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TM 5-3895-379-10 - Liberated Manuals

1. 0013 00 1 Engine Oil Level Check and 0014 00 1 Fuel Level Check and Fuel Water Separator Service 0016 00 1 Engine Coolant Check and 0017 00 1 Hydraulic Oil Level Check and Service 0018 00 1 Draining and Filling Fuel and Hydraulic Oil 0019 00 1 Vibratory Bearing Reservoir Check and Service Front and Rear Propel Gearbox Oil Check and Service CB534B 0021 00 1 Adjust Handrails for Operation or Stowage 0022 00 1 Drum Scraper 0023 00 1 Water Spray System Check and 0024 00 1 Water Spray Nozzle Check and 0025 00 1 References s l e lel qu b A UE DEVRE HIN 0026 00 1 Components of End Item COED and Basic Issue Items BII Lists 0027 00 1 Additional Authorization List 0028 00 1 Expendable and Durable Items 1465 0029 00 1 TM 5 3895 379 10 HOW TO USE THIS MANUAL NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need notify supervisor
2. TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee listed in publication FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TOTAL NO PAGE COLM NATIONAL STOCK REFERENCE FIGURE OF MAJOR NO NO NUMBER NO NO ITEMS SUPPORTED RECOMMENDED ACTION PART REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 THE METRIC SYSTEM AND EQUIVALENTS Linear Measure 1 Centimeter 10 Millimeters 0 01 Meters 0 3937 Inches 1 Meter 100 Centimeters 1000 Millimeters 39 37 Inches 1 Kilometer 1000 Meters 0 621 Miles Weights 1 Gram 0 001 Kilograms 1000 Milligrams 0 035 Ounces 1 Kilogram 1000 Grams 2 2 Pounds 1 Metric Ton 1000 Kilograms 1 Megagram 1 1 Short Tons Liquid Measure 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces Square Measure 1 Sq Centimeter 100 Sq Millimeters 0 155 Sq
3. oe Has USES Additional Authorization List AAL Adjust Handrails for Operation or Stowage Basic Issue Items BID List Chock Drums DLL EU re rr Loro Er ET Cleaning Procedures Ee Re aep o RR RE Reda Components Inspection d o o in eee Br eb er OO Eat de tat Removal OE 5 sue ote ug UI d E I SUA Oe Components of End Item COED List 2222222220 eee eee Controls and Indicators Corrosion Prevention and Control CPC Decals Data Plates and Stencils Decontamination Procedures Nuclear Biological and Chemical NBC Destruction of Army Materiel to Prevent Enemy Use Differences Between Models Door Assemblies Opening Closing Drum Scraper Service dere beet oer eR pees aoe Electrical System Theory of Operation Emergency Procedures da pluri v ais Engine Coolant Check and Service Oll Level Check eese Pte Se Oil Level Service os
4. 2 7 0010 00 21 Engine Misfires or Idles 1 4 4 0010 00 16 Engine Oil Pressure is Low Warning Light and Warning Horn On 0010 00 19 Engine Operating Temperature is Too High Warning Light and Warning Horn 0010 00 23 Engine Starts But Will Not Keep Running Engine Surges Speed Changes 2 0010 00 20 Engine Will Not Stop Running 0010 00 27 HYDRAULIC SYSTEM Hydraulic Oil Temperature is High Warning Light and Warning Horn 0010 00 33 Hydraulic Oil Pressure is Low Warning Light and Warning Horn 0010 00 34 STEERING Power Steering Pump Makes Noise and Steering Cylinder Rods Do Not Move Smoothly 0010 00 34 Roller Does Not Turn When Steering Wheel is Turned 0010 00 35 Roller Turns Slowly in 1 1 1 1 42 442 0010 00 35 Too Much Force is Needed to Turn Steering 0010 00 35 0009 00 1 TM 5 3895 379 10 TROUBLESHOOTING SYMPTOM INDEX CONTINUED 0009 00 Malfunction Sym
5. 2 111 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION WP 0001 00 General Information 1 0001 00 1 WP 0002 00 Equipment Description and 0002 00 1 WP 0003 00 Theory of Operation 0003 00 1 CHAPTER 2 OPERATING INSTRUCTIONS WP 0004 00 Description and Use of Operator s Controls and Indicators 0004 00 1 WP 0005 00 Operation Under Usual 0005 00 1 WP 0006 00 Operation Under Unusual 0006 00 1 WP 0007 00 Stowage and Decal Data Plate and Stencil 0007 00 1 TM 5 3895 379 10 Table of Contents Continued Page Number CHAPTER 3 JOPERATOR TROUBLESHOOTING WP 0008 00 Troubleshooting 0008 00 1 WP 0009 00 Troubleshooting Symptom Index 0009 00 1 WP 0010 00 Troubleshooting Procedures 0010 00 1 CHAPTER 4 MAINTENANCE INSTRUCTIONS WP 0011 00 Operator Preventive Maintenance Checks and Services PMCS 1 0011 00 1 WP 0012 00 Operator Preventive Maintenance Checks and Services PMCS 0012 00 1 General Maintenance
6. Nuclear Biological and Chemical NBC Decontamination Procedures Opening Closing Door Assemblies Operate Engine In Extreme Cold is bte oe ea eS Wh ns EE SA In Extreme Heat A RA ee t e RRR EA In Sandy or Dusty Conditions Vibratory System ED an en REPE SEEMS Water Spray System oak sae A A RB AE Park Roller Preparation for Transport 2 1 Preventive Maintenance Checks and Services PMCS Introduction 22 Ha ee se ee eet Table References Removal of Components Reporting Equipment Improvement Recommendations EIRs Roading Machine estais et e eR RR WG y TRE ee an Roller Mount Dismount Sandy or Dusty Conditions Operate in Slave Start Steering System Theory of Operation Stowage Guide nr ies ds Index 3 Work Package Page 0005 00 16 0001 00 3 0006 00 12 0005 00 20 0005 00 5 0006 00 8 0006 00 11 0006 00 11 0005 00 14 0005 00 12 0005 00 18 0005
7. i Turn valve knob 18 clockwise to close valve 21 13 94 j 20 NOTE 525 229 Push knob until resistance is felt brakes are released 2 Ur j Push knob 20 of manual brake release pump s 21 several times until brakes release k Unhook lanyard 11 from frame assembly 12 and hook lanyard to left side door assembly 10 Close left side door assembly 10 push handle 8 into latch 7 and close latch m Stow 13 mm wrench 5 64 in socket head screw key and 4 mm socket head screw key in toolbox ee TOOLBOX m Fred mi ee A pe L a 401 079 0006 00 6 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY PROCEDURES CONTINUED 3 Reset Parking Brakes After Manual Release WARNING Ensure that roller is secured to prevent any movement Roller may freewheel when brakes are released Ensure that path of roller travel is clear of personnel and equipment Failure to follow this warning may result in injury or death a Chock drums WP 0005 00 b Remove 13 mm wrench 4 mm socket head screw key and 5 64 in socket head screw key from toolbox Table 2 Items 4 11 and 12 WP 0027 00 c Lift latch 7 push handle 8 toward front of roller 9 and open left side door assembly 10 d Unhook lanyard 11 from left side door assembly 10 and hook lanyard to frame assembly 12 e Turn valve knob 18 counterclockwise to fully open valve 1
8. SERVICE PRIMARY RED WHEN ELEMENT LEVEL IS AT 22 VIEWING SED WINDOW A gt AR AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 25 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 10 Engine Operating Temperature is Too High c If air cleaner secondary Warning Light and Warning Horn On element is clogged notify Continued supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged or damaged fault is not corrected Install filter elements and cover and close two air filter housing latches Close left side door assembly WP 0005 00 Notify supervisor that engine temperature is too high warning light and warning horn on AIR CLEANER SECONDARY AR FILTER SERVICE SECONDA SERVICE 5 A SERVICE N a PRIMARY WHEN CENAS NR ANM oH ELEMENT VIEWING WINDOW AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 26 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 11
9. ua pO REESE HERE ERE ERU RR S TB 43 0239 TECHNICAL MANUALS Procedures for Destruction of Equipment to Prevent Enemy Use Mobility Equipment Command TM 750 244 3 Joint Oil Analysis Program Laboratory Manual Vol I Introduction Theory Benefits Customer Sampling Procedures Programs and Reports TD 33 1 37 1 NAVAIR 17 15 50 1 TM 38 301 1 Materials Used for Cleaning Preserving Abrading and Cementing Ordnance Materiel and Related Items Including TM 9 247 Operator s Unit Direct Support and General Support Maintenance Manual for Lead Acid Storage TM 9 6140 200 14 Operator s Unit Direct Support and General Support Maintenance Manual Including Repair Parts and Special Tools List for Semi Trailer Lowbed 40 Ton Construction Equipment Transporter M870 CCE CMI Load King Model 403LF NSN 2330 00 133 1731 Semitrailer Lowbed 40 Ton Construction Equipment Transporter M870 A1 NSN 2330 01 224 9245 TM 5 2330 378 14 amp P OTHER PUBLICATIONS Abbreviations and Acronyms d a dia ASME 14 38 1999 Army Logistics Readiness and 5 2 2 2 1 AR 700 138 Army Medical Department Expendable Durable Items CTA 8 100 Expendable Durable Ite
10. DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee listed in publication FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TOTAL NO PAGE COLM NATIONAL STOCK REFERENCE FIGURE OF MAJOR NO NO NUMBER NO NO ITEMS SUPPORTED RECOMMENDED ACTION PART REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 Use Part II reverse for Repair Parts and RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists RPSTL and Supply BLANK FORMS Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s M anual for Roller M otorized 379 1 Vibrating Tandem Steel Drums M odels me en CB534B and CB534C ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO
11. THEORY OF OPERATION CONTINUED 0003 00 WATER SPRAY SYSTEM 1 The water spray system is used to wet the front and rear drums to help prevent hot asphalt from sticking to the drum sur faces during compaction The water spray system consists of two identical but separate systems one at each end of the roller 2 The water spray system uses pumps controlled by a switch on the operator s console to provide water flow The switch has three positions off continuous spray and intermittent spray The continuous spray setting turns on the water spray system and water sprays on the drums continuously The intermittent spray switch position uses 15 second cycles of water spraying on the drums and no water spraying on the drums to reduce water consumption 3 There are three drain cocks that allow the water to be drained from the system The pumps pull water from two tanks and water spray screens which filter foreign materials from the water The water then enters the pump and is pumped to the spray bar There are seven spray nozzles in each spray bar which distribute the water evenly over the surface of the drums A check valve is located at the end of the spray bar to control the pressure of the water in the spray bars Excess water is sent past the check valve and back into the water tank On the CB534B only the front and rear water spray sys tems are connected by a tie line valve which allows one water spray system to supply pressurized water to th
12. ns ct ie bs se t cs Feet Per Minute lip desse horsepower bs dietus o e s inches e eh UC dat he o Poe ead ete Mee a ae ben bp ia ten are ee kilograms ID tote NE OR RIRs tee v e oe tad pounds KPH oe cele A MU REB Kilometers Per Hour MN Ve UR Mete ia delet tete elena millimeters MPH 224 2 Bad eh CIBUM CRI DU ES BU x E iui ue ris Miles Per Hour Pla acid a pounds per linear inch a Rollover Protective Structure TPM buch CC des Rl Salk e Acted tx hed revolutions per minute Ha BERN alate trae tots des Repair Parts and Special Tools Lists Nas ovde ghe EE vbt E etie oe Volts of alternating current Md a tee oh ette reus I a Le De boe iE bti s Volts of direct current siot rtu eee ire efte e tet e es Vibrations Per Minute GLOSSARY Amplitude The amount of vibratory movement measured from the start of one stroke to the start of the next Atticul te ei UE Re e Move or shift at pivot point or joint Compaction Den READER re The state of being pressed or
13. DO NOT perform fuel system checks inspections or main tenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth ing NOTE Use a container to catch any fuel that may drain from sys tem Dispose of fuel IAW local policy and ordinances Ensure that all spills are cleaned up Remove padlock and fuel cap a If fuel cap assembly vent is assembly and visually inspect restricted remove restriction vent for damage or restriction b If fuel cap assembly or vent is damaged notify supervisor to replace fuel cap assembly c If fuel cap assembly is not damaged or restricted go to Step 2 Open right and or left side a Open drain valve s and drain door assembly WP 0005 00 fuel water separator s 0016 00 b If engine still surges fault is not corrected Notify supervisor that engine surges 0010 00 20 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 9 Engine is Using More Fuel Than Usual 1 Open left side door assembly a If air cleaner primary element is and check air clogged clean by tapping filter service indicator for red element with hand to remove indication in viewing window dirt In
14. ENGINE OIL CHECK AND SERVICE 401 130 END OF WORK PACKAGE 0011 00 7 0011 00 8 Blank TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF NOTE e Review all WARNINGs CAUTIONS and NOTEs before per forming Operator PMCS on the roller Perform all weekly and before operation PMCS checks if a You are the assigned operator but have not operated the roller since the last weekly checks b You are operating the roller for the first time Unless otherwise indicated perform all lubrication and preven tive maintenance with roller parked on level ground transmis sion in N NEUTRAL with transmission lock lever in locked position brake lock lever engaged implements lowered to the ground and engine shut down Assistance from Field Maintenance is required to perform lubri cation services The CB534B Roller is illustrated unless otherwise noted Before Exterior of Look under roller for signs of fluid Any leakage of fuel or Class Roller leakage fuel oil and coolant III leakage of oil or coolant is found b Check warning and data labels for Any WARNING labels are damage cleanliness and readability missing or damaged beyond readability WARNING WARNING DATA LABEL ABEL DATA LAB
15. WARNING DO NOT use ether starting fluids to start roller in extreme cold weather The CB534B Roller is equipped with a water heater jacket The use of ether could result in injury or engine damage NOTE The CB534B Roller is equipped with an engine block heating element which can be connected to an AC out let when temperatures are below 32 F 0 C a If connected remove 120Vac cable extension cord from coolant heater before starting engine 1 Open left door assembly WP 0005 00 2 Lift latch 22 and remove 120Vac cable extension cord from coolant heater plug 23 and 120Vac outlet 3 Close left door assembly WP 0005 00 b Remove all ice and snow from machine as soon as possible c Prepare roller for operation in severe cold tem peratures according to FM 9 207 FM 31 70 and FM 31 71 as necessary d Drain fuel filter and fuel water separator before filling fuel tank to prevent any water in fuel from freezing This will also pre vent fuel filter from clogging e Start engine WP 0005 00 and allow engine to warm up for at least 15 minutes to reach normal operating temperature before beginning any operation f Watch fuel and warming lights closely Stop roller turn off engine Refer to operator troubleshooting procedures 00 Jand WP 0010 00 when any unusual readings occur c 120Vac CABLE 401 077 0006 00 9 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 000
16. machine into position beside dead roller so NATO slave connectors on machine and roller are side by side 3 Shut down live machine refer to live machine Operator s Manual 0006 00 1 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 SLAVE START ROLLER CONTINUED 4 10 11 12 13 Remove caps 1 from NATO connectors 2 on live machine and roller WARNING Lu e To avoid injury eye protection and acid resistant gloves must be worn when working around batteries Do not smoke use open flame make sparks or create other ignition sources around batteries If a battery is giving off gases it may explode and cause injury Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating damage to equipment and injury e Sulfuric acid contained in batteries can cause serious burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may result in injury or death Remove caps 3 from NATO slave cable connector 4 Plug NATO slave cable connector 4 into NATO con nectors 2 on live machine and roller Start live machine refer to live machine s Opera tor s Manual Operate live machine at high idle refer to li
17. 3 1 Using 24 mm wrench install new preformed packing 0 2 and 1 on elbow 3 2 Remove cap 9 from fuel tank 10 SS Fill fuel tank 10 with 55 gal 208 1 of fuel Install cap 9 on fuel tank 10 Stow 24 mm wrench in toolbox Close right door assembly WP 0005 00 Qv Ue ROUX qe 401 105 END OF WORK PACKAGE 0019 00 5 0019 00 6 Blank TM 5 3895 379 10 VIBRATORY BEARING RESERVOIR CHECK AND SERVICE 0020 00 THIS WORK PACKAGE COVERS Check Fill INITIAL SETUP Tools and Special Tools References Handle socket wrench Item 7 WP 0027 00 WP 0011 00 Operator Preventive Maintenance Material Parts Checks and Services PMCS Introduction Oil synthetic Item 15 WP 0029 00 Equipment Condition Rag wiping Item 16 WP 0029 00 Roller parked on level ground WP 0005 00 Container 1 qt capacity Vibratory system off WP 0005 00 NOTE e The roller vibratory system consists of two similar vibratory systems located at each end of roller The vibratory bearing reservoir oil level gauges are located on left side of front drum and right side of rear drum e This work package covers checking and servicing of one vibrating bearing reservoir Both vibratory bearing reservoirs are checked and serviced in the same way CHECK Start engine WP 0005 00 Move roller until bar 1 is at bottom of drum 2 Turn off enging WP 0005 00 Set parking brake WP 0005 00 Check oil level gaug
18. Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged and fault is not corrected install filter elements and cover and close two air cleaner housing latches Close left side door assembly KWP 0005 00 Notify supervisor of excessive fuel consumption AIR CLEANER SECONDARY AR FILTER di SECONDA SERVICE A SERVICE PRIMARY WHEN ELEMENT y mu Gi E VIEWING WINDOW AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 22 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 10 Engine Operating Temperature Is Too High 1 Check operating conditions a If ambient temperature is Warning Light and Warning Horn On and ambient temperature above 120 F 50 C allow When roller is operated roller to cool Operate roller in continuously in ambient low amplitude WP 0005 00 temperatures above 120 F and reduce travel speed 50 C at high amplitude and at high propel speed engine can easily overheat b If operating conditions and ambient temperature normal go to Step 2 2 Open right side door assembly a If alternator V belt is broken and check for component is faulty Close loose or broken alternator V right side door assembly belts 0005 00
19. Smoothly 2 Open right side door assembly WP 0005 00 and check for loose or broken alternator V belts 3 Check for air flow restriction in radiator and hydraulic oil cooler Check hydraulic oil level 0018 00 STEERING Check hydraulic oil level 0018 00 0010 00 34 CORRECTIVE ACTION a If alternator V belt is broken component is faulty Close right side door assembly 0005 00 and supervisor If alternator V belts are loose close right side door assembly WP 0005 00 Notify supervisor If alternator V belts are not loose or broken go to Step 3 If air flow through radiator is restricted remove restrictions If unable to remove restrictions close right side door assembly WP 0005 00 and notify supervisor If air flow through radiator is not restricted and material being compacted is not too hard close right side door assembly WP 0005 00 Fault is not corrected Notify supervisor If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 If hydraulic oil level is not low fault is not corrected Notify supervisor a If hydraulic oil levelis low fill hydraulic oil tank WP 0018 00 b If hydraulic oil is not low fault is not corrected supervisor Notify TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPE
20. WP 0029 00 Rag wiping Item 16 WP 0029 00 Fuel Item 6 7 or 8 WP 0029 00 Packing preformed 2 Drums chocked WP 0005 00 Container 55 gal minimum capacity fuel tank Left side door assembly opened hydraulic oil tank WP 0005 00 Container 15 5 gal minimum capacity CB534B Roller or 24 gal minimum capacity CB534C Right side door assembly opened fuel tank Roller 0005 00 DRAIN FUEL TANK y WARNING e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller e Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked clothing e Place portable fire extinguisher within reach prior to draining fuel tank e Fuel is very slippery To avoid injury wipe up spilled fuel with rags Before starting roller check that no fuel is spilled on or around machine NOTE e Dispose of fuel IAW local policy and ordinances e Fuel tank capacity is 55 gal 208 1 0019 00 1 TM 5 3895 379 10 DRAINING AND FILLING FUEL AND HYDRAULIC OIL TANKS CONTINUED 0019 00 DRAINING FUEL TANK CONTINUED 1 2 Remove 24 mm wrench from toolbox Using 24 mm wrench remove cap 1 and preformed packing 2 from elbow 3 Discard preformed pack ing Allow fuel to drain completely into containers 0019 00 2 401 102 TM 5 3895 379 10 DRAINI
21. nozzle pressure when drying parts with compressed air Use a maximum of 30 psi 207 kPa when cleaning components DO NOT direct compressed air against human skin Failure to follow this warning may result in injury or death Make sure air stream is directed away from user and other personnel in the area To prevent injury user must wear protective goggles or face shield y FUEL HANDLING DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity Failure to follow this warn ing may result in injury or equipment damage WARNING DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth AE ing WARNING HAZARDOUS WASTE DISPOSAL When servicing this roller performing maintenance or disposing of materials such as engine coolant hydraulic fluid lubricants battery acids or batteries consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 WARNING HEARING PROTECTION Your hearing can be PERMANENTLY DAMAGED if you are exposed to const
22. s responsibility User Responsibilities The user is responsible for 1 The costs associated with transporting the roller 2 Labor costs except as stated under Caterpillar Responsibilities 3 Local taxes if applicable 4 Parts shipping charges in excess of those which are usual and customary 5 Costs to investigate complaints unless the problem is caused by a defect in Caterpillar material or work manship 6 Giving timely notice of a warrantable failure and promptly making the product available for repair 7 Performance of the required maintenance and use of proper fuel oil lubricants and coolant Limitations Caterpillar is not responsible for failures resulting from 1 Any use or installation which Caterpillar judges improper 2 Attachments accessory items and parts not sold by Caterpillar 3 Abuse neglect and or improper repair 4 User s unreasonable delay in making the product available after being notified of a potential product prob lem NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY BY CATER PILLAR EXPRESS OR IMPLIED IS APPLICABLE TO ANY ITEM CATERPILLAR SELLS WHICH IS WARRANTED TO THE USER BY ITS MANUFACTURER THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICU LAR PURPOSE REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES AS SPECIFIED HEREIN
23. 0005 00 and go to Step 5 5 Check exhaust system exit tail If restrictions exist remove pipe for restrictions such as restrictions mud or ice If no restrictions exist and starting aid was used during attempt to start go to Step 6 If no restrictions exist and starting aid was not used during attempt to start go to Step 6 0010 00 4 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 1 Engine Cranks But Will Not Start or is Hard 6 On CB534B only turn fuse a If fuse filament is broken to Start Continued holder cap to left and remove notify supervisor for cap and fuse from fuse holder replacement labeled START AID Inspect fuse for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor that engine cranks but will not start or is hard to start KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE BROKEN FUSE 085348 ONLY FILAMENT 401 085 0010 00 5 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 2 Engine Starts But Will Not Keep Running 1 Check fuel level reading on a If fuel level gauge r
24. Blank DA Form 2028 UNIT MANUALS Army Motor Transport Units and FM 55 30 Basic Cold Weather Manual cit ns IA RTI RUSSES Ca Se ate A FM 31 70 Camouflage Concealment and 2 FM 20 3 Chemical and Biological Contamination Avoidance 2 1 FM 3 3 Desert Operations rU FM 90 3 First Ald EE FM 4 25 11 NBC Decontamination ie irae Re RA EO a ee ILE EIE RU ne da FM 3 5 NBG Field Handbook niet die eed die ee Den OP PR n RUM us FM 3 7 Northern Operations nn tee ea Di sed te ee be greed Shee Bh eee hoe ee heed es FM 31 71 Nuclear Contamination s sos oesi oeme eaa 3 3 1 Operations and Maintenance of Ordnance Materiel in Cold Weather FM 9 207 Recovery and Battlefield Damage Assessment and Repair FM 9 43 2 0026 00 1 TM 5 3895 379 10 REFERENCES CONTINUED 0026 00 TECHNICAL BULLETINS Color Marking and Camouflage Painting of Military Vehicles Construction Equipment and Materials Handling Equipment 25 2 TB 43 0209 Maintenance in the
25. CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES 0001 00 2 TM 5 3895 379 10 GENERAL INFORMATION CONTINUED 0001 00 WARRANTY INFORMATION CONTINUED 4 This warranty applies to all the geographic areas covered by the U S A and Canadian dealers only In other areas differ ent warranties may apply Copies of applicable warranties may be obtained by writing Caterpillar Inc 100 N E Adams Street Peoria IL 61829 3345 5 As used in this warranty the term Caterpillar means Caterpillar Inc or one of its subsidiaries except Caterpillar Overseas S A Caterpillar France S A Caterpillar U K Limited or Caterpillar Belgium S A whichever last sold the product involved NOMENCLATURE CROSS REFERENCE COMMON NAME OFFICIAL NOMENCLATURE Roll Ae ee ee Roller Motorized Vibrating Tandem Steel Drums Caterpillar Model CB534B and Model CB534C LIST OF ABBREVIATIONS NOTE Refer to ASME Y14 38 1999 for standard abbreviations ABBREVIATION DEFINITION he Mel Alternating Current o DIPL DIEI D Additional Authorization List A EE Basic Issue Items CW xo dn CEDE HS SCR URDU UR CECI EE Te ee clockwise true bbb USERS TR ERU PER Ua t bi PEE bd counterclockwise daN dede hu a a dec ad eo a abi deka Newton BPMU 22
26. CLUSTER HORN SWITCH a Start engine WP 0005 00 b Check that warning lights and warn ing horn go off within 15 seconds If warning lights and warning horn do not of off within 15 seconds shut engine off immediately and notify supervisor c Ensure fuel level gauge indicates adequate fuel for the mission Refuel if required WP 0015 00 0012 00 12 NOT FULLY MISSION CAPABLE IF Throttle control movement is not free PROPEL CONTROL LEVER PARKING BRAKE SWITCH LIGHTS SWITCH 401 028 Any warning light or horn stays on for more than 15 seconds after startup or comes on during operation TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 26 Con t Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before VPM TACHOMETER Before Before Before LOCATION ITEM TO CHECK SERVICE Gauges and Warning Indicators Propel Con trol Lever Backup Alarm Horn Work Lights PROCEDURE WARNING LIGHTS CLUSTER HORN SWITCH LIGHTS SWITCH AMPLITUDE SELECT SWITCH a With parking brake off parking brake switch pulled up check that propel control lever operates smoothly without sticking or binding in forward and reverse positions b Check that backup alarm sounds when propel control lever is placed in reverse position Check that horn
27. Chapter If anything looks wrong and you can t fix it write it on your DA Form 2404 or DA Form 5988 E If you find something seriously wrong IMMEDIATELY report it to supervisor Before performing preventive maintenance read all the checks required for the applicable interval and prepare all that is needed to make all the checks You ll always need a rag Item 16 WP 0029 00 or two 0011 00 1 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED gt ES PS WARNING Cleaning compound solvent MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ven tilated areas Keep away from open flames and other sources of ignition a Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious problem Clean as you work and as needed Use cleaning compound solvent Item 3 WP 0029 00 on all metal surfaces Use detergent Item 5 WP 0029 00 and water when you clean rubber plastic and painted surfaces D La WARNING When servicing roller performing maintenance or disposing of materials such as engine coolant hydraulic fluid lubricants battery acids or batteries and CARC paint consult your Field local hazardous waste dis posal center or safety office for local regulatory guidanc
