Attachment_0023__Vibratory_Roller_-_Type_II_-_TM_5-3895-383-10.pdf

TM 5-3895-383-10

HEADQUARTERS, DEPARTMENT OF THE ARMY 21 SEPTEMBER 1999

TECHNICAL MANUAL

OPERATOR’S

MANUAL

ROLLER, VIBRATORY,

SELF-PROPELLED,

Type II

CATERPILLAR MODEL CS-563D

NSN 3895-01-456-2735

Contract No. DAAE07-98-C-S007

Approved for public release;

distribution is unlimited.

INTRODUCTION 1-1

PREVENTIVE MAINTENANCE CHECKS

AND SERVICES (PMCS) AND

LUBRICATION INSTRUCTIONS 2-1

MILITARY-SPECIFIC OPERATION 3-1

CATERPILLAR KEBU7503-03,

OPERATION AND MAINTENANCE

MANUAL 4-1

REFERENCES A-1

COMPONENTS OF END ITEM (COEI)

AND BASIC ISSUE ITEMS (BII) LISTS B-1

ADDITIONAL AUTHORIZATION LIST C-1

STOWAGE AND SIGN GUIDE D-1

TRANSPORTABILITY INSTRUCTIONS E-1

ALPHABETICAL INDEX Index-1

CHANGE HEADQUARTERS

No. 1 DEPARTMENT OF THE ARMY

Washington, DC, 15 September 2003

OPERATOR’S MANUAL

FOR

ROLLER, VIBRATORY, SELF-PROPELLED,

Type II

CATERPILLAR MODEL CS-563D

NSN 3895-01-456-2735

Approved for public release; distribution is unlimited.

TM 5-3895-383-10, 21 September 1999, is changed as follows:

1. File this sheet in front of the manual for reference.

2. New or changed material is indicated by a vertical bar in the margin of the page.

3. Minor changes to illustrations are indicated by a miniature pointing hand.

4. Illustrations that are new or that have major revisions are indicated by a vertical bar adjacent to the art.

5. Remove old pages and insert new pages as indicated below.

Remove Pages Insert Pages e and f e and f A and B A and B 1-1 and 1-2 1-1 and 1-2 2-17 and 2-18 2-17 and 2-18 3-9 through 3-16 3-9 through 3-16 B-1 through B-2 B-1 through B-2 Back Cover Back Cover

By Order of the Secretary of the Army:

Official:

JOEL B. HUDSON

Administrative Assistant to the

Secretary of the Army 0306718

PETER J. SCHOOMAKER

General, United States Army

Chief of Staff

DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) 256549 requirements for TM 5-3895-383-10.

a

This section contains all WARNINGS contained in the military-specific supplemental data. All warnings contained in the Commercial Off-The-Shelf (COTS) Manual are not included herein.

CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU

Carbon monoxide is a colorless, odorless, DEADLY POISONOUS gas and when breathed deprives body of oxygen and causes SUFFOCATION. Breathing air with carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and coma. Permanent BRAIN DAMAGE or DEATH can result from severe exposure.

The following precautions MUST be followed to ensure personnel are safe when engine is operated for any purpose.

• DO NOT operate engine of vehicle in enclosed area without adequate ventilation.

• DO NOT idle engine for long periods without ventilation.

• DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment doors removed unless necessary for maintenance purposes.

• NEVER sleep on the Roller when the engine is idling.

• BE ALERT at all times during Roller operation for exhaust odors and exposure symptoms. If either are present, IMMEDIATELY EVACUATE AND VENTILATE the area. Affected personnel treatment shall be: expose to fresh air; keep warm, DO NOT PERMIT PHYSICAL EXERCISE; if necessary, give artificial respiration and get medical attention.

• BE AWARE: neither the gas particulate filter unit nor field protection mask for nuclear-biological-chemical protection will protect you from carbon monoxide poisoning.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION

Personnel hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of 85 dB (A) or greater. Wear approved hearing protection devices when working within 20 ft (6.1 m) of Roller. Personnel exposed to high noise levels shall participate in a hearing conservation program in accordance with DA Pam 40-501. Hearing loss occurs gradually but becomes permanent over time.

Do not turn vibratory system on while Roller is standing still on a very solid surface. A loss of steering can be experienced which could result in injury to personnel.

b

• Mount and dismount the Roller only where steps and/or handrails are provided.

• Clean shoes and wipe hands before climbing on Roller. Use handrails when mounting Roller.

• Inspect, clean, and have any necessary repairs made to steps prior to mounting the Roller.

• Always use “three-point contact” with Roller; face Roller when entering or leaving operator’s station.

Three-point contact means that three out of four arms and legs are in contact with Roller at all times during mount and dismount.

• ROPS canopy has 55 in.

(139.7 cm) clearance above operator platform at the lowest point. Use care when mounting or dismounting Roller to prevent injury to head.

• Never get on or off a moving Roller.

• Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment.

• Never jump off the Roller.

• Do not attempt to climb on or off the Roller while carrying tools or supplies.

Always apply parking brake before dismounting the Roller while the engine is running.

