Excavator John Deree

Transcript

TM 5-3805-294-10 TECHNICAL MANUAL OPERATOR'S MANUAL FOR HYDRAULIC EXCAVATOR (HYEX) (JOHN DEERE 240D LCR) TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH NSN 3805-01-573-0677 (EIC : ALL) DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY 0$5&+ TM 5-3805-294-10 WARNING SUMMARY This warning summary contains general safety and hazardous materials warnings that must be understood and applied during operation and maintenance of the machine. Failure to observe these precautions or operating this machine without training or instruction may result in serious injury or death to personnel. FIRST AID First aid is defined as "urgent and immediate lifesaving and other measures, which may be performed for casualties by nonmedical personnel when medical personnel are not immediately available." FOR FIRST AID INFORMATION, REFER TO FM 4-25.11. EXPLANATION OF SAFETY WARNING ICONS AIR PRESSURE - Human hand blocking air gun shows the need to reduce air pressure before use, or debris may injure user and/or damage equipment. BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria or viruses that present a danger to life or health. EAR PROTECTION - Headphones over ears show that noise level will harm ears. ELECTRICAL - Electrical wire to hand with electricity symbol running through human hand shows that shock hazard is present. EXPLOSION - Human figure in front of explosion symbol shows that the material may explode if subjected to high temperatures, sources of ignition, or high pressure. EXTREMELY COLD SURFACE - Hand touching object with ice formed on both shows that surface is extremely cold and can damage human tissue. EYE PROTECTION - Person with goggles shows that material will injure the eyes. a TM 5-3805-294-10 WARNING SUMMARY - Continued EXPLANATION OF SAFETY WARNING ICONS - Continued FIRE - Flame shows that material may ignite and cause burns. FIRE EXTINGUISHER - Fire extinguisher shows that material may ignite and a fire extinguisher should be within easy reach. HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential for improper lifting technique, and/or aid of assistant(s) and/or lifting device (as required). HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush and harm. HEAVY PARTS - Moving heavy object pinning human figure against stationary object shows that heavy, moving parts/objects present a danger to life or limb. HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb. HOT AREA - Hand over object radiating heats shows that part is hot and can burn. MOVING PARTS - Hand with fingers caught between gears shows that the moving parts of the equipment present a danger to life or limb. b TM 5-3805-294-10 WARNING SUMMARY - Continued EXPLANATION OF SAFETY WARNING ICONS - Continued POISON - Skull and crossbones symbol shows that dangerous gases, sprays, vapors, liquids, or materials contain compounds that present a danger to life or health. PROJECTILE HAZARD - Human body with object passing through it shows that a projectile hazard exists. RADIATION - Three circular wedges show that the material emits radioactive energy and can injure human tissue. SEAT BELT USE - Human figure wearing seat belt indicates a seat belt must be used to prevent injury or death in the event of a vehicle crash or rollover. SKIN IRRITATION - Hand radiating shows that material can cause skin irritation. SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents a danger of falling. STEAM HAZARD - Human engulfed in steam cloud shows steam hazard exists that could injure/burn human tissue. VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health. WARNING - Triangle with exclamation point within shows that a WARNING is present that indicates a potential hazard, which may cause injury or death to personnel. WARNING DESCRIPTIONS c TM 5-3805-294-10 WARNING SUMMARY - Continued WARNING Perform a complete walk around the machine prior to starting the engine. Ensure sufficient clearance from personnel and equipment for safe operation of machine. Prior to starting engine, sound horn to alert personnel. Failure to comply may result in injury or death to personnel. WARNING SAFE CLEARANCE: • Before moving the machine or operating the boom, ensure that the boom has at least 10 ft. (3 m) of clearance from overhead wires, power lines, or structures. If lines are near to your operating area, notify your supervisor prior to operating the boom. Failure to comply may result in injury or death to personnel. • Keep personnel clear of the machine when traveling. Failure to comply may result in injury or death to personnel. WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. WARNING DIESEL FUEL • Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow open flame or sparks in the vicinity while working on any part of fuel system. Keep fire d TM 5-3805-294-10 WARNING SUMMARY - Continued extinguisher within easy reach when working with fuel. Failure to comply may result in injury or death to personnel. • Spilled fuel is slippery and creates a hazardous condition. Clean up and properly dispose of spilled fuel as soon as possible. Failure to comply may result in injury or death to personnel. • Do not work on fuel system when engine is hot. Failure to comply may result in injury or death to personnel. • Safety glasses must be worn when working on pressurized systems. Failure to comply may result in injury or death to personnel. WARNING LUBRICATING OIL • Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure to comply may result in injury or death to personnel. • Spilled oil is slippery and creates a hazardous condition. Clean up and properly dispose of hydraulic oil. Failure to comply may result in injury or death to personnel. WARNING Ensure electrical power is off prior to working on all electrical connections. Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. WARNING LEAD-ACID BATTERIES • Avoid battery electrolyte contact with skin, eyes, and clothing. If battery electrolyte spills, take the following immediate action to stop burning effects: • External - If battery electrolyte contacts skin, immediately flush affected area with cold running water. Failure to comply may result in injury or death to personnel. • Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15 minutes and seek immediate medical attention. IMPORTANT - If only one eye is affected, ensure the affected eye is always kept lower than the unaffected eye, during both flushing e TM 5-3805-294-10 WARNING SUMMARY - Continued and transport. This will help keep the affected eye from draining into and contaminating the unaffected eye. Failure to comply may result in injury or death to personnel. • Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, a beaten egg, or vegetable oil and seek immediate medical attention. Failure to comply may result in injury or death to personnel. • Clothing or vehicle - Immediately flush area with cold water and neutralize battery electrolyte with baking soda or household ammonia solution. Failure to comply may result in injury or death to personnel. • Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do not allow hot, sparking, or glowing objects near batteries. If batteries are giving off gases, the presence of heat, flame, or spark may cause fire and/or explosion. Failure to comply may result in injury or death to personnel. • Wear proper eye protection, gloves, and an apron when working near batteries. Failure to comply may result in injury or death to personnel. WARNING Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating to skin and respiratory system. High concentrations of isocyanate can produce symptoms of itching and reddening of skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain during respiration, increased sputum production, and chest tightness. First aid for ingestion: do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention. Failure to comply may result in injury or death to personnel. WARNING If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal instructions. Failure to comply may result in injury or death to personnel. f TM 5-3805-294-10 WARNING SUMMARY - Continued WARNING Personnel hearing can be permanently damaged if exposed to constant high noise levels of 85 dB or greater. Failure to comply may result in injury to personnel. WARNING Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may result in injury or death to personnel. WARNING Do not operate bucket or any attachment if the quick attach wedge is not fully seated and the safety lock pin is not in the locked position . The bucket or attachment may fall. One exception to this rule is when specifically instructed to do so during the removing and installing of bucket or attachment to and from machine. Failure to comply may result in injury or death to personnel. WARNING CARBON MONOXIDE • 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, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death to personnel can result from severe exposure. • Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of HYEX is operated: 1. DO NOT operate engine in enclosed areas without adequate ventilation. g TM 5-3805-294-10 WARNING SUMMARY 2. DO NOT idle engine without adequate ventilation. 3. DO NOT drive machine with inspection plates or cover plates removed. 4. 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 carbon monoxide poisoning. THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION. Failure to comply may result in injury or death to personnel. h TM 5-3805-294-10 LIST OF EFFECTIVE PAGES/WORK PACKAGES NOTE: Zero in the "Change No." column indicates an original page or work package. Date of issue for the original manual is: Original 07 March 2011 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 54 AND TOTAL NUMBER OF WORK PACKAGES IS 100 CONSISTING OF THE FOLLOWING: CHANGE NO. PAGE/WP NO. Front Cover Warning summary (10 pgs) i-ii iii-xxiv How to use this manual (2 pgs) Chapter 1 title page Blank WP0001 (4 pgs) WP0002 (12 pgs) WP0003 (10 pgs) Chapter 2 title page Blank WP0004 (16 pgs) WP0005 (8 pgs) WP0006 (2 pgs) WP0007 (6 pgs) WP0008 (6 pgs) WP0009 (4 pgs) WP0010 (4 pgs) WP0011 (6 pgs) WP0012 (4 pgs) WP0013 (4 pgs) WP0014 (10 pgs) WP0015 (2 pgs) WP0016 (10 pgs) WP0017 (4 pgs) WP0018 (2 pgs) WP0019 (16 pgs) WP0020 (16 pgs) WP0021 (14 pgs) WP0022 (4 pgs) WP0023 (6 pgs) WP0024 (4 pgs) WP0025 (12 pgs) WP0026 (4 pgs) WP0027 (14 pgs) WP0028 (2 pgs) WP0029 (2 pgs) WP0030 (8 pgs) WP0031 (8 pgs) WP0032 (2 pgs) CHANGE NO. PAGE/WP NO. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP0033 (2 pgs) WP0034 (6 pgs) WP0035 (6 pgs) WP0036 (4 pgs) Chapter 3 title page Blank WP0037 (2 pgs) WP0038 (2 pgs) WP0039 (2 pgs) WP0040 (2 pgs) WP0041 (2 pgs) WP0042 (2 pgs) WP0043 (2 pgs) WP0044 (2 pgs) WP0045 (2 pgs) WP0046 (2 pgs) WP0047 (4 pgs) WP0048 (2 pgs) WP0049 (2 pgs) WP0050 (2 pgs) WP0051 (2 pgs) WP0052 (2 pgs) WP0053 (2 pgs) WP0054 (2 pgs) WP0055 (2 pgs) WP0056 (2 pgs) WP0057 (2 pgs) WP0058 (2 pgs) WP0059 (2 pgs) WP0060 (2 pgs) WP0061 (2 pgs) WP0062 (2 pgs) WP0063 (2 pgs) WP0064 (2 pgs) WP0065 (2 pgs) WP0066 (2 pgs) WP0067 (2 pgs) WP0068 (2 pgs) WP0069 (2 pgs) WP0070 (2 pgs) WP0071 (2 pgs) A 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 TM 5-3805-294-10 LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued CHANGE NO. PAGE/WP NO. WP0072 (2 pgs) WP0073 (2 pgs) WP0074 (2 pgs) WP0075 (2 pgs) Chapter 4 title page Blank WP0076 (4 pgs) WP0077 (40 pgs) Chapter 5 title page Blank WP0078 (2 pgs) WP0079 (2 pgs) WP0080 (6 pgs) WP0081 (2 pgs) WP0082 (2 pgs) WP0083 (2 pgs) WP0084 (8 pgs) WP0085 (4 pgs) WP0086 (2 pgs) CHANGE NO. PAGE/WP NO. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 WP0087 (6 pgs) WP0088 (4 pgs) WP0089 (4 pgs) WP0090 (4 pgs) WP0091 (4 pgs) WP0092 (6 pgs) WP0093 (2 pgs) Chapter 6 title page Blank WP0094 (4 pgs) WP0095 (6 pgs) WP0096 (2 pgs) WP0097 (2 pgs) WP0098 (4 pgs) WP0099 (2 pgs) WP0100 (22 pgs) INDEX-1 - INDEX-4 Inside back cover Back cover B 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 TM 5-3805-294-10 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 07 MARCH 2011 TECHNICAL MANUAL OPERATOR’S MANUAL FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 (EIC ALL) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is: [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726. A reply will be furnished to you. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.+($'48$57(56 i/ii blank TM 5-3805-294-10 TABLE OF CONTENTS Page No. WP Sequence No. How to Use this Manual Chapter 1 - OPERATOR GENERAL INFORMATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2 EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Right View of HYEX............................................................................................................. 0002-3 Table 1. Right View of HYEX............................................................................................................. 0002-3 Figure 2. Left View of HYEX................................................................................................................ 0002-4 Table 2. Left View of HYEX................................................................................................................ 0002-4 Figure 3. Data Plates........................................................................................................................... 0002-5 Table 3. Data Plates........................................................................................................................... 0002-5 Table 4. Equipment Data.................................................................................................................... 0002-6 Figure 4. HYEX Specifications............................................................................................................ 0002-7 Table 5. HYEX Specification.............................................................................................................. 0002-7 Figure 5. HYEX Working Ranges........................................................................................................ 0002-8 Table 6. HYEX Working Ranges........................................................................................................ 0002-9 Table 7. Front Lift Capacities........................................................................................................... 0002-10 Table 8. Side Lift Capacities............................................................................................................. 0002-11 Table 9. HYEX Weights With Attachments...................................................................................... 0002-12 Table 10. Deep Dig Arm Weights....................................................................................................... 0002-12 THEORY OF OPERATION.......................................................................................................................... WP 0003 Figure 1. Electrical System Components............................................................................................ 0003-2 Table 1. Electrical System Components............................................................................................ 0003-2 Figure 2. Hydraulic System Components............................................................................................ 0003-3 Table 2. Hydraulic System Components............................................................................................ 0003-3 Figure 3. Hydraulic System Components Continued........................................................................... 0003-4 Table 3. Hydraulic System Components Continued........................................................................... 0003-4 iii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Powertrain Components....................................................................................................... 0003-5 Table 4. Powertrain Components....................................................................................................... 0003-5 Figure 5. Fuel System Components.................................................................................................... 0003-6 Table 5. Fuel System Components.................................................................................................... 0003-6 Figure 6. High-Pressure Pump and Injectors...................................................................................... 0003-7 Table 6. High-Pressure Pump and Injectors...................................................................................... 0003-7 Figure 7. Cooling Package.................................................................................................................. 0003-8 Table 7. Cooling Package.................................................................................................................. 0003-8 Figure 8. Cooling System Components............................................................................................... 0003-9 Table 8. Cooling System Components............................................................................................... 0003-9 Chapter 2 - OPERATOR INSTRUCTIONS DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........................................... WP 0004 Table 1. Front Switch Panel............................................................................................................... 0004-1 Figure 1. Front Switch Panel............................................................................................................... 0004-1 Figure 2. Front Switch Panel Continued.............................................................................................. 0004-2 Table 2. Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3 Figure 3. Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3 Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued............................................. 0004-4 Table 3. Control Pedals and Levers................................................................................................... 0004-5 Figure 5. Control Pedals and Levers................................................................................................... 0004-5 Figure 6. Control Pedals and Levers Continued.................................................................................. 0004-6 Table 4. Left Console and Pilot Shutoff Lever.................................................................................... 0004-7 Figure 7. Left Console and Pilot Shutoff Lever.................................................................................... 0004-7 Table 5. Right and Left Pilot Control Levers....................................................................................... 0004-8 Figure 8. Right Pilot Control Lever...................................................................................................... 0004-8 Figure 9. Left Pilot Control Lever......................................................................................................... 0004-9 Table 6. Seat Controls...................................................................................................................... 0004-10 iv TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10. Seat Controls...................................................................................................................... 0004-10 Table 7. Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12 Figure 11. Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12 Table 8. Quick Latch Control............................................................................................................ 0004-13 Figure 12. Quick Latch Control............................................................................................................ 0004-13 Table 9. Cab Light Switch................................................................................................................ 0004-14 Figure 13. Cab Light Switch................................................................................................................ 0004-14 Table 10. Hydraulic Hose Reel........................................................................................................... 0004-15 Figure 14. Hydraulic Hose Reel........................................................................................................... 0004-15 DESCRIPTION AND USE OF MONITOR AND ALARMS........................................................................... WP 0005 Table 1. Monitor Buttons and Indicators............................................................................................. 0005-1 Figure 1. Monitor................................................................................................................................. 0005-1 Figure 2. Monitor Buttons.................................................................................................................... 0005-2 Figure 3. Main Menu............................................................................................................................ 0005-3 Figure 4. Monitor Indicators................................................................................................................. 0005-4 Table 2. Warning Indicators and Alarms............................................................................................ 0005-6 Figure 5. Warning Indicators and Alarms............................................................................................ 0005-6 Figure 6. Overload Alarm.................................................................................................................... 0005-7 ADJUSTING THE OPERATOR'S SEAT...................................................................................................... WP 0006 Figure 1. Operator's Seat Adjustments................................................................................................ 0006-1 STARTING THE ENGINE............................................................................................................................ WP 0007 Figure 1. Seat Belt............................................................................................................................... 0007-1 Figure 2. Pilot Shutoff Lever................................................................................................................ 0007-2 Figure 3. Engine Speed Dial Slow Idle................................................................................................ 0007-2 Figure 4. Key Switch ON..................................................................................................................... 0007-3 Figure 5. System Starting and Default Screen.................................................................................... 0007-3 Figure 6. Preheat Indicator.................................................................................................................. 0007-4 v TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 7. Key Switch to START........................................................................................................... 0007-4 Figure 8. Alarm indicator..................................................................................................................... 0007-5 Figure 9. Engine Speed Dial Turned to 1/3 Position........................................................................... 0007-5 Figure 10. Return Engine Speed Dial to Slow Idle................................................................................ 0007-6 MOVING THE HYEX................................................................................................................................... WP 0008 Figure 1. Pilot Shutoff Lever Unlocked................................................................................................ 0008-1 Figure 2. Boom and Arm Raised......................................................................................................... 0008-2 Figure 3. Travel Mode Switch.............................................................................................................. 0008-2 Figure 4. Moving Forward and Backwards.......................................................................................... 0008-3 Figure 5. Right Turn............................................................................................................................. 0008-4 Figure 6. Left Turn............................................................................................................................... 0008-4 Figure 7. Counter-Rotate..................................................................................................................... 0008-5 SHUTTING DOWN THE HYEX................................................................................................................... WP 0009 Figure 1. Machine In Parked Position.................................................................................................. 0009-1 Figure 2. Auto-Idle Switch and Engine Speed Dial.............................................................................. 0009-2 Figure 3. Engine Speed Dial................................................................................................................ 0009-3 Figure 4. Pilot Shutoff Lever................................................................................................................ 0009-3 Figure 5. Key Switch Turned OFF....................................................................................................... 0009-4 SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED................................................. WP 0010 Figure 1. Machine In Parked Position.................................................................................................. 0010-1 Figure 2. Auto-Idle Switch and Engine Speed Dial.............................................................................. 0010-2 Figure 3. Engine Speed Dial................................................................................................................ 0010-3 Figure 4. Pilot Shutoff Lever................................................................................................................ 0010-3 Figure 5. Key Switch Turned OFF....................................................................................................... 0010-4 OPENING AND CLOSING WINDOWS....................................................................................................... WP 0011 Figure 1. Open Windshield.................................................................................................................. 0011-1 Figure 2. Raise Windshield.................................................................................................................. 0011-2 vi TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Lock Windshield Open......................................................................................................... 0011-2 Figure 4. Release Windshield Latch.................................................................................................... 0011-3 Figure 5. Close Windshield.................................................................................................................. 0011-3 Figure 6. Latch Windshield.................................................................................................................. 0011-4 Figure 7. Open and Close Cab Door Window..................................................................................... 0011-4 Figure 8. Open Access Cover............................................................................................................. 0011-5 Figure 9. Open and Close Skylight Window........................................................................................ 0011-5 Figure 10. Close Access Cover............................................................................................................. 0011-6 USING THE RIFLE MOUNT........................................................................................................................ WP 0012 Figure 1. Stow Weapon In Rear Bracket............................................................................................. 0012-1 Figure 2. Stow Weapon In Front Bracket............................................................................................ 0012-2 Figure 3. Remove Weapon From Front Bracket.................................................................................. 0012-2 Figure 4. Remove Weapon From Rear Bracket.................................................................................. 0012-3 GENERAL MONITOR OPERATION............................................................................................................ WP 0013 Figure 1. Select Time Set Menu.......................................................................................................... 0013-1 Figure 2. Adjust Time.......................................................................................................................... 0013-2 Figure 3. Select Operating Conditions Menu....................................................................................... 0013-2 Figure 4. Reset Operating Conditions................................................................................................. 0013-3 REMOVING AND INSTALLING BUCKET................................................................................................... WP 0014 Figure 1. Unlock Safety Lock Pin........................................................................................................ 0014-1 Figure 2. Raise Boom.......................................................................................................................... 0014-2 Figure 3. Move Quick Latch Switch to Unlatch Position...................................................................... 0014-2 Figure 4. Extend Bucket Cylinder........................................................................................................ 0014-3 Figure 5. Retract Bucket Cylinder........................................................................................................ 0014-3 Figure 6. Lower Boom......................................................................................................................... 0014-4 Figure 7. Position Quick Latch Switch to Latch position...................................................................... 0014-4 Figure 8. Remove Quick Latch............................................................................................................ 0014-5 vii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9. Position Quick Latch Switch to Unlatch position.................................................................. 0014-6 Figure 10. Raise Boom for Clearance................................................................................................... 0014-6 Figure 11. Retract Wedges.................................................................................................................... 0014-7 Figure 12. Install Quick Latch................................................................................................................ 0014-7 Figure 13. Position Quick Latch Switch toLatch position....................................................................... 0014-8 Figure 14. Raise Boom.......................................................................................................................... 0014-8 Figure 15. Safety Pin Locked................................................................................................................ 0014-9 LIFTING WITH HYEX.................................................................................................................................. WP 0015 Figure 1. Lifting with Quick Latch Loop............................................................................................... 0015-2 OPERATING TECHNIQUES....................................................................................................................... WP 0016 Figure 1. Leveling Machine................................................................................................................. 0016-1 Figure 2. Add or Remove Material....................................................................................................... 0016-1 Figure 3. Arm Digging.......................................................................................................................... 0016-3 Figure 4. Bucket Digging..................................................................................................................... 0016-4 Figure 5. Planning Spoil Piles.............................................................................................................. 0016-5 Figure 6. Trenching............................................................................................................................. 0016-6 Figure 7. Cleaning Cave In.................................................................................................................. 0016-6 Figure 8. Trenching on a Slope........................................................................................................... 0016-7 Figure 9. Straight Line Trenching........................................................................................................ 0016-8 Figure 10. Back Filling........................................................................................................................... 0016-9 Figure 11. Truck Loading..................................................................................................................... 0016-10 OPERATING THE HYDRAULIC THUMB.................................................................................................... WP 0017 Figure 1. Clamping With Bucket.......................................................................................................... 0017-1 Figure 2. Clamping With Hydraulic Thumb.......................................................................................... 0017-2 Figure 3. Releasing Objects................................................................................................................ 0017-3 SELECTING AN ATTACHMENT ON THE MONITOR................................................................................ WP 0018 Figure 1. Select Attachment................................................................................................................ 0018-1 viii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Table 1. Attachment Selection........................................................................................................... 0018-1 Figure 2. Attachment Specification Screen......................................................................................... 0018-2 INSTALLING AND OPERATING THE CRUSH-ALL.................................................................................... WP 0019 Figure 1. Close Hydraulic Thumb Circuit............................................................................................. 0019-1 Figure 2. Move Quick Latch Switch to Unlatch Position...................................................................... 0019-2 Figure 3. Extend Bucket Cylinder........................................................................................................ 0019-3 Figure 4. Install Quick Latch................................................................................................................ 0019-3 Figure 5. Quick Latch Switch to Latch Position................................................................................... 0019-4 Figure 6. Position Crush-All................................................................................................................. 0019-4 Figure 7. Connect Auxiliary Supply Line.............................................................................................. 0019-5 Figure 8. Connect Auxiliary Return Line.............................................................................................. 0019-5 Figure 9. Crush-All Operation.............................................................................................................. 0019-7 Figure 10. Open Lid............................................................................................................................... 0019-9 Figure 11. Clearing Jam from Crush-All................................................................................................ 0019-9 Figure 12. Push Crush-All Rotor Backwards....................................................................................... 0019-10 Figure 13. Position Crush-All............................................................................................................... 0019-10 Figure 14. Disconnect Auxiliary Return Line....................................................................................... 0019-11 Figure 15. Disconnect Auxiliary Supply Line....................................................................................... 0019-12 Figure 16. Move Quick Latch Switch................................................................................................... 0019-12 Figure 17. Raise Boom........................................................................................................................ 0019-13 Figure 18. Remove Quick Latch.......................................................................................................... 0019-14 Figure 19. Move Quick Latch Switch................................................................................................... 0019-14 Figure 20. Open Hydraulic Thumb Circuit........................................................................................... 0019-15 INSTALLING AND OPERATING THE IMPACT BREAKER........................................................................ WP 0020 Figure 1. Close Hydraulic Thumb Circuit............................................................................................. 0020-1 Figure 2. Move Quick Latch Switch..................................................................................................... 0020-2 Figure 3. Raise Boom.......................................................................................................................... 0020-3 ix TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Quick Latch Wedges Retracted............................................................................................ 0020-3 Figure 5. Install Quick Latch................................................................................................................ 0020-4 Figure 6. Extend Bucket Cylinder........................................................................................................ 0020-4 Figure 7. Move Quick Latch Switch to Latch Position......................................................................... 0020-5 Figure 8. Quick Latch Wedges Engaged............................................................................................. 0020-5 Figure 9. Safety Pin to Lock Position................................................................................................... 0020-6 Figure 10. Connect Auxiliary Supply Line.............................................................................................. 0020-6 Figure 11. Connect Auxiliary Return Line.............................................................................................. 0020-7 Figure 12. Breaker Tool Lock Bolt......................................................................................................... 0020-8 Figure 13. Insert Breaker Tool............................................................................................................... 0020-9 Figure 14. Lock Breaker Tool................................................................................................................ 0020-9 Figure 15. Breaker Operation.............................................................................................................. 0020-10 Figure 16. Tool Removal..................................................................................................................... 0020-10 Figure 17. Remove Breaker Tool........................................................................................................ 0020-11 Figure 18. Lock Breaker Tool.............................................................................................................. 0020-11 Figure 19. Disconnect Auxiliary Return Line....................................................................................... 0020-12 Figure 20. Disconnect Auxiliary Supply Line....................................................................................... 0020-12 Figure 21. Safety Pin to Unlock Position............................................................................................. 0020-13 Figure 22. Raise Boom for Clearance................................................................................................. 0020-13 Figure 23. Move Quick Latch Switch to Unlatch Position.................................................................... 0020-14 Figure 24. Quick Latch Wedges Retracted.......................................................................................... 0020-14 Figure 25. Impact Breaker Removal.................................................................................................... 0020-15 Figure 26. Quick Latch Switch to Latch Position................................................................................. 0020-15 Figure 27. Open Hydraulic Thumb Circuit........................................................................................... 0020-16 INSTALLING AND OPERATING THE COMPACTOR................................................................................. WP 0021 Figure 1. Close Hydraulic Thumb Circuit............................................................................................. 0021-2 Figure 2. Move Quick Latch Switch..................................................................................................... 0021-3 x TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3. Raise Boom.......................................................................................................................... 0021-3 Figure 4. Quick Latch Wedges Retracted............................................................................................ 0021-4 Figure 5. Install Quick Latch................................................................................................................ 0021-4 Figure 6. Position Quick Latch............................................................................................................. 0021-5 Figure 7. Quick Latch Switch to Latch Position................................................................................... 0021-5 Figure 8. Raise Boom for Clearance................................................................................................... 0021-6 Figure 9. Engage Quick Latch Wedges............................................................................................... 0021-6 Figure 10. Lock Safety Lock.................................................................................................................. 0021-7 Figure 11. Connect Auxiliary Supply Line.............................................................................................. 0021-7 Figure 12. Connect Auxiliary Return Line.............................................................................................. 0021-8 Figure 13. Attachment Pedal Lock Release.......................................................................................... 0021-8 Figure 14. Disconnect Auxiliary Return Line......................................................................................... 0021-9 Figure 15. Connect Auxiliary Supply Line............................................................................................ 0021-10 Figure 16. Unlock Safety Lock............................................................................................................. 0021-10 Figure 17. Quick Latch Switch to Unlatch Position.............................................................................. 0021-11 Figure 18. Raise Boom........................................................................................................................ 0021-11 Figure 19. Disengage Quick Latch Wedges........................................................................................ 0021-12 Figure 20. Retract Bucket Cylinder...................................................................................................... 0021-12 Figure 21. Remove Quick Latch.......................................................................................................... 0021-13 Figure 22. Quick Latch Switch to Latch Position................................................................................. 0021-13 Figure 23. Close Hydraulic Thumb Circuit........................................................................................... 0021-14 OPERATING THE BARRIER GRAPPLE..................................................................................................... WP 0022 Figure 1. Lifting Barrier Grapple.......................................................................................................... 0022-2 OPERATING THE DEEP DIG ARM............................................................................................................ WP 0023 Figure 1. Deep Dig Control Pattern Switch.......................................................................................... 0023-1 Figure 2. Turn Auto Idle Switch On..................................................................................................... 0023-2 Figure 3. Pilot Shutoff Lever................................................................................................................ 0023-3 xi TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Turn RPM Dial...................................................................................................................... 0023-4 Figure 5. Cycle Deep Dig Arm Cylinders............................................................................................. 0023-5 MOVING MACHINE ON/OFF AN EMBANKMENT...................................................................................... WP 0024 Figure 1. Position Bucket..................................................................................................................... 0024-1 Figure 2. Upperstructure Rotated........................................................................................................ 0024-2 Figure 3. Position Bucket on Lower Level........................................................................................... 0024-3 Figure 4. Rotate Upperstructure to Upper Level.................................................................................. 0024-3 USING THE VANDAL PROTECTION KIT................................................................................................... WP 0025 Figure 1. Right Side Rear Cover Installation....................................................................................... 0025-1 Figure 2. Right Side Center Cover Installation.................................................................................... 0025-1 Figure 3. Right Side Front Cover Installation....................................................................................... 0025-2 Figure 4. Lock Bar Installation............................................................................................................. 0025-2 Figure 5. Front Door Cover Installation............................................................................................... 0025-3 Figure 6. Center Door Cover Installation............................................................................................. 0025-3 Figure 7. Lower Door Cover Installation.............................................................................................. 0025-4 Figure 8. Side Upper Glass Cover Installation.................................................................................... 0025-4 Figure 9. Side Lower Glass Cover Installation.................................................................................... 0025-5 Figure 10. Right Rear Cab Cover Installation........................................................................................ 0025-5 Figure 11. Left Rear Cab Cover Installation.......................................................................................... 0025-6 Figure 12. Left Rear Cab Cover Removal............................................................................................. 0025-6 Figure 13. Right Rear Cab Cover Removal........................................................................................... 0025-7 Figure 14. Side Lower Glass Cover Removal....................................................................................... 