28. FHANAS JONVHD PO DUJHLNAS JONVHD TO SOLV NISPOH YOLVENIA LN 21 REST TA TOT WEIST SEE BETTE EIE HAN H S Ny31 cov acy INAN 14 EDEN NEA IRE NAFHIS 114 dvd SAs DN O02 MalSAS 1303 sSHINOW 9 SHNOH 00S AERE 10 JONVHD 10 13 0 ty Set FEIENDEENS 32 5 NO SNfuv dilla JON GAD AD Ley 01115 SYOLYH idO SINIR HOLY NM 9 NY SEEREHEN VT SATIVA SAS 10 I INYUQAH 249 IVAB3INI JONVHO 7 0 21 330038 ONV OF 30 NOs HILT UNY HO 39NtHD LOL A 2 Se SHINOW SHNOH 5 052 SED ELE RMON SIAjT IG RELERTSEEERES BELER SHNOH 517270 AVHdS 931 VA HY 3H INOW4 NY3 2 TERRELL TEJER RES NINE NIVHO 43113 45341 FERERST 13431 _LNV1009 931 9 11417 ATK ANOVA 199 XOUHVAD 1300Ke yv Ie XOBNVID TION INOS MOLVUE A UV It NOH 4 PRE ESENCIA HOUMS 25 HILYMA WAISAS HILYM Hv ad WAISAS ive dove 530099 Y SUOLVIICNE METETE SUNOH NOLLVWHOANI ONY 32IAH3S Odd OL d gvllvAv 34V Suavag HvTlIdH31lVO 10
29. FLUSH WATER SPRAY SYSTEM CONTINUED 9 Turn engine start switch key 20 to ON position 10 Move water spray switch 21 to continuous spray position for 15 seconds 11 Move water spray switch 21 to center position 12 Turn engine start switch key 20 to OFF position 401 042 13 Remove lid 22 from water tank 2 14 Flush water tank 2 and water spray system with clean water ensuring that any debris or biological growth is removed from the system 15 Install lid 22 on water tank 2 401 117 0024 00 5 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CONTINUED 16 Close drain cock 18 on tie line 19 17 Turn valve handle 17 clockwise to close valve 18 Unhook lanyard 15 from frame assembly 16 and hook lanyard to door assembly 14 19 Close right side door assembly 14 push handle 12 into latch 11 and close latch TA NA JE MW LI 2 re E e N 9 9 e 5 o Cada us at SI 7 401 116 0024 00 6 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CONTINUED mb L WARNING e Cleaning compound solvent MIL PRF 680 Type III is an environmentally compliant and low toxic material However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ventilated
30. INITIAL SETUP Tools and Special Tools Equipment Condition Socket socket wrench Item 3 WP 0027 00 Roller parked on level ground WP 0005 00 Handle socket wrench Item 7 WP 0027 00 Drums chocked WP 0005 00 Engine off WP 0005 00 Materials Parts Rag wiping Item 16 WP 0029 00 NOTE There are four scraper assemblies located on front and rear of each drum All scraper assemblies are serviced the same way This work package covers one CB534B Roller scraper assembly The CB534C Roller scraper assembly is serviced the same way except as noted CLEANING AND INSPECTION 1 Wipe scraper with clean rag 2 Inspect scraper for cracks chips If damaged notify supervisor 3 Adjust scraper pressure Refer to Adjustment in this work package 0023 00 1 TM 5 3895 379 10 DRUM SCRAPER SERVICE CONTINUED 0023 00 ADJUSTMENT NOTE A small amount of pressure on the scraper is required 1 Remove 3 4 socket and 1 2 in drive ratchet from toolbox 2 Install 3 4 in socket on ratchet NOTE There are four locknuts on the CB534C Roller 3 Loosen eight bolts 1 two full turns 4 Loosen eight bolts 2 5 Position scraper 3 so that scraper 3 contacts drum 4 surface firmly and evenly from end to end without bending 6 Tighten eight bolts 1 and bolts 2 from center of scraper outward while applying downward pressure on spring 5 to ensure a small amount of pressure on the scraper TJ R
31. MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF 6 Before Air Filter Con t Service Indi PA A ei y WAN y DRAIN VALVE y WARNING DO NOT perform fuel water separator checks inspections or draining while smoking or when near fire or sparks Fuel may ignite causing injury death or damage to roller CAUTION Operation of roller with damaged fuel water separator can cause engine damage Before 0 1 Hours Fuel Water Check fuel water separator for leaks Any leakage from fuel water Separator or damage such as cracks separator is evident that fuel Primary water separator is damaged b Place container with minimum 1 qt 1 1 capacity under fuel water sepa rator c Open drain valve and drain fluid until only fuel comes out Close drain valve d Dispose of drained fluids in accor dance with local regulations 0012 00 3 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 7 Con t Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before Before Before 0 1 Hours 0 2 Hours LOCATION ITEM TO CHECK SERVICE Fuel Water Sep
32. be in line with valve when valve is open 0010 00 38 If water tank shutoff valves are not open open valves If water tank shutoff valves are open go to Step 3 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION WATER SPRAY SYSTEM CONTINUED 37 Spray Does Not Occur On Either Drum When Water Spray Switch is in Continuous Spray Position Continued WATER TANK SHUTOFF VALVE FRONT SIDE SHOWN REAR SIDE SIMILAR PLATE SHOWN REMOVED FOR CLARITY 3 Check water system for frozen water Turn fuse holder counterclockwise and remove cap and fuse from fuse holder labeled WATER SPRAY Inspect fuse for broken filament KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE PN CORRECTIVE ACTION 401 094 If water system is frozen notify supervisor If water system is not frozen go to Step 4 If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder If fuse filament is not broken component is faulty Install fuse and cap in fuse holder and notify supervisor BROKEN FUSE CB534B ONLY 0010 00 39 FILAMENT TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION WATER SPRAY SY
33. ganong OOOQu oon DUO A A e LOCATION ITEM TO CHECK SERVICE Coolant Steering Frame Lock Pin PROCEDURE d Install radiator cap on radiator Turn cap clockwise until tight e Pull lever back and close access cover on operator s platform Release lever f Close right side door assembly 0005 00 Check that steering frame lock pin is in unlocked position If steering frame lock pin is in locked position unlock steering frame WP 0005 00 LOCKED POSITION 0012 00 9 NOT FULLY MISSION CAPABLE IF 401 025 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before Before Before LOCATION ITEM TO CHECK SERVICE Driver Safety Canopy Rollover Protective Structure ROPS Front Water Tank Warning and Indicator Lights and Warning Horn THROTT CB534B PROCEDURE Check that ROPS is properly installed Check ROPS for damage such as cracks holes or broken welds and loose or missing mounting bolts Check level of water as indicated in water level gauge Ensure tank is full before operating roller 0024 00 a Turn on battery disconnect switch WP 0004 00 and insert key in engine start switch NOTE NOT FULLY MISSION CAPA
34. injury to personnel CAUTION The following procedure should always be used to stop the roller unless an emergency situation exists Damage to equipment can occur if parking brake is used to stop roller NOTE Turn vibration system off before stopping on hot asphalt 1l Roll with Both Drums Static Vibration may not be used at all on thin overlays of 1 in 25 mm or less The roller can also be run in the static mode for finish rolling to smooth out any drum marks TIN 25 MM OR LESS 401 049 2 Roll with Lead Drum Vibrating and Trailing Drum Static Some difficult asphalt mixes and mats less than 2 in 50 mm thick may require the operator to run with the lead drum vibrating and the trailing drum static 401 049 3 Roll with Both Drums Vibrating For maximum compaction when the laydown thickness is greater than 2 in 50 mm roll with both drums vibrating Lm m MM ZA 401 051 0005 00 17 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 ROLLING PROCEDURES CONTINUED NOTE Turn vibration system off before stopping on hot asphalt 4 Roll with Lead Drum Static and Trailing Drum Vibrating Running with the lead drum static and the trailing drum vibrating is not recommended since the static drum will tend to push the material PARK ROLLER NOTE CB534B and CB534C Rollers are parked the same way CB534B Roller is shown 1 Move roller to secure area on level gr
35. level position UNLOCKED POSITION 401 2166 0005 00 23 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 PREPARATION FOR TRANSPORT CONTINUED 2 y WARNING Lifting equipment used for lifting roller must be in good condition and of suitable load capacity Failure to follow this warning may result in injury death or damage to roller Improper use of lifting equipment and improper attachment to roller can result in injury or equipment damage Observe all standard rules of safety Use caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts supported only by lifting device Failure to follow this warning may cause injury or death NOTE CB534B Roller weighs 21 232 Ib 9631 kg CB534C Roller weighs 21 832 lb 9903 kg Lifting eyes are identified by a label that shows a hook and or the stencil LIFT HERE Attach crane or other suitable lifting device to front and rear lifting eyes 5 on both sides of roller Lift roller slowly to ensure roller stays level Position roller on shipping bed of transport vehicle or railcar CAUTION Blocks are placed to prevent excessive loads on drum support bearings Failure to chock drums may result in damage to roller When roller is in position place blocks high in center of yoke on each side o
36. sounds when horn switch is pressed Move lights switch through all posi tions and check that front and rear work lights illuminate 0012 00 13 NOT FULLY MISSION CAPABLE IF VIBRATION PUSH SWITCH PROPEL CONTROL LEVER PARKING BRAKE SWITCH VIBRATION CONTROL SWITCH DRUM SELECT SWITCH 401 029 Propel control lever does not operate in forward or reverse positions Backup alarm does not sound Work lights do not illuminate during low light or night operation TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL LOCATION ITEM TO CHECK SERVICE Vibration System c Check that vibration per minute Press vibration push switch to stop PROCEDURE NOT FULLY MISSION CAPABLE IF WARNING Do not turn vibratory system on while roller is standing still on a very solid surface A loss of steering could result in injury Move vibration control switch to automatic AUTO mode and ampli tude select switch to low pitch mode Turn vibratory push switch to ON vibratory system indicator light should illuminate VPM tachometer is working when vibratory system is engaged vibration Move the amplitude select switch to high pitch mode Press vibration push switch to start vibra tion Move the drum select swit
37. the roller 2 The engine start switch has three positions OFF ON and START In the OFF position no circuits have access to the batteries power In the ON position all circuits are fully powered In the START position electricity is directed from the batteries through a relay and a solenoid to the starter 3 A standard NATO connector is connected to the batteries to allow the operator to jump start the roller from another roller when the roller batteries are low A battery disconnect switch is provided to isolate the battery from the electrical system when the roller is not in use 4 With the engine running and the engine start switch in the ON position the alternator produces between 24 and 28 volts of electricity for charging the batteries and operating accessories The system is protected against overload by fuses and circuit breakers ENGINE START SWTICH ALTERNATOR STARTER BATTERY DISCONNECT SWITCH 0003 00 1 TM 5 3895 379 10 THEORY OF OPERATION CONTINUED 0003 00 PROPEL SYSTEM 1 The propel control lever when pushed forward causes the roller to go forward Pull the propel control lever backward to go in reverse The propel control lever controls the flow of pressurized hydraulic oil to the propel motors The hydrau lic propel motors located on the left of the front drum and the right of the rear drum turn the propel gearboxes which turn the
38. this work package POSITION FOR CHECKING SHOWN 401 108 11 Start engine WP 0005 00 12 Move roller to position opening for oil level check plug 1 at 12 o clock position 13 off enging WP 0005 00 14 Clean and inspect oil level check plug 1 15 Install oil level check plug 1 through access hole in gearbox 3 16 Stow 1 2 in drive ratchet 6 in extension and 5 16 in hex bit in toolbox CLEANING AND INSPECTION NOTE Notify Field Maintenance to replace plug if damaged 1 Clean plug 1 and area around plug openings Inspect threads on plug 1 for crossed or peeled condition 0021 00 2 TM 5 3895 379 10 FRONT AND REAR PROPEL GEARBOX OIL CHECK AND SERVICE CB534B CONTINUED 0021 00 FILL 1 Level check plug 1 is located at 9 o clock position and fill plug 2 is located at 12 o clock position 2 Turn off engine WP 0005 00 3 Remove fill plug 2 at 12 o clock position from gearbox 3 through access hole WARNING Oil is very slippery Immediately wipe up any spills Failure to follow this warning may cause injury CAUTION Do not overfill propel gearbox Damage to equipment may result from too much oil in propel gearbox NOTE Use a container to catch any oil that may drain from system Dispose of oil IAW local policy and ordinances 4 Add oil until oil level is at the bottom of the oil level check plug 1 opening Refer to Oil Level Check in this work package Install f
39. 0 1 Operator RAMS Ree 0005 00 12 Theory of Operation use eere ecl Ae a epa eeu 0003 00 5 Index 4 By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official SANDRA R RILEY Administrative Assistant to the Secretary of the Army 0515802 DISTRIBUTION To be distributed in accordance with the initial distribution requirements for IDN 256608 require ments for TM 5 3895 379 10 Use Part l reverse for Repair Parts and DATE RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists RPSTL and Supply BLANK FORMS Catalogs Supply Manuals SC SM 1 July 2005 For use of this form see AR 25 30 the proponent agency is OAASA Forward to proponent of publication or form Include Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s Manual for Roller Motorized 1 379 15 July 2005 Vibrating Tandem Steel Drums Models nenn CB534B and CB534C ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO 0017 00 2 Part number supplied for item 2 is incorrect TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct to addressee liste
40. 0 kw 2200 rpm Displacement ct aha bets trench Ee eoe RA ESO UE 243 cu in 4 0 1 Transmission e cito e Tte pre er br RT ee e Hydrostatic Speedin Low Range 2 2 20 CORRER RAE ENERGIE 4 5 mph 7 2 kph Speed in High Range icc voee ER Rr Rp Ep ec 7 0 mph 11 2 kph Vibratory System El ctrical System ke roe eu RENE RUM RA ERR RS 24 Volt Frequency ccrte C ee slam EROR 2520 42 Hz Nominal Amplitude LOW reece ertt ote E he te arabe tet ah 0 022 in 0 56 mm NE ee DE ate ey Ae desc IUS ce e Tee Gres 0 043 in 1 092 mm Centrifugal Force per Drum LOW sk ee ERE ne UNUS ERU HU I D AGENTUR RU RR 13480 Ib 6000 daN Hieh 2 32 A A A PRIOR HS A BERE 26550 Ib 11810 daN 0002 00 4 TM 5 3895 379 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Vibratory System Continued PLI ete ee tot ee SEES 161 Ib in 28 8 kg cm Centrifugal max iian ERE eee Stereo deere tetera nes 396 Ib in 70 7 kg cm Water Spray System Tank Material iiss dicta cb tite hed aie Abs batten de Aa e ne n Polyethylene Number of Pumps jee che se Reh tide HR pe ERE REUS 2 Number of Nozzles per 0 7 Number of Drain Cocks ii UA i
41. 00 22 0011 00 1 0012 00 1 0003 00 2 0026 00 1 0013 00 1 0001 00 1 0005 00 21 0005 00 4 0005 00 18 0006 00 1 0005 00 17 0006 00 11 0006 00 1 0003 00 3 0007 00 1 TM 5 3895 379 10 INDEX Continued Subject Work Package Page T Theory of Operation Basic Operations ccs dani ein ee er Cee RE E aa 0003 00 1 Electrical System 45x ges eee eee a VO eio RS 0003 00 1 Propel System o deer ah AH 0003 00 2 Steering System pc Mee ee REESE UAE NUS DEC 0003 00 3 Vibratory System la ad spe ex ER 0003 00 4 Water Spray System e mee eI e ERE FR Boek Ee RUE VER ERU Us 0003 00 5 Towing InstEUCLIOBS tra a E HUIUS S Hm ee de AIRES CORE 0005 00 21 Transport Preparation for cad a 0005 00 22 Troubleshooting Instr ctlOhs 522b a deoa 0008 00 1 Procedut s este sce PORRO Rn ER OUS pU MER BERR s stp 0010 00 1 Symptom Index nn een she RA EMEN De eR 0009 00 1 V Vibratory Bearing Reservoir Check ecc en ee le 0020 00 1 Fall ar ov 0020 00 2 System Operate Lo ore obe coat tp bt Eod EU S Pep 0005 00 14 Th ory of Operation i olet RD RUE d 0003 00 4 W Warranty Information 0001 00 1 Water Spray Nozzle Check and Service 0025 00 1 System Check and Service ner eae En 0024 0
42. 004 0007 00 1 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS LIFT HERE M cm E T a y gt TIEDOWN HERE H 5 N T l 5 M ZN na ENS nm LIFT L c BEES i lt Y TIEDOWN m J 0 LIFT di LIFT AND TIEDOWN POINTS ARE STENCILED ON THE MACHINE AT APPROPRIATE LOCATIONS 0007 00 2 TM 5 3895 379 10 0007 00 CONTINUED AND STENCIL GUIDE CONTINUED EO 89EL F21 05 08 0 52 3001 J Sc OZMO 4001 488 MOL 30 3A08 30 OL 382 MOL 3260130 OPMSL d ce 3AOBV asz NYJ ID JONVHO 3v012 9 1 1288297 LO WIAN e ESA OJAH LAIDUN v 39 030 NT HUNT ASAS HALY ANVIOOD WILSAS ON NOD HLINOW tc HO SHnOH 3OlAH3S 0002 CELE SEEE HOLY Id SOL 1snrav SHINON cl HO SUNOH NY RTVA WRC NVUC Gai ls sass so ET N3HM_YO SYNOH VENA FA OR 93A Eo TO tdi la JONVHD CEEE DIAUSS 0002 AUSAS ANY E Nd SAS JAYAN HIV 0001 AHSAa 53931 79 ID aha NYHUAH OQAHI ASAS DTI WHAM AD50SN 40 JEDLI Has 3 1231059 HIO TON 2 0 Dis
43. 004 PO for the location and function of all controls and indicators required for roller operation 3 CB534B Roller is shown unless otherwise indicated INITIAL ADJUSTMENTS AND DAILY CHECKS WARNING e Operators must wear protective head gear Failure of operators to wear protective head gear may result in serious injury or death Unlock steering frame before operation to prevent loss of steering that may cause injury or death 1 Unlock Steering Frame a Remove clip 1 and pin 2 from articulation yoke 3 b Lift and hold steering frame lock bolt 4 to top of slot in articulation yoke 3 c Install pin 2 in top hole in articulation yoke 3 ensuring steering frame lock bolt 4 is above pin 2 d Release steering frame lock bolt 4 and install clip 1 in pin 2 2 Lock Steering Frame a Remove clip 1 and pin 2 from articulation yoke 3 b Position steering frame lock bolt 4 to bottom of slot in articulation yoke 3 c Install pin 2 in bottom hole in articulation yoke 3 ensuring steering frame lock bolt 4 is below pin 2 d Install clip 1 in pin 2 UNLOCKED POSITION 401 2166 3 Adjust Handrails for Operation When rolling operations require operator to watch surfaces or edges of both drums such as side to side rolling operator station can be moved 90 degrees in either direction Handrails can be moved out to make room for the seat to travel fully back whil
44. 044 928 1 7930 00 282 9699 9140 00 286 5286 9140 00 286 5287 9140 00 286 5288 9140 00 286 5294 9140 00 286 5295 9140 00 286 5296 9130 01 031 5816 4 DESCRIPTION AND PART NUMBER ANTIFREEZE Permanent Ethylene Glycol Inhibited Heavy Duty 58536 A A 52624 1 Gallon Can 81349 MILA46153 5 Gallon Container 58536 A A 52624 55 Gallon Drum BRUSH Nylon 80020 A408848 2 CLEANING COMPOUND Solvent 81349 MIL PRF 680 5 Gallon Can 55 Gallon Drum CLOTH Cleaning 51200 MIRACLEWIPEL001 10 Pound Bale DETERGENT General Purpose Liquid 83421 7930 00 282 9699 1 Gallon Can DIESEL FUEL DF 1 Grade Arctic 81346 ASTM D 975 Bulk 5 Gallon Can 55 Gallon Drum DIESEL FUEL DF 2 Grade 81346 ASTM D 975 Bulk 5 Gallon Can 55 Gallon Drum FUEL TURBINE Aviation 81349 MILT83133 GR JP8 0029 00 2 GAL GAL GAL EA GAL GAL LB GAL GAL GAL GAL GAL GAL GAL GAL TM 5 3895 379 10 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0029 00 1 3 NATIONAL STOCK NUMBER 9150 01 197 7688 9150 01 197 7693 9150 01 197 7690 9150 01 197 7692 9150 00 402 4478 9150 00 402 2372 9150 00 49 11 7197 9150 01 035 5390 9150 01 035 5391 9150 01 035 5392 9150 00 001 9395 9150 01 035 5394 9150 00 189 6727 9150 00 186 6668 9150 00 191 2772 Table 1 Expendable and Durable
45. 10 COMPONENTS OF END ITEM COEI AND BASIC ISSUE ITEMS BII LISTS CONTINUED 0027 00 2 NATIONAL STOCK NUMBER 4930 00 253 2478 4930 00 497 5926 5120 00 189 7985 5120 01 054 7131 5120 01 054 7141 5120 01 355 1902 5120 00 227 8107 5120 00 240 8702 5120 01 367 3477 5120 01 045 4889 5120 00 224 2504 END WORK PACKAGE Table 2 Basic Issue Items List 3 DESCRIPTION CAGEC AND PART NUMBER LUBRICATING GUN HAND 11083 8F9866 COUPLING GREASE GUN Part of 8F9866 11083 9F2636 SOCKET SOCKET WRENCH TWELVE POINT 1 2 IN DRIVE 3 4 IN 05506 ST1224 WRENCH BOX AND OPEN END COMBINATION 13 MM 15526 600 13MMX13MM WRENCH BOX AND OPEN END COMBINATION 24 MM 05043 07 0 OPERATOR S MANUAL 5 3895 379 10 HANDLE SOCKET WRENCH 1 2 IN DRIVE 15 IN LONG 55719 SL936 EXTENSION SOCKET WRENCH 3 8 IN DRIVE 6 IN LONG 55719 FX6 ADAPTER SOCKET WRENCH 1 2 IN TO 3 8 IN DRIVE 39428 5523A54 SCREWDRIVER ATTACHMENT SOCKET WRENCH 5 16 IN 3 8 IN DRIVE 55719 FA10E KEY SOCKET HEAD SCREW 4 MM 74445 57124 KEY SOCKET HEAD SCREW 5 64 IN 88379 ARX132 20 0027 00 3 0027 00 4 Blank 4 USABLE ON CODE TM 5 3895 379 10 ADDITIONAL AUTHORIZATION LIST AAL 0028 00 SCOPE This work package lists additional items that you are authorized for support of the Roller Motorized Vibrating Tan
46. 18 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 6 Engine Oil Pressure is Low Warning Light Turn engine off immediately a If oil is below low mark oil and Warning Horn On Open right side door assembly level is low Install engine oil Check oil level gauge rod dipstick in tube WP 0014 00 Add WP 0014 00 and notify supervisor that engine oil pressure was low warning light and warning horn on If oil is between marks oil level is correct Fault is not corrected Install engine oil gauge rod dipstick in tube close right side door assembly and notify supervisor that engine oil pressure is low warning light and warning horn on LOW MARK pe E ZN 401 086 0010 00 19 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 7 Engine is Unusually Noisy 1 Check muffler and exhaust a If muffler or exhaust system for loose or damaged components are loose components damaged fault not corrected Notify supervisor that muffler or exhaust components are loose or damaged If muffler or exhaust components are not loose or damaged go to Step 2 8 Engine Surges Speed Changes WARNING
47. 2 Fill tank 2 with water Install lid 22 on tank 2 Remove chocks WP 0005 00 401 119 END WORK PACKAGE 0024 00 9 0024 00 10 Blank TM 5 3895 379 10 WATER SPRAY NOZZLE CHECK AND SERVICE 0025 00 THIS WORK PACKAGE COVERS Removal Cleaning and Inspection Installation INITIAL SETUP Materials Parts Equipment Condition Brush nylon Item 2 WP 0029 00 Engine off WP 0005 00 Detergent Item 5 WP 0029 00 Roller parked on level ground WP 0005 00 Rag wiping Item 16 WP 0029 00 Drums chocked WP 0005 00 NOTE e water spray system consists of two identical but separate systems located at each end of the roller Each system has seven nozzles on a spray bar e water spray nozzles are checked and serviced the same way This work package covers one nozzle REMOVAL 1 Remove cap 1 from clamp 2 by turning cap counterclockwise 2 Remove screen 3 seal 4 and nozzle 5 from cap 1 401 120 0025 00 1 TM 5 3895 379 10 WATER SPRAY NOZZLE CHECK AND SERVICE CONTINUED 0025 00 CLEANING AND INSPECTION 1 Clean screen seal nozzle and clamp with non sudsing detergent and water Remove difficult deposits with a stiff bristle brush gt Particles blown by compressed air hazardous DO NOT exceed 15 psi 103 kPa nozzle pressure when drying parts with compressed air Use a maximum of 30 psi 207 kPa when cleaning components DO NOT d
48. 34C Throttle Mechanically controlled by cable Electronic toggle switch high low Speedometer No Yes Starting Aid Water heater jacket Air inlet heater Handrails Design differences same function Design differences same function different look different look EQUIPMENT DATA General EV POs a aee ee o Se Fe E e A DA e ee bu etg se e ere nee ne Roller Motorized Vibrating Tandem Steel Drums sou e EE Caterpillar CB534B and CB534C Roller Length CB534B eee a b dx hanes 203 in 5156 mm Leneth CB5346 cities etoile tat tas oars cts chet i e esse Gao 195 in 4953 mm el Sh E UR S Whe US de eR he 118 in 2997 mm WIR eco la et Mi ce hh den et MA dae sth 73 in 1854 mm Height at Steering Wheel see eR 95 in 2413 mm Operating Weight CB534B 5 use NRR eye EE 21232 Ib 9631 kg 0002 00 3 TM 5 3895 379 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED General Continued Operating Weight 534 4 4 21832 Ib 9903 kg Static Tip An gle izing eed aii Es ORG UAR AER S RATER ERE 40 50 Functional Drum Width z ee Be MU ee oe ee ENDE 67 in 1700 mm Drum Diameter a Be es 51 in 1300 mm Drum Shell Thickness 25 ooo ell RD EL a
49. 3HHOO 9 33VS SI WHOM SIH LYHL IN3N 791003 F SIOOL WJ3dOHd NOILVIN CHOJNI Y TIAS ABVSS3O3N JHL SVH JH LVHL J73SWIH AJSILVS ISAW NOSH3d HOV3 ATlu3dOud OdWHOdH3d SSIINN SNOYSJONVG 38 NYO 3NIHIVW SIHL JO HO 39NVN3ANIVW NOIL vOIH8n 401 055 0007 00 3 NOILVOIdIINSOI NOILVOIJIINSO WIL DATA PLATE STOWAGE AND DECAL DECALS DATA PLATES AND STENCILS OILVOIHSD1 YHOLOVdMdNOD AHOIVHSIA 085348 DINA TM 5 3895 379 10 0007 00 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED DECALS DATA PLATES AND STENCILS CONTINUED 00 201 1 922 212 34 13 HAIAE NOLIVIS 5 0060 SD S Wi 0 XNVID Uo 1511 iV SING COLLININ WO NO LIOV MATE SA 2 1 AG NAGINI SONO TXA IH INEM ONV DE 40 MEL V HiIA 219 WW 35 1 SI Ud L NI SLITS SL aT AMO PRECI SHINOW 21 Wo END TA i ET EHE EEUU 391A93S 062 IMGMICNS ONY MALVA NIWA HO END THAYI HO X130 HAT 00 X130 EMT MUSAS MEVA EJ IW ATAJJM Y0 let JJIAHds 06 WIDE NOLLIS ANI Wa WTO m a Bar TV Wo SON SOTMNIS UI NOILVOYJLIMSOI Ml BAGS NOILVOISILNGQI WALI NOILVIIHANT YOLOVdNOD AMOLVHEIA 2756682 NOILVHYNOANI ONY 32IAM3S 3GIA Odd 01 39V IVAV SYW BVTIIdH31V 1234402 Y 34 5 SI dif 3 7 51001 M3dOlid
50. 6 00 OPERATE IN EXTREME COLD CONTINUED 3 Start Engine 534 WARNING DO NOT use ether starting fluids to start roller in extreme cold weather The CB534C Roller is equipped with an inlet manifold heater The use of ether could result in injury or engine damage a Open right door assembly and turn battery dis connect switch to ON position WP 0005 00 b Push down parking brake knob 24 to apply parking brake c Move propel control lever 5 to NEUTRAL position d Push vibration push switch 25 to OFF position e Move water spray switch 26 to center position 401 2006 f Move throttle control switch 27 to FAST position g Turn engine start switch 6 to ON position NOTE Do not press air inlet heater switch for more than 30 seconds without attempting to start engine Allow inlet heater 60 sec onds to cool down if engine is not cranked h Press and hold air inlet heater switch 28 for a minimum of 10 seconds and up to a maximum of 30 seconds depending on outside air tempera 28 ture i Turn engine start switch 6 to START position When engine starts release key j Disengage starter if engine does not start Con 21 tinue to press throttle control switch 27 NOTE Air inlet heater may be used after starting engine if engine is running rough HOURS JPEN k Repeat step i after 10 seconds When engine starts continue to press and hold 401 2005 air inlet heat
51. 9 f Tighten setscrew 17 in valve knob 18 using 5 64 in socket head screw key g Using 13 mm wrench loosen nuts 13 and 14 h Hold nuts 13 and 14 and turn screws 15 and 16 counterclockwise using 4 mm socket head screw key until stop is reached 1 Using 13 mm wrench tighten nuts 13 14 j Stow 13 mm wrench 5 64 in socket head screw key and 4 mm socket head screw key in toolbox 14 16 401 080 0006 00 7 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME COLD NOTE e nature of its purpose roller usually will not be operated in extremely cold temperatures When roller is required to operate during temperatures below 32 F 0 C observe the following procedures Procedures for operating in extreme cold are the same for the CB534B and CB534C Rollers except where noted 1 Introduction Extreme cold causes many problems Lubricants thicken or congeal a b may freeze or lose their electrical efficiency c Fuel may not readily atomize for combustion d Various materials become hard brittle and easily damaged e Cooling system requires adequate protection from extreme cold f Fuels lubricants and antifreeze require special storage handling and use 0006 00 8 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME COLD CONTINUED 2 Start Engine 534
52. 95 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL SEAT BELT LOCATION ITEM TO CHECK SERVICE Seat Belt NOT FULLY MISSION PROCEDURE CAPABLE IF NOTE A punch card is attached to the inboard side of the left seat belt retractor to record the age of the belt for replacement at the end of three years from the date of installation Check seat belt for security damage Seat belt is missing dam proper operation and expiration punch aged or three years have card date passed since seat belt was installed Notify supervisor for replacement of seat belt EXPIRATION DATE PUNCH CARD CATERPILLAR INSTALLATION DATE Pull belt from the belt side only for proper adjustment See maintenance manual for inspection amp replacement LOCATED ON LEFT SEAT SEAT BELT RETRACTOR BELT RETRACTOR 401 033 0012 00 18 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF Seat Belt RESILIENT MOUNT 401 034 NOTE There are 24 resilient mounts Six are located on each side of the front drum Six are located on each side o