Failure to comply may result in personal injury or death.

Water depth greater than 10 in. (254 mm) can cause personal injury and damage to the Roller. The Roller should not enter water deeper than 10 in. (254 mm).

c

• There is no clearance for personnel between frame and yoke when Roller turns. Severe injury or death from crushing could occur.

• Steering frame must be locked before lifting, transporting, or servicing Roller in articulation area with engine running to prevent serious injury or death from crushing.

• Unlock steering frame before operation to prevent loss of steering that may cause serious injury or death to personnel.

• Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective goggles and gloves, use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and, do not breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the flashpoint for drycleaning solvent type III is 200°F (93°C). Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning.

• DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPEN FLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent only in well-ventilated places.

• USE CAUTION when using cleaning solvents. Cleaning solvents evaporate quickly and can irritate exposed skin if solvents contact skin. In cold weather, contact of exposed skin with cleaning solvents can cause frostbite.

d

Fuel is very flammable and can explode easily. To avoid serious injury or death:

• Keep at least a B-C fire extinguisher within easy reach when working with fuel or fuel system.

• When refueling, stop engine and apply parking brake. Ensure no open flame is near area. Never smoke while working with fuel. Never add fuel when engine is running. Do not have a driver seated when adding fuel.

• Ground fuel funnel or nozzle against filler neck to prevent sparks and be sure to replace fuel tank cap. After fuel is added, securely close fuel cap assembly; a loose cap assembly can cause a fuel leak or be a fire hazard.

• Never overfill the tank or spill fuel. If fuel is spilled, clean fuel up immediately. Before starting vehicle, check that no fuel is spilled on or around vehicle.

Do not touch hot exhaust system with bare hands; injury to personnel will result.

Do not start or move Roller while anyone is under Roller. Severe injury or death could result.

Lock the seat into position before operating the Roller to prevent unexpected seat movement. Unexpected movement of seat can cause injury to personnel.

Do not perform fuel/water separator checks, inspections, or draining while smoking, or when near fire or sparks. Failure to comply may cause fuel to ignite and cause injury or death to personnel or damage to Roller.

e/(f blank)

• Ensure area around the Roller is clear of personnel before starting engine. Injury or death to personnel could result.

• Hearing protection is required for operator and also for all personnel working in and around the Roller while engine is running.

• Roller may freewheel when brakes are released.

• Ensure path of travel is free of personnel and equipment.

• Ensure that Roller is secured (chocked or tied down) to prevent undesired movement.

• Failure to follow instructions can result in injury or death to personnel.

Do not touch hot exhaust system with bare hands; injury to personnel will result.

If NBC exposure is suspected, all air filter media will be handled by personnel wearing full NBC protective equipment. Consult your unit NBC NCO for appropriate handling or disposal instructions.

Change 1

Change 1 A/(B blank)

INSERT LATEST UPDATED PAGES/WORK PACKAGES, DESTROY SUPERSEDED DATA

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: The portion of text affected by the updates is indicated by a vertical line in the outer margins of the page. Updates to illustrations are indicated by miniature pointing hands.

Updates to wiring diagrams are indicated by shaded areas.

Dates of issue for original and updated pages/work packages are:

Original...........21 September 1999 Change 1 .......15 September 2003

TOTAL NUMBER OF PAGES IN THIS PUBLICATION FOR FRONT AND REAR MATTER IS 50

AND TOTAL NUMBER OF WORK PACKAGES IS 104 CONSISTING OF THE FOLLOWING:

Page/WP No. *Revision No. Page/WP No. *Revision No. Page/WP No. *Revision No.

Front Cover 0 2-1 – 2-16 0 B-2 1

Title 0 2-17 1 B-3 – B-4 0 a – d 0 2-18 – 2-26 0 C-1 – C-2 0 e 1 3-1 – 3-8 0 D-1 – D-2 0 f 0 3-9 – 3-15 1 E-1 – E-16 0

A 1 3-16 – 3-22 0 Index 1 – Index 2

B 0 4-1 – 4-50 0 2028 Sample Front & Rear i – iv 0 A-1 – A-2 0 2028 Front & Rear

1-1 1 B-1 0 Back Cover 1

1-2 – 1-6 0

*Zero in this column indicates an original page or work package.

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 5-3895-383-10 Washington, D.C. 21 September 1999 i

OPERATOR’S MANUAL

FOR

ROLLER, VIBRATORY, SELF-PROPELLED,

Type II

CATERPILLAR MODEL CS-563D

NSN 3895-01-456-2735

Contract No. DAAE07-98-C-S007

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028-2 (Recommended Changes to Equipment Technical Publications), through the Internet, on the Army Electronic Product Support (AEPS) web site.

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 ON-LINE 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 or DA Form 2028-2, direct to: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-AC-NML, Rock Island, IL 61299-7630.

The e-mail address is amsta-ac-nml@ria.army.mil. The fax number is DSN 793-0726 or Commercial

(309) 782-0726.