0025-7 Figure 15. Side Upper Glass Cover Removal....................................................................................... 0025-8 Figure 16. Lower Door Cover Removal................................................................................................. 0025-8 Figure 17. Center Door Cover Removal................................................................................................ 0025-9 Figure 18. Front Door Cover Removal.................................................................................................. 0025-9 Figure 19. Lock Bar Removal.............................................................................................................. 0025-10 xii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 20. Right Side Front Cover Removal........................................................................................ 0025-10 Figure 21. Right Side Center Cover Removal..................................................................................... 0025-10 Figure 22. Right Side Rear Cover Removal........................................................................................ 0025-11 OPERATING THE HYDRAULIC HOSE REEL............................................................................................ WP 0026 Figure 1. Hydraulic Tool Attachment................................................................................................... 0026-1 Figure 2. Turn On Hydraulic Tool........................................................................................................ 0026-2 Figure 3. Turn Off Hydraulic Tool........................................................................................................ 0026-2 Figure 4. Hydraulic Tool Removal....................................................................................................... 0026-3 DECAL LOCATION GUIDE......................................................................................................................... WP 0027 Figure 1. Left Side, Rear Cab Window, and Top Decals..................................................................... 0027-1 Figure 2. Left Inside Door.................................................................................................................... 0027-2 Figure 3. Top Under Engine Cover...................................................................................................... 0027-2 Figure 4. Right Side on Hydraulic Reservoir....................................................................................... 0027-3 Figure 5. Right Side............................................................................................................................. 0027-3 Figure 6. Boom, Right Side, and Rear Cab Window........................................................................... 0027-4 Figure 7. Counterweight...................................................................................................................... 0027-4 Figure 8. Front and Rear Frame.......................................................................................................... 0027-5 Figure 9. Cab on Seat......................................................................................................................... 0027-5 Figure 10. Key Switch............................................................................................................................ 0027-5 Figure 11. Windshield............................................................................................................................ 0027-6 Figure 12. Side Window........................................................................................................................ 0027-6 Figure 13. Upper and Lower Right Side Window.................................................................................. 0027-7 Figure 14. Lower Right Side Window.................................................................................................... 0027-8 Figure 15. Vandal Protection Kit............................................................................................................ 0027-9 Figure 16. Upper Section Periodic Maintenance................................................................................. 0027-10 Figure 17. Lower Section Periodic Maintenance................................................................................. 0027-11 Figure 18. Ditch Cleaning Bucket........................................................................................................ 0027-12 xiii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 19. Heavy Duty Bucket............................................................................................................. 0027-12 Figure 20. Right Side Crush-All........................................................................................................... 0027-13 Figure 21. Left Side Crush-All............................................................................................................. 0027-13 Figure 22. Output Side Crush-All......................................................................................................... 0027-14 TOWING THE HYEX................................................................................................................................... WP 0028 LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................... WP 0029 OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)..................................................................... WP 0030 Figure 1. Press and Hold Back Button................................................................................................ 0030-1 Figure 2. Key Switch to ON Position................................................................................................... 0030-2 Figure 3. Release Back Button............................................................................................................ 0030-2 Figure 4. Highlight Service Menu........................................................................................................ 0030-3 Figure 5. Select Monitoring.................................................................................................................. 0030-3 Figure 6. Temperatures Displayed...................................................................................................... 0030-4 Figure 7. Start Engine.......................................................................................................................... 0030-4 Figure 8. Engine Speed Dial................................................................................................................ 0030-5 Figure 9. Check Engine and Hydraulic Oil Temperatures................................................................... 0030-5 Table 1. Machine Switch Selections................................................................................................... 0030-6 Figure 10. Raise Machine...................................................................................................................... 0030-6 OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER ................................................................... WP 0031 Figure 1. Press and Hold Back Button................................................................................................ 0031-1 Figure 2. Key Switch to ON Position................................................................................................... 0031-2 Figure 3. Release Back Button............................................................................................................ 0031-2 Figure 4. Highlight Service Menu........................................................................................................ 0031-3 Figure 5. Select Monitoring.................................................................................................................. 0031-3 Figure 6. Temperatures Displayed...................................................................................................... 0031-4 Figure 7. Start Engine.......................................................................................................................... 0031-4 Figure 8. Engine Idle Speed................................................................................................................ 0031-5 xiv TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9. Monitor Temperatures Displayed......................................................................................... 0031-5 Table 1. Machine Switch Selection.................................................................................................... 0031-6 Figure 10. Raise Machine...................................................................................................................... 0031-7 SLAVE STARTING...................................................................................................................................... WP 0032 Figure 1. Slave Receptacle................................................................................................................. 0032-2 SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................... WP 0033 Figure 1. Open and Close Roof Exit.................................................................................................... 0033-1 Figure 2. Emergency Exit Tool............................................................................................................ 0033-2 OPERATING THE COOLANT HEATER...................................................................................................... WP 0034 Figure 1. Coolant Heater Control Panel.............................................................................................. 0034-2 Figure 2. Adjusting Time and Day....................................................................................................... 0034-2 Figure 3. Setting Program................................................................................................................... 0034-3 Figure 4. Adjusting Run Time.............................................................................................................. 0034-4 Figure 5. Manually Start Coolant Heater............................................................................................. 0034-4 Figure 6. Manually Start Coolant Heater Continued............................................................................ 0034-5 MOVING UP/DOWN STEEP OR SLIPPERY SLOPES............................................................................... WP 0035 Figure 1. Buckle Seat Belt................................................................................................................... 0035-1 Figure 2. Pulling Machine Up.............................................................................................................. 0035-2 Figure 3. Buckle Seat Belt................................................................................................................... 0035-3 Figure 4. Pushing Machine.................................................................................................................. 0035-3 Figure 5. Traveling Down.................................................................................................................... 0035-4 FORDING THE HYEX................................................................................................................................. WP 0036 Figure 1. Fording Line......................................................................................................................... 0036-1 Figure 2. Pilot Shutoff Lever................................................................................................................ 0036-2 Figure 3. Check Monitor...................................................................................................................... 0036-2 Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE............................................... WP 0037 xv TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. TRAVEL ALARM DOES NOT OPERATE.................................................................................................... WP 0038 WINDSHIELD WIPER AND WASHER DO NOT OPERATE....................................................................... WP 0039 CAB DOME LIGHT DOES NOT OPERATE................................................................................................ WP 0040 BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE............................................................................ WP 0041 CAB FRONT WORK LIGHTS DO NOT OPERATE..................................................................................... WP 0042 CAB REAR WORK LIGHTS DO NOT OPERATE....................................................................................... WP 0043 LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE..................................................................... WP 0044 AIR CONDITIONER DOES NOT OPERATE............................................................................................... WP 0045 ENGINE CRANKS BUT DOES NOT START OR HARD TO START.......................................................... WP 0046 ENGINE WILL NOT CRANK........................................................................................................................ WP 0047 ENGINE RUNS POORLY............................................................................................................................ WP 0048 EXCESSIVE FUEL CONSUMPTION.......................................................................................................... WP 0049 EXCESSIVE OIL CONSUMPTION.............................................................................................................. WP 0050 ENGINE IDLES POORLY............................................................................................................................ WP 0051 AUTO-IDLE DOES NOT WORK.................................................................................................................. WP 0052 ENGINE NOT DEVELOPING FULL POWER.............................................................................................. WP 0053 ENGINE OIL PRESSURE LOW.................................................................................................................. WP 0054 ENGINE COOLANT TEMPERATURE ABOVE NORMAL........................................................................... WP 0055 ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE....................................................... WP 0056 ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE......................................................................... WP 0057 NO HYDRAULIC FUNCTIONS.................................................................................................................... WP 0058 HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER............................................. WP 0059 POWER DIG DOES NOT WORK................................................................................................................ WP 0060 HYDRAULIC OIL OVERHEATS.................................................................................................................. WP 0061 HYDRAULIC OIL FOAMS............................................................................................................................ WP 0062 NO SWING FUNCTION............................................................................................................................... WP 0063 SWING FUNCTION IS JERKY.................................................................................................................... WP 0064 xvi TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. SLOW TRAVEL SPEED ONLY................................................................................................................... WP 0065 TRAVEL IS JERKY...................................................................................................................................... WP 0066 ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED..................................................... WP 0067 QUICK LATCH DOES NOT OPERATE....................................................................................................... WP 0068 COMPACTOR DOES NOT OPERATE........................................................................................................ WP 0069 BREAKER DOES NOT OPERATE.............................................................................................................. WP 0070 BREAKER OPERATES SLOWLY............................................................................................................... WP 0071 CRUSH-ALL DOES NOT OPERATE........................................................................................................... WP 0072 BARRIER GRAPPLE DOES NOT HOLD LOAD......................................................................................... WP 0073 DEEP DIG DOES NOT OPERATE.............................................................................................................. WP 0074 HYDRAULIC HOSE REEL DOES NOT OPERATE..................................................................................... WP 0075 Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................... WP 0076 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0077 Table 1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES.......................... 0077-1 Figure 1. Exterior of Machine.............................................................................................................. 0077-3 Figure 2. Exterior of Machine Continued............................................................................................. 0077-4 Figure 3. Coolant Level....................................................................................................................... 0077-5 Figure 4. Engine Oil............................................................................................................................. 0077-6 Figure 5. Exhaust Components........................................................................................................... 0077-7 Figure 6. Hydraulic Reservoir Cap...................................................................................................... 0077-7 Figure 7. Fuel Tank and Fuel Level..................................................................................................... 0077-8 Figure 8. Fuel Filters............................................................................................................................ 0077-9 Figure 9. Engine Oil Filter.................................................................................................................... 0077-9 Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb................................................................ 0077-10 Figure 11. Bucket and Teeth............................................................................................................... 0077-11 Figure 12. Air Cleaner Housing and Hose Reel.................................................................................. 0077-12 xvii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 13. Batteries............................................................................................................................. 0077-13 Figure 14. Batteries Continued............................................................................................................ 0077-14 Figure 15. Cab Glass........................................................................................................................... 0077-15 Figure 16. Mirrors and Wiper Arm....................................................................................................... 0077-15 Figure 17. Cab Door, Hinges, and Latches......................................................................................... 0077-16 Figure 18. Fire Extinguisher................................................................................................................ 0077-17 Figure 19. Pedals and Levers.............................................................................................................. 0077-18 Figure 20. Pilot Control Levers............................................................................................................ 0077-19 Figure 21. Seat Belt............................................................................................................................. 0077-20 Figure 22. Ignition Switch.................................................................................................................... 0077-20 Figure 23. Monitor............................................................................................................................... 0077-21 Figure 24. Position Boom and Arm...................................................................................................... 0077-22 Figure 25. Hydraulic Oil Level Check.................................................................................................. 0077-22 Figure 26. Breaker............................................................................................................................... 0077-23 Figure 27. Compactor.......................................................................................................................... 0077-24 Figure 28. Crush-All............................................................................................................................. 0077-25 Figure 29. Barrier Grapple................................................................................................................... 0077-26 Figure 30. Deep Dig Arm and Bucket.................................................................................................. 0077-27 Figure 31. Deep Dig Bucket................................................................................................................ 0077-28 Figure 32. Ditch Cleaning Bucket........................................................................................................ 0077-29 Figure 33. Position Boom and Arm...................................................................................................... 0077-31 Figure 34. Hydraulic Oil Level Check.................................................................................................. 0077-31 Figure 35. Fuel Tank and Fuel Level Check........................................................................................ 0077-32 Figure 36. Engine Oil Check................................................................................................................ 0077-33 Figure 37. Engine Compartment......................................................................................................... 0077-33 Figure 38. Exterior of Machine Check................................................................................................. 0077-34 Figure 39. Swing Gearbox Oil Level Check......................................................................................... 0077-35 xviii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 40. Hydraulic Pump Oil Level Check........................................................................................ 0077-36 Figure 41. Serpentine Belt Check........................................................................................................ 0077-37 Figure 42. Air Conditioner Belt Check................................................................................................. 0077-38 Figure 43. Fan Check.......................................................................................................................... 0077-39 Chapter 5 - OPERATOR MAINTENANCE INSTRUCTIONS GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0078 TAKING ENGINE OIL SAMPLE.................................................................................................................. WP 0079 Figure 1. Engine Oil Sampling Valve................................................................................................... 0079-1 TRACK SAG CHECK .................................................................................................................................. WP 0080 Figure 1. Raise Machine...................................................................................................................... 0080-1 Figure 2. Rotate Track......................................................................................................................... 0080-2 Figure 3. Shut Machine Off.................................................................................................................. 0080-3 Figure 4. Measure Track Sag.............................................................................................................. 0080-4 Figure 5. Start Machine....................................................................................................................... 0080-5 Figure 6. Lower Machine..................................................................................................................... 0080-5 TIGHTENING TRACK TENSION................................................................................................................. WP 0081 Figure 1. Tighten Track....................................................................................................................... 0081-1 LOOSENING TRACK TENSION................................................................................................................. WP 0082 Figure 1. Loosen Track........................................................................................................................ 0082-1 TAKING HYDRAULIC OIL SAMPLE........................................................................................................... WP 0083 Figure 1. Hydraulic Oil Sampling Valve............................................................................................... 0083-1 CAB FUSE REPLACEMENT....................................................................................................................... WP 0084 Figure 1. Fuse Box Access Cover Removal........................................................................................ 0084-2 Figure 2. Main Fuse Box Cover Removal............................................................................................ 0084-3 Figure 3. Fuse Removal...................................................................................................................... 0084-4 Figure 4. Fuse Installation................................................................................................................... 0084-5 Figure 5. Main Fuse Box Cover Installation......................................................................................... 0084-6 xix TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6. Fuse Box Access Cover Installation..................................................................................... 0084-7 BUCKET TEETH REPLACEMENT.............................................................................................................. WP 0085 Figure 1. Tooth Removal..................................................................................................................... 0085-1 Figure 2. Tooth Installation.................................................................................................................. 0085-2 Figure 3. Bucket Tooth Removal......................................................................................................... 0085-2 Figure 4. Bucket Tooth Installation...................................................................................................... 0085-3 PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................................. WP 0086 Figure 1. Drain Fuel Filter/Water Separators....................................................................................... 0086-1 Figure 2. Drain Fuel Filter/Water Separators Continued..................................................................... 0086-2 PRIMARY AND SECONDARY AIR CLEANER SERVICE.......................................................................... WP 0087 Figure 1. Cover Removal..................................................................................................................... 0087-1 Figure 2. Primary Air Cleaner Removal............................................................................................... 0087-2 Figure 3. Secondary Air Cleaner Removal.......................................................................................... 0087-2 Figure 4. Primary Air Cleaner Service................................................................................................. 0087-3 Figure 5. Air Cleaner Housing Service................................................................................................ 0087-4 Figure 6. Cover and Dust Boot Service............................................................................................... 0087-4 Figure 7. Secondary Air Cleaner Installation....................................................................................... 0087-5 Figure 8. Primary Air Cleaner Installation............................................................................................ 0087-5 Figure 9. Cover Installation.................................................................................................................. 0087-6 HYDRAULIC RESERVOIR SERVICE......................................................................................................... WP 0088 Figure 1. Hydraulic Reservoir Cover Removal.................................................................................... 0088-1 Figure 2. Hydraulic Reservoir Sight Glass........................................................................................... 0088-2 Figure 3. Hydraulic Reservoir Cover Installation................................................................................. 0088-3 FRESH AIR FILTER SERVICE.................................................................................................................... WP 0089 Figure 1. Filter Removal...................................................................................................................... 0089-1 Figure 2. Inspect Seal.......................................................................................................................... 0089-2 Figure 3. Clean Filter........................................................................................................................... 0089-3 xx TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4. Clean Housing...................................................................................................................... 0089-3 Figure 5. Filter Installation................................................................................................................... 0089-4 AIR CONDITIONER/HEATER FILTER SERVICE....................................................................................... WP 0090 Figure 1. Filter Removal...................................................................................................................... 0090-1 Figure 2. Clean Filter........................................................................................................................... 0090-2 Figure 3. Clean Housing...................................................................................................................... 0090-3 Figure 4. Filter Installation................................................................................................................... 0090-3 DRAINING WATER AND SEDIMENT FROM FUEL TANK......................................................................... WP 0091 Figure 1. Remove Fuel Cap................................................................................................................ 0091-1 Figure 2. Drain Hose........................................................................................................................... 0091-2 Figure 3. Drain Valve........................................................................................................................... 0091-3 Figure 4. Install Fuel Cap.................................................................................................................... 0091-4 CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT..................................................................... WP 0092 Figure 1. Curtain Adjustment............................................................................................................... 0092-2 Figure 2. Clearance Check.................................................................................................................. 0092-3 Figure 3. Clamp Installation................................................................................................................. 0092-4 Figure 4. Spring Compression............................................................................................................. 0092-5 MAINTENANCE AFTER FORDING............................................................................................................ WP 0093 Figure 1. Draining Mud or Water......................................................................................................... 0093-1 Chapter 6 - OPERATOR SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0094 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................ WP 0095 Table 1. COMPONENTS OF END ITEM........................................................................................... 0095-2 Table 2. BASIC ISSUE ITEMS........................................................................................................... 0095-4 ADDITIONAL AUTHORIZATION LIST (AAL).............................................................................................. WP 0096 Table 1. Additional Authorization List................................................................................................. 0096-1 EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0097 xxi TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. SPECIAL PURPOSE KITS (SPK) LIST....................................................................................................... WP 0098 Table 1. Special Purpose Kits............................................................................................................ 0098-2 TROUBLESHOOTING NOTES................................................................................................................... WP 0099 HYEX TRANSPORTABILITY INSTRUCTIONS........................................................................................... WP 0100 Figure 1. Military Load Classification................................................................................................... 0100-1 Figure 2. HYEX Dimensions................................................................................................................ 0100-2 Figure 3. HYEX Transportation Data Plate.......................................................................................... 0100-3 Figure 4. HYEX Lifting and Tie Down Points....................................................................................... 0100-4 Table 1. HYEX Lift and Tie Down Information.................................................................................... 0100-4 Figure 5. M870 Loading....................................................................................................................... 0100-5 Figure 6. M870A1 Loading.................................................................................................................. 0100-6 Figure 7. M870A3 Loading.................................................................................................................. 0100-7 Figure 8. GIC Rail Clearance.............................................................................................................. 0100-8 Figure 9. Standard Cab Clearance...................................................................................................... 0100-9 Figure 10. Armored Cab Clearance..................................................................................................... 0100-10 Figure 11. HTTX Railcar Loading Overhead View.............................................................................. 0100-10 Figure 12. HTTX Railcar Loading Side View....................................................................................... 0100-11 Figure 13. C-5 Aircraft Loading........................................................................................................... 0100-11 Figure 14. C-17 Aircraft Loading......................................................................................................... 0100-12 Figure 15. Marine Loading................................................................................................................... 0100-12 Figure 16. Standard Rock Bucket........................................................................................................ 0100-13 Figure 17. Standard Ditch Cleaning Bucket........................................................................................ 0100-14 Figure 18. Standard Buckets Loaded On M870A1.............................................................................. 0100-15 Figure 19. Standard Buckets Loaded On M870A3.............................................................................. 0100-15 Figure 20. Deep Dig Arm..................................................................................................................... 0100-16 Figure 21. Deep Dig Bucket................................................................................................................ 0100-16 Figure 22. Deep Dig Ditch Cleaning Bucket........................................................................................ 0100-17 xxii TM 5-3805-294-10 TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 23. Crush-All............................................................................................................................. 0100-18 Figure 24. Compactor.......................................................................................................................... 0100-18 Figure 25. Impact Breaker................................................................................................................... 0100-19 Figure 26. Barrier Grapple................................................................................................................... 0100-19 Figure 27. Crush-All On M870A1........................................................................................................ 0100-20 Figure 28. Crush-All On M870A3........................................................................................................ 0100-20 Figure 29. Standard Buckets Loaded On HTTX Railcar...................................................................... 0100-21 Figure 30. Crush-All Loaded On HTTX Railcar................................................................................... 0100-21 Figure 31. Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.................... 0100-22 Figure 32. Deep Dig Arm and Buckets Loaded On HTTX Railcar....................................................... 0100-22 Index xxiii/xxiv blank TM 5-3805-294-10 HOW TO USE THIS MANUAL This Technical Manual (TM) is designed to help you safely and efficiently operate and maintain the Hydraulic Excavator Type 1 (HYEX), NSN 3805-01-573-0677. Instructions are included to cover most circumstances. However, it is impossible to address every scenario you may encounter. If you are unsure of what to do after looking in this TM, always contact your direct supervisor. These instructions provide the user with a general knowledge of the equipment, characteristics, and operating procedures of the HYEX. Troubleshooting and maintenance procedures are provided at crew maintenance levels. Operating instructions for most circumstances will be provided, but the user's best guide will be knowledge of the machine and its operation. In an emergency, a quick instinctive response based on that knowledge is essential. This manual contains a "References" Work Package (WP). Occasionally a different Technical Manual (TM) will be referenced in the text of this manual. A link will appear in parenthesis along with the manual that is referenced. The link lists the references WP in the manual. This will allow the user to see the TM number and the title. TABLE OF CONTENTS The table of contents provides a quick reference of each WP by Title and WP number, and lists each Figure and Table within that WP to assist in finding the required information except blank pages. WORK PACKAGE NUMBERS The WP number is found in the upper right corner of each page. It is also found at the bottom center of every page. INITIAL SETUP BLOCK The initial setup block contains information vital for the completion of the WP. In some instances, it may contain the words "Not Applicable". The following is a list of what is found in the initial setup block. 1. TOOLS AND SPECIAL TOOLS: These are all of the tools required to complete the tasks in the WP. 2. MATERIALS/PARTS: Any part to include oil, grease, or rags to complete the tasks in the WP. 3. PERSONNEL REQUIRED: Lists the number and Military Occupation Skill (MOS) required to complete the WP. 4. REFERENCES: When the reference is in the same manual, it will only list the WP number. If the reference is in a different manual, it will list the title and the WP number and will link you to the References WP for additional information. 5. EQUIPMENT CONDITION: This is how the machine needs to be configured before starting the work. 6. TIME TO COMPLETE: Not all WP will have the time to complete listed. Normally, maintenance and servicing procedures will list the time it should take to complete that WP. WARNINGS, CAUTIONS, AND NOTES Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure. Abbreviated formatted warnings are recognized when a warning in a WP has a single word that will be printed in all caps and BOLD. The full warning is in the warning summary and should be read prior to continuing the WP. Warning, caution, and note headings and certain essential information are printed in BOLD type for clarity. This is critical data to ensure personal safety, prevent damage to the machine, and clarify unique data or procedures used on the HYEX. xxv TM 5-3805-294-10 HOW TO USE THIS MANUAL - Continued CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Chapter 1 presents general information, as well as the characteristics, capabilities, and features of the HYEX. Also included in Chapter 1 is HYEX theory of operation. CHAPTER 2 OPERATOR INSTRUCTIONS Chapter 2 provides operator instructions for starting and shutting off the machine, operation of standard functions, and driving procedures. Chapter 2 also provides operator instructions for individual equipment items in the HYEX. Included are description and location of driver's controls, fire suppression system, and the coolant heater system. CHAPTER 3 TROUBLESHOOTING PROCEDURES Chapter 3 provides operator level troubleshooting procedures for various malfunctions that may occur during machine operation. The troubleshooting index is a quick reference by WP of the common malfunctions/symptoms which you may find during the operation or maintenance of the HYEX or its attachments. CHAPTER 4 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Chapter 4 lists operator level preventive maintenance checks and services (PMCS) that are performed before machine operation, while it is being operated, and after the mission is completed. The PMCS table lists the item to be checked or serviced, the check or service procedure, and the criteria for determining whether the equipment being checked is ready for its mission. CHAPTER 5 MAINTENANCE INSTRUCTIONS Chapter 5 lists maintenance instructions the crew can perform on the machine. CHAPTER 6 SUPPORTING INFORMATION Chapter 6 lists the regulations, forms, pamphlets, field manuals, technical bulletins, and technical manuals that apply to this manual. Chapter 6 also includes Components of End Item (COEI), Basic Issue Items (BII), Additional Authorization List (AAL), and Expendable/Durable supplies and materials lists. xxvi TM 5-3805-294-10 CHAPTER 1 OPERATOR GENERAL INFORMATION FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0001 OPERATOR MAINTENANCE GENERAL INFORMATION SCOPE This manual contains instructions for operation, operator troubleshooting, and operator-performed maintenance on the Hydraulic Excavator Type 1 (HYEX). The HYEX is used for construction operations. MAINTENANCE FORMS AND RECORDS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094); or AR 700-138, Army Logistics Readiness and Sustainability (WP 0094). REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your HYEX 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. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/ aespublic.cfm (scroll down and choose "Submit Quality Deficiency Report" bar). The internet form lets you choose to submit an EIR, a Product Quality Deficiency Report (PDQR) or a Warranty Claim Action (WCA). You may also submit your information using an SF Form 368 (Product Quality Deficiency Report). You can send your SF Form 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094), and mail it to us at: Department of the Army, U.S. Army Tank-Automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 38397-5000. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materials is a continuing concern. It is important that any corrosion problems with the HYEX be reported so that the problem can be corrected and improvements can be made to prevent the problem in the future. While corrosion is typically associated with rusting of metals, corrosion 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 (WP 0094). Use of key words, such as corrosion, rust, deterioration, and cracking, will ensure that the information is identified as a CPC problem. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE For procedures to destroy the HYEX to prevent its use by the enemy, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (WP 0094). PREPARATION FOR STORAGE OR SHIPMENT Contact Field Maintenance for instructions on preparation for storage or shipment. WARRANTY INFORMATION The HYEX is warranted by John Deere. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record (WP 0094). Refer to TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D LC (WP 0094). 