53. AL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED J ___ SHIPPINGDATAFOR 9 CB534B VIBRATORY COMPACTOR NOTE DIMENSIONS ARE IN INCHES 4 E NOTE INSTALL STEERING LOCK 4 CABLES Wu d BEFORE LIFTING 220 00 LONG 7 7 4 LIFT EYES CAP x 12 810 LBS EACH 085348 _ SIDE BLOCKING 4 PLACES 1 4 TIEDOWNS CAP 16 6 BLOCK HEIGHT 13 333 LBS EACH 4 PLACES ROLLER BLOCKING 2 CABLES AT 90 4 PLACES AT EACH TIEDOWN OVERALL LENGTH 203 IN SHIPPING WEIGHT 20 930 LBS mo OVERALL HEIGHT 118 IN SHIPPING TONNAGE 253 TON N OVERALL WIDTH 73 IN X SHIPPING CUBAGE 1 012 CU FT 124 1369 04 SHIPPING DATA FOR CB534C VIBRATORY COMPACTOR F NOTE DIMENSIONS ARE IN INCHES NOTE INSTALL STEERING LOCK 4 CABLES BEFORE LIFTING 240 00 LONG 4 LIFT EYES CAP 13 224 LBS EACH 085340 SIDE BLOCKING PLACES TIEDOWNS CAP 6 13 333 LBS EACH 16 6 BLOCK HEIGHT 4 PLACES ROLLER BLOCKING 2 CABLES AT 9D 4 PLACES AT EACH TIEDOWN OVERALL LENGTH 203 IN SHIPPING WEIGHT 20 000 LBS OVERALL HEIGHT 118 IN SHIPPING TONNAGE 25 3 TON OVERALL WIDTH 73 IN SHIPPING CUBAGE 1 012 CU FT 0007 00 7 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED G H 401 063 401 062 401 061 CONNECT STEERING FRAME LOCK J BETWEEN FRONT AND REAR FRAMES BEFORE LIFTING TRANSPO
54. B534B ONLY DIESEL OR JP 8 401 065 FUEL ONLY 401 067 0007 00 9 401 066 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED ROLLER MOTORIZED VIBRATING TANDEM 10 AIR TRANSPORTABLE MODEL ES CONTA SER LL DATE MFD DATE SHIPPEDLC 1 PAINTED WITH CARC PAINT MFD BY CATERPILLAR INC CAGE CODE ei Be Cae CATERPILLAR y cy CATERPILLAR c NN 534 59400921 PARTS ORDFR USA 401 2188 CAT CATERPILLAR CAT CATERPILLAR TRADEMARKS OF CATERPILLAR INC PEORIA ILLINOIS U S A MARCA REGISTRADA REGO MARQUE D POS E WETTIG GEDEPONEERD w a s MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING LETTERS PATENT SWEO PATENTS SVENSK PATENT NOS JAPAN PAT TENT NOS FRANCE BREVETE D INVENTION NOS 440194 1712238 2753125 360793 2652015 459063 7071581 2809530 459063 8500483 ITALY PATENTS BREVETTATO NOS RMAN PATENTS NOS GREAT BRITAIN PATENT NOS 360793 459063 BELGIAN PATENTS BHEVET BELGE NOS 6909227 459063 3607 NETHERLAND PATENT NOS 2236066 ani 7 160 5418 1 R 401 2189 ALTERNATOR Ma 401 069 401 070 LOCATED ON UNDERSIDE OF OPERATOR PLATFORM 0007 00 10 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CON
55. BLE IF Mounting bolts are loose or missing or ROPS is damaged or missing Do NOT allow engine to start during this check b Turn engine start switch to ON posi tion and observe warning and indica tor lights and warning horn c Return key to OFF position and remove key from engine start switch THROTTLE CONTROL CB534B ENGINE START SWITCH PARKING BRAKE SWITCH THROTTLE CONTROL LE LOCK SWITCH CB534C 0012 00 10 Warning and indicator lights and warning horn do not function PROPEL CONTROL LEVER 401 2183 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before Before LOCATION ITEM TO CHECK SERVICE Operator Sta tion Neutral Start Switch PROCEDURE a Check that rotation lock operates freely and locks operator station in place WP 0005 00 NOTE NOT FULLY MISSION CAPABLE IF Rotation lock is missing or will not lock in holes in oper ator platform Operator station will not pivot full 180 degrees unless handrails are adjusted for operation b Check that aan station ey pivots 180 degrees WP 0005 00 WP 0005 00 Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of 85 DB or greater Hear ing protection is required when operating roller or
56. C OIL TANK WARNING Oil is very slippery Immediately wipe up any spills Failure to follow this warning may cause injury NOTE Hydraulic oil tank capacity of the CB534B Roller is 15 5 gal 59 1 Hydraulic oil tank capacity of the CB534C Roller is 24 gal 91 1 Refer to KEY in WP 0011 00 for type of oil 1 Using 24 mm wrench install new preformed packing 5 and cap 4 on union 6 Remove cap 7 from hydraulic tank 8 Fill hydraulic tank 8 with hydraulic oil Install cap 7 on hydraulic tank 8 Stow 24 mm wrench in toolbox Close left side door assembly WP 0005 00 ON BS 0019 00 4 TM 5 3895 379 10 DRAINING AND FILLING FUEL AND HYDRAULIC OIL TANKS CONTINUED 0019 00 FILL FUEL TANK WARNING e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller e Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked clothing e Place portable fire extinguisher within reach prior to refueling e DO NOT overfill tank If fuel starts foaming from fuel tank stop immediately to avoid fuel spillage e Fuel is very slippery If fuel is spilled clean fuel up immediately to avoid injury Before starting roller check that no fuel is spilled on or around machine NOTE Fuel tank capacity is 55 gal 208 1 I
57. CTION STEERING CONTINUED 27 Too Much Force Is Needed to Turn Steering Wheel 28 Roller Does Not Turn When Steering Wheel is Turned 29 Roller Turns Slowly in Both Directions 30 Roller Will Not Move When Propel Control Lever Is Operated Check hydraulic oil level 0018 00 Check hydraulic oil level 0018 00 Check hydraulic oil level 0018 00 PROPEL SYSTEM 1 Check that parking brake is not engaged parking brake switch is illuminated while parking brake is engaged Check that parking brake switch was not released with propel control lever out of neutral 0010 00 35 CORRECTIVE ACTION a If hydraulic oil is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault is not corrected Notify supervisor a If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault is not corrected Notify supervisor a If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault is not corrected Notify supervisor a If parking brake is engaged pull parking brake switch up to release parking brake b If parking brake is not engaged go to Step 2 Move propel control lever to neutral Press down then pull up parking brake switch If symptom persists go to Step 3 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00
58. Does Not Operale cesset RE ER ep Ne OhEN ESSE ESG REESE RASS 0010 00 32 Horn Does Not Operate Oho 0010 00 31 No Power to Accessories With Engine 1 0010 00 32 Starter Does Not Turn or Turns 1 1 4 4 0010 00 29 Starter Turns But Does Not Crank 2 1 0010 00 29 Starting Aid Switch Does Not Work CB534B Roller Only 0010 00 30 Roller Has No Electrical Power 2 bas eee Nee ae Beep Lewes deans NU e rs 0010 00 27 Vibrations Per Minute VPM Gauge Does Not Operate 0010 00 32 Warning and Indicator Lights Do Not Operate 0010 00 30 Work Lights and Gauge Lights Do Not Operate 0010 00 31 ENGINE Engine Cranks But Will Not Start or is Hard to Start Engine Exhaust Smokes Excessively Too Much Black or Gray 5 0010 00 14 Engine is o eoe Riedie M E aquse Oso qus ena uds 0010 00 10 Engine is Unusually Noisy regia creer ek 0010 00 20 Engine is Using More Fuel Than
59. E OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED 43 44 45 gt u Ss gt _ LM XA AL WG x LA 46 ey p SL TS 29 4 7 m a Ly XO MENO oa 4 WW Agee 04 AM A 401 016 CONTROL OR INDICATOR FUNCTION Alternator Circuit Breaker Reset Button Push to reconnect alternator circuit to provide power to roller Circuit breaker will trip in the event of electrical system overload Air Filter Service Indicator Indicates condition of air filter Air filter requires service when red appears in viewing window or when the arrow is at the 22 in position Push reset button on top of service indicator after filter service is complete Engine Heater Connector Attach a cable extension cord with 120Vac to this connection to warm engine coolant overnight during cold weather Manual Brake Release Valve Pressing knob manually pumps hydraulic oil to release brakes This action can be used for short distance moving of roller when engine is off or unable to be started Manual Brake Release Needle Valve Locked open for normal operation Unlock setscrew and close valve to use manual brake release pump 0004 00 10 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED LOCATED INSIDE OPERAT
60. EL GEARBOXES PROPEL HYDRAULIC PUMP 401 007 PROPEL MOTORS 0003 00 2 TM 5 3895 379 10 THEORY OF OPERATION CONTINUED 0003 00 STEERING SYSTEM 1 The steering system is based on a 60 40 articulation 40 of the roller is located in front of the articulation pivot point 60 is located in the rear The front drum is attached to the yoke assembly while the rear drum is attached to the frame assembly Two hydraulic steering cylinders provide the motive force to steer the roller by articulating shifting the yoke and frame of the roller to change the path of travel The steering wheel controls the direction of travel by actuating a hydraulic steering control valve which directs pressurized hydraulic oil to the hydraulic steering cylinders The steering system s hydraulic steering pump has two functions The primary purpose is providing pressurized hydrau lic oil used in steering the roller Secondarily the steering system hydraulic pump is used to charge the propel system STEERING WHEEL STEERING CONTROL VALVE FRAME ASSEMBLY YOKE ASSEMBLY STEERING CYLINDERS 401 008 0003 00 3 TM 5 3895 379 10 THEORY OF OPERATION CONTINUED 0003 00 VIBRATORY SYSTEM 1 The hydraulic vibratory motors located on the left of the front drum and the right of the rear drum turn an eccentric ee weight located inside each drum As the eccentric weight spins kinetic energy creates forces that cause t
61. EL me DATA LABEL WARNING Men i MAY WARNING LABEL DATA WARNINGLABEL WARNING LABEL NK SHS 401 018 0012 00 1 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before Before Before Before Before LOCATION ITEM TO CHECK SERVICE Work Lights Engine Left Side Electrical Wires Hydraulic Hoses Air Filter Service Indi cator PROCEDURE Check front work lights for broken lenses a Open left side door assembly 0005 00 Check rear of engine for accumu lated grease oil Check for loose or frayed wires and loose connections Check for crimped torn or damaged hydraulic hoses Check indicator viewing window and arrow while engine is shut off If red color is in view in window and arrow is at 22 in position service air cleaner WP 0010 00 NOT FULLY MISSION CAPABLE IF Excessive accumulation of grease oil is found Wires are frayed or loose or connectors are loose Hydraulic hoses are crimped torn or damaged Red color appears in viewing window arrow is at 22 in position AIR FILTER SERVICE INDICATOR SERVICE WHEN AS DE LEVEL IS AT 22 ET Gre EXA AL CEN 2 SERVICE WHEN RED 401 019 0012 00 2 TM 5 3895 379 10 OPERATOR PREVENTIVE
62. ENGINE COOLANT CHECK AND SERVICE 0017 00 THIS WORK PACKAGE COVERS Check and Fill INITIAL SETUP Materials Parts Equipment Condition Antifreeze Item 1 WP 0029 00 Engine off WP 0005 00 Rag wiping Item 16 WP 0029 00 Roller parked on level ground WP 0005 00 Drums chocked WP 0005 00 Right side door assembly opened WP 0005 00 2 E WARNING DO NOT service cooling system unless engine has cooled This is a pressurized cooling system and escaping steam or hot coolant may cause burns DO NOT remove radiator cap when engine is hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause burns Wear effective eye glove and skin protection when handling coolants Failure to do so may cause injury 0017 00 1 TM 5 3895 379 10 ENGINE COOLANT CHECK AND SERVICE 0017 00 CHECK AND FILL 1 Pull lever 1 and open access door 2 Release lever 2 Remove radiator 3 by turning left slowly to relieve coolant system pressure 3 Check coolant level Coolant level should be approximately 3 in 7 6 cm below fill port CAUTION Do not fill coolant system with water only Use ethylene glycol mixture antifreeze with water Failure to do so will result in damage to engine 4 If necessary fill radiator 4 with 50 50 mixture of water antifreeze to approximately 3 in 7 6 cm below fill port 5 Install radi
63. ESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 14 Starter Turns But Does Not Crank Engine 2 Turn fuse holder cap a If fuse filament is broken Continued counterclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled KEY START Inspect cap in fuse holder fuse for broken filament Fault is not corrected Notify supervisor 15 Warning and Indicator Lights Do Not Turn fuse holder cap a If fuse filament is broken Operate counterclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled GAUGES Inspect fuse cap in fuse holder for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor 16 Starting Aid Switch Does Not Work For CB534B Roller only turn If fuse filament is broken CB534B Roller Only fuse holder cap counterclockwise notify supervisor for and remove cap and fuse from replacement Install fuse and fuse holder labeled START AID cap in fuse holder Inspect fuse for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor 17 Backup Alarm Does Not Work Turn fuse holder cap a If fuse filament is broken coun
64. Engine Will Not Stop Running Place battery disconnect switch in OFF position WP 0005 00 If engine will not stop running notify supervisor ELECTRICAL SYSTEM 12 Roller Has No Electrical Power 1 Open right side door assembly a If disconnect switch is not in WP 0005 00 and check that ON position turn switch to ON battery disconnect switch is in position Close right side door ON position assembly WP 0005 00 If disconnect switch is in position close right side door assembly WP 0005 00 and go to Step 2 2 Open left side door assembly If roller still has no electrical WP 0005 00 and press power close left side door alternator circuit breaker assembly WP 0005 00 and go to button Step 3 0010 00 27 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 12 Roller Has No Electrical Power Continued ALTERNATOR CIRCUIT BREAKER BUTTON 401 090 3 Turn fuse holder cap to leftand a If fuse filament is broken remove cap and fuse from fuse notify supervisor for holder labeled KEY START replacement Install fuse and Inspect fuse for broken cap in fuse holder filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor KEY START BACKUP ALARM
65. FF center position d On CB534B Roller only turn throttle lock 12 counterclockwise until throttle control 13 moves up and down freely e On CB534B Roller push and hold button 14 and pull throttle control 13 out to high idle position near to or fully up f On CB534C Roller move throttle control switch 15 to fast HARE position 401 2228 0005 00 7 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED WARNING DO NOT start roller engine in enclosed areas without adequate ventilation Failure to follow this warning may result in permanent brain damage or death due to carbon monoxide poisoning CAUTION e operate starter motor for more than 30 seconds at a time After 30 seconds allow starter motor to cool for at least two minutes before attempting to start engine again Excessive heating of starter motor may result in damage or early starter failure Keep engine rpm low until engine oil pressure indicator light and horn go off Stop engine if indicator light does not go off within ten seconds Notify supervisor to perform troubleshooting before restarting engine e Failure to keep engine rpm low until engine oil pressure indicator light and horn go off can result in tur bocharger damage g Turn engine start switch key 16 to START clockwise position to crank engine Release key when engine starts h CB534B Roller only immediately
66. IBRATING TANDEM STEEL DRUMS CATERPILLAR MODEL CB534B NSN 3895 01 396 2822 CATERPILLAR MODEL CB534C NSN 3895 01 502 4005 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or if you know of a way to improve the pro cedures please let us know Submit your DA Form 2028 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 e mail your letter DA Form 2028 direct to AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The e mail address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 SUPERSEDURE NOTICE This manual supersedes TM 5 3895 379 10 dated 27 March 2000 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Table of Contents Page Number eee ee eee al How To Use This Manual 74
67. INTRODUCTION 1 This revised manual is designed to help you operate the CB534B and CB534C Roller Motorized Vibrating Tandem Steel Drums and perform operator troubleshooting and maintenance on the roller 2 This manual is written in work package format a Chapters divide the manual into major categories of information e g Introductory Information with Theory of Operation Operating Instructions Operator Troubleshooting Operator Maintenance Instructions and Support ing Information b Each Chapter is divided into work packages which are identified by 6 digit number e g 0001 00 0002 00 etc located on the upper right hand corner of each page The work package page number e g 0001 00 1 0001 00 2 etc is located centered at the bottom of each page c Ifa Change Package is issued to this manual added work packages use the 5 ang 6 digits of their number to indicate new material For instance work packages inserted between WP 0001 00 WP 0002 OOjare numbered WP 0001 01 WP 0001 02 etc 3 Scan through this manual to become familiar with its organization and contents before attempting to operate or maintain the roller CONTENTS OF THIS MANUAL 1 Warning Summary is located at the beginning of this manual Become familiar with these warnings before operating or performing operator troubleshooting or maintenance on the roller 2 Al Table of Contents located in the front of the manual lists all chapters an
68. ITIONS CONTINUED 0005 00 OPENING CLOSING DOOR ASSEMBLIES y WARNING e There is no clearance for personnel between frame and yoke when roller turns Injury or death from crushing could occur e Steering frame must be locked before lifting transporting or servicing roller in articulation area to pre vent injury or death from crushing NOTE Right and left side door assemblies are opened and closed the same way Right side door assembly is shown 1 Open Door Assembly a If opening door to check or service engine compartment with engine running shut off engine and lock steering frame Refer to Initial Adjustments and Daily Checks and Operate Engine in this work package b Liftlatch 1 pull handle 2 up and toward front of roller 3 and open door assembly 4 c Unhook lanyard 5 from eye on door assembly 4 and hook to eye on frame assembly 6 2 Close Door Assembly Unhook lanyard 5 from frame assembly 6 and hook to door assembly 4 Close and hold door assembly 4 tightly against frame Push handle 2 into latch 1 and close latch If steering frame was locked shut off engine and unlock steering frame Refer to Initial Adjustments and Daily Checks and Operate Engine in this work package ao 0005 00 20 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 ROADING MACHINE 1 Perform a walk around inspection of roller 2 Measure fluid levels in various compartm
69. Inches 1 Sq Meter 10 000 Sq Centimeters 10 76 Sq Feet 1 Sq Kilometer 1 000 000 Sq Meters 0 0386 Sq Miles Cubic Measure 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet Temperature 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 Multiply By To Change To Multiply By Inches Centimeters 2 540 Centimeters Inches 0 394 Feet Meters 0 305 Meters Feet 3 280 Yards Meters 0 914 Meters Yards 1 094 Miles Kilometers 1 609 Kilometers Miles 0 621 Sq Inches Sq Centimeters 6 451 Sq Centimeters Sq Inches 0 155 Sq Feet Sq Meters 0 093 Sq Meters Sq Feet 10 764 Sq Yards Sq Meters 0 836 Sq Meters Sq Yards 1 196 Sq Miles Sq Kilometers 2 590 Sq Kilometers Sq Miles 0 386 Acres Sq Hectometers 0 405 Sq Hectometers Acres 2 471 Cubic Feet Cubic Meters 0 028 Cubic Meters Cubic Feet 35 315 Cubic Yards Cubic Meters 0 765 Cubic Meters Cubic Yards 1 308 Fluid Ounces Milliliters 29 573 Milliliters Fluid Ounces 0 034 Pints Liters 0 473 Liters Pints 2 113 Quarts Liters 0 946 Liters Quarts 1 057 Gallons Liters 3 785 Liters Gallons 0 264 Ounces Grams 28 349 Grams Ounces 0 035 Pounds Kilog
70. Items List Continued 4 DESCRIPTION CAGEC AND PART NUMBER GREASE Automotive and Artillery GAA 81349 M 10924 A 1 1 4 Ounce Tube 81349 M 10924 B 14 Ounce Cartridge 81349 M 10924 C 1 3 4 Pound Can 81349 10924 35 Pound OIL Lubricating Arctic OEA 81349 MIL PRF 46167 1 Quart Can 81349 MIL PRF 46167 5 Gallon Drum 81349 MIL PRF 46167 55 Gallon Drum OIL Lubricating GO 75 81349 MIL PRF 2105 1 Quart Can 5 Gallon Can OIL Lubricating GO 80W 90 81349 MIL PRF 2105 1 Quart Can 5 Gallon Can 55 Gallon Drum OIL Lubricating OE HDO 10 81349 MIL PRF 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum 0029 00 3 TM 5 3895 379 10 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0029 00 1 END WORK PACKAGE 3 NATIONAL STOCK NUMBER 9150 01 152 4117 9150 01 152 4118 9150 01 152 4119 7920 00 205 1711 7930 00 634 3935 Table 1 Expendable and Durable Items List Continued 4 DESCRIPTION CAGEC AND PART NUMBER OIL Lubricating OE HYDO 15W 40 81349 MIL PRF 2104 1 Quart Can 5 Gallon Can 55 Gallon Drum OIL Synthetic ISO 220 11083 4C6767 15958 Syntho Gear EP 220 19135 SHC 630 Quart Can RAG Wiping 64067 7920 00 205 1711 50 Pound Bale SOAP Laundry 200 Pound Container 0029 00 4 TM 5 3895 379 10 INDEX Subject Abbreviations Eist ot
71. LL BE HANDLED BY PER SONNEL WEARING FULL NBC PROTEC TIVE EQUIPMENT SEE OPERATOR MAINTENANCE MANUAL 7690 01 114 3702 To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 TM 5 3895 379 10 WARNING 2 2 PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has cooled This is a pressurized cooling system and escaping steam or hot coolant may cause serious burns DO NOT remove radiator cap when engine is hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause burns Wear effective eye glove and skin protection when handling coolants Failure to do so may cause injury WARNING ROLLER OPERATION Use caution and maintain three point contact at all times when mounting or dismounting roller to avoid injury or death BE ALERT for personnel in the area while operating roller Always check to ensure area is clear of personnel and obstructions before moving Failure to follow this warning may result in injury or death Use of seat belt while operating roller is mandatory Fasten belt BEFORE operating Trying to fasten belt while operating creates a hazardous condition Failure to follow this warning may result in injury or death DO NOT allow riders on roller Failure to follow this war
72. MCS for DSWR Continued INTERVAL 0 2 Hours LOCATION ITEM TO CHECK SERVICE Steering Hydraulic Oil Level Warm Oil Check Fuel Tank Water Spray System Water Spray System Muffler Exhaust Pipes NOT FULLY MISSION PROCEDURE CAPABLE IF Check for any unusual steering noise Steering binds or is unre binding or difficulty in turning sponsive CAUTION Do not overfill hydraulic oil tank Damage to hydraulic system components may occur NOTE The roller should be parked on level surface when checking the hydraulic oil level Hydraulic oil is checked warm and cold Run engine at least five minutes before performing warm oil check Check that hydraulic oil level is Hydraulic oil level is below between the high and low marks on the LOW level mark or above label beside the hydraulic oil tank sight HIGH level mark on label gauge If level is below LOW level mark fill hydraulic tank WP 0018 00 Refuel WP 0015 00 Drain and flush front and rear water tanks Service all strainers WP 0024 001 Remove water spray screen element WP 0024 00 b Clean bowl and element with water c Install water spray screen element WP 0024 00 d Repeat steps a through c for second water tank located on the opposite end of the roller Check muffler and exhaust system for decay damage and loose com ponenets 0012 00 17 TM 5 38
73. NG AND FILLING FUEL AND HYDRAULIC OIL TANKS CONTINUED 0019 00 DRAIN HYDRAULIC OIL TANK A WARNING e At operating temperature hydraulic oil is hot Allow hydraulic oil to cool before disconnecting any hydraulics Failure to do may cause injury e is very slippery Immediately wipe up any spills Failure to follow this warning may cause injury NOTE e Use container to catch draining oil Dispose of oil LAW local policy and ordinances e Hydraulic oil tank capacity of the CB534B Roller is 15 5 gal 59 1 Hydraulic oil tank capacity of the CB534C Roller is 24 gal 91 1 1 Remove 24 mm wrench from toolbox 2 Using 24 mm wrench remove cap 4 and preformed packing 5 from union 6 Discard preformed pack ing 3 Allow hydraulic oil to drain completely into container 401 103 0019 00 3 TM 5 3895 379 10 DRAINING AND FILLING FUEL AND HYDRAULIC OIL TANKS CONTINUED 0019 00 CLEANING AND INSPECTION CAUTION Dirt grit and metallic particles can cause damage to hydraulic and engine components Cap and hose assembly should be clean before cap is installed 1 Inspect for metallic particles in cap 2 Inspect union and elbow threads and threads for damage 3 Clean caps union elbow and around union and elbow 4 Clean cap threads and hydraulic tank hose assembly threads with clean hydraulic oil and rags 5 Notify supervisor for replacement of lost or damaged parts FILL HYDRAULI
74. NOLLYR MOANI Y TITAS AHVSS3O3N IHL SVH LVHL JTSSWIH AdSILVS ASNW NOSHSd HIVI A B3dOHd SSIINN S0H39NVG NVJ 3NIHOVN 40 HIVd3H 3ONVN3INIVW NOILVODN8 DEINUYA Y 401 055 0007 00 4 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED FOR PROPER RIDE o ADJUST YELLOW POINTER FLUSH WITH TUBE WHILE SEATED LIGHTS 121 3988 401 057 401 056 401 2042 CB534B CB534C 0007 00 5 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED KEY START BACKUP ALARM WATER SPRAY STARTAO BRAKE A WARNING DO NOT OPERATE WORK ON THIS UNLESS YOU HAVE READ AND UNDERSTAND THE WARNINGS IM THE OPERATION AND Fi TO FOLLOW HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH CONTACT ANY CATER PILLAR DEALER FOR REPLACEMENT MANUALS PROPER CARE CB534B WARNING DO NOT OPERATE OR WORK OW THIS MACHINE UML UNDERSTAND THE INSTRUCTIONS AND ESS YOU HAVE READ AND WARMINGS IN THE OPERATION AND MAINTENANCE MANUALS FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARMNGS COULD RESULT IN INJURY OR DEATH CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS PROPER CARE 15 YOUR RESPONSIBILITY 085340 401 2043 0007 00 6 TM 5 3895 379 10 STOWAGE AND DEC
75. OCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION ELECTRICAL SYSTEM CONTINUED 23 No Power to Accessories With Engine Running Continued 2 Turn fuse holder counterclockwise and remove cap and fuse from fuse holder labeled KEY START Inspect fuse for broken filament KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE CORRECTIVE ACTION a If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor BROKEN FUSE 401 085 HYDRAULIC SYSTEM 1 Check hydraulic oil level 0018 00 24 Hydraulic Oil Temperature is High Warning Light and Warning Horn On 0010 00 33 FILAMENT a If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault is not corrected Notify supervisor 401 087 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION HYDRAULIC SYSTEM CONTINUED 24 Hydraulic Oil Temperature is High Warning Light and Warning Horn On Continued 25 Hydraulic Oil Pressure is Low Warning Light and Warning Horn On 26 Power Steering Pump Makes Noise and Steering Cylinder Rods Do Not Move
76. OR STATION dl Sep MN y Sy WHITE FILTER INDICATOR 401 017 CONTROL OR INDICATOR FUNCTION Vibratory Bearing Oil Level Gauge Vibratory bearing oil level for front and rear vibratory bearing reservoirs can be checked with this sight gauge when drum is positioned with welded rod at bottom of the drum Warning Horn Sounds alarm during same time warning lights are illuminated Water Tank Drain Plug Turn the tee handle and remove the drain plug to drain water from the water tank A drain plug is located on each of the water tanks Water Tank Shut off Valve Closes or opens the flow of water from the water tank to the water spray screen during screen cleaning Hydraulic Oil Filter Indicator Indicates amount of contamination collected inside hydraulic oil filter When white indicator reaches the red zone filter needs to be replaced Engine Oil Gauge Rod Dipstick Indicates level of oil in crankcase of engine Two marks are provided to indicate acceptable high and low levels When the oil is below the low level add oil to the engine END OF WORK PACKAGE 0004 00 11 0004 00 12 Blank TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS 0005 00 GENERAL 1 This work package contains instructions for safely operating the CB534B and CB534C Rollers Motorized Vibrating Tandem Steel Drums under usual conditions Unusual conditions are defined and described in WP 0006 00 2 Refer to WP 0
77. ORRECTIVE ACTION ENGINE CONTINUED 2 Engine Starts But Will Not Keep Running Continued 3 Remove strainer and visually inspect fuel in fuel tank If fuel tank is empty fuel level gauge does not operate Install strainer and fill fuel tank with fuel WP 0015 00 Notify supervisor that fuel level gauge does not operate If fuel is contaminated notify supervisor If fuel tank contains clean fuel install strainer fuel cap assembly and padlock and go to Step 4 4 Open right and or left side a Open fuel water separator s door assembly WP 0005 00 drain valve s and drain separator s WP 0016 00 If engine still does not keep running go to Step 5 Open left side door assembly WP 0005 00 Check air filter If air cleaner primary element is clogged clean by tapping service indicator for red element with hand to remove indication on viewing dirt Install secondary and window Red indicates a primary filter elements and clogged air cleaner primary or secondary element If filter service indicator shows red in viewing window unlatch two air cleaner housing latches and remove cover Remove primary and secondary elements from air cleaner housing 0010 00 8 cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Trou