TABLE OF CONTENTS

Page

CHAPTER 1 INTRODUCTION.......................................................................................... 1-1

Section I. General Information ..................................................................................... 1-1 Section II. Equipment Description and Data ................................................................ 1-4

CHAPTER 2 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

AND LUBRICATION INSTRUCTIONS ..................................................... 2-1

CHAPTER 3 MILITARY-SPECIFIC OPERATION .......................................................... 3-1

Section I. Operation Under Usual Conditions ............................................................. 3-1 Section II. Operation Under Unusual Conditions....................................................... 3-16

CHAPTER 4 CATERPILLAR KEBU7503-03,

OPERATION AND MAINTENANCE MANUAL......................................... 4-1

ii

TABLE OF CONTENTS (CONT)

Page

APPENDIX A REFERENCES.............................................................................................. A-1

APPENDIX B COMPONENTS OF END ITEM (COEI) AND

BASIC ISSUE ITEMS (BII) LISTS ............................................................ B-1

Section I. Introduction .................................................................................................. B-1 Section II. Components of End Item.............................................................................. B-2

Section III. Basic Issue Items.......................................................................................... B-3

APPENDIX C ADDITIONAL AUTHORIZATION LIST .................................................... C-1

Section I. Introduction .................................................................................................. C-1 Section II. Additional Authorization List...................................................................... C-2

APPENDIX D STOWAGE AND SIGN GUIDE................................................................... D-1

APPENDIX E TRANSPORTABILITY INSTRUCTIONS .................................................. E-1

ALPHABETICAL INDEX................................................................................................................ Index-1 iii/(iv blank)

HOW TO USE THIS MANUAL

This manual is designed to help operate and maintain the Caterpillar Model CS-563D, NSN 3895-01-456-2735, Type II Self-propelled Vibratory Roller. The Roller is a commercially available unit and is altered slightly for military use. This contains a commercial off-the-shelf (COTS) manual with supplemental data to support military-specific maintenance and operation. Listed below are some of the special features that are included to help locate and use the needed information:

Chapter One contains information specific to the military model.

Chapter Two contains the operator’s Preventive Maintenance Checks and Services (PMCS) and Lubrication Instructions.

Chapter Three contains operation instructions specific to the military model.

Chapter Four is the commercial off-the-shelf manual from the manufacturer.

Appendix A lists references related to this manual.

Appendix B contains Components of End Item and Basic Issue Items Lists.

Appendix C covers an Additional Authorized List for the Roller.

Appendix D contains the Stowage and Sign Guide for the Roller.

Appendix E contains the Transportability Instructions. This appendix was added for information only and is not authorization for the operator to perform tasks or maintain additional tools on the vehicle.

An alphabetical index is provided to help locate main items in the text.

FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

The operator shall read through this manual and become familiar with the contents before attempting to operate the Roller.

Read all WARNINGS and CAUTIONS before performing any procedure.

Any information in Chapters One, Two, and Three (Military-specific Operation) overrides any conflicting information contained in Chapter Four (manufacturer’s commercial off-the-shelf manual).

1-1

CHAPTER 1

INTRODUCTION

Para Contents Page

1-1. Scope ............................................................................................................................................ 1-1 1-2. Maintenance Forms and Records............................................................................................... 1-1 1-3. Corrosion Prevention and Control (CPC) .................................................................................. 1-3 1-4. Destruction of Army Materiel to Prevent Enemy Use.............................................................. 1-3 1-5. Reporting Equipment Improvement Recommendations (EIR) ................................................ 1-3 1-6. Location and Description of Military-Specific Components ..................................................... 1-5

Section I. GENERAL INFORMATION

1-1. SCOPE

a. Type of Manual. Operator's Manual.

b. Model Number and Equipment Name. Caterpillar Model CS-563D, Roller, Vibratory, Self-propelled, Type II, NSN 3895-01-456-2735.

The Type II Roller is shown in Figure 1-1 (page 1-2), Figure 1-2 (page 1-2), Figure 1-3 (page 1-2), and Figure 1-4 (page 1-2).

c. The engine compartment has been modified with the addition of hood guide plates illustrated below. These plates serve as a guide to assist hood closure.

d. Purpose of Equipment. The Type II Self-propelled Vibratory Roller, from here on referred to as the Roller, is a self-propelled roller designed to compact soil and gravel bases for parking lots, runways, streets, roads, and highways.

1-2. MAINTENANCE FORMS AND RECORDS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738-750, The Army Maintenance Management System (TAMMS) (Maintenance Management

UPDATE).

1-2

Figure 1-1. Type II Self-propelled Vibratory Roller

Caterpillar Model CS-563D – Left Front View

Figure 1-3. Type II Self-propelled Vibratory Roller (with Pad-foot Shell Installed)

Caterpillar Model CS-563D – Left Front View

Figure 1-2. Type II Self-propelled Vibratory Roller

Caterpillar Model CS-563D - Right Rear View

Figure 1-4. Type II Self-propelled Vibratory Roller (with Pad-foot Shell Installed)

Caterpillar Model CS-563D - Right Rear View

1-3

1-3. CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with the Roller be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.

