Excavator John Deree

June 4, 2018 | Author: Budi Waskito | Category: Fires, Exhaust Gas, Air Conditioning, Carbon Monoxide, Battery (Electricity)
Share
Report this link


Description

TM 5-3805-294-10TECHNICAL 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 " column indicates an original page or work package.TM 5-3805-294-10 LIST OF EFFECTIVE PAGES/WORK PACKAGES NOTE: Zero in the "Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 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 . 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. 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. 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.Continued CHANGE 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 LIST OF EFFECTIVE PAGES/WORK PACKAGES . PAGE/WP NO. army.C.TM 5-3805-294-10 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON. or if you would like to recommend any improvements to the procedures in this publication. The e-mail address is: tacomlcmc.. The fax number is DSN 793-0726 or Commercial (309) 782-0726. Army TACOM Life Cycle Management Command. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. MI 48397-5000. The Internet address is https://aeps.+($'48$57(56 i/ii blank . distribution is unlimited.S. If you find any errors.army. You may also mail. Army TACOM Life Cycle Management Command. or fax your comments or DA Form 2028 directly to the U.daform2028@us. ATTN: AMSTA-LCL-MPP / TECH PUBS.Approved for public release. The postal mail address is U. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet. D. e-mail. on the Army Electronic Product Support (AEPS) website. 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.mil. 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.S. Fill out the form and click on SUBMIT. A reply will be furnished to you. 11 Mile Road. Warren.ria. DISTRIBUTION STATEMENT A . please let us know. 6501 E.mil. . ........ 0002-3 Table 1................................... WP 0002 Figure 1.......................................... Equipment Data..................................... 0002-7 Figure 5............................................................................................ HYEX Working Ranges...................................................................... HYEX Working Ranges............................................ Hydraulic System Components....................................................... Hydraulic System Components. Side Lift Capacities........................................ 0002-12 THEORY OF OPERATION........ 0002-5 Table 4.............................................................................................. 0003-2 Table 1.............................................................................. 0003-3 Figure 3......................................... 0002-12 Table 10................................ 0002-11 Table 9................................ 0002-5 Table 3................................................ Front Lift Capacities....................... 0002-3 Figure 2................................................................... 0002-8 Table 6..................................................... 0002-10 Table 8.................................................................................................................................................. Right View of HYEX.................................................................................................................................................................... HYEX Specifications........................................................... WP 0003 Figure 1.......................................... WP 0001 Table 1.................................................... 0002-9 Table 7........ 0003-4 Table 3........................................................................................... How to Use this Manual Chapter 1 ............ 0002-6 Figure 4.................... Deep Dig Arm Weights..................... HYEX Weights With Attachments........... 0003-2 Figure 2............................... 0001-2 EQUIPMENT DESCRIPTION AND DATA...................................................................................... Data Plates........................................................................................................ HYEX Specification................................................................... Left View of HYEX.................................................................................. 0002-4 Figure 3......... Left View of HYEX...................................................................... 0003-4 iii ..................................................................................................................... 0003-3 Table 2................................................... WP Sequence No....................... 0002-4 Table 2............................................... Hydraulic System Components Continued.................................... 0002-7 Table 5...................... Data Plates................................................OPERATOR GENERAL INFORMATION GENERAL INFORMATION................... Electrical System Components...........................................TM 5-3805-294-10 TABLE OF CONTENTS Page No................................................................ List of Abbreviations/Acronyms.................................................................................................................... Electrical System Components...... Hydraulic System Components Continued............................ Right View of HYEX................... .......................................................................... Cooling System Components............................................................................................... Left Console and Pilot Shutoff Lever..................OPERATOR INSTRUCTIONS DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........................................ 0004-1 Figure 1.................................................................... WP 0004 Table 1............................................................... Powertrain Components............. Cooling Package.................. Left Console and Pilot Shutoff Lever....... High-Pressure Pump and Injectors........................................................................................... 0003-5 Figure 5..................................................... Fuel System Components....... Figure 4................................. Powertrain Components................................................................................................................................Continued Page No............................ High-Pressure Pump and Injectors......................... 0003-7 Figure 7....................................... Left Pilot Control Lever.......... 0003-6 Figure 6................................... 0004-4 Table 3........................... Heater/Air Conditioner (A/C) Controller and Radio Continued.................................. Fuel System Components......................... 0004-8 Figure 9............... 0004-3 Figure 4....................... Cooling System Components............... Control Pedals and Levers Continued............................................................................................... 0003-6 Table 5............................................................................................... 0003-8 Table 7.. 0004-2 Table 2................. 0004-5 Figure 6............................................ Right and Left Pilot Control Levers...................................................................................................................................................................................................................................................................................... Heater/Air Conditioner (A/C) Controller and Radio........... WP Sequence No.... Heater/Air Conditioner (A/C) Controller and Radio........................................................................TM 5-3805-294-10 TABLE OF CONTENTS ...... Control Pedals and Levers..................................... 0004-9 Table 6.................................... 0004-7 Table 5................................................................. Front Switch Panel............ 0004-10 iv ............. 0004-8 Figure 8............................................................. 0003-9 Table 8............................................................ 0003-5 Table 4................................ 0004-1 Figure 2.. 0003-9 Chapter 2 . Control Pedals and Levers.............................................................................................. Front Switch Panel Continued... Right Pilot Control Lever....................................... Front Switch Panel............................................... 0004-5 Figure 5................................................... 0004-3 Figure 3.................................. 0003-7 Table 6........................................ Cooling Package.................................... 0003-8 Figure 8.................................... 0004-6 Table 4............ 0004-7 Figure 7................................................................. Seat Controls.............................. ................................................................... Monitor Buttons and Indicators........................................................ Key Switch ON.............................................................................................. Engine Speed Dial Slow Idle.................................................................................................... 0004-14 Table 10.......................................... 0007-4 v ............. Hydraulic Hose Reel............... 0004-13 Table 9............ Cab Door Release Lever and Coolant Heater Display.... 0005-6 Figure 6....................................................................................................................................................... Operator's Seat Adjustments....................................... Seat Controls................................................................................................................................. Monitor Buttons.................................................................. 0007-3 Figure 6................................................. 0006-1 STARTING THE ENGINE..... Cab Door Release Lever and Coolant Heater Display........................................................ Seat Belt............................................................................... 0005-6 Figure 5............. Quick Latch Control.......................................................................................................... 0004-12 Figure 11..................................................................................................................................... 0004-15 Figure 14........... 0004-15 DESCRIPTION AND USE OF MONITOR AND ALARMS.......................................... Monitor Indicators............................................................ 0004-10 Table 7... Warning Indicators and Alarms.............. Figure 10............................................................................................................................................ Pilot Shutoff Lever................... System Starting and Default Screen..... 0005-1 Figure 1........ 0004-13 Figure 12.... Cab Light Switch................................. Main Menu........................................................................................................................ Preheat Indicator................................. 0007-3 Figure 5............................. 0005-3 Figure 4........................................Continued Page No.............................. WP 0005 Table 1.................................. 0005-2 Figure 3.................................................................................................................................................................. WP Sequence No................. Cab Light Switch................ Monitor...................... Overload Alarm............. 0004-12 Table 8........ 0004-14 Figure 13..................... 0007-2 Figure 3...... 0007-2 Figure 4.................................................................................................... 0005-1 Figure 2................................................................................................... WP 0007 Figure 1......................................................... 0007-1 Figure 2..................... 0005-4 Table 2.................................................................................................................. WP 0006 Figure 1....................................................TM 5-3805-294-10 TABLE OF CONTENTS . 0005-7 ADJUSTING THE OPERATOR'S SEAT................. Warning Indicators and Alarms............................................................................................................... Hydraulic Hose Reel........... Quick Latch Control.................................................................................................................................. ................................................... WP 0011 Figure 1................. Moving Forward and Backwards.............................. Right Turn............................................................................................................................................................................................... WP 0010 Figure 1............................ Figure 7.................................. 0008-5 SHUTTING DOWN THE HYEX...................................................................................................................................................... 0009-3 Figure 5.................................................................. WP Sequence No. 0009-2 Figure 3....................... Boom and Arm Raised..... 0010-4 OPENING AND CLOSING WINDOWS.. WP 0009 Figure 1............................................................ Key Switch Turned OFF................................................ 0009-3 Figure 4............................... Raise Windshield................................................................ 0010-3 Figure 5.. Engine Speed Dial.................................................. Machine In Parked Position..........................TM 5-3805-294-10 TABLE OF CONTENTS ................................................................ Auto-Idle Switch and Engine Speed Dial....................................................................... Travel Mode Switch...................................... 0008-2 Figure 4............................................................................................................................................................................................................................................................................................. Pilot Shutoff Lever................................... Pilot Shutoff Lever Unlocked......................................... 0011-1 Figure 2..... Engine Speed Dial......................................... Left Turn................... 0010-2 Figure 3.............................................................. Machine In Parked Position............... 0007-5 Figure 9.............. 0008-4 Figure 6........................................ 0007-6 MOVING THE HYEX..................................................... Alarm indicator.........................................................................................................................Continued Page No............................ 0010-1 Figure 2................... Return Engine Speed Dial to Slow Idle..................... Open Windshield........................ Auto-Idle Switch and Engine Speed Dial............................................................ Key Switch to START............................................ WP 0008 Figure 1............................................ 0010-3 Figure 4.... 0008-4 Figure 7.................................................................................................... 0008-2 Figure 3..................................................................... Engine Speed Dial Turned to 1/3 Position................................ 0009-1 Figure 2....................... 0011-2 vi ............................................................................................................ Key Switch Turned OFF................................................... Pilot Shutoff Lever........... Counter-Rotate...................................................... 0007-4 Figure 8......... 0008-1 Figure 2......... 0009-4 SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED...................................................................................................................................................................................... 0008-3 Figure 5...................................................................................... 0007-5 Figure 10............................................... ...................................... Figure 3................................................... Raise Boom..... 0012-2 Figure 3..........................................TM 5-3805-294-10 TABLE OF CONTENTS .. 0014-4 Figure 8........ 0012-1 Figure 2....... 0011-4 Figure 8....................................................................... 0014-2 Figure 3............................................................................................................................................................................................................................................................................................................................................................................................. WP 0014 Figure 1........... 0013-2 Figure 3............. Adjust Time..................................................... Extend Bucket Cylinder....................... Lock Windshield Open............................................................................................................................................................. WP Sequence No............... WP 0013 Figure 1......................................................................... Open and Close Skylight Window................. Open Access Cover..................................... Remove Weapon From Rear Bracket............... Reset Operating Conditions................ 0014-5 vii ............................................................................................................................................................................. Move Quick Latch Switch to Unlatch Position.. 0011-2 Figure 4.................................. Open and Close Cab Door Window......................................................................................................................... 0014-3 Figure 6.. 0014-4 Figure 7.......................................................... WP 0012 Figure 1....................... 0011-4 Figure 7............. Lower Boom............................................................................. 0011-6 USING THE RIFLE MOUNT......................... Remove Quick Latch................ Position Quick Latch Switch to Latch position.................................................................................................................................. Release Windshield Latch.......... 0013-2 Figure 4.. Close Windshield............................................... 0011-3 Figure 6...................................................................................................................................................................... Select Operating Conditions Menu.........Continued Page No........................ Close Access Cover........... Stow Weapon In Front Bracket................................................................................... 0014-2 Figure 4........... 0012-2 Figure 4...................................................................... Stow Weapon In Rear Bracket....................................... Unlock Safety Lock Pin................. 0011-5 Figure 10................................. 0013-3 REMOVING AND INSTALLING BUCKET................................................................................................................................................................ Remove Weapon From Front Bracket............ 0011-5 Figure 9......... 0012-3 GENERAL MONITOR OPERATION................................................................................................... 0014-1 Figure 2.......................... 0014-3 Figure 5....................................... Latch Windshield. 0013-1 Figure 2............................................................................................................ 0011-3 Figure 5................................ Retract Bucket Cylinder......................... Select Time Set Menu. ........................................................... Safety Pin Locked................................................... Back Filling........... 0018-1 viii ......................... Position Quick Latch Switch toLatch position........... Raise Boom........................................................................................................ 0016-8 Figure 10... 0016-3 Figure 4.......................................................................................... WP 0018 Figure 1....................... 0016-6 Figure 8...............................................TM 5-3805-294-10 TABLE OF CONTENTS . WP 0015 Figure 1................................................................. Clamping With Bucket............................. 0016-5 Figure 6............. 0014-6 Figure 10................. 0016-7 Figure 9............... Position Quick Latch Switch to Unlatch position....................... 0017-3 SELECTING AN ATTACHMENT ON THE MONITOR............................................................................................. Add or Remove Material..................................................................................................... 0014-6 Figure 11...................................... Install Quick Latch..................................................................................................................................... Trenching............... 0016-4 Figure 5....................................... WP 0016 Figure 1... 0016-1 Figure 2........................................................................................................................ Cleaning Cave In. Releasing Objects...................................................................... Lifting with Quick Latch Loop............................................................ 0017-2 Figure 3.......................................................................................................................................................................................................... 0014-7 Figure 13................................................. 0016-1 Figure 3................. Arm Digging............................................................................................................................................ WP 0017 Figure 1................................................................ 0016-10 OPERATING THE HYDRAULIC THUMB.......................................................................... Figure 9............................................................................................ 0014-9 LIFTING WITH HYEX.....................................................................................................................................................................................................................Continued Page No.......... Leveling Machine.................................................. Retract Wedges.......................................................................................... Bucket Digging............................................................................................................................................................... Planning Spoil Piles.... 0016-9 Figure 11..................... Select Attachment.................................................................................. Straight Line Trenching......... 0017-1 Figure 2.......................... 0014-7 Figure 12............................................................................. Truck Loading........................... 0014-8 Figure 14............................................................................... Clamping With Hydraulic Thumb.................. 0014-8 Figure 15................... Raise Boom for Clearance............... WP Sequence No............................ 0015-2 OPERATING TECHNIQUES.......................... 0016-6 Figure 7........................ Trenching on a Slope................................................. ................ WP Sequence No....................... Disconnect Auxiliary Return Line....................................................................................................................................... Position Crush-All....................................................TM 5-3805-294-10 TABLE OF CONTENTS .......................................................................................................................................................................................................................................................................... 0019-12 Figure 16................. 0018-2 INSTALLING AND OPERATING THE CRUSH-ALL.............. Position Crush-All.......................................................................... 0019-11 Figure 15............................. 0019-9 Figure 11.................... Connect Auxiliary Return Line............................................................... Move Quick Latch Switch to Unlatch Position........... Open Hydraulic Thumb Circuit............................................................................................................. 0019-14 Figure 20............................ 0019-5 Figure 8....................... Attachment Selection.. Crush-All Operation.............. 0019-13 Figure 18................................................................................................................................... Close Hydraulic Thumb Circuit.......................................................Continued Page No............................................................................. 0019-2 Figure 3......................................................... 0019-7 Figure 10................................................................................................................................................................................................................................................... 0019-3 Figure 5...................... 0019-10 Figure 14............................ Move Quick Latch Switch.. 0019-10 Figure 13................. Quick Latch Switch to Latch Position............... 0019-14 Figure 19................... 0019-1 Figure 2........................................... 0019-4 Figure 6...... Open Lid............................................................................ Table 1................................................. Extend Bucket Cylinder................................................. Connect Auxiliary Supply Line................................................................................................................................................................... WP 0020 Figure 1...................................................................................................... 0019-5 Figure 9......... 0018-1 Figure 2................................. WP 0019 Figure 1........................... Push Crush-All Rotor Backwards........ Attachment Specification Screen................................................. Move Quick Latch Switch........ 0020-2 Figure 3...... Raise Boom....... Move Quick Latch Switch.............. 0019-15 INSTALLING AND OPERATING THE IMPACT BREAKER................... Close Hydraulic Thumb Circuit.. 