0001-1 TM 5-3805-294-10 LIST OF ABBREVIATIONS/ACRONYMS Table 1. List of Abbreviations/Acronyms. Abbreviation/Acronym Description AAL Additional Authorization List A/C Air Conditioning ACC Accessory AEPS Army Electronic Product Support A/I or A.I. Auto-Idle AOAP Army Oil Analysis Program BII Basic Issue Items CAGEC Commercial and Government Entity Code cm Centimeter COEI Components of End Item CPC Corrosion Prevention and Control CTA Common Table of Allowance E Economy ECU Engine Control Unit EDRS Electronic Deficiency Reports EIR Equipment Improvement Record FC Full-Cool FH Full-Heat ft Feet gal Gallon h Hour HET Heavy Equipment Transport hp Horsepower H/P High Power 0001-2 0001 TM 5-3805-294-10 LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. List of Abbreviations/Acronyms - Continued. HYEX Hydraulic Excavator in. Inch INT Intermittent kg Kilogram kohm Kilo ohm L Liter L/h Liter/hour m Meter mm Millimeter P Power PMCS Preventive Maintenance Checks and Services P/N Part Number psi Pounds per Square Inch QDR Quality Deficiency Report TAMMS The Army Maintenance Management System END OF WORK PACKAGE 0001-3/4 blank 0001 TM 5-3805-294-10 0002 OPERATOR MAINTENANCE EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Overview The Hydraulic Excavator Type 1 (HYEX), NSN 3805-01-573-0677, is a 21-24 Metric Ton, diesel powered, crawler mounted, hoe type hydraulic excavator. The HYEX digs, elevates, swings, and dumps material by action of the boom, the arm, and the bucket. The HYEX is powered by a John Deere six-cylinder, PowerTech, 414 cu in. (6.8 L) engine driving two identical variable displacement, bent-axis, piston type hydraulic pumps and a fixed displacement, external gear pilot pump. The hydraulic pumps and pilot pump combination provide the hydraulic and control pressure for the machine to operate. Propulsion is provided by two-speed hydraulic travel motors, (one on each side), that drive two track chains with 51 triple semi-grouser 32 in. (800 mm) wide track shoes. Each hydraulic travel motor is of a bidirectional planetary drive/ axial piston motor design with spring applied and hydraulically released travel brakes. The HYEX upper structure is capable of continuous 360–degree rotation driven by a swing gearbox and bidirectional swing motor mounted on top of the swing gearbox. The swing motor has a spring applied and hydraulically released park brake. The park brake prevents the upperstructure from uncontrolled swinging. The swing park brake is released when swing, boom, arm, or bucket function is actuated. The boom, arm, hydraulic thumb, and bucket hydraulic cylinders provide linear actuation for their associated components. These cylinders vary in size, but are similar in design and function. The HYEX is configured with a retractable hydraulic hose reel, with pressure and return hoses of 50 ft (15.24 m) length and 0.5 in. (1.27 cm) diameter, located on the cab side of the excavator to operate hand-held tools. The hydraulic circuit is a controlled pressure source with adjustable flow rates between 8-12 GPM (30.28-45.42 LPM) with adjustable nominal pressure limit of 2,000 psi (137.89 bar). Operating Capabilities The HYEX can excavate undisturbed hard, medium, and soft soils to a minimum depth range of 22-24 ft (6.7-7.3 m). It has a minimum horizontal bucket reach at ground level of 30 ft (9.14 m). Maximum possible bucket and stick forces are capable of penetrating and excavating very difficult soils (such as caliche) and conditions (such as frozen soils). The HYEX is capable of dumping into the Family of Medium Tactical Vehicles (FMTV), 5 ton with a bed height of 6 ft 9 in., to a M917 20 ton with a bed height of 10 ft 2 in. HYEX is capable of dumping into an Engineer Mission Module (EMM) when on equal level ground. The HYEX operates under environmental climatic conditions from -25°F to 120°F (-31.6°C to 48.8°C) without restriction, and when required, down to -40°F (-40°C) using the coolant heater cold weather starting kit. The HYEX will start and operate during and after fording operations in fresh water in any depth up to 40 in. (1 m) including wave action. Attachments for HYEX are connected to the excavator arm (stick) using the Quick Latch (a hydraulic quick connect/ disconnect coupler system) and hydraulic quick-disconnect hydraulic hose connections on the arm. The only exception is the Deep Digging Attachment Arm that must be pinned directly to the end of the excavator arm. 0002-1 TM 5-3805-294-10 0002 Attachments The HYEX digging and loading attachments are as follows: Heavy Duty Bucket (for general purpose excavating and in material, such as dense clay and light rock) with • heaped capacity of 1.5 sq yd (1.25 sq m), a 42 in. (107 cm) outside lip width, and five pick-shaped pointed teeth. Heavy Duty Bucket (for use with the deep digging attachment) with heaped capacity of 0.5 sq yd (0.41 sq • m), 30 in. (76 cm) outside lip width, and four pick-shaped pointed teeth. Ditch Cleaning Bucket (Utility) with heaped capacity of 1.33 sq yd (1.11 sq m), 60 in. (152 cm) outside lip • width, and no teeth. Ditch Cleaning Bucket (Utility), (for use with the deep digging attachment) with heaped capacity of 0.75 sq • yd (0.62 sq m), 60 in. (152 cm) outside lip width, and no teeth. Hydraulic thumb clamp is configured to work with heavy duty bucket listed above, and is compatible with • the ditch cleaning bucket listed above. The hydraulic thumb will fully retract or fold back when not in use, enabling unhampered use of bucket(s), and can be pinned in the fully retracted position directly to the end of the excavator arm (stick). Deep Digging Attachment Arm (20 ft (6.09 m) long) is pinned directly to the end of the excavator arm (stick). • The Deep Digging Attachment Arm allows attachment of either the 30 in. (76 cm), 0.5 sq yd (0.41 sq m), digging bucket (with teeth), or the 60 in. (152 cm), 0.75 sq yd (0.62 sq m), ditch cleaning bucket (no teeth). This attachment uses additional counterweight and control selections to enable operation for digging to a depth of 40 ft (12.19 m). The HYEX construction attachments are as follows: Hydraulic Impact Breaker (impact energy class of 5,000 lb-ft (6779 N•m)), with operating weight between • 4,500-5,500 lb (2041.2-2494.7 kg), capable of 450 full-stroke blows/min and using a tool with a diameter of 5.5 in. (13.97 cm). Each Hydraulic Impact Breaker is supplied with a moil point (1 each), a chisel point (1 each), and a blunt point (1 each). Hydraulic Driven Plate Compactor with a base plate size of 23.5 X 40 X 1.5 in. (59.69 X 101.6 X 3.81 cm) • operating at 2100 blows/min and 15,250 lbs (6917.28 kg) of impulse force. Hydraulic Crushing Attachment (Crush-All) is capable of operating as a loader, hopper, feeder, crusher, and • conveyor. The Crush-All is capable of crushing concrete with and without rebar, stone, asphalt, brick, block, and debris with a minimum size of 24 in. wide x 24 in. long x 10 in. thick (60.96 cm wide x 60.96 cm long x 25.4 cm thick) and has minimum hopper capacity of 0.6 cu. yd (0.45 cu m). The Crush-All has reversible strike plates to increase the operational serviceability interval. Barrier Grapple is capable of lifting, moving, and emplacing barriers weighing 400-16,000 lb (181.4-7257.4 • kg) with a barrier width of 6-12 in. (15.24-30.48 cm). The barrier grapple has a fully automatic actuator which allows the barriers to be lifted, latched, placed, and unlatched automatically without the aid of an assistant. 0002-2 TM 5-3805-294-10 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 5 6 8 7 4 3 2 1 9 HYEX00104 Figure 1. Table 1. Right View of HYEX. Right View of HYEX. 1 FUEL TANK. Contains JP-8, diesel, or other NATO-approved fuels for engine operation. 2 HYDRAULIC RESERVOIR. Contains hydraulic oil for the hydraulic system. 3 HYDRAULIC PUMPS. Draws hydraulic fluid from the hydraulic reservoir and provides hydraulic pressure and control pressure to the rest of the hydraulic system. 4 COUNTERWEIGHT. Adds stability to the machine during digging and lifting operations. 5 ARM CYLINDER. Extends and retracts the arm. 6 BOOM CYLINDERS. Raises and lowers the boom. 7 ATTACHMENT CYLINDER. Curls the bucket while digging and allows for dumping. 8 HYDRAULIC THUMB CYLINDER. Extends and retracts the hydraulic thumb. 9 TOOL BOX. Used for storage of Basic Issue Items (BII). 0002-3 TM 5-3805-294-10 0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued 20 17 10 16 11 19 12 16 18 15 13 Figure 2. Table 2. 14 HYEX00105 Left View of HYEX. Left View of HYEX. 10 ENGINE. Drives the hydraulic pumps and the pilot pump. 11 RADIATOR. Contains coolant which provides engine cooling. 12 BATTERIES. Two 12-volt batteries provide current for the electrical system. 13 CAB. All digging and travel functions are controlled by the operator. 14 TRAVEL MOTORS. Drives the machine forward or backward and provides turning capability. 15 BUCKET. Used for digging operations. 16 ARM. Used to connect quick latch or different attachments depending on mission. 17 HYDRAULIC THUMB. Used with the bucket attachment to clamp and lift. 18 UNDERCARRIAGE. Consists of the lower structure and the track assemblies. 19 UPPERSTRUCTURE. Consists of the upperstructure, engine/hydraulic pump compartment, cab, boom and arm, and accessories. 20 HYDRAULIC HOSE REEL. Quick attach hose reel used to power hydraulic tools and accessories. 0002-4 TM 5-3805-294-10 0002 IDENTIFICATION PLATES Maintain, in a secure location, an up-to-date inventory of all product and component serial numbers. Regularly verify that identification plates have not been removed. Report any evidence of tampering to appropriate agencies and order duplicate plates. Mark your machine with your own numbering system and take color photographs from several angles of each plate. 22 21 HYEX01506 Figure 3. Table 3. Data Plates. Data Plates. 21 IDENTIFICATION PLATE. The identification plate has the model, serial number, registration number, manufacture's name and the warranty information on it. 22 SERIAL NUMBER PLATE. Has the machine serial on it. 0002-5 TM 5-3805-294-10 EQUIPMENT DATA Table 4. Equipment Data. ENGINE: Model PowerTech Manufacturer John Deere Horsepower (2,000 rpm) 177 hp (132 kW) Number of Cylinders 6 Displacement 414 cu in. (6.8 L) CAPACITIES: Fuel Tank 132 gal (500 L) Cooling System 7.9 gal (29.9 L) Engine Oil (including oil filter) 6.5 gal (24.6 L) Hydraulic Reservoir 64.2 gal (243 L) Hydraulic System 74 gal (280 L) Swing Gearbox 2.4 gal (9.1 L) Travel Gearbox (each) 2.1 gal (7.9 L) Pump Drive Gearbox 1.2 qt (1.1 L) 0002-6 0002 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued 5 4 6 12 3 7 9 1 8 2 10 11 HYEX00106 Figure 4. Table 5. HYEX Specifications. HYEX Specification. ITEM DESCRIPTION MEASUREMENT SPECIFICATION 1 Sprocket Center to Idler Center Distance 12 ft 7 in. (3840 mm) 2 Undercarriage Length 15 ft 3 in. (4640 mm) 3 Counterweight Clearance Distance 3 ft 7 in. (1090 mm) 4 Rear End Swing Radius Distance 9 ft 8 in. (2940 mm) 5 Upper Structure Width (excluding back mirrors) Distance 9 ft 6 in. (2890 mm) 6 Cab Height 9 ft 11 in. (3020 mm) 7 Minimum Ground Clearance Distance 1 ft 6 in. (460 mm) 8 Center of Sprocket to Center of Sprocket Distance 8 ft 6 in. (2590 mm) 9 Track Shoes Width 32 in. (800 mm) 10 Undercarriage Width 133 in. (2780 mm) 11 Machine Overall Length 399 in. (10134 mm) 12 Machine Transport Height 122 in. (3099 mm) 13 Machine Shipping Weight 66,000 lb (29937 kg) 0002-7 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued 3 4 5 1 9 2 6 7 8 HYEX00107 Figure 5. HYEX Working Ranges. 0002-8 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued Table 6. HYEX Working Ranges. ITEM DESCRIPTION MEASUREMENT SPECIFICATION 1 Maximum Digging reach Distance 35 ft 6 in. (10810 mm) 2 Maximum Digging reach at Ground Level Distance 34 ft 11 in. (10640 mm) 3 Minimum Swing Radius Radius 11 ft 4 in. (3460 mm) 4 Maximum Cutting Height Height 34 ft 6 in. (10520 mm) 5 Maximum Dumping Height Height 24 ft 9 in. (7540 mm) 6 Maximum Digging Depth Depth 24 ft 7 in. (7490 mm) 7 Maximum Digging Depth (flat bottom) Depth 24 ft 1 in. (7330 mm) 8 Maximum Vertical Wall Depth 21 ft 9 in. (6630 mm) 9 Tail Swing Radius Radius 9 ft 8 in. (2940 mm) 0002-9 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued NOTE Ratings are at quick latch lift hook, using standard counterweight, situated on firm, level, uniform supporting surface, and with the machine configured with the standard arm and bucket. Ratings do not apply to any attachments. HYEX is equipped with an overload alarm. When lifting over the side and the weight limit is exceeded the alarm will sound until weight limit is within range. Table 7. Front Lift Capacities. LIFTING OVER FRONT IN 1,000 lb (454 kg) ft (m) 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 20 (6.10) 25 (7.62) 30 (9.14) 7.55 lb (3.42 kg)* 15 (4.57) 8.52 lb (3.86 kg)* 8.61 lb (3.90 kg)* 6.26 lb (2.84 kg)* 10 (3.05) 14.69 lb (6.66 kg)* 11.56 lb (5.24 kg)* 10.05 lb (4.56 kg)* 8.09 lb (3.66 kg)* 5 (1.25) 20.76 lb (9.41 kg)* 14.49 lb (6.57 kg)* 11.62 lb (5.27 kg)* 9.68 lb (4.39 kg) Ground Line 24.56 lb (11.14 kg)* 16.88 lb (7.65 kg)* 12.79 lb (5.80 kg) 9.46 lb (4.29 kg) 13.06 lb (5.92 kg)* 25.71 lb (11.66 kg)* 17.90 lb (8.11 kg) 12.48 lb (5.66 kg) 9.31 lb (4.22 kg) 22.51 lb (10.21 kg)* 25.00 lb (11.33 kg)* 17.77 lb (8.06 kg) 12.39 lb (5.62 kg) 29.63 lb (13.43 kg)* 22.54 lb (10.22 kg)* 16.71 lb (7.57 kg)* 12.31 lb (5.58 kg) 17.28 lb (7.83 kg)* 12.10 lb (5.48 kg)* -5 (-1.52) -10 (-3.05) -15 (-4.57) -20 (6.10) 15.60 lb (7.07 kg)* * Hydraulically Limited Capacity 0002-10 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued Table 8. Side Lift Capacities. LIFTING OVER SIDE IN 1,000 lb (454 kg) ft (m) 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 20 (6.10) 25 (7.62) 30 (9.14) 7.55 lb (3.42 kg)* 15 (4.57) 8.52 lb (3.86 kg)* 8.61 lb (3.90 kg)* 6.26 lb (2.84 kg)* 10 (3.05) 14.69 lb (6.66 kg)* 11.56 lb (5.24 kg)* 8.88 lb (4.02 kg) 6.29 lb (2.85 kg) 5 (1.52) 18.90 lb (8.57 kg) 12.10 lb (5.48 kg) 8.39 lb (3.80 kg) 6.04 lb (2.73 kg) Ground Line 17.62 lb (7.99 kg) 11.35 lb (5.14 kg) 7.96 lb (3.61 kg) 5.81 lb (2.63 kg) 13.06 lb (5.92 kg)* 17.16 lb (7.78 kg) 10.92 lb (4.95 kg) 7.68 lb (3.48 kg) 5.67 lb (2.57 kg) 22.51 lb (10.21 kg)* 17.15 lb (7.77 kg) 10.80 lb (4.89 kg) 7.59 lb (3.44 kg) 29.63 lb (13.44 kg)* 17.46 lb (7.91 kg) 10.96 lb (4.97 kg) 7.77 lb (3.52 kg) 17.28 lb (7.83 kg)* 11.53 lb (5.22 kg) -5 (-1.52) -10 (-3.05) -15 (-4.57) -20 (6.10) 15.60 lb (7.07 kg)* * Hydraulically Limited Capacity 0002-11 TM 5-3805-294-10 0002 EQUIPMENT DATA - Continued HYEX weights with attachments. Table 9. HYEX Weights With Attachments. Machine Weight Attachment and Weight Total weight 66,000 (29937 kg) Barrier Grappler 750 lb (341 kg) 66,750 lb (30277 kg) 66,000 (29937 kg) Compactor 840 lb (381 kg) 66,840 lb (30318 kg) 66,000 (29937 kg) Heavy Duty Bucket 1,600 lb (726 kg). 67,600 lb (30663 kg) 66,000 (29937 kg) Ditching Bucket 1,600 lb (726 kg) 67,600 lb (30663 kg) 66,000 (29937 kg) Breaker 4,900 lb (2223 kg) 70,900 lb (32160 kg) 66,000 (29937 kg) Crush-All 5,800 lb (2631 kg) 71,800 lb (32568 kg) Deep dig arm weighs 3,000 lb (1361 kg) and additional counterweight with four mounts and two spacer plates for deep dig arm operation weigh 1,550 lb (703 kg). Table 10. Deep Dig Arm Weights. Machine/Deep Dig Arm/ Counterweight Attachment and Weight Total Weight 67,550 lb (30640 kg) Deep Dig Bucket 1,000 lb (454 kg) 68,550 lb (31094 kg) 67,550 lb (30640 kg) Deep Ditch Cleaning Bucket 1,000 lb 68,550 lb (31094 kg) (454 kg) END OF WORK PACKAGE 0002-12 TM 5-3805-294-10 0003 OPERATOR MAINTENANCE THEORY OF OPERATION SCOPE This section explains how components of the HYEX work together. A functional description is given for the engine, Electronic Control Unit (ECU), fuel system, cooling system, electrical system, and hydraulic system. Engine The engine is a John Deere 6068H PowerTech Plus, 6.8L, 6-cylinder diesel engine. The 6068H includes a turbocharger, electronic control unit, 4-valve per cylinder head, electronic fuel injectors, and a high-pressure common rail fuel system. The 6068H is air-to-air after cooled to help reduce exhaust emissions while maintaining low-speed torque. The engine application includes a hydraulically-driven cool-on-demand fan system. ECU The electronic control system serves as an engine governor, controlling the engine speed by delivering fuel, in precise amounts, and at precise time according to a given set of engine conditions in relation to piston position. In order to achieve this, the control system performs the following functions: • Constantly monitors engine operating conditions • Performs system diagnosis • Notify operator of machine faults through the monitor • Can derate or shut down engine to prevent damage 0003-1 TM 5-3805-294-10 0003 ECU - Continued Electrical System 2 3 4 5 1 HYEX01511 Figure 1. Electrical System Components. Table 1. Electrical System Components. 1 Batteries The batteries provide power for the electrical circuits. Two 12-volt batteries are connected in series to provide 24-volt starting power. 2 Alternator The alternator provides 28-volt, 80-amp. current to charge the batteries and operate the electrical system. 3 Starter Motor Part of the starting circuit, the starter motor is used to turn the engine flywheel fast enough to start the engine. 4 Slave Receptacle The slave receptacle can be used to charge the batteries and slave start the engine from an external power source. The slave receptacle can also be used to charge and slave start other equipment. 5 Fuse Panel The fuse panel provides centrally located fuses that will open the battery circuit if there is a shorted, grounded wire or excessive current draw by a defective component in the corresponding circuit. When the circuit is open, no current will flow through the electrical system. Fuses are easily replaced. If a fuse continually trips, the affected component or vehicle electrical system requires repair. 0003-2 TM 5-3805-294-10 0003 Hydraulic System 10 11 14 13 15 9 16 12 7 8 17 HYEX01512 6 Figure 2. Table 2. Hydraulic System Components. Hydraulic System Components. 6 Main Pumps The HYEX has two main hydraulic pumps that supply hydraulic oil for all functions including boom, arm, bucket, swing, and travel. 7 Pilot Pump The pilot pump is a small gear pump that keeps oil moving through the pilot system. It also provides the pressure to move the spools in the main hydraulic valve and to release the spring-applied hydraulically-released swing and park brakes. 8 Hydraulic Reservoir The hydraulic reservoir is pressurized ensuring that hydraulic oil is always supplied to the pumps. 9 Main Control Valve The control valve consists of two monoblock valves referred to as the left control valve and right control valve. There is a spool in each valve to control the boom, arm, and travel functions. All other functions are supplied by a single spool in one or the other of the valves. All spools are moved by pilot oil. Each valve section controls the flow rate and direction for its hydraulic circuit. 0003-3 TM 5-3805-294-10 0003 Hydraulic System - Continued 10 11 14 13 15 9 16 12 7 8 17 HYEX01512 6 Figure 3. Hydraulic System Components Continued. Table 3. Hydraulic System Components Continued. 10 Pilot Signal Manifold The pilot signal manifold is in the pilot system between the pilot control valves and the control valve and regulators. The manifold receives a pilot signal from the pilot control valves and sends the signal on multiple paths simultaneously so there is little lag between operation of the pilot control valves, pump stroke, and function movement. 11 Swing Motor The swing motor uses hydraulic pressure supplied by the pumps to make the upper structure rotate. It has a spring-applied hydraulically-released swing brake. The swing brake engages as soon as the swing controls are released. 12 Rotary Manifold The rotary manifold allows the upper structure of the machine to rotate relative to the undercarriage while still supplying hydraulic oil to the travel motors. 13 Boom Cylinders The boom cylinders are attached to the main frame and the boom. When activated they raise and lower the boom. 14 Arm Cylinder The arm cylinder is attached between the boom and the arm. When activated, this cylinder moves the arm in and out. 0003-4 TM 5-3805-294-10 0003 Hydraulic System - Continued Table 3. Hydraulic System Components Continued - Continued. 15 Hydraulic Thumb Cylinder The hydraulic thumb cylinder is attached between the arm and the thumb. When activated, this cylinder extends and retracts the hydraulic thumb. The hydraulic thumb cylinder circuit can be closed to provide the hydraulic power to operate the crush-all, breaker, compactor and deep dig arm accessories. 16 Bucket Cylinder The bucket cylinder is attached between the arm and the quick latch. When activated, this cylinder extends and curls the bucket or attachments. 17 Load Holding Valves Reduced leakage valves are used in the boom head-end circuit and arm rodend circuit. The function of a reduced leakage valve is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve. Powertrain 21 18 20 19 HYEX01513 Figure 4. Table 4. Powertrain Components. Powertrain Components. 18 Track Chain Adjuster The track chain adjuster is located between the frame and the track chain idler. Grease is added or removed to adjust the track sag. The recoil spring is located with the track chain adjuster and absorbs shocks to the tracks and track chain idler. 19 Track The track assembly consists of the chain and shoes. The travel motor drives the track to move the machine. 20 Rollers The machine has two carrier rollers and nine lower track rollers on each side of the machine. The rollers guide the tracks and keep the tracks in contact with the ground. 21 Travel Motor The travel motors are located inside the tracks to prevent damage during operation. The travel system has a spring-applied hydraulically-released parking brake. The parking brake engages as soon as the travel controls are released. 0003-5 TM 5-3805-294-10 0003 Fuel System 22 24 27 23 25 26 HYEX01514 28 Figure 5. Fuel System Components. Table 5. Fuel System Components. 22 Fuel Transfer Pump The fuel transfer pump pulls fuel from the fuel tank through the water separator and sends it through the fuel filters to the high-pressure fuel injection pump. 23 Primary Fuel/Water Separator The primary water separator keeps large particles and contaminants from entering the high-pressure fuel pump. 24 Secondary Fuel/Water Separator The secondary water separator keeps small particles and contaminants from entering the pressure fuel pump. 25 Lubricity Canister The lubricity canister is a spin-on canister with a lubricant that is slowly released into the fuel. To enable use of all types of diesel fuels. 26 Fuel Tank The fuel tank has 132 gal (500 liter) capacity and is equipped with a low fuel level alarm and vented fill cap. 27 Fuel Tank Strainer The strainer is designed to keep debris from entering the fuel system. 28 Fuel Tank Drain Valve The drain valve is used to remove water and debris from the fuel tank. 0003-6 TM 5-3805-294-10 0003 Fuel System - Continued 30 29 HYEX01515 Figure 6. Table 6. High-Pressure Pump and Injectors. High-Pressure Pump and Injectors. 29 High-Pressure Fuel Pump The high-pressure fuel pump increases the fuel pressure to send exact amounts of fuel to the injector nozzles. 30 Fuel Injectors The fuel injectors turn the stream of fuel into a fine spray, which permits good combustion in the cylinder. There is one nozzle for each cylinder. The injectors are located under the rocker arm cover. 0003-7 TM 5-3805-294-10 0003 Fuel System - Continued Cooling 31 33 32 34 HYEX01516 Figure 7. Table 7. Cooling Package. Cooling Package. 31 Radiator Coolant circulates through the radiator to be cooled after leaving the cylinder block. 32 Hydraulic Oil Cooler The hydraulic oil cooler uses air from the fan to cool the oil before returning it to the reservoir. 33 Charge Air Cooler The charge air cooler cools the air supplied to the engine to decrease fuel consumption and emissions. 34 Fuel Cooler Fuel is circulated across the cooler to lower fuel temperature. 0003-8 TM 5-3805-294-10 0003 Cooling - Continued 35 36 37 HYEX01517 Figure 8. Table 8. Cooling System Components. Cooling System Components. 35 Coolant Surge Tank The coolant surge tank is where the coolant level is checked and added. 36 Engine Oil Cooler Coolant from the radiator passes through the engine oil cooler to maintain a safe operating temperature. 37 Fan The variable speed fan is located at the front of the engine and is driven by a hydraulic motor. The speed of the fan is varied to provide the amount of airflow that the engine coolant, charge air cooler, or hydraulic cooler need, ensuring maximum fuel efficiency, reduced noise levels, and faster engine warm up. A reversing function reverses the cooling fan to help clean the cooling package of dirt and debris. END OF WORK PACKAGE 0003-9/10 blank TM 5-3805-294-10 CHAPTER 2 OPERATOR INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0004 OPERATOR MAINTENANCE DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS INTRODUCTION The following tables and illustrations provide the description and use of the controls and indicators pertaining to the front switch panel, heater and air conditioner control panel, control pedals and levers, left console, left and right control levers, seat controls and arm rest, coolant heater and cab door, and warning indicators and alarms. Table 1. Front Switch Panel. 3 4 5 6 1 Figure 1. 2 7 HYEX00867 Front Switch Panel. Key Control/Indicator Function 1 Washer/Wiper Switch Wiper switch has several positions. The OFF position stops the wipers from operating and parks them. The INT position operates the wipers intermittently at the interval selected by the switch position. The ON position operates the wipers continuously. To operate the washer, push and hold switch down for no more than 20 seconds. Note that the wiper will not operate unless the windshield is completely closed. 2 Operating Lights Switch This is a three-position switch. The first position turns on the drive light. Front Switch panel will also illuminate. The second position turns on the boom work lights, the front cab work lights, and the drive light. If the default screen on the monitor is displayed, the background goes from white to black. 0004-1 TM 5-3805-294-10 0004 Table 1. Front Switch Panel - Continued. Key Control/Indicator Function 3 Engine Speed Dial The dial is used to increase or decrease engine speed. 3 4 5 6 1 Figure 2. 2 7 HYEX00867 Front Switch Panel Continued. 4 Auto-Idle (A/I) Switch This is a two-position switch. In the ON position, it will reduce the engine speed after 4 seconds when control levers are in the neutral position. In the OFF position the operator can set the engine speed to improve machine control. 5 Power Mode Switch This is a three-position switch. The H/P mode is used when more hydraulic power is desired for raising the boom and rolling the bucket during excavation work. The Power (P) mode is used when performing general digging operations. The Economy (E) mode is used to increase fuel efficiency and reduces noise level. 6 Travel Mode Switch This is a two-position switch. It is used to select fast or slow speed of travel. 7 Key Switch This is a four-position switch. When in the OFF position, the key can be removed. Moving the switch to the ACC position allows the radio to be turned on or off. In the ON position, all electrical functions will operate. Move and release the switch to the START position starts the machine. 0004-2 TM 5-3805-294-10 Table 2. 0004 Heater/Air Conditioner (A/C) Controller and Radio. 16 9 15 14 13 10 12 11 8 HYEX00868 17 Figure 3. Heater/Air Conditioner (A/C) Controller and Radio. Key Control/Indicator Function 8 Blower Fan Speed Buttons Increases or decreases the speed of the blower fans. Turns on blower fans when A/C is off. 9 Monitor Display Displays blower fan speed, selected air vent, and temperature setting. 10 A/C Button When pressed, it turns on the air conditioning (A/C) and illuminates the A/C indicator. 11 AUTO Button When pressed, it turns on the AUTO and A/C indicators. Air flow-in temperature at the vent, blower fan speed, vent locations, and fresh air port are then automatically controlled. 0004-3 TM 5-3805-294-10 0004 Table 2. Heater/Air Conditioner (A/C) Controller and Radio - Continued. Key Control/Indicator Function 12 OFF Button When pressed the A/C and blower fans will turn off. Blower fans will turn on if one of the blower fan speed buttons is pressed even if the OFF button is on or off. 16 9 15 14 13 10 12 11 8 HYEX00868 17 Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued. 13 Temperature Control Buttons Press buttons to set temperature from full-cool (FC) to full-heat (FH). The monitor display will show FC or FH. 14 Recirculating Mode Button Press the recirculating mode button to close the fresh air vent and circulate air already in the cab. 15 Fresh Air Mode Button Press fresh air mode to route outside air into the cab. 16 Mode Button Press to select air vent. Selected vent will display on the monitor display. 17 Radio Display The radio display contains standard AM/FM radio tuning and volume controls. 0004-4 TM 5-3805-294-10 Table 3. 22 23 0004 Control Pedals and Levers. 21 20 18 19 HYEX00869 Figure 5. Control Pedals and Levers. Key Control/Indicator Function 18 Attachment Pedal Primarily used to open and close the hydraulic thumb. When attachments are connected, hydraulic valve selection will disable the hydraulic thumb and enable this pedal to operate the attachment. 19 Attachment Pedal Lock Locks attachment pedal in the neutral position to disable the hydraulic thumb or any attachments that are connected. 20 Right Travel Pedal Controls the direction of travel and steers the machine. Pushing down on the top of the pedal moves the machine forward. Pushing down on the bottom of the pedal moves the machine backwards. 21 Right Travel Lever Use this hand lever to perform the same functions as the right travel pedal with increased control. Pushing forward on the lever moves the machine forward. Pulling the lever moves the machine backwards. 0004-5 TM 5-3805-294-10 Table 3. 0004 Control Pedals and Levers - Continued. Key Control/Indicator Function 22 Left Travel Pedal Controls the direction of travel and steers the machine. Pushing down on the top of the pedal moves the machine forward. Pushing down on the bottom of the pedal moves the machine backwards. 22 23 21 20 18 19 HYEX00869 Figure 6. Control Pedals and Levers Continued. 23 Left Travel Lever Use this hand lever to perform the same functions as the left travel pedal with increased control. Pushing forward on the lever moves the machine forward. Pulling the lever moves the machine backwards. 0004-6 TM 5-3805-294-10 Table 4. 0004 Left Console and Pilot Shutoff Lever. 24 25 26 27 28 HYEX00870 Figure 7. Left Console and Pilot Shutoff Lever. Key Control/Indicator Function 24 Pilot Shutoff Lever Controls hydraulic functions on the machine. With the lever in the locked position, hydraulic functions are not operational. In the unlocked position, all hydraulic functions operate. The engine will not start with the lever in the unlocked position. 25 Travel Alarm Switch After the initial 13-second alarm, depressing the right half of the switch will shut the alarm off. 26 Rear Cab Work Lights Switch Turns the rear cab work lights on and off. 27 Auxiliary Control Switch Disables the right joystick left and right button auxiliary function. 28 Reversing Cooling Fan Switch This is a three position switch that controls the direction that the cooling fan is moving. AUTO: Every 60 minutes the cooling fan will automatically reverse direction for 15 seconds without intervention from the operator. OFF Fan resumes normal operation. MANUAL: Fan will reverse direction for 15 seconds when right portion of switch is pressed. 0004-7 TM 5-3805-294-10 Table 5. 0004 Right and Left Pilot Control Levers. 31 32 30 29 HYEX00871 Figure 8. Right Pilot Control Lever. Key Control/Indicator Function 29 Right Pilot Control Lever When pushed forward, the boom lowers. When pulled back, the boom raises. When pulled left, the bucket will curl. When pushed right, the bucket will dump. When released the lever will return to the neutral position. 30 Power Dig Button Pressing the power dig button gives the operator an 8-second increase in hydraulic power. 31 Left Button Auxiliary Function Used to close crush-all lid if connected. 32 Right Button Auxiliary Function Used to open crush-all lid if connected. 0004-8 TM 5-3805-294-10 0004 Table 5. Right and Left Pilot Control Levers - Continued. Key Control/Indicator Function 33 Left Pilot Control Lever When pushed forward, the arm will go out. When pulled back, the arm will come in. When pushed left, machine swings left. When pulled right, machine swings right. When released, lever returns to the neutral position. 34 33 HYEX00872 Figure 9. 34 Horn Button Left Pilot Control Lever. When pressed the horn will sound. 0004-9 TM 5-3805-294-10 Table 6. 0004 Seat Controls. 39 40 35 38 37 36 41 HYEX00873 Figure 10. Seat Controls. Key Control/Indicator Function 35 Seat Angle Lever Allows seat to be adjusted to a desired angle. 36 Seat Adjustment Handle Pull up handle to adjust the seat forward or backward. 37 Seat Weight Adjustment Knob Turn knob to adjust seat suspension to the proper weight of the operator. 38 Lumbar Adjustment Squeeze ball to add air for desired lumbar firmness. Press button next to ball to release air. 0004-10 TM 5-3805-294-10 Table 6. 0004 Seat Controls - Continued. Key Control/Indicator Function 39 Backrest Adjustment Lever Pull up lever to release backrest and adjust to desired position, then release lever. 40 Armrest Angle Adjustment Turn dial to adjust armrest to desired angle. 41 Seat Assembly Adjustment Lever Pull handle to slide entire seat to desired distance from travel pedals. 0004-11 TM 5-3805-294-10 Table 7. 0004 Cab Door Release Lever and Coolant Heater Display. 43 44 45 46 47 48 42 HYEX00874 Figure 11. Cab Door Release Lever and Coolant Heater Display. Key Control/Indicator Function 42 Cab Door Release Lever Push down to release cab door from the locked open position. 43 Coolant Heater Display Displays date and time. 44 Clock Button Pressing button displays date and time and allows to change date and time settings. 45 Preset Button Press the preset button to program the desired time to start cycle. 46 Heat Display Display will flash when a program is activated or if the coolant heater is manually operated. 47 Lower Button Used to lower time, date, or operating time depending on current screen. 0004-12 TM 5-3805-294-10 Table 7. 0004 Cab Door Release Lever and Coolant Heater Display - Continued. Key Control/Indicator Function 48 Raise Button Used to raise time, date, or operating time depending on current screen. Table 8. Quick Latch Control. 49 50 HYEX00875 Figure 12. Quick Latch Control. Key Control/Indicator Function 49 Quick Latch Switch Used to lock and unlock quick latch. 50 Quick Latch Light Illuminates when switch is in unlatch position. 0004-13 TM 5-3805-294-10 Table 9. 0004 Cab Light Switch. 51 HYEX01316 Figure 13. Cab Light Switch. Key Control/Indicator Function 51 Cab Light Switch Cab light has a two-position switch that turns the light on and off. It will only illuminate with the key switch turned on. (Not present when armored cab is installed). 0004-14 TM 5-3805-294-10 Table 10. 0004 Hydraulic Hose Reel. 52 54 53 55 HYEX00876 Figure 14. Hydraulic Hose Reel. Key Control/Indicator Function 52 Hydraulic Hose Reel Used for hydraulic tools. 53 Hydraulic Tool Circuit Switch Moved to the on position when using hydraulic tools. 54 Hydraulic Tool Flow Regulator Used to regulate the flow of hydraulic fluid when using the hydraulic hose reel. 55 Deep Dig Control Pattern Switch Moved to the on position when using deep dig arm to enable the deep dig control pattern. END OF WORK PACKAGE 0004-15/16 blank TM 5-3805-294-10 0005 OPERATOR MAINTENANCE DESCRIPTION AND USE OF MONITOR AND ALARMS INTRODUCTION The following tables and illustrations provide the description and use of the monitor buttons, indicators, and warning indicators. Table 1. Monitor Buttons and Indicators. A.I. 7777.7 h F1 F2 H F F3 F4 E 17.3 L/h C 8:01 1 2 6 1 2 3 4 5 7 8 9 0 F1 F2 F3 F4 3 5 4 Figure 1. HYEX00858 Monitor. Key Control/Indicator Function 1 Button 1 Press button to key in the number 1 or use as instructed depending on current screen. 2 Button 2 Press button to key in the number 2 or use as instructed depending on current screen. 3 Button 3 Press button to key in the number 3 or use as instructed depending on current screen. 4 Button 4 Press button to key in the number 4 or use as instructed depending on current screen. 5 Button 5 Press button to key in the number 5 or use as instructed depending on current screen. 0005-1 TM 5-3805-294-10 Table 1. 0005 Monitor Buttons and Indicators - Continued. Key Control/Indicator Function 6 Button 6/Return to Default Screen Button Press button to key in the number 6, or to return to the default screen. A.I. 7777.7 h F1 F2 H F F3 F4 E 17.3 L/h C 11 8:01 1 2 6 3 4 5 7 8 9 0 F1 F2 F3 F4 12 13 14 6 7 8 Figure 2. 9 10 HYEX00859 Monitor Buttons. 7 Button 7/F1 function button Press button to key in the number 7 or to select the desired preset optional function from any screen. 8 Button 8/F2 function button Press button to key in the number 8 or to select the desired preset optional function from any screen. 9 Button 9/F3 function button Press button to key in the number 9 or to select the desired preset optional function from any screen. 10 Button 0/F4 function button Press button to key in the number 0 or to select the desired preset optional function from any screen. 11 Select Button Use button as instructed depending on current screen. 12 Back Button Use button as instructed depending on current screen. 0005-2 TM 5-3805-294-10 Table 1. 0005 Monitor Buttons and Indicators - Continued. Key Control/Indicator Function 13 Hour Meter Button Without key inserted or with key switch OFF, press and hold button to display default screen and hour meter. 14 Alarm Indicator Light Lights when an abnormality has occurred. Main Menu Time Set Attachment Adjustment Operating Conditions Maintenance Settings 1 2 3 4 5 6 7 8 9 0 F1 F2 F3 F4 15 HYEX01319 Figure 3. 15 Menu Button Main Menu. Press button to display main menu from any screen. Main menu includes time set, attachment adjustment, operating conditions, and maintenance settings. 0005-3 TM 5-3805-294-10 Table 1. 0005 Monitor Buttons and Indicators - Continued. Key Control/Indicator Function 16 Coolant Temperature Gauge Indicates the engine coolant temperature. Needle should be around the center of the scale during operation. 17 18 19 20 21 22 24 A.I. 7777.7 h 23 25 F1 F2 H F F3 F4 E 28 17.3 L/h C 8:01 16 1 2 3 4 5 29 27 6 7 8 9 0 F1 F2 F3 F4 26 HYEX00860 30 Figure 4. Monitor Indicators. 17 Work Mode Indicator The icon for the current attachment being used is displayed. 18 Auto-Idle Indicator When selecting auto-idle from the front switch panel, the auto-idle icon displays. 19 Auxiliary Indicator Optional auxiliary data icon displays. 20 Auxiliary Indicator Optional auxiliary data icon displays. 21 Auxiliary Indicator Optional auxiliary data icon displays. 22 Engine Preheat Indicator If preheat is required, the preheat icon is displayed. 23 Hour Meter Total machine operation hours counted since the machine started working are displayed in the unit of hour (h). One digit after the decimal point indicates tenths of an hour (6 minutes). 0005-4 TM 5-3805-294-10 Table 1. Monitor Buttons and Indicators - Continued. Key Control/Indicator Function 24 F1 Function Button Indicator Optional indicator icon is displayed. 25 F2 Function Button Indicator Optional indicator icon is displayed. 26 F3 Function Button Indicator Optional indicator icon is displayed. 27 F4 Function Button Indicator Optional indicator icon is displayed. 28 Fuel Gauge Shows level of fuel in fuel tank. 29 Fuel Rate Display Fuel consumption in Liter/hour (L/h) is displayed. 30 Clock Indicates present time. 0005-5 0005 TM 5-3805-294-10 Table 2. 31 0005 Warning Indicators and Alarms. 33 32 36 35 34 39 37 38 HYEX00861 Figure 5. Warning Indicators and Alarms. Key Control/Indicator Function 31 Engine Overheat Alarm Displays when engine coolant temperature has abnormally increased. 32 Engine Warning Alarm Displays when engine has an abnormal operating condition. 33 Engine Oil Pressure Alarm Displays when oil pressure has decreased. 34 Alternator Alarm Displays when an abnormality in the electrical system has occurred. 0005-6 TM 5-3805-294-10 0005 Table 2. Warning Indicators and Alarms - Continued. Key Control/Indicator Function 35 Remaining Fuel Alarm Displays when fuel level is low. 36 Hydraulic Oil Filter Alarm Displays when hydraulic filter is clogged. 37 Air Cleaner Clogged Alarm Displays when air cleaner are clogged. 38 Work Mode Alarm Displays when work mode is abnormal. 39 Pilot Shutoff Lever Alarm Displays when pilot shutoff system is abnormal. 40 HYEX00862 Figure 6. 40 Overload Alarm Overload Alarm. Illuminates when an overload condition exists when digging. END OF WORK PACKAGE 0005-7/8 blank TM 5-3805-294-10 0006 OPERATOR MAINTENANCE ADJUSTING THE OPERATOR'S SEAT INITIAL SETUP: Not Applicable ADJUSTMENT NOTE Proper seat adjustment is achieved when operator can reach the foot control pedals and the travel levers easily with the seat belt buckled. 1. Push down on handle (Figure 1, Item 1) to tilt seat (Figure 1, Item 2). 13 9 8 11 10 12 2 6 1 7 3 5 4 Figure 1. HYEX00145 Operator's Seat Adjustments. 2. Turn knob (Figure 1, Item 3) to set operator weight. 3. Pull up on handle (Figure 1, Item 4) to slide seat (Figure 1, Item 2). 4. Push on lever (Figure 1, Item 5) to slide seat (Figure 1, Item 2) and controls (Figure 1, Item 6). 0006-1 TM 5-3805-294-10 ADJUSTMENT - Continued 5. Squeeze bulb (Figure 1, Item 7) to increase lumbar support. 6. Push button (Figure 1, Item 8) to decrease lumbar support. 7. Pull up on handle (Figure 1, Item 9) to unlock backrest (10). 8. Raise or lower headrest (Figure 1, Item 11) to desired height. 9. Tilt headrest (Figure 1, Item 11) to desired angle. 10. Turn dial (Figure 1, Item 12) on underside of armrest (Figure 1, Item 13) to adjust angle. END OF TASK END OF WORK PACKAGE 0006-2 0006 TM 5-3805-294-10 0007 OPERATOR MAINTENANCE STARTING THE ENGINE INITIAL SETUP: Equipment Condition Before operations Preventive Maintenance Checks and Services performed. (WP 0077) Operators seat adjusted. (WP 0006) STARTING THE ENGINE WARNING Perform a complete walk around the machine prior to starting the engine. Ensure sufficient clearance from personnel and equipment for safe operation of machine. Prior to starting engine sound horn to alert personnel. Failure to comply may result in injury or death to personnel. 1. Buckle the seat belt (Figure 1, Item 1). 1 HYEX00090 Figure 1. Seat Belt. NOTE Engine will not start unless pilot shutoff lever is in the LOCKED (up) position. 2. Place pilot shutoff lever (Figure 2, Item 2) in LOCKED (up) position. 0007-1 TM 5-3805-294-10 0007 STARTING THE ENGINE - Continued 2 HYEX00091 Figure 2. 3. Pilot Shutoff Lever. Turn engine speed dial (Figure 3, Item 3) to slow idle position. 3 HYEX00092 Figure 3. 4. Engine Speed Dial Slow Idle. Turn key switch (Figure 4, Item 4) to ON position. 0007-2 TM 5-3805-294-10 0007 STARTING THE ENGINE - Continued 4 HYEX00093 Figure 4. Key Switch ON. NOTE When the ignition key is turned to the ON position, the "System Starting" screen will display for about 2 seconds. The default screen will then be displayed. 5. Wait for "System Starting" screen (Figure 5, Item 5) to change to default screen (Figure 5, Item 6). 6 5 System Starting... 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX00094 Figure 5. System Starting and Default Screen. NOTE At approximately 32°F (0°C) or below, the pre-heat indicator will be displayed for up to 15 seconds depending on engine fuel temperature. 6. Wait until engine preheat indicator (Figure 6, Item 7) is no longer displayed. 0007-3 TM 5-3805-294-10 0007 STARTING THE ENGINE - Continued 7 A.I. 7777.7 h F1 F2 H F F3 F4 E 17.3 L/h C 8:01 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX00095 Figure 6. Preheat Indicator. CAUTION • Never operate starter longer than 20 seconds at a time. If engine fails to start, return key switch to OFF position and wait 2 minutes before attempting to start again. Failure to comply may result in damage to equipment. • After a false start, wait until engine stops spinning before turning the key again. Failure to comply may result in damage to equipment. NOTE Key switch will return to ON position when key is released. 7. Turn key switch (Figure 7, Item 4) to START position and release when engine starts. 4 HYEX00099 Figure 7. Key Switch to START. 0007-4 TM 5-3805-294-10 0007 STARTING THE ENGINE - Continued CAUTION • If alarm indicators are still displayed after starting the engine, immediately shut down the engine. Failure to comply may result in damage to equipment. • Do not run engine at fast idle or rapidly accelerate engine until it has reached normal operating temperature. Failure to comply may result in damage to equipment. 8. After the engine is started, ensure that no alarm indicators (Figure 8, Item 8) are displayed. 8 HYEX00096 Figure 8. 9. Alarm indicator. Move engine speed dial (Figure 9, Item 3) right 1/3 and allow engine to idle for 30 seconds. 3 HYEX00100 Figure 9. 10. Engine Speed Dial Turned to 1/3 Position. Turn engine speed dial (Figure 10, Item 3) to slow idle position until machine reaches normal operating temperature. 0007-5 TM 5-3805-294-10 0007 STARTING THE ENGINE - Continued 3 HYEX00092 Figure 10. Return Engine Speed Dial to Slow Idle. END OF TASK END OF WORK PACKAGE 0007-6 TM 5-3805-294-10 0008 OPERATOR MAINTENANCE MOVING THE HYEX INITIAL SETUP: Equipment Condition Engine running. (WP 0007) MOVING THE HYEX WARNING • Before moving the machine or operating the boom, ensure that the boom has at least 10 ft (3 m) of clearance from overhead wires, power lines, or structures. If lines are near to your operating area, notify your supervisor prior to operating the boom. Failure to comply may result in injury or death to personnel. • Keep personnel clear of the machine when traveling. Failure to comply may result in injury or death to personnel. NOTE • If traveling long distances, ensure that travel motors are at the back of the machine. • If travel motors are at the front of the machine, the machine moves in opposite direction as described in these procedures. • When traveling up slopes, keep the bucket on the uphill side and just above the ground. • When traveling down a slope, operate control pedals or levers slowly. 1. Move pilot shutoff lever (Figure 1, Item 1) to the unlocked (down) position. 1 120 LOCK HYEX00146 Figure 1. Pilot Shutoff Lever Unlocked. 0008-1 TM 5-3805-294-10 0008 MOVING THE HYEX - Continued 2. Raise boom (Figure 2, Item 2) and arm (Figure 2, Item 3) off of ground to allow for sufficient visibility and to keep machine stable. 2 3 HYEX00147 Figure 2. Boom and Arm Raised. CAUTION When traveling over rough terrain, reduce travel speed to avoid undercarriage damage. Failure to comply may result in damage to equipment. NOTE If carrying a heavy load, keep travel mode switch in the low position for more control of the machine. 3. Move travel mode switch (Figure 3, Item 4) to high position. 4 HYEX00148 Figure 3. Travel Mode Switch. NOTE Travel speed of machine is controlled by the foot pedals or travel levers. 0008-2 TM 5-3805-294-10 0008 MOVING THE HYEX - Continued 4. Push down on the front of both foot pedals (Figure 4, Items 5 and 6), or push both travel levers (Figure 4, Items 7 and 8) forward to move HYEX forward. 7 8 5 6 HYEX01297 Figure 4. Moving Forward and Backwards. 5. Push down on the rear of both foot pedals (Figure 4, Items 5 and 6) or pull both travel levers (Figure 4, Items 7 and 8) to move the HYEX backwards. 6. Allowing both foot pedals (Figure 4, Items 5 and 6), or both travel levers (Figure 4, Items 7 and 8) to return to center, will stop the HYEX. END OF TASK STEERING THE HYEX WARNING • Keep personnel clear of the machine when traveling. Failure to comply may result in injury or death to personnel. • Use care when backing the machine. Watch clearances. Have an assistant direct you if you cannot see where you are going. Failure to comply may result in injury or death to personnel. NOTE If travel motors are at the front of the machine, the machine moves in opposite direction as described in these procedures. 0008-3 TM 5-3805-294-10 0008 STEERING THE HYEX - Continued 1. Pushing front of left foot pedal (Figure 5, Item 5) or push left travel lever (Figure 5, Item 7) forward with right foot pedal (Figure 5, Item 6) and right travel lever (Figure 5, Item 8) at center turns the HYEX right. 7 8 5 6 HYEX01296 Figure 5. 2. Right Turn. Pushing front of right foot pedal (Figure 6, Item 6) or push right travel lever (Figure 6, Item 8) forward with left foot pedal (Figure 6, Item 5) and left travel lever (Figure 6, Item 7) at center turns the HYEX left. 7 8 5 6 HYEX01295 Figure 6. 3. Left Turn. Pushing front of left foot pedal (Figure 7, Item 6), or push left travel lever (Figure 7, Item 8) forward and push down on rear of right foot pedal (Figure 7, Item 7) or pull right travel lever (Figure 7, Item 8) back to counterrotate. 0008-4 TM 5-3805-294-10 0008 STEERING THE HYEX - Continued 7 8 5 6 HYEX01291 Figure 7. 4. Counter-Rotate. Allowing both foot pedals (Figure 7, Items 5 and 6) or both travel levers (Figure 7, Items 7 and 8) to return to center will stop the HYEX. END OF TASK END OF WORK PACKAGE 0008-5/6 blank TM 5-3805-294-10 0009 OPERATOR MAINTENANCE SHUTTING DOWN THE HYEX INITIAL SETUP: References WP 0004 References (cont.) WP 0011 WP 0010 SAFELY PARK HYEX 1. Park machine (Figure 1, Item 1) on solid, level surface. 2 3 4 1 HYEX02418 Figure 1. Machine In Parked Position. NOTE Do not force bucket on or in the ground. Bucket should be resting on the ground. 2. Keeping angle between arm (Figure 1, Item 2) and boom (Figure 1, Item 3), position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004) END OF TASK SHUT DOWN ENGINE 1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position. 0009-1 TM 5-3805-294-10 0009 SHUT DOWN ENGINE - Continued 6 5 HYEX00153 Figure 2. Auto-Idle Switch and Engine Speed Dial. CAUTION Turbocharger may be damaged if engine is not shut down properly. Failure to comply may result in damage to equipment. NOTE Engine speed dial shown approximately at 1/3 position. 2. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load. 3. Turn engine speed dial (Figure 3, Item 6) to slow idle position. 0009-2 TM 5-3805-294-10 0009 SHUT DOWN ENGINE - Continued 6 HYEX00154 Figure 3. 4. Engine Speed Dial. Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position. 7 HYEX00155 Figure 4. 5. Pilot Shutoff Lever. Turn key switch (Figure 5, Item 8) to OFF position and remove key. 0009-3 TM 5-3805-294-10 0009 SHUT DOWN ENGINE - Continued 8 HYEX00157 Figure 5. Key Switch Turned OFF. CAUTION Ensure all windows and doors are closed when machine is parked to prevent electrical system damage during inclement weather. Failure to comply may result in damage to equipment. 6. Close windows. (WP 0011) END OF TASK END OF WORK PACKAGE 0009-4 TM 5-3805-294-10 0010 OPERATOR MAINTENANCE SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED INITIAL SETUP: References WP 0004 WP 0011 Equipment Condition Engine running. (WP 0007) SAFELY PARK MACHINE 1. Park machine (Figure 1, Item 1) on solid, level surface. 