If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency Report. Use of keywords such as “corrosion,” “rust,” “deterioration,” or “cracking” will ensure that the information is identified as a CPC problem. Submit the form to the address specified in DA PAM 738-750.

1-4. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

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

1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your Roller needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on an SF368 (Product Quality Deficiency Report). Mail it to us at:

Commander, US Army Tank-automotive and Armaments Command

ATTN: AMSTA-AC-NML

Rock Island, IL 61299-7630

A reply will be furnished to you. You may also provide DA Form 2028-2 information to TACOM via datafax or e-mail.

TACOM's datafax number for AMSTA-AC-NML is:

DSN 793-0726

or commercial (309) 872-0726

The e-mail address is: amsta-ac-nml@ria.army.mil

Army Electronic Product Support: http://aeps.ria.army.mil

1-4

Section II. EQUIPMENT DESCRIPTION AND DATA

1-5 (1-6 blank)

1-6. LOCATION AND DESCRIPTION OF MILITARY-SPECIFIC COMPONENTS

(1) DECONTAMINATION KIT BRACKET. The decontamination kit bracket holds the NBC decontamination kit.

(2) ETHER START SYSTEM. The ether start system provides for the introduction of ether into the engine intake system to aid in starting the engine in temperatures below 32°F (0°C).

(3) BACK UP ALARM CUT-OFF SWITCH. The back-up alarm cut-off switch allows the operator to disengage the back up alarm during periods of required low noise levels.

(4) NATO CONNECTOR. The NATO connector is a standard receptacle with which one vehicle can be “jump-started” with another in the event of battery failure.

(5) UNIVERSAL BUMPER. The universal bumper provides the ability to scrape excess material from either the smooth drum or the installed pad-foot shell. When the pad-foot shell is installed, the smooth drum scraper plates are stowed on the front of the bumper.

(6) HYDRAULIC OIL SAMPLING VALVE. The hydraulic oil sampling valve provides an easy means to collect a sample of hydraulic oil for Army Oil Analysis Plan (AOAP) analysis.

(7) KEYLESS START SYSTEM. The military Roller requires no key to start the engine or engage the electrical system. Keyless switches are used for the engine start switch and the battery disconnect switch.

(8) STOWAGE BOX. The stowage box holds the tools needed for the operator to do all authorized maintenance.

(9) RIFLE MOUNTING BRACKET. The rifle mounting bracket holds the operator’s weapon.

(10) MANUAL BRAKE RELEASE PUMP. The manual brake release pump and valve provide a means to release the parking brake while the engine is not running. The Roller has a hydrostatic transmission system which activates the brakes in the absence of positive hydraulic pressure. The pump provides pressure directly to the brakes for temporary release.

(11) ENGINE OIL SAMPLING VALVE. The engine oil sampling valve provides an easy means to collect a sample of engine oil for Army Oil Analysis Plan (AOAP) analysis.

2-1

CHAPTER 2

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

(PMCS) AND LUBRICATION INSTRUCTIONS

2-1. PMCS Introduction ......................................................................................................................2-1 2-2. PMCS Procedures ........................................................................................................................2-1 2-3. Shortened Maintenance Intervals...............................................................................................2-3 2-4. Additional Maintenance Inspections ..........................................................................................2-3 2-5. Leakage Classification and Definition........................................................................................2-3 2-6. General Lubrication Instructions ...............................................................................................2-4 2-7. PMCS Column Entry Explanation .............................................................................................2-6 2-8. PMCS Table..................................................................................................................................2-6

2-1. PMCS INTRODUCTION

Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing equipment to keep it in good condition and to prevent breakdowns. As the Roller’s operator, your mission is to:

Be sure to perform your PMCS each time you operate the Roller. Always do your PMCS in the same order, so it gets to be a habit. Once you’ve had some practice, you’ll quickly spot anything wrong.

Do your BEFORE PMCS just before you operate the Roller or any of the Roller components. Pay attention to WARNINGS, CAUTIONS, and NOTES.

Do your DURING PMCS while you operate the Roller. Pay attention to WARNINGS, CAUTIONS, and NOTES.

Do your AFTER PMCS right after operating the Roller or any of the Roller components. Pay attention to WARNINGS, CAUTIONS, and NOTES.

Do your WEEKLY PMCS once a week.

Use DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet) to record any faults that you don’t immediately fix.

2-2. PMCS PROCEDURES

a. PMCS, Table 2-1 (Page 2-7), lists inspections and care required to keep your Roller in good operating condition. This table is set up so you can do BEFORE and AFTER PMCS while walking around the Roller.

b. The “INTERVAL” column of Table 2-1 tells you when to do a certain check or service.

c. The “PROCEDURE” column of Table 2-1 tells you how to do required checks and services. Carefully follow these instructions.

d. The “EQUIPMENT NOT READY/AVAILABLE IF:” column in Table 2-1 tells you when your Roller is non-mission capable and why the Roller cannot be used.