0020-3 ix ..................................................................... Clearing Jam from Crush-All.... Raise Boom.............................................................................................................. Install Quick Latch............... Remove Quick Latch.......................................................................... 0020-1 Figure 2.................... 0019-9 Figure 12................................................ 0019-12 Figure 17........ Disconnect Auxiliary Supply Line... 0019-4 Figure 7....................................... 0019-3 Figure 4.......................................................... ....................................................................... Lock Breaker Tool......................... 0020-8 Figure 13............................... 0020-11 Figure 18............... 0020-14 Figure 25......................................................................................... 0020-4 Figure 6.. Safety Pin to Unlock Position. Quick Latch Wedges Retracted............................................................................................................. Disconnect Auxiliary Return Line.............. Extend Bucket Cylinder..... Move Quick Latch Switch to Unlatch Position......................... Disconnect Auxiliary Supply Line.................................. Quick Latch Wedges Engaged.................... Breaker Tool Lock Bolt............................... Figure 4.................. Lock Breaker Tool.................................................................................................................. 0020-11 Figure 19..................................... Quick Latch Switch to Latch Position........................................ 0020-14 Figure 24.............. Insert Breaker Tool................................................... 0020-5 Figure 9...... 0020-12 Figure 20.... Impact Breaker Removal..................................... Breaker Operation.. Install Quick Latch........................................ 0020-9 Figure 14.............................................. Connect Auxiliary Supply Line................................. Move Quick Latch Switch to Latch Position................................................................................................ Tool Removal........................................................................................................................................................... 0020-13 Figure 23......................................................................................................................................................................................................................................................TM 5-3805-294-10 TABLE OF CONTENTS ............................................................................... 0020-10 Figure 16.. Raise Boom for Clearance...................... 0020-12 Figure 21.................................................... Open Hydraulic Thumb Circuit............................. 0020-6 Figure 11............. Remove Breaker Tool................................. Safety Pin to Lock Position............................. 0020-6 Figure 10...................................................................... WP 0021 Figure 1............................ 0021-3 x .............. 0020-16 INSTALLING AND OPERATING THE COMPACTOR.............................................. 0020-3 Figure 5.......................................... Close Hydraulic Thumb Circuit.......................................................................................... 0021-2 Figure 2................................................................................................. Quick Latch Wedges Retracted.......................................................................................................................Continued Page No......... 0020-5 Figure 8.............................. Connect Auxiliary Return Line...... 0020-15 Figure 27... 0020-9 Figure 15.. 0020-15 Figure 26.......................................................... 0020-7 Figure 12........................ 0020-4 Figure 7..................................................................... Move Quick Latch Switch.......................... 0020-10 Figure 17..................................................................................................................................... 0020-13 Figure 22.............................................. WP Sequence No............................................... .................................................. 0021-13 Figure 23... Retract Bucket Cylinder... 0023-3 xi ............................... Raise Boom for Clearance.................................................................................................................................................................. 0023-1 Figure 2................................... Connect Auxiliary Supply Line...................................................... Lock Safety Lock.......... Attachment Pedal Lock Release.......................................................................... Deep Dig Control Pattern Switch..................... 0021-3 Figure 4.......... Connect Auxiliary Supply Line................................................................... WP Sequence No.................................................................. WP 0022 Figure 1............................................................................................... Turn Auto Idle Switch On........................................................................................................ Remove Quick Latch.......................... Close Hydraulic Thumb Circuit................................ 0021-6 Figure 9...................................................................................................................................................................................................................................................... 0021-4 Figure 6....................................................... Quick Latch Wedges Retracted................ 0021-8 Figure 14............................................................................................. 0022-2 OPERATING THE DEEP DIG ARM..................................... 0021-8 Figure 13........................................................................ Lifting Barrier Grapple........................................ Unlock Safety Lock.................. 0021-7 Figure 12.......................................................................... 0021-5 Figure 7..............................................TM 5-3805-294-10 TABLE OF CONTENTS .. Install Quick Latch.......... Position Quick Latch.............................................. 0021-6 Figure 10................................. Raise Boom................................................................................................ Figure 3..................... Engage Quick Latch Wedges.................................................................................................. Quick Latch Switch to Latch Position....................................................... 0021-13 Figure 22. 0021-10 Figure 16..............Continued Page No......................................... Raise Boom............................................ WP 0023 Figure 1............................................................................................ Disengage Quick Latch Wedges............................................ 0023-2 Figure 3......................................... 0021-10 Figure 17.............................................. 0021-4 Figure 5............................. 0021-11 Figure 18........................... 0021-12 Figure 21.... 0021-14 OPERATING THE BARRIER GRAPPLE.......... Disconnect Auxiliary Return Line.............................. 0021-9 Figure 15........................ Quick Latch Switch to Latch Position...... Pilot Shutoff Lever........................ 0021-7 Figure 11.... 0021-12 Figure 20............................................. 0021-11 Figure 19.................................... Quick Latch Switch to Unlatch Position....................................................... 0021-5 Figure 8.................................................................................................................................... Connect Auxiliary Return Line......................................................... .................. Right Side Front Cover Installation. 0025-7 Figure 14....................................................................... Right Rear Cab Cover Installation................................ 0023-4 Figure 5..................................... 0025-7 Figure 15...................................................................................................... Side Lower Glass Cover Installation............................. 0024-2 Figure 3.............................................................................................................................................................................................................. Position Bucket on Lower Level.................................................................................................... Side Upper Glass Cover Installation......................................................... Cycle Deep Dig Arm Cylinders....................................................................................... Right Side Center Cover Installation................................... Center Door Cover Installation............................................... Front Door Cover Installation.................................. 0025-5 Figure 11..................................................... 0025-9 Figure 19. 0025-10 xii .................................... Upperstructure Rotated................... 0025-6 Figure 13............................ 0025-2 Figure 5.................................. 0025-8 Figure 17.................................... 0025-4 Figure 8............................... Lock Bar Installation............................................................. Lock Bar Removal.............................................................................................................................. 0024-3 USING THE VANDAL PROTECTION KIT.......................................TM 5-3805-294-10 TABLE OF CONTENTS ......................................... Lower Door Cover Installation....................... 0025-5 Figure 10........................ 0025-6 Figure 12................................ 0023-5 MOVING MACHINE ON/OFF AN EMBANKMENT.............. Lower Door Cover Removal.......................................................... Left Rear Cab Cover Installation...................... WP 0024 Figure 1...... 0025-4 Figure 9............................. Right Side Rear Cover Installation...................................................................................................................................................................................... 0025-2 Figure 4............ Left Rear Cab Cover Removal... 0025-1 Figure 2............................................ 0025-3 Figure 6................................................................ Rotate Upperstructure to Upper Level.................. Position Bucket...................... WP 0025 Figure 1.. Side Upper Glass Cover Removal.................................... Right Rear Cab Cover Removal........................................................................................................ 0024-3 Figure 4......... 0025-3 Figure 7........................................................................................................................................................... Front Door Cover Removal........................................................................... Figure 4.......... 0024-1 Figure 2............. 0025-9 Figure 18......................................................... Center Door Cover Removal............. Side Lower Glass Cover Removal.............................................. 0025-8 Figure 16.............................. WP Sequence No..... Turn RPM Dial......................................................Continued Page No................................................. 0025-1 Figure 3. ............................................................................................................................... 0027-3 Figure 5.... 0027-2 Figure 4............................................ WP 0026 Figure 1...................... and Top Decals...................................................................... 0027-4 Figure 8... Cab on Seat.......................................................................................................................................................................................................................................................................... 0027-12 xiii ......................... Rear Cab Window.............. Right Side..................... Top Under Engine Cover............................................................ 0025-11 OPERATING THE HYDRAULIC HOSE REEL............................................................................................................................. Left Inside Door. Turn On Hydraulic Tool...................................................... 0026-2 Figure 4................................................................................. Right Side........................... Ditch Cleaning Bucket.......................... 0027-3 Figure 6.......................... 0027-7 Figure 14.............................................................................. 0026-1 Figure 2........................................ 0027-11 Figure 18....................... Upper Section Periodic Maintenance.......................... 0027-5 Figure 10.................................................... 0027-8 Figure 15................. Side Window..................................................................................................................... 0027-5 Figure 9...................................................Continued Page No.................................................................................................... Right Side Front Cover Removal....................... 