78. RTING OR SERVICING MACHINE NO CLEARANCE FOR PERSON IN THIS AREA WHEN MACHINE TURNS SEVERE INJURY OR DEATH FROM CRUSHING COULD OCCUR IN ARTICULATION AREA DISCONNECT LOCK AND SECURE BEFORE RESUMING OPERATION 5P 7244 4 401 063 A WARNING STRUCTURAL DAMAGE AN OVERTURN MODIFICATION ALTERATION OR IMPROPER REPAIR CAN IMPAIR THIS STRUCTURE S PROTECTION CAPABILITY THEREBY VOIDING THIS CERTIFICATION DO NOT WELD ON OR DRILL HOLES IN THE STRUCTURE CONSULT A CATERPILLAR DEALER TO DETERMINE THIS STRUCTURE S LIMITATIONS WITHOUT VOIDING ITS CERTIFICATION ROLLOVER ROPS AND FALLING OBJECT FOPS PROTECTIVE STRUCTURE CERTIFICATION THIS STRUCTURE WHEN PROPERLY INSTALLED ON A MACHINE WHICH IS NOT ALTERED TO EXCEED THE CERTIFICATION TEST MASS MEETS AT THE TIME OF INSTALLATION CRITERIA ESTABLISHED BY SAE J1040 APR88 SAE J231 1 ISO 3471 1994 150 3449 1992 LEVEL II ISO 3471 1 1986 CERTIFICATION TEST MASS MODEL NO LB CB 534C 11500 25 300 CATERPILLAR INC PEORIA ILLINOIS USA 150 4280 1 401 2182 0007 00 8 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE CONTINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED ANGUS PALM Box 610 Watertown SD 57201 CATERPILLAR MODEL CB534B MAX WT 25 250 LBS 11 453 KG MEETS SAE J231 JAN81 J1040 APR88 MEETS ISO 3449 1984 3471 1 1986 PART NO 117 1347 SUPP 101812 SERIAL NO XXXXXXX N C
79. S STARTAID BRAKE BROKEN FUSE FILAMENT 401 085 0010 00 31 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 21 Fuel Gauge Does Not Operate Turn fuse holder cap a If fuse filament is broken counterclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled GAUGES Inspect fuse cap in fuse holder for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor 22 Vibrations Per Minute VPM Gauge Does Turn fuse holder cap If fuse filament is broken Not Operate counterclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled GAUGES Inspect fuse cap in fuse holder for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor 23 No Power to Accessories With Engine 1 Open left side door assembly If roller still has no electrical Running WP 0005 00 and press power fault is not corrected alternator circuit breaker Close left side door assembly button WP 0005 00 Go to Step 2 ALTERNATOR CIRCUIT BREAKER BUTTON 401 093 0010 00 32 TM 5 3895 379 10 TROUBLESHOOTING PR
80. S for DSWR Continued LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF a Pull lever on underside of operator platform back and open access cover on operator platform Release lever 2 WARNING DO NOT service cooling system unless engine has cooled This is a pressurized cooling system and escaping steam or hot cool ant may cause burns DO NOT remove radiator cap when engine is hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause burns Wear effective eye glove and skin protection when handling coolants Failure to do so may cause injury RADIATOR FILL CAP ACCESS COVER EL 352 4 XE AE Te gt Y D LEVER 25 gt TA I Ho TL Lm Lu 401 023 b Slowly open radiator fill cap by turning cap to the left until pressure starts to release from radiator Wait until pressure is fully released before removing cap c Check that coolant level is approxi Coolant level is low mately 3 in 7 6 cm below fill port If coolant level is low add coolant WP 0017 00 0012 00 8 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL 18 Con t Before
81. SERVICE INDICATOR 55 E AIR CLEANER HOUSING LATCHES 0010 00 13 AIR CLEANER HOUSING So SY CORRECTIVE ACTION a If air cleaner primary element is clogged clean by tapping element with hand to remove dirt Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left 00 door assembly WP 0005 00 b If air cleaner primary element is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 SECONDARY ELEMENT PRIMARY ELEMENT SS 555555555556 555 55555 e eM Sg 55594 55555 25559555594 REIN SS AIR CLEANER 401 084 HOUSING COVER TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 3 Engine is Sluggish Continued c If air cleaner secondary element is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged and fault is not corrected install filter elements an
82. STEM CONTINUED 38 Spray Does Not Occur On Either Drum When Water Spray Switch is in Intermittent Spray Position 1 Check water level gauges for water in water tanks Indicator needle pointing full left indicates tank is empty On CB534B check that the water tank shutoff valve at each water tank is open Valve handle will be in line with valve when valve is open Check water system for frozen water Turn fuse holder cap counterclockwise and remove cap and fuse from fuse holder labeled WATER SPRAY Inspect fuse for broken filament KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE 39 Spray Occurs On One Drum Only 401 085 1 Check water level gauges for water in tanks Indicator needle pointing full left indicates tank is empty 0010 00 40 CORRECTIVE ACTION a If water level is low add water WP 0024 00 b If water level is not low go to Step 2 If water tank shutoff valves are not open open valves If water tank shutoff valves are open go to Step 3 If water is frozen notify supervisor If water in system is not frozen go to Step 4 If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder If fuse filament is not broken component is faulty Install fuse and cap in fuse holder and notify supervisor BROKEN FUSE FILAMENT a If water level is low add water WP 0024 00 b If water level
83. Selector Switch Controls the use of water from the front or rear water tank For CB534C Only front water tank move switch forward For the rear water tank move switch rearward Horn Switch Press to sound horn Propel Speed Range Switch Allows the roller to operate in either low tortoise or high hare propel speed modes Throttle Control Circuit Breaker Reset Push to reset throttle control circuit to provide power to throttle Button control Circuit breaker will trip in the event of electrical system malfunction 0004 00 7 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED 401 014 CONTROL OR INDICATOR FUNCTION Fore aft Lever Adjusts seat forward or backward when pulled to left Seat Belt Provides for operator safety during operation of roller Seat belts must be worn each time the roller is moved Rotation Lock Lever locks operator station in five positions on operator platform Holes in operator platform are located to position operator station direct forward and 45 degrees and 90 degrees in either direction Pull up on lever to release pin to allow platform rotation Ride Adjustment Indicator Ride adjustment is correct when the rod is aligned with the tube Lift Lever Adjusts seat height when pressed down Release of lever locks seat height into position Ride Adjustment Knob Adjusts firmness
84. TINUED 0007 00 DECALS DATA PLATES AND STENCILS CONTINUED 24 VOLTS 5R8331 401 071 HIGH INTENSITY NOISE HEARING PROTECTION REQUIRED WITHIN 19 FEET WHEN OPERATING 1 5610 1 401 072 STARTING PROCEDURE FOR MACHINES WITH THERMAL STARTING AID THERMAL STARTING AID UNIT BY HOLOING THE THERMAL STARTING A OR zu SECONDS ROTTLE IN FULLY OPEN Hi TER FOR NOT MORE THAT STARTS CONTINUE TO DEPRESS 3TiNG AID TOGGLE SWITCH UNTIL ENGINE 401 073 END OF WORK PACKAGE 0007 00 11 0007 00 12 Blank TM 5 3895 379 10 CHAPTER 3 OPERATOR TROUBLESHOOTING TM 5 3895 379 10 TROUBLESHOOTING INSTRUCTIONS 0008 00 GENERAL 1 This chapter provides information for identifying and correcting malfunctions which may develop while operating the CB534B and CB534C Rollers Motorized Vibrating Tandem Steel Drums Troubleshooting procedures for CB534B and CB534C Rollers are the same except where noted 2 Troubleshooting Symptom Index in WP 0009 00 lists common malfunctions which may occur and refers you to the proper page in WP 0010 00 for a troubleshooting procedure 3 If you are unsure of the location of an item mentioned in troubleshooting refer to WP 0002 00 or WP 0004 00 4 Before performing troubleshooting read and follow all safety instructions found in the Warning Summary at the front of this manual 5 The Troubleshooting Symptom Index cannot list all malfunctions t
85. TM 5 3895 379 10 TECHNICAL MANUAL OPERATOR S MANUAL FOR ROLLER MOTORIZED VIBRATING TANDEM STEEL DRUMS CATERPILLAR MODEL CB534B NSN 3895 01 396 2822 CATERPILLAR MODEL CB534C NSN 3895 01 502 4005 SUPERSEDURE NOTICE This manual supersedes TM 5 3895 379 10 dated 27 March 2000 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY JULY 2005 TM 5 3895 379 10 WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment Failure to observe these precautions could result in injury or death Also included are explanations of safety and hazardous materials icons used within the technical manual BIOLOGICAL abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health CHEMICAL drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue EAR PROTECTION Headphones over ears show that noise level will harm ears ELECTRICAL electrical wire to arm with electricity symbol running through human body shows that shock hazard is present EYE PROTECTION person with goggles shows that the material will injure the eyes FIRE flame shows that a material may ignite and cause burns FLYING PARTICLES arrows bouncing off f
86. TRAL position or engine is not running Roller is equipped with a manual brake release pump to release brakes a Chock drums WP 0005 00 b Liftlatch 7 push handle 8 toward front of roller 9 and open left side door assembly 10 c Unhook lanyard 11 from left side door assembly 10 and hook lanyard to frame assembly 12 INH ig TOOLBOX EU 9 401 079 0006 00 4 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY PROCEDURES CONTINUED CAUTION Spring force must be relieved in propel system multifunction valve pressure limiters to prevent propel sys tem damage NOTE Brakes are locked in absence of hydraulic oil pressure Manual brake release pump provides hydraulic oil pressure needed to release brakes d Remove 13 mm wrench 4 mm socket head screw key and 5 64 in socket head screw key Table 2 Items 4 11 and 12 WP 0027 00 from toolbox e Loosen nuts 13 and 14 using 13 mm wrench f Turn screws 15 and 16 clockwise CW using 4 mm socket head screw key until stop is reached to relieve spring force on propel system multifunction valve pressure limiters g Using 13 mm wrench tighten nuts 13 and 14 14 16 401 080 0006 00 5 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY PROCEDURES CONTINUED h Loosen setscrew 17 in knob 18 using 5 64 in socket head screw key
87. Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION PROPEL SYSTEM CONTINUED 3 Check hydraulic oil level 0018 00 30 Roller Will Not Move When Propel Control Lever is Operated Continued 4 Turn fuse holder counterclockwise and remove cap and fuse from fuse holder labeled BRAKE Inspect fuse for broken filament KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE CORRECTIVE ACTION a If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow go to Step 4 If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder If fuse filament is not broken fault not corrected Install fuse and cap in fuse holder and notify supervisor BROKEN FUSE 401 085 Check hydraulic oil level 0018 00 31 Propel System Engages Very Slowly When Making a Shift 32 Propel System Does Not Change Speeds When Propel Speed Switch Is Moved Turn fuse holder cap counterclockwise and remove cap and fuse from fuse holder labeled BRAKE Inspect fuse for broken filament 0010 00 36 FILAMENT a Ifhydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault not corrected Notify supervisor If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder If fuse filament is no
88. USUAL CONDITIONS 0006 00 GENERAL WARNING Operators must wear protective head gear Failure of operators to wear protective head gear may result in serious injury or death This work package contains instructions for safely operating the CB534B and CB534C Rollers Motorized Vibrating Tandem Steel Drums under unusual conditions In addition to normal preventive maintenance special care must be taken to keep roller operational in extreme temperatures and other environmental conditions SLAVE START ROLLER WARNING e When slave starting roller use NATO slave cable that DOES NOT have loose or missing insulation e DO NOT proceed with slave starting if correct slave cable is not available CAUTION e DO NOT allow live machine and dead roller to come in contact with each other during slave start ing Failure to follow this caution may cause electrical system damage Under no circumstances can the roller be started by being towed or pushed Failure to follow this cau tion will damage roller NOTE e If machine other than another roller is used to slave start machine refer to Operator s Manual for live machine for any special slave starting procedures e Slave start procedures the same for CB534B and CB534C Rollers CB534B Roller is shown e Slave starting is a two person task Start live machine with a good charging system and battery refer to machine Operator s Manual 2 Move live
89. Use caution when climbing on roller Maintain three point contact at all times and use rear steps and handrails Be aware that footing may be slippery Mount and dismount roller only where steps and hand rails are provided Failure to follow this warning may result in injury or death e Rollover Protection System ROPS canopy has 55 in 139 7 cm clearance above operator platform at lowest point Use care when mounting or dismounting roller to prevent injury to head e Ensure that left side door assembly and latch are securely closed before attempting to mount or dis mount operator platform Failure to follow this warning may cause injury 1 Mount Roller a Stand facing roller 1 b Using handrails 2 and steps 3 climb onto operator platform 4 2 Dismount Roller a Grasp handrails 2 and turn to face center of 2 roller 1 b Using handrails 2 and steps 3 climb off oper ator platform 4 to ground NO 401 039 0005 00 4 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE WARNING e Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of 85 DB or greater Hearing protection is required when operating roller or when working on roller while it is operating Failure to wear hearing protection may result in hearing loss There is no clearance for personnel between frame and yoke when roller turns Se
90. WATER SPRAY GAUGES STARTAID BRAKE BROKEN FUSE FILAMENT 401 085 0010 00 28 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 13 Starter Does Not Turn or Turns Slowly 1 Open left side door assembly If roller still has no electrical and press power close left side door alternator circuit breaker assembly WP 0005 00 and go to button Step 2 Turn fuse holder caps a If either fuse filament is counterclockwise and remove broken notify supervisor for caps and fuses from fuse replacement Install fuses and holders labeled KEY START caps in fuse holders and BRAKE Inspect fuses for broken filament If fuse filaments are not broken fault is not corrected Install fuses and caps in fuse holders and notify supervisor ALTERNATOR CIRCUIT BREAKER BUTTON 4 vj zg a ANS 04 P 401 091 BROKEN FUSE FILAMENT 14 Starter Turns But Does Not Crank Engine 1 Open left side door assembly If roller still has no electrical WP 0005 00 and press power fault is not corrected alternator circuit breaker Close left side door assembly button WP 0005 00 and go to Step 2 KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE BROKEN FUSE FILAMENT 0010 00 29 TM 5 3895 379 10 TROUBL
91. ace with face shield shows that particles flying through the air will harm face SZ 2 TM 5 3895 379 10 HEAVY PARTS heavy object on human figure shows that heavy parts present a danger to life or limb HOT AREA hand over object radiating heat shows that part is hot and can burn HYDRAULIC FLUID PRESSURE hydraulic fluid spraying human figure shows that fluid escap ing under great pressure can cause injury or death RADIOACTIVE identifies a material that emits radioactive energy and can injure human tissue or organs VAPOR human figure in a cloud shows that material vapors present a danger to life or health TM 5 3895 379 10 FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 WARNING CARBON MONOXIDE EXHAUST GASES CAN KILL Carbon monoxide is a colorless odorless deadly poison which when breathed deprives the body of oxygen and causes suffocation Exposure to air containing carbon monoxide produces symptoms of headache dizzi ness loss of muscular control apparent drowsiness and coma Permanent brain damage or death can result from severe exposure Carbon monoxide occurs in exhaust fumes of internal combustion engines Carbon monoxide can become dan gerously concentrated under conditions of inadequate ventilation The following precautions must be observed to ensure safety of personnel when engine of tractor is operated DO NOT operate roller engine in enclosed areas without adequate ventil
92. ainer 1 qt capacity Engine off Roller parked on level ground WP 0005 00 Drums chocked WP 0005 00 Left side door assembly opened CB534B 0005 00 e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Place portable fire extinguisher within reach prior to draining fuel water separator e Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked clothing e Fuel is very slippery If fuel is spilled clean fuel up immediately Before starting roller check that no fuel is spilled under machine 0016 00 1 TM 5 3895 379 10 FUEL WATER SEPARATOR SERVICE CONTINUED 0016 00 DRAIN NOTE Use container to catch any fuel or water that may drain from system Dispose of fuel IAW local policy and ordinances 1 Open valve 1 by turning counterclockwise and allow fluid to drain until only fuel drains from fuel water separator 2 2 Close valve 1 by turning clockwise nl Til AA 401 2190 3 Close left side door assembly WP 0005 00 4 Remove chocks WP 0005 00 END OF WORK PACKAGE 0016 00 2 TM 5 3895 379 10
93. air cleaner housing latches Reset air filter service indicator Close left mi door assembly WP 0005 100 AIR CLEANER SECONDARY AIR FILTER SERVICE INDICATOR HOUSING ELEMENT SERVICE N 9 ES SSS SY b KICK Se VIEWING SQ Qu 55555556 5 SS 55005505 3 RIOS gt 255555555955 55520555504 WINDOW y gt _ gt 55554 Y YI AIR CLEANER HOUSING LATCHES 0010 00 3 PRIMARY ELEMENT 5555554 S lt A AIR CLEANER 401 084 HOUSING COVER TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 1 Engine Cranks But Will Not Start or is Hard b If air cleaner primary element to Start Continued is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner secondary element is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged and fault is not corrected install filter elements and cover and close two air cleaner housing latches Close left side door assembly WP
94. all not operate roller for periods longer than 3 hours Operator may resume 3 hour period of roller operation after 1 hour of rest Operating roller for periods longer than 3 continual hours may cause injury to personnel from exposure to high whole body vibration levels WARNING PROTECTIVE HEAD GEAR Operators must wear protective head gear Failure of operators to wear protective head gear may result in serious injury or death WARNING OPERATION AND MAINTENANCE Do not operate or maintain this machine unless you have read and understand the instructions and warnings in the operation and maintenance sections of this manual Failure to follow the instructions or heed the warn ings could result in injury or death TM 5 3895 379 10 LIST OF EFFECTIVE PAGES WORK PACKAGES Date of issue for original manual is Original 15 July 2005 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 28 AND TOTAL NUMBER OF WORK PACKAGES IS 29 CONSISTING OF THE FOLLOWING Page WP Change No No Cover Back Blank atoh A B Blank i to iv WP 0001 00 to 0029 00 Index 1 to Index 4 DA Form 2028 Sample DA Form 2028 Metric Conversion Chart Back Cover O OC O Zero in this column indicates an original page or work package A B Blank TM 5 3895 379 10 TECHNICAL MANUAL HEADQUARTERS TM 5 3895 379 10 DEPARTMENT OF THE ARMY Washington D C 15 July 2005 OPERATOR S MANUAL FOR ROLLER MOTORIZED V
95. and supervisor b If alternator drive V belts are loose notify supervisor c If alternator V belts are not loose or broken go to Step 3 ACCESS ALTERNATOR V BELTS 401 087 0010 00 23 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 MALFUNCTION Table 1 Troubleshooting Procedures Continued TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 10 Engine Operating Temperature is Too High 3 Check for air flow restriction a If air flow through radiator is Warning Light and Warning Horn On in radiator restricted remove restriction Continued If unable to remove restrictions notify supervisor b If air flow through radiator is not restricted go to Step 4 WARNING DO NOT service cooling system unless engine has cooled This is a pressurized cooling system and escaping steam or hot coolant may cause burns DO NOT remove cooling system radiator cap when engine is hot Allow engine to cool down Loosen cap to first stop and let any pressure out of cooling system then remove cap Failure to follow this warning may cause burns Pull lever and open access a Ifradiator coolant level is low door Release lever Remove add coolant WP 0017 00 radiator cap and check for b If radiator coolant level is proper coolant level in radiator correct fault is not corrected WP 0017 00 Install radiator cap on radiator pull lever bac
96. ant high noise levels of 85 DB or greater Hearing protection is required when operating roller or when working on roller while it is operating Failure to wear hearing protection may result in hearing loss TM 5 3895 379 10 WARNING HEAVY PARTS Lifting equipment used for lifting machine must be in good condition and of suitable load capacity Failure to follow this warning may result in injury death or damage to roller Improper use of lifting equipment and improper attachment to roller can result in injury or equipment damage Observe all standard rules of safety Use caution when handling heavy parts Provide adequate support and use assistance during procedure Ensure that any lifting device used is in good condition and of suitable load capacity Keep clear of heavy parts sup ported only by lifting device Failure to follow this warning may cause injury or death WARNING ECHA 2 HOT COMPONENTS Hot oil or metal parts can cause burns Wear insulated gloves long sleeves and eye protection when working with heated parts m WARNING M NBC EXPOSURE If NBC exposure is suspected personnel wearing protective equipment must handle all air cleaner media Con sult your NBC Officer or NBC NCO for appropriate handling or disposal procedures NBC contaminated filters must be handled using adequate precautions FM 21 40 and must be disposed of by trained personnel IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WI
97. arator Primary Hydraulic Oil Level Cold Oil Check Rear Water Tank Work Lights PADLOCK PROCEDURE e Close left side door assembly 0005 00 NOTE NOT FULLY MISSION CAPABLE IF Hydraulic oil is checked cold and warm Roller must be on level surface to have accurate level reading Check that hydraulic oil level is between the high and low marks on the label beside the hydraulic oil tank sight gauge If level is below LOW level mark fill hydraulic tank with hydrau lic oil WP 0019 00 Check level of water as indicated in water level gauge Ensure tank is full before operating roller WP 0024 00 Check rear work lights for broken lenses HYDRAULIC OIL TANK FILL CAP LABEL 401 024 0012 00 4 HYDRAULIC OIL TANK SIGHT GAUGE TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF Work Lights RIGHT SIDE DOOR ASSEMBLY 401 021 RADIATOR Before Engine Right a Open right side door assembly Side 0005 00 b Check front of engine for accumu Excessive accumulation of lated grease oil grease oil is found Before Radiator Check radiator for damage signs of Class III coolant leaks are leakage and debri
98. areas Keep away from open flames and other sources of ignition e Particles blown by compressed air are hazardous DO NOT exceed 15 psi 103 kPa nozzle pressure when drying parts with compressed air Use a maximum of 30 psi 207 kPa when cleaning compo nents DO NOT direct compressed air against human skin Failure to follow this warning may result in injury or death Make sure air stream is directed away from user and other personnel in the area To pre vent injury user must wear protective goggles or face shield 20 Clean sediment bowl 7 and screen 8 with solvent cleaning compound 21 Wipe strainer assembly 10 clean with rag If any component is damaged notify supervisor to obtain replacement 22 Install new O ring 8 screen 9 and sediment bowl 7 on strainer assembly 10 401 115 0024 00 7 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CONTINUED 23 Insert cap assembly 3 in nipple 4 and turn tee han 4 3 TEE HANDLE dle clockwise until cap assembly is tightly sealed inside nipple 401 118 24 Turn drain cock 5 on line 6 clockwise to close drain cock 5 6 401 114 0024 00 8 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 FILL WATER TANK Remove lid 22 and strainer 23 from water tank 2 Remove any debris from water strainer 23 Install strainer 23 in water tank
99. asses of leakage you need to know to be able to determine the status of the roller Learn and be familiar with them and remember when in doubt notify supervisor CAUTION Operation is allowable with Class I and Class leakage EXCEPT for fuel where NO leaks are allowed WHEN IN DOUBT NOTIFY SUPERVISOR When operating with Class I or Class II leaks check fluid levels more frequently Class III leaks must be reported immediately to supervisor Failure to do this will result in damage to roller and or components 0011 00 2 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED NOTE Notify supervisor of any leaks you cannot fix Leakage Definitions for PMCS Class I Leakage indicated by wetness or discoloration but not great enough to form drops Class Leakage great enough to form drops but not enough to cause drops to drip from the item being checked inspected Class III Leakage great enough to form drops that fall from the item being checked inspected GENERAL LUBRICATION PROCEDURES NOTE Lubrication instructions contained in this PMCS are MANDATORY Overall view of lubrication points is located in the Lubrication Chart at the end of this work package Localized views are located following the Lubrication Chart Specific lubrication instructions are contained in the PMCS Table in WP 0012 00 The roller is enro
100. ation DO NOT idle roller engine without adequate ventilation DO NOT drive roller with inspection plates or cover plates removed Pe Ia ES BE ALERT for exhaust poisoning symptoms They are Headache Dizziness Sleepiness Loss of muscular control 5 If you see another person with exhaust poisoning symptoms Remove person from area Expose to fresh air Keep person warm Do not permit physical exercise Administer cardiopulmonary resuscitation CPR if necessary Notify a medic 6 BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from car bon monoxide poisoning The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation TM 5 3895 379 10 WARNING ARTICULATION AREA HAZARDS 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 injury or death from crushing Unlock steering frame before operation to prevent loss of steering that may cause injury or death J gt WARNING BATTERIES To avoid injury eye protection and acid resistant gloves must be worn when working around batteries Do not smoke use open flame make sparks or create other ignition sources around batteries If a battery is giving off gases it can ex
101. ation of columns found in the tabular listings 1 Column 1 Illustration Number Illus Number This column indicates the number of the illustration that shows the item 2 Column 2 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes 3 Column 3 Description CAGEC and Part Number Indicates the Federal item name in all capital letters and if required a minimum description in parentheses to identify and locate the item The entry for each item ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number 4 Column 4 Usable on Code Indicates a code if the item needed is not the same for different models of equipment Usable on Codes for the roller are Usable On Code Used On VRP CB534B Roller SWR CB534C Roller 5 Column 5 Unit of Measure Indicates how the item is issued for the National Stock Number shown in Column 2 6 Column 6 Quantity Required Qty Rqd Indicates the quantity of the item required 0027 00 1 TM 5 3895 379 10 O 401 122 Table 1 Components of End Item List 2 3 4 NATIONAL DESCRIPTION CAGEC USABLE STOCK NUMBER AND PART NUMBER ON CODE 5340 01 181 2579 PADLOCK 11083 5P 8502 5340 01 257 6042 KEY 11083 5 8500 5930 00 7 15 1939 KEY SWITCH 13445 8398 10 11 1 401 123 0027 00 2 TM 5 3895 379
102. ator cap 3 on radiator 4 by turning cap to full right 6 Pull lever 1 and close access door 2 7 Release lever to lock access door in position 8 Close right side door assembly WP 0005 00 9 Remove chocks WP 0005 00 END OF WORK PACKAGE 0017 00 2 TM 5 3895 379 10 HYDRAULIC OIL LEVEL CHECK AND SERVICE 0018 00 THIS WORK PACKAGE COVERS Check Hydraulic Oil Level Fill Hydraulic Oil Tank INITIAL SETUP Materials Parts Equipment Condition Oil lubricating Item 10 or 13 WP 0029 00 Engine off WP 0005 00 Rag wiping Item 16 WP 0029 00 Roller parked on level ground WP 0005 00 References Drums chocked WP 0005 00 WP 0011 00 Operator Preventive Maintenance Checks and Services PMCS Introduction CHECK HYDRAULIC OIL LEVEL 1 Observe hydraulic oil level indicator 1 NOTE Oil level shall be maintained between FULL and ADD lines on decal located beside hydraulic oil level indicator 2 Add hydraulic oil as necessary Refer to Fill Hydraulic Oil Tank in this work package 0018 00 1 TM 5 3895 379 10 HYDRAULIC OIL LEVEL CHECK AND SERVICE CONTINUED 0018 00 FILL HYDRAULIC OIL TANK WARNING e DO NOT remove hydraulic oil cap assembly when hydraulic system is hot Allow hydraulic oil to cool Loosen slowly and let any pressure out of hydraulic system then remove cap Failure to follow this warning may cause burns e Oil is very slippery Immediately wipe up any spi