2-2

2-2. PMCS PROCEDURES (CONT)

e. When something looks wrong and that you cannot fix, write down the problem on your DA Form 2404 or DA Form 5988-E. IMMEDIATELY report the problem to your supervisor.

f. When you do your PMCS, you will always need a rag or two. Following are checks that are common to the entire Roller:

• Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective goggles and gloves;

use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and, do not breathe vapors.

Keep away from heat or flame. Never smoke when using solvent; the flashpoint for drycleaning solvent type III is 200°F (93°C). Failure to do so may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning.

• DO NOT SMOKE when using cleaning solvent. NEVER USE IT NEAR AN OPEN FLAME. Be sure there is a fire extinguisher nearby and use cleaning solvent only in well-ventilated places.

• USE CAUTION when using cleaning solvents. Cleaning solvents evaporate quickly and can irritate exposed skin if solvents contact skin. In cold weather, contact of exposed skin with cleaning solvents can cause frostbite.

(1) Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious problem. Clean as you work and as needed. Use drycleaning solvent (P-D-680, Type III) on all metal surfaces. Use soap and water when you clean rubber or plastic material.

(2) Rust and Corrosion. Check Roller body and frame for rust and corrosion. When any bare metal or corrosion exists, clean and apply a thin coat of oil. Report bare metal or corrosion to your supervisor.

(3) Bolts, Nuts, and Screws. Check all 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.

When you find a bolt, nut, or screw you think is loose, tighten it or report it to your supervisor.

(4) Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. When you find a bad weld, report it to your supervisor.

(5) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.

(6) Hoses and Fluid Lines. Look for wear, damage, and leaks, and make sure clamps and fittings are tight.

Wet spots show leaks, but a stain around a fitting or connector can also mean a leak. When a leak comes from a loose fitting or connector, tighten it. Report when something is broken or worn out to your supervisor.

g. When you check for “operating conditions,” you look to see if the component is serviceable.

2-3

2-3. SHORTENED MAINTENANCE INTERVALS

Local conditions of extreme heat, dust, cold, or wetness dictate that service intervals shall be shortened.

2-4. ADDITIONAL MAINTENANCE INSPECTIONS

Additional maintenance inspections are required for the following reasons:

a. Prolonged storage. Inspect Rollers that have been stored for a period of three months or more.

b. Initial preparation upon receipt.

c. Preparation for storage.

2-5. LEAKAGE CLASSIFICATION AND DEFINITION

It is necessary for you to know how fluid leakage affects the status of the Roller. The following are types/classes of leakage an operator needs to know to be able to determine the status of the Roller. Learn these leakage definitions and remember - when in doubt, notify your supervisor.

• Equipment operation is allowable with minor leakages (Class I or II) with exception to fuel leakage.

Of course, consideration must be given to fluid capacity in the item/system being checked/inspected.

When in doubt, notify your supervisor.

• When operating with Class I or II leaks, continue to check fluid levels as required in your PMCS.

• Any fuel leak or Class III leaks should be reported immediately to your supervisor.

a. CLASS I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.

b. CLASS II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.

c. CLASS III - Leakage of fluid great enough to form drops that fall from item being checked/inspected.

2-4

2-6. GENERAL LUBRICATION INSTRUCTIONS

Do not start or move Roller while anyone is under Roller. Severe injury or death could result.

NOTE

These instructions are mandatory.

a. Intervals. Intervals (on-condition or hard-time) and the related man-hour times are based on normal operation. The man-hour time specified is the time needed to do all the services prescribed for a particular interval. On-condition (OC) oil sample intervals shall be applied unless changed by the Army Oil Analysis Program (AOAP) laboratory. Change the hard-time interval when lubricants are contaminated or when operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The calendar interval will be extended during periods of low activity. When extended, adequate preservation precautions must be taken. Hard-time intervals will be applied in the event AOAP laboratory support is not available. Hard-time intervals must be applied during the warranty period. Intervals shown in this lubrication section are based on calendar and hourly times or calendar times and mileage. An example of a calendar and hourly lubrication is: M/60 HR, in which M stands for monthly and 60 HR stands for 60 hours of Roller operation.

The lubrication is to be performed at whichever interval occurs first for the Roller. Special lubrication intervals and services are shown by the use of an asterisk (*) symbol.

• Drycleaning Solvent (P-D-680, Type III) is TOXIC and flammable. Wear protective goggles and gloves;

use only in a well-ventilated area; avoid contact with skin, eyes, and clothes; and, do not breathe vapors.

Keep away from heat or flame. Never smoke when using solvent; the flashpoint for type III drycleaning solvent is 200°F (93°C). Failure to do so can result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush eyes with water and get immediate medical attention. DO NOT use diesel fuel, gasoline, or benzene (benzol) for cleaning.

b. Clean Fitting Before Lubricating. Clean parts with drycleaning solvent or equivalent. Dry before lubricating.

c. Lubrication After Fording. When fording occurs, lubricate all grease fittings outside and underneath Roller.

d. Lubrication After High-Pressure Washing. After high-pressure washing, lubricate all grease fittings outside and underneath the Roller.

2-5

e. Oil Filter Statement. Oil filters shall be changed as applicable, when:

(1) They are known to be contaminated or clogged.