0027-1 Figure 2........ 0027-2 Figure 3............. 0027-4 Figure 7............................................................................ Right Side Rear Cover Removal........................ Windshield............................................ 0026-3 DECAL LOCATION GUIDE............................................................ 0027-6 Figure 12.................................................................. Right Side on Hydraulic Reservoir............................... Hydraulic Tool Attachment.............. Lower Right Side Window......................................... 0025-10 Figure 22...................................... 0027-5 Figure 11......... 0027-9 Figure 16..... 0026-2 Figure 3.... WP 0027 Figure 1...... WP Sequence No.................... 0025-10 Figure 21.. Counterweight...................... Vandal Protection Kit................................................................................................................................................................................... Upper and Lower Right Side Window....................... Left Side............. 0027-10 Figure 17..... Figure 20............................................................ Lower Section Periodic Maintenance....................................................... Turn Off Hydraulic Tool..... 0027-6 Figure 13...................................................................................... Front and Rear Frame...................................................................................................................... Key Switch................... and Rear Cab Window...................................................................... Hydraulic Tool Removal.................... Right Side Center Cover Removal....................................................................... Boom..............TM 5-3805-294-10 TABLE OF CONTENTS ................ .......................... 0030-2 Figure 4.................................... 0030-3 Figure 5....................................................................................................................... 0030-6 OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER ....................................................................................................................................................................................... Figure 19...................................... 0031-1 Figure 2. 0031-2 Figure 4. 0027-14 TOWING THE HYEX......................... 0031-4 Figure 7............................ 0030-4 Figure 7............................... 0030-3 Figure 6........................ 0031-2 Figure 3....... 0031-3 Figure 5....................................................................................................................................................... Highlight Service Menu......................................................................................................................................................................................................................................... 0027-13 Figure 22............................................................. Highlight Service Menu................................................................... Press and Hold Back Button................................................... 0030-6 Figure 10...................................... WP 0030 Figure 1...................................... Select Monitoring....................................... Output Side Crush-All......................... WP 0031 Figure 1..................................... 0030-4 Figure 8................................................. Left Side Crush-All.................................. 0030-5 Figure 9.................................................................................................................................. Raise Machine.................................... Press and Hold Back Button...................................................................................................................................................................................... Release Back Button..... Release Back Button......................................................................................................................................TM 5-3805-294-10 TABLE OF CONTENTS ................... Engine Speed Dial........................................ Key Switch to ON Position............................................................................. 0030-1 Figure 2..................... Temperatures Displayed.... WP 0028 LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................................................................................... WP Sequence No................ Engine Idle Speed..................................... WP 0029 OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C).................................. 0031-5 xiv ...............................Continued Page No.................. Key Switch to ON Position.................................................................... 0027-13 Figure 21........................................ Check Engine and Hydraulic Oil Temperatures............... Heavy Duty Bucket................................................ Temperatures Displayed......................................................... 0030-2 Figure 3........................................................................................................ Select Monitoring.. 0031-3 Figure 6.. 0031-4 Figure 8............................... 0027-12 Figure 20... Machine Switch Selections.................................................... 0030-5 Table 1........................... Start Engine........................ Right Side Crush-All...... Start Engine..................................................... .................................... WP 0034 Figure 1.............................................. 0034-4 Figure 5............................................... Slave Receptacle.............................................................................. WP 0035 Figure 1...................................................................... Fording Line............. Adjusting Run Time.................................................... 0033-2 OPERATING THE COOLANT HEATER................................ Manually Start Coolant Heater Continued............................ Open and Close Roof Exit....................................... Buckle Seat Belt.................................................................................................................................................................................................................................. Figure 9... 0034-2 Figure 2................................. 0031-7 SLAVE STARTING.................................... Setting Program...................................................................................................... Pulling Machine Up......... 0035-3 Figure 4................... Raise Machine....................................... Monitor Temperatures Displayed......... Manually Start Coolant Heater........................................................... Adjusting Time and Day................. Coolant Heater Control Panel.... 0036-2 Figure 3........... 0036-2 Chapter 3 ...................................................................................................................... 0033-1 Figure 2...............................................................................................................Continued Page No........................................................................OPERATOR TROUBLESHOOTING PROCEDURES TROUBLESHOOTING SYMPTOM INDEX .......................................... 0034-2 Figure 3................................... WP 0036 Figure 1........................................................................OPERATOR MAINTENANCE....................TM 5-3805-294-10 TABLE OF CONTENTS .............................................................................. 0034-3 Figure 4................... WP 0033 Figure 1..................................................................................................................................... 0035-4 FORDING THE HYEX......................................................................................................................................... 0036-1 Figure 2........................................................................................................................................................................................................................................................... Traveling Down. 0032-2 SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)........ 0035-2 Figure 3.... WP 0032 Figure 1............ Pilot Shutoff Lever..................................................... Pushing Machine............. 0031-5 Table 1........................................................................................................................................... 0035-1 Figure 2......... WP Sequence No. 0035-3 Figure 5....................... Machine Switch Selection........................................ Emergency Exit Tool............................... Buckle Seat Belt.................................................................. 0034-5 MOVING UP/DOWN STEEP OR SLIPPERY SLOPES.................................................................................................................. 0034-4 Figure 6................. Check Monitor...... 0031-6 Figure 10............................................. WP 0037 xv .. ...... WP 0039 CAB DOME LIGHT DOES NOT OPERATE............................................................ WP 0041 CAB FRONT WORK LIGHTS DO NOT OPERATE........................................................................................................................................................................................................................................................... WP 0060 HYDRAULIC OIL OVERHEATS....................................................................................................................................................................................................... WP 0051 AUTO-IDLE DOES NOT WORK............................................ WP Sequence No......... WP 0049 EXCESSIVE OIL CONSUMPTION........................................................................................... WP 0062 NO SWING FUNCTION.................................... WP 0064 xvi ..................................... WP 0047 ENGINE RUNS POORLY....................................................... WP 0053 ENGINE OIL PRESSURE LOW............................ AND DRIVE LIGHTS DO NOT OPERATE............................................................................................................................................................................................................................................................................................... WP 0040 BOOM.......................................................................................................................................................................................................... TRAVEL ALARM DOES NOT OPERATE................................................... CAB....... WP 0055 ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE................ WP 0048 EXCESSIVE FUEL CONSUMPTION.................................................................................. WP 0063 SWING FUNCTION IS JERKY........................................ WP 0059 POWER DIG DOES NOT WORK........................ WP 0061 HYDRAULIC OIL FOAMS.......................................................................Continued Page No....................................... WP 0042 CAB REAR WORK LIGHTS DO NOT OPERATE...........................................................................................TM 5-3805-294-10 TABLE OF CONTENTS .................... WP 0052 ENGINE NOT DEVELOPING FULL POWER......................................................................................................................... WP 0045 ENGINE CRANKS BUT DOES NOT START OR HARD TO START.................................................................................................................. WP 0044 AIR CONDITIONER DOES NOT OPERATE.. WP 0038 WINDSHIELD WIPER AND WASHER DO NOT OPERATE............................................................................................................................................................................................................................................. WP 0050 ENGINE IDLES POORLY.. WP 0056 ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE.................................... WP 0043 LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE.................. WP 0058 HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER............................ WP 0057 NO HYDRAULIC FUNCTIONS.................................................................................................. WP 0054 ENGINE COOLANT TEMPERATURE ABOVE NORMAL.................................................................................................................................................... WP 0046 ENGINE WILL NOT CRANK........................................................ ................................................................... 0077-5 Figure 4.................................................. Hydraulic Reservoir Cap......... Air Cleaner Housing and Hose Reel.................................. WP 0077 Table 1...................................................... WP 0071 CRUSH-ALL DOES NOT OPERATE..................................................................................................... Engine Oil...........................Continued Page No.......................................................... WP 0074 HYDRAULIC HOSE REEL DOES NOT OPERATE.............................. WP 0073 DEEP DIG DOES NOT OPERATE............................. Engine Oil Filter...................................................................................................TM 5-3805-294-10 TABLE OF CONTENTS .............................................................. 