2 3 1 4 HYEX01637 Figure 1. Machine In Parked Position. NOTE Do not force bucket on or in the ground. Bucket should be resting on the ground. 2. Keeping angle between deep dig arm (Figure 1, Item 2) and arm (Figure 1, Item 3) at approximately 90 degrees, position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004) END OF TASK SHUT DOWN ENGINE 1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position. 0010-1 TM 5-3805-294-10 0010 SHUT DOWN ENGINE - Continued 6 5 HYEX01507 Figure 2. Auto-Idle Switch and Engine Speed Dial. CAUTION Turbocharger may be damaged if engine is not shut down properly. Failure to comply may result in damage to equipment. NOTE Engine speed dial shown approximately at 1/3 position. 2. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load. 3. Turn engine speed dial (Figure 3, Item 6) to slow idle position. 0010-2 TM 5-3805-294-10 0010 SHUT DOWN ENGINE - Continued 6 HYEX01508 Figure 3. 4. Engine Speed Dial. Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position. 7 HYEX01509 Figure 4. 5. Pilot Shutoff Lever. Turn key switch (Figure 5, Item 8) to OFF position and remove key. 0010-3 TM 5-3805-294-10 0010 SHUT DOWN ENGINE - Continued 8 HYEX01510 Figure 5. Key Switch Turned OFF. CAUTION Ensure all windows and doors are closed when machine is parked to prevent electrical system damage during inclement weather. Failure to comply may result in damage to equipment. 6. Close windows. (WP 0011) END OF TASK END OF WORK PACKAGE 0010-4 TM 5-3805-294-10 0011 OPERATOR MAINTENANCE OPENING AND CLOSING WINDOWS INITIAL SETUP: Not Applicable WINDSHIELD NOTE • The wiper will not operate with windshield open. • The washer can operate with windshield open. 1. Pull lock pin (Figure 1, Item 1) inward and rotate into notch. 2 1 3 HYEX00160 Figure 1. Open Windshield. 2. Pull on latch release bar (Figure 1, Item 2) to open windshield (Figure 1, Item 3). 3. Lift on handle (Figure 2, Item 4) to raise windshield (Figure 2, Item 3) until it latches open. 0011-1 TM 5-3805-294-10 0011 WINDSHIELD - Continued 4 3 HYEX00161 Figure 2. Raise Windshield. WARNING Lock pin must be used to secure upper front window in raised position. Failure to comply may result in injury or death to personnel. 4. Release lock pin (Figure 3, Item 1) from notch and slide into cab frame lock hole (Figure 3, Item 5). 5 1 HYEX00162 Figure 3. 5. Lock Windshield Open. To close the windshield, pull lock pin (Figure 4, Item 1) inward from cab frame lock hole (Figure 4, Item 5) and rotate into notch. 0011-2 TM 5-3805-294-10 0011 WINDSHIELD - Continued 1 5 2 HYEX00163 Figure 4. Release Windshield Latch. WARNING Window closes rapidly when released. Use lower handle to prevent window from free falling. Failure to comply may result in injury or death to personnel. 6. Pull on latch release bar (Figure 4, Item 2). 7. Hold handle (Figure 5, Item 4) and lower windshield (Figure 5, Item 3) until it is latched in the closed position. 4 3 HYEX00161 Figure 5. 8. Close Windshield. Press glass (Figure 6, Item 3) until bar (Figure 6, Item 2) snaps into place. 0011-3 TM 5-3805-294-10 0011 WINDSHIELD - Continued 2 1 3 HYEX00160 Figure 6. 9. Latch Windshield. Release lock pin (Figure 6, Item 1) from notch. END OF TASK CAB DOOR WINDOW 1. To open, release latch (Figure 7, Item 6) and slide cab door window (Figure 7, Item 7) forward. 6 7 HYEX01411 Figure 7. 2. Open and Close Cab Door Window. To close, slide cab door window (Figure 7, Item 7) to rear until latch (Figure 7, Item 6) engages. END OF TASK 0011-4 TM 5-3805-294-10 0011 SKYLIGHT WINDOW (SECONDARY EXIT) 1. Slide access cover (Figure 8, Item 8) open. 8 HYEX03377 Figure 8. 2. Open Access Cover. To open, release two latches (Figure 9, Item 9) and push up on handle (Figure 9, Item 10). 10 9 9 HYEX00167 Figure 9. Open and Close Skylight Window. 3. To close, pull down on handle (Figure 9, Item 10) and engage two latches (Figure 9, Item 9). 4. Slide access cover (Figure 10, Item 8) closed. 0011-5 TM 5-3805-294-10 0011 SKYLIGHT WINDOW (SECONDARY EXIT) - Continued 8 HYEX03377 Figure 10. Close Access Cover. END OF TASK END OF WORK PACKAGE 0011-6 TM 5-3805-294-10 0012 OPERATOR MAINTENANCE USING THE RIFLE MOUNT INITIAL SETUP: Not Applicable STOW NOTE Rifle mount is designed to store an M4 with optics, M240B, M249, or M16 series weapon with and without M203 grenade launcher. 1. Place butt of weapon in rear mounting bracket (Figure 1, Item 1). 1 HYEX00999 Figure 1. 2. Stow Weapon In Rear Bracket Place barrel of weapon in front mounting bracket (Figure 2, Item 2). 0012-1 TM 5-3805-294-10 0012 STOW - Continued 3 2 4 HYEX00998 Figure 2. Stow Weapon In Front Bracket 3. If necessary, loosen two handles (Figure 2, Item 3) and slide front mounting bracket (Figure 2, Item 2) on two rails (Figure 2, Item 4). 4. Tighten two handles (Figure 2, Item 3). END OF TASK REMOVE 1. Lift barrel of weapon from front mounting bracket (Figure 3, Item 2). 3 2 4 HYEX00998 Figure 3. Remove Weapon From Front Bracket 2. Remove butt of weapon from rear mounting bracket (Figure 4, Item 1). 0012-2 TM 5-3805-294-10 0012 REMOVE - Continued 1 HYEX00999 Figure 4. Remove Weapon From Rear Bracket END OF TASK END OF WORK PACKAGE 0012-3/4 blank TM 5-3805-294-10 0013 OPERATOR MAINTENANCE GENERAL MONITOR OPERATION INITIAL SETUP: Equipment Condition Engine running. (WP 0007) TIME ADJUSTMENT NOTE After approximately 1 minute the monitor will return to the default screen. 1. Press menu button. Main Menu TIME SET Time Set Attachment Adjustment Operating Conditions SELECT BUTTON Maintenance Settings BUTTON 1 1 6 BUTTON 2 2 3 4 5 7 8 9 0 F1 F2 F3 F4 MENU BUTTON HYEX00057 Figure 1. Select Time Set Menu. 2. Press button 1 or button 2 until the Time Set menu is highlighted. 3. Press select button to open Time Set menu. 0013-1 TM 5-3805-294-10 0013 TIME ADJUSTMENT - Continued 4. Press button 1 or button 2 to select date or time. Time Set 2005 / 12 / 12 : BUTTON 1 23 23 SELECT BUTTON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 BACK BUTTON BUTTON BUTTON BUTTON 2 3 4 Figure 2. HYEX00058 Adjust Time. 5. Press button 3 or button 4 to adjust date or time up or down. 6. After desired date and time is achieved, press button 1 or button 2 until the apply setting icon is highlighted. 7. Press select button and "Data is being applied" will display on the screen. 8. Press back button until default screen is displayed. END OF TASK DISPLAYING OPERATING CONDITIONS 1. Press menu button 1. Main Menu Time Set OPERATING CONDITIONS Attachment Adjustment Operating Conditions Maintenance Settings SELECT BUTTON 1 6 BUTTON 1 2 3 4 7 8 9 0 F1 F2 F3 F4 BUTTON 2 Figure 3. 5 BACK BUTTON MENU BUTTON Select Operating Conditions Menu. 2. Press button 1 or button 2 until the Operating Conditions menu is highlighted. 3. Press select button. 0013-2 HYEX00059 TM 5-3805-294-10 0013 DISPLAYING OPERATING CONDITIONS - Continued 4. Operating Conditions menu will be displayed. Operating Conditions Reset Data. OK? SELECT BUTTON 1 2 6 3 4 5 7 8 9 0 F1 F2 F3 F4 BACK BUTTON HYEX00060 Figure 4. Reset Operating Conditions. 5. To reset data, press select button. 6. The Reset Data. OK? is displayed. 7. If reset is not desired, press back button. 8. When finished with menu, press back button until default screen is displayed. END OF TASK MAINTENANCE SETTINGS Maintenance settings are to be accessed only by the Field Level maintainer. END OF TASK END OF WORK PACKAGE 0013-3/4 blank TM 5-3805-294-10 0014 OPERATOR MAINTENANCE REMOVING AND INSTALLING BUCKET INITIAL SETUP: References WP 0007 Equipment Condition Machine safely parked and shut down. (WP 0009) REMOVING BUCKET WARNING With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. NOTE The ditch cleaning bucket and 42 inch rock bucket are removed the same way. 42 inch rock bucket shown. 1. Lift and rotate safety lock pin lever (Figure 1, Item 1). 1 HYEX03379 Figure 1. Unlock Safety Lock Pin. 2. Start engine. (WP 0007) 3. Raise boom (Figure 2, Item 2) to allow adequate ground clearance for bucket (Figure 2, Item 3). 0014-1 TM 5-3805-294-10 0014 REMOVING BUCKET - Continued 2 3 HYEX03380 Figure 2. 4. Raise Boom. Move quick latch switch (Figure 3, Item 4) to unlatch position. 4 HYEX00939 Figure 3. 5. Move Quick Latch Switch to Unlatch Position. Fully extend bucket cylinder (Figure 4, Item 5) until quick latch wedges (Figure 4, Item 6) are fully retracted. 0014-2 TM 5-3805-294-10 0014 REMOVING BUCKET - Continued 5 6 HYEX03387 Figure 4. Extend Bucket Cylinder. WARNING With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. 6. Slowly retract bucket cylinder (Figure 5, Item 5) and position quick latch (Figure 5, Item 7) in vertical position. 5 7 HYEX03384 Figure 5. Retract Bucket Cylinder. NOTE Ensure that arm is just past the vertical position prior to setting bucket on the ground. 7. Slowly lower boom (Figure 6, Item 2) and place bucket (Figure 6, Item 3) on ground. 0014-3 TM 5-3805-294-10 0014 REMOVING BUCKET - Continued 2 3 HYEX03382 Figure 6. 8. Lower Boom. Move quick latch switch (Figure 7, Item 4) in latch position. 4 HYEX00939 Figure 7. 9. Position Quick Latch Switch to Latch position. Remove quick latch (Figure 8, Item 7) from bucket (Figure 8, Item 3). 0014-4 TM 5-3805-294-10 0014 REMOVING BUCKET - Continued 7 3 HYEX03389 Figure 8. Remove Quick Latch. END OF TASK INSTALLING BUCKET WARNING With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. NOTE The ditch cleaning bucket and 42 inch rock bucket are installed the same way. 42 inch rock bucket shown. 1. Move quick latch switch (Figure 9, Item 4) in the unlatch position. 0014-5 TM 5-3805-294-10 0014 INSTALLING BUCKET - Continued 4 HYEX00939 Figure 9. 2. Position Quick Latch Switch to Unlatch position. Raise boom (Figure 10, Item 2) to allow for adequate ground clearance. 2 HYEX03385 Figure 10. Raise Boom for Clearance. WARNING With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. 3. Slowly extend bucket cylinder (Figure 11, Item 5) until quick latch wedges (Figure 11, Item 6) are fully retracted. 0014-6 TM 5-3805-294-10 0014 INSTALLING BUCKET - Continued 5 6 HYEX03383 Figure 11. 4. Retract Wedges. Position quick latch (Figure 12, Item 7) in vertical position. 5 7 3 HYEX03381 Figure 12. Install Quick Latch. 5. Install quick latch (Figure 12, Item 7) to bucket (Figure 12, Item 3). 6. Extend bucket cylinder (Figure 12, Item 5) until quick latch (Figure 12, Item 7) is resting on bucket (Figure 12, Item 3). 7. Move quick latch switch (Figure 13, Item 4) in latch position. 0014-7 TM 5-3805-294-10 0014 INSTALLING BUCKET - Continued 4 HYEX00939 Figure 13. Position Quick Latch Switch toLatch position. 8. Raise boom (Figure 14, Item 2) to allow for ground clearance. 2 5 6 HYEX03386 Figure 14. Raise Boom. 9. Fully extend bucket cylinder (Figure 14, Item 5) to ensure quick latch wedges (Figure 14, Item 6) are fully engaged. 10. Position bucket (Figure 15, Item 3) on ground. 0014-8 TM 5-3805-294-10 0014 INSTALLING BUCKET - Continued 1 3 HYEX03378 Figure 15. 11. Safety Pin Locked. Rotate safety lock pin lever (Figure 15, Item 1) to lock position. END OF TASK END OF WORK PACKAGE 0014-9/10 blank TM 5-3805-294-10 OPERATOR MAINTENANCE LIFTING WITH HYEX INITIAL SETUP: Tools and Special Tools Suitable Lifting Device Equipment Condition Engine running. (WP 0007) Personnel Required Horizontal Construction Engineer 12N (2) LIFTING WARNING LIFTING GUIDELINES: • Do not use machine to lift personnel. Failure to comply may result in injury or death to personnel. • Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death to personnel. • Ensure load does not exceed the capacity of machine or lifting device. Failure to comply may result in injury or death to personnel. • Lift load only as high as necessary. Failure to comply may result in injury or death to personnel. • Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may result in injury or death to personnel. • Personnel must remain clear of lifted items. Failure to comply may result in injury or death to personnel. NOTE • Use a suitable lifting device and tether lines to guide load. • Coordinate hand signals with assistant prior to lifting. 1. Secure lifting device (Figure 1, Item 1) to load (Figure 1, Item 2). 0015-1 0015 TM 5-3805-294-10 0015 LIFTING - Continued 4 6 5 3 1 2 HYEX00919 Figure 1. Lifting with Quick Latch Loop. 2. Curl bucket (Figure 1, Item 3) and retract arm (Figure 1, Item 4). 3. Attach lifting device (Figure 1, Item 1) to quick latch loop (Figure 1, Item 5). 4. With the aid of an assistant, raise load (Figure 1, Item 2) and verify stability of load and machine (Figure 1, Item 6) before moving the machine. END OF TASK END OF WORK PACKAGE 0015-2 TM 5-3805-294-10 0016 OPERATOR MAINTENANCE OPERATING TECHNIQUES INITIAL SETUP: Equipment Condition Engine running. (WP 0007) LEVELING MACHINE NOTE Operating on a firm, level surface optimizes machine stability. 1. Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material. HYEX01483 Figure 1. 2. Leveling Machine. If necessary, use bucket to add or remove material to level the worksite. HYEX01484 Figure 2. 3. Add or Remove Material. If material is added, drive over new material to compact it until the worksite feels stable. END OF TASK 0016-1 TM 5-3805-294-10 ARM DIGGING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. CAUTION • When bucket cylinder is fully extended, do not strike the ground or use the bucket for tamping. Failure to comply may result in damage to equipment. • Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down walls using swing motion. Failure to comply may result in damage to equipment. • Do not side load bucket, swing bucket to level material, or strike objects from the side with the bucket. Failure to comply may result in damage to equipment. • If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket lightly does not work. Failure to comply may result in damage to equipment. NOTE • Initial cut should be approximately 4 ft (122 cm) long and 3-4 in. (76-102 mm) deep. • Remaining cuts should be approximately 4 ft (122 cm) long and 4-6 in. (102-152 mm) deep. 1. Position arm in a vertical position. 0016-2 0016 TM 5-3805-294-10 0016 ARM DIGGING - Continued HYEX01486 Figure 3. Arm Digging. 2. Move arm away from machine approximately 2 ft (61 cm). 3. While retracting arm curl bucket as bucket fills. END OF TASK BUCKET DIGGING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. CAUTION • When bucket cylinder is fully extended, do not strike the ground or use the bucket for tamping. Failure to comply may result in damage to equipment. • Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down walls using swing motion. Failure to comply may result in damage to equipment. • Do not side load bucket, swing bucket to level material, or strike objects from the side with the bucket. Failure to comply may result in damage to equipment. 0016-3 TM 5-3805-294-10 0016 BUCKET DIGGING - Continued • If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket lightly does not work. Failure to comply may result in damage to equipment. NOTE • Ensure that correct bucket is used for the type of material being excavated. • Excavate in thin layers to fragment material and to ease in dumping material from the bucket. This especially applies to sticky materials. • For power digging and for working in confined areas, use the bucket cylinder for digging. 1. Lower bucket to the digging area. HYEX01485 Figure 4. Bucket Digging. 2. Use boom to force bucket into ground. 3. Retract arm and curl bucket at the same time until bucket is full. 4. If bucket stalls, raise boom slightly then continue to curl bucket . 5. If arm stalls, roll back bucket to break out. END OF TASK 0016-4 TM 5-3805-294-10 0016 PLANNING SPOIL PILES WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Place spoil piles at least 3 ft (1 m) away from excavation. The deeper the excavation, the further away the spoil pile should be placed. HYEX01487 Figure 5. Planning Spoil Piles. 2. If required, place spoil piles for convenient truck loading or backfilling. 3. On slopes, place spoil piles on the upper side of the slope to improve machine stability and ease backfilling. END OF TASK TRENCHING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. 0016-5 TM 5-3805-294-10 0016 TRENCHING - Continued • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Before starting work, walk the site to uncover hazards and to plan the job. HYEX01504 Figure 6. Trenching. 2. Check for buried utility lines, pipes, and gas or oil pipelines. 3. Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench. 4. The deeper the trench, the further away the spoil pile should be placed. END OF TASK CLEANING A CAVE IN 1. If you cannot clean a cave in from the machine's current position, DO NOT back over the trench. HYEX01503 Figure 7. Cleaning Cave In. 2. Drive the machine to the cave in. 3. Park the machine at a 90 degree angle to the trench with the travel motors to the rear of the machine. 0016-6 TM 5-3805-294-10 0016 CLEANING A CAVE IN - Continued 4. Clean cave in from the side of the trench. END OF TASK TRENCHING ON A SLOPE WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. NOTE The deeper the trench the further away the spoil pile should be. 1. When trenching across a slope, level the machine so that the bottom of the trench will be level. HYEX01488 Figure 8. Trenching on a Slope. 2. Level machine by counter-rotating tracks or by digging a shelf. 3. Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling. END OF TASK 0016-7 TM 5-3805-294-10 0016 STRAIGHT LINE TRENCHING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. NOTE The deeper the trench, the further away the spoil pile should be. 1. Drive two stakes in the ground at the beginning of the trench. HYEX01489 Figure 9. Straight Line Trenching. 2. Drive the first stake immediately behind the start point of the trench. Drive the second stake approximately 30 ft (9 m) behind the first stake. 3. Use stakes as a sight gauge. They are especially helpful when the machine is moved often. END OF TASK BACKFILLING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. 0016-8 TM 5-3805-294-10 0016 BACKFILLING - Continued • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. CAUTION Do not use side of bucket to backfill. Failure to comply may result in damage to equipment. NOTE The bucket side can be used for finish grading. 1. Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine. HYEX01490 Figure 10. 2. Back Filling. Use material from spoil pile to backfill. END OF TASK 0016-9 TM 5-3805-294-10 0016 TRUCK LOADING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Position bucket and slowly dump load in vehicle at the front center of the bed. HYEX01491 Figure 11. 2. Truck Loading. Continue to fill bed from front to rear. END OF TASK END OF WORK PACKAGE 0016-10 TM 5-3805-294-10 0017 OPERATOR MAINTENANCE OPERATING THE HYDRAULIC THUMB INITIAL SETUP: Not Applicable GENERAL HYDRAULIC THUMB INFORMATION The hydraulic thumb was designed to be used for the following: 1. Clamping and lifting. 2. Medium duty scrap handling. 3. Demolition of wood and brick structures. 4. Medium duty land clearing/grubbing. 5. Bulky loose materials. 6. Logging. The hydraulic thumb was not designed and should not be used for the following: 1. Ripping up concrete or asphalt. 2. Quarry applications. 3. Heavy scrap handling. 4. Heavy land clearing. 5. Heavy grubbing. 6. Breaking ledge rock. CLAMPING WITH THE BUCKET 1. Position hydraulic thumb (Figure 1, Item 1) near the object to be picked up. 1 2 HYEX01175 Figure 1. 2. Clamping With Bucket. Curl the bucket (Figure 1, Item 2) until it begins to force the object to the hydraulic thumb (Figure 1, Item 1). 0017-1 TM 5-3805-294-10 0017 CLAMPING WITH THE BUCKET - Continued 3. Gently move the bucket control to pick the object up without crushing it. END OF TASK CLAMPING WITH THE HYDRAULIC THUMB NOTE This method is less precise and should only be used when there is no concern about crushing the object being lifted. 1. Position hydraulic thumb (Figure 2, Item 1) in the store position. 1 2 HYEX01174 Figure 2. Clamping With Hydraulic Thumb. 2. Curl bucket (Figure 2, Item 2) and position it near or in contact with the object being picked up. 3. Move hydraulic thumb (Figure 2, Item 1) to grasp and clamp the object. END OF TASK 0017-2 TM 5-3805-294-10 0017 MOVING AND RELEASING CLAMPED OBJECTS WARNING • Never lift clamped objects over personnel. The possibility of the clamped object to fall always exists. Failure to comply may result in injury or death to personnel. • Always keep object close to machine when lifting with the hydraulic thumb and bucket. When the object is moved away from the machine using the boom or arm, the machine becomes unstable and could roll over. Failure to comply may result in injury or death to personnel. • Always look before releasing a load. Never release load while moving or turning. Failure to comply may result in injury or death to personnel. 1. Move object to desired location. 1 2 HYEX01174 Figure 3. 2. Releasing Objects. Retract either the hydraulic thumb (Figure 3, Item 1) or bucket (Figure 3, Item 2) to release object. END OF TASK END OF WORK PACKAGE 0017-3/4 blank TM 5-3805-294-10 0018 OPERATOR MAINTENANCE SELECTING AN ATTACHMENT ON THE MONITOR INITIAL SETUP: Equipment Condition Engine running. (WP 0007) SELECTING ATTACHMENT 1. Press F1 button and Work Mode screen will be displayed. Work Mode Dig Breaker 1 Crusher 1 2 1 Pulverizer 1 1 BUTTON 1 1 6 F1 BUTTON Breaker 2 1 1 2 1 1 2 3 4 5 7 8 9 0 F1 F2 F3 F4 BUTTON 5 BUTTON BUTTON BUTTON 2 3 4 Figure 1. 2. HYEX00172 Select Attachment. Use the following table to select attachment. Table 1. Attachment Selection. Attachment to be used Monitor key pad button Attachment mode to be selected Bucket/Thumb 1 Dig Breaker 2 Breaker 1 Compactor 3 Breaker 2 Crush-All 4 Pulverizer 1 Deep dig arm 5 Crusher 1 0018-1 TM 5-3805-294-10 0018 SELECTING ATTACHMENT - Continued 3. The attachment specification screen will be displayed. Breaker 1 Maximum Pump Flow Rate 288.0 L/min Maximum Engine Speed 1800 min-1 Valve Selector O/T Accumulator 2-Speed Selector OFF 2ndary Hydraulic Relief Selector ON OFF SELECT BUTTON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX00173 Figure 2. Attachment Specification Screen. 4. Verify the attachment specifications are the same as displayed on the monitor. 5. Press the select button. The default screen will be displayed. END OF TASK END OF WORK PACKAGE 0018-2 TM 5-3805-294-10 0019 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE CRUSH-ALL INITIAL SETUP: Tools and Special Tools Wrench, Open End, 2 1/2 in. (63.5 mm) (WP 0095, Table 2, Item 15) Wrench, Open End, 3 in. (76 mm) (WP 0095, Table 2, Item 14) Wrench, Open End, Adjustable 0.95 in. (24 mm) (WP 0095, Table 2, Item 19) References (cont.) WP 0009 WP 0018 WP 0092 Equipment Condition Safely park and shutdown machine. (WP 0009) Bucket removed. (WP 0014) Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 INSTALLING CRUSH-ALL 1. Start machine. (WP 0007) 2. Retract hydraulic thumb cylinder (Figure 1, Item 1). 3 4 2 6 1 5 3 HYEX03392 Figure 1. Close Hydraulic Thumb Circuit. 3. Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). 4. Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4). 0019-1 TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL - Continued WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 5. Using prybar to push pin (Figure 1, Item 3), install pin in thumb lock position (Figure 1, Item 5). 6. Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3). NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 7. Close two auxiliary circuit shut off valves (Figure 1, Item 6). 8. Move quick latch switch (Figure 2, Item 7) to unlatch position. 7 HYEX03393 Figure 2. 9. Move Quick Latch Switch to Unlatch Position. Fully extend bucket cylinder (Figure 3, Item 8) to ensure quick latch wedges (Figure 3, Item 9) are fully retracted. 0019-2 TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL - Continued 8 9 HYEX03394 Figure 3. 10. Extend Bucket Cylinder. Retract bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is in the vertical position. 8 10 11 HYEX03397 Figure 4. Install Quick Latch. 11. Install quick latch (Figure 4, Item 10) to crush-all (Figure 4, Item 11). 12. Extend bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is resting on crush-all (Figure 4, Item 11). 13. Move quick latch switch (Figure 5, Item 7) to latch position. 0019-3 TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL - Continued 7 HYEX03393 Figure 5. Quick Latch Switch to Latch Position. 14. Raise boom (Figure 6, Item 12) to allow adequate ground clearance of crush-all (Figure 6, Item 11). 12 14 13 8 9 11 HYEX03395 Figure 6. Position Crush-All. 15. Curl crush-all (Figure 6, Item 11) as in Figure 6 until quick latch wedges (Figure 6, Item 9) are fully engaged to crush-all (Figure 6, Item 11). 16. Rotate safety lock pin lever (Figure 6, Item 13) to lock position. 17. Extend arm cylinder (Figure 6, Item 14) and lower boom (Figure 6, Item 12) to position crush-all (Figure 6, Item 11) on ground. 18. Shutdown machine. (WP 0009) 19. Clean cap (Figure 7, Item 15) and machine quick disconnect (Figure 7, Item 16) with rag. 0019-4 TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL - Continued 18 16 17 15 HYEX01501 Figure 7. Connect Auxiliary Supply Line. 20. Clean plug (Figure 7, Item 17) and attachment quick disconnect (Figure 7, Item 18) with rag. 21. Remove cap (Figure 7, Item 15) from machine quick disconnect (Figure 7, Item 16). 22. Remove plug (Figure 7, Item 17) from attachment quick disconnect (Figure 7, Item 18). 23. Connect attachment quick disconnect (Figure 7, Item 18) to machine quick disconnect (Figure 7, Item 16). 24. Clean plug (Figure 8, Item 19) and machine quick disconnect (Figure 8, Item 20) with rag. 27 28 29 26 24 22 20 23, 25 19, 21 HYEX01502 Figure 8. Connect Auxiliary Return Line. 25. Clean cap (Figure 8, Item 21) and attachment quick disconnect (Figure 8, Item 22) with rag. 26. Remove plug (Figure 8, Item 19) from machine quick disconnect (Figure 8, Item 20). 27. Remove cap (Figure 8, Item 20) from attachment quick disconnect (Figure 8, Item 21). 28. Connect attachment quick disconnect (Figure 8, Item 22) to machine quick disconnect (Figure 8, Item 20). 29. Clean plug (Figure 8, Item 23) and machine quick disconnect (Figure 8, Item 24). 30. Clean cap (Figure 8, Item 25) and attachment quick disconnect (Figure 8, Item 26) with rag. 31. Remove plug (Figure 8, Item 23) from machine quick disconnect Figure 8, Item (24). 32. Remove cap (Figure 8, Item 25) from attachment quick disconnect (Figure 8, Item 26). 33. Connect attachment quick disconnect (Figure 8, Item 26) to machine quick disconnect (Figure 8, Item 25). 0019-5 TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued 34. Remove cap (Figure 8, Item 27) from connector (Figure 8, Item 28). 35. Attach connector (Figure 8, Item 29) to connector (Figure 8, Item 28). END OF TASK OPERATION 1. Start machine. (WP 0007) 2. Select the Pulverizer 1 on the monitor. (WP 0018) 3. Turn on the Auxiliary Control Switch. (WP 0004) 4. Adjust discharge size as needed. (WP 0092) WARNING • Ensure operator protection guard is installed prior to operation. Failure to comply may result in injury or death to personnel. • Crush-All can throw objects at any time during operation. Ensure personnel maintain distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel. • Do not reach into machine to remove debris. Failure to comply may result in injury or death to personnel. • Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may result in injury or death to personnel. CAUTION Do not overload Crush-All, strike objects or ground, or use sides of Crush-All to move material. Failure to comply may result in damage to equipment. NOTE • When crushing concrete, asphalt, brick, block, or softer stone, the maximum feed size is 18 in. x 18 in. (45.72 cm x 45.72 cm). • When crushing slag, limestone, or other materials with dirt, the maximum feed size is 15 in. x 5 in. (38.1 cm x 12.7 cm). • To reduce dust output, wet down material prior to crushing. 5. Place engine at full speed while crushing. (WP 0004) 6. Lift Crush-All (Figure 9, Item 11) approximately 6 ft (182.8 cm) off ground. 0019-6 0019 TM 5-3805-294-10 0019 OPERATION - Continued 34 31 30 32 33 11 HYEX01499 Figure 9. Crush-All Operation. 7. Curl crush-all (Figure 9, Item 11) to vertical position. 8. Release attachment pedal lock (Figure 9, Item 30). 9. Press attachment pedal (Figure 9, Item 31) to turn on Crush-All (Figure 9, Item 11). 10. Allow Crush-All (Figure 9, Item 11) to run for 5 minutes with no load. 11. Press attachment pedal (Figure 9, Item 31) and press button (Figure 9, Item 32) to open lid (Figure 9, Item 33). NOTE Scooping material is best performed by arming into the material, then boom up and curl as the Crush-All is elevated above material. 12. Scoop material and raise Crush-All (Figure 9, Item 11) away from material. 13. Curl Crush-All (Figure 9, Item 11) to vertical position. NOTE Reduce dust by keeping bottom of Crush-All close to stock pile. 14. Swing Crush-All (Figure 9, Item 11) over stock pile. 15. Press button (Figure 9, Item 34) to close lid (Figure 9, Item 32). 16. Allow all material to pass through crush-all (Figure 9, Item 11). NOTE To avoid jamming, hold attachment pedal until all material has been discharged. 17. Release attachment pedal (Figure 9, Item 31) to turn off crush-all (Figure 9, Item 11). 0019-7 TM 5-3805-294-10 0019 OPERATION - Continued 18. Engage attachment pedal lock (Figure 9, Item 30). END OF TASK JAMMING WARNING • Ensure operator protection guard is installed prior to operation. Failure to comply may result in injury or death to personnel. • Crush-All can throw objects at any time during operation. Ensure personnel maintain distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel. • Do not reach into machine to remove debris. Failure to comply may result in injury or death to personnel. • Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may result in injury or death to personnel. CAUTION Do not attempt to clear jam by striking Crush-All on ground. Failure to comply may result in damage to equipment. NOTE • These steps may be used to clear uncrushable material from machine. • It may be necessary to shake Crush-All. 1. Press attachment pedal (Figure 10, Item 31) and press button (Figure 10, Item 32) to open lid (Figure 10, Item 33). 0019-8 TM 5-3805-294-10 0019 JAMMING - Continued 31 32 33 HYEX03431 Figure 10. 2. Open Lid. Retract bucket cylinder (Figure 11, Item 8) to dump crush-all (Figure 10, Item 11) upside down and allow material to fall out. 8 11 HYEX03148 Figure 11. Clearing Jam from Crush-All. 3. Safely park and shutdown machine. (WP 0009) 4. Use a sturdy piece of lumber to push rotor (Figure 12, Item 34) in reverse. 0019-9 TM 5-3805-294-10 0019 JAMMING - Continued 35 34 HYEX03149 Figure 12. Push Crush-All Rotor Backwards. 5. If material is jammed between the curtain (Figure 12, Item 35) and rotor (Figure 12, Item 34), raise curtain. (WP 0092) 6. If material will not dislodge, contact Field Level Maintenance. END OF TASK REMOVING CRUSH-ALL 1. Raise boom (Figure 13, Item 12) to allow adequate ground clearance of crush-all (Figure 13, Item 11). 12 14 11 HYEX03432 Figure 13. Position Crush-All. 2. Curl crush-all (Figure 13, Item 11) under as shown in Figure 13. 3. Extend arm cylinder (Figure 13, Item 14), lower boom (Figure 13, Item 12), and position crush-all (Figure 13, Item 11) on ground. 4. Shutdown machine. (WP 0009) 0019-10 TM 5-3805-294-10 0019 REMOVING CRUSH-ALL - Continued 5. Remove connector (Figure 14, Item 29) from connector (Figure 14, Item 28). 27 28 29 26 24 22 20 23, 25 19, 21 HYEX01502 Figure 14. Disconnect Auxiliary Return Line. 6. Install cap (Figure 14, Item 27) to connector (Figure 14, Item 28). 7. Clean attachment quick disconnect (Figure 14, Item 26) and machine quick disconnect (Figure 14, Item 24) with rag. 8. Clean cap (Figure 14, Item 25) and plug (Figure 14, Item 23) with rag. 9. Remove attachment quick disconnect (Figure 14, Item 26) from machine quick disconnect (Figure 14, Item 24). 10. Install cap (Figure 14, Item 25) to attachment quick disconnect (Figure 14, Item 26). 11. Install plug (Figure 14, Item 23) to machine quick disconnect (Figure 14, Item 24). 12. Clean attachment quick disconnect (Figure 14, Item 22) and machine quick disconnect (Figure 14, Item 20) with rag. 13. Clean cap (Figure 14, Item 21) and plug (Figure 14, Item 19) with rag. 14. Remove attachment quick disconnect (Figure 14, Item 22) from machine quick disconnect (Figure 14, Item 20). 15. Install cap (Figure 14, Item 21) to attachment quick disconnect (Figure 14, Item 22). 16. Install plug (Figure 14, Item 19) to machine quick disconnect (Figure 14, Item 20). 17. Clean attachment quick disconnect (Figure 15, Item 18) and machine quick disconnect (Figure 15, Item 16) with rag. 0019-11 TM 5-3805-294-10 0019 REMOVING CRUSH-ALL - Continued 18 16 17 15 HYEX01501 Figure 15. Disconnect Auxiliary Supply Line. 18. Clean cap (Figure 15, Item 15) and plug (Figure 15, Item 17) with rag. 19. Remove attachment quick disconnect (Figure 15, Item 18) from machine quick disconnect (Figure 15, Item 16). 20. Install plug (Figure 15, Item 17) to attachment quick disconnect (Figure 15, Item 18). 21. Install cap (Figure 15, Item 15) to machine quick disconnect (Figure 15, Item 16). 22. Start machine. (WP 0007) 23. Move quick latch switch (Figure 16, Item 7) to unlatch position. 7 HYEX03393 Figure 16. Move Quick Latch Switch. 24. Raise boom (Figure 17, Item 12) to allow adequate ground clearance of crush-all (Figure 17, Item 11). 0019-12 TM 5-3805-294-10 0019 REMOVING CRUSH-ALL - Continued 12 14 13 8 9 11 HYEX03433 Figure 17. 25. Raise Boom. Lift and rotate safety lock pin lever (Figure 17, Item 13) to unlock position. WARNING With quick latch wedges disengaged from crush-all, the crush-all could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing crush-all. Slowly retract or extend bucket cylinder when removing or installing crush-all. Failure to comply may result in injury or death to personnel. 26. Fully extend bucket cylinder (Figure 17, Item 8) until quick latch wedges (Figure 17, Item 9) are fully retracted. 27. Retract bucket cylinder (Figure 17, Item 8), arm cylinder (Figure 17, Item 14), and lower boom to position crushall (Figure 17, Item 11) on the ground. 28. Retract bucket cylinder (Figure 18, Item 8) and position quick latch (Figure 18, Item10) in vertical position. 0019-13 TM 5-3805-294-10 0019 REMOVING CRUSH-ALL - Continued 8 10 11 HYEX03397 Figure 18. Remove Quick Latch. 29. Remove quick latch (Figure 18, Item 10) from crush-all (Figure 18, Item 11). 30. Move quick latch switch (Figure 19, Item 7) to latch position. 7 HYEX03393 Figure 19. Move Quick Latch Switch. 31. Lower arm (Figure 20, Item 35) to ground. 0019-14 TM 5-3805-294-10 0019 REMOVING CRUSH-ALL - Continued 3 4 2 4 1 6 5 3 5 35 HYEX01500 Figure 20. Open Hydraulic Thumb Circuit. NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 32. Open two auxiliary circuit shut off valves (Figure 20, Item 6). 33. Remove retaining clip (Figure 20, Item 2) from pin (Figure 20, Item 3). WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 34. Retract or extend thumb cylinder (Figure 20, Item 1) to remove pin (Figure 20, Item 3) from thumb lock position (Figure 20, Item 5). 35. Install pin (Figure 20, Item 3) in storage position (Figure 20, Item 4). 36. Install retaining pin (Figure 20, Item 2) on pin (Figure 20, Item 3). 37. Shutdown machine. (WP 0009) END OF TASK END OF WORK PACKAGE 0019-15/16 blank TM 5-3805-294-10 0020 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE IMPACT BREAKER INITIAL SETUP: Tools and Special Tools Screwdriver, Pry Bar, 12 in. (304 mm) Long (WP 0095, Table 2, Item 11) Wrench, Open End, Adjustable 0.95 in. (24 mm) (WP 0095, Table 2, Item 19) Wrench, Open End, 2 1/2 in. (63.5 mm) (WP 0095, Table 2, Item 15) Wrench, Open End, 3 in. (76 mm) (WP 0095, Table 2, Item 14) Materials/Parts (cont.) (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) Materials/Parts Grease, Automotive and Artillery, GAA Equipment Condition Machine safely parked and shutdown. (WP 0009) Bucket removed. (WP 0014) References WP 0007 WP 0009 WP 0018 INSTALLING IMPACT BREAKER 1. Start the machine. (WP 0007) 2. Retract hydraulic thumb cylinder (Figure 1, Item 1). 3 4 2 6 1 5 3 HYEX01321 Figure 1. Close Hydraulic Thumb Circuit. 3. Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). 4. Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4). 0020-1 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 5. With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5). 6. Install retaining clip (Figure 1, Item 2) to pin (Figure 1, Item 3). NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 7. Close two auxiliary circuit shutoff valves (Figure 1, Item 6). 8. Move quick latch switch (Figure 2, Item 7) to UNLATCH position. 7 HYEX03398 Figure 2. Move Quick Latch Switch. 9. Raise boom (Figure 3, Item 8) to allow for adequate ground clearance. 0020-2 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued 8 HYEX03399 Figure 3. 10. Raise Boom. Fully extend bucket cylinder (Figure 4, Item 9) to ensure quick latch wedges (Figure 4, Item 10) are fully retracted. 9 10 HYEX03400 Figure 4. 11. Quick Latch Wedges Retracted. Retract bucket cylinder (Figure 5, Item 9) until quick latch (Figure 5, Item 11) is in the vertical position. 0020-3 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued 9 8 11 12 HYEX03402 Figure 5. 12. Install Quick Latch. Install quick latch (Figure 5, Item 11) to impact breaker (Figure 5, Item 12). WARNING With quick latch wedges disengaged from impact breaker, the impact breaker could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing impact breaker. Slowly retract or extend bucket cylinder when removing or installing impact breaker. Failure to comply may result in injury or death to personnel. 13. With the aid of an assistant slowly raise boom (Figure 5, Item 8) to allow for adequate ground clearance of quick latch (Figure 5, Item 11). 14. Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on impact breaker (Figure 6, Item 12) 9 12 11 HYEX03403 Figure 6. Extend Bucket Cylinder. 0020-4 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued 15. Move quick latch switch (Figure 7, Item 7) to LATCH position. 7 HYEX03398 Figure 7. 16. Move Quick Latch Switch to Latch Position. Extend bucket cylinder (Figure 8, Item 9) until quick latch wedges (Figure 8, Item 10) are fully engaged to impact breaker (Figure 8, Item 12). 9 10 12 HYEX03401 Figure 8. Quick Latch Wedges Engaged. 17. Retract bucket cylinder (Figure 8, Item 9) and place impact breaker (Figure 8, Item 12) on ground. 18. Shutdown machine. (WP 0009) 19. Rotate safety lock pin lever (Figure 9, Item 13) to lock position. 0020-5 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued HYEX03406 13 Figure 9. 20. Safety Pin to Lock Position. Clean cap (Figure 10, Item 14) and machine quick disconnect (Figure 10, Item 15) with rag. 17 15 16 14 HYEX01322 Figure 10. Connect Auxiliary Supply Line. 21. Clean plug (Figure 10, Item 16) and attachment quick disconnect (Figure 10, Item 17) with rag. 22. Remove cap (Figure 10, Item 14) from machine quick disconnect (Figure 10, Item 15). 23. Remove plug (Figure 10, Item 16) from attachment quick disconnect (Figure 10, Item 17). 24. Connect attachment quick disconnect (Figure 10, Item 17) to machine quick disconnect (Figure 10, Item 15). 25. Clean plug (Figure 11, Item 18) and machine quick disconnect (Figure 11, Item 19) with rag. 0020-6 TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER - Continued 21 19 18 20 HYEX01323 Figure 11. Connect Auxiliary Return Line. 26. Clean cap (Figure 11, Item 20) and attachment quick disconnect (Figure 11, Item 21) with rag. 27. Remove plug (Figure 11, Item 18) from machine quick disconnect (Figure 11, Item 19). 28. Remove cap (Figure 11, Item 20) from attachment quick disconnect (Figure 11, Item 21). 29. Connect attachment quick disconnect (Figure 11, Item 21) to machine quick disconnect (Figure 11, Item 19). END OF TASK TOOL INSTALLATION NOTE • Select the proper tool before operation. • Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to medium hardness. • Moil is for demolition of medium hardness rock or materials except layered rock. • Blunt is for breaking large, medium hardness rocks into smaller pieces. 1. Press and turn lock bolt (Figure 12, Item 22) to unlocked position with slot (Figure 12, Item 23) pointed to the tool end of breaker (Figure 12, Item 12). 0020-7 TM 5-3805-294-10 0020 TOOL INSTALLATION - Continued 22 23 24 12 26 25 HYEX01326 Figure 12. Breaker Tool Lock Bolt. 2. Push the retaining axle (Figure 12, Item 24) out of the breaker (Figure 12, Item 12) through hole (Figure 12, Item 25). 3. Repeat Steps 1 and 2 for other retaining axle. 4. Lubricate bushing (Figure 12, Item 26) with grease. WARNING Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. Failure to comply may result in injury or death to personnel. NOTE Ensure cavity is free of debris and tool is properly lubricated. 5. With the aid of an assistant and suitable lifting device, slide tool (Figure 13, Item 27) into breaker (Figure 13, Item 12) with side notches (Figure 13, Item 28) in alignment with axle slots (Figure 13, Item 29). 0020-8 TM 5-3805-294-10 0020 TOOL INSTALLATION - Continued 29 12 27 28 HYEX01327 Figure 13. 6. Insert Breaker Tool. Install retaining axle (Figure 14, Item 24) to breaker (Figure 14, Item 12). 12 24 23 22 HYEX01328 Figure 14. Lock Breaker Tool. 7. Press and turn lock bolt (Figure 14, Item 22) to locked position with slot (Figure 14, Item 23) pointed to top of breaker (Figure 14, Item 12). 8. Repeat Steps (Figure 14, Item 6) and (Figure 14, Item 7) for other retaining axle. END OF TASK OPERATING IMPACT BREAKER 1. Start the machine. (WP 0007) 2. Select work mode BREAKER 1 on the monitor. (WP 0018) CAUTION Breaker must be lubricated every 2 hours of use and every hour during dusty conditions. Failure to comply may result in damage to the attachment. NOTE • Keep tool perpendicular to work surface. • Keep machine close to work area. • Maintain constant, even pressure as tool penetrates work surface. 0020-9 TM 5-3805-294-10 0020 OPERATING IMPACT BREAKER - Continued • Increase down pressure when strokes have a metallic sound. • Decrease down pressure when strokes cause strong vibrations in the machine. 3. Release attachment pedal lock (Figure 15, Item 30). 30 8 31 12 HYEX01520 Figure 15. Breaker Operation. 4. Apply boom (Figure 15, Item 8) down pressure to impact breaker (Figure 15, Item 12) on work area. 5. Press attachment pedal (Figure 15, Item 31) to start impact breaker (Figure 15, Item 12). 6. Release attachment pedal (Figure 15, Item 31) to stop impact breaker (Figure 15, Item 12) before retracting from work area. 7. Engage attachment pedal lock (Figure 15, Item 30). END OF TASK TOOL REMOVAL 1. Raise breaker (Figure 16, Item 12) off ground and extend bucket cylinder (Figure 16, Item 9) until breaker is horizontal. 9 24 12 23 25 22 HYEX03440 Figure 16. Tool Removal. 0020-10 TM 5-3805-294-10 0020 TOOL REMOVAL - Continued 2. Press and turn lock bolt (Figure 16, Item 22) to unlocked position with slot (Figure 16, Item 23) pointed to the tool end of breaker (Figure 16, Item 12). 3. Push the retaining axle (Figure 16, Item 24) out of the breaker (Figure 16, Item 12) through hole (Figure 16, Item 25). 4. Repeat Steps 2 and 3 for other retaining axle. WARNING Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. Failure to comply may result in injury or death to personnel. 5. With the aid of an assistant and suitable lifting device, slide tool (Figure 17, Item 27) out of breaker (Figure 17, Item 12). 12 27 HYEX03439 Figure 17. 6. Remove Breaker Tool. Install retaining axle (Figure 18, Item 24) to breaker (Figure 18, Item 12). 12 24 23 22 HYEX01328 Figure 18. 7. Lock Breaker Tool. Press and turn lock bolt (Figure 18, Item 22) to locked position with slot (Figure 18, Item 23) pointed to top of breaker (Figure 18 , Item 12). 0020-11 TM 5-3805-294-10 0020 TOOL REMOVAL - Continued 8. Repeat Steps 6 and 7 for other retaining axle. END OF TASK REMOVING IMPACT BREAKER 1. Safely park and shut down machine. (WP 0009) 2. Clean machine quick disconnect (Figure 19, Item 19) and attachment quick disconnect (Figure 19, Item 21) with rag. 21 19 18 20 HYEX01323 Figure 19. Disconnect Auxiliary Return Line. 3. Clean cap (Figure 19, Item 20) and plug (Figure 19, Item 18) with rag. 4. Remove attachment quick disconnect (Figure 19, Item 21) from machine quick disconnect (Figure 19, Item 19). 5. Install cap (Figure 19, Item 20) to attachment quick disconnect (Figure 19, Item 21). 6. Install plug (Figure 19, Item 18) to machine quick disconnect (Figure 19, Item 19). 7. Clean machine quick disconnect (Figure 20, Item 15) and attachment quick disconnect (Figure 20, Item 17) with rag. 17 15 16 14 HYEX01322 Figure 20. Disconnect Auxiliary Supply Line. 8. Clean cap (Figure 20, Item 14) and plug (Figure 20, Item 16) with rag. 9. Remove attachment quick disconnect (Figure 20, Item 17) from machine quick disconnect (Figure 20, Item 15). 0020-12 TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER - Continued 10. Install plug (Figure 20, Item 16) to attachment quick disconnect (Figure 20, Item 17). 11. Install cap (Figure 20, Item 14) to machine quick disconnect (Figure 20, Item 15). 12. Lift and rotate safety lock pin lever (Figure 21, Item 13) to unlock position. HYEX03406 13 Figure 21. Safety Pin to Unlock Position. 13. Start the machine. (WP 0007) 14. Raise boom (Figure 22, Item 8) to allow for adequate ground clearance. 8 HYEX03399 Figure 22. 15. Raise Boom for Clearance. Move quick latch switch (Figure 23, Item 7) to UNLATCH position. 0020-13 TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER - Continued 7 HYEX03398 Figure 23. Move Quick Latch Switch to Unlatch Position. 16. Extend bucket cylinder (Figure 24, Item 9) until quick latch wedges (Figure 24, Item 10) are fully retracted. 9 10 12 HYEX03401 Figure 24. 17. Quick Latch Wedges Retracted. Retract bucket cylinder (Figure 25, Item 9) until tool end of impact breaker (Figure 25, Item 12) is resting on ground and quick latch (Figure 25, Item 11) is in vertical position. 0020-14 TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER - Continued 9 8 11 12 HYEX03402 Figure 25. Impact Breaker Removal. 18. Lower boom (Figure 25, Item 8) until impact breaker (Figure 25, Item 12) is resting on ground. 19. Remove quick latch (Figure 25, Item 11) from impact breaker (Figure 25, Item 12). 20. Move quick latch switch (Figure 26, Item 7) to LATCH position. 7 HYEX03398 Figure 26. Quick Latch Switch to Latch Position. NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 21. Open two auxiliary circuit shutoff valves (Figure 27, Item 6). 0020-15 TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER - Continued 3 4 2 6 1 5 3 HYEX01321 Figure 27. Open Hydraulic Thumb Circuit. 22. Remove retaining pin (Figure 27, Item 2) from pin (Figure 27, Item 3). WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 23. With the aid of an assistant, extend or retract thumb cylinder (Figure 27, Item 1), as needed, while using prybar to remove pin (Figure 27, Item 3) from thumb lock position (Figure 27, Item 5). 24. Install pin (Figure 27, Item 3) in storage position (Figure 27, Item 4). 25. Install retaining pin (Figure 27, Item 2) to pin (Figure 27, Item 3). 26. Safely park and shut down machine. (WP 0009) END OF TASK END OF WORK PACKAGE 0020-16 TM 5-3805-294-10 0021 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE COMPACTOR INITIAL SETUP: Tools and Special Tools Screwdriver, Pry Bar, 12 in. (304 mm) Long (WP 0095, Table 2, Item 11) Wrench, Open End, Adjustable 0.95 in. (24 mm) (WP 0095, Table 2, Item 19) Wrench, Open End, 2 1/2 in. (63.5 mm) (WP 0095, Table 2, Item 15) Wrench, Open End, 3 in. (76 mm) (WP 0095, Table 2, Item 14) References (cont.) WP 0009 WP 0018 Equipment Condition Safely park and shutdown machine. (WP 0009) Bucket removed. (WP 0014) Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 INSTALLING COMPACTOR 1. Start machine. (WP 0007) WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. 2. Retract hydraulic thumb cylinder (Figure 1, Item 1). 0021-1 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 3 4 2 6 1 5 3 HYEX03411 Figure 1. Close Hydraulic Thumb Circuit. 3. Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). 4. Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4). WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 5. With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5). 6. Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3). NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 7. Close two auxiliary circuit shut off valves (Figure 1, Item 6). 8. Move quick latch switch (Figure 2, Item 7) to UNLATCH position. 0021-2 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 7 HYEX03412 Figure 2. 9. Move Quick Latch Switch. Raise boom (Figure 3, Item 8) to allow for adequate ground clearance. 8 HYEX03413 Figure 3. 10. Raise Boom. Fully extend bucket cylinder (Figure 4, Item 9) to ensure quick latch wedges (Figure 4, Item 10) are fully retracted. 0021-3 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 9 10 HYEX03414 Figure 4. Quick Latch Wedges Retracted. 11. Retract bucket cylinder (Figure 5, Item 9) until quick latch (Figure 5, Item 11) is in the vertical position. 9 11 12 HYEX03415 Figure 5. Install Quick Latch. 