(2) At prescribed hard-time intervals.

f. AOAP Sampling. Engine oil shall be sampled at 50 hours of operation or 90 days, whichever occurs first, for Active Army Units. Reserve and National Guard activities will use 50 hours or 180 days, whichever occurs first, as prescribed interval. Hydraulic oil shall be sampled once a year. Sampling will be performed as prescribed by DA Pam 738-750.

g. Warranty Hard-time Statement. For equipment under manufacturers’ warranty, hard-time oil service intervals shall be followed for the duration of the warranty. Intervals shall be shortened when lubricants are known to be contaminated or when operation is under adverse conditions (such as longer-than-usual operating hours, extended idling periods, and extreme dust).

h. Operator’s Lubrication Requirements. The following lubrication table gives an overview of lubricants and intervals the operator will need.

Operator’s Lubrication Requirements

Location Temperature Range

Lubricant MIL Symbol

(NATO Code) Specification

Capacity Interval Man-hour

Hydraulic oil tank

Above 0°F (-18°C) HO, SAE 10W

MIL-PRF-2104

21.1 gallons (80 liters)

Before 0.1

-25°F (-32°C) to 0°F (-18°C) HO, 0W20

MIL-L-46167

During

Steering cylinder pins, steering pins, blade cylinder pins, and blade pivot pins

Above -25°F (-32°C) GAA

MIL-G-10924

MIL-G-23827

As required W 0.1

Engine crankcase Above 5°F (-15°C) EO, 15W40

MIL-PRF-2104

After 0.1

-25°F (-32°C) to 5°F (-15°C) EO Sub-zero

MIL-L-46167

5.3 gallons (20 liters [with filter])

EO = Engine Oil GAA = Grease, Automotive and Artillery HO = Hydraulic Oil

Operator’s Coolant Requirements

Location Period

Lubricant MIL Symbol

(NATO Code) Specification

Capacity Interval Man-hour

Cooling System During warranty period ELC 8 gallons (30 liters)

Before 0.1

Cooling System After warranty expiration A-A-52624 8 gallons (30 liters)

Before 0.1

2-6

2-7. PMCS COLUMN ENTRY EXPLANATION

a. Item No. Column. The checks and services are numbered in interval order showing a walk-around sequence around the Roller. Use these numbers in the “TM Item No.” column on DA Form 2404 or DA Form 5988-E when recording faults that you don’t immediately fix.

b. Interval Column. This column indicates when the lubrication, check, and/or service should be performed.

c. Man-hour Column. This column indicates the man-hours required to perform the lubrication, check, and/or service. Man-hours are stated to the nearest 10th of an hour.

d. Location, Item to be Checked or Serviced Column. The underlined items listed in this column are divided into groups indicating the portion of the equipment of which they are a part, i.e. brakes, fuel, engine. Under these groupings a few common words are used to identify the specific item being checked.

e. Procedure Column. This column contains procedures required to perform the checks and services.

f. Equipment Not Ready/Available If: Column. This column contains the criteria that cause the equipment to be classified as EQUIPMENT NOT READY/AVAILABLE because of inability to perform its primary mission. An entry in this column will:

(1) Identify conditions that make the equipment not available for readiness reporting purposes.

(2) Deny use of the equipment until corrective maintenance has been performed.

2-8. PMCS TABLE

Refer to Table 2-1 for operator/crew PMCS procedures for the Roller.

2-7

Table 2-1. Operator Preventive Maintenance Checks and Services

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

1 Before 0.1 Exterior of Roller

Look under Roller for signs of fluid leakage (fuel, oil, and coolant).

Any leakage of fuel or class III leakage of oil or coolant is found.

2 Before 0.1 Exterior of Roller

Check warning and data labels for damage, cleanliness, and readability.

Any WARNING labels are missing or damaged beyond readability.

3 Before 0.1 Steering Frame Lock Pin

Check that steering frame lock pin is in unlocked position. If steering frame lock pin is in locked position, unlock steering frame (page 3-2).

Lock pin is damaged or missing.

2-8

Table 2-1. Operator Preventive Maintenance Checks and Services - CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

4 Before 0.1 Hydraulic Hoses

Check for crimped, torn, or damaged hydraulic hoses.

Hydraulic hoses are crimped, torn, or damaged.

5 Before 0.1 Tires and Wheels

a. Visually inspect tires for proper inflation.

b. Check for obvious damage such as cuts, gouges, abrasions, cracks, damage that extends to the cord body, leaks, or bulges.

c. Check for loose or missing lug nuts or broken studs.

d. Check for missing valve caps.

Tires are visibly under-inflated or flat.

Any tires have cuts, gouges, abrasions, cracks, damage that extends to the cord body, leaks, or bulges.

One or more lug nuts are loose or missing.

One or more studs are broken off.

2-9

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

6 Before 0.1 Engine Right Side

Open hood assembly (Chapter 4).