0077-12 xvii ............................. WP 0069 BREAKER DOES NOT OPERATE.............................................................................. 0077-7 Figure 7............................................................................................................................................................. 0077-6 Figure 5......................................................................................... WP Sequence No................................... SLOW TRAVEL SPEED ONLY.............................. Boom..........................................OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION ....................................... 0077-10 Figure 11................................................................... WP 0066 ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED.................................................................PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS). 0077-9 Figure 10.............................................................................................................................................................................. Exterior of Machine......................................................... OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES....... Fuel Filters.......................................... 0077-9 Figure 9........... Exterior of Machine Continued........................ Arm..................... WP 0067 QUICK LATCH DOES NOT OPERATE.................................................................................................................................................. Coolant Level.................... 0077-4 Figure 3.............................................................. 0077-3 Figure 2..... WP 0076 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)................ WP 0075 Chapter 4 .. Quick Latch.......................................... Exhaust Components........................................................................... Fuel Tank and Fuel Level......................................................... 0077-1 Figure 1................. 0077-7 Figure 6................. WP 0065 TRAVEL IS JERKY............................................................................................ WP 0068 COMPACTOR DOES NOT OPERATE.......... 0077-11 Figure 12............................................................ WP 0072 BARRIER GRAPPLE DOES NOT HOLD LOAD............................................ WP 0070 BREAKER OPERATES SLOWLY.............................................. 0077-8 Figure 8........................................................................................................................................... and Hydraulic Thumb... Bucket and Teeth.................................................................. .............................. Mirrors and Wiper Arm...................................................................................... and Latches........................................................... 0077-33 Figure 37... 0077-17 Figure 19................................. Swing Gearbox Oil Level Check............................................................................................ 0077-34 Figure 39.................... Deep Dig Bucket......... Ditch Cleaning Bucket..................................................... 0077-14 Figure 15........ Crush-All.............................................................................................. Pedals and Levers.............................................. 0077-31 Figure 34....................................................... Breaker..................................................... Hydraulic Oil Level Check.............. Position Boom and Arm....................... Hinges..................................................... Hydraulic Oil Level Check...... Exterior of Machine Check....... 0077-19 Figure 21............................................................ Barrier Grapple........................ 0077-29 Figure 33... 0077-32 Figure 36........................................ 0077-16 Figure 18......................... 0077-22 Figure 26............................................................................. Position Boom and Arm. Pilot Control Levers............................................................................................................................................................................................................................................ Deep Dig Arm and Bucket...................TM 5-3805-294-10 TABLE OF CONTENTS ... 0077-20 Figure 22....................................................................... Ignition Switch.. Fuel Tank and Fuel Level Check................................. Monitor................................ 0077-15 Figure 16...................... 0077-25 Figure 29........................................... Cab Glass....... 0077-23 Figure 27................................................. Engine Compartment.....................................Continued Page No.............................................. 0077-33 Figure 38.............................................................................................................................................................. Engine Oil Check................................................................................................................................................ 0077-26 Figure 30.......... 0077-28 Figure 32.............. Figure 13....................................... 0077-18 Figure 20............................... 0077-13 Figure 14......................................................................................................................... 0077-24 Figure 28......................................................................... Batteries.......................................................................... 0077-27 Figure 31................................... Compactor...................................................................... Cab Door............................................................................................. 0077-35 xviii ............................... 0077-31 Figure 35........................... Batteries Continued................................................ WP Sequence No.............................................................................................................................. 0077-20 Figure 23........ Seat Belt................................. 0077-21 Figure 24....................................................................................................................... 0077-22 Figure 25................ Fire Extinguisher................................................. 0077-15 Figure 17................................................................................ ........................................ 0080-4 Figure 5................................................ 0082-1 TAKING HYDRAULIC OIL SAMPLE............. Raise Machine............ 0084-2 Figure 2...................................................................... 0081-1 LOOSENING TRACK TENSION............................. Shut Machine Off....................................... Lower Machine.................................................................................................................................................................................................................................................................................................................................................... 0080-2 Figure 3........................................................................................ Hydraulic Pump Oil Level Check................................................................................................... WP 0083 Figure 1................................................................................................................................................. 0077-39 Chapter 5 ..............................................................................................OPERATOR MAINTENANCE INSTRUCTIONS GENERAL MAINTENANCE INSTRUCTIONS......................................... Figure 40...................................... 0077-37 Figure 42............................ 0084-5 Figure 5..................................................................................................... Loosen Track.............. WP 0081 Figure 1..................... 0084-3 Figure 3... 0077-38 Figure 43................. Serpentine Belt Check.......................................................................................... Fuse Box Access Cover Removal..... 0080-5 Figure 6..................................... WP 0082 Figure 1............. Engine Oil Sampling Valve................................................................ 0077-36 Figure 41............................ 0080-3 Figure 4.................................Continued Page No..................................................................................................................................TM 5-3805-294-10 TABLE OF CONTENTS ............................................................................................................. Main Fuse Box Cover Removal............................................... Air Conditioner Belt Check............ Fuse Removal..... 0080-5 TIGHTENING TRACK TENSION.................... WP 0080 Figure 1......... Start Machine............................ Fan Check......................................... 0083-1 CAB FUSE REPLACEMENT............................................................ Measure Track Sag....... WP Sequence No.......................... WP 0079 Figure 1.............................................................................................................. 0084-6 xix ..................... WP 0078 TAKING ENGINE OIL SAMPLE........................................................... Main Fuse Box Cover Installation... 0079-1 TRACK SAG CHECK ................................................................................................................................................................................................... Hydraulic Oil Sampling Valve.................. Tighten Track.................. 0084-4 Figure 4... WP 0084 Figure 1................. 0080-1 Figure 2........ Rotate Track..................................................................................................................... Fuse Installation..................................................................................................................................................................................................................................................... ................................................................................ 0088-1 Figure 2....................................... Bucket Tooth Removal..................... 0087-5 Figure 9.................................................... Hydraulic Reservoir Cover Installation................................. Hydraulic Reservoir Cover Removal.................................... 0088-3 FRESH AIR FILTER SERVICE................................................................................................................... Drain Fuel Filter/Water Separators........................ Figure 6................... Secondary Air Cleaner Removal................................................... 0087-4 Figure 6.......................... 0087-5 Figure 8........................................................................Continued Page No....................TM 5-3805-294-10 TABLE OF CONTENTS ................ Cover Installation.................... 0087-3 Figure 5...................................................................................................................................................................................... Filter Removal................ 0085-2 Figure 4............................................................ 0087-1 Figure 2............................... 0089-3 xx ..................................................................................................................................................................................................... Inspect Seal................................................................................... Cover Removal....................................................................................................................................................... 0086-2 PRIMARY AND SECONDARY AIR CLEANER SERVICE................... Air Cleaner Housing Service............................................... WP 0088 Figure 1.......................................................................... 0087-4 Figure 7............................. 0087-2 Figure 3........ 0089-2 Figure 3.............................................................................. 0086-1 Figure 2........................................... WP 0086 Figure 1........................................................................................................................................ 0085-2 Figure 3................................................................................................ 0085-3 PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................ Drain Fuel Filter/Water Separators Continued........ 0087-2 Figure 4................................ 0088-2 Figure 3..... WP 0089 Figure 1......................................................... 0085-1 Figure 2....... WP 0085 Figure 1................................................................. 0089-1 Figure 2..................... Cover and Dust Boot Service............................................. 0087-6 HYDRAULIC RESERVOIR SERVICE........... Primary Air Cleaner Installation.................................... Fuse Box Access Cover Installation....................................................... WP 0087 Figure 1........ Primary Air Cleaner Removal................ Tooth Installation.................................... Clean Filter............. Hydraulic Reservoir Sight Glass............... WP Sequence No.................................... Secondary Air Cleaner Installation.................................................................................... Bucket Tooth Installation.............................................................................................. Primary Air Cleaner Service..................................................................... Tooth Removal..... 0084-7 BUCKET TEETH REPLACEMENT..................................... .................................................................................................................. 0090-3 Figure 4....... Drain Valve.................................................................................................. WP 0091 Figure 1................................................ 0090-2 Figure 3....................................................................................... Clamp Installation.......... Clean Housing..................................................................................................................................... 0092-3 Figure 3............................................... 0096-1 EXPENDABLE AND DURABLE ITEMS LIST.. 0091-2 Figure 3.............................................................................. Filter Installation.............................................................................................................. 0090-3 DRAINING WATER AND SEDIMENT FROM FUEL TANK... Drain Hose................................................................ Install Fuel Cap................TM 5-3805-294-10 TABLE OF CONTENTS .......................... BASIC ISSUE ITEMS..................... 0092-2 Figure 2.................Continued Page No................... 0092-5 MAINTENANCE AFTER FORDING................. COMPONENTS OF END ITEM.......... WP 0097 xxi ................................................................. WP 0095 Table 1. Figure 4....................................................................... WP Sequence No............................................................................................... Filter Installation. 0090-1 Figure 2.................................................... Curtain Adjustment.......................................................................... 0093-1 Chapter 6 .................................................................................................................................................................................................................. 0089-4 AIR CONDITIONER/HEATER FILTER SERVICE..................... Remove Fuel Cap......... Draining Mud or Water.................................................................. 0092-4 Figure 4.....................................................OPERATOR SUPPORTING INFORMATION REFERENCES........... Filter Removal............................... 0095-2 Table 2......................................... 0095-4 ADDITIONAL AUTHORIZATION LIST (AAL).... Spring Compression............................................................. WP 0090 Figure 1........................... WP 0093 Figure 1.................................................................................................................................................................................................................................................................................................................................... 0091-3 Figure 4............ 0091-4 CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT......................... 0089-3 Figure 5............................................................................................................................................................................ 0091-1 Figure 2.................... WP 0096 Table 1................ WP 0094 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................................................ WP 0092 Figure 1................................................................................................................................. Clean Housing....................................................................................................................... Additional Authorization List.. Clean Filter......................... Clearance Check.................... .................................................................................... 0100-11 Figure 14................................... Deep Dig Bucket..........................Continued Page No......................... Marine Loading............................................................................................. WP Sequence No............. Military Load Classification.......... 0098-2 TROUBLESHOOTING NOTES............ 0100-7 Figure 8.............................. SPECIAL PURPOSE KITS (SPK) LIST............................. 0100-12 Figure 15......... C-17 Aircraft Loading................. 0100-16 Figure 22............................ 0100-15 Figure 20.............................................. 0100-9 Figure 10....................................................... Standard Buckets Loaded On M870A3...................................................................................... 0100-10 Figure 12......................................... GIC Rail Clearance........................ HYEX Transportation Data Plate...................................................................................................................................... 0100-6 Figure 7....................................... 0100-10 Figure 11................................................................................... 0100-4 Figure 5.................... Deep Dig Arm................ HYEX Dimensions.... 0100-16 Figure 21.................................................................................................................... Standard Buckets Loaded On M870A1................................................. 0100-5 Figure 6................................................. 0100-12 Figure 16.............................................................................................. WP 0100 Figure 1............................................ HYEX Lift and Tie Down Information....... 0100-13 Figure 17............................................................................................... Armored Cab Clearance.......................................................................................................................................................... M870 Loading... 0100-15 Figure 19. Standard Ditch Cleaning Bucket................. M870A3 Loading............................................................... WP 0098 Table 1................. 0100-3 Figure 4........................................................................................ WP 0099 HYEX TRANSPORTABILITY INSTRUCTIONS........................................................................ M870A1 Loading............................................................ 0100-4 Table 1........................................................ Special Purpose Kits............ 0100-8 Figure 9........................................... Deep Dig Ditch Cleaning Bucket............................................. 0100-11 Figure 13........... 0100-17 xxii ........................................... HTTX Railcar Loading Overhead View........... HYEX Lifting and Tie Down Points.......... 0100-14 Figure 18........................................................... HTTX Railcar Loading Side View............................................................................................................................................................................................................................................................................................... C-5 Aircraft Loading................... Standard Cab Clearance........................TM 5-3805-294-10 TABLE OF CONTENTS ....................................... Standard Rock Bucket........................................................ 0100-1 Figure 2.......................... 0100-2 Figure 3......................................................................................................... .................................................................. Impact Breaker.............................. Crush-All On M870A1......................TM 5-3805-294-10 TABLE OF CONTENTS ........................................................................................................... 0100-19 Figure 27....... 0100-20 Figure 29............................ Impact Breaker.............................................................. Standard Buckets Loaded On HTTX Railcar.............................................................................................................................. and Barrier Grapple Loaded On HTTX Railcar...... 0100-22 Index xxiii/xxiv blank ...... Compactor.......................... 0100-18 Figure 25....... WP Sequence No............................... 0100-20 Figure 28............................... 0100-18 Figure 24........................................................................................................................... Barrier Grapple......................... Deep Dig Arm and Buckets Loaded On HTTX Railcar...... 0100-19 Figure 26........... 0100-21 Figure 30................................................... Crush-All........................ Crush-All Loaded On HTTX Railcar..... Figure 23............Continued Page No......................................... 0100-21 Figure 31.. 0100-22 Figure 32............................................... Crush-All On M870A3................... Compactor........ . Operating instructions for most circumstances will be provided. Abbreviated formatted warnings are recognized when a warning in a WP has a single word that will be printed in all caps and BOLD. INITIAL SETUP BLOCK The initial setup block contains information vital for the completion of the WP. Instructions are included to cover most circumstances. This is critical data to ensure personal safety. If you are unsure of what to do after looking in this TM. It is also found at the bottom center of every page. prevent damage to the machine.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). but the user's best guide will be knowledge of the machine and its operation. 5. 3. Warning. a quick instinctive response based on that knowledge is essential. The full warning is in the warning summary and should be read prior to continuing the WP. always contact your direct supervisor. WORK PACKAGE NUMBERS The WP number is found in the upper right corner of each page. or rags to complete the tasks in the WP. TABLE OF CONTENTS The table of contents provides a quick reference of each WP by Title and WP number. 4. caution. 2. Normally. CAUTIONS. and NOTES before performing any procedure. WARNINGS. and note headings and certain essential information are printed in BOLD type for clarity. EQUIPMENT CONDITION: This is how the machine needs to be configured before starting the work. In an emergency. CAUTIONS. it will only list the WP number. However. 1. Troubleshooting and maintenance procedures are provided at crew maintenance levels. REFERENCES: When the reference is in the same manual. AND NOTES Read all WARNINGS. These instructions provide the user with a general knowledge of the equipment. This manual contains a "References" Work Package (WP). This will allow the user to see the TM number and the title. 6. A link will appear in parenthesis along with the manual that is referenced. xxv . NSN 3805-01-573-0677. TOOLS AND SPECIAL TOOLS: These are all of the tools required to complete the tasks in the WP. Occasionally a different Technical Manual (TM) will be referenced in the text of this manual. and clarify unique data or procedures used on the HYEX. it may contain the words "Not Applicable". The link lists the references WP in the manual. PERSONNEL REQUIRED: Lists the number and Military Occupation Skill (MOS) required to complete the WP. The following is a list of what is found in the initial setup block. In some instances. maintenance and servicing procedures will list the time it should take to complete that WP. it is impossible to address every scenario you may encounter. MATERIALS/PARTS: Any part to include oil. TIME TO COMPLETE: Not all WP will have the time to complete listed. characteristics. and operating procedures of the HYEX. grease. and lists each Figure and Table within that WP to assist in finding the required information except blank pages. 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. and after the mission is completed. and the coolant heater system. EQUIPMENT DESCRIPTION. and driving procedures. CHAPTER 5 MAINTENANCE INSTRUCTIONS Chapter 5 lists maintenance instructions the crew can perform on the machine. Chapter 2 also provides operator instructions for individual equipment items in the HYEX. the check or service procedure. operation of standard functions.TM 5-3805-294-10 HOW TO USE THIS MANUAL . Additional Authorization List (AAL). forms. Included are description and location of driver's controls. The PMCS table lists the item to be checked or serviced. pamphlets. and the criteria for determining whether the equipment being checked is ready for its mission. 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. field manuals. technical bulletins. Also included in Chapter 1 is HYEX theory of operation. and features of the HYEX. CHAPTER 3 TROUBLESHOOTING PROCEDURES Chapter 3 provides operator level troubleshooting procedures for various malfunctions that may occur during machine operation. Basic Issue Items (BII). 