12. Install quick latch (Figure 5, Item 11) to compactor (Figure 5, Item 12). 13. Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on compactor (Figure 6, Item 12). 0021-4 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 9 11 12 HYEX03416 Figure 6. 14. Position Quick Latch. Move quick latch switch (Figure 7, Item 7) to LATCH position. 7 HYEX03412 Figure 7. Quick Latch Switch to Latch Position. WARNING With quick latch wedges disengaged from compactor, the compactor could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing compactor. Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to comply may result in injury or death to personnel. 15. Raise boom (Figure 8, Item 8) to allow for adequate ground clearance. 0021-5 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 8 HYEX03413 Figure 8. Raise Boom for Clearance. 16. Extend bucket cylinder (Figure 9, Item 9) until quick latch wedges (Figure 9, Item 10) are fully engaged to compactor (Figure 9, Item 12). 9 12 10 HYEX03417 Figure 9. Engage Quick Latch Wedges. 17. Retract bucket cylinder (Figure 9, Item 9) and position compactor (Figure 9, Item 12) on ground. 18. Shutdown machine. (WP 0009) 19. Rotate safety lock pin lever (Figure 10, Item 13) to lock position. 0021-6 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 13 HYEX03418 Figure 10. 20. Lock Safety Lock. Clean cap (Figure 11, Item 14) and machine quick disconnect (Figure 11, Item 15) with rag. 17 15 16 14 HYEX03419 Figure 11. Connect Auxiliary Supply Line. 21. Clean plug (Figure 11, Item 16) and attachment quick disconnect (Figure 11, Item 17) with rag. 22. Remove cap (Figure 11, Item 14) from machine quick disconnect (Figure 11, Item 15). 23. Remove plug (Figure 11, Item 16) from attachment quick disconnect (Figure 11, Item 17). 24. Connect attachment quick disconnect (Figure 11, Item 17) to machine quick disconnect (Figure 11, Item 15). 25. Clean plug (Figure 12, Item 18) and machine quick disconnect (Figure 12, Item 19) with rag. 0021-7 TM 5-3805-294-10 0021 INSTALLING COMPACTOR - Continued 21 19 18 20 HYEX03420 Figure 12. Connect Auxiliary Return Line. 26. Clean cap (Figure 12, Item 20) and attachment quick disconnect (Figure 12, Item 21) with rag. 27. Remove plug (Figure 12, Item 18) from machine quick disconnect (Figure 12, Item 19). 28. Remove cap (Figure 12, Item 20) from attachment quick disconnect (Figure 12, Item 21). 29. Connect attachment quick disconnect (Figure 12, Item 21) to machine quick disconnect (Figure 12, Item 19). END OF TASK OPERATING THE COMPACTOR 1. Start the machine. (WP 0007) 2. Select Breaker 2 on the monitor. (WP 0018) 3. Release attachment pedal lock (Figure 13, Item 22). 22 23 12 24 HYEX01325 Figure 13. Attachment Pedal Lock Release. 4. Press attachment pedal (Figure 13, Item 23) to turn on compactor (Figure 13, Item 12). 5. Position compactor (Figure 13, Item 12) on work surface. 6. Apply boom down pressure to deflect rubber isolators (Figure 13, Item 24) approximately half way. 0021-8 TM 5-3805-294-10 0021 OPERATING THE COMPACTOR - Continued 7. Move compactor (Figure 13, Item 12) over work surface while continuing to apply down pressure. 8. Release attachment pedal (Figure 13, Item 23) to stop compactor (Figure 13, Item 12). 9. Engage attachment pedal lock (Figure 13, Item 22). 10. Safely park and shutdown machine. (WP 0009) END OF TASK REMOVING THE COMPACTOR 1. Clean attachment quick disconnect (Figure 14, Item 21) and machine quick disconnect (Figure 14, Item 19) with rag. 21 19 18 20 HYEX03420 Figure 14. Disconnect Auxiliary Return Line. 2. Clean cap (Figure 14, Item 20) with rag. 3. Clean plug (Figure 14, Item 18) with rag. 4. Remove attachment quick disconnect (Figure 14, Item 21) from machine quick disconnect (Figure 14, Item 19). 5. Install cap (Figure 14, Item 20) to attachment quick disconnect (Figure 14, Item 21). 6. Install plug (Figure 14, Item 18) to machine quick disconnect (Figure 14, Item 19). 7. Clean attachment quick disconnect (Figure 15, Item 17) and machine quick disconnect (Figure 15, Item 15) with rag. 0021-9 TM 5-3805-294-10 0021 REMOVING THE COMPACTOR - Continued 17 15 16 14 HYEX03419 Figure 15. Connect Auxiliary Supply Line. 8. Clean plug (Figure 15, Item 16) with rag. 9. Clean cap (Figure 15, Item 14) with rag. 10. Remove attachment quick disconnect (Figure 15, Item 17) from machine quick disconnect (Figure 15, Item 15). 11. Install plug (Figure 15, Item 16) to attachment quick disconnect (Figure 15, Item 17). 12. Install cap (Figure 15, Item 14) to machine quick disconnect (Figure 15, Item 15). 13. Rotate safety lock pin lever (Figure 16, Item 13) to unlock position. 13 HYEX03421 Figure 16. Unlock Safety Lock. 14. Start the machine. (WP 0007) 15. Move quick latch switch (Figure 17, Item 7) to UNLATCH position. 0021-10 TM 5-3805-294-10 0021 REMOVING THE COMPACTOR - Continued 7 HYEX03412 Figure 17. Quick Latch Switch to Unlatch Position. 16. Raise boom (Figure 18, Item 8) to allow for adequate ground clearance. 8 HYEX03413 Figure 18. Raise Boom. WARNING With quick latch wedges disengaged from compactor, the compactor could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing compactor. Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to comply may result in injury or death to personnel. 17. Extend bucket cylinder (Figure 19, Item 9) until quick latch wedges (Figure 19, Item 10) are disengaged from compactor (Figure 19, Item 12). 0021-11 TM 5-3805-294-10 0021 REMOVING THE COMPACTOR - Continued 9 12 10 HYEX03417 Figure 19. Disengage Quick Latch Wedges. 18. Retract bucket cylinder (Figure 20, Item 9) until quick latch (Figure 20, Item 11) is in vertical position. 9 11 HYEX03422 Figure 20. Retract Bucket Cylinder. NOTE Removal of the arm/quick latch from the compactor is seldom done the same way twice. A combination of slow and smooth boom down and arm in movements is required. 19. Fully retract arm cylinder (Figure 21, Item 24). 0021-12 TM 5-3805-294-10 0021 REMOVING THE COMPACTOR - Continued 24 8 9 11 12 25 Figure 21. 20. HYEX03424 Remove Quick Latch. Lower boom (Figure 21, Item 8) until compactor plate (Figure 21, Item 25) is just touching the ground. NOTE The compactor will likely become wedged between the ground the quick latch/arm until it "pops" out of the hooks. When this wedged situation occurs, ensure that the tracks do not begin to raise. If tracks begin to raise: stop movements, raise boom, and try again. 21. Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure 21, Item 12), then begin to boom down while continuing to arm in until quick latch (Figure 21, Item 11) is removed from compactor. 22. Move quick latch switch (Figure 22, Item 7) to LATCH position. 7 HYEX03412 Figure 22. Quick Latch Switch to Latch Position. NOTE There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 0021-13 TM 5-3805-294-10 0021 REMOVING THE COMPACTOR - Continued 23. Open two auxiliary circuit shutoff valves (Figure 23, Item 6). 3 4 2 6 1 5 3 HYEX03411 Figure 23. Close Hydraulic Thumb Circuit. 24. Remove retaining pin (Figure 23, Item 2) from pin (Figure 23, Item 3). WARNING Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. NOTE Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 25. With the aid of an assistant, extend or retract thumb cylinder (Figure 23, Item 1), as needed, while using prybar to remove pin (Figure 23, Item 3) from thumb lock position (Figure 23, Item 5). 26. Install pin (Figure 23, Item 3) in storage position (Figure 23, Item 4). 27. Install retaining pin (Figure 23, Item 2) to pin (Figure 23, Item 3). 28. Safely park and shutdown machine. (WP 0009) END OF TASK END OF WORK PACKAGE 0021-14 TM 5-3805-294-10 0022 OPERATOR MAINTENANCE OPERATING THE BARRIER GRAPPLE INITIAL SETUP: Tools and Special Tools Lifting Device, Minimum Capacity 16,000 lbs (72574.8 kg) Equipment Condition Engine running. (WP 0007) BARRIER GRAPPLE OPERATION WARNING LIFTING GUIDELINES: • Do not use machine to lift personnel. Failure to comply may result in injury or death to personnel. • Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death to personnel. • Ensure load does not exceed the capacity of machine or lifting device. Failure to comply may result in injury or death to personnel. • Lift load only as high as necessary. Failure to comply may result in injury or death to personnel. • Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may result in injury or death to personnel. • Personnel must remain clear of lifted items. Failure to comply may result in injury or death to personnel. NOTE Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16,000 lb (7257.48 kg). 1. Attach barrier grapple (Figure 1, Item 1) to quick latch loop (Figure 1, Item 2) with suitable lifting device (Figure 1, Item 3). 0022-1 TM 5-3805-294-10 0022 BARRIER GRAPPLE OPERATION - Continued 2 3 1 4 HYEX02585 Figure 1. Lifting Barrier Grapple. 2. Position barrier grapple (Figure 1, Item 1) near center of barrier (Figure 1, Item 4). 3. Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from lifting device (Figure 1, Item 3). The barrier grapple will automatically close on the barrier. CAUTION Avoid jerky lifting, striking, and poor alignment with barriers. Failure to comply may result in damage to equipment. 4. Slowly raise barrier grapple (Figure 1, Item 1) and barrier (Figure 1, Item 4). 5. Position barrier (Figure 1, Item 4) in desired location. 6. Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from lifting device (Figure 1, Item 3). The barrier grapple will automatically latch open and release the barrier. 0022-2 TM 5-3805-294-10 BARRIER GRAPPLE OPERATION - Continued 7. Raise barrier grapple (Figure 1, Item 1). END OF TASK END OF WORK PACKAGE 0022-3/4 blank 0022 TM 5-3805-294-10 0023 OPERATOR MAINTENANCE OPERATING THE DEEP DIG ARM INITIAL SETUP: References WP 0010 WP 0077 Equipment Condition Engine running. WP 0007 DEEP DIG ARM OPERATION CAUTION Do not attempt to extend the arm cylinder with the deep dig arm attached. The deep dig arm can strike the machine. Failure to comply may result in damage to equipment. NOTE After the Deep Dig Attachment has been installed on the machine, the following steps must be performed to enable Deep Dig Arm Operation. 1. Remove clip (Figure 1, Item 1) from switch bracket (Figure 1, Item 2). HYEX01519 3 Figure 1. Deep Dig Control Pattern Switch. 2. Move switch (Figure 1, Item 3) to ON position and install pin (Figure 1, Item 1). 3. Switch A/I (Figure 2, Item 4) to on position 0023-1 2 1 TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION - Continued 4 HYEX03404 Figure 2. Turn Auto Idle Switch On. 4. Move pilot shutoff lever (Figure 3, Item 5) to unlocked position (down). 0023-2 TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION - Continued 5 HYEX01518 Figure 3. 5. Pilot Shutoff Lever. Turn RPM dial (Figure 4, Item 6) to max RPM setting. 0023-3 TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION - Continued 6 HYEX03405 Figure 4. Turn RPM Dial. NOTE • When the deep dig control pattern switch is in the ON position, the arm cylinder is controlled by the attachment pedal and can only be retracted. • The arm cylinder can only be retracted. It is necessary to occasionally retract the arm cylinder due to the weight of the deep dig arm. • With the deep dig control pattern switch in the ON position, the pilot control levers operate in the same way. 6. Slowly cycle bucket cylinder (Figure 5, Item 5) and deep dig bucket cylinder (Figure 5, Item 6) until full smooth movement of each cylinder is obtained. 0023-4 TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION - Continued 5 6 HYEX01636 Figure 5. Cycle Deep Dig Arm Cylinders. 7. Park and shut down machine. (WP 0010) 8. Check hydraulic oil level. (WP 0077) END OF TASK END OF WORK PACKAGE 0023-5/6 blank TM 5-3805-294-10 0024 OPERATOR MAINTENANCE MOVING MACHINE ON/OFF AN EMBANKMENT INITIAL SETUP: Not Applicable MOVING MACHINE ON AN EMBANKMENT CAUTION Do not allow machine to impact the ground with the bucket absorbing the force. Failure to comply may result in damage to equipment. 1. Position flat surface of bucket (Figure 1, Item 1) on upper level of embankment with arm (Figure 1, Item 2) to boom (Figure 1, Item 3) angle at 90 degrees. 3 5 2 4 1 HYEX01102 Figure 1. Position Bucket. 2. Lower boom (Figure 1, Item 3) to raise undercarriage until front of tracks (Figure 1, Item 4) clear edge of embankment. 3. Drive machine (Figure 1, Item 5) towards upper level as arm (Figure 1, Item 2) is retracted. 4. Slowly raise boom (Figure 1, Item 3) until tracks (Figure 1, Item 4) are resting on upper level of embankment. 5. Rotate upper structure (Figure 2, Item 6) 180 degrees towards lower level of embankment. 0024-1 TM 5-3805-294-10 0024 MOVING MACHINE ON AN EMBANKMENT - Continued 6 5 3 2 4 1 HYEX01104 Figure 2. Upperstructure Rotated. 6. Position flat surface of bucket (Figure 2, Item 1) on lower level of embankment with arm (Figure 2, Item 2) to boom (Figure 2, Item 3) angle at 90 degrees. 7. Drive machine (Figure 2, Item 5) towards upper level while extending arm (Figure 2, Item 2) until machine is completely on upper level of embankment. END OF TASK MOVING MACHINE OFF AN EMBANKMENT CAUTION Do not allow machine to impact the ground with the bucket absorbing the force. Failure to comply may result in damage to equipment. 1. Position flat surface of bucket (Figure 3, Item 1) on lower level of embankment with arm (Figure 3, Item 2) to boom (Figure 3, Item 3) angle at 90 degrees. 0024-2 TM 5-3805-294-10 0024 MOVING MACHINE OFF AN EMBANKMENT - Continued 5 3 2 4 1 HYEX00689 Figure 3. Position Bucket on Lower Level. 2. Drive machine (Figure 3, Item 5) towards lower level while raising boom (Figure 3, Item 3) and retracting arm (Figure 3, Item 2) until front of tracks (Figure 3, Item 4) reach lower level of embankment. 3. Raise bucket (Figure 4, Item 1) off of the ground and rotate upper structure (Figure 4, Item 6) 180 degrees towards upper level of embankment. 6 3 2 5 1 4 HYEX01103 Figure 4. 4. Rotate Upperstructure to Upper Level. Position flat surface of bucket (Figure 4, Item 1) on upper level of embankment with arm (Figure 4, Item 2) to boom (Figure 4, Item 3) angle at 90 degrees. 0024-3 TM 5-3805-294-10 0024 MOVING MACHINE OFF AN EMBANKMENT - Continued 5. Lower boom (Figure 4, Item 3) slightly and drive machine (Figure 4, Item 5) towards lower level as the arm (Figure 4, Item 2) is extended. 6. When tracks (Figure 4, Item 4) clear upper level of embankment, slowly raise boom (Figure 4, Item 3) until machine (Figure 4, Item 5) is on lower level. END OF TASK END OF WORK PACKAGE 0024-4 TM 5-3805-294-10 0025 OPERATOR MAINTENANCE USING THE VANDAL PROTECTION KIT INITIAL SETUP: Not Applicable RIGHT SIDE CAB INSTALLATION 1. Position cover (Figure 1, Item 1) on cab hook (Figure 1, Item 2) and behind brackets (Figure 1, Item 3). 2 1 3 HYEX01548 Figure 1. 2. Right Side Rear Cover Installation. Position cover (Figure 2, Item 4) on cab hook (Figure 2, Item 5) and behind brackets (Figure 2, Item 6). 5 4 6 HYEX01549 Figure 2. Right Side Center Cover Installation. 0025-1 TM 5-3805-294-10 0025 RIGHT SIDE CAB INSTALLATION - Continued 3. Position cover (Figure 3, Item 7) on cab hook (Figure 3, Item 8) and behind brackets (Figure 3, Item 9). 8 7 9 HYEX01550 Figure 3. 4. Right Side Front Cover Installation. Position plate (Figure 4, Item 10) over tabs (Figure 4, Item 11) and turn lock (Figure 4, Item 12) to lock in place. 11 10 11 12 HYEX01551 Figure 4. Lock Bar Installation. END OF TASK LEFT SIDE CAB INSTALLATION 1. Position cover (Figure 5, Item 13) over door hook (Figure 5, Item 14) and behind brackets (Figure 5, Item 15). 0025-2 TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION - Continued 14 13 15 HYEX01552 Figure 5. 2. Front Door Cover Installation. Position cover (Figure 6, Item 16) over cab hook (Figure 6, Item 17) and behind brackets (Figure 6, Item 18). 17 16 18 HYEX01553 Figure 6. 3. Center Door Cover Installation. Position cover (Figure 7, Item 19) over hooks (Figure 7, Item 20) and behind brackets (Figure 7, Item 21). 0025-3 TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION - Continued 20 20 21 24 23 22 Figure 7. 19 HYEX01554 Lower Door Cover Installation. 4. Position hinge (Figure 7, Item 22) over tab (Figure 7, Item 23) and turn lock (Figure 7, Item 24) to lock in place. 5. Position cover (Figure 8, Item 25) over cab hooks (Figure 8, Item 26) and behind bracket (Figure 8, Item 27). 26 26 25 27 HYEX01555 Figure 8. Side Upper Glass Cover Installation. 6. Position cover (Figure 9, Item 28) over hooks (Figure 9, Item 29) and behind brackets (Figure 9, Item 30). 0025-4 TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION - Continued 29 30 28 33 32 31 HYEX01556 Figure 9. 7. Side Lower Glass Cover Installation. Place hinge (Figure 9, Item 31) over tab (Figure 9, Item 32) and turn lock (Figure 9, Item 33) to lock in place. END OF TASK REAR CAB INSTALLATION 1. Position cover (Figure 10, Item 34) over cab hook (Figure 10, Item 35) and behind brackets (Figure 10, Item 36). 34 35 36 Figure 10. 2. HYEX01557 Right Rear Cab Cover Installation. Position cover (Figure 11, Item 37) over tab (Figure 11, Item 38) and behind brackets (Figure 11, Item 39). 0025-5 TM 5-3805-294-10 0025 REAR CAB INSTALLATION - Continued 38 40 39 37 Figure 11. 3. HYEX01558 Left Rear Cab Cover Installation. Turn lock (Figure 11, Item 40) to lock in place. END OF TASK REAR CAB REMOVAL 1. Turn lock (Figure 12, Item 40) to unlock. 38 40 39 37 HYEX01558 Figure 12. Left Rear Cab Cover Removal. 2. Remove cover (Figure 12, Item 37) from behind brackets (Figure 12, Item 39) and from tab (Figure 12, Item 38). 0025-6 TM 5-3805-294-10 0025 REAR CAB REMOVAL - Continued 3. Remove cover (Figure 13, Item 34) from behind brackets (Figure 13, Item 36) and cab hook (Figure 13, Item 35). 34 35 36 Figure 13. HYEX01557 Right Rear Cab Cover Removal. END OF TASK LEFT SIDE CAB REMOVAL 1. Turn lock (Figure 14, Item 33) to unlock and remove hinge (Figure 14, Item 31) from tab (Figure 14, Item 32). 29 30 28 33 32 31 HYEX01556 Figure 14. Side Lower Glass Cover Removal. 2. Remove cover (Figure 14, Item 28) from behind brackets (Figure 14, Item 30) and hooks (Figure 14, Item 29). 3. Remove cover (Figure 15, Item 25) from behind bracket (Figure 15, Item 27) and cab hooks (Figure 15, Item 26). 0025-7 TM 5-3805-294-10 0025 LEFT SIDE CAB REMOVAL - Continued 26 26 25 27 HYEX01555 Figure 15. Side Upper Glass Cover Removal. 4. Turn lock (Figure 16, Item 24) to unlock and remove hinge (Figure 16, Item 22) from tab (Figure 16, Item 23). 20 20 21 24 23 22 19 HYEX01554 Figure 16. Lower Door Cover Removal. 5. Remove cover (Figure 16, Item 19) from behind brackets (Figure 16, Item 21) and hooks (Figure 16, Item 20). 6. Remove cover (Figure 17, Item 16) from behind brackets (Figure 17, Item 18) and cab hooks (Figure 17, Item 17). 0025-8 TM 5-3805-294-10 0025 LEFT SIDE CAB REMOVAL - Continued 17 16 18 HYEX01553 Figure 17. 7. Center Door Cover Removal. Remove cover (Figure 18, Item 13) from behind brackets (Figure 18, Item 15) and door hooks (Figure 18, Item 14). 14 13 15 HYEX01552 Figure 18. Front Door Cover Removal. END OF TASK RIGHT SIDE CAB REMOVAL 1. Turn lock (Figure 19, Item 12) to unlock and remove plate (Figure 19, Item 10) from tabs (Figure 19, Item 11). 0025-9 TM 5-3805-294-10 0025 RIGHT SIDE CAB REMOVAL - Continued 11 10 11 12 HYEX01551 Figure 19. 2. Lock Bar Removal. Remove cover (Figure 20, Item 7) from behind brackets (Figure 20, Item 9) and cab hook (Figure 20, Item 8). 8 7 9 HYEX01550 Figure 20. Right Side Front Cover Removal. 3. Remove cover (Figure 21, Item 4) from behind brackets (Figure 21, Item 6) and cab hook (Figure 21, Item 5). 5 4 6 HYEX01549 Figure 21. Right Side Center Cover Removal. 0025-10 TM 5-3805-294-10 0025 RIGHT SIDE CAB REMOVAL - Continued 4. Remove cover (Figure 22, Item 1) from behind brackets (Figure 22, Item 3) and cab hook (Figure 22, Item 2). 2 1 3 HYEX01548 Figure 22. Right Side Rear Cover Removal. END OF TASK END OF WORK PACKAGE 0025-11/12 blank TM 5-3805-294-10 0026 OPERATOR MAINTENANCE OPERATING THE HYDRAULIC HOSE REEL INITIAL SETUP: Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Machine safely parked and shut down. (WP 0009) References WP 0007 WP 0009 CONNECTING HYDRAULIC TOOL 1. Remove cover (Figure 1, Item 1) from quick coupler (Figure 1, Item 2). 5 6 2 4 1 3 HYEX01097 Figure 1. Hydraulic Tool Attachment. 2. Remove cover (Figure 1, Item 3) from quick coupler (Figure 1, Item 4). 3. Using a clean rag, wipe quick coupler (Figure 1, Item 2) and (Figure 1, Item 4) and couplers on tool to be connected. 4. Connect quick coupler (Figure 1, Item 2) on return hose (Figure 1, Item 5) to hydraulic tool. 5. Connect quick coupler (Figure 1, Item 4) on supply hose (Figure 1, Item 6) to hydraulic tool. 6. Start engine. (WP 0007) 0026-1 TM 5-3805-294-10 0026 CONNECTING HYDRAULIC TOOL - Continued 7. Move hand held hydraulic tool circuit switch (Figure 2, Item 7) to ON position. 8 7 HYEX01096 Figure 2. 8. Turn On Hydraulic Tool. Adjust flow regulator (Figure 2, Item 8) to tool specification. END OF TASK DISCONNECTING HYDRAULIC TOOL 1. Move flow regulator (Figure 3, Item 8) to lowest setting. 8 7 HYEX01096 Figure 3. Turn Off Hydraulic Tool. 2. Move hand held hydraulic tool circuit switch (Figure 3, Item 7) to OFF position. 3. Shut engine off. (WP 0009) 0026-2 TM 5-3805-294-10 0026 DISCONNECTING HYDRAULIC TOOL - Continued 4. Operate hydraulic tool to relieve pressure from hoses. 5. Disconnect quick coupler (Figure 4, Item 4) on supply hose (Figure 4, Item 6) from hydraulic tool. 5 6 2 4 1 3 HYEX01097 Figure 4. Hydraulic Tool Removal. 6. Disconnect quick coupler (Figure 4, Item 2) on return hose (Figure 4, Item 5) from hydraulic tool. 7. Install cover (Figure 4, Item 3) to quick coupler (Figure 4, Item 4). 8. Install cover (Figure 4, Item 1) to quick coupler (Figure 4, Item 2). END OF TASK END OF WORK PACKAGE 0026-3/4 blank TM 5-3805-294-10 0027 OPERATOR MAINTENANCE DECAL LOCATION GUIDE INITIAL SETUP: Not Applicable DECALS This work package shows the typical location of all decals on the machine and attachments. Some are located inside access panels or under the engine cover. 240D 24 VOLTS DC SLAVE RECEPTACLE LCR D DIESEL ONLY HYEX01457 Figure 1. Left Side, Rear Cab Window, and Top Decals. 0027-1 TM 5-3805-294-10 0027 DECALS - Continued DRY AIR CLEANER 1. If equipped with automatic dust unloader vale, periodically clear valve by squeezing or if equipped with dust cup, service daily. 2. If tractor is equipped with an air cleaner restriction indicator, clear the primary element at the next refueling or daily service period if: a. Indicator light on the instrument panel glows with the engine running, or b.Manual indicator on the outlet of the air cleaner shows red. 3. If tractor is not equipped with restriction indicator, service the filter element every 250 hours or whem engine loses power or smokes excessively. 4. Stop engine before removing filter element. 5. Service according to instructions on primary element. 6. Replace primary element yearly or if damaged or when if no longer responds to cleaning, whichever occurs first. 7. If equipped with safety air cleaner or safety element, replace yearly or ans required. DO NOT ATTEMPT TO CLEAN SAFETY CLEANER OR ELEMENT. DO NOT USE OIL HYEX01449 Figure 2. Left Inside Door. HYEX01448 Figure 3. Top Under Engine Cover 0027-2 TM 5-3805-294-10 0027 DECALS - Continued IMPORTANT OIL LEVEL Fully Retracted Fully Retracted 3’ Without Bucket Check oil level cold with excavator in position shown above. HYEX01447 Figure 4. Right Side on Hydraulic Reservoir. FUEL TANK SUMP WATER DRAIN TRANSPORTATION DATA Drain water and sediment from fuel tank every 50 hours or weekly. Allow water to settle to tank bottom before draining. It may be possible when valve is opened that fuel may drain out at first. Wait several seconds to allow enough time for water to drain through hose. Drain water and sediment into container and dispose of properly. GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD - 60,000 LB. NO. OF SLINGS REQUIRED LENGTH OF SLINGS 4 12 FT. - EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS SWING CENTERLINE T247868 CENTER OF GRAVITY 44 MM [1.7 IN.] 1212 MM [47.5 IN.] HYEX01445 Figure 5. Right Side. 0027-3 TM 5-3805-294-10 0027 DECALS - Continued LIFT ENGINE OIL SAMPLE VALVE HYD OIL SAMPLE VALVE HYEX01444 Figure 6. Boom, Right Side, and Rear Cab Window. HYEX01446 Figure 7. Counterweight. 0027-4 TM 5-3805-294-10 0027 DECALS - Continued TIEDOWN HYEX01442 Figure 8. Front and Rear Frame. LOCK HYEX01450 Figure 9. O FF Cab on Seat. AC C ON S TA RT HYEX01530 Figure 10. Key Switch. 0027-5 TM 5-3805-294-10 0027 DECALS - Continued CAUTION FRONT WINDOW HANDLE Avoid injury from slip or fall. DO NOT use as a handhold. T223082 Window handle will move with the front window. HYEX01531 Figure 11. Windshield. 240DLC LIFT IN 1000 LBS. WITH 1920 LB. BUCKET, 11 FT. 10 IN. ARM AND 32 INCH SHOES 10' 15' 20' 25' IMPORTANT 30' 7.55* 7.55* 8.52* 8.52* 8.61* 8.61* 6.26* 6.26* 14.69* 11.56* 10.05* 14.69* 11.56* 8.88 8.09* 6.29 20.76* 14.49* 11.62* 18.90 12.10 8.39 9.68 6.04 24.56* 16.88* 12.79 17.62 11.35 7.96 9.46 5.81 13.06* 25.71* 17.90 13.06* 17.16 10.92 12.48 7.68 15.60* 22.51* 25.00* 17.77 15.60* 22.51* 17.15 10.80 12.39 7.59 SECONDARY EXIT Use tool to break window. 9.31 5.67 Always keep tool in machine. T190393 29.63* 22.54* 16.71* 12.31 29.63* 17.46 10.96 7.77 17.28* 12.10* 17.28* 11.53 RED - OVER THE FRONT BLACK - OVER THE SIDE *HYDRAULICALLY LIMITED NOTE: SEE OPERATOR'S MANUAL FOR MORE ACCURATE INFORMATION HYEX01532 T218383 Figure 12. Side Window. 0027-6 TM 5-3805-294-10 0027 DECALS - Continued CAUTION ATTACHMENT MODE SELECTION PROCEDURE 1. Press Key F1 to display the work mode screen. 2. While referring to the table below, press the key corresponding to the attachment mode you are going to use. Attachment to be used Bucket or Thumb Attachment mode Key No. to be selected 1 Excavation Hammer/ Breaker Alternative Hammer/Breaker 2 Breaker 1 3 Breaker 2 Pulverizer 4 Pulverizer 1 Crusher 5 Crusher 1 Work Mode Breaker 2 Dig 2 Breaker 1 1 1 1 6 1 Pulverizer 1 1 1 To prevent injury from the front window falling, lock window in place with the lock pin. T187353 Crusher 1 2 2 1 1 3 4 5 7 8 9 0 F1 F2 F3 F4 DANGER 2 F1 4 3 Serious injury or death can result from contact with electric lines. Never move any part of unit or load closer to electric line than 3 M [10 FT.] plus twice the line insulator length. 5 WORK MODE SCREEN 3. The specifications of the selected attachment mode are displayed on the screen and the attachment hydraulic circuit is shifted to match operation of the selected attachment. 4. Press the CONFIRM. The screen is returned to the STANDARD screen and the attachment becomes operable. Crusher 1 Maximum Pump Flow Rate 420 L/min Maximum Engine Speed 1900 min-1 Valve Selector C/V Accumulator 2-Speed Selector ON 2ndary Hydraulic Relief Selector OFF OFF T146667 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 CONFIRM ATTACHMENT SPECIFICATION SCREEN Affix this label to interior glass of operator's cab T223619 CAUTION Alternate control patterns are available for this machine. Always verify control response before operating. T201519 HYEX01533 Figure 13. Upper and Lower Right Side Window. 0027-7 TM 5-3805-294-10 0027 DECALS - Continued ENGINE OPERATION STARTING - Set RPM's (dial or throttle position) at low idle, turn key on and wait until glow plug warm-up indicator turns off; turn key to start and crank for 20 seconds maximum or less if required. Allow 2 minutes between cranking attempts. DO NOT USE ETHER AS A STARTING AID. STOPPING - Reduce RPM's to low idle for 2 minutes with no load. Stop engine. ENGINE STALL - Remove load, restart immediately. Run 30 seconds at half speed before adding load. H min1 L ENGINE RPM CONTROL Turn CW to increase Turn CCW to decrease A/I H/P P E AVOID DEATH OR SERIOUS INJURY - READ AND UNDERSTAND THE OPERATOR'S MANUAL AND SAFETY MANUAL PRIOR TO OPERATING THIS MACHINE. Controls may be changed for attachment or operator preference. Try control pattern before operating. Always lower working tools to the ground and engage hydraulic control lockout lever before leaving operator's seat. Keep riders off machine. AUTOMATIC SPEED CHANGE OFF CAUTION Avoid contact between boom/attachments and overhead obstacles whenever operating, traveling or transporting machine. A/I - Auto Idle Engine speed is temporarily reduced, if control levers are in Neutral for 4 seconds. Keep bystanders clear of machine; especially before moving boom, swinging upperstructure or traveling. POWER MODE H/P - Select for heavy digging, maximum productivity. Upperstructure position affects travel direction. Try pedals or levers to determine travel direction before moving machine. P - Select for standard digging E - Select for light digging, maximum fuel economy. Avoid tipping - Do not lift or move objects that exceed machine stability. T219580 Avoid parking machine on an incline. T159887 WARNING • AVOID SERIOUS CRUSHING INJURY FROM BOOM • NEVER place any part of body beyond window bars or frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. • DO NOT remove window bars. If window is missing or broken, replace immediately. D3067125 S HYEX01536 Figure 14. Lower Right Side Window. 0027-8 TM 5-3805-294-10 0027 DECALS - Continued 1. 2. 3. COVERS ARE SHOWN BELOW TO AID IN DETERMINING LOCATION ON CAB. START THE COVER INSTALLATION AT THE REAR OF THE CAB. CONTINUE INSTALLATION IN THE ORDER SHOWN BELOW. (RIGHT SIDE, FRONT, LEFT SIDE) LOCK COVERS AFTER INSTALLATION. 2 1 3 1 2 1 4 2 1 2 4 3 5 CAB, REAR CAB, RIGHT SIDE CAB, FRONT 3 5 CAB, LEFT SIDE T218467 HYEX01538 Figure 15. Vandal Protection Kit. 0027-9 TM 5-3805-294-10 0027 DECALS - Continued 240DLCR PERIODIC MAINTENANCE T260750 REFER TO OPERATOR'S MANUAL FOR DETAILED INFORMATION INTERVAL HOURS ITEM NO. AS REQUIRED 4 23 24 26 FUEL TANK INLET SCREEN WINDSHIELD WASHER FLUID AIR CLEANER TRACK SAG 1 1 1 2 REMOVE AND CLEAN (A) ADD AS REQUIRED CHECK - CLEAN DUST VALVE AND/OR ELEMENT (A) CHECK - ADJUST (A) 7 HYDRAULIC SYSTEM OIL LEVEL 1 16 20 ENGINE OIL LEVEL ENGINE COOLANT LEVEL 1 1 CHECK WITH EXTENDED BUCKET CYLINDER, RETRACTED ARM CYLINDER AND BUCKET ON GROUND (A) CHECK (A) COOLANT LEVEL TO BE ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD 5 12 FUEL TANK SUMP WATER SEPARATOR 1 1 DRAIN WATER AND SEDIMENT (A) DRAIN WATER 29 WORKING TOOL PIVOTS 4 GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS. GREASE DAILY WHEN WORKING IN WATER 3 6 10 12 14 16 19 20 21 22 24 SWING GEARBOX OIL LEVEL HYDRAULIC TANK SUMP ENGINE OIL FILTER DOSER ELEMENT PUMP DRIVE GEARBOX ENGINE OIL A/C BELT RADIATOR COOLANT LEVEL BATTERY WATER LEVEL TRAVEL GEARBOX OIL LEVEL AIR CLEANER 1 1 1 1 1 1 1 1 2 2 1 CHECK DIPSTICK DRAIN WATER SEDIMENT (A) REPLACE (A) (C) REPLACE (A) CHECK DIPSTICK DRAIN AND REFILL CHECK AND ADJUST CHECK - LEVEL IN BOTTLE BETWEEN "MAX COLD" AND "MIN COLD" MARKS (A) CHECK - TO BOTTOM OF FILLER NECK - CLEAN AND TIGHTEN TERMINALS CHECK - REMOVE PLUG CLEAN ELEMENT 1 FRONT END PIN JOINTS 16 2 10 12 13 16 18 25 27 28 SWING BEARING GEAR ENGINE OIL FILTER WATER SEPARATOR FILTER FUEL FILTER ENGINE OIL AIR INTAKE HOSES FRESH AIR FILTER CAB RECIRCULATING AIR FILTER SWING BEARING 1 1 1 1 1 2 1 1 2 GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS. GREASE DAILY WHEN WORKING IN WATER GREASE - ADD 1 LB. [0.5 Kg] (A) (D) REPLACE (A) (C) REPLACE (A) REPLACE - 500 HOURS OR AS REQUIRED (A) DRAIN AND REFILL (B) (C) CHECK FOR CRACKS AND LOOSE CONNECTIONS (A) CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS GREASE - 8 SHOTS EACH - EVERY 45º FOR ONE REVOLUTION (A) 3 9 11 14 15 19 24 SWING GEAR BOX OIL HYDRAULIC OIL FILTER PILOT CONTROL OIL FILTER PUMP DRIVE GEARBOX ENGINE CRANKCASE VENT TUBE SERPENTINE BELT AIR CLEANER 1 1 1 1 1 1 1 DRAIN AND REFILL (A) REPLACE (A) REPLACE (A) DRAIN AND REFILL REMOVE AND CLEAN (A) INSPECT AND REPLACE AS NECESSARY REPLACE ELEMENTS AND DUST VALVE MPL-SEE LUBRICANTS JD FILTER JD FILTER EO-SEE LUBRICANTS 8 17 20 HYDRAULIC SYSTEM OIL ENGINE VALVE LASH RADIATOR 1 1 1 HYDO-SEE LUBRICANTS 22 TRAVEL GEARBOX OIL 2 DRAIN AND REFILL EVERY 2000 HOURS. CLEAN SUCTION SCREEN (A) REFER TO SERVICE MANUAL DRAIN, FLUSH AND REFILL WITH PROPER COOLANT. FILL RADIATOR, FILL BOTTLE TO ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD (A) DRAIN AND REFILL EACH (A) 10 OR DAILY 50 OR WEEKLY MAINTENANCE POINTS ITEM 100 250 500 1000 2000 DESCRIPTION APPROVED MATERIAL MPGM-SEE LUBRICANTS HYDO-SEE LUBRICANTS EO-SEE LUBRICANTS PROPER COOLANT (A) MPGM-SEE LUBRICANTS JD FILTER JD ELEMENT EO-SEE LUBRICANTS EO-SEE LUBRICANTS PROPER COOLANT (A) DISTILLED WATER MPL-SEE LUBRICANTS MPGM-SEE LUBRICANTS JD FILTER JD FILTER JD FILTER EO-SEE LUBRICANTS JD FILTER JD FILTER MPGM-SEE LUBRICANTS JD FILTER AND VALVE PROPER COOLANT (A) MPL-SEE LUBRICANTS HYEX01534 Figure 16. Upper Section Periodic Maintenance. 0027-10 TM 5-3805-294-10 0027 DECALS - Continued (A) SEE OPERATOR'S MANUAL. (B) FOR BREAK IN OR REBUILD, SEE OPERATOR'S MANUAL. (C) USE OF JP8 JET FUEL OR DIESEL FUEL WITH SULFUR CONTENT GREATER THAN 2000 PPM [0.20%] WILL REDUCE THE ENGINE OIL AND FILTER CHANGE INTERVAL TO 250 HOURS WITH PREMIUM OILS. (D) DRAIN WATER FROM GREASE SUMP WHEN IN WATER ABOVE TRACK. DRAIN AND REFILL CAPACITIES ITEM U.S. MEASURE FUEL TANK COOLING SYSTEM ENGINE CRANKCASE (INCLUDING FILTER) HYDRAULIC RESERVOIR HYDRAULIC SYSTEM SWING BEARING GEAR SWING GEAR REDUCTION TRAVEL GEARBOX (EACH) PUMP DRIVE GEARBOX 132 GAL 31.6 QT 26 QT (6.5 GAL) 39 GAL 63.4 GAL 22 LB 7.5 QT 6.5 QT 1.2 QT METRIC 500 L 29.9 L 24.6 L 147.6 L 240 L 10 Kg 7L 6.2 L 1.1 L 1 2 4 3 5 6 7 10 11 12 13 9 8 14 15 16 17 18 19 20 29 28 27 26 25 24 23 22 21 LUBRICANTS AIR TEMPERATURE RANGE DURING FILL PERIOD RECOMMENDED LUBRICANTS °F - 40 - 22 -4 14 32 50 68 86 104 122 °C - 40 - 30 - 20 - 10 0 10 20 30 40 50 [EO] ENGINE OIL SAE 15W40 USE • JOHN DEERE PLUS 50 • ENGINE OILS MEETING: MILITARY SPECIFICATIONS MIL-PRF-2104 • VISCOSITY GRADE SAE 15W40 IS PREFERRED (1) - MAY USE MIL-PRF-46167 ARCTIC OIL BUT DRAIN INTERVAL IS REDUCED TO ONE-HALF OF NORMAL SAE 10W30 SAE 5W30 SAE 0W40 SAE 30 (1) ARCTIC OIL [HYDO] HYDRAULIC OIL SAE 10W30 2000 HOUR CHANGE INTERVAL •FACTORY FILLED WITH JD PLUS 50 10W30 •MEETING MILITARY SPECIFICATIONS MIL-PRF-2104 •MEETING MILITARY SPECIFICATIONS ARTIC MIL-PRF-46167 •MEETING MILITARY SPECIFICATIONS BIOBASED MIL-PRF-32073 SAE 5W30 SAE 15W40 MIL-46167 MIL-32073-GR1 MIL-32073-GR5 SAE 90: 85W140 [MPL] MULTIPURPOSE LUBRICANT USE SAE 80W90 • JOHN DEERE API GL-5 GEAR OIL SAE 75W • OILS MEETING API GL-5 OR MILITARY SPECIFICATIONS MIL-L-2105B OR MIL-L-2105C ARCTIC OIL [MPGM] MULTIPURPOSE GREASE WITH MOLYBDENUM DISULFIDE NLGI NO. 2 J.D. HIGH TEMP/EP USE • JOHN DEERE MOLY HIGH-TEMPERATURE EXTREME PRESSURE (EP) GREASE • SAE MULTIPURPOSE EP GREASE CONTAINING 3 TO 5% MOLYBDENUM DISULFIDE NLGI NO. 0 OR 1 ARCTIC GREASE HYEX01535 Figure 17. Lower Section Periodic Maintenance. 0027-11 TM 5-3805-294-10 0027 DECALS - Continued WARNING TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT. HYEX01441 Figure 18. Ditch Cleaning Bucket. WARNING TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT. HYEX01440 Figure 19. Heavy Duty Bucket. 0027-12 TM 5-3805-294-10 0027 DECALS - Continued HYEX01437 Figure 20. Right Side Crush-All. HYEX01438 Figure 21. Left Side Crush-All. 0027-13 TM 5-3805-294-10 0027 DECALS - Continued DANGER DANGER SHUT OFF EXCAVATOR PRIOR TO MAINTENANCE ALL PERSONNEL STAND CLEAR FLYING DEBRIS DANGER DANGER HIGH PRESSURE HYDRAULIC SYSTEM DO NOT OPERATE WITHOUT GUARDS HYEX01439 Figure 22. Output Side Crush-All. END OF TASK END OF WORK PACKAGE 0027-14 TM 5-3805-294-10 0028 OPERATOR MAINTENANCE TOWING THE HYEX INITIAL SETUP: Not Applicable TOWING CAUTION The travel motors require hydraulic pressure to release the parking brakes. Do not attempt to tow the HYEX without Field Maintenance support. Field Maintenance must prepare the travel motors before the HYEX can be towed. Failure to comply may result in damage to equipment. In the event during operation of the HYEX the machine becomes disabled and needs to be towed, notify Field level maintenance. END OF TASK END OF WORK PACKAGE 0028-1/2 blank TM 5-3805-294-10 0029 OPERATOR MAINTENANCE LOWERING BOOM WITHOUT HYDRAULIC PRESSURE INITIAL SETUP: Not Applicable LOWERING BOOM In the event during operation of the HYEX the machine becomes disabled and the boom needs to be lowered, notify Field level maintenance. END OF TASK END OF WORK PACKAGE 0029-1/2 blank TM 5-3805-294-10 0030 OPERATOR MAINTENANCE OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C) INITIAL SETUP: References WP 0004 References (cont.) WP 0005 WP 0018 STARTING NOTE • In extreme cold conditions, an extended warm-up period will be necessary. • Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. 1. Press and hold back button. BACK BUTTON HYEX01413 Figure 1. 2. Press and Hold Back Button. Turn key switch (Figure 2, Item 1) to ON position. 0030-1 TM 5-3805-294-10 0030 STARTING - Continued 1 HYEX01414 Figure 2. Key Switch to ON Position. 3. Release back button when monitor goes to default screen. 4. Press menu button. BACK BUTTON MENU BUTTON Figure 3. 5. Release Back Button. Press button one or button two until service menu is highlighted. 0030-2 HYEX01415 TM 5-3805-294-10 0030 STARTING - Continued Main Menu Fuel Rate Display/No Display Back Monitor Settings SERVICE MENU Language/ Service Menu SELECT BUTTON 1 BUTTON 1 2 6 3 4 5 7 8 9 0 F1 F2 F3 F4 BUTTON 2 HYEX01416 Figure 4. Highlight Service Menu. 6. Press the select button. 7. Press button one or button two until monitoring is highlighted then press the select button. Service Menu Troubleshooting Monitoring Ver. Controller Version MONITORING SELECT BUTTON BUTTON 2 1 2 3 4 5 BUTTON 1 6 7 8 9 0 F1 F2 F3 F4 HYEX01417 Figure 5. 8. Select Monitoring. Press button 1 or 2 until the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed. (WP 0005) 0030-3 TM 5-3805-294-10 0030 STARTING - Continued Monitoring Hydraulic Oil Temperature 0 oC Coolant Temperature (E) 0 oC Actual Engine Speed 0 Fuel Temperature 0 oC ON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01418 Figure 6. Temperatures Displayed. NOTE If hydraulic oil temperature is 32°F (0°C) or below, engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36°F (2°C). 9. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts. 1 HYEX01419 Figure 7. 10. Start Engine. Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at fast or slow idle. 0030-4 TM 5-3805-294-10 0030 STARTING - Continued 2 HYEX01420 Figure 8. 11. Engine Speed Dial. Ensure engine coolant and hydraulic oil temperatures are above 0°F (-18°C) before proceeding to Step 12. Monitoring Hydraulic Oil Temperature 0 oC Coolant Temperature (E) 0 oC Actual Engine Speed 0 Fuel Temperature 0 oC ON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01418 Figure 9. Check Engine and Hydraulic Oil Temperatures. NOTE During warm-up procedures, if the upper structure is over the side and the boom cylinders are fully raised, the overload alarm may sound even if the machine is not in an overload condition. Lower the boom cylinders until the alarm is no longer displayed. 12. Set machine switch selections for temperatures between 5° and 32°F (-15° and 0°C) per Table 1. 0030-5 TM 5-3805-294-10 0030 STARTING - Continued Table 1. Machine Switch Selections. Engine Speed Speed Dial to Half Speed Power Mode Switch Position High Power (HP) Mode Auto-Idle (A/I) Switch Position OFF Travel Speed Switch Slow (Turtle) 13. Select dig mode on monitor. (WP 0018) WARNING Clear the area of all personnel during machine warm up procedures. Machine can move unexpectedly. Failure to comply may result in injury or death to personnel. CAUTION Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot spots in the control valve. Failure to comply may result in damage to equipment. 14. Operate swing, boom, arm, hydraulic thumb, and bucket functions slowly and short distances initially in each direction. (WP 0004) 15. Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is obtained. 16. Swing upperstructure (Figure 10, Item 3) 90 degrees. 5 6 3 7 Figure 10. 4 HYEX01421 Raise Machine. 17. Place round side of bucket (Figure 10, Item 4) on ground. 18. Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees, slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground. 0030-6 TM 5-3805-294-10 0030 STARTING - Continued 19. Operate travel lever for raised track for approximately 5 minutes. (WP 0004) 20. Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure back 90 degrees. 21. Repeat Steps 14 to 18 for opposite track. END OF TASK END OF WORK PACKAGE 0030-7/8 blank TM 5-3805-294-10 0031 OPERATOR MAINTENANCE OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER INITIAL SETUP: References WP 0004 References (cont.) WP 0018 WP 0034 STARTING NOTE • Contact Field Maintenance to ensure that all fluids meet the requirements for the current operating conditions. • In extreme cold conditions, an extended warm-up period will be necessary. • Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. 1. If temperature is 5°F (-15°C) or below, operate coolant heater for 30 minutes. (WP 0034) 2. Press and hold back button. BACK BUTTON HYEX01423 Figure 1. Press and Hold Back Button. 0031-1 TM 5-3805-294-10 0031 STARTING - Continued 3. Turn key switch (Figure 2, Item 1) to ON position. 1 HYEX01424 Figure 2. 4. Key Switch to ON Position. Release back button when monitor goes to default screen. BACK BUTTON MENU BUTTON Figure 3. Release Back Button. 5. Press menu button. 6. Press button one or button two until service menu is highlighted. 0031-2 HYEX01415 TM 5-3805-294-10 0031 STARTING - Continued Main Menu Fuel Rate Display/No Display Back Monitor Settings SERVICE MENU Language/ Service Menu SELECT BUTTON 1 BUTTON 1 2 6 3 4 5 7 8 9 0 F1 F2 F3 F4 BUTTON 2 HYEX01430 Figure 4. Highlight Service Menu. 7. Press the select button. 8. Press button one or button two until monitoring is highlighted, then press the select button. MONITORING Service Menu Troubleshooting Monitoring Ver. Controller Version SELECT BUTTON 1 2 3 4 5 BUTTON 1 6 7 8 9 0 F1 F2 F3 F4 BUTTON 2 HYEX01431 Figure 5. Select Monitoring. 0031-3 TM 5-3805-294-10 0031 STARTING - Continued 9. Ensure the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed. Monitoring Hydraulic Oil Temperature 0 oC Coolant Temperature (E) 0 oC Actual Engine Speed 0 Fuel Temperature 0 oC ON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01432 Figure 6. Temperatures Displayed. NOTE If hydraulic oil temperature is 32°F (0°C) or below, engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36°F (2°C). 10. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts. 1 HYEX01433 Figure 7. 11. Start Engine. Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at fast or slow idle. 0031-4 TM 5-3805-294-10 0031 STARTING - Continued 2 HYEX01434 Figure 8. 12. Engine Idle Speed. Monitor engine coolant and hydraulic oil. Once the oil temperatures reach 0°F (-18°C) the High Power (HP) mode can be selected. Monitoring Hydraulic Oil Temperature 0 oC Coolant Temperature (E) 0 oC Actual Engine Speed 0 Fuel Temperature 0 oC ON 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01432 Figure 9. Monitor Temperatures Displayed. 0031-5 TM 5-3805-294-10 0031 STARTING - Continued NOTE During warm-up procedures, if the upper structure is over the side and the boom cylinders are fully raised, the overload alarm may sound even if the machine is not in an overload condition. Lower the boom cylinders until the alarm is no longer displayed. 13. Set machine switch selections for temperatures between 5°F (-15°C) and below per Table 1. Table 1. Machine Switch Selection. Machine Specification Temperatures 5° to 0°F (-15° to -18°C) Temperature Below 0°F (-18°C) Engine Speed Speed Dial to Half Speed Speed Dial to Half Speed Power Mode Switch Position High Power (HP) Mode Economy (E) Mode Auto-Idle (A/I) Switch Position OFF OFF Travel Speed Switch Slow (Turtle) Slow (Turtle) 14. Select dig mode on monitor. (WP 0018) WARNING Clear the area of all personnel during machine warm up procedures. Machine can move unexpectedly. Failure to comply may result in injury or death to personnel. CAUTION Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot spots in the control valve. Failure to comply may result in damage to equipment. 15. Operate swing, boom, arm, and bucket functions slowly and short distances initially in each direction. (WP 0004) 16. Continue cycling cylinders by increasing travel each cycle until full smooth movement of function is obtained. 17. Swing upperstructure (Figure 10, Item 3) 90 degrees. 0031-6 TM 5-3805-294-10 0031 STARTING - Continued 5 6 3 7 Figure 10. 4 HYEX01435 Raise Machine. 18. Place round side of bucket (Figure 10, Item 4) on ground. 19. Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees, slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground. 20. Operate travel lever for raised track for approximately 5 minutes. (WP 0004) 21. Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure back 90 degrees. 22. Repeat Steps 15 to 19 for opposite track. END OF TASK END OF WORK PACKAGE 0031-7/8 blank TM 5-3805-294-10 OPERATOR MAINTENANCE SLAVE STARTING INITIAL SETUP: References WP 0007 SLAVE STARTING WARNING An explosive gas is produced while batteries are in use or being charged. Keep flames and sparks away from battery area. Ensure batteries are charged in a well-ventilated area. Failure to comply may result in injury or death to personnel. NOTE Ensure that booster vehicle is equipped with a slave receptacle. 1. Contact Field Maintenance to get a slave cable. 2. Connect the slave cable to booster vehicle slave receptacle. 3. Remove cap (Figure 1, Item 1) from slave receptacle (Figure 1, Item 2). 0032-1 0032 TM 5-3805-294-10 0032 SLAVE STARTING - Continued 2 1 HYEX00866 Figure 1. Slave Receptacle. 4. Connect slave cable to slave receptacle (Figure 1, Item 2). 5. Run booster vehicle at a speed just above idle. Refer to booster vehicle Operator's Manual. 6. Start engine. (WP 0007) 7. After starting machine, return booster vehicle to idle. Refer to booster vehicle Operator's Manual. 8. Remove the slave cable from slave receptacle (Figure 1, Item 2). 9. Install cap (Figure 1, Item 1) to slave receptacle (Figure 1, Item 2). 10. Remove slave cable from booster vehicle. END OF TASK END OF WORK PACKAGE 0032-2 TM 5-3805-294-10 0033 OPERATOR MAINTENANCE SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT) INITIAL SETUP: Not Applicable SKYLIGHT WINDOW (SECONDARY EXIT) 1. Slide back liner. 2. Release two latches (Figure 1, Item 1). 2 1 1 HYEX00943 Figure 1. 3. Open and Close Roof Exit. Push on handle (Figure 1, Item 2) and exit machine. END OF TASK REAR WINDOW (EMERGENCY EXIT) 1. Remove emergency exit tool (Figure 2, Item 3) from holder (Figure 2, Item 4). 0033-1 TM 5-3805-294-10 0033 REAR WINDOW (EMERGENCY EXIT) - Continued 5 4 3 HYEX00944 Figure 2. Emergency Exit Tool. WARNING When using emergency exit tool to break glass, shield eyes and face from broken glass. Failure to comply may result in injury or death to personnel. 2. Using emergency exit tool (Figure 2, Item 3) smash rear window (Figure 2, Item 5). One or two strikes with emergency exit tool (Figure 2, Item 3) should shatter glass. 3. Push remaining glass from window edges and exit machine. END OF TASK END OF WORK PACKAGE 0033-2 TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING THE COOLANT HEATER INITIAL SETUP: Not Applicable COOLANT HEATER OPERATION WARNING • The coolant heater must be switched off while the fuel tank on the machine is being filled. Failure to comply may result in injury or death to personnel. • DO NOT operate engine or coolant heater in a closed place without proper ventilation. Failure to comply may result in injury or death to personnel. CAUTION If a fault arises during coolant heater operation, the heat symbol will flash on the control panel display and a three-digit fault code will be displayed. Shut down the coolant heater and notify field maintenance. Failure to comply may result in damage to equipment. NOTE • Coolant heater is only required to be used when temperature is -25° F (-32° C) or colder. • The timer can control operation of the coolant heater for up to 7 days in advance. • The default timer setting is for the coolant heater to operate for 120 minutes before automatically turning off. 0034-1 0034 TM 5-3805-294-10 0034 COOLANT HEATER OPERATION - Continued 1. The coolant heater control panel (Figure 1, Item 1) is located on left outer console of operator's seat. 2 1 M0 20:30 HYEX00023 Figure 1. Coolant Heater Control Panel. 2. The coolant heater control panel display (Figure 1, Item 2) indicates a weekday and time and allows programming of heater cycle times. END OF TASK ADJUSTING COOLANT HEATER TIME AND DAY NOTE All symbols will flash on coolant heater control panel (Figure 2, Item 1) display after extended power loss. The clock requires resetting to ensure proper operation of the coolant heater. 1. Push and hold clock button (Figure 2, Item 3) until time (Figure 2, Item 4) indicator begins to flash. 4 7 M0 3 20:30 1 3 5 6 HYEX00022 Figure 2. Adjusting Time and Day. 2. Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust time up or down. 3. When time is correct wait approximately 5 seconds and day (Figure 2, Item 7) will begin to flash. 4. Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust day (Figure 2, Item 7) up or down. 5. When day (Figure 2, Item 7) is correct wait approximately 5 seconds and day will stop flashing. 