7 Before 0.1 Electrical Wires, Hydraulic Hoses, and Fuel Lines

a. Check for loose or frayed wires and loose connectors.

b. Check for crimped, torn, or damaged hydraulic hoses.

c. Check for crimped, torn, or damaged fuel lines.

d. Check for fuel leaks.

Wires are frayed or loose or connectors are loose.

Hydraulic hoses are crimped, torn, or damaged.

Fuel lines are crimped, torn, or damaged.

Any fuel is leaking.

2-10

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

Do not perform fuel/water separator checks, inspections or draining while smoking, or when near fire or sparks. Failure to comply may cause fuel to ignite and cause injury or death to personnel or damage to Roller.

Operation of Roller with damaged fuel/water separator can cause engine damage.

8 Before 0.1 Fuel/Water Separator

a. Check fuel/water separator for leaks or damage such as cracks.

b. Place container with minimum 1 qt (1 l) capacity under fuel/water separator.

c. Open drain valve and drain fluid until only fuel comes out. Close drain valve.

d. Dispose of drained fluids in accordance with local regulations.

Any leakage from fuel/water separator is evident or fuel/water separator is damaged.

2-11

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

9 Before 0.1 Hydraulic Oil Level (Cold Oil Check)

NOTE

• Hydraulic oil shall be checked cold and warm.

• Roller must be on level surface for an accurate level reading.

• Disregard markings on sight gauge. Maintain hydraulic oil level according to label markings.

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 hydraulic oil.

Hydraulic oil level is below “LOW” level mark, or above “HIGH” level mark on label.

10 Before 0.1 Air Filter Service Indicator

Check indicator viewing window and arrow while engine is shut off.

Red color appears in viewing window/arrow is at or above 22 INCHES position.

Notify Unit Maintenance for air cleaner element replacement.

2-12

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.

Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

11 Before 0.1 Coolant Check that coolant is present in radiator sight gauge. If coolant is not present, add coolant.

Coolant level is low.

12 Before 0.1 Radiator and Hydraulic Oil Cooler

Check radiator and hydraulic oil cooler for damage, signs of leakage, and debris that can restrict air flow.

Radiator or hydraulic oil cooler is damaged, leaking, or debris is restricting air flow.

13 Before 0.1 Engine Left Side

Electrical Wires and Hydraulic Hoses

a. Check for loose or frayed wires and loose connectors.

b. Check for crimped, torn, or damaged hydraulic hoses.

Wires are frayed or loose or connectors are loose.

Hydraulic hoses are crimped, torn, or

2-13

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

14 Before 0.1 Vee Belts a. Check for damaged or missing vee belts. Any vee belt is loose, missing, broken, greasy, peeling, glazed, cracked to the belt fiber, has more than one crack (1/8 inch in depth or 50% of belt thickness), or has frays more than 2 inches long.

b. Close hood assembly (Chapter 4).

2-14

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

15 Before 0.1 Worklights Check four worklights for broken lenses and bulbs.

Bulbs are broken.

16 Before 0.1 Steps, Operator Platform, and Handholds

a. Inspect steps and handholds for grease, dirt, mud or other foreign material that may cause dangerous climbing environment. Remove any foreign material from steps, operator platform, or handholds.

b. Inspect steps, operator platform, and handholds for damage such as cracks, broken welds, and loose or missing mounting bolts and nuts.

Grease, dirt, mud or other foreign material that may cause dangerous climbing environment is present.

Mounting bolts or nuts are loose or missing or steps, operator platform, or handholds are damaged.

17 Before 0.1 Driver Safety Canopy (Rollover Protection Structure

[ROPS])

Check driver safety canopy (ROPS) for damage such as cracks, holes, broken welds, and loose or missing mounting bolts and nuts.

Mounting bolts or nuts are loose or missing or ROPS is

2-15

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

• Ensure area around the Roller is clear of personnel before starting engine. Injury or death to personnel could result.

• Hearing protection is required for operator and also for all personnel working in and around the Roller while engine is running.

18 Before 0.1 Warning and Indicator Lights and Warning Horn

a. Turn on battery disconnect switch (page 3-5).

NOTE

Do not allow engine to start during this check.

b. Turn engine start switch to ON position; observe warning and indicator lights.

c. Return engine start switch to OFF position.

Warning and indicator lights do not illuminate.

19 Before 0.1 Horn Check that horn sounds when horn switch is pressed.

2-16

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

20 Before 0.1 Neutral Start Switch

a. Ensure that area is free of personnel and path of travel is clear.

b. Pull up parking brake switch to release parking brake.

c. Position propel control lever in full forward position.

NOTE

Do not allow engine to start during this check.

d. Hold engine start switch in start position while moving propel control lever to full back (reverse), to full forward, and then to center (neutral/stop) position. Turn engine start switch to OFF position.

Engine attempts to start before control lever is in neutral position.

21 Before 0.1 Throttle Control Switch

a. Start engine and warm up engine (Para 3-4).

Keep throttle control switch in low RPM (forward) position until after en-gine oil pressure indicator light goes out. If light does not go out within ten seconds, notify Unit Maintenance.

b. Position throttle control switch back-ward to high RPM and back to low RPM positions, checking for high and low engine speeds.