103. atory bearing reservoir oil is at correct level fault is not corrected Notify supervisor If hydraulic oil level is low fill hydraulic oil tank WP 0018 00 b If hydraulic oillevelis notlow fault is not corrected Notify supervisor If fuse filament is broken notify supervisor for replacement Install fuse and cap in fuse holder TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION VIBRATORY SYSTEM CONTINUED 35 Vibratory System Will Not Forward and Reverse Travel Continued b If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor KEY START BACKUP ALARM WATER SPRAY GAUGES STARTAID BRAKE BROKEN FUSE CB534B ONLY FILAMENT 401 085 Place drum select switch is in center both drums position 36 Vibration Occurs in Only One Drum If fault is not corrected notify supervisor WATER SPRAY SYSTEM 37 Spray Does Not Occur On Either Drum When Water Spray Switch is in Continuous Spray Position 1 Check water level gauges for a If water level is low add water WP 0024 00 water in water tanks Indicator needle pointing full left indicates tank is empty If water level is not low go to Step 2 On CB534B check that the water tank shutoff valve at each tank is open Valve handle will
104. ayed fabric breaks caused by sharp kinks or chafing against other parts of the unit Inspect metal tubing lines for kinks Inspect fitting threads for damage Replace any defective parts Check for leaks after assembly and during initial operation period Visually inspect all castings and weldments for cracks Inspect all wiring for chafed or burned insulation Inspect all terminal connectors for loose connections and broken parts CLEANING PROCEDURES 1 2 For exterior cleaning of frame and structural components use detergent Hem 5 WP 0009 00 in a solution as recom mended on the container Leave application on surface for approximately 10 minutes before rinsing Rinse with hot or cold water under pressure If available use hot water under 80 120 Ib 551 827 kPa pressure An ordinary garden hose may be used if no other equipment is available If pressurized water supply is not available wash painted surfaces with a solution of 1 4 cup soap Item 17 WP 0029 00 to one gallon of water gt ES E WARNING y Cleaning compound solvent MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ven tilated areas Keep away from open flames and other sources of ignition NOTE Do not use dielectric grease on electrical connectors Electrical parts such as coils connectors switches and insulating wirin
105. bleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 2 Engine Starts But Will Not Keep Running b If air cleaner primary element Continued is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner secondary element is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements not clogged and fault is not corrected install filter elements and cover and close two air cleaner housing latches Close left side door assembly WP 0005 00 Notify supervisor AIR CLEANER SECONDARY MR ELEMENT SERVICE WHEN SERVICE HE PRIMARY gt ELEMENT 4 MI VIEWING SAT WINDOW A AIR CLEANER AIR CLEANER HOUSING LATCHES HOUSING COVER ion 0010 00 9 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 3 Engine is Sluggish 1 Check fuel level reading on a If fuel level gau
106. ch to for ward front drum center both and rear rear drum Move vibration control switch to manual MAN mode g Press vibration push switch to turn on the vibration system vibratory system indicator light should illumi nate 0012 00 14 can be experienced which b Move roller forward WP 0005 00 Vibratory system has not activated when roller travel is close to full speed Vibratory system does not operate in both high and low pitch modes Vibratory system does not operate in front both and rear drums Vibratory system does not activate TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before LOCATION ITEM TO CHECK SERVICE Vibration System Propel Speed Range Switch Water Spray System PROCEDURE a Move propel speed range switch to low tortoise and the high hare positions b Press vibration push switch to turn off the vibration system and stop roller WP 0004 00 Move water spray switch to intermit tent forward position for 60 seconds and then to continuous back position for 10 seconds 0012 00 15 NOT FULLY MISSION CAPABLE IF WATER SPRAY SWITCH 401 030 Propel system does not oper ate or change to low tor toise and high hare propel mode as sw
107. ck we ES 3 Numberiof Screens 2 4 4 2 2 2 2 2 2 WE EV alee ie PER RP aa ee 2 END OF WORK PACKAGE 0002 00 5 0002 00 6 Blank TM 5 3895 379 10 THEORY OF OPERATION 0003 00 INTRODUCTION 1 This work package explains how components of the Roller Motorized Vibrating Tandem Steel Drums work together A functional description is given for the electrical system propel system steering system vibratory system and water spray system 2 Theory of Operation is the same for the CB534B and CB534C Rollers CB534B Roller is shown BASIC OPERATION 1 The roller is designed to compact asphalt and gravel bases for constructing parking lots roads landing strips and other asphalt paved areas 2 The roller is controlled by a single operator 3 The roller operates in vibratory mode using twin vibrating drums as the means for compacting surface material 4 The roller operates in static mode in order to smooth surface material 5 An on board water spray system is provided to prevent hot asphalt from sticking to the drum surfaces ELECTRICAL SYSTEM 1 The electrical system operates on 24 volts negative ground It is powered by two 12 volt batteries connected in series to produce 24 volts The electricity stored in the batteries is used to start the engine and separate accessories When started the engine drives an alternator that produces electricity to both maintain battery voltage and power electrical compo nents on
108. ctor plus tips Refer to the appropriate warranty statement for coverage details This warranty does not apply to Caterpillar brand batteries which are covered by a differ ent Caterpillar warranty 0001 00 1 TM 5 3895 379 10 GENERAL INFORMATION CONTINUED 0001 00 WARRANTY INFORMATION CONTINUED 3 The warranty is subject to the following a Warranty Period 1 For the CB534B Roller the warranty period is 6 months starting from date of delivery to the first user 2 For the CB534C Roller the warranty period is 12 months starting from the date of delivery to the first user Caterpillar Responsibilities If a defect in material or workmanship is found during the warranty period Caterpil lar will during normal working hours and at a place of business of a Caterpillar or other authorized source 1 Provide at Caterpillar s expense new Major Component Exchange MCE Remanufactured or Caterpil lar approved repaired parts or assembled components needed to correct the defect NOTE Items replaced under this warranty become the property of Caterpillar 2 Replace lubricating oil filters antifreeze and other service items made unusable by the defect 3 Provide labor needed to correct the defect except in the case of a new replacement engine originally installed by other than a Caterpillar dealer or other authorized source In that case labor is limited to repair only and removal and installation is the user
109. culation 0006 00 11 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN SANDY OR DUSTY CONDITIONS CONTINUED 4 Check and drain fuel water separatof WP 0016 00 5 Closely monitor all gauges and warning lights to ensure machine is not affected by dusty conditions 6 Park roller in sheltered area out of wind If a sheltered area is not available park roller facing into wind to prevent sand or dust from blowing into radiator 7 Cover instrument panel with vandal guard down air restriction indicator hydraulic oil level indicator fuel tank fill cap hydraulic oil tank fill cap and work lights when machine is parked for extended periods of time in extremely dusty conditions 8 Cover exhaust outlet to prevent dust from blowing into exhaust system 9 Cover open space in fuel tank fill hole when adding fuel to fuel tank 10 Clean spouts of fuel containers and areas around filler caps on fuel tank before adding fuel Under extremely sandy or dusty conditions filter fuel when filling tank 11 Ensure engine and transmission oil filler tubes are cleaned before gage rods are removed to check fluid levels Clean accumulations of sand and dirt from around any fluid filler location before checking or adding fluids FORDING CAUTION DO NOT enter water deeper than 10 in 25 cm Fording in water depth greater than 10 in 25 cm can cause damage to equipment 1 Test depth of water and ensure firmne
110. d cover and close two air filter housing latches Close left side door assembly WP 0005 00 and notify supervisor 4 Engine Exhaust Smokes Excessively Too ge If air cleaner primary element Much Black or Gray Smoke 1 Open left side door assembly WP 0005 00 and check air filter service indicator for red indication in viewing window Red indicates a clogged air cleaner primary or secondary is clogged clean by tapping element with hand to remove dirt Install secondary and primary filter elements and cover and close two air cleaner element If filter service s indicator shows red in viewing housing latches Reset air filter window unlatch two air service indicator Close left cleaner housing latches and side door assembly WP 0005 remove cover Remove 00 primary and secondary elements for air cleaner housing b If air cleaner primary element 0010 00 14 is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air service indicator Close left side door assembly WP 0005 00 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 4 Engine Exhaust Smokes Excessively Too c If air cleaner secondary Much Black or Gray Smoke Continued eleme
111. d in publication FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TOTAL NO PAGE COLM NATIONAL STOCK REFERENCE FIGURE OF MAJOR NO NO NUMBER NO NO ITEMS SUPPORTED RECOMMENDED ACTION PART IIl REMARK ks S Or SUI fi ment of publications and Nal s be M wi TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 Use Part II reverse for Repair Parts and RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists RPSTL and Supply BLANK FORMS Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s M anual for Roller M otorized 379 1 Vibrating Tandem Steel Drums M odels me en CB534B and CB534C ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION DA FORM 2028 FEB 74 REPLACES DA FORM 2028 1 DEC 68 WHICH WILL BE USED APD V4 00 TO Forward direct t
112. d work packages in the publication a Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses for the submittal of corrections to this manual b If you cannot find what you are looking for in the Zable of Contents refer to the alphabetical Index at the back of the manual 3 Introductory Information with Theory of Operation provides general information on the manual and the roller 4 Operating Instructions explains and illustrates all operator s controls and indicators and contains a Stowage and Decal Data Plate and Stencil Guide It also describes how to perform all operating procedures for the roller Opera tion Under Usual Conditions and Operation Under Unusual Conditions overs all Operator Troubleshooting WP 0009 O0 contains a Troubleshooting Symptom Index If the roller mal functions this index should always be consulted to locate the appropriate troubleshooting procedure 6 Chapter 4 deals with Operator Maintenance Instructions Major areas covered are Preventive Maintenance Checks and Services PMCS and operator level maintenance tasks includes Supporting Information References Components of End COEI and Basic Issue Items Lists Additional Authorization List AAL and Expendable and Durable Items List TM 5 3895 379 10 FEATURES OF THIS MANUAL 1 WARNINGs CAUTIONS NOTEs subject headings and other importan
113. dem Steel Drums GENERAL This list identifies items that do not have to accompany the roller and that do not have to be turned in with it These items are authorized to you by CTA MTOE TDA or JTA EXPLANATION OF COLUMNS 1 Column 1 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes 2 Column 2 Description CAGEC and Part Number Indicates the Federal item name in all capital letters followed by a minimum description when needed The entry for each item ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number 3 Column 3 Usable on Code Indicates a code if the item needed is not the same for different models of equipment Usable on Codes for the roller are Usable On Code Used On VRP CB534B Roller SWR CB534C Roller 4 Column 4 Unit of Measure Indicates how the item is issued for the National Stock Number shown in Column 1 5 Column 5 Qty Auth Indicates the quantity authorized Table 1 Additional Authorization List 1 2 3 NATIONAL DESCRIPTION CAGEC USABLE ON STOCK NUMBER AND PART NUMBER CODE 4210 00 889 2221 Extinguisher Fire 16236 CS4210 0008CEFN END OF WORK PACKAGE 0028 00 1 0028 00 2 Blank TM 5 3895 379 10 EXPENDABLE AND DURABLE ITEMS LIST 0029 00 SCOPE This work package lists expendable and durable items you w
114. e 3 Oil level should fill half of viewing area of oil level gauge OY Wi che uas CEXS ue Fill vibratory bearing reservoir when required Refer to Fill in this work package 401 106 0020 00 1 TM 5 3895 379 10 VIBRATORY BEARING RESERVOIR CHECK AND SERVICE CONTINUED 0020 00 FILL 1 Remove 1 2 in drive ratchet from toolbox WARNING Oil is very slippery Immediately wipe up any spills Failure to follow this warning may cause injury NOTE Use a container to catch any oil that may drain from system Dispose of oil IAW local policy and ordinances Remove plug 4 from vibratory reservoir 5 using 1 2 in drive ratchet Add WP 0011 00 Clean plug 4 and area around plug opening Inspect threads plug 4 for crossed or peeled condition NOTE Notify Field Maintenance for replacement of damaged plug 6 Install plug 4 in vibratory reservoir 5 using 1 2 in drive ratchet Tighten plug securely 7 Stow 1 2 in drive ratchet in toolbox 401 2179 END OF WORK PACKAGE 0020 00 2 TM 5 3895 379 10 FRONT AND REAR PROPEL GEARBOX OIL CHECK AND SERVICE CB534B 0021 00 THIS WORK PACKAGE COVERS Oil Level Check Cleaning and Inspection Fill INITIAL SETUP Tools and Special Tools Materials Parts Handle socket wrench Item 7 WP 0027 00 Oil lubricating gear Item 11 and 12 WP 0029 00 Extension Item 8 WP 0027 00 Rag wiping Item 16 WP 0029 00 Adapt
115. e If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 b Hazardous Waste Disposal Ensure all spills are cleaned up and disposed of IAW local policy and ordinances c Rust and Corrosion Check metal parts for rust and corrosion If any bare metal or corrosion exists clean and apply a light coat of lubricating oil Item 13 WP 0029 00 Report it to supervisor d Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one is loose notify supervisor e Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to supervisor f Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Reconnect loose connectors Ensure that wires are in good condition g Hoses and Fluid Lines Look for wear damage and signs of leaks Check for loose clamps and fittings Wet spots indicate leaks but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fitting or connector notify supervisor If something is broken or worn out report it to supervisor h Fluid Leakage It is necessary for you to know how fluid leakage affects the status of the roller The following are definitions of the types cl
116. e a eee oe ee hee ek US 0 71 in 18 mm Curb Clearance ii oL Ee Me ee Swe t ee ka 16 in 406 mm Side Clearance ois er xen RS einge edes cbe bora ote neh 3 in 76 mm Wheelb se iA 2 2 Bann t E een kat 124 in 3150 mm Steering Angle Left Right ci ni RR Bh ee hE EN I BAERT NA 35 Minimum Turning Angle Inside Drum Edge s eed ae bh old oak Gls os 164 in 4166 mm Outside Drum Edge c hs RAGS v t 231 in 5867 mm Weight at Front eese recta eer een ans he e cede al de t te se 10330 Ib 4686 kg WeightatRearDfum cubo ee ee ee ie nn 11530 Ib 5230 kg Refill Capacities Engine Oll es E US elle debuts 2 3 gal 9 1 Fuel Tank 5 282 20 a ceps inate 55 gal 208 1 Hydraulic Tank EBIIABD ui 8er rr SEE Ee ERE REA 15 5 gal 59 1 Hydraulic Tank CB534C ici a Be ce es 24 gal 91 1 Front and Rear Vibratory Bearing 3 1 gal 12 1 Water Tanki ci otn ES RICE RECIPERE ESI 132 gal 500 1 each Cooling System nep ERU dete UR pex GRECE e OR EI EROR ERY eue 7 3 gal 28 D Front Propel Gearbox i sse Edu eg eee E EE RR 0 5 gal 21 Rear Propel Gearbox ea SSI SRA ag 0 6 gal 2 4 1 Power Train Engine ae ne d e d le be OR RASEN ak pons Caterpillar 3045T Turbocharged Four cylinder diesel HOtSepO WEE d ss re en matte eds bU reti eb bs 107 hp 8
117. e ee REG eb Apes 0010 00 42 END OF WORK PACKAGE 0009 00 2 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES 0010 00 Table 1 Troubleshooting Procedures MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE 1 Engine Cranks But Will Not Start or is Hard 1 Check fuel level reading on a If fuel level gauge reads to Start fuel level gauge empty fill fuel tank with fuel WP 0015 00 b If fuel level gauge indicates fuel in tank go to Step 2 FUEL LEVEL GAUGE II 48 CB534B SHOWN 401 030 0010 00 1 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 1 Engine Cranks But Will Not Start or is Hard to Start Continued WARNING DO NOT perform fuel system checks inspections or main tenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth ing NOTE Use a container to catch any fuel that may drain from sys tem Dispose of fuel IAW local policy and ordinances Ensure that all spills are cleaned up 2 Remove padlock fuel cap a If fuel tank is empty fuel level assembly and strainer and gauge does not operate Install visually inspect tank for
118. e in 90 degree rotation Size and space requirements of the operator will determine if adjustment of handrails is needed Refer td WP 0022 00 when handrail adjustment is required 0005 00 1 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 INITIAL ADJUSTMENTS AND DAILY CHECKS CONTINUED 4 Adjust Seat TOR Lock seat in position before operating roller to prevent unexpected seat movement Failure to follow this WARNING warning may cause injury NOTE Adjust seat at the beginning of each shift or when changing operators Adjust seat until all controls can be comfortably reached when operator s back is against seat Sit on seat 5 facing forward with your back against seat Move and hold fore aft lever 6 to left away from seat 5 Slide seat 5 forward or backward to a position where all operator station controls can be comfortably reached Release fore aft lever 6 to lock seat in position Rock back and forth to ensure seat is locked into position Turn knob 7 until indicator 8 is flush with tube 9 Lift lever 10 and adjust seat height to a position where all operator station controls can be comfortably reached Release lever 10 A d 24 5 AD il 401 036 0005 00 2 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 INITIAL ADJUSTMENTS AND DAILY CHECKS CONTINUED 5 6 Operate Seat Belt Use of
119. e items 2 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 3 corrosion problem is identified it can be reported using SF Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 3 WARRANTY INFORMATION 1 Caterpillar warrants the following products sold by it and operating within the area specified under Limitations to be free from defects in material and workmanship a New earthmoving construction materials handling and paving product machines designated by Caterpillar as hav ing a 6 month unlimited hour warranty See your Caterpillar dealer for a complete listing of covered models b New engines used as replacements in such Caterpillar machines c Attachments installed on such machines prior to delivery 2 An additional warranty against breakage is applicable to certain Caterpillar Ground Engaging Tools An additional war ranty against wear is also applicable to certain weld on landfill compa
120. e located on the left side of the rear drum and the right side of the front drum Scrapers The scrapers keep drums clean to provide a smooth compacted surface Engine Compartment The engine and hydraulic pumps are located in this compartment The engine and pumps power the steering propel and vibratory systems 0002 00 2 TM 5 3895 379 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED COMPONENT DESCRIPTION Drums The drums provide a smooth surface for surface material compaction Propel Motors The propel motors provide power to the drums to move the roller They are located on the right side of the rear drum and the left side of the front drum Yoke Assembly The yoke assembly provides support for the front drum and pivots on the frame assembly for steering Work Lights The work lights provide light for use in poor visibility situations They are located at front and rear of roller Water Tanks The water tanks hold water for delivery to the drums via the water spray nozzles on the spray bars A water tank is mounted above each drum Toolbox The toolbox holds the tools the operator needs to do all authorized maintenance Operator Station The pivoting console may be moved 90 degrees to the left or right to increase visibility The gauges and controls move with the console for easy operation DIFFERENCES BETWEEN MODELS CB534B CB5
121. e nozzles of the other water spray system in the event of failure of one of the pumps NOZZLES WATER TANK SPRAY BAR DRAIN VALVE TIE LINE STRAINER VALVE DRAIN VALVE PUMP Een CB534B END OF WORK PACKAGE 0003 00 5 0003 00 6 Blank TM 5 3895 379 10 CHAPTER 2 OPERATING INSTRUCTIONS TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS 0004 00 GENERAL 1 Before operating the CB534B or CB534C Roller Motorized Vibrating Tandem Steel Drums read and become familiar with the location and function of all operator controls and indicators as described in this work package 2 CBS34B Roller is shown unless otherwise indicated 0004 00 1 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS ON POSITION OFF START POSITION POSITION THIS SYMBOL DOES NOT APPLY TO ENGINE START SWITCH ON MILITARY MODEL STEERING WHEEL NOT SHOWN FOR CLARITY CONTROL OR INDICATOR FUNCTION Vibration Per Minute VPM Tachometer Indicates vibrations per minute frequency of drum vibration Gauge reading indicates the VPM of weight shafts of drum s selected by the position of the vibratory mode control switch Vibratory System Indicator When illuminated indicates the vibration push switch is in the ON position Turn Signal Indicator Not used Lights Indicator When illuminated ind
122. eads fuel level gauge empty fill fuel tank with fuel WP 0015 00 b If fuel level gauge indicates fuel in tank go to Step 2 FUEL LEVEL GAUGE CB534B SHOWN 401 030 0010 00 6 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 2 Engine Starts But Will Not Keep Running Continued WARNING DO NOT perform fuel system checks inspections or main tenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth ing NOTE Use a container to catch any fuel that may drain from sys tem Dispose of fuel IAW local policy and ordinances Ensure that all spills are cleaned up Remove padlock fuel cap a If fuel cap assembly vent is assembly and strainer and restricted remove restriction visually inspect vent for damage or restriction If fuel cap assembly or vent is damaged notify supervisor If fuel cap assembly is not damaged or restricted go to Step 3 STRAINER FUEL CAP ASSEMBLY FUEL TANK 401 083 0010 00 7 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION C
123. ebris or biological growth and prevents damage to the system in the event of freezing temperatures b Drain water tanks WP 0024 00 at the end of each work day 401 046 OPERATE VIBRATORY SYSTEM WARNING Do not operate roller for periods longer than 3 hours Operator may resume 3 hour period of roller operation after 1 hour of rest Operating roller for periods longer than 3 continual hours may cause injury to personnel from exposure to high whole body vibration levels NOTE Operation of vibratory system is the same for CB534B and CB534C Rollers CB534B Roller is shown 1 Select Front or Rear Drum a Move drum select switch 1 to activate vibratory system to front drum b Move drum select switch 1 to center position to activate vibratory system to both drums c Move drum select switch 1 to rear to activate vibratory system to rear drum 0005 00 14 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE VIBRATORY SYSTEM CONTINUED 2 Select Manual or Automatic Mode NOTE In automatic mode vibratory system acti vates automatically when propel control lever is moved to forward or reverse posi tion The speed needed to activate vibra tory system can be adjusted by Field Maintenance Move the vibratory control switch 2 forward to activate the vibratory system in the automatic mode NOTE When the vibration control switch is in the rear position the vibratory s
124. ed not faster than 1 2 mph 2 km h to a convenient location for repair or transport These instructions are for emergencies only Always transport roller when a long distance move is required e The roller can be towed a short distance or can be pulled from the mud while the engine is running if the power train and steering system are working The operator on towed roller must steer in direction of tow e CB534B Roller weighs 21 232 Ib 9631 kg CB534C Roller weighs 21 832 Ib 9903 kg Attach tow bar with a minimum capacity of 21 232 Ib 9631 kg to CB534B Roller Attach tow bar with a minimum capacity of 21 832 Ib 9903 kg to CB534C Roller 0005 00 21 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 TOWING INSTRUCTIONS CONTINUED If the engine is not running manually release parking brakq WP 0006 00 1 2 Refer to FM 9 43 2 and attach tow bar to roller at tiedown points 3 Attach tow bar to towing vehicle 4 Refer to FM 9 43 2 and slowly tow the disabled roller PREPARATION FOR TRANSPORT NOTE e Preparation for transport procedures are the same for CB534B and CB534C Rollers CB534B Roller is shown e Obey all state and local laws governing characteristics of a load height weight width and length Observe all regulations governing wide loads Ensure that cooling system has proper antifreeze mix if transporting roller to a colder climate 1 General Transport Instructions a In
125. emove 3 4 in socket from ratchet and stow both tools in toolbox 8 Remove chocks WP 0005 00 401 111 END OF WORK PACKAGE 0023 00 2 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE 0024 00 THIS WORK PACKAGE COVERS Check Water Level Drain and Flush Water Spray System Fill Water Tank INITIAL SETUP Materials Parts Equipment Condition Cleaning compound solvent Item 3 WP 0029 00 Engine off WP 0005 00 Rag wiping Item 16 WP 0029 00 Roller parked on level ground WP 0005 00 Drums chocked WP 0005 00 NOTE e Water spray system is checked and serviced in a similar way for CB534B and CB534C Rollers CB534B Roller is shown Differences in the CB534C Roller will be pointed out as they occur e water spray system consists of two identical but separate systems located at each end of the roller Each system has seven nozzles on a spray bar e This work package covers checking and servicing the front water spray system The rear water spray system is checked and serviced the same way CHECK WATER LEVEL Check water level gauge 1 located on water tank 2 Fill if necessary 401 112 0024 00 1 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CAUTION Water spray system must be drained at the end of each work day and filled at the beginning of the next work day Draining ensures the removal of debris or biolo
126. ents WP 0011 00jand WP 0012 00 3 Check with proper officials to obtain required licenses 4 Install any required flags signals and lights 5 Travel at moderate speed and observe all roller speed limitations 6 If traveling a long distance stop roller after 30 minutes to allow roller to cool down TOWING INSTRUCTIONS WARNING e Before towing ensure tow bar is in good working condition Use of a weak tow bar could result in injury or death e Incorrectly towing a roller may cause injury or death e Do not allow an operator on roller unless engine is running and the operator can control steering and or braking Uncontrolled roller may cause injury or death e Do not use a chain or cable for pulling A chain or cable link can break causing injury e towing vehicle should be as large or larger than the roller Any vehicle used to tow the roller shall have enough brake capacity weight and power to control both vehicles for the grade and distance involved e To provide sufficient control and braking when moving a disabled roller downhill a larger towing vehi cle or additional vehicles connected to the rear of the towed roller is required Turning on a slope will reduce the stability of both the towing vehicle and the towed roller and could result in a tip over accident NOTE When towing attach tow bar to tiedown points NOTE e Towing instructions are for moving a disabled roller a short distance at a low spe