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. capabilities. Chapter 6 also includes Components of End Item (COEI). and Expendable/Durable supplies and materials lists.Continued CHAPTER 1 GENERAL INFORMATION. xxvi . AND THEORY OF OPERATION Chapter 1 presents general information. CHAPTER 6 SUPPORTING INFORMATION Chapter 6 lists the regulations. and technical manuals that apply to this manual. fire suppression system. while it is being operated. as well as the characteristics. CHAPTER 2 OPERATOR INSTRUCTIONS Chapter 2 provides operator instructions for starting and shutting off the machine. TM 5-3805-294-10 CHAPTER 1 OPERATOR GENERAL INFORMATION FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 . . PREPARATION FOR STORAGE OR SHIPMENT Contact Field Maintenance for instructions on preparation for storage or shipment. Product Quality Deficiency report (WP 0094).S. Let us know why you don’t like the design or performance. 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. Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (WP 0094). 6501 E.cfm (scroll down and choose "Submit Quality Deficiency Report" bar). The Army Maintenance Management System (TAMMS) Users Manual (WP 0094). corrosion can also include deterioration of other materials. and cracking.TM 5-3805-294-10 0001 OPERATOR MAINTENANCE GENERAL INFORMATION SCOPE This manual contains instructions for operation. 11 Mile Road. U. and operator-performed maintenance on the Hydraulic Excavator Type 1 (HYEX). swelling. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your HYEX needs improvement. Refer to TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D LC (WP 0094). The warranty starts on the date found in block 23 of DA Form 2408-9. 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. or breaking of these materials may be a corrosion problem. such as corrosion. 0001-1 . If a corrosion problem is identified. The internet form lets you choose to submit an EIR. will ensure that the information is identified as a CPC problem. rust. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materials is a continuing concern. Army Tank-Automotive and Armaments Command. While corrosion is typically associated with rusting of metals. Use of key words. MI 38397-5000. or AR 700-138. Army Logistics Readiness and Sustainability (WP 0094). operator troubleshooting. You can send your SF Form 368 via e-mail.army. such as rubber and plastic. deterioration. PDQR MS 268. Send us an EIR. are the only one who can tell us what you don’t like about your equipment.mil/ aespublic. WARRANTY INFORMATION The HYEX is warranted by John Deere. You. AMSRD-TAR-E. The Army Maintenance Management System (TAMMS) Users Manual (WP 0094). We will send you a reply. Unusual cracking. the easiest and fastest way to report problems or suggestions is to go to https://aeps. If you have Internet access.ria. let us know. and mail it to us at: Department of the Army. it can be reported using Standard Form 368. a Product Quality Deficiency Report (PDQR) or a Warranty Claim Action (WCA). regular mail. or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8. Equipment Control Record (WP 0094). The HYEX is used for construction operations. the user. You may also submit your information using an SF Form 368 (Product Quality Deficiency Report). 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. Warren. softening. 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 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. TM 5-3805-294-10 LIST OF ABBREVIATIONS/ACRONYMS . 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 .Continued.Continued Table 1. HYEX Hydraulic Excavator in. List of Abbreviations/Acronyms . . 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 77 kg) 10.14) 7.83 kg)* 11.22 kg) -5 (-1.90 lb (8.57 kg) 22.28 lb (7.88 lb (4.96 lb (4.55 lb (3.63 kg) 13.80 lb (4.99 kg) 11.29 lb (2.62) 30 (9.89 kg) 7.96 lb (3.26 lb (2.14 kg) 7.69 lb (6.57 kg) 12.52 kg) 17.60 lb (7.48 kg) 5.04 lb (2.42 kg)* 15 (4.56 lb (5.44 kg) 29.05) -15 (-4. LIFTING OVER SIDE IN 1.Continued Table 8.46 lb (7.53 lb (5.67 lb (2.57) 8.52) 18.10 lb (5.66 kg)* 11.52 lb (3.35 lb (5.91 kg) 10.000 lb (454 kg) ft (m) 5 (1.52) 10 (3.52) -10 (-3.16 lb (7.90 kg)* 6.68 lb (3.57) 20 (6.02 kg) 6.10) 25 (7.51 lb (10.77 lb (3.80 kg) 6.59 lb (3.95 kg) 7.97 kg) 7.10) 20 (6.81 lb (2.57) -20 (6.39 lb (3.21 kg)* 17.86 kg)* 8. Side Lift Capacities.24 kg)* 8.61 lb (3.61 kg) 5.07 kg)* * Hydraulically Limited Capacity 0002-11 .TM 5-3805-294-10 0002 EQUIPMENT DATA .85 kg) 5 (1.05) 15 (4.05) 14.44 kg)* 17.84 kg)* 10 (3.73 kg) Ground Line 17.92 lb (4.62 lb (7.63 lb (13.15 lb (7.06 lb (5.48 kg) 8.92 kg)* 17.78 kg) 10.10) 15. TM 5-3805-294-10 0002 EQUIPMENT DATA .550 lb (30640 kg) Deep Ditch Cleaning Bucket 1.600 lb (726 kg).000 (29937 kg) Breaker 4.550 lb (30640 kg) Deep Dig Bucket 1.600 lb (30663 kg) 66.000 (29937 kg) Ditching Bucket 1.750 lb (30277 kg) 66. Table 10. HYEX Weights With Attachments.550 lb (703 kg).550 lb (31094 kg) (454 kg) END OF WORK PACKAGE 0002-12 .840 lb (30318 kg) 66.900 lb (2223 kg) 70.600 lb (30663 kg) 66. Machine/Deep Dig Arm/ Counterweight Attachment and Weight Total Weight 67.900 lb (32160 kg) 66.000 (29937 kg) Compactor 840 lb (381 kg) 66.000 (29937 kg) Crush-All 5. Deep Dig Arm Weights.600 lb (726 kg) 67.000 lb (1361 kg) and additional counterweight with four mounts and two spacer plates for deep dig arm operation weigh 1. 67. Table 9.000 (29937 kg) Heavy Duty Bucket 1.000 lb (454 kg) 68.000 (29937 kg) Barrier Grappler 750 lb (341 kg) 66.550 lb (31094 kg) 67.800 lb (32568 kg) Deep dig arm weighs 3.000 lb 68. Machine Weight Attachment and Weight Total weight 66.Continued HYEX weights with attachments.800 lb (2631 kg) 71. 6-cylinder diesel engine. and at precise time according to a given set of engine conditions in relation to piston position. and a high-pressure common rail fuel system. 4-valve per cylinder head. Engine The engine is a John Deere 6068H PowerTech Plus. electronic fuel injectors. 6. Electronic Control Unit (ECU). and hydraulic system. 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. The 6068H includes a turbocharger. electrical system. In order to achieve this. fuel system.TM 5-3805-294-10 0003 OPERATOR MAINTENANCE THEORY OF OPERATION SCOPE This section explains how components of the HYEX work together. The 6068H is air-to-air after cooled to help reduce exhaust emissions while maintaining low-speed torque. A functional description is given for the engine.8L. 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 . cooling system. electronic control unit. in precise amounts. 3 Starter Motor Part of the starting circuit. 5 Fuse Panel The fuse panel provides centrally located fuses that will open the battery circuit if there is a shorted. 2 Alternator The alternator provides 28-volt. Fuses are easily replaced. Electrical System Components. 1 Batteries The batteries provide power for the electrical circuits. current to charge the batteries and operate the electrical system. 4 Slave Receptacle The slave receptacle can be used to charge the batteries and slave start the engine from an external power source. 0003-2 . If a fuse continually trips. When the circuit is open. Two 12-volt batteries are connected in series to provide 24-volt starting power. Electrical System Components.Continued Electrical System 2 3 4 5 1 HYEX01511 Figure 1. the starter motor is used to turn the engine flywheel fast enough to start the engine. Table 1. 80-amp.TM 5-3805-294-10 0003 ECU . The slave receptacle can also be used to charge and slave start other equipment. the affected component or vehicle electrical system requires repair. no current will flow through the electrical system. grounded wire or excessive current draw by a defective component in the corresponding circuit. 7 Pilot Pump The pilot pump is a small gear pump that keeps oil moving through the pilot system. 8 Hydraulic Reservoir The hydraulic reservoir is pressurized ensuring that hydraulic oil is always supplied to the pumps. and travel. and travel functions. 9 Main Control Valve The control valve consists of two monoblock valves referred to as the left control valve and right control valve. swing. arm. bucket. Hydraulic System Components. 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. There is a spool in each valve to control the boom. Each valve section controls the flow rate and direction for its hydraulic circuit. Table 2. 6 Main Pumps The HYEX has two main hydraulic pumps that supply hydraulic oil for all functions including boom. All other functions are supplied by a single spool in one or the other of the valves. 0003-3 . Hydraulic System Components.TM 5-3805-294-10 0003 Hydraulic System 10 11 14 13 15 9 16 12 7 8 17 HYEX01512 6 Figure 2. arm. All spools are moved by pilot oil. 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. When activated they raise and lower the boom. The swing brake engages as soon as the swing controls are released.Continued 10 11 14 13 15 9 16 12 7 8 17 HYEX01512 6 Figure 3. 10 Pilot Signal Manifold The pilot signal manifold is in the pilot system between the pilot control valves and the control valve and regulators. It has a spring-applied hydraulically-released swing brake. When activated. 11 Swing Motor The swing motor uses hydraulic pressure supplied by the pumps to make the upper structure rotate. Hydraulic System Components Continued. 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. this cylinder moves the arm in and out.TM 5-3805-294-10 0003 Hydraulic System . and function movement. 13 Boom Cylinders The boom cylinders are attached to the main frame and the boom. pump stroke. Hydraulic System Components Continued. 0003-4 . 14 Arm Cylinder The arm cylinder is attached between the boom and the arm. Table 3. When activated. compactor and deep dig arm accessories. breaker. Table 4. 21 Travel Motor The travel motors are located inside the tracks to prevent damage during operation. The rollers guide the tracks and keep the tracks in contact with the ground.TM 5-3805-294-10 0003 Hydraulic System .Continued. Hydraulic System Components Continued . Powertrain Components. The function of a reduced leakage valve is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve. 19 Track The track assembly consists of the chain and shoes. When activated. The travel system has a spring-applied hydraulically-released parking brake. 20 Rollers The machine has two carrier rollers and nine lower track rollers on each side of the machine. The travel motor drives the track to move the machine. 17 Load Holding Valves Reduced leakage valves are used in the boom head-end circuit and arm rodend circuit. Powertrain Components. 18 Track Chain Adjuster The track chain adjuster is located between the frame and the track chain idler. The parking brake engages as soon as the travel controls are released. this cylinder extends and curls the bucket or attachments. The recoil spring is located with the track chain adjuster and absorbs shocks to the tracks and track chain idler. Grease is added or removed to adjust the track sag. 16 Bucket Cylinder The bucket cylinder is attached between the arm and the quick latch.Continued Table 3. The hydraulic thumb cylinder circuit can be closed to provide the hydraulic power to operate the crush-all. Powertrain 21 18 20 19 HYEX01513 Figure 4. this cylinder extends and retracts the hydraulic thumb. 0003-5 . 15 Hydraulic Thumb Cylinder The hydraulic thumb cylinder is attached between the arm and the thumb. TM 5-3805-294-10 0003 Fuel System 22 24 27 23 25 26 HYEX01514 28 Figure 5. 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. 24 Secondary Fuel/Water Separator The secondary water separator keeps small particles and contaminants from entering the pressure fuel pump. 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. 27 Fuel Tank Strainer The strainer is designed to keep debris from entering the fuel system. Fuel System Components. Table 5. 25 Lubricity Canister The lubricity canister is a spin-on canister with a lubricant that is slowly released into the fuel. 0003-6 . Fuel System Components. 28 Fuel Tank Drain Valve The drain valve is used to remove water and debris from the fuel tank. 23 Primary Fuel/Water Separator The primary water separator keeps large particles and contaminants from entering the high-pressure fuel pump. Table 6. The injectors are located under the rocker arm cover. High-Pressure Pump and Injectors. There is one nozzle for each cylinder.TM 5-3805-294-10 0003 Fuel System . 30 Fuel Injectors The fuel injectors turn the stream of fuel into a fine spray. which permits good combustion in the cylinder. 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. 0003-7 .Continued 30 29 HYEX01515 Figure 6. 34 Fuel Cooler Fuel is circulated across the cooler to lower fuel temperature.Continued Cooling 31 33 32 34 HYEX01516 Figure 7. 0003-8 . Table 7.TM 5-3805-294-10 0003 Fuel System . Cooling Package. Cooling Package. 32 Hydraulic Oil Cooler The hydraulic oil cooler uses air from the fan to cool the oil before returning it to the reservoir. 31 Radiator Coolant circulates through the radiator to be cooled after leaving the cylinder block. 33 Charge Air Cooler The charge air cooler cools the air supplied to the engine to decrease fuel consumption and emissions. END OF WORK PACKAGE 0003-9/10 blank . Cooling System Components. reduced noise levels. 35 Coolant Surge Tank The coolant surge tank is where the coolant level is checked and added. charge air cooler.Continued 35 36 37 HYEX01517 Figure 8. and faster engine warm up. ensuring maximum fuel efficiency. 37 Fan The variable speed fan is located at the front of the engine and is driven by a hydraulic motor. or hydraulic cooler need. The speed of the fan is varied to provide the amount of airflow that the engine coolant. A reversing function reverses the cooling fan to help clean the cooling package of dirt and debris. Cooling System Components.TM 5-3805-294-10 0003 Cooling . 36 Engine Oil Cooler Coolant from the radiator passes through the engine oil cooler to maintain a safe operating temperature. Table 8. . TM 5-3805-294-10 CHAPTER 2 OPERATOR INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 . . and the drive light. left and right control levers. seat controls and arm rest. the background goes from white to black. left console. control pedals and levers. The second position turns on the boom work lights. 