Throttle control switch does not change engine speed.

2-17

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

22 Before 0.1 Engine Check for excessive exhaust smoke, unusual engine noise, rough running, or misfiring engine.

Excessive exhaust smoke, unusual engine noise, rough running, or misfiring engine.

Always apply parking brake before dismounting the Roller while the engine is running. Failure to comply may result in personal injury or death.

23 Before 0.1 Hydraulic Oil Filter

With engine operating at high idle (throttle control switch in backward position), check that the white filter indicator is not in red zone.

White filter indicator is in the red zone.

2-18

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

24 Before 0.1 Leveling Blade

NOTE

Engine must be above low idle speed to operate leveling blade.

a. Move the leveling blade control lever backward to raise the blade.

b. Move the leveling blade control lever to the center position to hold the blade in position.

c. Move the leveling blade control lever forward to lower the blade.

d. Move the leveling blade control lever backward to raise the blade to full up position.

Leveling blade will not raise.

Leveling blade will not hold.

Leveling blade will not lower.

25 Before 0.1 Propel Control Lever/Back Up Alarm

a. Check that propel control lever operates smoothly without sticking or binding in forward and reverse positions.

NOTE

Back up alarm will not operate if back up alarm cutoff switch is turned OFF (Para 3-6).

b. Check that back up alarm sounds when propel control lever is placed in reverse position.

c. Return propel control lever to neutral position.

Propel control lever does not operate in forward or reverse position.

Back up alarm does not sound while cutoff switch is turned ON.

2-19

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

26 Before 0.1 Propel Speed Range Switch

Move propel speed range switch to low (back) and the high (forward) positions.

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 or death to personnel.

Propulsion system does not operate or change to low (tortoise) and high (hare) propulsion mode as switch is moved.

27 Before 0.1 Vibration System

a. Move vibratory control switch to low amplitude mode. Turn vibration on/off switch on.

Vibratory system does not operate in low amplitude mode.

b. Press vibration on/off switch to stop vibration. Move the vibratory control switch to high amplitude mode. Press vibration on/off switch to start vibration.

Vibratory system does not operate in both high and low amplitude modes.

c. Move variable frequency control to full left and full right.

d. Check that VPM (Vibrations Per Minute) gauge is functioning and shows changes in vibration frequency.

If VPM gauge does not properly function, contact Unit Maintenance.

Frequency of vibration does not change.

VPM gauge does not operate or does not change as vibration frequency changes.

2-20

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

28 Before 0.1 Steering Check for any unusual steering noise, binding, or difficulty in turning.

Steering binds or is unresponsive.

29 Before 0.1 Worklights a. Move worklights switch through all positions and check that front and rear worklights illuminate.

b. Turn engine off and apply parking brake, unless mission starts immediately.

Worklights do not illuminate (if operation is to occur during low light or night time).

30 During 0.1 Gauges Monitor all gauges and indicator lights. Any gauge stops working, or any indicator light comes on, during operation, shut engine OFF and notify Unit Mainte-nance.

2-21

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

31 During 0.1 Hydraulic Oil Level (Warm Oil Check)

Do not overfill hydraulic oil tank.

Damage to hydraulic system components may occur.

NOTE

• The Roller must be parked on a level surface when checking the hydraulic oil level.

• Hydraulic oil shall be checked warm and cold. Engine shall be run at least five minutes before performing warm oil check.

• Disregard markings on sight gauge.

Maintain hydraulic oil level according to label markings.

a. Open access door assembly.

b. 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 hydraulic oil (page 2-5).

c. Close access door assembly.

Hydraulic oil level is below “LOW” level mark, or above “HIGH” level mark on label.

32 After 0.1 Fuel Level Check fuel level gauge. Fill fuel tank, if level is low.

Fuel level is very low or empty.

2-22

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

33 After 0.1 Engine Oil Level

a. Open access door assembly.

b. Check engine oil level. If engine oil level is low, add oil (Chapter 4).

c. If engine oil level is too high, notify Unit Maintenance that engine is overfilled with oil.

d. Close access door assembly.

Engine oil level is low.

Engine oil level is high.

34 Weekly 0.1 Steering Pins Remove grease gun from stowage box.

Apply grease to steering pin grease fittings.

35 Weekly 0.1 Steering Cylinder Pins

Apply grease to steering cylinder grease fittings.

2-23

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

36 Weekly 0.1 Blade Cylinder Pivot

Apply grease to blade cylinder pivot grease fittings.

37 Weekly 0.1 Blade Pivot a. Apply grease to blade pivot grease fittings.

b. Stow grease gun in stowage box.

2-24

Table 2-1. Operator Preventive Maintenance Checks and Services – CONT.

Item No.

Interval Man-hour

Item to be Checked or

Serviced Procedure

Equipment Not Ready/Available if:

38 Weekly 0.1 Vibratory Drum Rubber Mounts

NOTE

There are 10 vibratory drum rubber mounts. Six are located on the left side of the drum. Four are located on the right side of the drum.

Check rubber mounts for…