127. er Item 9 WP 0027 00 Equipment Condition Screwdriver attachment socket wrench Item 10 WP 0027 00 Engine on WP 0005 00 Container 1 qt capacity Roller parked on level ground WP 0005 00 NOTE e roller propel system consists of two similar propel systems located at each end of the roller Propel gearbox oil level plugs are located on right side of front drum and left side of rear drum e This work package covers checking and servicing of one propel gearbox Both propel gearboxes are checked and serviced in the same way 0021 00 1 TM 5 3895 379 10 FRONT AND REAR PROPEL GEARBOX OIL CHECK AND SERVICE CB534B CONTINUED 0021 00 OIL LEVEL CHECK 1 Move roller until level check plug 1 is located at 12 o clock position and fill plug 2 is located at 3 o clock position 2 Turn engine WP 0005 00 3 Remove 1 2 in drive ratchet 6 in extension adapter and 5 16 in hex bit from toolbox n pu Es 4 Attach 1 2 in drive ratchet adapter and 5 16 in hex bit to 6 in extension 5 Remove oil level check plug 1 at 12 o clock posi tion from gearbox 3 through access hole Start engine WP 0005 00 Move roller to position opening for oil level check plug 1 at 9 o clock position 8 Turn off engine WP 0005 00 9 Maintain oil level to bottom of level check plug 1 opening 10 Tf oil level is low skip steps 10 through 15 and go to Cleaning and Inspection in
128. er close fuel supply valves 1 On CB534C Roller close fuel supply valves 2 Place container under drain valve 3 Open drain valve 3 on bottom of filter element 4 and drain fuel into container For the CB534B Roller open fuel supply valves 1 For CB534C Roller open fuel supply valves 2 RA 0015 00 2 TM 5 3895 379 10 FUEL LEVEL CHECK AND SERVICE CONTINUED 0015 00 DRAIN FUEL FILTER CONTINUED 401 2230 0015 00 3 TM 5 3895 379 10 FUEL LEVEL CHECK AND SERVICE CONTINUED 0015 00 FILL FUEL TANK Remove padlock 2 from fuel cap assembly 3 Remove fuel cap assembly 3 from fuel tank 4 by turning cap counterclockwise until free from tank Inspect strainer 5 for debris If debris is found remove strainer 5 from fuel tank 4 and remove debris A A ip If removed install strainer 5 in fuel tank 4 NOTE Fuel tank capacity is 55 gal 208 1 6 Fill tank 4 with diesel or JP 8 fuel only 7 Immediately after filling install fuel cap assembly 3 on fuel tank 4 by turning fuel assembly clockwise 8 Install padlock 2 on fuel cap assembly 3 one eye left of lock stop nn Ld fa LOCK STOP 401 099 9 Remove chocks WP 0005 00 END OF WORK PACKAGE 0015 00 4 TM 5 3895 379 10 FUEL WATER SEPARATOR SERVICE 0016 00 THIS WORK PACKAGE COVERS Drain INITIAL SETUP Materials Parts Equipment Condition Cont
129. er switch 28 until engine runs smoothly m Move throttle control switch 27 to SLOW posi tion after engine starts 0006 00 10 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME HEAT 10 CAUTION e Operating during periods of extreme heat ambient temperatures above 100 F 38 C can cause engine and hydraulic systems to overheat Engine temperatures above 230 F 110 C and hydraulic oil temperatures above 250 F 121 C can cause damage to engine and hydraulic system components Check engine coolant temperature warning light and hydraulic oil temperature warning light often during periods of extreme heat to prevent damage to engine and hydraulic system e Gaskets seals are more likely to leak when engine and hydraulic system operating temperatures high Check engine and hydraulic oil levels more often during periods of extreme heat to prevent dam age to engine and hydraulic system components Check for leaks around gaskets seals and fittings more often Check engine oil level WP 0014 00 monitor engine coolant temperature warning light Check hydraulic oil level WP 0018 00 Jand monitor hydraulic oil temperature warning light Check cooling system often a If engine coolant temperature or hydraulic oil temperature warning lights illuminate stop roller and allow engine to run at idle for a few minutes to cool down b When warning lights have gone
130. erator troubleshooting and maintenance on the CB534B and CB534C Rollers Motorized Vibrating Tandem Steel Drums 2 Equipment Name and Model Number Roller Motorized Vibrating Tandem Steel Drums Caterpillar Models CB534B and CB534C 3 Purpose of Equipment The CB534B and CB534C Rollers are self propelled and designed to compact asphalt and gravel bases for parking lots streets roads and highways MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for roller maintenance will be those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System TAMMS as contained in the Maintenance Management Update REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRs 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 roller Let us know why you don t like the design or performance Put it on an SF Form 368 Product Quality Deficiency Report Mail it to us at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island Illinois 61299 7630 We ll send you a reply CORROSION PREVENTION AND CONTROL CPC 1 Corrosion Prevention and Control CPC of Army materiel is a continuing concern It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in futur
131. erse Brakes are activated when in the NEUTRAL middle position Backup alarm sounds when in reverse Parking Brake Switch Applies the parking brake when pressed Releases the parking brake when pulled up Water Spray Switch Turns the water spray system to off center position continuous pull back or intermittent push forward modes Vibration Control Switch Turns the vibratory system to manual MAN or automatic AUTO modes 0004 00 6 0004 00 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED CB534C SHOWN 29 24 28 21 26 31 401 2164 CONTROL OR INDICATOR FUNCTION Drum Select Switch Activates the vibratory systems in the front push forward rear pull back or both drums center position Amplitude Select Switch Turns the amplitude of vibration to high push forward and low pull back pitches Lights Circuit Breaker Reset Button Push to reset lighting circuit to provide power to lights Circuit breaker will trip in the event of electrical system malfunction Lights Switch Rotate the 4 position switch to control the work light Beginning from the full right rotation position one is OFF Second position turns instrument panel lights ON Third position turns front work lights only ON Fourth position turns front and rear work lights ON Water Tank
132. f roller in front and rear Chock drums Refer to Chock Drums in this work package 0005 00 24 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 PREPARATION FOR TRANSPORT CONTINUED h Press parking brake switch 6 to apply parking brake i Turn engine start switch 7 to OFF position and remove key j Turn off battery disconnect switch Refer to Operate Engine in this work package 401 2174 k Ensure that all locks and vandal guard 8 are in place and secure CAUTION Exhaust opening must be closed prior to shipping Turbocharger damage can result if the turbocharger rotates without the engine running l Cover exhaust opening 9 with tape to prevent debris from entering exhaust system and turbo charger and to prevent turbocharger from rotat ing m Proceed to Tie Down Roller in this work pack 9 oer age 0005 00 25 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 PREPARATION FOR TRANSPORT CONTINUED 3 Load Roller onto M870 Series Trailer CAUTION To prevent damage to roller drum surface areas during loading and unloading it is necessary to construct a trailer approach ramp Refer to TM 5 2330 378 14 amp P This ramp must be utilized during loading and unloading operations a Construct a trailer approach ramp utilizing oak planks provided as with trailer b Slowly move roller forward and up on to approach ramp When roller is in positi
133. f the rear drum Resilient Check resilient mounts for damage Resilient mounts are dam Blocks cracking splitting and loose mounting aged cracked split or have hardware loose mounting hardware 0 3 Hours Front and Check vibratory bearing reservoir oil Oil level is low Rear Vibra level If oil level is low tory Bearing fill reservoir with oil Reservoir Front and Check front and rear propel gearbox oil Oil level is low Rear Propel level If oil level is low fill propel Gearbox gearbox with oil WP 0021 00 Level 0012 00 19 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued LOCATION ITEM TO CHECK NOT FULLY MISSION INTERVAL SERVICE PROCEDURE CAPABLE IF Front and Clean inspect and check adjustment Drum scraper is damaged or Rear Drum WP 0023 00 worn beyond adjustment Scrapers 0 2 Hours Front and Apply GAA grease Item 9 WP 0029 Rear Ring to two grease fittings at front and Bearings rear ring bearings WP 0011 00 END OF WORK PACKAGE 0012 00 20 TM 5 3895 379 10 GENERAL MAINTENANCE INSTRUCTIONS 0013 00 INSPECTION OF COMPONENTS 1 2 Clean all parts before inspection Check for defects such as physical distortion wear cracks and pitting Check all hose surfaces for broken or fr
134. filter elements cover and close two air filter housing latches Go to Step 2 AIR CLEANER SECONDARY AIR FILTER SERVICE ih SECONDA SERVICE WHEN SERVICE PRIMARY d 59 N ELEMENT VIEWING WINDOW AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 17 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 5 Engine Misfires or Idles Rough Continued WARNING DO NOT perform fuel system checks inspections or main tenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth ing NOTE Use a container to catch any fuel that may drain from sys tem Dispose of fuel IAW local policy and ordinances Ensure that all spills are cleaned up 2 Open right and or left side a Open fuel water separator s door assembly WP 0005 00 drain valve s and drain separator s WP 0016 00 b If engine still idles rough fault is not corrected Notify supervisor AIR CLEANER SECONDARY AR HOUSING ELEMENT le 4 T De SERVICE v PRIMARY SERVICE RED Tal hl ELEMENT VIEWING WINDOW AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00
135. fuel strainer in tank and fill fuel WP 0015 00 tank with fuel WP 0015 00 Notify supervisor that fuel gauge does not operate If fuel tank contains fuel replace strainer fuel cap assembly and padlock and go to Step 3 STRAINER FUEL CAP ASSEMBLY FUEL TANK PADLOCK 401 083 0010 00 2 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION ENGINE CONTINUED 1 Engine Cranks But Will Not Start or is Hard 3 Open left side door assembly to Start Continued and open fuel water separator drain valve to drain water from fuel water separator WP 0016 00 Close drain valve On CB534C only also drain fuel water separator on right side of engine compartment Check air filter service indicator for red indication in viewing window Red indicates a clogged air cleaner primary or secondary element If filter service indicator shows red in viewing window unlatch two air cleaner housing latches and remove cover Remove primary and secondary elements from air cleaner housing CORRECTIVE ACTION a If engine still does not start go to Step 4 b If engine starts close right and or left side door assembly WP 0005 00 If air cleaner primary element is clogged clean by tapping element with hand to remove dirt Install secondary and primary filter elements and cover and close two
136. fuel water separator is evident or fuel water separator is damaged Any V belt is loose miss ing broken greasy peeling glazed cracked to the belt fiber has more than one crack 1 8 in in depth or 50 or belt thickness or has frays more than 2 in long TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before LOCATION ITEM TO CHECK NOT FULLY MISSION SERVICE PROCEDURE CAPABLE IF V Belts INEA N CRACKED SPLIT GLAZED Before N Water Pump Check for coolant leakage at radiator hoses and water pump a A small amount of coolant leakage Class III coolant leaks are across the surface of the water pump evident seals is normal This leakage is required in order to provide lubrica tion for this type of seal b A hole is provided in the water pump housing in order to allow this cool ant seal lubricant to drain from the pump housing Intermittent leakage of small amounts of coolant from this hole indicates normal operation It is not an indication of water pump seal failure or a faulty water pump 0012 00 7 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMC
137. g shall not be soaked or sprayed with cleaning solutions Clean these parts with a clean dry cloth moistened with cleaning compound solvent Item 3 WP 0029 00 REMOVAL OF COMPONENTS 1 Ensure that adequate clearance is available for removal of component Disassemble roller to extent necessary to provide adequate working clearance Remove parts only when service is required Do not disassemble a component further than necessary to accomplish ser vice ASSEMBLY AND INSTALLATION Ensure that all parts are clean and dry before installation If you lose or damage a component during servicing notify supervisor for replacement END OF WORK PACKAGE 0013 00 1 0013 00 2 Blank TM 5 3895 379 10 ENGINE OIL LEVEL CHECK AND SERVICE 0014 00 THIS WORK PACKAGE COVERS Check Engine Oil Level Service Engine Oil Level INITIAL SETUP Materials Parts Oil lubricating Item 10 13 or 14 WP 0029 00 Rag wiping Item 16 WP 0029 00 Container 1 qt capacity References WP 0011 00 Operator Preventive Maintenance Check and Services PMCS Introduction WARNING iz Equipment Condition Engine off Roller parked on level ground WP 0005 00 Drums chocked WP 0005 00 Right side door assembly opened WP 0005 00 e 15 very slippery Immediately wipe up any spills Failure to follow this warning may cause injury e Hot oil or metal parts can cause burns Wear insulated gloves long sleeves and eye protection whe
138. gate cause Throttle Control Switch CB534C Only A two position switch used to control the engine speed Select low tortoise for low engine idle speed or high hare for high engine idle speed Throttle Control Controls the engine Revolutions Per Minute RPM Push and hold button to allow push pull movement of throttle control Push throttle control down to reduce engine speed Pull throttle control up to increase engine rpm Release button at the desired throttle position Turn throttle lock full right to lock the throttle control at a desired engine rpm Turn the throttle lock full left to release the throttle control to change engine rpm 0004 00 4 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED 401 2197 CONTROL OR INDICATOR FUNCTION Speedometer CB534C Only Indicates roller s ground speed in FPM Feet Per Minute x 10 and km h 0004 00 5 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED CONTROLS AND INDICATORS CONTINUED CONTROL OR INDICATOR Vibration Push Switch CB534C SHOWN 401 2164 FUNCTION Turns the vibratory system on by pressing once or off by pressing again Propel Control Lever Controls the direction and speed of travel for the roller Push forward to go forward Pull all the way back to go in rev
139. ge reads fuel level gauge empty fill fuel tank with fuel WP 0015 00 b If fuel level gauge indicates fuel in tank go to Step 2 FUEL LEVEL GAUGE CB534B SHOWN 401 030 0010 00 10 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 3 Engine is Sluggish Continued WARNING DO NOT perform fuel system checks inspections or main tenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked cloth ing NOTE Use a container to catch any fuel that may drain from sys tem Dispose of fuel IAW local policy and ordinances Ensure that all spills are cleaned up Remove padlock fuel cap a If fuel cap assembly vent is assembly and strainer and restricted remove restriction visually inspect vent for damage or restriction b If fuel cap assembly or vent is damaged notify supervisor to replace fuel cap assembly c If fuel cap assembly is not damaged or restricted go to Step 3 STRAINER FUEL CAP REMOVE AN FUEL TANK Q PADLOCK dicio E 401 083 0010 00 11 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Proced
140. gical growth and prevents damage to the system in the event of freezing temperatures NOTE Steps 1 through 4 cover draining of front water tank Rear water tank is drained the same way 1 Turn tee handle cap assembly 3 counterclockwise until cap assembly be removed from nipple 4 2 Allow water to completely drain from water tank 2 401 113 0024 00 2 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CONTINUED 3 Open drain cock 5 drain water from line 6 5 6 401 114 4 Remove sediment bowl 7 O ring 8 and screen 9 from strainer assembly 10 and allow water to drain Discard ring ON CB534B ONLY 401 115 0024 00 3 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND FLUSH WATER SPRAY SYSTEM CONTINUED 5 Lift latch 11 pull handle 12 toward front of roller 13 and open right side door assembly 14 WP 0005 00 6 Unhook lanyard 15 from door assembly 14 and hook lanyard to frame assembly 16 7 Turn valve handle 17 to open position 8 Open drain cock 18 and drain water from tie line 19 MEN E NENTE A IL f E e ToS N E 9 e 5 o Cada at E SI 7 401 116 0024 00 4 TM 5 3895 379 10 WATER SPRAY SYSTEM CHECK AND SERVICE CONTINUED 0024 00 DRAIN AND
141. h week e Monthly procedures must be done once each month Man Hours Column This column indicates man hours required to complete prescribed lubrication Location Item to Check Service Column This column provides the location and item to be checked or serviced NOTE The WARNINGs and CAUTIONS appearing in your PMCS table should always be observed WARNINGs and CAUTIONS appear before applicable procedures You must observe these WARNINGS to prevent injury to yourself and others and CAUTIONS to prevent the roller from being damaged Procedure Column This column gives the procedure you must perform to check or service the item listed in the Item to Check Service column to know if the roller is ready or available for its intended mission You must perform the procedure at the time stated in the interval column Not Fully Mission Capable If Column Information in this column tells you what faults will keep the roller from being capable of performing its primary mission If you perform check service procedures that show faults listed in this column the equipment is not mission capable Follow standard operating procedures for maintaining the equipment or reporting equipment failure GENERAL PMCS PROCEDURES 1 Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If the roller does not perform as required refer to the appropriate troubleshooting procedure in
142. hat may occur nor all tests or inspections and correc tive actions If a malfunction is not listed or is not corrected by the listed corrective actions notify supervisor 6 When troubleshooting a malfunction Locate the symptom or symptoms in WP 0009 00 that best describe the malfunction b Turn to the page in WP 0010 00 where the troubleshooting procedures for the malfunction in question are described Headings at the top of each page show how each troubleshooting procedure is organized MALFUNCTION TEST OR INSPECTION in step number order and CORRECTIVE ACTION c Perform each step in the order listed until the malfunction is corrected DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so EXPLANATION OF COLUMNS The columns in Table 1 in WP 0010 00 defined as follows 1 MALFUNCTION A visual or operational indication that something is wrong with the equipment 2 TEST OR INSPECTION A procedure to isolate the problem in a system or component 3 CORRECTIVE ACTION A procedure to correct the problem END OF WORK PACKAGE 0008 00 1 0008 00 2 Blank TM 5 3895 379 10 TROUBLESHOOTING SYMPTOM INDEX 0009 00 Malfunction Symptom Troubleshooting Procedure Page ELECTRICAL SYSTEM Alternator Indicatords OM yess cies DHE Oe eoe en Peete sys TERES E mds 0010 00 30 Backup Alarm Does Not 2 0010 00 30 Fuel Gauge
143. he drum to vibrate which intensifies the roller compaction of surface material The eccentric weight is a chamber filled with steel shot and has a weight attached to one side Inside the chamber are baffles As the weight is turned one direction the baf fle collects the steel shot on the same side as the weight to produce a severe imbalance in the rotation The imbalance causes the entire drum to vibrate This is the high amplitude As the weight is turned the other direction the baffle col lects the steel shot on the opposite side as the weight to produce a mild imbalance in the rotation causing less vibration This is the low amplitude Each drum is isolated from the rest of the roller by twenty four rubber isolation blocks The isolation blocks allow the operator to remain in relative comfort as the drums are fully vibrating The vibratory system gets its power from the vibratory hydraulic pump which is attached to the propel hydraulic pump which is attached to the engine The vibration control switches control the varied vibratory modes by activating electric solenoids in the hydraulics of the vibratory system The operator can select which drum vibrates how the system is activated and the severity of the vibration action BAFFLE STEEL SHOT ECCENTRIC WEIGHT WEIGHT HYDRAULIC VIBRATORY MOTOR ISOLATION BLOCKS 401 009 HYDRAULIC VIBRATORY MOTOR 0003 00 4 TM 5 3895 379 10
144. icates the lights are on Water Spray System Indicator When illuminated indicates the water spray system is activated Service Hourmeter Displays the total number of hours the engine has been operated Fuel Level Gauge Indicates the amount of diesel fuel or JP 8 in the fuel tank Starting Aid Switch On the CB534B the starting aid switch powers the cold start heater which warms a small amount of fuel that enters the combustion chamber The heater is used in cold weather to help start the engine On the CB534C the switch powers the air inlet heater which warms the air that enters the engine Engine Start Switch Ignition key controls the mode of engine and electrical system The START full right position is used to crank the engine for starting The ON right position is used to activate all electrical circuits and allows the engine to run once it is started The OFF left position stops the engine and shuts down all electrical circuits 0004 00 2 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED 401 2171A CONTROL OR INDICATOR FUNCTION Steering Wheel Controls roller direction of travel Hydraulic Oil Temperature Warning Light IIluminates to warn operator of overheating of the hydraulic oil in the system If the indicator does not go out shortly after the engine is started or if the indicator comes on whi
145. ill need to operate and maintain the Roller Motorized Vibrating Tandem Steel Drums This listing is for informational purposes only and is not authority to requisition the listed items These items are authorized to you by CTA 50 970 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items or CTA 8 100 Army Medical Department Expendable Durable Items EXPLANATION OF COLUMNS 1 Column 1 Item Number This number is assigned to the entry in the listing and is referenced in the narrative instruc tions to identify the item e g Use antifreeze Item 1 WP 0029 00 2 Column 2 Level This column identifies the lowest level of maintenance that requires the listed item C Operator Crew 3 Column 3 National Stock Number This is the National Stock Number assigned to the item which you can use to req uisition it 4 Column 4 Description CAGEC and Part Number This provides the other information you need to identify the item 5 Column 5 Unit of Measure U M This column shows the physical measurement or count of an item such as gallon dozen gross etc 0029 00 1 TM 5 3895 379 10 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0029 00 1 Table 1 Expendable and Durable Items List 3 NATIONAL STOCK NUMBER 6850 01 441 3218 6850 00 18 1 7933 6850 01 441 3223 7920 00 056 5525 6850 01 474 2320 6850 01 474 2321 7920 00
146. ill plug 2 through access hole in gearbox 3 6 Move roller until the oil level check plug 1 opening is at 12 o clock position and fill plug 2 is at 3 o clock position ph Install oil level check plug 1 through access hole in gearbox 3 8 Stow 1 2 in drive ratchet 6 in extension and 5 16 in hex bit in toolbox END OF WORK PACKAGE 0021 00 3 0021 00 4 Blank TM 5 3895 379 10 ADJUST HANDRAILS FOR OPERATION OR STOWAGE 0022 00 THIS WORK PACKAGE COVERS Adjust for Operation Adjust for Stowage INITIAL SETUP Tools and Special Tools Equipment Condition Wrench box and open end combination Item 5 Engi 0005 00 gine WP 0027 00 Personnel Required Roller parked on level ground WP 0005 00 Two Drums chocked WP 0005 00 ADJUST FOR OPERATION 1 Remove 24 mm wrench from toolbox WARNING Use caution when handling heavy parts Provide adequate support and use assistance during procedure Failure to follow this warning may cause injury CAUTION Failure to hold handrail assembly in place during removal will allow handrail assembly to fall and become damaged 2 While assistant holds left handrail assembly 1 remove two bolts 2 and washers 3 from plate assemblies 4 using 24 mm wrench 3 Lower handrail assembly 1 until holes in handrail align with middle holes in plate assemblies 4 Install two washers 3 and bolts 2 in middle holes in handrail assembly 1 and plate assemblie
147. irect compressed air against human skin Failure to follow this warning may result in injury or death Make sure air stream is directed away from user and other personnel in the area To prevent injury user must wear protective goggles or face shield 2 Use a cleaning cloth or compressed air to dry metal parts 3 Check cap and clamp for cracks and wear on locking parts 4 Check screen for crushing corrosion or tears 5 Check seal for cracks tears or other signs of deterioration 6 Check nozzle for clogging corrosion or excessive wear Js Notify supervisor for replacement of lost or damaged parts INSTALLATION NOTE Slot in nozzle faces down toward drum surface when installed 1 Install nozzle 5 seal 4 and screen 3 in cap 1 9 ey INSTALL 401 121 0025 00 2 TM 5 3895 379 10 WATER SPRAY NOZZLE CHECK AND SERVICE CONTINUED 0025 00 INSTALLATION CONTINUED NOTE Ensure that cap is securely snapped into locked position An insecurely installed cap will result in loss of components when water spray system is operated 2 Install cap 1 on clamp 2 by turning cap clockwise until cap snaps into locked position on clamp 3 Remove chocks WP 0005 00 END OF WORK PACKAGE 0025 00 3 0025 00 4 Blank TM 5 3895 379 10 CHAPTER 5 SUPPORTING INFORMATION TM 5 3895 379 10 REFERENCES 0026 00 SCOPE This work package lists all forms field manuals technical bulletins technica
148. is not low go to Step 2 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION WATER SPRAY SYSTEM CONTINUED 39 Spray Occurs On One Drum Only 2 On CB534B check that the a If water tank shutoff valve is Continued water tank shutoff valve at the not open open valve non operating tank is open Valve handle will be in line with the valve when the valve is open b If water tank shutoff valve is open go to Step 3 WATER TANK SHUTOFF VALVE FRONT SIDE SHOWN REAR SIDE SIMILAR PLATE SHOWN REMOVED FOR CLARITY 401 094 3 Check for pinched or damaged a If water line s is pinched or water lines damaged component is faulty Notify supervisor b If water lines are not pinched or damaged fault is not corrected Notify supervisor 0010 00 41 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION WATER SPRAY SYSTEM CONTINUED 40 Water Spray Pressure is Low 1 Check for open drain cocks a If drain cock s is open close drain cock s b If drain cock s is closed go to me MT E 41 14 DRAIN COCK 401 095 2 Check for clogged corroded a If water spray nozzle s is or damaged water spray dirty clean and install noz
149. itch is moved Water spray system does not operate or operates in inter mittent or continuous mode only TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL FAN BLADE LOCATION ITEM TO CHECK SERVICE Hydraulic Oil Filter CB534B PROCEDURE NOT FULLY MISSION CAPABLE IF WARNING Engine compartment contains a partially exposed fan blade Use caution around front of engine if engine is running Failure to comply may result in injury a Open right side door assembly 0005 00 b With engine operating at high idle throttle control near to or fully up have assistant check that the white filter indicator is not in red zone Notify supervisor if white filter indi cator is in red zone c Close right side door assembly 0005 00 RED ZONE Check for excessive exhaust smoke unusual engine noise rough running or misfiring engine 0012 00 16 White filter indicator is in the red zone CB534B ONLY WHITE FILTER INDICATOR HYDRAULIC OIL FILTER INDICATOR 401 031 Excessive exhaust smoke unusual engine noise rough running or misfiring engine are noted TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services P
