMPERATURE
5/9 (F - 32) = C
212 Fahrenheit is equivalent to 100 Celsius
90 Fahrenheit is equivalent to 32.2 Celsius
32 Fahrenheit is equivalent to 0 Celsius
9/5 C + 32 = F
APPROXIMATE CONVERSION FACTORS

TO CHANGE
TO
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...................
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 ...................
TO CHANGE
TO
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......................
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 ............................
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
MULTIPLY BY
0.394
3.280
1.094
0.621
0.155
10.764
1.196
0.386
2.471
35.315
1.308
0.034
2.113
1.057
0.264
0.035
2.205
1.102
0.738
0.145
2.354
0.621
PIN: 077421-000
This fine document...

Was brought to you by me:
Liberated Manuals -- free army and government manuals

Why do I do it? I am tired of sleazy CD-ROM sellers, who take publicly
available information, slap watermarks and other junk on it, and sell it.
Those masters of search engine manipulation make sure that their sites that
sell free information, come up first in search engines. They did not create it...
They did not even scan it... Why should they get your money? Why are not
letting you give those free manuals to your friends?
I am setting this document FREE. This document was made by the US
Government and is NOT protected by Copyright. Feel free to share,
republish, sell and so on.
I am not asking you for donations, fees or handouts. If you can, please
provide a link to liberatedmanuals.com, so that free manuals come up first in
search engines:
<A HREF=http://www.liberatedmanuals.com/>Free Military and Government Manuals</A>
Sincerely
Igor Chudov
http://igor.chudov.com/

Cat 3054 Engine

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Cat 3054 Engine

Uploaded by

Copyright:

Available Formats

TM 5-3895-382-24

UNIT, DIRECT SUPPORT

PREVENTIVE MAINTENANCE CHECKS

Important Safety Information, SENR7733-07

Torque Specifications, SENR3130-06

Specifications, 3054 Engine, SENR5815-04

Systems Operation, Testing and Adjusting

Disassembly and Assembly, 3054 Engine,

Disassembly & Assembly, 3054 Engine

Disassembly & Assembly, 3054 Engine

Specifications, Propel System,

Systems Operation, Testing & Adjusting

Specifications, Vibratory System,

Systems Operation, Testing & Adjusting,

CATERPILLAR MODEL CS-433C

Specifications, Systems Operation, Testing &

NSN 3895-01-456-2733 (Type I)

Specifications, Systems Operation, Testing &

Disassembly & Assembly, Machine Systems,

Contract No. DAAE07-98-C-S007

Approved for public release;

MAINTENANCE ALLOCATION CHART (MAC)

HEADQUARTERS, DEPARTMENT OF THE ARMY

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION

Use handrails when

Severe injury to personnel may

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Dates of issue for original and updated pages/work packages are:

*Zero in this column indicates an original page or work package.

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL

Approved for public release; distribution is unlimited.

TM 5-3895-382-24, 21 September 1999, is changed as follows:

File this sheet in front of the manual for reference.

By Order of the Secretary of the Army:

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL

CATERPILLAR MODEL CS-433C

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

SERVICE UPON RECEIPT & UNIT PMCS ..............................................................1-1

Service Upon Receipt .............................................................................................1-2

MILITARY-SPECIFIC MAINTENANCE INSTRUCTIONS ..........................................2-1

IMPORTANT SAFETY INFORMATION, SENR7733-07 ............................................3-1

TORQUE SPECIFICATIONS, SENR3130-06 ...........................................................4-1

SPECIFICATIONS, 3054 ENGINE, SENR5815-04 ...................................................5-1

SYSTEMS OPERA TION, TESTING AND ADJUSTMENT, 3054

DISASSEMBLY & ASSEMBLY, 3054 ENGINE, SENR6241-06 .................................7-1

DISASSEMBLY & ASSEMBLY, 3054 ENGINE SUPPLEMENT, KENR2604...............8-1

DISASSEMBLY & ASSEMBLY, 3054 ENGINE SUPPLEMENT, KENR2644-01 ..........9-1

SPECIFICATIONS, PROPEL SYSTEM, KENR2645-02 ..........................................10-1

SYSTEMS OPERATION, TESTING & ADJUSTMENT, PROPEL SYSTEM,

SPECIFICATIONS, VIBRATORY SYSTEM, KENR2647-02.....................................12-1

SYSTEMS OPERATION, TESTING & ADJUSTMENT, VIBRATORY

SPECIFICATIONS, SYSTEMS OPERATION, TESTING & ADJUSTMENT,

SPECIFICATIONS, SYSTEMS OPERATION,

DISASSEMBLY & ASSEMBLY, MACHINE SYSTEMS, KENR2643-01.....................16-1

REFERENCES ...................................................................................................... A-1

MAINTENANCE ALLOCATION CHART (MAC) ....................................................... B-1

Introduction ........................................................................................................... B-1

SCHEMATICS ....................................................................................................... C-1

ALPHABETICAL INDEX................................................................................... Index-1

FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

Pad-foot Shell Kit

1-4. CORROSION PREVENTION AND CONTROL (CPC)

1-5. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)