0034-2 TM 5-3805-294-10 0034 ADJUSTING COOLANT HEATER TIME AND DAY - Continued 6. Time (Figure 2, Item 4) and day (Figure 2, Item 7) is set. END OF TASK SETTING AND SELECTING COOLANT HEATER PROGRAM NOTE • The coolant heater control panel can program three start cycle times within a 24-hour period or one start cycle per day for 7 days. Only one program can be activated at one time. • Pressing the preset button (Figure 3, Item 8) until memory display is blank will delete programs in memory. 1. Press the preset button (Figure 3, Item 8) until the desired program number (Figure 3, Item 9) begins to flash. 4 7 M0 9 3 20:30 8 Figure 3. 5 6 HYEX01315 Setting Program. 2. Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust start time (Figure 3, Item 4) up or down. 3. When start time (Figure 3, Item 4) is set, wait approximately 5 seconds and day (Figure 3, Item 7) will begin to flash. 4. Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust day (Figure 3, Item 7) up or down. 5. When day (Figure 3, Item 7) is set, wait approximately 5 seconds and day will stop flashing. 6. Start time (Figure 3, Item 4) and day (Figure 3, Item 7) is set. 7. Program number (Figure 3, Item 9) will be displayed. 8. Repeat Steps 1 through 7 if additional days of programing is desired. END OF TASK ADJUSTING COOLANT HEATER RUN TIME NOTE • The maximum amount of time for the coolant heater will run is 120 minutes. 0034-3 TM 5-3805-294-10 0034 ADJUSTING COOLANT HEATER RUN TIME - Continued • Adjusting the run time must be performed every time a start program is selected. 1. Press the heater button (Figure 4, Item 10) and the preselected run time (Figure 4, Item 11) will appear on the display (Figure 4, Item 2). 2 11 120 10 5 6 HYEX00021 Figure 4. Adjusting Run Time. 2. Press the left arrow button (Figure 4, Item 5) or right arrow button (Figure 4, Item 6) to adjust run time (Figure 4, Item 11) up or down. 3. After desired run time (Figure 4, Item 11) is selected, wait approximately 5 seconds and run time is set. END OF TASK USING COOLANT HEATER MANUALLY 1. Press heater button (Figure 5, Item 10) and the coolant heater will start and run. 11 120 10 Figure 5. 5 6 HYEX00020 Manually Start Coolant Heater. 2. If desired, press the left arrow button (Figure 5, Item 5) or right arrow button (Figure 5, Item 6) to adjust run time (Figure 5, Item 11) up or down. 3. To manually shut coolant heater off press the heater button (Figure 6, Item 10). The coolant heater will do a normal cool-down cycle and then turn itself off. 0034-4 TM 5-3805-294-10 0034 USING COOLANT HEATER MANUALLY - Continued 11 120 10 Figure 6. 5 6 HYEX00020 Manually Start Coolant Heater Continued. END OF TASK END OF WORK PACKAGE 0034-5/6 blank TM 5-3805-294-10 0035 OPERATOR MAINTENANCE MOVING UP/DOWN STEEP OR SLIPPERY SLOPES INITIAL SETUP: Not Applicable PULLING MACHINE UP WARNING This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Buckle seat belt (Figure 1, Item 1). 1 HYEX00687 Figure 1. 2. Buckle Seat Belt. Position undercarriage so travel motors (Figure 2, Item 2) will be on the uphill end of machine (Figure 2, Item 3). 0035-1 TM 5-3805-294-10 0035 PULLING MACHINE UP - Continued 6 4 5 3 2 HYEX00674 Figure 2. Pulling Machine Up. 3. Push bucket (Figure 2, Item 4) into the ground on the top of the slope. 4. While using travel pedals pull the machine using the boom (Figure 2, Item 5) and arm cylinder (Figure 2, Item 6) to assist the travel motors (Figure 2, Item 2). END OF TASK PUSHING MACHINE UP WARNING This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Buckle seat belt (Figure 3, Item 1). 0035-2 TM 5-3805-294-10 0035 PUSHING MACHINE UP - Continued 1 HYEX00687 Figure 3. 2. Buckle Seat Belt. Position undercarriage so travel motors (Figure 4, Item 2) will be on the uphill end of machine (Figure 4, Item 3). 3 6 5 2 4 HYEX00677 Figure 4. 3. Pushing Machine. Push bucket (Figure 4, Item 4) into the ground at the base of the slope. 0035-3 TM 5-3805-294-10 0035 PUSHING MACHINE UP - Continued 4. While using travel pedals push the machine using the boom (Figure 4, Item 5) and arm cylinder (Figure 4, Item 6) to assist the travel motors (Figure 4, Item 2). END OF TASK TRAVELING DOWN WARNING This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Position undercarriage so travel motors (Figure 5, Item 2) will be on the uphill end of machine (Figure 5, Item 3). 3 6 5 2 4 HYEX00677 Figure 5. 2. Traveling Down. Using the boom (Figure 5, Item 5) and arm cylinder (Figure 5, Item 6) position bucket (Figure 5, Item 4) so it will drag the ground while traveling down the slope. 0035-4 TM 5-3805-294-10 TRAVELING DOWN - Continued 3. Slowly travel down the slope. END OF TASK END OF WORK PACKAGE 0035-5/6 blank 0035 TM 5-3805-294-10 0036 OPERATOR MAINTENANCE FORDING THE HYEX INITIAL SETUP: References WP 0093 FORDING CAUTION Do not ford water unless depth is known. Water deeper than 40.0 in. (1.0 m) may enter machine systems and damage operating components. Failure to comply may result in damage to equipment. NOTE Use travel control levers during fording operations to maintain better control of machine speed. 1. Ensure bottom at fording site is firm enough that 40 in. (1 m) maximum fording depth will not be exceeded and machine will not become mired. HYEX01311 Figure 1. Fording Line. 2. Ensure that engine is operating normally and is at normal operating temperature. 3. Move pilot shutoff lever (Figure 2, Item 1) to unlocked (down) position. 0036-1 TM 5-3805-294-10 0036 FORDING - Continued 1 Figure 2. 4. HYEX00367 Pilot Shutoff Lever. Ensure that there are no alarms indicated on monitor (Figure 3, Item 2). 5 2 4 3 Figure 3. HYEX00368 Check Monitor. 5. Position travel speed selector (Figure 3, Item 3) in slow position. 6. Raise engine speed dial (Figure 3, Item 4) to 1/3 throttle position. 7. Move travel levers (Figure 3, Item 5) forward 1/4 travel. 8. Enter the water slowly to minimize surges of backwash into the upperstructure. 9. If machine accidently enters water deeper than 40 in. (1.0 m), move travel levers (Figure 3, Item 5) back 1/4 travel and slowly back machine out of deep water. 0036-2 TM 5-3805-294-10 FORDING - Continued 10. After fording perform, maintenance after fording. (WP 0093) END OF TASK END OF WORK PACKAGE 0036-3/4 blank 0036 TM 5-3805-294-10 CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0037 OPERATOR MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure ELECTRICAL SYSTEM 1. Travel Alarm Does Not Operate ....................................................................................................... WP 0038 2. Windshield Wiper and Washer Do Not Operate ............................................................................... WP 0039 3. Cab Dome Light Does Not Operate ................................................................................................. WP 0040 4. Boom, Cab, And Drive Lights Do Not Operate ................................................................................. WP 0041 5. Cab Front Work Lights Do Not Operate ........................................................................................... WP 0042 6. Cab Rear Work Lights Do Not Operate ............................................................................................ WP 0043 7. Low Note and High Note Horns Do Not Operate ............................................................................. WP 0044 8. Air Conditioner Does Not Operate ................................................................................................... WP 0045 ENGINE 1. Engine Cranks But Will Not Start Or Hard To Start .......................................................................... WP 0046 2. Engine Will Not Crank ...................................................................................................................... WP 0047 3. Engine Runs Poorly ......................................................................................................................... WP 0048 4. Excessive Fuel Consumption ........................................................................................................... WP 0049 5. Excessive Oil Consumption .............................................................................................................. WP 0050 6. Engine Idles Poorly .......................................................................................................................... WP 0051 7. Auto-Idle Does Not Work ................................................................................................................. WP 0052 8. Engine Not Developing Full Power .................................................................................................. WP 0053 9. Engine Oil Pressure Low .................................................................................................................. WP 0054 10. Engine Coolant Temperature Above Normal ................................................................................... WP 0055 11. Engine Emits Excessive Black Or Gray Exhaust Smoke ................................................................. WP 0056 12. Engine Emits Excessive White Exhaust Smoke ............................................................................... WP 0057 HYDRAULICS SYSTEM 1. No Hydraulic Functions .................................................................................................................... WP 0058 2. Hydraulic Functions Are Slow Or Have Little Or No Power .............................................................. WP 0059 3. Power Dig Does Not Work ............................................................................................................... WP 0060 4. Hydraulic Oil Overheats ................................................................................................................... WP 0061 5. Hydraulic Oil Foams ......................................................................................................................... WP 0062 0037-1 TM 5-3805-294-10 0037 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure 6. No Swing Function ........................................................................................................................... WP 0063 7. Swing Function Is Jerky ................................................................................................................... WP 0064 8. Slow Travel Speed Only ................................................................................................................... WP 0065 9. Travel Is Jerky .................................................................................................................................. WP 0066 10. Engine Stops When Travel Or Control Lever Actuated .................................................................... WP 0067 11. Quick Latch Does Not Operate ........................................................................................................ WP 0068 12. Compactor Does Not Operate .......................................................................................................... WP 0069 13. Breaker Does Not Operate ............................................................................................................... WP 0070 14. Breaker Operates Slowly ................................................................................................................. WP 0071 15. Crush-All Does Not Operate ............................................................................................................ WP 0072 16. Barrier Grapple Does Not Hold Load ............................................................................................... WP 0073 17. Deep Dig Does Not Operate ............................................................................................................ WP 0074 18. Hydraulic Hose Reel Does Not Operate ........................................................................................... WP 0075 END OF WORK PACKAGE 0037-2 TM 5-3805-294-10 0038 OPERATOR MAINTENANCE TRAVEL ALARM DOES NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Travel Alarm Does Not Operate. Malfunction Travel Alarm Fuse Blown. Test or Inspection 1. Remove F5 OPT.1 (ALT) 5A fuse. (WP 0084) 2. Visually inspect F5 OPT.1 (ALT) 5A fuse for blown fuse. END OF WORK PACKAGE 0038-1/2 blank Corrective Action 1. If fuse blown, replace F5 OPT. 1 (ALT) 5A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0039 OPERATOR MAINTENANCE WINDSHIELD WIPER AND WASHER DO NOT OPERATE INITIAL SETUP: References WP 0009 WP 0011 WP 0084 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Windshield Wiper and Washer Do Not Operate. Malfunction 1. 2. Upper Front Window Not Fully Closed. Windshield Wiper and Washer Fuse Blown. Test or Inspection 1. If machine is equipped with a Supplemental Armor Set, proceed to Malfunction 2. 2. Check upper front window to ensure window is fully closed. (WP 0011) 1. Shut engine off. (WP 0009) 2. Remove F2 WIPER 10A fuse. (WP 0084) 3. Visually inspect F2 WIPER 10A fuse for blown fuse. END OF WORK PACKAGE 0039-1/2 blank Corrective Action 1. If fully closed, proceed to Malfunction 2. 2. If not fully closed, readjust and close upper front window. (WP 0011) 1. If fuse blown, replace F2 WIPER 10A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0040 OPERATOR MAINTENANCE CAB DOME LIGHT DOES NOT OPERATE INITIAL SETUP: References WP 0004 WP 0009 WP 0084 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Cab Dome Light Does Not Operate. Malfunction 1. 2. Test or Inspection Cab Dome Light Switch is OFF (up). Radio and Dome Light Fuse Blown. Check cab dome light switch position. (WP 0004) 1. Shut engine off. (WP 0009) 2. Remove F11 RADIO 5A fuse. (WP 0084) 3. Visually inspect F11 RADIO 5A fuse for blown fuse. END OF WORK PACKAGE 0040-1/2 blank Corrective Action 1. If switch is ON (down), proceed to Malfunction 2. 2. If switch is OFF (up), position cab dome light switch ON (down). (WP 0004) 1. If fuse blown, replace F11 RADIO 5A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0041 OPERATOR MAINTENANCE BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Boom, Cab, And Drive Lights Do Not Operate. Malfunction Work and Drive Lights Fuse Blown. Test or Inspection 1. Remove F1 LAMP 20A fuse. (WP 0084) 2. Visually inspect F1 LAMP 20A fuse for blown fuse. END OF WORK PACKAGE 0041-1/2 blank Corrective Action 1. If fuse blown, replace F1 LAMP 20A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0042 OPERATOR MAINTENANCE CAB FRONT WORK LIGHTS DO NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Cab Front Work Lights Do Not Operate. Malfunction Cab Front Work Lights Fuse Blown. Test or Inspection 1. Remove F22 CAB LAMP FRONT 10A fuse. (WP 0084) 2. Visually inspect F22 CAB LAMP FRONT 10A fuse for blown fuse. END OF WORK PACKAGE 0042-1/2 blank Corrective Action 1. If fuse blown, replace F22 CAB LAMP FRONT 10A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0043 OPERATOR MAINTENANCE CAB REAR WORK LIGHTS DO NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Cab Rear Work Lights Do Not Operate. Malfunction Cab Rear Work Lights Fuse Blown. Test or Inspection 1. Remove F23 CAB LAMP REAR 10A fuse. (WP 0084) 2. Visually inspect F23 CAB LAMP REAR 10A fuse for blown fuse. END OF WORK PACKAGE 0043-1/2 blank Corrective Action 1. If fuse blown, replace F23 CAB LAMP REAR 10A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0044 OPERATOR MAINTENANCE LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Low Note And High Note Horns Do Not Operate. Malfunction Horn Fuse Blown. Test or Inspection 1. Remove F17 HORN 10A fuse. (WP 0084) 2. Visually inspect F17 HORN 10A fuse for blown fuse. END OF WORK PACKAGE 0044-1/2 blank Corrective Action 1. If fuse blown, replace F17 HORN 10A fuse. (WP 0084) 2. If fuse not blown, notify Field Maintenance. TM 5-3805-294-10 0045 OPERATOR MAINTENANCE AIR CONDITIONER DOES NOT OPERATE INITIAL SETUP: References WP 0077 WP 0084 WP 0089 WP 0090 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Air Conditioner Does Not Operate. Malfunction 1. 2. 3. Air Conditioner and Heater 5A Fuse Blown. Air Conditioner and Heater 20A Fuse Blown. Fresh Air Filter Clogged or Damaged. Test or Inspection 1. Remove F15 AIRCON 5A fuse. (WP 0084) 2. Visually inspect F15 AIRCON 5A fuse for blown fuse. 1. Remove F3 HEATER 20A fuse. (WP 0084) 2. Visually inspect F3 HEATER 20A fuse for blown fuse. 1. Remove fresh air filter. (WP 0089) 2. Visually inspect fresh air filter and housing for clog and damage. 0045-1 Corrective Action 1. If fuse blown, replace F15 AIRCON 5A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 2. 1. If fuse blown, replace F3 HEATER 20A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 3. 1. If clogged, service fresh air filter and housing. (WP 0089) 2. If damaged, notify Field Maintenance. 3. If not clogged and not damaged, proceed to Malfunction 4. TM 5-3805-294-10 0045 Table 1. Air Conditioner Does Not Operate - Continued. Malfunction 4. 5. 6. Air Conditioner/ Heater Filter Clogged or Damaged. Air Conditioner Condenser Dirty or Damaged. Air Conditioner Belt Worn or Damaged. Test or Inspection 1. Remove air conditioner/heater filter. (WP 0090) 2. Visually inspect air conditioner/heater filter and housing for clog and damage. Visually inspect air conditioner/heater condenser for dirt and damage. (WP 0077) Visually inspect air conditioner belt for wear and damage. (WP 0077) END OF WORK PACKAGE 0045-2 Corrective Action 1. If clogged, service air conditioner/heater filter and housing. (WP 0090) 2. If damaged, notify Field Maintenance. 3. If not clogged and not damaged, proceed to Malfunction 5. 1. If dirty, clean air conditioner condenser. (WP 0077) 2. If damaged, notify Field Maintenance. 3. If not dirty and not damaged, proceed to Malfunction 6. 1. If worn or damaged, notify Field Maintenance. 2. If not worn and not damaged, notify Field Maintenance. TM 5-3805-294-10 0046 OPERATOR MAINTENANCE ENGINE CRANKS BUT DOES NOT START OR HARD TO START INITIAL SETUP: References WP 0005 WP 0007 WP 0009 WP 0077 References (cont.) WP 0086 WP 0087 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Cranks But Does Not Start or Hard to Start. Malfunction 1. 2. 3. Test or Inspection Engine Cranks Slowly. Fuel Level Low. Air Cleaners Dirty or Clogged. Crank engine. (WP 0007) 1. Turn key switch to ON position, but DO NOT START ENGINE. (WP 0007) 2. Visually inspect monitor to verify at least 1/4 tank of fuel is available. (WP 0005) 3. Turn key switch to OFF position. (WP 0009) 1. Start engine. (WP 0007) 2. Observe monitor for air cleaner clogged alarm. (WP 0005) 0046-1 Corrective Action 1. If engine cranks slowly, notify Field Maintenance. 2. If engine does not crank slowly, proceed to Malfunction 2. 1. If fuel level is low, service machine. (WP 0077) 2. If fuel level is OK, proceed to Malfunction 3. TM 5-3805-294-10 0046 Table 1. Engine Cranks But Does Not Start or Hard to Start - Continued. Malfunction Test or Inspection 3. 4. 5. Leaking Fuel Lines and Fittings. Fuel Filter/Water Separators Contain Water or Sediment. Shut down engine. (WP 0009) Visually inspect fuel lines and fittings for leakage. (WP 0077) 1. Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) 2. Start engine. (WP 0007) END OF WORK PACKAGE 0046-2 Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaner. (WP 0087) 2. If air cleaner clogged alarm is not displayed, proceed to Malfunction 4. 1. If fuel lines and fittings are leaking, notify Field Maintenance. 2. If fuel lines and fittings are not leaking, proceed to Malfunction 5. 1. If engine starts, malfunction corrected. 2. If engine does not start, notify Field Maintenance. TM 5-3805-294-10 0047 OPERATOR MAINTENANCE ENGINE WILL NOT CRANK INITIAL SETUP: References WP 0005 WP 0007 WP 0009 References (cont.) WP 0077 WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Will Not Crank. Malfunction 1. 2. Pilot Shutoff Lever in UNLOCKED (down) Position. Discharged Batteries. Test or Inspection 1. Place pilot shutoff lever in LOCK (up) position. (WP 0007) 2. Start engine. (WP 0007) 1. Turn key switch to ON position, but DO NOT START ENGINE. (WP 0007) 2. Observe monitor for battery warning alarm. (WP 0005) 3. Turn key switch to OFF position. (WP 0009) 0047-1 Corrective Action 1. If engine starts, malfunction corrected. 2. If engine does not crank, proceed to Malfunction 2. 1. If monitor displays battery warning alarm, notify Field Maintenance. 2. If monitor does not display battery warning alarm, proceed to Malfunction 3. TM 5-3805-294-10 0047 Table 1. Engine Will Not Crank - Continued. Malfunction 3. Blown Fuses. Test or Inspection 1. Corrective Action Remove the following fuses: • F8 ECM 20A fuse. (WP 0084) • F10 CONTROLLER 5A fuse. (WP 0084) • F16 POWER ON 5A fuse. (WP 0084) 2. 4. Corroded or Loose Battery Connections. Visually inspect fuses for blown fuse. Visually inspect batteries for corroded or loose connections. (WP 0077) END OF WORK PACKAGE 0047-2 1. If fuse blown, replace fuse. (WP 0084) 2. If no fuse blown, proceed to Malfunction 4. 1. If battery connections are corroded or loose, notify Field Maintenance. 2. If battery connections are not corroded or loose, notify Field Maintenance that engine does not crank. TM 5-3805-294-10 0048 OPERATOR MAINTENANCE ENGINE RUNS POORLY INITIAL SETUP: References WP 0005 WP 0007 WP 0009 WP 0077 WP 0086 References (cont.) WP 0087 WP 0091 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Engine Runs Poorly. Malfunction 1. 2. Air Cleaners Dirty or Clogged. Fuel Filter/Water Separators Contain Water or Sediment. Test or Inspection 1. Observe monitor for air cleaner clogged alarm. (WP 0005) 2. Shut down engine. (WP 0009) 1. Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) 2. Start engine. (WP 0007) 0048-1 Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. 1. If engine runs properly, malfunction corrected. 2. If engine runs poorly, Malfunction 3. TM 5-3805-294-10 0048 Table 1. Engine Runs Poorly - Continued. Malfunction 3. Fuel Tank is Contaminated. Test or Inspection 1. Shut down engine. (WP 0009) 2. Drain water and sediment from fuel tank. (WP 0091) 3. Clean fuel strainer. (WP 0077) 4. Start engine. (WP 0007) END OF WORK PACKAGE 0048-2 Corrective Action 1. If clean fuel does not become present, Notify Field Maintenance. 2. If clean fuel becomes present, proceed to Step 3. 1. If engine runs properly, malfunction corrected. 2. If engine runs poorly, shut down engine. (WP 0009) Notify Field Maintenance. TM 5-3805-294-10 0049 OPERATOR MAINTENANCE EXCESSIVE FUEL CONSUMPTION INITIAL SETUP: References WP 0005 WP 0009 References (cont.) WP 0077 WP 0087 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Excessive Fuel Consumption. Malfunction 1. 2. Air Cleaners Dirty or Clogged. Leaking Fuel Lines and Fittings. Test or Inspection 1. Observe monitor for air cleaner clogged alarm. (WP 0005) 2. Shut down engine. (WP 0009) Visually inspect fuel lines and fittings for leakage. (WP 0077) END OF WORK PACKAGE 0049-1/2 blank Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. 1. If fuel lines or fittings are leaking, notify Field Maintenance. 2. If fuel lines or fittings are not leaking, notify Field Maintenance. TM 5-3805-294-10 0050 OPERATOR MAINTENANCE EXCESSIVE OIL CONSUMPTION INITIAL SETUP: References WP 0005 WP 0009 References (cont.) WP 0077 WP 0087 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Excessive Oil Consumption. Malfunction 1. 2. Air Cleaners Dirty or Clogged. Oil Shows Signs Of Contamination. Test or Inspection 1. Observe monitor for air cleaner clogged alarm. (WP 0005) 2. Shut down engine. (WP 0009) Visually inspect engine oil dipstick for coolant or fuel contaminants. (WP 0077) Oil containing coolant will have a creamy brown appearance or oil containing fuel will be diluted and smell like fuel. END OF WORK PACKAGE 0050-1/2 blank Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. 1. If oil dipstick shows signs of contaminants, notify Field Maintenance. 2. If oil dipstick shows no signs of contaminants, notify Field Maintenance. TM 5-3805-294-10 0051 OPERATOR MAINTENANCE ENGINE IDLES POORLY INITIAL SETUP: References WP 0005 WP 0007 WP 0009 WP 0077 References (cont.) WP 0086 WP 0087 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Idles Poorly. Malfunction 1. 2. Warning Lights and Alarms are Present. Fuel Filter/Water Separators Contain Water or Sediment. Test or Inspection 1. Start engine. (WP 0007) If engine does not immediately idle poorly, allow engine to run until engine starts to exhibit poor idle symptoms. 2. Observe monitor (WP 0005) for warning lights and alarms. 3. Shut down engine. (WP 0009) 1. Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) 2. Start engine. (WP 0007) 0051-1 Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If any other warning lights and alarms are present, notify Field Maintenance. 3. If no warning lights and alarms are present, proceed to Malfunction 2. 1. If engine idles properly, malfunction corrected. 2. If engine idles poorly, proceed to Malfunction 3. TM 5-3805-294-10 0051 Table 1. Engine Idles Poorly - Continued. Malfunction 3. Leaking Fuel Lines and Fittings. Test or Inspection 1. Shut down engine. (WP 0009) 2. Visually inspect fuel lines and fittings for leakage. (WP 0077) END OF WORK PACKAGE 0051-2 Corrective Action 1. If fuel lines and fittings are leaking, notify Field Maintenance. 2. If fuel lines and fittings are not leaking, notify Field Maintenance. TM 5-3805-294-10 0052 OPERATOR MAINTENANCE AUTO-IDLE DOES NOT WORK INITIAL SETUP: References WP 0004 WP 0005 WP 0009 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Auto-Idle Does Not Work. Malfunction 1. 2. 3. Engine Speed Does Not Lower With Auto-Idle (A. I.) Turned ON. Auto-Idle (A. I.) Indicator Not Displayed On Monitor. Hydraulic Operations Being Performed. Test or Inspection 1. Turn engine speed dial to high idle position (H). (WP 0004) 2. Turn A.I. switch to ON position. (WP 0004) Verify A.I. indicator is displayed on monitor. (WP 0005) Verify if hydraulic operations are being performed. (WP 0004) 0052-1 Corrective Action 1. If engine speed lowers in 4 - 6 seconds, proceed to Malfunction 4. 2. If engine speed does not lower in 4 - 6 seconds, proceed to Malfunction 2. 1. If A. I. indicator is not displayed on monitor with A. I. switch in ON position, shut down engine. (WP 0009) Notify Field Maintenance. 2. If A. I. indicator is displayed on monitor, proceed to Malfunction 3. 1. If hydraulic operations are being performed, cease any hydraulic operations being performed, verify engine speed adjusts to A. I. speed within 4 - 6 seconds. (WP 0004) If engine speed does not adjust to A.I. speed within 4 - 6 seconds, shut down engine. (WP 0009) Notify Field Maintenance. TM 5-3805-294-10 0052 Table 1. Auto-Idle Does Not Work - Continued. Malfunction 4. Engine Speed Does Not Raise With Auto-Idle (A. I.) Turned ON and Hydraulic Functions Being Performed. Test or Inspection Operate hydraulic functions. (WP 0004) END OF WORK PACKAGE 0052-2 Corrective Action 2. If hydraulic operations are not being performed, shut down engine. (WP 0009) Notify Field Maintenance. 1. If engine speed raises, no fault at this time. Shut down engine. (WP 0009) 2. If engine speed does not raise, shut down engine. (WP 0009) Notify Field Maintenance. TM 5-3805-294-10 0053 OPERATOR MAINTENANCE ENGINE NOT DEVELOPING FULL POWER INITIAL SETUP: References WP 0005 WP 0009 References (cont.) WP 0077 WP 0087 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Engine Not Developing Full Power. Malfunction 1. 2. 3. Air Cleaners Dirty or Clogged. Exhaust Pipes Dented or Restricted. Leaking Fuel Lines or Fittings. Test or Inspection 1. Observe monitor for air cleaner clogged alarm. (WP 0005) 2. Shut down engine. (WP 0009) Visually inspect exhaust pipes and muffler for dents and restrictions. (WP 0077) Visually inspect fuel lines and fittings for leakage. (WP 0077) END OF WORK PACKAGE 0053-1/2 blank Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. 1. If exhaust pipes are dented or restricted, notify Field Maintenance. 2. If exhaust pipes are not dented or restricted, proceed to Malfunction 3. 1. If fuel lines and fittings are leaking, notify Field Maintenance. 2. If fuel lines and fittings are not leaking, notify Field Maintenance. TM 5-3805-294-10 0054 OPERATOR MAINTENANCE ENGINE OIL PRESSURE LOW INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Oil Pressure Low. Malfunction Low Engine Oil Level. Test or Inspection Check engine oil level. (WP 0077) END OF WORK PACKAGE 0054-1/2 blank Corrective Action 1. If engine oil level is low, service machine. (WP 0077) 2. If engine oil level is full, notify Field Maintenance. TM 5-3805-294-10 0055 OPERATOR MAINTENANCE ENGINE COOLANT TEMPERATURE ABOVE NORMAL INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Coolant Temperature Above Normal. Malfunction 1. 2. 3. 4. Engine Coolant Level Low. Engine Oil Level Low. Radiator Damaged or Has Foreign Objects/Debris. Surge Tank Cap is Loose. Test or Inspection Visually inspect engine coolant level. (WP 0077) Visually inspect engine oil level. (WP 0077) Visually inspect radiator for damage, foreign objects and debris. (WP 0077) Visually inspect surge tank cap for looseness or damage. (WP 0077) END OF WORK PACKAGE 0055-1/2 blank Corrective Action 1. If level is low, service radiator. (WP 0077) 2. If level is not low, proceed to Malfunction 2. 1. If level is low, service engine. (WP 0077) 2. If level is not low, proceed to Malfunction 3. 1. If radiator has foreign objects/ debris, remove foreign objects/ debris. 2. If radiator is damaged, notify Field Maintenance. 3. If radiator does not have foreign objects/debris or does not have damage, proceed to Malfunction 4. 1. If cap is loose, secure cap. 2. If cap is damaged, notify Field Maintenance. 3. If cap is not damaged or loose, notify Field Maintenance. TM 5-3805-294-10 0056 OPERATOR MAINTENANCE ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE INITIAL SETUP: References WP 0005 WP 0009 WP 0087 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Engine Emits Excessive Black Or Gray Exhaust Smoke. Malfunction Air Cleaners Dirty or Clogged. Test or Inspection 1. Observe monitor for air cleaner clogged alarm. (WP 0005) 2. Shut down engine. (WP 0009) END OF WORK PACKAGE 0056-1/2 blank Corrective Action 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) 2. If air cleaner clogged alarm is not displayed, notify Field Maintenance. TM 5-3805-294-10 0057 OPERATOR MAINTENANCE ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE INITIAL SETUP: References WP 0007 WP 0009 WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Emits Excessive White Exhaust Smoke. Malfunction 1. 2. Test or Inspection Oil Shows Signs Of Contamination. White Exhaust Smoke Excessive at Normal Operating Temperature. Visually inspect engine oil dipstick for coolant or fuel contaminants. (WP 0077) Oil containing coolant will have a creamy brown appearance or oil containing fuel will be diluted and smell like fuel. 1. Operate engine to normal operating temperature. (WP 0007) 2. Observe engine exhaust. 3. Shut down engine. (WP 0009) END OF WORK PACKAGE 0057-1/2 blank Corrective Action 1. If oil dipstick shows signs of contaminants, notify Field Maintenance. 2. If oil dipstick shows no signs of contaminants, Malfunction 2. 1. If engine emits white exhaust, notify Field Maintenance. 2. If engine does not emit white exhaust, no fault at this time. TM 5-3805-294-10 0058 OPERATOR MAINTENANCE NO HYDRAULIC FUNCTIONS INITIAL SETUP: References WP 0004 WP 0009 References (cont.) WP 0077 WP 0088 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. No Hydraulic Functions. Malfunction 1. 2. Pilot Shutoff Lever in LOCK (up) Position. Hydraulic Oil Level Low. Test or Inspection 1. Place pilot shutoff lever in UNLOCKED (down) position. (WP 0004) 2. Operate control pedals and levers. (WP 0004) 3. Shut engine off. (WP 0009) Check hydraulic oil level. (WP 0077) END OF WORK PACKAGE 0058-1/2 blank Corrective Action 1. If hydraulic functions operate, malfunction corrected. 2. If hydraulic functions do not operate, proceed to Malfunction 2. 1. If hydraulic oil level is correct, notify Field Maintenance. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) TM 5-3805-294-10 0059 OPERATOR MAINTENANCE HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER INITIAL SETUP: References WP 0030 WP 0031 WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Functions Are Slow or Have Little or No Power. Malfunction 1. 2. 3. Hydraulic Oil Level Low. Hydraulic Oil Cold. Hydraulic Reservoir Fill Cap is Damaged or Missing Hardware. Test or Inspection Check hydraulic oil level. (WP 0077) Corrective Action 1. If hydraulic oil level is correct, proceed to Malfunction 2. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) Perform operating in cold weather below 5°F (-15°C) (WP 0031) or operating in cold weather 32° to 5°F (0° to -15°C). (WP 0030) 1. If hydraulic functions operate properly, malfunction corrected. 2. If hydraulic functions do not operate properly, proceed to Malfunction 3. Visually inspect hydraulic reservoir fill cap for damage or missing hardware. (WP 0077) 1. If damaged or missing hardware, notify Field Maintenance. 2. if not damaged or missing hardware, notify Field Maintenance. END OF WORK PACKAGE 0059-1/2 blank TM 5-3805-294-10 0060 OPERATOR MAINTENANCE POWER DIG DOES NOT WORK INITIAL SETUP: References WP 0077 WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Power Dig Does Not Work. Malfunction 1. 2. Solenoid Fuse Blown. Hydraulic Oil Hoses Damaged or Has Leaks. Test or Inspection 1. Remove F4 SOLENOID 10A fuse. (WP 0084) 2. Visually inspect F4 SOLENOID 10A fuse for blown fuse. Visually inspect hydraulic oil hoses for damage and leaks. (WP 0077) END OF WORK PACKAGE 0060-1/2 blank Corrective Action 1. If fuse blown, replace F4 SOLENOID 10A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 2. 1. If damaged or leaking, notify Field Maintenance. 2. If not damaged or leaking, notify Field Maintenance. TM 5-3805-294-10 0061 OPERATOR MAINTENANCE HYDRAULIC OIL OVERHEATS INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Oil Overheats. Malfunction 1. 2. Cooling Package Has Damage, Foreign Objects/ Debris. Hydraulic Oil Level Low. Test or Inspection Visually inspect cooling package for damage, foreign objects/debris. (WP 0077) Check hydraulic oil level. (WP 0077) END OF WORK PACKAGE 0061-1/2 blank Corrective Action 1. If damaged, notify Field Maintenance. 2. If not damaged but has foreign objects/debris, remove foreign objects/debris. 3. If not damaged and does not have foreign objects/debris, proceed to Malfunction 2. 1. If hydraulic oil level is correct, notify Field Maintenance. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) TM 5-3805-294-10 0062 OPERATOR MAINTENANCE HYDRAULIC OIL FOAMS INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Oil Foams. Malfunction 1. 2. Hydraulic Oil Level Low. Hydraulic Oil Hoses are Damaged. Test or Inspection Check hydraulic oil level. (WP 0077) Visually inspect hydraulic oil hoses for damage. (WP 0077) END OF WORK PACKAGE 0062-1/2 blank Corrective Action 1. If hydraulic oil level is correct, proceed to Malfunction 2. 2. If hydraulic oil level is low, fill oil to proper level. (WP 0088) 3. If hydraulic oil level is high, notify Field Maintenance. 1. If hydraulic oil hoses are damaged, notify Field Maintenance. 2. If hydraulic oil hoses are not damaged, notify Field Maintenance. TM 5-3805-294-10 0063 OPERATOR MAINTENANCE NO SWING FUNCTION INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. No Swing Function. Malfunction Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) END OF WORK PACKAGE 0063-1/2 blank Corrective Action 1. If hydraulic oil level is correct, notify Field Maintenance. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) TM 5-3805-294-10 0064 OPERATOR MAINTENANCE SWING FUNCTION IS JERKY INITIAL SETUP: References LO 5-3805-294-13 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Swing Function Is Jerky. Malfunction Lack of Grease in Swing Bearing. Test or Inspection Visually inspect swing bearing grease fittings (LO 5-3805-294-13). (WP 0094) END OF WORK PACKAGE 0064-1/2 blank Corrective Action 1. If swing bearing lacks grease, lubricate swing bearing grease fittings (LO 5-3805-294-13). (WP 0094) 2. If swing bearing does not lack grease, notify Field Maintenance. TM 5-3805-294-10 0065 OPERATOR MAINTENANCE SLOW TRAVEL SPEED ONLY INITIAL SETUP: References WP 0077 WP 0084 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Slow Travel Speed Only. Malfunction 1. 2. Solenoid Fuse Blown. Hydraulic Oil Level Low. Test or Inspection 1. Remove F4 SOLENOID 10A fuse. (WP 0084) 2. Visually inspect F4 SOLENOID 10A fuse for blown fuse. Check hydraulic oil level. (WP 0077) END OF WORK PACKAGE 0065-1/2 blank Corrective Action 1. If fuse blown, replace F4 SOLENOID 10A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 2. 1. If hydraulic oil level is correct, notify Field Maintenance. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) TM 5-3805-294-10 0066 OPERATOR MAINTENANCE TRAVEL IS JERKY INITIAL SETUP: References WP 0077 WP 0080 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Travel is Jerky. Malfunction 1. 2. Incorrect Track Chain Tension. Debris in Track Frame. Test or Inspection Check track chain sag. (WP 0080) Visually inspect track frame for jammed debris. (WP 0077) END OF WORK PACKAGE 0066-1/2 blank Corrective Action 1. If track chain sag is within specification, proceed to Malfunction 2. 2. If track chain sag is not within specification, adjust track chain tension. (WP 0080) 1. If jammed with debris, remove debris. 2. If not jammed with debris, notify Field Maintenance. TM 5-3805-294-10 0067 OPERATOR MAINTENANCE ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED INITIAL SETUP: References WP 0007 WP 0008 WP 0086 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Engine Stops When Travel or Control Lever Actuated. Malfunction Fuel Filter/Water Separators Contain Water or Sediment. Test or Inspection 1. Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) 2. Start engine. (WP 0007) 3. Move HYEX. (WP 0008) END OF WORK PACKAGE 0067-1/2 blank Corrective Action 1. If engine stops when either control lever is actuated, notify Field Maintenance. 2. If engine stops when travel is actuated, notify Field Maintenance. 3. If engine does not stop while moving, malfunction corrected. TM 5-3805-294-10 0068 OPERATOR MAINTENANCE QUICK LATCH DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0014 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Quick Latch Does Not Operate. Malfunction 1. 2. 3. Quick Latch Switch Does not Operate. Test or Inspection 1. Set quick latch switch to UNLATCH position. (WP 0014) 2. Observe quick latch warning light and alarm. 3. Observe quick latch for movement. Safety Lock Pin Lever in Locked Position. Quick Hitch Fuse Blown. Check quick latch safety lock pin lever position. (WP 0014) 1. Shut down engine. (WP 0009) 2. Remove F26 QUICK HITCH 5A fuse. (WP 0084) 3. Visually inspect F26 QUICK HITCH 5A fuse for blown fuse. 0068-1 Corrective Action 1. If warning light and alarm are off, notify Field Maintenance. 2. If warning light and alarm is on, proceed to Malfunction 2. 1. If in locked position, place quick latch safety lock pin lever in unlocked position. (WP 0014) 2. If in unlocked position, proceed to Malfunction 3. 1. If fuse blown, replace F26 QUICK HITCH 5A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 4. TM 5-3805-294-10 0068 Table 1. Quick Latch Does Not Operate - Continued. Malfunction 4. Quick Latch Has Jammed Debris. Test or Inspection Visually inspect quick latch for jammed debris. (WP 0077) END OF WORK PACKAGE 0068-2 Corrective Action 1. If quick latch does have jammed debris, remove jammed debris. (WP 0077) 2. If quick latch does not have jammed debris, notify Field Maintenance. TM 5-3805-294-10 0069 OPERATOR MAINTENANCE COMPACTOR DOES NOT OPERATE INITIAL SETUP: References WP 0077 WP 0020 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Compactor Does Not Operate. Malfunction 1. 2. 3. Hydraulic Supply Quick Disconnect Not Fully Seated. Hydraulic Return Quick Disconnect Not Fully Seated. Compactor Has Jammed Debris. Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0077) Visually inspect hydraulic return quick disconnect. (WP 0077) Visually inspect compactor for jammed debris. (WP 0077) END OF WORK PACKAGE 0069-1/2 blank Corrective Action 1. If quick disconnect is fully seated, proceed to Malfunction 2. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. 1. If quick disconnect is fully seated, proceed to Malfunction 3. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. 1. If compactor does have jammed debris, remove jammed debris. (WP 0077) 2. If compactor does not have jammed debris, notify Field Maintenance. TM 5-3805-294-10 0070 OPERATOR MAINTENANCE BREAKER DOES NOT OPERATE INITIAL SETUP: References WP 0020 WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Breaker Does Not Operate. Malfunction 1. 2. 3. Hydraulic Supply Quick Disconnect Not Fully Seated. Hydraulic Return Quick Disconnect Not Fully Seated. Breaker Has Jammed Debris. Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0077) Visually inspect hydraulic return quick disconnect. (WP 0077) Visually inspect breaker for jammed debris. (WP 0077) END OF WORK PACKAGE 0070-1/2 blank Corrective Action 1. If quick disconnect is fully seated, proceed to Malfunction 2. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. 1. If quick disconnect is fully seated, proceed to Malfunction 3. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. 1. If breaker does have jammed debris, remove jammed debris. (WP 0077) 2. If breaker does not have jammed debris, notify Field Maintenance. TM 5-3805-294-10 0071 OPERATOR MAINTENANCE BREAKER OPERATES SLOWLY INITIAL SETUP: References WP 0009 WP 0018 References (cont.) WP 0077 WP 0088 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Breaker Operates Slowly. Malfunction 1. 2. 3. Test or Inspection Breaker Attachment Not Selected. Hydraulic Supply Hose is Damaged or Has Leaks. Hydraulic Return Hose is Damaged or Has Leaks. Check attachment selection on monitor. (WP 0018) 1. Shut down engine. (WP 0009) 2. Visually inspect hydraulic supply hose. (WP 0077) Visually inspect hydraulic return hose. (WP 0077) 0071-1 Corrective Action 1. If breaker attachment is selected, proceed to Malfunction 2. 2. If breaker attachment is not selected, select breaker attachment on monitor. (WP 0018) 1. If hydraulic supply hose is damaged or leaking, notify Field Maintenance. 2. If hydraulic supply hose is not damaged or leaking, proceed to Malfunction 3. 1. If hydraulic return hose is damaged or leaking, notify Field Maintenance. 2. If hydraulic return hose is not damaged or leaking, proceed to Malfunction 4. TM 5-3805-294-10 0071 Table 1. Breaker Operates Slowly - Continued. Malfunction 4. Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) END OF WORK PACKAGE 0071-2 Corrective Action 1. If hydraulic oil level is correct, notify Field Maintenance. 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) TM 5-3805-294-10 0072 OPERATOR MAINTENANCE CRUSH-ALL DOES NOT OPERATE INITIAL SETUP: References WP 0020 WP 0077 WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Crush-All Does Not Operate. Malfunction 1. 2. 3. 12-Volt Power Outlet Fuse Blown. Hydraulic Supply Quick Disconnect Not Fully Seated. Hydraulic Return Quick Disconnect Not Fully Seated. Test or Inspection 1. Remove F6 OPT.2 (ALT) 10A fuse. (WP 0084) 2. Visually inspect F6 OPT.2 (ALT) 10A fuse for blown fuse. Visually inspect hydraulic supply quick disconnect. (WP 0077) Visually inspect hydraulic return quick disconnect. (WP 0077) 0072-1 Corrective Action 1. If fuse blown, replace F6 OPT. 2 (ALT) 10A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 2. 1. If quick disconnect is fully seated, proceed to Malfunction 3. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. 1. If quick disconnect is fully seated, proceed to Malfunction 4. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) 3. If quick disconnect is damaged, notify Field Maintenance. TM 5-3805-294-10 0072 Table 1. Crush-All Does Not Operate - Continued. Malfunction 4. Crush-All Has Jammed Debris. Test or Inspection Visually inspect crush-all for jammed debris. (WP 0077) END OF WORK PACKAGE 0072-2 Corrective Action 1. If crush-all does have jammed debris, remove jammed debris. (WP 0077) 2. If crush-all does not have jammed debris, notify Field Maintenance. TM 5-3805-294-10 0073 OPERATOR MAINTENANCE BARRIER GRAPPLE DOES NOT HOLD LOAD INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Barrier Grapple Does Not Hold Load. Malfunction Grip pads worn. Test or Inspection Visually inspect grip pads. (WP 0077) END OF WORK PACKAGE 0073-1/2 blank Corrective Action 1. If grip pads worn, notify Field Maintenance. 2. If grip pads not worn, notify Field Maintenance. TM 5-3805-294-10 0074 OPERATOR MAINTENANCE DEEP DIG DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0023 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Deep Dig Does Not Operate. Malfunction 1. 2. 3. Test or Inspection Deep Dig Control Pattern Switch is OFF. Cab Auxiliary Power Connector One Fuse Blown. Hydraulic Supply Quick Disconnect Not Fully Seated. Check deep dig control pattern switch position. (WP 0023) 1. Shut down engine. (WP 0009) 2. Remove F13 AUX 10A fuse. (WP 0084) 3. Visually inspect F13 AUX 10A fuse for blown fuse. 1. Visually inspect hydraulic supply quick disconnect. (WP 0077) 2. Visually inspect hydraulic return quick disconnect. (WP 0077) 3. Visually inspect hydraulic supply hose for damage. (WP 0077) 0074-1 Corrective Action 1. If switch is OFF, set deep dig control pattern switch to ON. (WP 0023) 2. If switch is ON, proceed to Malfunction 2. 1. If fuse blown, replace F13 AUX 10A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 3. TM 5-3805-294-10 0074 Table 1. Deep Dig Does Not Operate - Continued. Malfunction Test or Inspection 4. Visually inspect hydraulic return hose for damage. (WP 0077) END OF WORK PACKAGE 0074-2 Corrective Action 1. If quick disconnect(s) is not fully seated, reconnect quick disconnect properly. (WP 0023) 2. If quick disconnect(s) is damaged, notify Field Maintenance. 3. If hose(s) is damaged, notify Field Maintenance. 4. If quick disconnects are fully seated and hoses are not damaged, notify Field Maintenance. TM 5-3805-294-10 0075 OPERATOR MAINTENANCE HYDRAULIC HOSE REEL DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0026 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Hose Reel Does Not Operate. Malfunction 1. 2. 3. Test or Inspection Hand Held Hydraulic Tool Circuit Switch is OFF. Cab Auxiliary Power Connector One Fuse Blown. Hydraulic Supply Quick Disconnect Not Fully Seated. Check hand held hydraulic tool circuit switch position. (WP 0026) 1. Shut down engine. (WP 0009) 2. Remove F13 AUX 10A fuse. (WP 0084) 3. Visually inspect F13 AUX 10A fuse for blown fuse. Visually inspect hydraulic supply quick disconnect. (WP 0077) 0075-1 Corrective Action 1. If switch is OFF, set hand held hydraulic tool circuit switch to ON. (WP 0026) 2. If switch is ON, proceed to Malfunction 2. 1. If fuse blown, replace F13 AUX 10A fuse. (WP 0084) 2. If fuse not blown, proceed to Malfunction 3. 1. If quick disconnect is fully seated, proceed to Malfunction 4. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0026) 3. If quick disconnect is damaged, notify Field Maintenance. TM 5-3805-294-10 0075 Table 1. Hydraulic Hose Reel Does Not Operate - Continued. Malfunction 4. 5. 6. Hydraulic Return Quick Disconnect Not Fully Seated. Test or Inspection Visually inspect hydraulic return quick disconnect. (WP 0077) Corrective Action 1. If quick disconnect is fully seated, proceed to Malfunction 5. 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0026) 3. If quick disconnect is damaged, notify Field Maintenance. Hydraulic Tool Supply Hose Has Damage. Visually inspect hydraulic tool supply hose for damage. (WP 0077) 1. If hose is not damaged, proceed to Malfunction 6. 2. If hose is damaged, notify Field Maintenance. Hydraulic Tool Return Hose Has Damage. Visually inspect hydraulic tool return hose for damage. (WP 0077) 1. If hose is not damaged, notify Field Maintenance. 2. If hose is damaged, notify Field Maintenance. END OF WORK PACKAGE 0075-2 TM 5-3805-294-10 CHAPTER 4 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0076 OPERATOR MAINTENANCE INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES NOTE • If the machine has reached the initial 250 hours of operation, contact field level maintenance to perform the initial 250 hour service. • Tools supplied on the machine are to be used for Preventive Maintenance Checks and Services (PMCS). Rags are also required for removing dirt and grease. • PMCS intervals should be performed more frequently when operating under unusual conditions. • Perform PMCS on attachments only if they are to be used for the current mission. This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The PMCS tables contain checks and services necessary to ensure that the machine is ready for operation. Maintenance is performed at specified intervals using the PMCS tables. Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable. Components in good condition are: not bent or twisted, chafed or burned, broken, or cracked. There should be no signs of wear, fraying, dents, collapsing, tears, cuts, or deterioration. Damage is any condition that affects safety or prevents a part or assembly from functioning normally or would render the machine unserviceable for mission requirements. MAINTENANCE RECORDS AND FORMS Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The completed forms and records have several uses. They are a permanent record of services, repairs, and modifications made to the machine. They are reports to maintenance personnel, and to the Commander. They serve as a checklist to track previous machine malfunctions and repair actions. Record results of PMCS on DA Form 2404, Equipment Inspection and Maintenance Worksheet, or DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet. For the information needed on forms and records, refer to DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual. GENERAL MAINTENANCE PROCEDURES • Cleanliness: Dirt, grease, oil, and debris can conceal serious problems. Use solvent cleaning compound on all metal surfaces and soapy water on rubber or plastic surfaces. • Bolts, Nuts, and Screws: Check for loose bolts, nuts, and screws, as well as for those that are missing, bent, or broken. Tighten or replace as necessary. If parts cannot be checked with a tool, look for signs of chipped paint, bare metal, or rust around bolt heads. • Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a damaged weld is discovered, notify Field Level Maintenance. • Electric Wires and Connectors: Look for cracked or broken insulation, exposed wires, and loose or broken connectors. Tighten loose connectors and ensure wires are in good shape. • Fluid Hoses, Tubes, and Fittings: Look for wear, damage, or leaks. Ensure clamps and fittings are tight. Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If connectors or fittings are loose or if hoses, tubes, or fittings are broken or worn out, notify Field Level Maintenance. 0076-1 TM 5-3805-294-10 0076 WARNINGS AND CAUTIONS Always observe the warnings and cautions appearing in your PMCS table. Warnings and cautions appear before the applicable procedure. You must observe these warnings and cautions to prevent serious injury to personnel or to prevent damage to the equipment. ARMY OIL ANALYSIS PROGRAM (AOAP) The engine and hydraulic oil and filters replacement are governed by the AOAP program. Samples for the engine are taken every 90 days and once yearly for the hydraulic system. If sampling is not feasible due to mission, then hard time intervals apply for oil and filter changes. LUBRICATION INSTRUCTIONS • During adverse weather or unusually dusty conditions, lubrication may be required on a daily basis. • After fording operations, lubricate all lubrication points below fording line. • For detailed lubrication instructions, refer to: LO 5-3805-294-13 Lubrication Instructions for the Hydraulic Excavator (HYEX). PMCS COLUMN DESCRIPTION The PMCS table columns are described as follows: Item Number The order that the PMCS should be performed. Use the item number when recording results on the DA Form 2404, Equipment Inspection and Maintenance Worksheet or the DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet. Interval Lists the interval at which the check or service is to be performed. Item to be Inspected Lists the item being checked or serviced. Procedures Describes the procedure for the check or service. Equipment Not Ready or Available If Describes a condition that renders the machine not mission capable. 0076-2 TM 5-3805-294-10 0076 Types of Preventive Maintenance Checks and Services (PMCS) For each service interval, perform all checks and services listed and all checks and services associated with any lower service interval. • Before: Do the Before (B) PMCS before operating the machine. Pay attention to the WARNINGS and CAUTIONS. • During: Do the During (D) PMCS while machine or its components are in operation. Pay attention to the WARNINGS and CAUTIONS. • After: Do the After (A) PMCS after operating the machine. Pay attention to the WARNINGS and CAUTIONS. • Monthly: Do the Monthly (M) PMCS once a month on the machine. Pay attention to the WARNINGS and CAUTIONS. Always perform PMCS in the same order, every time. Once practiced, problems can be spotted quickly. If an item or component being inspected is inoperable or damaged, either troubleshoot by following instructions in the Troubleshooting Section of this manual or repair and/or replace as described in the related maintenance task. If there appears to be a malfunction that cannot be repaired immediately, complete either DA Form 2404,or DA Form 5988-E. FLUID LEAKAGE • Class I: Seepage of fluid (as indicated by wetness or discoloration) not sufficient enough to form drops. • Class II: Leakage of fluid sufficient enough to form drops, but not sufficient enough to cause the drops to drip from the item being inspected. • Class III: Leakage of fluid sufficient enough to form drops that fall from the item being inspected. END OF WORK PACKAGE 0076-3/4 blank TM 5-3805-294-10 0077 OPERATOR MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INITIAL SETUP: Materials/Parts Antifreeze, Arctic Type (WP 0097, Table 1, Item 1) Antifreeze (WP 0097, Table 1, Item 2) Engine Oil (WP 0097, Table 1, Item 13) Gloves (WP 0097, Table 1, Item 10) Goggles (WP 0097, Table 1, Item 10) Grease (WP 0097, Table 1, Item 10) Penetrating Oil (WP 0097, Table 1, Item 14) Rags, Wiping (WP 0097, Table 1, Item 15) References LO 5-3805-294-13 (WP 0094) Table 1. ITEM NO. INTERVAL References (cont.) TM 5-3805-295-13&P (WP 0094) WP 0007 WP 0009 WP 0034 WP 0080 WP 0085 WP 0087 WP 0088 WP 0089 WP 0090 WP 0091 WP 0094 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES ITEM TO BE CHECKED OR SERVICED PROCEDURE WARNING Personnel hearing can be permanently damaged if exposed to constant high noise levels of 85 dB or greater. Failure to comply may result in injury to personnel. WARNING Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in 0077-1 EQUIPMENT NOT READY/ AVAILABLE IF: TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE the up position, and engine shut off. Failure to comply may result in injury or death to personnel. WARNING Ensure electrical power is off prior to working on all electrical connections. Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel. CAUTION New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine. NOTE Perform Operator's Before PMCS checks if: • You are the assigned operator but have not operated the machine since the last PMCS was performed. 0077-2 EQUIPMENT NOT READY/ AVAILABLE IF: TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED INTERVAL EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE • You are operating the machine for the first time. • Only perform PMCS on attachments if they are to be operated for current mission. • The lubrication order is to be used in conjunction with the PMCS. • For Armored Cab PMCS, refer to TM 5-3805-295-13&P. 1 Before Exterior of Machine Perform walk-around inspection of the machine exterior. Check on ground under machine (Figure 1, Item 1) for evidence of fluid leakage such as oil, coolant, or fuel. Class III oil or coolant leaks. Any fuel leakage is evident. Check machine (Figure 1, Item 1) for obvious damage that would impair operation. Damage that would impair operation is evident. 3 1 4 Figure 1. 2 Exterior of Machine. 0077-3 HYEX01001 TM 5-3805-294-10 Table 1. ITEM NO. 2 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED INTERVAL Before Left and Right Track Chain and Rollers EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Check for loose or missing track shoe (Figure 2, Item 2) and track bolts. Loose or missing track shoe. One or more bolts missing from track shoe. 3 1 4 2 HYEX01001 Figure 2. Exterior of Machine Continued. 3 Before Coolant Surge Tank Check for oil leakage from carrier roller (Figure 2, Item 3) or support rollers (Figure 2, Item 4). Oil leaking from carrier roller or support roller. Check that coolant is at the MIN COLD line (Figure 3, Item 5) on the surge tank (Figure 3, Item 6). Coolant level below MIN COLD level. 0077-4 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 7 6 Figure 3. 5 HYEX01002 Coolant Level. If coolant is low, remove surge tank cap (Figure 3, Item 7) and fill as required. 4 Before Engine Oil Level Check that the surge tank (Figure 3, Item 6) is not damaged. Surge tank has a Class III leak. Check that surge tank cap (Figure 3, Item 7) is present and is not broken or cracked. Cap is missing or is unserviceable. Check oil level on the dipstick (Figure 4, Item 8) and ensure that it is between the ADD and FULL marks. Engine oil level below the ADD mark or engine oil is overfull. 0077-5 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 8 9 HYEX01003 Figure 4. Engine Oil. If engine oil is low, remove cap (Figure 4, Item 9) and add oil as required (LO 5-3805-294-13). (WP 0094) 5 Before Engine Compartment Check engine compartment for obvious damage or leaks in hoses or lines. Any damage that would impair safe operation of the machine. 6 Before Exhaust Components Check exhaust components for leaks, loose parts, dents, or damage. Loose, leaking, or damaged components. 0077-6 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE HYEX03409 Exhaust Components. Figure 5. 7 Before Hydraulic Reservoir Cap 11 Press button (Figure 6, Item 10) on hydraulic reservoir cap (Figure 6, Item 11) to ensure that it is operational and that cap is not broken. Hydraulic reservoir cap is broken, missing, or button cannot be pressed. 10 HYEX01004 Figure 6. 8 Before Fuel Tank Hydraulic Reservoir Cap. Check fuel tank (Figure 7, Item 12) for evidence of leaks. 0077-7 Any signs of leaks from fuel tank. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 14 13 12 HYEX01005 Figure 7. Fuel Tank and Fuel Level. Ensure fuel tank is full. To fill fuel tank: • Remove fuel cap (Figure 7, Item 13). • Fill fuel tank (Figure 7, Item 12) until band (Figure 7, Item 14) is visible. • Install fuel cap (Figure 7, Item 13). 9 Before Fuel Filters Check primary fuel filter (Figure 8, Item 15), fuel/water separator (Figure 8, Item 16), and fuel lubricity filter (Figure 8, Item 17) for evidence of leaks. 0077-8 Any fuel leak. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 16 15 18 17 HYEX01006 Figure 8. Fuel Filters. 10 Before Hydraulic Oil Filter Check hydraulic oil filter (Figure 8, Item 18) for evidence of leaks. Any Class III leak. 11 Before Hydraulic Pump Compartment Check hydraulic pump compartment for obvious damage or leaks in lines or hoses. Any damage that would impair safe operation of machine. 12 Before Engine Oil Filter Check engine oil filter (Figure 9, Item 19) for evidence of leaks. Any Class III leak. 19 HYEX01007 Figure 9. Engine Oil Filter. 0077-9 TM 5-3805-294-10 Table 1. ITEM NO. 13 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL Before 0077 ITEM TO BE CHECKED OR SERVICED Boom, Arm, Quick Latch, Hydraulic Thumb EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Check boom (Figure 10, Item 20), arm (Figure 10, Item 21), quick latch (Figure 10, Item 22), and hydraulic thumb (Figure 10, Item 23) for damage that would impair operation. 24 Damage that impairs proper operation. 27 20 25 26 23 21 24 26 24 22 24 HYEX01008 Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb. Check cylinders (Figure 10, Item 24) for leaks. Any Class III leak. Check hydraulic lines (Figure 10, Item 25) and hoses (Figure 10, Item 26) for leaks. Any Class III leak. Check for presence of hydraulic thumb pin (Figure 10, Item 27). 14 Before NOTE Bucket Only check bucket or attachment to be used for current mission. Check bucket (Figure 11, Item 28) for cracks and missing teeth. 0077-10 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Replace teeth as required. (WP 0085) 28 HYEX01009 Figure 11. 15 Before Primary and Secondary Air Cleaner Housing Bucket and Teeth. Check bucket for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. Inspect and clean primary and secondary air cleaner housing (Figure 12, Item 29) for damage or missing parts. (WP 0087) Primary and secondary air cleaner housing cracked or cover missing. 0077-11 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 29 30 33 32 31 HYEX01395 Figure 12. Air Cleaner Housing and Hose Reel. Squeeze ejector (Figure 12, Item 30) to remove dust. 16 Before Hose Reel, Hoses, Deep Dig Control Switch, and Hand Held Hydraulic Switch Check deep dig control pattern switch (Figure 12, Item 31) to ensure it is in the OFF position. If deep dig arm is installed, ensure that deep dig control pattern switch (Figure 12, Item 31) is in the ON position. Any lines are cracked, frayed, or broken. Check hydraulic hand held tool circuit switch (Figure 12, Item 32) to ensure it is in the OFF position. Check hydraulic hose reel and hoses (Figure 12, Item 33) for damage and leaks. 0077-12 Any class III leak. TM 5-3805-294-10 Table 1. ITEM NO. 17 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE Before Batteries WARNING EQUIPMENT NOT READY/ AVAILABLE IF: LEAD-ACID BATTERIES Remove four wing nuts (Figure 13, Item 34), washers (Figure 13, Item 35), and two covers (Figure 13, Item 36) from batteries (Figure 13, Item 37). Check batteries (Figure 13, Item 37) for leaks or cracks. Batteries show signs of leaking or have cracks. 40 41 36 34, 35 37 38 Figure 13. 39 HYEX01011 Batteries. Check battery cables (Figure 13, Item 38) for looseness. Install two covers (Figure 13, Item 36) to batteries (Figure 13, Item 37) with four wing nuts (Figure 13, Item 0077-13 Battery cables are loose. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 34) and washers (Figure 13, Item 35). 18 Before Cooling Package Check cooling package (Figure 13, Item 39) for leaks and damage. Any Class III coolant leak. 19 Before Fuel Cooler Check fuel cooler (Figure 14, Item 40) and fuel lines for leaks. Any fuel leak. 40 41 36 34, 35 37 Figure 14. 38 39 HYEX01011 Batteries Continued. Check windshield washer reservoir (Figure 14, Item 41) for fluid and damage. Fill as required. 20 Before Cab Glass Check cooling compartment for obvious damage or leaks. Any damage that would impair safe operation of the machine. Any fuel leak or class III fluid leaks. Check cab glass (Figure 15, Item 42) for cracks or chips. Any broken glass that impairs the operators vision. Any glass missing. 0077-14 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 42 42 42 42 HYEX01012 Figure 15. 21 Before Mirrors, Wiper, and Operator Protection Guard Cab Glass. Check that mirrors (Figure 16, Item 43) are present and serviceable. 43 43 45 44 HYEX01396 Figure 16. Mirrors and Wiper Arm. Check that operator protection guard (Figure 16, Item 44) is present and serviceable. 0077-15 Operator protection guard missing. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Check that wiper arm and blade (Figure 16, Item 45) are serviceable. 22 Before Door, Door Hinges, and Latches Check that hinges (Figure 17, Item 46) allow door (Figure 17, Item 47) to swing freely. 46 Door is difficult to open or close. 47 48 48 46 HYEX03430 Figure 17. 23 Before Fire Extinguisher Cab Door, Hinges, and Latches. Check that door (Figure 17, Item 47) and latches (Figure 17, Item 48) lock and release in open and closed positions. Door fails to latch or latches fail to release. Check that fire extinguisher (Figure 18, Item 49) is present and is fully charged. Fire extinguisher is missing, has been discharged, or has an expired date of service. 0077-16 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 49 HYEX01013 Figure 18. 24 Before Cab Pedals and Levers Fire Extinguisher. Check that left and right travel pedal and lever (Figure 19, Item 50) move freely through their full range of travel. 0077-17 Left or right travel pedal or lever are binding or do not move freely through full range of travel. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL 50 ITEM TO BE CHECKED OR SERVICED 50 EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 50 50 51 52 HYEX01399 Figure 19. 25 Before Pilot Control Levers Pedals and Levers. Check that attachment pedal (Figure 19, Item 51) moves freely through range of travel and attachment pedal lock (Figure 19, Item 52) is operational. Attachment pedal does not move freely or attachment pedal lock does not operate. Check left (Figure 20, Item 53) and right (Figure 20, Item 54) pilot control levers to ensure that they move freely through full range of motion. Left or right pilot control lever binds or will not move through full range of motion. 0077-18 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 54 53 HYEX01397 Figure 20. Pilot Control Levers. 26 Before Horn Press horn button to ensure horn sounds. Horn does not sound. 27 Before Seat Belt Check that seat belt (Figure 21, Item 55) is not frayed and fastens together. Seat belt is frayed or will not fasten together. 0077-19 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 55 HYEX01398 Figure 21. 28 Before Monitor Seat Belt. Turn ignition switch (Figure 22, Item 56) to ON position. 56 HYEX01014 Figure 22. Ignition Switch. 0077-20 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: NOTE If default screen is not displayed after start up screen, wait 10 seconds to ensure default screen will be displayed. Check that monitor (Figure 23, Item 57) comes on, then goes to default screen. Monitor does not come on. Monitor does not go to default screen. 57 System Starting... 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01015 Figure 23. Monitor. 29 Before Starter Start engine. (WP 0007) Engine does not start or starter makes unusual noises. 30 Before Lights Check that all lights operate. Lights do not operate. 31 Before Wipers and Washer Fluid Check that wipers and washer pump works and has fluid. Wipers do not operate. 32 Before Hydraulic Oil Level To check hydraulic oil level: • Fully extend arm (Figure 24, Item 58). Sight glass has class III leak. 0077-21 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: • Curl bucket (Figure 24, Item 59). • Lower boom (Figure 24, Item 60) until bucket is resting on the ground. 60 58 59 Figure 24. HYEX01016 Position Boom and Arm. 61 HYEX01017 Figure 25. Hydraulic Oil Level Check. To fill hydraulic reservoir: • Open right door and ensure that hydraulic oil is between marks on sight glass (Figure 25, Item 61). Fill as required. •Shut down engine. (WP 0009) •Service hydraulic reservoir. (WP 0088) 0077-22 Reservoir is empty. Sight glass is broken or damaged. Any Class III leaks. TM 5-3805-294-10 Table 1. ITEM NO. 33 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED Before Breaker EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE NOTE Only perform PMCS on attachments that are required for current mission. Check breaker (Figure 26, Item 62) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. 63 HYEX01018 62 Figure 26. 34 Before Compactor Breaker. Check breaker hydraulic hoses (Figure 26, Item 63) for leaks and breaker for problems that would impair operation. Any class III leak. Check compactor (Figure 27, Item 64) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. 0077-23 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 65 64 HYEX01019 Figure 27. 35 Before Crush-All Compactor. Check compactor hydraulic hoses (Figure 27, Item 65) for leaks and compactor for problems that would impair operation. Any class III leak. Check crush-all (Figure 28, Item 66) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. 0077-24 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE 66 Figure 28. 67 EQUIPMENT NOT READY/ AVAILABLE IF: HYEX01020 Crush-All. Check hydraulic hoses (Figure 28, Item 67) for leaks and crush-all for problems that would impair operation. 36 Before Lubricate Lubricate crush-all daily before each use (LO 5-3805-294-13). (WP 0094) 37 Before Barrier Grapple Check barrier grapple (Figure 29, Item 68) for loose, broken, or missing hardware or mounting bracket damage. 0077-25 Any class III leak. Loose, broken, or missing hardware or mounting bracket is cracked. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 69 68 HYEX02987 Figure 29. Barrier Grapple. Check barrier grapple for missing or damaged pads. Barrier grapple pad missing or damaged. Check that barrier grapple lifting device (Figure 29, Item 69) does not have broken strands. Barrier grapple cable is kinked or three or more strands are broken. 38 Before Barrier Grapple Actuator Lubricate actuator before use with penetrating oil. 39 Before Deep Dig Arm Check deep dig arm (Figure 30, Item 70) for loose, broken, or missing hardware or damage. 0077-26 Any loose, broken, or missing hardware or damage. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 72 71 70 HYEX01306 Figure 30. 40 Before Deep Dig Bucket Deep Dig Arm and Bucket. Check deep dig arm hydraulic hoses (Figure 30, Item 71) for leaks, damage, or fraying. Any class III leak. Check deep dig ditch cleaning bucket (Figure 30, Item 72) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. Check bucket (Figure 31, Item 73) for cracks and missing teeth. Replace teeth as required. (WP 0085) 0077-27 TM 5-3805-294-10 Table 1. ITEM NO. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED 73 Before PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: HYEX01307 Figure 31. 41 0077 Ditch Cleaning Bucket Deep Dig Bucket. Check bucket (Figure 31, Item 73) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. Check bucket (Figure 32, Item 74) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. 0077-28 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 74 HYEX01308 Figure 32. Ditch Cleaning Bucket. 42 During Monitor Check monitor during operation for any alarm. If alarm sounds or is displayed on monitor, perform corrective procedures as needed or shut down engine. (WP 0009) Any alarm sounds or is displayed on monitor. 43 During Engine speed Dial Turn engine speed dial and ensure engine speed increases. Engine speed dial does not operate. 44 During Right-Hand Console Switches Operate right-hand console switches. Switches do not operate. 45 During Hydraulic Cylinders Check that all hydraulic cylinders operate smoothly and through full range of travel. Hydraulic cylinders do not operate normally or have class III leak. 46 During Travel Motor, Steering, and Brakes Travel machine forward a short distance and ensure that: • Machine travels in a straight line. •Steers left and right. •Track chain does not make any unusual or popping noises. If machine doesn't travel in a straight line. Machine does not steer left or right. Track chain makes unusual 0077-29 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE •When travel levers or pedals are released machine stops. •Travel levers and pedals return to center when released. EQUIPMENT NOT READY/ AVAILABLE IF: or popping noises. Machine does not stop when travel levers or pedals are released. Travel levers or pedals do not return to center when released. 47 During Travel Alarm Ensure travel alarm operates when machine is moved. Travel alarm does not operate. 48 During Swing Motor and Swing Brake Swing upperstructure left or right approximately 90 degrees then release pilot control levers and ensure upperstructure stops. Upperstructure does not stop or drifts. 49 During Air Conditioner/Heater Ensure air conditioner/heater blower motor operates. Blower motor does not operate when turned on. 50 During Breaker CAUTION Breaker must be lubricated every 2 hours of use and every hour during dusty conditions. Failure to comply may result in damage to the attachment. During extreme dusty conditions, lubricate breaker after every hour of use LO 5-3805-294-13. (WP 0094) 51 After Hydraulic Oil Level To check hydraulic oil level: • Fully extend arm (Figure 33, Item 58). • Curl bucket (Figure 33, Item 59). • Lower boom (Figure 33, Item 60) until bucket is resting on the ground. • Open right door and ensure that hydraulic oil is 0077-30 Sight glass has class III leak. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: between marks on sight glass (Figure 34, Item 61). Fill as required. 60 58 59 Figure 33. HYEX01016 Position Boom and Arm. 61 HYEX01017 Figure 34. Hydraulic Oil Level Check. To fill hydraulic reservoir: •Shut down engine. (WP 0009) •Service hydraulic reservoir. (WP 0088) •Start engine. (WP 0007) •Safely park and shut down engine. (WP 0009) 52 After Fuel Tank and Strainer Check fuel tank and strainer (Figure 35, Item 12) for evidence of leaks or damage. 0077-31 Any signs of leaks or damage to fuel tank or strainer, or strainer is missing. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 14 13 12 HYEX01005 Figure 35. Fuel Tank and Fuel Level Check. Ensure fuel tank is full. To fill fuel tank: • Remove fuel cap (Figure 35, Item 13). • Fill fuel tank (Figure 35, Item 12) until band (Figure 35, Item 14) is visible. • Install fuel cap (Figure 35, Item 13). 53 After CAUTION Engine Oil Level New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine. Check oil level on the dipstick (Figure 36, Item 8) and ensure that it is between the ADD and FULL marks. 0077-32 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 8 9 HYEX01003 Figure 36. Engine Oil Check. If engine oil is low, remove cap (Figure 36, Item 9) and add oil as required. 54 After Engine Compartment, Belts, and Hoses Check engine compartment for obvious damage or leaks in hoses or lines. Check belts for cuts or frays. HYEX03410 Figure 37. Engine Compartment. 0077-33 Any damage that would impair safe operation of the machine. TM 5-3805-294-10 Table 1. ITEM NO. 55 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED After Exterior of Machine EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Perform walk-around inspection of the machine exterior. Check on ground under machine (Figure 38, Item 1) for evidence of fluid leakage such as oil, coolant, or fuel. Class III oil or coolant leaks. Any fuel leakage is evident. Check machine (Figure 38, Item 1) for obvious damage that would impair operation. Damage that would impair operation is evident. 1 2 Figure 38. HYEX01400 Exterior of Machine Check. Check left and right track chains (Figure 38, Item 2) for missing shoes and mounting hardware. 56 Monthly CAUTION Swing Gearbox Oil New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine. 0077-34 Any missing track shoes or mounting hardware. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE Check that swing gearbox oil is between marks on dipstick (Figure 39, Item 75). 76 EQUIPMENT NOT READY/ AVAILABLE IF: Oil level is not on dipstick. 75 HYEX01410 Figure 39. Swing Gearbox Oil Level Check. To add oil: • Remove cap (Figure 39, Item 76). • Add oil until it is between the marks on the dipstick (Figure 39, Item 75). • Install cap (Figure 39, Item 76). 57 Monthly Hydraulic Pump Gearbox Oil Check hydraulic pump gearbox oil level on dipstick (Figure 40, Item 77). 0077-35 Oil level is below the "L" mark. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 78 L H 77 2 HYEX01409 Figure 40. Hydraulic Pump Oil Level Check. To add oil: • Remove cap (Figure 40, Item 78). • Add oil until it reaches the "H" mark on the dipstick (Figure 40, Item 77). • Install cap (Figure 40, Item 78). 58 Monthly Primary and Final Fuel Filter/Water Separators Service primary and final fuel filter/ water separators. (WP 0086) 59 Monthly Fuel Tank Drain sediment from fuel tank. (WP 0091) 60 Monthly Coolant Heater Run coolant heater (WP 0034) for 5 minutes to keep water pump from seizing. 0077-36 TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 61 Monthly Primary and Secondary Air Cleaner Service primary and secondary air cleaner. (WP 0087) 62 Monthly Serpentine Belt Check serpentine belt (Figure 41, Item 79) for cracks, cuts and frays. Serpentine belt is cut, broken, or frayed. 79 HYEX01401 Figure 41. 63 Monthly Air Conditioner Belt Serpentine Belt Check. Check air conditioner belt (Figure 42, Item 80) for cracks and cuts. 0077-37 Air conditioner belt is cut or broken. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 80 HYEX01402 Figure 42. 64 Monthly Fan Air Conditioner Belt Check. Check fan (Figure 43, Item 81) for damage, debris, and hydraulic leaks. 0077-38 Any damage that would impair safe operation of machine. Any debris that would block air flow through radiator. Any class III hydraulic leak. TM 5-3805-294-10 Table 1. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 81 HYEX01403 Figure 43. Fan Check. 65 Monthly Track Sag Check track sag. (WP 0080) 66 Monthly Fresh Air Filter Service fresh air filter. (WP 0089) 67 Monthly Air Conditioner/Heater Filter Service Service air conditioner/heater filter. (WP 0090) 68 Monthly Lubrication Perform 100 lubrication in accordance with, LO 5-3805-294-13. (WP 0094) END OF TASK END OF WORK PACKAGE 0077-39/40 blank TM 5-3805-294-10 CHAPTER 5 OPERATOR MAINTENANCE INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0078 OPERATOR MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS INITIAL SETUP: Not Applicable GENERAL MAINTENANCE NOTE Instructions in this section provide general procedures to be followed for maintenance authorized at the operator level. Specific instructions are found in the operator maintenance section of this manual. This section covers general maintenance instructions for the machine. Read all CAUTIONS and WARNINGS that apply to all maintenance instructions. Follow these maintenance practices when working on the machine. Prior to starting any inspection or maintenance procedure, ensure that machine is safely parked and shut down. INSPECTION Electrical Parts. Inspect wiring harnesses for cracked, broken, chafed, bare, and burned insulation, or bare wires. Inspect all terminal connectors for loose connections and broken parts. Inspect connectors for corrosion or signs of sparking. This is an indication of a malfunction within the terminal. Notify Field Level maintenance of any part found to be defective. Tubing and Hosing. Check all hose surfaces for wear, damage, broken, or frayed coverings, and leaks. Check for breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If a connector or fitting is loose, broken, or worn out, notify Field Level maintenance. Metal Parts. Check bolts, nuts, and screws for obvious looseness. Also check for missing, bent, or broken pieces. They cannot all be checked with a tool, but look for chipped paint, bare metal, or rust around bolt heads. Look for loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Visually inspect all castings and weldments for cracks. 0078-1 TM 5-3805-294-10 0078 CLEANING WARNING Never use fuel to clean parts. Fuel is highly flammable. Failure to comply may result in injury or death to personnel. Rubber Parts. Do not clean rubber parts in solvent cleaning compound. Wipe parts clean with a dry, cleaning cloth. Machine Exterior. Steam clean all exterior parts thoroughly. If pressurized water is not available, wash painted surfaces of machine with solution of 1/4 cup of soap chips, to 1 gallon (4 L) of water. Electrical Parts. Electrical parts such as coils, junction blocks, switches, and electrical parts that contain insulation materials should not be soaked or sprayed with cleaning solutions. Clean these parts with a cleaning cloth moistened with cleaning compound. Clean rubber parts with hot, soapy water and soft cloths. Do not clean with solvents. END OF TASK END OF WORK PACKAGE 0078-2 TM 5-3805-294-10 0079 OPERATOR MAINTENANCE TAKING ENGINE OIL SAMPLE INITIAL SETUP: Materials/Parts Bottle, Oil Sample (WP 0097, Table 1, Item 3) Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Engine running. (WP 0007) Time to Complete 0.2 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) SAMPLING ENGINE 1. Clean dirt from around cap (Figure 1, Item 1). 1 3 2 HYEX00909 Figure 1. Engine Oil Sampling Valve. 2. Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2). 3. Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full. 4. Release valve (Figure 1, Item 3). 5. Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2). END OF TASK END OF WORK PACKAGE 0079-1/2 blank TM 5-3805-294-10 0080 OPERATOR MAINTENANCE TRACK SAG CHECK INITIAL SETUP: References (cont.) WP 0007 WP 0009 WP 0081 WP 0082 Tools and Special Tools Measuring Tape (WP 0095, Table 2, Item 10) Materials/Parts Grease (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Engine running. (WP 0007) Personnel Required Horizontal Construction Engineer 12N (2) Time to Complete 0.5 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) RAISING MACHINE NOTE Sag for left and right side tracks is checked the same way. 1. Swing upperstructure (Figure 1, Item 1) 90 degrees. 3 4 1 5 Figure 1. 2 HYEX00383 Raise Machine. 2. Place round side of bucket (Figure 1, Item 2) on ground. 3. Keeping angle between boom (Figure 1, Item 3) and arm (Figure 1, Item 4) between 90 and 110 degrees, slowly lower boom (Figure 1, Item 3) to raise track (Figure 1, Item 5) off ground. END OF TASK 0080-1 TM 5-3805-294-10 0080 TRACK SAG CHECK 1. Mark track (Figure 2, Item 5) to measure two full rotations of track in each direction. 5 Figure 2. Rotate Track. 2. Rotate track (Figure 2, Item 5) forward two full rotations and in reverse two full rotations. 3. Move pilot shutoff lever (Figure 3, Item 6) to locked (up) position. 0080-2 HYEX00491 TM 5-3805-294-10 0080 TRACK SAG CHECK - Continued 7 6 Figure 3. HYEX01309 Shut Machine Off. 4. Turn key switch (Figure 3, Item 7) to OFF position. 5. Measure for a distance of 11.8-13.2 in. (300-335 mm) between surface of track (Figure 4, Item 5) and bottom of track frame (Figure 4, Item 8) at middle track roller (Figure 4, Item 9). 0080-3 TM 5-3805-294-10 0080 TRACK SAG CHECK - Continued 8 9 HYEX00838 5 Figure 4. Measure Track Sag. 6. If track sag is more than 13.2 in. (335 mm), Tighten Track Tension. (WP 0081) 7. If track sag is less than 11.8 in. (300 mm), Loosen Track Tension. (WP 0082) 8. If track sag is within limits, go to Lowering Machine task in this work package. END OF TASK LOWERING MACHINE 1. Turn key switch (Figure 5, Item 7) to ON position and start engine. 0080-4 TM 5-3805-294-10 0080 LOWERING MACHINE - Continued 7 HYEX01309 6 Figure 5. Start Machine. 2. Move pilot shutoff lever (Figure 5, Item 6) to unlocked (down) position. 3. Slowly raise boom (Figure 6, Item 3) until track (Figure 6, Item 5) is resting on ground. 3 4 1 5 Figure 6. Lower Machine. 0080-5 2 HYEX00383 TM 5-3805-294-10 LOWERING MACHINE - Continued 4. Raise boom (Figure 6, Item 3), arm (Figure 6, Item 4), and bucket (Figure 6, Item 2) off ground. 5. Swing upperstructure (Figure 6, Item 1) 90 degrees. 6. Safely park and shutdown machine. (WP 0009) END OF TASK END OF WORK PACKAGE 0080-6 0080 TM 5-3805-294-10 0081 OPERATOR MAINTENANCE TIGHTENING TRACK TENSION INITIAL SETUP: References DA FORM 5988-E or DA FORM 2404 (WP 0094) WP 0080 Tools and Special Tools Grease Gun (WP 0095, Table 2, Item 4) Materials/Parts Grease (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Track sag checked. (WP 0080) Personnel Required Horizontal Construction Engineer 12N Time to Complete 0.1 Hour(s) TIGHTENING TRACK 1. Add a small amount of grease to grease fitting (Figure 1, Item 1). 1 Figure 1. 2. Tighten Track. Check track sag. (WP 0080) END OF TASK END OF WORK PACKAGE 0081-1/2 blank HYEX00384 TM 5-3805-294-10 0082 OPERATOR MAINTENANCE LOOSENING TRACK TENSION INITIAL SETUP: Tools and Special Tools Wrench, Open End, 24 mm (WP 0095, Table 2, Item 4) References DA FORM 5988-E or DA FORM 2404 (WP 0094) WP 0007 Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Track sag checked. (WP 0080) Personnel Required Horizontal Construction Engineer 12N Time to Complete 0.1 Hour(s) LOOSENING TRACK TENSION 1. Loosen nut (Figure 1, Item 1) and allow a small amount of grease to escape. 1 HYEX00385 Figure 1. 2. Tighten nut (Figure 1, Item 1). 3. Check track sag. (WP 0080) Loosen Track. END OF TASK END OF WORK PACKAGE 0082-1/2 blank TM 5-3805-294-10 0083 OPERATOR MAINTENANCE TAKING HYDRAULIC OIL SAMPLE INITIAL SETUP: Materials/Parts Bottle, Oil Sample (WP 0097, Table 1, Item 3) Rags, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Engine running. (WP 0007) Time to Complete 0.2 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) SAMPLING HYDRAULIC OIL 1. Clean dirt from around cap (Figure 1, Item 1). 3 1 2 HYEX00908 Figure 1. Hydraulic Oil Sampling Valve. 2. Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2). 3. Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full. 4. Release valve (Figure 1, Item 3). 5. Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2). END OF TASK END OF WORK PACKAGE 0083-1/2 blank TM 5-3805-294-10 OPERATOR MAINTENANCE CAB FUSE REPLACEMENT INITIAL SETUP: Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.2 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) REMOVAL NOTE • All fuses from both main and auxiliary fuse boxes are removed the same way. Main fuse box shown. • Spare fuses are located in the fuse box. After using a spare fuse, notify Field maintenance to get a replacement fuse. 1. Remove fuse box access cover (Figure 1, Item 1) from cab rear tray (Figure 1, Item 2). 0084-1 0084 TM 5-3805-294-10 0084 REMOVAL - Continued 2 1 HYEX00089 Figure 1. 2. Fuse Box Access Cover Removal. Remove main fuse box cover (Figure 2, Item 3) from main fuse box (Figure 2, Item 4). 0084-2 TM 5-3805-294-10 0084 REMOVAL - Continued 3 4 HYEX00097 Figure 2. Main Fuse Box Cover Removal. 3. Locate fuse in question using key found on fuse box cover (Figure 2, Item 3). 4. Remove fuse (Figure 3, Item 5) from main fuse box (Figure 3, Item 4). 0084-3 TM 5-3805-294-10 0084 REMOVAL - Continued 5 4 HYEX00098 Figure 3. Fuse Removal. END OF TASK INSTALLATION CAUTION Use only a fuse having the same amperage as noted on fuse box cover. Using a fuse with higher amperage than specified could cause damage to the electrical system. Failure to comply may result in damage to equipment. NOTE All fuses from both main and auxiliary fuse boxes are installed the same way. Main fuse box shown. 1. Install fuse (Figure 4, Item 5) to main fuse box (Figure 4, Item 4). 0084-4 TM 5-3805-294-10 0084 INSTALLATION - Continued 5 4 HYEX00098 Figure 4. 2. Fuse Installation. Install main fuse box cover (Figure 5, Item 3) to main fuse box (Figure 5, Item 4). 0084-5 TM 5-3805-294-10 0084 INSTALLATION - Continued 3 4 HYEX00097 Figure 5. 3. Main Fuse Box Cover Installation. Install fuse box access cover (Figure 6, Item 1) to cab rear tray (Figure 6, Item 2). 0084-6 TM 5-3805-294-10 0084 INSTALLATION - Continued 2 1 HYEX00089 Figure 6. Fuse Box Access Cover Installation. END OF TASK END OF WORK PACKAGE 0084-7/8 blank TM 5-3805-294-10 0085 OPERATOR MAINTENANCE BUCKET TEETH REPLACEMENT INITIAL SETUP: Tools and Special Tools Hammer, Hand, 3 lb (WP 0095, Table 2, Item 5) Punch, Pin (WP 0095, Table 2, Item 9) Equipment Condition Machine safely parked and shut down. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.2 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) HEAVY DUTY BUCKET TOOTH REMOVAL 1. Using hammer and pin punch, drive out pin (Figure 1, Item 1) from tooth (Figure 1, Item 2) and shank (Figure 1, Item 3). 3 1 Figure 1. 2. 2 Tooth Removal. Remove tooth (Figure 1, Item 2) from shank (Figure 1, Item 3). END OF TASK 0085-1 HYEX01282 TM 5-3805-294-10 0085 HEAVY DUTY BUCKET TOOTH INSTALLATION 1. Position tooth (Figure 2, Item 2) on shank (Figure 2, Item 3). 3 1 Figure 2. 2. 2 HYEX01282 Tooth Installation. Using hammer, drive pin (Figure 2, Item 1) to tooth (Figure 2, Item 2) and shank (Figure 2, Item 3) until seated. END OF TASK DEEP DIG BUCKET TOOTH REMOVAL 1. Using hammer and pin punch, drive out pin (Figure 3, Item 4) from tooth (Figure 3, Item 5) and shank (Figure 3, Item 6). 4 5 6 HYEX01281 Figure 3. Bucket Tooth Removal. 0085-2 TM 5-3805-294-10 0085 DEEP DIG BUCKET TOOTH REMOVAL - Continued 2. Remove tooth (Figure 3, Item 5) from shank (Figure 3, Item 6). END OF TASK DEEP DIG BUCKET TOOTH INSTALLATION 1. Position tooth (Figure 4, Item 5) on shank (Figure 4, Item 6). 4 5 6 HYEX01281 Figure 4. 2. Bucket Tooth Installation. Using hammer, drive pin (Figure 4, Item 4) to tooth (Figure 4, Item 5) and shank (Figure 4, Item 6) until seated. END OF TASK END OF WORK PACKAGE 0085-3/4 blank TM 5-3805-294-10 0086 OPERATOR MAINTENANCE PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE INITIAL SETUP: Tools and Special Tools Pan, Drain Equipment Condition Machine safely parked and shut down (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.1 Hour(s) DRAIN FUEL FILTER/WATER SEPARATORS WARNING DIESEL FUEL 1. Disconnect wiring harness connector D01 (Figure 1, Item 1) from water in fuel (WIF) sensor (Figure 1, Item 2). 3 2 1 4 5 HYEX00103 Figure 1. Drain Fuel Filter/Water Separators. 0086-1 TM 5-3805-294-10 0086 DRAIN FUEL FILTER/WATER SEPARATORS - Continued NOTE Place drain pan under fuel/water separators prior to draining. 2. Loosen, but do not remove WIF sensor (Figure 2, Item 2), and drain water/sediment from primary fuel filter/ water separator (Figure 2, Item 3) for approximately 30 seconds. 3 2 1 4 5 HYEX00103 Figure 2. Drain Fuel Filter/Water Separators Continued. 3. Tighten WIF sensor (Figure 2, Item 2). 4. Connect wiring harness connector D01 (Figure 2, Item 1) to WIF sensor (Figure 2, Item 2). 5. Loosen, but do not remove valve (Figure 2, Item 4), and drain water/sediment from final fuel filter/water separator (Figure 2, Item 5) for approximately 30 seconds. 6. Tighten valve (Figure 2, Item 4). END OF TASK END OF WORK PACKAGE 0086-2 TM 5-3805-294-10 0087 OPERATOR MAINTENANCE PRIMARY AND SECONDARY AIR CLEANER SERVICE INITIAL SETUP: Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Engine off. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.4 Hour(s) REMOVAL 1. Lift lever (Figure 1, Item 1) and rotate cover (Figure 1, Item 2) counterclockwise. 3 1 2 HYEX00073 Figure 1. Cover Removal. 2. Remove cover (Figure 1, Item 2) from air cleaner housing (Figure 1, Item 3). 3. Remove primary air cleaner (Figure 2, Item 4) from air cleaner housing (Figure 2, Item 3). 0087-1 TM 5-3805-294-10 0087 REMOVAL - Continued 3 4 HYEX00074 Figure 2. Primary Air Cleaner Removal. 4. Remove secondary air cleaner (Figure 3, Item 5) from air cleaner housing (Figure 3, Item 3). 5 3 HYEX00075 Figure 3. Secondary Air Cleaner Removal. END OF TASK 0087-2 TM 5-3805-294-10 0087 SERVICING AIR CLEANERS WARNING Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel. NOTE • Contact field level maintenance for an air hose and air nozzle to service the air cleaner. • Secondary air cleaner does not require servicing, only replacement. 1. Lightly tap primary air cleaner (Figure 4, Item 4) to remove major amount of dirt from primary air cleaner. 4 HYEX00076 Figure 4. Primary Air Cleaner Service. 2. Start from inside, top of primary air cleaner (Figure 4, Item 4), blow remainder of debris out of primary air cleaner. 3. Work around and inward of primary air cleaner (Figure 4, Item 4) until primary air cleaner has been completely blown out. 4. Wipe out air cleaner housing (Figure 5, Item 3) with a clean rag. 0087-3 TM 5-3805-294-10 0087 SERVICING AIR CLEANERS - Continued 3 HYEX00077 Figure 5. Air Cleaner Housing Service. 5. Wipe inside of cover (Figure 6, Item 2) with a clean rag and squeeze dust boot (Figure 6, Item 6) to remove dust. 2 HYEX00078 6 Figure 6. Cover and Dust Boot Service. END OF TASK INSTALLATION NOTE Dust valve will be at the 6 O'clock position when air cleaner cover is installed. 1. Install secondary air cleaner (Figure 7, Item 5) to air cleaner housing (Figure 7, Item 3). 0087-4 TM 5-3805-294-10 0087 INSTALLATION - Continued 3 5 HYEX00084 Figure 7. 2. Secondary Air Cleaner Installation. Install primary air cleaner (Figure 8, Item 4) to air cleaner housing (Figure 8, Item 3). 3 4 HYEX00074 Figure 8. 3. Primary Air Cleaner Installation. Position cover (Figure 9, Item 2) on air cleaner housing (Figure 9, Item 3). 0087-5 TM 5-3805-294-10 0087 INSTALLATION - Continued 3 2 1 HYEX00083 Figure 9. 4. Cover Installation. Rotate cover (Figure 9, Item 2) clockwise until lever (Figure 9, Item 1) locks. END OF TASK END OF WORK PACKAGE 0087-6 TM 5-3805-294-10 0088 OPERATOR MAINTENANCE HYDRAULIC RESERVOIR SERVICE INITIAL SETUP: Tools and Special Tools Wrench, Allen 5 mm (0.196 in.) (WP 0095, Table 2, Item 16) References LO 5-3805-294-13 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) Materials/Parts Lubricating Oil, Engine (WP 0097, Table 1, Item 13) Time to Complete 0.4 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) FILLING HYDRAULIC RESERVOIR WARNING Hydraulic system operates at high pressures and temperatures. Always allow hydraulic oil to cool and relieve pressure in hydraulic reservoir before working on hydraulic system. Wear eye protection and gloves to prevent injury. Open lines and hoses slowly and wait for any residual pressure to relieve before continuing to open lines and hoses. Failure to comply may result in injury or death to personnel. 1. Press button (Figure 1, Item 1) to relieve pressure from hydraulic reservoir (Figure 1, Item 2). 1 3 4 2 HYEX00085 Figure 1. Hydraulic Reservoir Cover Removal. 2. Remove four screws (Figure 1, Item 3) and hydraulic reservoir cover (Figure 1, Item 4) from hydraulic reservoir (Figure 1, Item 2). 0088-1 TM 5-3805-294-10 0088 FILLING HYDRAULIC RESERVOIR - Continued WARNING LUBRICATING OIL 3. Fill hydraulic reservoir (Figure 2, Item 2) until oil is between marks (Figure 2, Item 5) on sight glass (Figure 2, Item 6). LO 5-3805-294-13 (WP 0094) 5 2 6 HYEX00086 Figure 2. Hydraulic Reservoir Sight Glass. 4. Ensure O-ring (Figure 3, Item 7) is present and is not damaged. If O-ring is missing or damaged, notify field maintenance. 0088-2 TM 5-3805-294-10 0088 FILLING HYDRAULIC RESERVOIR - Continued 4 3 7 2 HYEX00087 Figure 3. Hydraulic Reservoir Cover Installation. 5. Install hydraulic reservoir cover (Figure 3, Item 4) to hydraulic reservoir (Figure 3, Item 2) with four screws (Figure 3, Item 3). END OF TASK END OF WORK PACKAGE 0088-3/4 blank TM 5-3805-294-10 0089 OPERATOR MAINTENANCE FRESH AIR FILTER SERVICE INITIAL SETUP: Equipment Condition Machine safely parked and shut down. (WP 0009) Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.2 Hour(s) References TM 5-3805-295-13&P (WP 0094) DA FORM 5988-E or DA FORM 2404 (WP 0094) REMOVAL NOTE After the fresh air filter has been serviced three times, it must be replaced by Field Maintenance. 1. Move two tabs (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3). 1 1 3 Figure 1. 2. Filter Removal. Inspect seal (Figure 2, Item 4) on filter (Figure 2, Item 2). 0089-1 2 HYEX00168 TM 5-3805-294-10 0089 REMOVAL - Continued 4 2 Figure 2. 3. HYEX00169 Inspect Seal. If seal (Figure 2, Item 4) is damaged, contact field maintenance. END OF TASK SERVICE WARNING Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel. NOTE • Contact field level maintenance for an air hose and air nozzle to service the air filter. • If HYEX is equipped with a Supplemental Armor Set, refer to and use procedure found in TM 5-3805-295-13&P. 1. Lightly tap filter (Figure 3, Item 2) with hand. 0089-2 TM 5-3805-294-10 0089 SERVICE - Continued 2 HYEX00170 Figure 3. Clean Filter. CAUTION Always blow compressed air from the inside to the outside of the air cleaner when servicing. Blowing compressed air from the outside to the inside could damage the air cleaner. Failure to comply may result in damage to equipment. 2. Blow remainder of debris from filter (Figure 3, Item 2). 3. Wipe inside of housing (Figure 4, Item 3) with clean rag. 3 HYEX00171 Figure 4. Clean Housing. END OF TASK 0089-3 TM 5-3805-294-10 0089 INSTALLATION 1. Install filter (Figure 5, Item 2) to housing (Figure 5, Item 3). 1 1 3 Figure 5. 2. Filter Installation. Ensure tabs (Figure 5, Item 1) lock. END OF TASK END OF WORK PACKAGE 0089-4 2 HYEX00168 TM 5-3805-294-10 0090 OPERATOR MAINTENANCE AIR CONDITIONER/HEATER FILTER SERVICE INITIAL SETUP: Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Equipment Condition Engine OFF. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.2 Hour(s) REMOVAL NOTE After air conditioner/heater has been serviced three times it must be replaced by Field Maintenance. 1. Move tab (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3). 2 Figure 1. 2. 3 1 HYEX00187 Filter Removal. Check tab (Figure 1, Item 1) on filter (Figure 1, Item 2) and replace filter if tab broken. END OF TASK SERVICE NOTE Contact Field level maintenance for an air hose and air nozzle to service the air cleaner. 1. Lightly tap filter (Figure 2, Item 2) with hand. 0090-1 TM 5-3805-294-10 0090 SERVICE - Continued HYEX00188 2 Figure 2. Clean Filter. WARNING Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel. CAUTION Always blow compressed air from the inside to the outside of the air cleaner when servicing. Blowing compressed air from the outside to the inside could damage the air cleaner. Failure to comply may result in damage to equipment. 2. Blow remainder of debris from filter (Figure 2, Item 2). 3. Wipe inside of housing (Figure 3, Item 3) with clean rag. 0090-2 TM 5-3805-294-10 0090 SERVICE - Continued HYEX00190 3 Figure 3. Clean Housing. END OF TASK INSTALLATION 1. Install filter (Figure 4, Item 2) to housing (Figure 4, Item 3). 2 Figure 4. 2. Filter Installation. Ensure tab (Figure 4, Item 1) locks. END OF TASK END OF WORK PACKAGE 0090-3/4 blank 3 1 HYEX00187 TM 5-3805-294-10 0091 OPERATOR MAINTENANCE DRAINING WATER AND SEDIMENT FROM FUEL TANK INITIAL SETUP: Tools and Special Tools Pan, Drain Equipment Condition Machine safely parked and shut down (WP 0009) Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) Time to Complete 0.2 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) DRAINING WATER AND SEDIMENT NOTE Contact Field Maintenance for drain pan. 1. Remove fuel tank fill cap (Figure 1, Item 1). 