150. k and close access door Release lever Close right side door assembly WP 0005 00 and go to Step 5 ACCESS DOOR RADIATOR RADIATOR CAP 401 088 0010 00 24 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 10 Engine Operating Temperature is Too High 5 Open left side door assembly a If air cleaner primary element Warning Light and Warning Horn On and check air is clogged clean by tapping Continued filter service indicator for red element with hand to remove indication in viewing window dirt Install secondary and Red indicates a clogged air primary filter elements and cleaner primary or secondary cover and close two air cleaner element If filter service housing latches Reset air filter indicator shows red in viewing service indicator Close left window unlatch two air side door assembly WP 0005 cleaner housing latches and 00 remove cover Remove primary and secondary elements from air cleaner housing b If air cleaner primary element is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 AIR FILTER SERVICE AIR CLEANER SECONDARY INDICATOR HOUSING ELEMENT
151. l 2 4 1 GO 75 GO 75 GO 80W 90 0011 00 4 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED LUBRICANT Front Vibratory Bearing Reservoir Check Level Add View B Hydraulic Oil Tank HYDO Check Level Add View C Rear Ring Bearing GAA 2 Fittings View D Rear Propel Gear GO box Check Level Add View A 0011 00 5 GAA LUBRICANT Front Ring Bear ing 2 Fittings View D Front Propel Gearbox Check Level Add View Engine Oil Check Level Add View E Rear Vibratory Bearing Reser voir Check Level Add View B TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED CHECK LEVEL FILL 01 126 VIEW A PROPEL GEARBOX FRONT AND REAR CHECK HYDRAULIC ADD OIL OIL LEVEL 401 128 VIEW C HYDRAULIC OIL TANK CHECK LEVEL 401 127 VIEW B VIBRATORY BEARING RESERVOIR FRONT AND REAR LUBRICATE VIEW D RING BEARING FRONT AND REAR 0011 00 6 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED CHECK OIL LEVEL HIGH MARK ADD OIL VIEW E
152. l manuals and other publications referenced in this manual and which apply to the operation of the Roller Motorized Vibrating Tandem Steel Drums PUBLICATION INDEXES The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this technical manual Consolidated Army Publications and Forms DA PAM 25 30 Consolidated Publication of Component Lists 0 0 eect e EM 0074 Functional User s Manual for the Army Maintenance Management System DA PAM 738 750 Using Unit Supply System Manual 2 PAM 710 2 1 FORMS Refer to DA Pam 738 750 The Army Maintenance Management System TAMMS for instructions on the use of mainte nance forms Equipment Inspection and Maintenance DA Form 2404 DA Form 5988 E Maintenance Request 2 23 een CREUSE RON ER DI En he e Misa Gee bee DA Form 2407 Organization Control Record for Equipment 4 4 DA Form 2401 Preventive Maintenance Schedule and 2 DD Form 314 Product Quality Deficiency 2 22 1 SF Form 368 Recommended Changes to Publications and
153. le the engine is running operator should stop engine and notify supervisor Engine Oil Pressure Warning Light Illuminates to warn operator of low engine oil pressure or a system malfunction If the indicator does not go out shortly after the engine is started or if the indicator comes on while the engine is running operator should stop engine and notify supervisor Engine Coolant Temperature Warning Illuminates to warn operator of overheating of the engine coolant Light or a system malfunction If the indicator does not go out shortly after the engine is started or if the indicator comes on while the engine is running operator should stop engine notify supervisor Hydraulic Oil Pressure Warning Light Illuminates to warn operator of a malfunction causing low hydraulic system pressure If the indicator does not go out shortly after the engine is started or if the indicator comes on while the engine is running operator should stop engine and notify supervisor 0004 00 3 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED 401 2171 CONTROL OR INDICATOR FUNCTION Alternator Indicator Illuminates to warn the operator of an alternator malfunction If the indicator does not go out in 15 seconds after the engine is started or if the indicator comes on while the engine is running operator should shut down roller and investi
154. lled in the Army Oil Analysis Program AOAP for sampling of engine and hydraulic system oil e Refer to FM 9 207 for lubrication in arctic operation 1 Included in this PMCS are lubrication services to be performed by the operator 2 Lubrication intervals are based on normal operation Lubricate more during constant use and less during inactive periods Use correct grade of lubricant for seasonal temperature expected Refer to the KEY at the end of this work package 3 For roller under manufacturer s warranty hardtime intervals shall be followed Shorten intervals if lubricants are known to be contaminated or if operation is under adverse conditions e g longer than usual operating hours extended idling periods extreme dust etc 4 Keep all lubricants in a closed container and store a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready for use e WARNING Cleaning compound solvent MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ven tilated areas Keep away from open flames and other sources of ignition 5 Clean area around lubrication points with cleaning compound solvent Item 3 WP 0029 00 jor equivalent before lubricat ing equipment Keep all external part
155. lls Failure to follow this warning may cause injury 1 Remove padlock 2 from hydraulic oil cap assembly 3 2 Lift lever and remove hydraulic oil cap assembly 3 from hydraulic oil tank 4 by turning cap counterclockwise 3 Remove strainer 5 from hydraulic oil tank 4 and inspect for debris Remove debris as necessary LEVER 4 Clean and install strainer 5 in hydraulic oil tank 4 Refer to KEY in WP 0011 00 for quantity and type of oil 5 Add oil through strainer 5 and fill tube 6 until oil level indicator 1 is between FULL and ADD marks on decal located beside hydraulic oil level indicator 6 Lift lever and install hydraulic oil cap assembly 3 on hydraulic oil tank 4 by turning cap clockwise Vs Install padlock 2 on hydraulic oil cap assembly 3 while lever is fully down DECAL 401 101 END WORK PACKAGE 0018 00 2 TM 5 3895 379 10 DRAINING AND FILLING FUEL AND HYDRAULIC OIL TANKS 0019 00 THIS WORK PACKAGE COVERS Drain Fuel Tank Drain Hydraulic Oil Tank Cleaning and Inspection Fill Fuel Tank Fill Hydraulic Oil Tank INITIAL SETUP Tools and Special Tools References Wrench box_and open end combination Item 5 WP 0011 00 Operator Preventive Maintenance WP 0027 00 Checks and Services PMCS Introduction Materials Parts Equipment Condition Engine off WP 0005 00 Roller parked on level ground WP 0005 00 Oil lubricating Item 10 or 13
156. m 6 7 or 8 WP 0029 00 Engine off WP 0005 00 Container 1 qt capacity Roller parked on level ground WP 0005 00 Drums chocked WP 0005 00 WARNING e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller e DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury death or damage to roller e Wear fuel resistant gloves when handling fuels and promptly wash exposed skin and change fuel soaked clothing e Place portable fire extinguisher within reach prior to refueling e DO NOT overfill tank If fuel starts foaming from fuel tank stop immediately to avoid fuel spillage is very slippery If fuel is spilled clean fuel up immediately Before starting roller check that no fuel is spilled on or around machine NOTE Fuel level check and service is performed the same way for the CB534B and CB534C Rollers The CB534B Roller is shown 0015 00 1 TM 5 3895 379 10 FUEL LEVEL CHECK AND SERVICE CONTINUED 0015 00 CHECK FUEL LEVEL 1 Check fuel level gauge 1 2 Fill tank as necessary Refer to Fill Fuel Tank in this work package 401 2197 DRAIN FUEL FILTER NOTE Use a container to catch fuel drained from system Dispose of fuel IAW policy and ordinances Ensure all spills are cleaned up On CB534B Roll
157. me way CB534B Roller is shown 1 Move Roller Forward NOTE Parking brake switch will be illuminated while parking brake is engaged Pull up on parking brake switch 1 to disengage parking brake b Slowly push the propel control lever 2 forward away from center to move the roller forward c To move roller faster push the propel control lever 2 further forward CAUTION The following procedure should always be used to stop the roller unless an emer gency situation exists Damage to equip ment can occur if parking brake is used to stop roller 2 Stop Roller Move the propel control lever 2 to the center position to stop the roller 3 Move Roller in Reverse a Slowly pull the propel control lever 2 back away from center to move the roller in reverse 401 046 b To move roller faster pull the propel control lever 2 further back 0005 00 16 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 ROLLING PROCEDURES WARNING e Operator shall not operate roller for periods longer than 3 hours Operator may resume 3 hour period of roller operation after 1 hour of rest Operating roller for periods longer than 3 continual hours may cause injury to personnel from exposure to excessive body vibration levels from roller e Do not turn roller vibratory system on while roller is standing still on a very solid surface loss of steering can be experienced which could result in
158. move key d Unhook lanyard 5 from frame assembly 6 and hook lanyard to door assembly 4 e Close right side door assembly 4 push handle 2 into latch 1 and close latch EA 0 401 044 0005 00 11 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE WATER SPRAY SYSTEM NOTE Water spray system is operated the same way for CB534B and CB534C Rollers CB534B Roller is shown 1 Check Water Tank Level CAUTION Water spray system must be drained at the end of each work day and filled at the beginning of the next work day Draining ensures the removal of debris or biological growth and prevents damage to the system in the event of freezing temperatures a Observe water level at front and rear water level gauges 1 CAUTION Operating water spray system for pro longed periods without water in tanks will result in damage to water spray pumps b When required fill water tanks WP 0024 00 2 Operate Water Spray System 401 045 CAUTION e Always check level in water tanks prior to operating water spray system Failure to follow this caution may cause damage to water spray system e Contaminated water can cause perfor mance and reliability problems in water spray system NOTE e Use continuous spray in high temper ature and low humidity conditions to keep drums wet e Use intermittent water spray to con serve water a For intermittent wate
159. ms Except Medical Class V Repair Parts and Heraldic CTA 50 970 END OF WORK PACKAGE 0026 00 2 TM 5 3895 379 10 COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS BII LISTS 0027 00 SCOPE This work package lists COEI and BII for the Roller Motorized Vibrating Tandem Steel Drums to help you inventory items required for safe and efficient operation GENERAL The COEI and BII information is divided into the following lists 1 Table 1 Components of End Item List This listing is for informational purposes only and is not authority to requisition replacements These items are part of the end item but are removed and separately packaged for transportation or ship ment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items 2 Table 2 Basic Issue Items List These are the minimum essential items required to place the roller in operation to oper ate it and to perform emergency repairs Although shipped separately packaged BII must be with the roller during opera tion and whenever it is transferred between property accounts This manual is your authority to request requisition replacement BII based on TOE MTOE authorization of end item Illustrations are furnished to assist you in identifying the items EXPLANATION OF COLUMNS Below is an explan
160. n working with heated parts NOTE Use container to catch any oil that may drain from system Dispose of oil IAW local policy and ordinances CHECK ENGINE OIL LEVEL 1 Remove gauge rod dipstick 1 from gauge rod dip stick tube 2 and wipe clean 2 Insert gauge rod dipstick 1 in gauge rod diptick tube 2 3 Remove gauge rod dipstick 1 from gauge rod dip stick tube 2 4 Check engine oil level Oil level should be between marks on gauge rod dipstick 1 5 Install gauge rod dipstick 1 in gauge rod dipstick tube 2 6 If necessary add engine oil Refer to Service Engine Oil Level in this work package 0014 00 1 401 097 TM 5 3895 379 10 ENGINE OIL LEVEL CHECK AND SERVICE SERVICE ENGINE OIL LEVEL 1 Remove cap 3 from oil filler assembly 4 CAUTION Do not overfill crankcase or damage will occur to engine NOTE For quantity and type refer to KEY in WP 0011 00 2 Add oil to crankcase 3 Install oil cap 3 on oil filler assembly 4 4 Check engine oil level Oil level should be between marks on gauge rod dipstick 1 5 Close right side door assembly WP 0005 00 401097 6 Remove chocks WP 0005 00 END OF WORK PACKAGE 0014 00 2 TM 5 3895 379 10 FUEL LEVEL CHECK AND SERVICE 0015 00 THIS WORK PACKAGE COVERS Check Fuel Level Drain Fuel Filter Fill Fuel Tank INITIAL SETUP Materials Parts Equipment Condition Fuel Ite
161. nd check air filter service indicator for red indication in viewing window Red indicates a clogged air cleaner primary or secondary is clogged clean by tapping element with hand to remove dirt Install secondary and primary filter elements and cover and close two air cleaner element If filter service indicator shows red in viewing service indicator Close left window unlatch two air side door assembly WP 0005 cleaner housing latches and 00 remove cover Remove primary and secondary elements from air cleaner housing housing latches Reset air filter b If air cleaner primary element is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 0010 00 16 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 5 Engine Misfires or Idles Rough Continued c If air cleaner secondary element is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged and fault is not corrected install
162. ning may result in injury or death Do not turn roller 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 WARNING SLAVE STARTING When slave starting machine use NATO slave cable that DOES NOT have loose or missing insulation DO NOT proceed if correct cable is not available DO NOT use civilian type jumper cables TM 5 3895 379 10 WARNING TOWING ROLLER Before towing ensure tow bar is in good working condition Use of a weak tow bar could result in injury or death Incorrectly towing a roller may cause injury or death Do not allow an operator on roller unless engine is running and the operator can control steering and or brak ing Uncontrolled roller may cause injury or death Do not use a chain or cable for pulling A chain or cable link can break causing injury The towing vehicle should be as large or larger than the roller Any vehicle used to tow the roller shall have enough brake capacity weight and power to control both vehicles for the grade and distance involved To provide sufficient control and braking when moving a disabled roller downhill a larger towing vehicle or additional vehicles connected to the rear of the towed roller is required Turning on a slope will reduce the stability of both the towing vehicle and the towed roller and could result in a tip over accident WARNING WHOLE BODY VIBRATION Operator sh
163. nt is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 If air cleaner elements are not clogged and starting aid was used during attempt to start install filter elements and cover and close two air filter housing latches Close left side door assembly WP 0005 and go to Step 2 AIR CLEANER SECONDARY AR FILTER SERVICE M SECONDA SERVICE WHEN SERVICE 1 PRIMARY EN WHEN ol ELEMENT LEVELIS fu aee OF VA Cho AT 22 3 VIEWING WINDOW AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 15 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued TEST OR INSPECTION ENGINE CONTINUED 4 Engine Exhaust Smokes Excessively Too Much Black or Gray Smoke Continued MALFUNCTION CORRECTIVE ACTION e If air cleaner elements are not clogged and starting aid was not used during attempt to start fault is not corrected Install filter elements and cover and close two air filter housing latches Close left side door assembly WP 0005 00 Notify supervisor that engine exhaust smokes excessively 5 Engine Misfires or Idles Rough 1 Open left side door assembly a If air cleaner primary element WP 0005 00 a
164. o addressee listed in publication FROM Activity and location Include ZIP Code PART REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS SUPPLY MANUALS PUBLICATION NUMBER DATE TOTAL NO PAGE COLM NATIONAL STOCK REFERENCE FIGURE OF MAJOR NO NO NUMBER NO NO ITEMS SUPPORTED RECOMMENDED ACTION PART REMARKS Any general remarks or recommendations or suggestions for improvement of publications and blank forms Additional blank sheets may be used if more space is needed TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION APD V4 00 Use Part II reverse for Repair Parts and RECOMMENDED CHANGES TO PUBLICATIONS AND Special Tool Lists RPSTL and Supply BLANK FORMS Catalogs Supply Manuals SC SM For use of this form see AR 25 30 the proponent agency is OAASA TO Forward to proponent of publication or form Include ZIP Code FROM Activity and location Include ZIP Code PART I ALL PUBLICATIONS EXCEPT RPSTL AND SC SM AND BLANK FORMS PUBLICATION FORM NUMBER DATE TITLE Operator s M anual for Roller M otorized 379 1 Vibrating Tandem Steel Drums M odels me en CB534B and CB534C ITEM PAGE PARA LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON NO TYPED NAME GRADE OR TITLE TELEPHONE EXCHANGE AUTOVON SIGNATURE PLUS EXTENSION
165. of ride Tighten for firmer ride loosen for less firm ride 0004 00 8 TM 5 3895 379 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED CNS ZN A A 9 noo KO OO MOONY 401 015 CONTROL OR INDICATOR FUNCTION Battery Disconnect Switch and Key Disconnects negative battery cable to ground connection by turning battery disconnect key counterclockwise while roller is not in operation Insert and turn key clockwise to connect battery cable to ground connection Fuel Hydraulic Oil Tank Sight Gauge Measures level of hydraulic oil in fuel hydraulic oil tank Level can be observed in glass tube FULL COLD and ADD levels are indicated on gauge Water Level Gauge Measures water level in water spray system tanks Needle on gauge indicates level Full left is empty full right is full There is a water level gauge located on both tanks Steering Frame Lock Locks steering system in place for shipping needs by moving position of pin up to lock and down to steer Tie Line Valve CB534B Connects front and rear water spray systems One system can be used to pump water for both if other system pump fails Turning the valve handle 90 degrees away from water lines isolates front and rear water spray systems 0004 00 9 TM 5 3895 379 10 DESCRIPTION AND US
166. on on trailer bed do the follow ing 1 Apply parking brake Refer to Operate M870 SERIES Engine in this work package TRAILER 2 Turn the engine start switch to OFF posi tion and remove key Refer to Operate Engine in this work package RAMP 3 Turn battery disconnect switch to OFF position Refer to Operate Engine in this work package 4 Ensure that all locks and vandal guard are in place and secure Refer to Lift Machine onto Shipping Bed in this work package 401 2095 CAUTION Exhaust opening must be closed prior to shipping Turbocharger damage can result if the turbocharger rotates without engine running 5 Cover exhaust opening with tape to prevent debris from entering exhaust system and turbocharger and to prevent turbocharger from rotating 0005 00 26 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 PREPARATION FOR TRANSPORT CONTINUED 4 Tie Down Roller WARNING Improper lifting or tiedowns can allow load to shift Use slings rated for a minimum of 21 232 Ib 9631 kg for the CB543B Roller Use slings rated for a minimum of 21 832 Ib 9903 kg for the CB534C Roller Fail ure to follow this warning may cause injury or damage to equipment Secure roller by using tie down locations 10 at each corner of roller hl 401 004 401 001 END OF WORK PACKAGE 0005 00 27 0005 00 28 Blank TM 5 3895 379 10 OPERATION UNDER UN
167. ound 2 Turn off vibratory system Refer to Operate Vibratory System in this work package 3 Move propel control lever 1 to the center position to stop roller NOTE Parking brake switch will be illuminated while parking brake is engaged and engine start switch is in ON position 4 Press parking brake switch 2 to engage parking 401 046 brake NOTE Drain the water tanks at the end of each work day to prevent freezing and biological growth from occurring during periods of roller inactivity Turn off water spray system Refer to Operate Water Spray System in this work package 6 Shut down engine Refer to Operate Engine in this work package 7 Dismount roller Refer to Mounting and Dismounting Roller in this work package NOTE Battery disconnect switch should be turned off at the end of each work day 8 Ensure that battery disconnect switch is turned off and key is removed Refer to Operate Engine in this work package 0005 00 18 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 CHOCK DRUMS NOTE e Chock front and rear of each drum to prevent movement e Before unchocking drums ensure parking brake is applied Chock front and rear drums whenever maintenance is being performed on roller 2 Chock front and rear drums in accordance with local policy 3 When roller is operational remove chocks 401 2194 0005 00 19 TM 5 3895 379 10 OPERATION UNDER USUAL COND
168. out resume operation as necessary Clean and lubricate roller with correct grade of lubricants to help prevent deterioration Have Field Maintenance change air fuel transmission and hydraulic filter elements at shorter than normal intervals as designated in Field Maintenance PMCS Perform operator PMCS more often than normal WP 0011 and WP 0012 00 Do not fill fuel tank completely Extreme heat causes fuel to expand and overflow Ensure that water is as free as possible of mineral deposits before adding coolant mixture to radiator Local desert water sources have high mineral deposits that will clog radiator Ensure that water antifreeze mixture is 50 50 This mixture raises coolant boiling point to help prevent overheating High temperatures can damage hoses Check radiator fuel and lubricant hoses for leaks around fittings Notify supervi sor if hoses are damaged Park roller under cover or in the shade if possible OPERATE IN SANDY OR DUSTY CONDITIONS NOTE The roller normally operates in dusty conditions and PMCS instructions are designed to handle these condi tions However in deserts dust conditions are more extreme and certain checks and services are required more often than normal Check engine coolant temperature and engine oil pressure frequently Check air restriction indicator more often to ensure air cleaner is not becoming clogged Keep radiator core free of dust leaves and any other obstructions to air cir
169. packed together cord eo eine cbe e n Na eee Dt bm eos br ode db Eee NP Offset Hydrostatic iui eC s RR Rx ER RS A a A Pressure exerted or transmitted by liquid at rest Static ces URP ue exe EL ue EE QC ORE Valais Vea Without movement END OF WORK PACKAGE 0001 00 3 0001 00 4 Blank TM 5 3895 379 10 EQUIPMENT DESCRIPTION AND DATA 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES NOTE Characteristics capabilities and features are the same for the CB534B and CB534C Rollers Motorized Vibrating Tandem Steel Drums except as noted 1 Characteristics a roller is designed to be operated by one operator b motion of the roller is controlled by the operator using a steering wheel and propel control lever joystick c Theroller is propelled by a hydrostatic transmission driven by a four cylinder turbocharged engine d Compaction is achieved with two cylindrical drums Hydraulic motor driven eccentric weights produce vibration a in the drums which enhances compaction Capabilities and Features The roller has a static tip angle range of 40 to 50 degrees The static tip angle is the slope angle where a stationary roller will begin to tip over to the side when it is parallel to the slope in straight ahead travel position 1 Roller operating stability depends upon many factors including operating speed steering braking terrain conditions fluid levels and most of all operato
170. plode and cause injury Remove all jewelry such as rings ID tags watches and bracelets If jewelry or a tool contacts a battery terminal a direct short will result in instant heating or electric shock dam age to equipment and injury Sulfuric acid contained in batteries can cause burns If battery corrosion or electrolyte makes contact with skin eyes or clothing take immediate action to stop the corrosive burning effects Failure to follow these procedures may cause injury or death Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately Skin Flush with large amounts of cold water until all acid is removed Seek medical attention as required Internal If corrosion or electrolyte is ingested drink large amounts of water or milk Follow with milk of magnesia beaten egg or vegetable oil Seek medical attention immediately Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia TM 5 3895 379 10 gt WARNING E CLEANING COMPOUND SOLVENT Cleaning compound solvent MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well ven tilated areas Keep away from open flames and other sources of ignition WARNING 2 COMPRESSED AIR Particles blown by compressed air are hazardous DO NOT exceed 15 psi 103 kPa
171. ptom Troubleshooting Procedure Page PROPEL SYSTEM Propel System Does Not Change Speeds When Propel Speed Switch is 0010 00 36 Propel System Engages Very Slowly When Making a 5 0010 00 36 Roller Will Not Move When Propel Control Lever is 0010 00 35 VIBRATORY SYSTEM Vibration Frequency Start up is Slow Time Lag After Travel Starts is 0010 00 37 Vibration Mechanism is 2 0010 00 37 Vibration Occurs in Only One 22 0010 00 38 Vibratory System Will Not Work Forward and Reverse Travel 0010 00 37 WATER SPRAY SYSTEM Nozzle Spray Pattern is 2 2 1 0010 00 43 Spray Does Not Occur On Either Drum When Water Spray Switch is in Continuous Spray Position 0010 00 38 Spray Does Not Occur On Either Drum When Water Spray Switch is in Intermittent Spray Position 0010 00 40 Spray Occurs On One Drum 4 4 4 4 0010 00 40 Water Consumption is Unequal Between Tanks 0010 00 43 Water Spray Pressure is 222222 22 44 e
172. push and hold button 14 and push throttle control 13 down to low idle position near to or fully down for engine warm up Release button i On CB534B Roller only when desired low idle is reached turn throttle lock 12 clockwise to lock throttle control 13 in position j On CB534C Roller only push throttle control switch 15 to slow TORTOISE position once engine is started NOTE Vibration push switch turns vibratory system on by pressing once or off by pressing again There is no way to tell if the vibratory system is on or off when the engine is not running k Ensure that vibration push switch 17 is turned off 0005 00 8 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED 401 2228 3 Warm Up Engine Above 32 F 0 C CAUTION Keep engine rpm low until engine oil pressure warning light goes out If oil pressure gauge does not indicate oil pressure or engine oil indicator light does not go out within ten seconds stop engine and investigate cause before starting again a Observe the following guidelines for engine warm up 1 If temperature is greater than 32 F 09 warm up engine for approximately 15 minutes 2 If temperature is less than 32 F 0 C warm up engine for approximately 30 minutes 3 If temperature is less than O F 32 C or if hydraulic functions are sluggish additional time may be required b Allow a cold engine to wa
173. r Separator Service 1 0016 00 1 G GlOSSaty c ete trot ceed A le S 0001 00 3 H Hydraulic Oil Level Check ove tbe ii le Cad 0018 00 1 Oil Tank Dran sc cos ern ee es aah date 0019 00 3 Onl Panky Fill 22 AAA GCE rn Re a Eee 0019 00 4 Initial Adjustments and Daily Checks 0005 00 1 Inspection of Components 0013 00 1 L List Abbreviations cesse tier A ER PEPEGNNMURS MESES IU Due IS 0001 00 3 Additional Authorization List 0028 00 1 Basic Issue Items BID 2 222 222 a dS 0027 00 1 Components of End Item COED 0027 00 1 Location and Description of Major Components 0002 00 2 Lubrication Chart nd e e cuu pe hs cb bt ed 0011 00 5 General Procedures conis dd nee ren 0011 00 3 Key 0011 00 4 M Maintenance Forms Records and Reports 0001 00 1 Mount and Dismount Roller 2 1 0005 00 4 Index 2 Subject Move Roller TM 5 3895 379 10 INDEX Continued M Continued Nomenclature Cross Reference
174. r s skill and judgement 2 The best operating roller stability indicator is the human operator with the ability to comprehend working conditions based on the relevant environmental situation and the operator s feel for the roller to predeter mined situations potential hazards and determine the proper operating decisions to keep the roller in a safe operating mode Vibration selection allows independent vibratory or static operation of either drum Two amplitudes of vibration high and low are always available to the operator to accommodate the needs of a variety of operations A water spray system wets the drum to help prevent hot asphalt from sticking to the drum surfaces during the com pacting operation Water spray can be constant or intermittent to accommodate the needs of a variety of environ ments Two identical but separate tanks each with their own pump and filter are located on the front and rear of the roller and allow for extended operation between fill ups A tie line is provided allowing the operator to use one pump and tank to supply water to spray both drums in the event of failure of the other pump 60 40 articulation simplifies maneuvering of the roller 60 of the roller is behind the pivot while 40 is ahead of the pivot This allows the operator to concentrate on only one drum when entering or leaving a curve and decrease risk of damage when moving roller away from curbs or other stationary objects Operator station pi
175. r spray move water spray switch 2 to forward position 401 046 b For continuous water spray move water spray switch 2 to rear position 0005 00 12 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE WATER SPRAY SYSTEM CONTINUED 3 Override Failed Water Spray System Pump a fF NOTE Water spray system consists of two identical but separate systems located at each end of the roller If pump of one system fails operator can open the tie line valve to supply water flow to both systems For the CB534C Roller use switches on operator console to select proper pump and tank for use Refer td WP 0005 00 Lift latch 3 pull handle 4 toward front of roller 5 and open right side door assembly 6 Unhook lanyard 7 from door assembly 6 and hook lanyard to frame assembly 8 Turn tie line valve 9 to OPEN position Unhook lanyard 7 from frame assembly 8 and hook lanyard to door assembly 6 Close right side door assembly 6 push handle 4 into latch 3 and close latch EAN 401 047 0005 00 13 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE WATER SPRAY SYSTEM CONTINUED 4 Water Spray System Off a Move water spray switch 2 to center position CAUTION Water spray system must be drained at the end of each work day and filled at the beginning of the next work day Draining ensures the removal of d
176. rams 0 454 Kilograms Pounds 2 205 Short Tons Metric Tons 0 907 Metric Tons Short Tons 1 102 Pound Feet Newton Meters 1 356 Newton Meters Pound Feet 0 738 Pounds per Sq Kilopascals 6 895 Kilopascals Pounds per Sq 0 145 Inch Inch Miles per Gallon Kilometers per Liter 0 425 Kilometers per Liter Miles per Gallon 2 354 Miles per Hour Kilometers per Hour 1 609 Kilometers per Hour Miles per Hour 0 621 PIN 077802 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 lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor ch
177. rm up at low idle for a minimum of five minutes Complete warm up requires approxi mately 15 minutes in temperatures above 32 F 0 C c Observe warning and indicator lights frequently during warm up d Cycle all steering and propel controls several times to allow warm hydraulic oil to circulate through all cylinders and lines 0005 00 9 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED 4 Shut Down Engine CAUTION Stopping engine immediately after it has been working under load can cause overheating and accelerated wear of engine components Failure to run engine at low idle for five minutes after operation may cause damage to engine NOTE Engine shutdown is the same for CB534B and CB534C Rollers CB534B Rollers is shown a With roller stopped run engine at low idle for five minutes b Turn engine start switch key 16 to OFF position Remove key from switch 401 2214 0005 00 10 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED 5 Turn Off Battery Disconnect Switch NOTE Turn battery disconnect switch off at the end of each work day a Lift latch 1 push handle 2 toward front of roller 3 and open right side door assembly 4 b Unhook lanyard 5 from door assembly 4 and hook lanyard 5 to frame assembly 6 c Turn key 7 until battery disconnect switch 8 is in OFF position Re
178. roller drums The propel speed switch is a toggle switch that controls whether the propel system operates in high speed range hare or low speed range tortoise by activating the shift solenoid to change the flow rate of hydrau lic oil to the propel gearboxes Inside each propel gearbox is a brake which is automatically engaged when there is no hydraulic pressure resulting from the activation of the propel system in forward or reverse When the roller needs to be moved while the engine is not run ning a manual brake release pump can be used to release the brakes Brake and neutral start relays in the system prevent movement of the roller during the starting procedure The power for the propel system comes from a four cylinder turbocharged diesel engine mounted in the center of the roller The engine is attached to the propel hydraulic pump which provides the pressure charge for the propel system The fuel hydraulic oil tank consists of the hydraulic tank located on the left side and the fuel tank located on the right side Although the tanks are welded together they are separate in their function The CB534B Roller hydraulic oil tank holds 15 5 gallons 59 liters of hydraulic oil The CB534C Roller hydraulic tank holds 24 gallons 91 liters of hydrau lic oil The fuel tank holds 55 gallons 208 liters of diesel or JP 8 fuel to supply the engine PROPEL CONTROL LEVER FUEL HYDRAULIC OIL TANK DRUM Pm lt DRUM PROP
179. s 4 Tighten bolts securely using 24 mm wrench 5 Repeat steps through 4 for right handrail 6 Stow 24 mm wrench in toolbox HANDRAILS POSITIONED Vr TOOLBOX w A OPERATION A At 401 2195 0022 00 1 TM 5 3895 379 10 ADJUST HANDRAILS FOR OPERATION OR STOWAGE CONTINUED 0022 00 ADJUST FOR STOWAGE 1 Remove 24 mm wrench from toolbox Be WARNING Use caution when handling heavy parts Provide adequate support and use assistance during procedure Fail ure to follow this warning may cause injury CAUTION Failure to hold handrail assembly in place during removal will allow handrail assembly to fall and become damaged 2 While assistant holds left handrail assembly 1 remove two bolts 2 and washers 3 from plate assemblies 4 using 24 mm wrench 3 Raise handrail assembly 1 until holes in handrail align with top holes in plate assemblies 4 4 Install two washers 3 and bolts 2 in middle holes in handrail assembly 1 and plate assemblies 4 Tighten bolts securely using 24 mm wrench HANDRAILS HANDRAIL N TOOLBOX IN STOWED STOWAGE POSITION 401 2196 5 Repeat steps through 4 for right handrail 6 Stow 24 mm wrench in toolbox 7 Remove chocks WP 0005 00 END OF WORK PACKAGE 0022 00 2 TM 5 3895 379 10 DRUM SCRAPER SERVICE 0023 00 THIS WORK PACKAGE COVERS Cleaning and Inspection Adjustment
180. s ea ERRORES a Operate ccce RO Ue She A E A ARS Equipment Characteristics Capabilities and Features ae ta det A A ro Equipment Improvement Recommendation EIRs Reporting Expendable and Durable Items 46 Index 1 Work Package Page 0001 00 3 0028 00 1 0022 00 1 0027 00 1 0005 00 19 0013 00 1 0013 00 1 0013 00 1 0027 00 1 0004 00 2 0001 00 1 0007 00 2 0006 00 12 0001 00 1 0002 00 3 0005 00 20 0023 00 1 0003 00 1 0006 00 3 0017 00 1 0014 00 1 0014 00 2 0005 00 5 0002 00 1 0002 00 3 0001 00 1 0029 00 1 TM 5 3895 379 10 INDEX Continued Subject Work Package Page E Continued Extreme Cold Operate 0006 00 8 Extreme Heat Operate nak 22 2 0 2080 PA SNR Ba bias bake 0006 00 11 F Fording sre a LIE Tid IUIUS GUTEN ee Ae E QUT ts 0006 00 12 Front and Rear Propel Gearbox Oil Check and Service 534 0021 00 1 Fuel Fill Tank soe tec eee s ost E e ERI D e e ee s oae 0015 00 4 Filter kde tre beh ee c bou e slik 0015 00 2 Level Check REND ECRIRE p TEE RU 0015 00 2 Tank DT 0019 00 1 Tank ae WP PUPPI 0019 00 5 Fuel Wate
181. s of equipment not requiring lubrication free of lubricants After lubrication wipe off excess lubricant to prevent accumulation of foreign matter 6 Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA Pam 738 750 for forms and procedures to record and report any findings 0011 00 3 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL LUBRICATION PROCEDURES CONTINUED NOTE Only lubricants authorized for use by the operator are listed in this KEY KEY EXPECTED TEMPERATURES LUBRICANT REFILL Above 15 F 40 F to 15 F 40 F to 65 F COMPONENT CAPACITY Above 9 C 4 C to 26 C 4 C to 54 C INTERVALS OE HDO D Daily Lubricating Oil ICE W Weekly Tactical Service M Monthly MIL PRF 2104 OEA 30 Lubricating Oil ICE Arctic MIL PRF 46167 Engine Crankcase 2 3 gal OE HDO 15 40 OE HDO 10 OEA 30 91 Hydraulic Oil Tank 15 5 gal OE HYDO 10 OE HYDO 10 59 1 CB534B Roller 24 gal OEA 30 91 D CB534C Roller GAA Grease Automotive and Artillery Front and Rear Ring Bear As Reqd ings 50 Synthetic Oil ISO 220 Front and Rear Vibratory 3 1 gal 12 1 All Temperatures Bearing Reservoirs GO Lubricating Oil MIL PRF 2105 Front Propel Gearbox 0 5 gal 2 1 GO 75 GO 75 GO 80W 90 Rear Propel Gearbox 0 6 ga
182. s that can restrict air evident Radiator is damaged flow or debris is restricting air flow Before Electrical Check for loose or frayed wires and Wires are frayed or loose or Wires loose connectors connectors are loose Before Hydraulic Check for crimped torn or damaged Hydraulic hoses are crimped Hoses hydraulic hoses torn or damaged Before 0 2 Hours Engine Oil Check engine oil level If engine oil Level level is low add oil WP 0014 00 Engine oil level is low 0012 00 5 TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before 0 1 Hours LOCATION ITEM TO CHECK SERVICE Fuel Water Separator Secondary CB534C Only PROCEDURE NOT FULLY MISSION CAPABLE IF WARNING DO NOT perform fuel water separator checks inspections or draining while smoking or when near fire or sparks Fuel may ignite causing injury death or damage to roller a Check fuel water separator for leaks or damage such as cracks b Place container with minimum qt capacity under fuel water sepa rator c Open drain valve and drain fluid until only fuel comes out Close drain valve d Dispose of drained fluid in accor dance with local regulations Check for damaged or missing V belts 0012 00 6 Any leakage from
183. seat belt while operating roller is mandatory Fasten belt BEFORE driving Trying to fasten belt while WARNING driving creates a hazardous condition Failure to follow this warning may result in injury or death Fasten Seat Belt 1 Sit on seat 5 hold gripper 11 and extend seat belt 12 from retractor 13 2 Insert extrusion 14 into buckle 15 until securely latched Unfasten Seat Belt 1 Push button 16 and remove extrusion 14 from buckle 15 2 Allow seat belt 12 to slowly retract into retractor 13 Adjust Operator Station Position WARNING Do NOT operate roller with operator sta tion in unlocked position Failure to follow this warning may cause injury or death NOTE When rolling operations require operator to watch surfaces or edges of both drums such as side to side rolling operator sta tion can be moved 90 degrees in either direction Holes are provided to lock operator station in 45 degree or 90 degree position Pull lever 17 up and move operator station 18 to desired position Align bottom top of lever 17 with hole in oper ator platform 19 Release lever 17 to lock operator station 18 in position Ensure that lever 17 is securely seated in hole in operator platform 19 0005 00 3 E 401 037 401 038 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 MOUNT AND DISMOUNT ROLLER WARNING e
184. sor TM 5 3895 379 10 CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION 0011 00 GENERAL 1 To ensure that the CB534B 534 Rollers Motorized Vibrating Tandem Steel Drums are ready for operation at all times they must be inspected on a regular basis so that defects may be found and corrected before they result in injury or equipment failure or damage The PMCS Table in WP 0012 00 contains systematic instructions on inspections lubrications services adjustments and corrections to be performed by the operator to keep the roller in good operating condition and ready for its primary mis sion EXPLANATION OF TABLE ENTRIES 1 Item Number Item No Column Numbers in this column are for reference When completing DA Form 2404 or DA Form 5988 E Equipment Inspection and Maintenance Worksheet include the item number for the check service indicat ing a fault Item numbers also appear in the order that you must perform checks and services for the interval listed Interval Column This column tells you when you must perform the procedure in the procedure column a Before procedures must be done immediately before you operate the roller b During procedures must be done while you are operating the roller c After procedures must be done immediately after you have operated the roller d Weekly procedures must be done once eac
185. ss and consistency of bottom surface Do NOT attempt to ford if depth exceeds 10 in 25 cm 2 Ensure all gauges are indicating normal operating pressure and temperature 3 Stop roller at edge of water 4 Enter water slowly 25 After fording wash roller and wipe clean and dry 6 Perform lubrication services as soon as possible with assistance from Field Maintenance NUCLEAR BIOLOGICAL AND CHEMICAL NBC DECONTAMINATION PROCEDURES The decontamination kit bracket is mounted on the rear of the roller Refer to TM 3 4320 214 12 amp P for operation of the decontamination Kit END OF WORK PACKAGE 0006 00 12 TM 5 3895 379 10 STOWAGE AND DECAL DATA PLATE AND STENCIL GUIDE 0007 00 INTRODUCTION 1 This work package shows the location for stowage of equipment and materials required to be carried on the Roller Motor ized Vibrating Tandem Steel Drums 2 This work package also includes illustrations showing the location of all decals data plates and stencils on the Roller 3 Decal and data plates are the same for the CB534B and CB534C Rollers except where noted CB534B Roller is shown STOWAGE GUIDE 1 The equipment stowage locator is designed to help inventory items required for safe and efficient operation 2 The equipment locator is representative of and applicable AAL stowage on the roller Refer to WP 0027 00 for a list ing of and AAL items c EN 9 D 401
186. stall secondary and Red indicates a clogged air primary filter elements and cleaner primary or secondary cover and close two air cleaner element If filter service housing latches Reset air filter indicator shows red in viewing service indicator Close left side window unlatch two air door assembly WP 0005 00 cleaner housing latches and remove cover Remove primary and secondary elements from air cleaner housing If air cleaner primary element is torn or ripped notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches Reset air filter service indicator Close left side door assembly WP 0005 00 AIR CLEANER SECONDARY HOUSING ELEMENT SERVICE e PRIMARY 7 7 da ELEMENT AT 22 AIM VIEWING Xu Say 555555570 555 h 555555555550659 LAS 555 gt RR eM LX Z S AIR CLEANER HOUSING LATCHES AIR CLEANER 401 084 HOUSING COVER 0010 00 21 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 9 Engine is Using More Fuel Than Usual c If air cleaner secondary Continued element is clogged notify supervisor for replacement Install secondary and primary filter elements and cover and close two air cleaner housing latches
187. t broken fault not corrected Install fuse and cap in fuse holder and notify supervisor TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION VIBRATORY SYSTEM 33 Vibration Frequency Start up is Slow Time Lag After Travel Starts is Excessive 34 Vibration Mechanism is Noisy 35 Vibratory System Will Not Work Forward and Reverse Travel NOTE When systems are cold cold bearing friction can cause slow vibration frequency start up travel starts 1 Ensure that systems are warm 2 Check vibratory bearing reservoir for correct level of oil WP 0020 00 Check vibratory bearing reservoir for correct level of oil WP 0020 00 1 Check hydraulic oil level 0018 00 2 Turn fuse holder cap counterclockwise and remove cap and fuse from fuse holder labeled VIBE Inspect fuse for broken filament 0010 00 37 and excessive lag time after Stop roller and allow systems to warm up before attempting mission If symptom persists go to Step 2 a If vibratory bearing reservoir is low of oil fill vibratory bearing reservoir WP 0020 b If vibratory bearing reservoir oil is at correct level and soil condition and base are correct fault is not corrected Notify supervisor If vibratory bearing reservoir oil is low fill vibratory bearing reservoir WP 0020 00 If vibr
188. t information are highlighted in BOLD print as visual aid WARNING A WARNING indicates a hazard which may result in injury or death CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in dam age to equipment NOTE A NOTE is a statement containing information that will make the procedures easier to perform 2 Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis 3 Within a procedural step reference may be made to another work package in this manual or to another manual These ref erences indicate where you should look for more complete information If you are told Start engine WP 0005 00 go tq WP 0005 00 in this manual for instructions on starting engine 4 Illustrations are placed after and as close to the procedural steps to which they apply Callouts placed on the art are text or numbers 5 Numbers located at lower right corner of art e g 401 001 401 002 etc are art control numbers and are used for tracking purposes only 6 Technical instructions include metric units as well as standard units For your reference a Metric Conversion Chart is located on the inside back cover of the manual TM 5 3895 379 10 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION TM 5 3895 379 10 GENERAL INFORMATION 0001 00 SCOPE 1 Type of Manual This manual is used for operating and performing op
189. terclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled BACKUP ALARM cap in fuse holder Inspect fuse for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor 18 Alternator Indicator Is On Open left side door assembly If alternator indicator is still on and press fault is not corrected Close left alternator circuit breaker button side door assembly 00 Notify supervisor 0010 00 30 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM CONTINUED 19 Work Lights and Gauge Lights Do Not Press lights circuit breaker If work lights and gauge lights Operate button still do not operate fault is not corrected Notify supervisor 9 2 CBSMB SHOWN LIGHTS CIRCUIT BREAKER BUTTON 401 092 20 Horn Does Not Operate Turn fuse holder cap a If fuse filament is broken counterclockwise and remove notify supervisor for cap and fuse from fuse holder replacement Install fuse and labeled BACKUP ALARM cap in fuse holder Inspect fuse for broken filament If fuse filament is not broken fault is not corrected Install fuse and cap in fuse holder and notify supervisor KEY START BACKUP ALARM WATER SPRAY GAUGE
190. udov com
191. ures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE CONTINUED 3 Engine is Sluggish Continued 3 Remove strainer and visually a If fuel tank is empty fuel level inspect fuel in fuel tank gauge does not operate Install strainer and fill fuel tank with fuel WP 0015 00 Notify supervisor If fuel is contaminated with dirt drain fuel tank and fill with clean fuel WP 0019 00 Notify supervisor If fuel tank contains clean fuel install strainer fuel assembly and padlock and go to Step 4 4 Open right and or left side a Open fuel water separator s door assembly WP 0005 00 drain valve s and drain separator s WP 0016 00 If engine is still sluggish go to Step 5 If engine is no longer sluggish close left side door assembly WP 0005 00 0010 00 12 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION 3 Engine is Sluggish Continued SERVICE WHEN VIEWING WINDOW SERVICE TEST OR INSPECTION ENGINE CONTINUED 5 Check air filter service indicator for red indication in viewing window Red indicates a clogged air cleaner primary or secondary element If filter service indicator shows red in viewing window unlatch two air cleaner housing latches and remove cover Remove primary and secondary elements from air cleaner housing AIR FILTER
192. ve machine s Operator s Manual while attempting to start roller engine WP 0005 00 When roller engine is running smoothly remove NATO slave cable connectors 4 from NATO connec tors 2 of live machine and roller Install caps 3 on NATO slave cable connectors 4 Install caps 1 on NATO connectors 2 on live machine and roller Move and park live machine refer to live machine s Operator s Manual Shut off live machine refer to live machine s Operator s Manual 0006 00 2 401 082 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY PROCEDURES NOTE Emergency procedures for the CB534B and CB534C Rollers are the same CB534B Roller is shown 1 Emergency Shutdown a Stop roller by moving propel control lever 5 to NEUTRAL position b engine start switch 6 fully counterclockwise This will shut down power to all systems at once 401 2174 0006 00 3 TM 5 3895 379 10 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 EMERGENCY PROCEDURES CONTINUED 2 Manual Release of Parking Brakes WARNING Ensure that roller is secured to prevent movement Roller may freewheel when brakes are released Ensure that path of roller travel is clear of personnel and equipment Failure to follow this warning may result in injury or death NOTE Roller brakes are automatically engaged when the propel control lever is in NEU
193. vere injury or death from crushing could occur e Steering frame must be locked before 72277 77 lifting transporting or servicing ZA GL roller in articulation area to prevent UWA GR N injury or death from crushing e Unlock steering frame before opera tion to prevent loss of steering that may cause injury or death 0005 00 5 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED 1 Turn On Battery Disconnect Switch NOTE Turn battery disconnect switch on at the beginning of each work day a Lift latch 1 push handle 2 toward front of roller 3 and open right side door assembly 4 b Unhook lanyard 5 from door assembly 4 and hook lanyard to frame assembly 6 c Insert and turn key 7 until battery disconnect switch 8 is in connected position d Unhook lanyard 5 from frame assembly 6 and hook lanyard to door assembly 4 e Close right side door assembly 4 push handle 2 into latch 1 and close latch 401 041 0005 00 6 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE ENGINE CONTINUED 2 Start Engine Above 32 F 0 C a Push down parking brake knob 9 to ensure parking brake is engaged NOTE Engine will not start unless propel control lever is in NEUTRAL position b Move propel control lever 10 to NEUTRAL position center c Move water spray switch 11 to O
194. vestigate travel route for overpass clearances Ensure that there is adequate clearance for roller being trans ported Refer tq WP 0002 00 for roller dimensions b Before loading roller remove ice snow and other slippery material from loading dock and truck bed to prevent slippage of roller and shifting while in transit c Before loading roller place chock block in front of and behind trailer or railcar wheels Apply parking brake d Travel at moderate speed and observe all speed limitations when transporting roller 0005 00 22 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 PREPARATION FOR TRANSPORT CONTINUED 2 Lift Machine onto Shipping Bed NOTE Refer to Equipment Data ih WP 0002 00 and roller shipping date plate WP 0007 00 for information on roller dimensions and weights and for instructions on lift points a Ensure that all water tanks are empty WP 0024 00 WARNING Steering frame must be locked before lifting roller to prevent injury or death from crushing b Lock steering frame as follows 1 Remove clip 1 and pin 2 from articu lation yoke 3 2 Position steering frame lock bolt 4 to bottom of slot in articulation yoke 3 3 Install pin 2 in bottom hole in articula tion yoke 3 ensuring steering frame lock bolt 4 is below pin 2 4 Install clip 1 in pin 2 c Position crane or other lifting device so that roller will be lifted in
195. vots 90 degrees in either direction to allow the operator to view drum surfaces and edges during back and forth rolling operation The gauges and controls move with the operator station The Roll Over Protective Structure ROPS canopy helps protect the operator from potential hazards resulting from equipment roll over and falling objects 0002 00 1 TM 5 3895 379 10 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS NOTE Location and description of major components are the same for the CB534B and CB534C Rollers CB534B Roller is shown na Stee E E t DJ fi 10 9 8 6 2022 DESCRIPTION Rollover Protective Structure The ROPS canopy helps protect the operator from potential hazards ROPS resulting from equipment roll over and falling objects Fuel Hydraulic Oil Tank The fuel and hydraulic tanks are connected yet separate Fuel is stored in the right side The left side stores hydraulic oil Water Spray Bars The water spray bars spray the drum surfaces with water to help prevent hot asphalt from sticking to the drums There is a water spray bar located above front and rear drum Frame Assembly The frame assembly provides a means of support for the roller components Vibratory Motors The vibratory motors turn eccentric weights inside the drums which create vibrating force that aids in surface material compaction They ar
196. when work ing on roller while it is operating Failure to wear hearing protection may result in hearing loss Ensure area around the roller is clear of personnel before starting engine Failure to follow this warning may cause injury or death a Push propel control lever forward b Pull up on parking brake switch to release parking brake c Ensure that area is free of personnel and path of travel is clear d Position propel control lever in full forward position e Insert key in engine start switch NOTE Do NOT allow engine to start during this check Hold engine start switch key in START position while slowly mov ing propel control lever to full back REVERSE and then to center NEUTRAL STOP position Turn engine start switch to OFF position 0012 00 11 Engine attempts to start before control lever is in NEUTRAL position TM 5 3895 379 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for DSWR Continued INTERVAL Before Before LOCATION ITEM TO CHECK SERVICE Throttle Con trol CB534B Gauges and Warning Indicators PROCEDURE Turn throttle lock counterclockwise press and hold button down and pull throttle control fully up fully down checking for free movement without sticking or binding Release button WARNING LIGHTS
197. ystem can be activated at any time including while the roller is stopped b Move the vibratory control switch 2 to the rear position to activate the vibratory system in the 401 046 manual mode 3 Turn Vibratory System On and Off 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 CAUTION Never start or stop the roller abruptly Damage to the propel and braking systems can occur NOTE When the vibration push switch is on the vibratory system indicator light will be on while the engine is run ning a Press the vibration push switch 3 to turn the vibratory system on b Press the vibration push switch 3 again to turn the vibratory system off 0005 00 15 TM 5 3895 379 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE VIBRATORY SYSTEM CONTINUED 4 Amplitude Select Mode NOTE As the drum vibrates it travels in an up and down motion The vertical distance is called amplitude This vertical movement is how the roller creates compaction of the surface material a Move the amplitude select switch 4 to the for ward position to operate the vibratory system in the high pitch mode b Move the amplitude select switch 4 to the rear position to operate the vibratory system in the low pitch mode 401 048 MOVE ROLLER NOTE CB534B and CB534C Rollers are moved the sa
198. zles WP 0025 00 nozzle s Notify supervisor for replacement of components If water spray nozzles are not clogged corroded or damaged fault is not corrected Notify supervisor 0010 00 42 TM 5 3895 379 10 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION WATER SPRAY SYSTEM CONTINUED 41 Water Consumption is Unequal Between Tanks 1 On CB534B check that the water tank shutoff valve at the non operating tank is open Valve handle will be in line with the valve when the valve is open WATER TANK SHUTOFF VALVE FRONT SIDE SHOWN REAR SIDE SIMILAR 42 Nozzle Spray Pattern is Inconsistent END OF WORK PACKAGE gt PLATE SHOWN REMOVED FOR CLARITY 2 Check for pinched or damaged water lines 3 Check and service water spray nozzles WP 0025 00 Check and service water spray nozzles WP 0025 00 0010 00 43 0010 00 44 Blank CORRECTIVE ACTION a If water tank shutoff valve is not open open valve b If water tank shutoff valve is open go to Step 2 401 094 a If a water line s is damaged component is faulty notify supervisor b If water lines are not damaged fault is not corrected Notify supervisor If malfunction continues fault is is corrected Notify supervisor If malfunction continues fault is not corrected Notify supervi

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