1 HYEX01298 Figure 1. 2. Remove Fuel Cap. Position drain pan under drain hose (Figure 2, Item 2). 0091-1 TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT - Continued 2 HYEX00914 Figure 2. 3. Drain Hose. Open drain valve (Figure 3, Item 3) and drain water and sediment until a clear stream of fuel comes out. 0091-2 TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT - Continued 3 HYEX00915 Figure 3. 4. Close drain valve (Figure 3, Item 3). 5. Dispose of waste properly. 6. Install fuel tank fill cap (Figure 4, Item 1). Drain Valve. 0091-3 TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT - Continued 1 HYEX01298 Figure 4. Install Fuel Cap. END OF TASK END OF WORK PACKAGE 0091-4 TM 5-3805-294-10 OPERATOR MAINTENANCE CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT INITIAL SETUP: Tools and Special Tools Wrench 2-1/4 Wrench 2-1/2 (WP 0095, Table 2, Item 15) Equipment Condition Machine safely parked and shut down (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.3 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) DISCHARGE ADJUSTMENT WARNING Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may result in injury or death to personnel. NOTE • Ensure curtain is set to desired discharge size before Crush-All operation. • There are no disassembly requirements to perform discharge adjustments. Adjustment points are on the outside of the machine. • There are two adjustment points for lower curtain. Adjustment procedure is identical for both points and must be adjusted at same time. • Raise curtain to increase discharge size. • Lower curtain to decrease discharge size. • To reduce dust, increase discharge size. • Repeat steps for opposite side. 1. Loosen nut (Figure 1, Item 1) on nut (Figure 1, Item 2) and rod (Figure 1, Item 3). 0092-1 0092 TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT - Continued 3 5 6 7, 8, 9 10 11 4 2 1 HYEX03092 Figure 1. Curtain Adjustment. 2. Loosen nut (Figure 1, Item 2) on rod (Figure 1, Item 3) to release tension from spring (Figure 1, Item 4). 3. Using wrench provided with crush-all loosen nut (Figure 1, Item 5) on nut (Figure 1, Item 6) and rod (Figure 1, Item 3). 4. Remove bolt (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and washer (Figure 1, Item 9) from clamp (Figure 1, Item 10) and plate (Figure 1, Item 11). 5. Remove clamp (Figure 1, Item 10) from nut (Figure 1, Item 6) and plate (Figure 1, Item 11). 6. Turn nut (Figure 2, Item 6) to raise or lower curtain (Figure 2, Item 12). 0092-2 TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT - Continued 6 12 14 13 HYEX03093 Figure 2. Clearance Check. CAUTION Ensure surface of blow bar does not touch curtain. Failure to comply may result in damage to equipment. 7. Turn rotor (Figure 2, Item 13) manually. Verify curtain (Figure 2, Item 12) does not touch rotor (Figure 2, Item 13) or blow bars (Figure 2, Item 14). 8. Position clamp (Figure 3, Item 10) on nut (Figure 3, Item 6) and plate (Figure 3, Item 11). 0092-3 TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT - Continued 3 5 6 11 7, 8, 9 10 HYEX03094 Figure 3. Clamp Installation. 9. Install clamp (Figure 3, Item 10) on plate (Figure 3, Item 11) with bolt (Figure 3, Item 7), lockwasher (Figure 3, Item 8), and washer (Figure 3, Item 9). 10. Using wrench provided with crush-all tighten nut (Figure 3, Item 5) against nut (Figure 3, Item 6) on rod (Figure 3, Item 3). 11. Tighten nut (Figure 4, Item 2) and compress spring (Figure 4, Item 4) to align marks (Figure 4, Item 15) and (Figure 4, Item 16). 0092-4 TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT - Continued 3 4 16 15 2 1 HYEX03095 Figure 4. 12. Spring Compression. Tighten nut (Figure 4, Item 1) against nut (Figure 4, Item 2) on rod (Figure 4, Item 3). END OF TASK END OF WORK PACKAGE 0092-5/6 blank TM 5-3805-294-10 0093 OPERATOR MAINTENANCE MAINTENANCE AFTER FORDING INITIAL SETUP: Tools and Special Tools Grease Gun (WP 0095, Table 2, Item 4) Wrench 17 mm (WP 0095, Table 2, Item 17) References LO 5-3805-294-13 (WP 0094) DA FORM 5988-E or DA FORM 2404 (WP 0094) Materials/Parts Grease, Automotive and Artillery (WP 0097, Table 1, Item 10) Equipment Condition Machine safely parked and shut down. (WP 0094) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0.5 Hour(s) DRAINING MUD OR WATER 1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from cover (Figure 1, Item 3). 1, 2 3, 4 5 HYEX03286 Figure 1. Draining Mud or Water. 2. Remove cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from machine (Figure 1, Item 5) and allow mud or water to completely drain. 3. Remove any contaminated grease. 4. Install cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) to machine (Figure 1, Item 5) with two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2). 0093-1 TM 5-3805-294-10 DRAINING MUD OR WATER - Continued 5. If grease was removed, notify field level maintenance to service swing gear and swing bearing. END OF TASK END OF WORK PACKAGE 0093-2 0093 TM 5-3805-294-10 CHAPTER 6 OPERATOR SUPPORTING INFORMATION FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 TM 5-3805-294-10 0094 OPERATOR MAINTENANCE REFERENCES SCOPE This work package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in this manual. ARMY REGULATIONS AR 25-52 Authorized Abbreviations and Brevity Codes AR 310-25 Dictionary of United States Army Terms AR 385-40 Accident Reporting and Records AR 385-55 Prevention of Motor Vehicle Accidents AR 700-138 Army Logistics Readiness and Sustainability DEPARTMENT OF ARMY PAMPHLETS (DA PAM) DA PAM 25-30 Consolidated Index of Army Publications and Blank Forms DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual FIELD MANUALS FM 1-02 Military Symbols FM 3-11.5 Chemical, Biological, Radiological, and Nuclear Decontamination FM 3-97.6 Mountain Operations FM 4-25.11 First Aid FM 7-1 Military Training Management FM 9-207 Operation and Maintenance of Ordnance Material in Cold Weather (0°F to -65°F) FM 20-3 Camouflage FM 21-305 Manual for Wheeled Vehicle Driver FM 31-70 Basic Cold Weather FM 31-71 Northern Operations FM 38-700 & 701 Preservation and Packing of Military Supplies and Equipment FM 55-15 Transportation Reference Data FM 90-3 Desert Operations 0094-1 TM 5-3805-294-10 0094 FORMS DA Form 2404 Equipment Inspection and Maintenance Worksheet DA Form 2408-9 Equipment Control Record DA Form 5988-E Equipment Inspection and Maintenance (Electronic) Worksheet DD Form 1149 Requisition and Invoice/Shipping Document DD Form 1266 Request for Special Hauling Permit DD Form 250 Material Inspection and Receiving Report SF 368 Product Quality Deficiency Report MILITARY HANDBOOK (MIL-HDBK) MIL-HDBK-1791 Designing for Internal Aerial Delivery in Fixed Winged Aircraft MILITARY STANDARD (MIL-STD) MIL-STD-810 Enviromental Test Methods and Engineering Guidelines MIL-STD-1366 Interface Standard for Transportability Criteria TECHNICAL BULLLITENS TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D LC TB 9-2300-281-35 Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles TB 43-0209 Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials Handling Equipment TB 43-0216 Safety and Hazard Warnings for Operation and Maintenance of TACOM Equipment TB 55-45 Certification of Military Equipment for Transport in AMC/ CRAF Aircraft TB 740-97-2 Preservation of USAMECOM Mechanical Equipment for Shipment and Storage TECHNICAL MANUALS LO 5-3805-294-13 Lubrication Instructions for the Hydraulic Excavator (HYEX) TM 5-3805-295-13&P Operator's and Field Level Maintenance Manual for Supplemental Armor Set for Hydraulic Excavator (HYEX) (John Deere 240D LCR) 0094-2 TM 5-3805-294-10 0094 TECHNICAL MANUALS - Continued TM 9-2330-381-13 Operator and Field Maintenance Manual for the Semitrailer, Transporter, Heavy Equipment TM 21-40 Chemical, Biological, Radiological, and Nuclear Defense TM 38-250/AFR 71-4 Preparation of Hazardous Materials for Military Air Shipment TM 55-2200-001-12 Transportability Guidance for Application of Blocking, Bracing and Tiedown Materiels for Rail Transport TM 750-244-6 Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use END OF WORK PACKAGE 0094-3/4 blank TM 5-3805-294-10 0095 OPERATOR MAINTENANCE COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS INTRODUCTION Scope This work package lists COEI and BII for the Hydraulic Excavator (HYEX) to help you inventory items for safe operation of the equipment. General The COEI and BII information is divided into the following lists: Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the HYEX. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Basic Issue Items (BII). These essential items are required to place the (HYEX) in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the Hydraulic Excavator during operation and when it is transferred between property accounts. Listing these items is your authority to request/ requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items. Explanation of Columns in the COEI List and BII List Column (1) Item Number. Gives you the reference number of the item listed. Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in initial capital letters) followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. There are no usable on codes for this equipment. Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (2). Column (6) Qty Rqr. Indicates the quantity required. 0095-1 TM 5-3805-294-10 Table 1. 0095 COMPONENTS OF END ITEM (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION, PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Ditch Cleaning Bucket C909323-623315 (8U941) EA 1 Quick Latch C909332(1J955) EA 1 Rock Bucket, 42 in. 909325-623327(8U941) EA 1 Hydraulic Thumb 70N0013(3PSD7) EA 1 1 HYEX01340 2 2540-01-478-1207 HYEX01359 3 HYEX01341 4 HYEX01360 0095-2 TM 5-3805-294-10 Table 1. 0095 COMPONENTS OF END ITEM - Continued (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION, PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR EA 1 5 2590-01-474-7812 Vandal Protection Kit AP33356 (75755) HYEX01342 0095-3 TM 5-3805-294-10 Table 2. 0095 BASIC ISSUE ITEMS (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION, PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Bag, Mason 204900 (3PSD7) EA 1 Cap 811438500 (1BVQ2) EA 4 Cap, Pin U42984 (3PSD7) EA 4 Gun, Grease, Lever Action, 12 in. (304.8 mm) 7Y26518 (3PSD7) EA 1 Hammer, Hand, 3 lb (1.36 kg) B3-3LB(72987) EA 1 Operator's Manual TM 5-3805-294-10 EA 1 Plug, Hex 37 Degree Flare, -12 205324(1BVQ2) EA 4 Plug, Hex 37 Degree Flare, -6 R39783 (3PSD7) EA 4 1 HYEX03287 2 HYEX03288 3 HYEX03289 4 HYEX01349 5 HYEX03327 6 TM 5-3805-294-10 TECHNICAL MANUAL OPERATOR'S MANUAL FOR HYDRAULIC EXCAVATOR (HYEX) (JOHN DEERE 240D LCR) TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH NSN 3805-01-573-0677 (EIC : ALL) DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY XXXX XXXX HYEX01339 7 HYEX03290 8 HYEX03291 0095-4 TM 5-3805-294-10 Table 2. 0095 BASIC ISSUE ITEMS - Continued (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION, PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Punch, Drift 70-195(08292) EA 1 Tape, Measuring 25 FT 68-445 (08292) EA 1 Screwdriver, Pry Bar, 12 in. (305 mm) Long B107.60 (05047) EA 1 Tooth, Surface Ripping TX400 (1J955) EA 5 Vice Grips 67-460 (08292) EA 1 Wrench, Open End, 3 in. (76 mm) T183966 (75755) EA 1 9 5120 -01-434-9835 HYEX03325 10 5210-01-434-9515 HYEX03326 11 5120 -01-434-9171 HYEX01348 12 3815-01-475-0710 HYEX03292 13 HYEX01355 14 HYEX01346 0095-5 TM 5-3805-294-10 Table 2. 0095 BASIC ISSUE ITEMS - Continued (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION, PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Wrench, Open End, 2 1/2 in. (63.5 mm) AT189507 (75755) EA 2 Wrench, Allen, 5 mm (0.196 in.) B18.3.2M (05047) EA 1 Wrench, Open End, 17 mm 52-217 (08292) EA 1 Wrench, Open End, 24 mm 52-224 (08292) EA 1 Wrench, Open End, Adjustable, 0.95 in. (24 mm) Jaw Opening, 15 in. (381 mm) Long 11655778-3 (19207) EA 1 15 HYEX01345 16 5120-01-045-4889 HYEX01344 17 HYEX01356 18 5120 - 01-581-3318 HYEX01356 19 5120-00-240-5328 HYEX01343 END OF WORK PACKAGE 0095-6 TM 5-3805-294-10 0096 OPERATOR MAINTENANCE ADDITIONAL AUTHORIZATION LIST (AAL) INTRODUCTION SCOPE This work package lists additional items you are authorized for the support of the Hydraulic Excavator (HYEX). GENERAL This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it. These items are all authorized to you by CTA, MTOE, TDA, or JTA. Explanation of Columns in the AAL Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (2) - Description, Part Number/(CAGEC). Identifies the Federal item name (in Initial capital letters) followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. Column (4) - Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (1). Column (5) - Quantity Recommended (Qty Recom). Indicates the quantity recommended. Table 1. Additional Authorization List. (1) (2) (3) (4) (5) NATIONAL STOCK NUMBER (NSN) DESCRIPTION, PART NUMBER/ (CAGEC) USABLE ON CODE U/I QTY RECOM EA 1 Compactor IHC 00130FT (1N0L6) END OF WORK PACKAGE 0096-1/2 blank TM 5-3805-294-10 0097 OPERATOR MAINTENANCE EXPENDABLE AND DURABLE ITEMS LIST Introduction Scope This work package lists expendable/durable supplies and materials you will need to operate and maintain the Hydraulic Excavator (HYEX). This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expandable/Durable Items List Column (1) - Item Number This number is assigned to the entry in the listing and is referenced in the initial setup narrative instructions to identify the material. Column (2) - Level This column identifies the lowest level of maintenance that requires the listed item. • C -- Operator/Crew • F -- Field • H -- Below Depot • D -- Depot Column (3) - National Stock Number (NSN) This is the NSN assigned to the item which you can use to requisition it. Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N) This column provides the other information you need to identify the item. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (5) - Unit of Issue (U/I) Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc. Table 1. Expendable and Durable Items List (1) (2) (3) (4) (5) ITEM NO. LEVEL NATIONAL STOCK NUMBER (NSN) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) U/I 1 C 6850-01-441-3248 Antifreeze, Permanent, Type: Arctic Grade 55-Gallon Drum A-A-52624 (58536) 0097-1 DR TM 5-3805-294-10 Table 1. 0097 Expendable and Durable Items List - Continued (1) (2) (3) (4) (5) ITEM NO. LEVEL NATIONAL STOCK NUMBER (NSN) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) U/I 2 C 6850-01-441-3257 Antifreeze, Permanent, Ethylene Glycol, Inhibited 5Gallon Can A-A-52624 (58536) CO 3 C 8125-01-193-3440 Bottle, Oil Sample M44054 TYPE III (81349) BX 4 C 6850-00-926-2275 Cleaning Compound, Windshield 1-pt Can 0854-000 (0FTT5) BX 5 C 9130-01-031-5816 Fuel, JP8 Bulk MILT83133 GR JP8 (81349) GL 6 C 9140-01-413-7511 Fuel, DF-2, Regular Bulk W-F-800 (81348) GL 7 C 9140-00-286-5294 Fuel, DF-2, Regular Bulk ASTM D 975 (58536) GL 8 C 9140-01-412-1311 Fuel, DF-1, Winter Bulk W-F-800 (81348) GL 9 C 9140-00-286-5286 Fuel, DF-1, Winter Bulk AA52557-1 (58536) GL 10 C 9150-01-197-7688 Grease, Automotive and Artillery, GAA 2-1/4-oz Tube M-10924-A (81349) TU 11 C 9150-00-111-6256 Lubricating Oil, OEA Ice, Subzero 1-qt Can MIL-PRF-46170 (81349) QT 12 C 9150-00-111-6255 Lubricating Oil, OEA Ice, Subzero 5-gal Can MIL-PRF-46170 (81349) GL 13 C 9150-01-438-6076 Lubricating Oil, Engine OE/HDO 15W-40 1-qt Can MIL-PRF-2104 (81349) QT 14 C 9150-00-973-9504 Penetrating Oil Can, 8 oz Can L3 (77628) CN 15 C 7920-00-148-9666 Rag, Wiping 7920-00-148-9666 (80244) BE END OF WORK PACKAGE 0097-2 TM 5-3805-294-10 0098 OPERATOR MAINTENANCE SPECIAL PURPOSE KITS (SPK) LIST SCOPE This work package lists the Special Purpose Kits (SPKs) for support of the Hydraulic Excavator (HYEX) Type 1. Where to find operation instructions and troubleshooting procedures for the SPKs are also provided. OPERATION INSTRUCTIONS FOR SPKS For instructions on how to select the SPKs on the operators monitor, go to Selecting an Attachment On the Monitor (WP 0018). To operate the SPKs go to Operating the Barrier Grapple (WP 0022), Installing and Operating the Compactor and Breaker (WP 0020), or Installing and Operating the Crush-All (WP 0019). The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX Type 1 by Field Maintenance. To operate the Deep Dig Arm, go to Operating the Deep Dig Arm (WP 0023). TROUBLESHOOTING PROCEDURES FOR SPKS To find troubleshooting procedures for the SPK items, go to the Troubleshooting Index (WP 0037). INTRODUCTION TO THE SPECIAL PURPOSE KITS LIST Special Purpose Kits (SPK) listed in Table 1 are for information purposes only and are not the authority to requisition replacements. These items are part of the HYEX Type 1, but they are removed and separately packaged for transportation or shipment. 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 help you find and identify the items. EXPLANATION OF COLUMNS IN TABLE 1 Column (1) Item Number. Gives you the reference number of the item listed. Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. There are no usable on codes for this equipment. Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (2). Column (6) QTY RQD. Indicates the quantity required. 0098-1 TM 5-3805-294-10 0098 SCOPE - Continued SPECIAL PURPOSE KITS Table 1. (1) ITEM NO. (2) NATIONAL STOCK NUMBER 1 Special Purpose Kits. (3) DESCRIPTION, PART NUMBER/(CAGEC) (4) USABLE ON CODE (5) U/I (6) QTY RQD Arm, Long Reach 502113 (1BVQ2) EA 1 Barrier Grapple KL16000-1 (1V7ZO) EA 1 Breaker, Impact 205146 (1BVQ2) EA 1 Counterweight 305156 (1BVQ2) EA 1 HYEX02525 2 HYEX02522 3 3830-01-585-2734 HYEX02520 4 HYEX02526 0098-2 TM 5-3805-294-10 0098 SCOPE - Continued Table 1. 5 Special Purpose Kits - Continued. Crush-All 502063 (1BVQ2) EA 1 Excavator Bucket (Deep Dig) 70G0001 (3PSD7) EA 1 Bucket, Scoop Loader (Deep Dig) 70G0002 (3PSD7) EA 1 HYEX02521 6 HYEX02523 7 HYEX02524 END OF WORK PACKAGE 0098-3/4 blank TM 5-3805-294-10 0099 OPERATOR MAINTENANCE TROUBLESHOOTING NOTES Troubleshooting Notes This paragraph contains troubleshooting information for locating and correcting some operating troubles which may develop in the HYEX. This manual cannot list all possible malfunctions that may occur, nor can it include all tests, inspections, and corrective actions. Notify field maintenance personnel if a malfunction is not listed, unless a malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed. Procedures. The troubleshooting symptom index lists possible malfunctions that may be experienced during operation of machine or components. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections and corrective actions. Lubrication. When instructions to lubricate, grease, oil, or add oil appear in the troubleshooting table, refer to Operator Preventive Maintenance Checks and Services. (WP 0077) END OF WORK PACKAGE 0099-1/2 blank TM 5-3805-294-10 0100 OPERATOR MAINTENANCE HYEX TRANSPORTABILITY INSTRUCTIONS HYEX TRANSPORTABILITY INSTRUCTIONS. The HYEX can be transported via highway, rail, marine, C-5, and C-17 air transport and meets all weight and dimensional requirements while in its standard configuration with no reduction or sectionalization required. TRANSPORTABILITY RELATED PUBLICATIONS. Additional information on transport procedures can be found in: 1. TB 9-2300-281-35, Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles WP 0094. 2. TM 38-250/AFR 71-4, Preparation of Hazardous Materials for Military Air Shipment WP 0094. TRANSPORTABILITY RELATED DEFINITIONS. Technical terms that may be helpful while preparing the HYEX for transportation are: 1. Center of Gravity (CG). The balance point of a suspended item. The HYEX counterweight is used to shift CG to the rear. 2. Curb Weight (CW). Total weight of operational HYEX including fuel, all system fluids, and on-vehicle Basic Issue Items (BII). CW does not include crew weight, which in this case, is less than one percent of the gross vehicle weight. 3. Gross Vehicle Weight (GVW). CW plus payload. For transport purposes, there is no payload. Therefore, the GVW equals the CW. MILITARY LOAD CLASSIFICATION. The Military Load Classifications (MLC) for the HYEX are as follows: 1. HYEX Standard Cab System - MLC 32 2. HYEX Armored Cab System - MLC 34 HYEX03197 Figure 1. Military Load Classification. 0100-1 TM 5-3805-294-10 0100 HYEX SHIPPING WEIGHT. 1. HYEX with Standard Cab shipping weight, without bucket or attachment = 58,900 lbs 2. HYEX with Armored Cab shipping weight without bucket or attachment = 63,000 lbs HYEX HIGHWAY TRANSPORTABILITY. NOTE • The HYEX is self-propelled at speeds up to 3.4 mph. • The unit transportation officer must contact local authorities to ensure the HYEX is not required to have special permits prior to highway transporting. The HYEX transport height is 10 feet 1 inch so it is capable of normal highway transport on trailers that have a bed height of 40 inches or less. HYEX is transportable on common military trailers, especially the M870A1 and M870A3. The HYEX is outfitted with a hydraulic quick latch for rapid exchange of attachments. HYEX can normally be transported over the road with any of the standard buckets attached. Attaching the Crush-All for shipment may cause the HYEX to exceed the 13 feet 6 inches transport height requirement. 33 FT. 4 IN. [10.15 M] 11 FT. 1 IN. [3.39 M] 10 FT. 1 IN. [3.07 M] HYEX01365 Figure 2. HYEX Dimensions. HYEX RAIL TRANSPORTABILITY. Due to the 30 inch track shoe requirement, the HYEX will have to be subjected to restrictive routes for rail movements. The HYEX may easily be rail transported via routes subjected to DOD clearance diagrams. HYEX can be transported via rail with any of the standard buckets attached. HYEX MARINE TRANSPORTABILITY. The HYEX can be shipped as roll-on/roll-off, LASH, SEABEE, water-way barge, or boat. On deck storage is permissible with some protection for cylinder rods. The HYEX height of 10 feet 1 inch allows the sea shipment within the LASH lighter. 0100-2 TM 5-3805-294-10 0100 HYEX LIFTING AND TIE DOWN PROVISIONS. HYEX Transportation Data Plate shows location of the lifting points, tie down points, and machine center of gravity (CG). TRANSPORTATION DATA GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD - 60,000 LB. NO. OF SLINGS REQUIRED LENGTH OF SLINGS 4 12 FT. - EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS SWING CENTERLINE 44 MM [1.7 IN.] CENTER OF GRAVITY 1212 MM [47.5 IN.] HYEX03192 Figure 3. HYEX Transportation Data Plate. The following values are the HYEX Design Load Capabilities: 1. TieDown Provisions 1 and 2; a. Longitudinal = 92,250 lbs b. Vertical = 124,200 lbs 2. Tie Down Provisions 3 and 4; a. Longitudinal = 110.250 lbs b. Vertical = 110,250 lbs 3. Lift Provisions; a. Rated design limit = 60,000 lbs, each shackle b. Ultimate design factor 5:1 0100-3 TM 5-3805-294-10 0100 HYEX LIFTING AND TIE DOWN PROVISIONS - Continued. HYEX LIFT AND TIE DOWN PROVISIONS TIE DOWN 2 TIE DOWN 4 TIE DOWN 3 CAB TIE DOWN 1 LIFT POINTS =TIE DOWN 1 =TIE DOWN 2 =TIE DOWN 3 =TIE DOWN 4 HYEX03063 Figure 4. HYEX Lifting and Tie Down Points. Table 1. HYEX Lift and Tie Down Information. Provision QTY Location (Relative to CG) 1 - Tie Down 2 39 in. forward 30 in. below 56 in. 2 - Tie Down 2 26 in. forward 25 in. below 7 in. 3 - Tie Down 2 43 in. aft 30 in. below 56 in. 4 - Tie Down 2 30 in. aft 25 in. below 7 in. Lift Points 4 120 in. aft 5 in. below 15 in. 0100-4 Lateral TM 5-3805-294-10 0100 HIGHWAY: Figure (5) shows the HYEX on an M870 semi trailer. The top view also shows a possible M870 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport. 1 FOOT EXTENSION BOTH SIDES A A 13 FT. 6 IN. HEIGHT CLEARANCE LINE M870 TRAILER SECTION A-A HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 240D LCR Figure 5. M870 Loading. 0100-5 HYEX03073 TM 5-3805-294-10 0100 HIGHWAY: - Continued Figure (6) shows the HYEX on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport. 1 FOOT EXTENSION BOTH SIDES A A 13 FT. 6 IN. HEIGHT CLEARANCE LINE M870A1 TRAILER SECTION A-A HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 250D LCR Figure 6. M870A1 Loading. 0100-6 HYEX03072 TM 5-3805-294-10 0100 HIGHWAY: - Continued Figure (7) shows the HYEX on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport. A A 13 FT. 6 IN. HEIGHT CLEARANCE LINE M870A3 TRAILER SECTION A-A HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 240D LCR Figure 7. M870A3 Loading. 0100-7 HYEX03069 TM 5-3805-294-10 0100 RAIL: HYEX is equipped with 30 inch track shoes, which require the HYEX to have special rail routing. The armored HYEX has the same exterior dimensions as the standard cab model, so the armored cab version was not shown in the GIC envelope. The HYEX requires special routing for rail systems requiring the GIC dimensions. Figures (8), (9), and (10) show the HYEX modeled in various rail envelopes. HYEX RAIL DIAGRAM 51.4 INCH HIGH RAILCAR GIC RAIL CLEARANCE WITH STANDARD CAB HYEX03078 Figure 8. GIC Rail Clearance. 0100-8 TM 5-3805-294-10 0100 RAIL: - Continued HYEX RAIL DIAGRAMS AAR RAIL CLEARANCE WITH STANDARD CAB DOD RAIL CLEARANCE WITH STANDARD CAB HYEX03080 Figure 9. Standard Cab Clearance. 0100-9 TM 5-3805-294-10 0100 RAIL: - Continued HYEX RAIL DIAGRAMS AAR RAIL CLEARANCE WITH ARMORED CAB DOD RAIL CLEARANCE WITH ARMORED CAB HYEX03064 Figure 10. Armored Cab Clearance. Figures (11) and (12) show the proposed HYEX tie down configurations on the HTTX railcar. HYEX01370 Figure 11. HTTX Railcar Loading Overhead View. 0100-10 TM 5-3805-294-10 0100 RAIL: - Continued HYEX01371 Figure 12. HTTX Railcar Loading Side View. AIR: The HYEX meets the requirements of MIL-HDBK-1791, Designing for Internal Aerial Delivery in Fixed Winged Aircraft (WP 0094) for transport on C-17 and C-5 aircraft. Figure (13) shows model of the HYEX, both standard and armored cab, inside the C-5 aircraft design envelope. The model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft. HYEX DIAGRAMS INSIDE C-5 AIRCRAFT STANDARD CAB ARMORED CAB LOAD RAMP CLEARANCE GROUND PLANE BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE Figure 13. BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE HYEX03066 C-5 Aircraft Loading. 0100-11 TM 5-3805-294-10 0100 AIR: - Continued Figure (14) shows model of the HYEX, both standard and armored cab, inside the C-17 aircraft design envelope. The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft. HYEX DIAGRAMS INSIDE C-17 AIRCRAFT STANDARD CAB ARMORED CAB LOAD RAMP CLEARANCE LOAD RAMP CLEARANCE GROUND PLANE BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE HYEX03065 Figure 14. C-17 Aircraft Loading. MARINE: Marine tie-down restraint depends on the size of the ship (decreasing on larger vessels), the expected sea state to be encountered, and the stow location of a given ship. Generally, the restraint required will increase for locations high and forward (or aft) in the ship. The most severe conditions will occur on exposed "weather decks," where strong wind and wet conditions add to the problem. A ship’s crew may require additional lashing on exposed decks. Belowdeck locations that are closer to the vessel’s center of gravity and rotation will experience less severe motion. HYEX01372 Figure 15. Marine Loading. 0100-12 TM 5-3805-294-10 0100 HYEX STANDARD BUCKET AND SPECIAL PURPOSE KITS (SPK) TRANSPORTABILITY. All HYEX attachments have lifting and tie-down provisions included for ease in preparing for transport. The standard HYEX quick latch system enables ease in changing attachments. The HYEX attachments can be directly chained down to railcar/trailer for transport. HYEX Attachments Weights are as follows: 1. Standard Rock Bucket, 42 in. = 3,000 lb (1361 kg) 2. Standard Ditch Cleaning Bucket = 2,337 lb (1060 kg) 3. Impact Breaker = 4,970 lb (2254 kg) 4. Crush-All = 7,450 lb (3379 kg) 5. Barrier Grapple = 870 lb (395 kg) 6. Plate Compactor = 2,200 lb (998 kg) 7. Deep Dig Arm = 3,440 lb (1560 kg) STANDARD BUCKET TIE DOWN PROVISIONS. Figure (16) shows the Standard Rock Bucket lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03083 Figure 16. Standard Rock Bucket. 0100-13 TM 5-3805-294-10 0100 STANDARD BUCKET TIE DOWN PROVISIONS - Continued. Figure (17) shows the Standard Ditch Cleaning Bucket lifting and tie-down provisions. TIE DOWN PROVISIONS Figure 17. HYEX03087 Standard Ditch Cleaning Bucket. HIGHWAY: Figure (18) shows the Standard Buckets on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down configuration. 0100-14 TM 5-3805-294-10 0100 HIGHWAY: - Continued HYEX STANDARD BUCKETS ON M870A1 TRAILER HYEX03071 Figure 18. Standard Buckets Loaded On M870A1. Figure (19) shows the Standard Buckets on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down configuration. HYEX STANDARD BUCKETS ON M870A3 TRAILER HYEX03068 Figure 19. Standard Buckets Loaded On M870A3. 0100-15 TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS. Figure (20) shows the Deep Dig Arm lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03089 Figure 20. Deep Dig Arm. Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions. TIE DOWN PROVISIONS Figure 21. HYEX03086 Deep Dig Bucket. Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions. 0100-16 TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued. TIE DOWN PROVISIONS HYEX03085 Figure 22. Deep Dig Ditch Cleaning Bucket. 0100-17 TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued. Figure (23) shows the Crush-All lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03084 Figure 23. Crush-All. Figure (24) shows the Compactor lifting and tie-down provisions. TIE DOWN PROVISIONS Figure 24. Compactor. 0100-18 HYEX03082 TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued. Figure (25) shows the Impact Breaker lifting and tie-down provisions. TIE DOWN PROVISIONS Figure 25. HYEX03081 Impact Breaker. Figure (26) shows the Barrier Grapple lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03147 Figure 26. Barrier Grapple. 0100-19 TM 5-3805-294-10 0100 CRUSH-ALL TIE DOWNS FOR HIGHWAY TRANSPORT. Figure (27) shows the Crush-All loaded on M870A1 semi trailer. The top view also shows possible M870A1 tie down configuration. HYEX CRUSH-ALL ATTACHMENTS ON M870A1 TRAILER HYEX03070 Figure 27. Crush-All On M870A1. Figure (28) shows the Crush-All loaded on M870A3 semi trailer. The top view also shows possible M870A3 tie down configuration. HYEX CRUSH-ALL ON M870A3 TRAILER HYEX03067 Figure 28. Crush-All On M870A3. 0100-20 TM 5-3805-294-10 0100 TRANSPORTING ON RAIL. Figures (29) through (32) shows the Standard Buckets and Special Purpose Kits loading and tie downs on a HTTX railcar. The top view also shows possible HTTX railcar tie down configurations. BUCKETS ON HTTX RAILCAR HYEX03077 Figure 29. Standard Buckets Loaded On HTTX Railcar. HYEX CRUSH-ALL ATTACHMENT ON HTTX RAILCAR HYEX03076 Figure 30. Crush-All Loaded On HTTX Railcar. 0100-21 TM 5-3805-294-10 0100 TRANSPORTING ON RAIL - Continued. HYEX IMPACT BREAKER, COMPACTOR, AND BARRIER GRAPPLE ON HTTX RAILCAR HYEX03074 Figure 31. Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar. HYEX DEEP DIG ATTACHMENTS ON HTTX RAILCAR HYEX03075 Figure 32. Deep Dig Arm and Buckets Loaded On HTTX Railcar. END OF WORK PACKAGE 0100-22 TM 5-3805-294-10 INDEX Subject WP Sequence No.-Page No. A ADDITIONAL AUTHORIZATION LIST (AAL).......................................................................... ADJUSTING THE OPERATOR'S SEAT................................................................................. AIR CONDITIONER DOES NOT OPERATE.......................................................................... AIR CONDITIONER/HEATER FILTER SERVICE................................................................... AUTO-IDLE DOES NOT WORK............................................................................................. WP 0096-1 WP 0006-1 WP 0045-1 WP 0090-1 WP 0052-1 B BARRIER GRAPPLE DOES NOT HOLD LOAD..................................................................... BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE....................................................... BREAKER DOES NOT OPERATE......................................................................................... BREAKER OPERATES SLOWLY........................................................................................... BUCKET TEETH REPLACEMENT......................................................................................... WP 0073-1 WP 0041-1 WP 0070-1 WP 0071-1 WP 0085-1 C CAB DOME LIGHT DOES NOT OPERATE............................................................................ CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................ CAB FUSE REPLACEMENT................................................................................................... CAB REAR WORK LIGHTS DO NOT OPERATE................................................................... COMPACTOR DOES NOT OPERATE................................................................................... COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS................... CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT................................................. CRUSH-ALL DOES NOT OPERATE...................................................................................... WP 0040-1 WP 0042-1 WP 0084-1 WP 0043-1 WP 0069-1 WP 0095-1 WP 0092-1 WP 0072-1 D DECAL LOCATION GUIDE..................................................................................................... DEEP DIG DOES NOT OPERATE......................................................................................... DESCRIPTION AND USE OF MONITOR AND ALARMS....................................................... DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS....................... DRAINING WATER AND SEDIMENT FROM FUEL TANK.................................................... WP 0027-1 WP 0074-1 WP 0005-1 WP 0004-1 WP 0091-1 E ENGINE COOLANT TEMPERATURE ABOVE NORMAL...................................................... ENGINE CRANKS BUT DOES NOT START OR HARD TO START...................................... ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE................................... ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE..................................................... ENGINE IDLES POORLY....................................................................................................... ENGINE NOT DEVELOPING FULL POWER......................................................................... ENGINE OIL PRESSURE LOW.............................................................................................. ENGINE RUNS POORLY........................................................................................................ ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED................................ ENGINE WILL NOT CRANK................................................................................................... EQUIPMENT DESCRIPTION AND DATA.............................................................................. EXCESSIVE FUEL CONSUMPTION...................................................................................... EXCESSIVE OIL CONSUMPTION......................................................................................... EXPENDABLE AND DURABLE ITEMS LIST......................................................................... Index-1 WP 0055-1 WP 0046-1 WP 0056-1 WP 0057-1 WP 0051-1 WP 0053-1 WP 0054-1 WP 0048-1 WP 0067-1 WP 0047-1 WP 0002-1 WP 0049-1 WP 0050-1 WP 0097-1 TM 5-3805-294-10 INDEX - Continued Subject WP Sequence No.-Page No. F FORDING THE HYEX............................................................................................................. FRESH AIR FILTER SERVICE............................................................................................... WP 0036-1 WP 0089-1 G GENERAL INFORMATION..................................................................................................... GENERAL MAINTENANCE INSTRUCTIONS........................................................................ GENERAL MONITOR OPERATION....................................................................................... WP 0001-1 WP 0078-1 WP 0013-1 H HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER........................ HYDRAULIC HOSE REEL DOES NOT OPERATE................................................................ HYDRAULIC OIL FOAMS....................................................................................................... HYDRAULIC OIL OVERHEATS.............................................................................................. HYDRAULIC RESERVOIR SERVICE..................................................................................... HYEX TRANSPORTABILITY INSTRUCTIONS...................................................................... WP 0059-1 WP 0075-1 WP 0062-1 WP 0061-1 WP 0088-1 WP 0100-1 I INSTALLING AND OPERATING THE COMPACTOR............................................................ INSTALLING AND OPERATING THE CRUSH-ALL............................................................... INSTALLING AND OPERATING THE IMPACT BREAKER.................................................... INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...... WP 0021-1 WP 0019-1 WP 0020-1 WP 0076-1 L LIFTING WITH HYEX.............................................................................................................. LOOSENING TRACK TENSION............................................................................................. LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE................................................. LOWERING BOOM WITHOUT HYDRAULIC PRESSURE..................................................... WP 0015-1 WP 0082-1 WP 0044-1 WP 0029-1 M MAINTENANCE AFTER FORDING........................................................................................ MOVING MACHINE ON/OFF AN EMBANKMENT................................................................. MOVING THE HYEX............................................................................................................... MOVING UP/DOWN STEEP OR SLIPPERY SLOPES.......................................................... WP 0093-1 WP 0024-1 WP 0008-1 WP 0035-1 N NO HYDRAULIC FUNCTIONS............................................................................................... NO SWING FUNCTION.......................................................................................................... WP 0058-1 WP 0063-1 O OPENING AND CLOSING WINDOWS................................................................................... OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)................................................. OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER .............................................. OPERATING TECHNIQUES................................................................................................... OPERATING THE BARRIER GRAPPLE................................................................................ OPERATING THE COOLANT HEATER................................................................................. OPERATING THE DEEP DIG ARM........................................................................................ Index-2 WP 0011-1 WP 0030-1 WP 0031-1 WP 0016-1 WP 0022-1 WP 0034-1 WP 0023-1 TM 5-3805-294-10 INDEX - Continued Subject WP Sequence No.-Page No. O OPERATING THE HYDRAULIC HOSE REEL........................................................................ OPERATING THE HYDRAULIC THUMB................................................................................ WP 0026-1 WP 0017-1 P POWER DIG DOES NOT WORK............................................................................................ PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)..................................... PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE............................ PRIMARY AND SECONDARY AIR CLEANER SERVICE...................................................... WP 0060-1 WP 0077-1 WP 0086-1 WP 0087-1 Q QUICK LATCH DOES NOT OPERATE.................................................................................. WP 0068-1 R REFERENCES........................................................................................................................ REMOVING AND INSTALLING BUCKET............................................................................... WP 0094-1 WP 0014-1 S SELECTING AN ATTACHMENT ON THE MONITOR............................................................ SHUTTING DOWN THE HYEX............................................................................................... SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED............................. SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................................................................................................................................... SLAVE STARTING.................................................................................................................. SLOW TRAVEL SPEED ONLY............................................................................................... SPECIAL PURPOSE KITS (SPK) LIST................................................................................... STARTING THE ENGINE....................................................................................................... SWING FUNCTION IS JERKY................................................................................................ WP 0018-1 WP 0009-1 WP 0010-1 WP 0033-1 WP 0032-1 WP 0065-1 WP 0098-1 WP 0007-1 WP 0064-1 T TAKING ENGINE OIL SAMPLE.............................................................................................. TAKING HYDRAULIC OIL SAMPLE....................................................................................... THEORY OF OPERATION..................................................................................................... TIGHTENING TRACK TENSION............................................................................................ TOWING THE HYEX............................................................................................................... TRACK SAG CHECK ............................................................................................................. TRAVEL ALARM DOES NOT OPERATE............................................................................... TRAVEL IS JERKY.................................................................................................................. TROUBLESHOOTING NOTES............................................................................................... TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE........................... WP 0079-1 WP 0083-1 WP 0003-1 WP 0081-1 WP 0028-1 WP 0080-1 WP 0038-1 WP 0066-1 WP 0099-1 WP 0037-1 U USING THE RIFLE MOUNT.................................................................................................... USING THE VANDAL PROTECTION KIT.............................................................................. WP 0012-1 WP 0025-1 W WINDSHIELD WIPER AND WASHER DO NOT OPERATE................................................... Index-3/4 blank WP 0039-1 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is ODISC4. Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 Your mailing address DATE Date you filled out this form. PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS Title PUBLICATION/FORM NUMBER DATE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU TM  ITEM NO. PAGE NO. PARAGRAPH LINE NO. * TYPED NAME, GRADE OR TITLE Your Name DA FORM 2028, FEB 74 0DUFK +<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK FIGURE TABLE NO. NO. RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). *Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature Your Signature REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00 TO: (Forward direct to addressee listed in publication) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 FROM: (Activity and location) (Include ZIP Code) DATE Date you filled out this form Your address PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU DATE  0 MarFK  +<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK PUBLICATION NUMBER TM PAGE NO. COLM NO. LINE NO. NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION SAMPLE PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.) TYPED NAME, GRADE OR TITLE Your Name TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE Your Signature USAPPC V3.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. PARAGRAPH LINE NO. * 0 MarFK FIGURE TABLE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). *Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00 TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; DATE TM  PAGE NO. COLM NO. LINE NO. NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER PART III – REMARKS TYPED NAME, GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (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.) TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE USAPPC V3.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. PARAGRAPH LINE NO. * 0 MarFK FIGURE TABLE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). *Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00 TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; DATE TM  PAGE NO. COLM NO. LINE NO. NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER PART III – REMARKS TYPED NAME, GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (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.) TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE USAPPC V3.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. PARAGRAPH LINE NO. * 0 MarFK FIGURE TABLE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). *Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00 TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; DATE TM  PAGE NO. COLM NO. LINE NO. NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER PART III – REMARKS TYPED NAME, GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (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.) TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE USAPPC V3.00 RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. PARAGRAPH LINE NO. * 0 MarFK FIGURE TABLE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). *Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE DA FORM 2028, FEB 74 TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00 TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(; DATE TM  PAGE NO. COLM NO. LINE NO. NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER PART III – REMARKS TYPED NAME, GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (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.) TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE USAPPC V3.00 By Order of the Secretary of the Army: GEORGE W. CASEY, JR. General, United States Army Chief of Staff Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1103409 Distribution: To be distributed in accordance with the Initial Distribution Number (IDN) 257856 requirements for TM 5-3805-294-10. 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 SQUARE MEASURE 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles WEIGHTS 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Lb 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons CUBIC MEASURE 1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet TEMPERATURE 5/9 ( F - 32) = C 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 LIQUID MEASURE 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces APPROXIMATE CONVERSION FACTORS MULTIPLY BY 1 CM 2 3 4 5 2 6 7 2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 1.609 1 Centimeters . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . . Kilometers per Hour . . . . . . . . . . . INCHES Inches . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . Square Feet . . . . . . . . . . . . Square Yards . . . . . . . . . . . Square Miles . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . Gallons. . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . Pounds/Sq Inch . . . . . . . . . Miles per Gallon . . . . . . . . Miles per Hour . . . . . . . . . . TO 0 TO CHANGE 3 8 TO CHANGE TO MULTIPLY BY 9 10 11 12 13 14 15 6 0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621 5 Inches . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . . . Miles. . . . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . . . Pounds. . . . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . . 4 Centimeters . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . Meters. . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . Sq Centimeters . . . . . . . . . Square Meters . . . . . . . . . . Square Meters . . . . . . . . . . Square Kilometers . . . . . . Sq Hectometers . . . . . . . . Cubic Meters ............. Cubic Meters . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . Metrication . . . . . . . . . . . . . Newton-Meters . . . . . . . . . Kilopascals . . . . . . . . . . . . . Km per Liter . . . . . . . . . . . . Km per Hour. . . . . . . . . . . . PIN 086698-000