2 7 HYEX00867 Front Switch Panel. push and hold switch down for no more than 20 seconds. Front Switch Panel. To operate the washer. heater and air conditioner control panel. The ON position operates the wipers continuously. Key Control/Indicator Function 1 Washer/Wiper Switch Wiper switch has several positions. the front cab work lights.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. The OFF position stops the wipers from operating and parks them. The first position turns on the drive light. 3 4 5 6 1 Figure 1. and warning indicators and alarms. If the default screen on the monitor is displayed. Note that the wiper will not operate unless the windshield is completely closed. Table 1. Front Switch panel will also illuminate. The INT position operates the wipers intermittently at the interval selected by the switch position. coolant heater and cab door. 0004-1 . 2 Operating Lights Switch This is a three-position switch. When in the OFF position.Continued. 2 7 HYEX00867 Front Switch Panel Continued. the key can be removed. Move and release the switch to the START position starts the machine. 4 Auto-Idle (A/I) Switch This is a two-position switch. The Economy (E) mode is used to increase fuel efficiency and reduces noise level. all electrical functions will operate. it will reduce the engine speed after 4 seconds when control levers are in the neutral position. In the ON position. Front Switch Panel . Key Control/Indicator Function 3 Engine Speed Dial The dial is used to increase or decrease engine speed. In the OFF position the operator can set the engine speed to improve machine control. It is used to select fast or slow speed of travel. In the ON position. 7 Key Switch This is a four-position switch. 6 Travel Mode Switch This is a two-position switch. 5 Power Mode Switch This is a three-position switch. Moving the switch to the ACC position allows the radio to be turned on or off. 0004-2 .TM 5-3805-294-10 0004 Table 1. 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. 3 4 5 6 1 Figure 2. Heater/Air Conditioner (A/C) Controller and Radio. 16 9 15 14 13 10 12 11 8 HYEX00868 17 Figure 3. blower fan speed. 0004 Heater/Air Conditioner (A/C) Controller and Radio. it turns on the AUTO and A/C indicators. 0004-3 . 10 A/C Button When pressed. vent locations. 11 AUTO Button When pressed. it turns on the air conditioning (A/C) and illuminates the A/C indicator. selected air vent. Turns on blower fans when A/C is off. Key Control/Indicator Function 8 Blower Fan Speed Buttons Increases or decreases the speed of the blower fans. and fresh air port are then automatically controlled. 9 Monitor Display Displays blower fan speed.TM 5-3805-294-10 Table 2. Air flow-in temperature at the vent. and temperature setting. 17 Radio Display The radio display contains standard AM/FM radio tuning and volume controls. The monitor display will show FC or FH. Blower fans will turn on if one of the blower fan speed buttons is pressed even if the OFF button is on or off.Continued. Key Control/Indicator Function 12 OFF Button When pressed the A/C and blower fans will turn off. 16 9 15 14 13 10 12 11 8 HYEX00868 17 Figure 4. 16 Mode Button Press to select air vent. Heater/Air Conditioner (A/C) Controller and Radio . 14 Recirculating Mode Button Press the recirculating mode button to close the fresh air vent and circulate air already in the cab. 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). 0004-4 .TM 5-3805-294-10 0004 Table 2. Selected vent will display on the monitor display. 15 Fresh Air Mode Button Press fresh air mode to route outside air into the cab. 19 Attachment Pedal Lock Locks attachment pedal in the neutral position to disable the hydraulic thumb or any attachments that are connected. 0004-5 . 21 Right Travel Lever Use this hand lever to perform the same functions as the right travel pedal with increased control. Pushing down on the bottom of the pedal moves the machine backwards. Control Pedals and Levers. Pulling the lever moves the machine backwards. 22 23 0004 Control Pedals and Levers. When attachments are connected. hydraulic valve selection will disable the hydraulic thumb and enable this pedal to operate the attachment. Key Control/Indicator Function 18 Attachment Pedal Primarily used to open and close the hydraulic thumb. 20 Right Travel Pedal Controls the direction of travel and steers the machine. Pushing forward on the lever moves the machine forward. Pushing down on the top of the pedal moves the machine forward.TM 5-3805-294-10 Table 3. 21 20 18 19 HYEX00869 Figure 5. TM 5-3805-294-10 Table 3. 22 23 21 20 18 19 HYEX00869 Figure 6. Pushing forward on the lever moves the machine forward. 0004-6 . Pushing down on the bottom of the pedal moves the machine backwards. 23 Left Travel Lever Use this hand lever to perform the same functions as the left travel pedal with increased control.Continued. 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. 0004 Control Pedals and Levers . Pulling the lever moves the machine backwards. 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. depressing the right half of the switch will shut the alarm off. 0004 Left Console and Pilot Shutoff Lever. With the lever in the locked position. hydraulic functions are not operational. In the unlocked position. 24 25 26 27 28 HYEX00870 Figure 7. 26 Rear Cab Work Lights Switch Turns the rear cab work lights on and off. 0004-7 .TM 5-3805-294-10 Table 4. all hydraulic functions operate. Key Control/Indicator Function 24 Pilot Shutoff Lever Controls hydraulic functions on the machine. OFF Fan resumes normal operation. 25 Travel Alarm Switch After the initial 13-second alarm. Left Console and Pilot Shutoff Lever. 27 Auxiliary Control Switch Disables the right joystick left and right button auxiliary function. The engine will not start with the lever in the unlocked position. MANUAL: Fan will reverse direction for 15 seconds when right portion of switch is pressed. 31 32 30 29 HYEX00871 Figure 8. 32 Right Button Auxiliary Function Used to open crush-all lid if connected. 31 Left Button Auxiliary Function Used to close crush-all lid if connected.TM 5-3805-294-10 Table 5. the boom raises. 30 Power Dig Button Pressing the power dig button gives the operator an 8-second increase in hydraulic power. the bucket will dump. 0004-8 . Right Pilot Control Lever. Key Control/Indicator Function 29 Right Pilot Control Lever When pushed forward. the boom lowers. When pulled back. When pushed right. When released the lever will return to the neutral position. the bucket will curl. 0004 Right and Left Pilot Control Levers. When pulled left. 0004-9 . Right and Left Pilot Control Levers . When pulled back.Continued. Key Control/Indicator Function 33 Left Pilot Control Lever When pushed forward. When pressed the horn will sound. machine swings left.TM 5-3805-294-10 0004 Table 5. the arm will come in. When pushed left. lever returns to the neutral position. 34 Horn Button Left Pilot Control Lever. the arm will go out. 34 33 HYEX00872 Figure 9. machine swings right. When released. When pulled right. 37 Seat Weight Adjustment Knob Turn knob to adjust seat suspension to the proper weight of the operator. 36 Seat Adjustment Handle Pull up handle to adjust the seat forward or backward. 38 Lumbar Adjustment Squeeze ball to add air for desired lumbar firmness. Seat Controls. 0004-10 . Press button next to ball to release air. Key Control/Indicator Function 35 Seat Angle Lever Allows seat to be adjusted to a desired angle. 0004 Seat Controls.TM 5-3805-294-10 Table 6. 39 40 35 38 37 36 41 HYEX00873 Figure 10. Key Control/Indicator Function 39 Backrest Adjustment Lever Pull up lever to release backrest and adjust to desired position. 40 Armrest Angle Adjustment Turn dial to adjust armrest to desired angle.Continued. 0004 Seat Controls . then release lever.TM 5-3805-294-10 Table 6. 0004-11 . 41 Seat Assembly Adjustment Lever Pull handle to slide entire seat to desired distance from travel pedals. 0004 Cab Door Release Lever and Coolant Heater Display. 43 Coolant Heater Display Displays date and time. or operating time depending on current screen. 44 Clock Button Pressing button displays date and time and allows to change date and time settings. 0004-12 . Key Control/Indicator Function 42 Cab Door Release Lever Push down to release cab door from the locked open position. 43 44 45 46 47 48 42 HYEX00874 Figure 11.TM 5-3805-294-10 Table 7. Cab Door Release Lever and Coolant Heater Display. 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. 45 Preset Button Press the preset button to program the desired time to start cycle. 50 Quick Latch Light Illuminates when switch is in unlatch position. Key Control/Indicator Function 49 Quick Latch Switch Used to lock and unlock quick latch. Quick Latch Control. Quick Latch Control.Continued.TM 5-3805-294-10 Table 7. date. Key Control/Indicator Function 48 Raise Button Used to raise time. or operating time depending on current screen. Table 8. 0004-13 . 0004 Cab Door Release Lever and Coolant Heater Display . 49 50 HYEX00875 Figure 12. 0004 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. (Not present when armored cab is installed). Cab Light Switch. 0004-14 . It will only illuminate with the key switch turned on.TM 5-3805-294-10 Table 9. 51 HYEX01316 Figure 13. END OF WORK PACKAGE 0004-15/16 blank . 55 Deep Dig Control Pattern Switch Moved to the on position when using deep dig arm to enable the deep dig control pattern. Hydraulic Hose Reel. 53 Hydraulic Tool Circuit Switch Moved to the on position when using hydraulic tools. 52 54 53 55 HYEX00876 Figure 14. 54 Hydraulic Tool Flow Regulator Used to regulate the flow of hydraulic fluid when using the hydraulic hose reel. 0004 Hydraulic Hose Reel.TM 5-3805-294-10 Table 10. Key Control/Indicator Function 52 Hydraulic Hose Reel Used for hydraulic tools. . indicators. 2 Button 2 Press button to key in the number 2 or use as instructed depending on current screen.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. Monitor Buttons and Indicators.I. Table 1. 0005-1 . 7777. A.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. and warning indicators. 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.7 h F1 F2 H F F3 F4 E 17. 5 Button 5 Press button to key in the number 5 or use as instructed depending on current screen. TM 5-3805-294-10 Table 1.I. 7777. 9 10 HYEX00859 Monitor Buttons. 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.Continued. or to return to the default 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. 0005-2 . 12 Back Button Use button as instructed depending on current screen. 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.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 Button 9/F3 function button Press button to key in the number 9 or to select the desired preset optional function from any screen. 11 Select Button Use button as instructed depending on current screen. A.7 h F1 F2 H F F3 F4 E 17. 0005 Monitor Buttons and Indicators . Key Control/Indicator Function 6 Button 6/Return to Default Screen Button Press button to key in the number 6. 15 Menu Button Main Menu. 0005 Monitor Buttons and Indicators . press and hold button to display default screen and hour meter.Continued. and maintenance settings. Key Control/Indicator Function 13 Hour Meter Button Without key inserted or with key switch OFF. attachment adjustment. 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.TM 5-3805-294-10 Table 1. Press button to display main menu from any screen. 0005-3 . operating conditions. Main menu includes time set. Monitor Indicators. 21 Auxiliary Indicator Optional auxiliary data icon displays. 17 Work Mode Indicator The icon for the current attachment being used is displayed.TM 5-3805-294-10 Table 1. 20 Auxiliary Indicator Optional auxiliary data icon displays.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. 22 Engine Preheat Indicator If preheat is required. Needle should be around the center of the scale during operation. the preheat icon is displayed. 19 Auxiliary Indicator Optional auxiliary data icon displays. the auto-idle icon displays. 0005 Monitor Buttons and Indicators . 7777. 18 Auto-Idle Indicator When selecting auto-idle from the front switch panel.I. 0005-4 .Continued. 17 18 19 20 21 22 24 A.7 h 23 25 F1 F2 H F F3 F4 E 28 17. One digit after the decimal point indicates tenths of an hour (6 minutes). Key Control/Indicator Function 16 Coolant Temperature Gauge Indicates the engine coolant temperature. 23 Hour Meter Total machine operation hours counted since the machine started working are displayed in the unit of hour (h). 26 F3 Function Button Indicator Optional indicator icon is displayed. Monitor Buttons and Indicators .Continued. 29 Fuel Rate Display Fuel consumption in Liter/hour (L/h) is displayed.TM 5-3805-294-10 Table 1. Key Control/Indicator Function 24 F1 Function Button Indicator Optional indicator icon is displayed. 30 Clock Indicates present time. 25 F2 Function Button Indicator Optional indicator icon is displayed. 27 F4 Function Button Indicator Optional indicator icon is displayed. 0005-5 0005 . 28 Fuel Gauge Shows level of fuel in fuel tank. Warning Indicators and Alarms. 32 Engine Warning Alarm Displays when engine has an abnormal operating condition. 33 32 36 35 34 39 37 38 HYEX00861 Figure 5.TM 5-3805-294-10 Table 2. Key Control/Indicator Function 31 Engine Overheat Alarm Displays when engine coolant temperature has abnormally increased. 31 0005 Warning Indicators and Alarms. 0005-6 . 34 Alternator Alarm Displays when an abnormality in the electrical system has occurred. 33 Engine Oil Pressure Alarm Displays when oil pressure has decreased. Key Control/Indicator Function 35 Remaining Fuel Alarm Displays when fuel level is low.Continued. 40 Overload Alarm Overload Alarm. 36 Hydraulic Oil Filter Alarm Displays when hydraulic filter is clogged. 39 Pilot Shutoff Lever Alarm Displays when pilot shutoff system is abnormal. 37 Air Cleaner Clogged Alarm Displays when air cleaner are clogged. 40 HYEX00862 Figure 6.TM 5-3805-294-10 0005 Table 2. Warning Indicators and Alarms . Illuminates when an overload condition exists when digging. END OF WORK PACKAGE 0005-7/8 blank . 38 Work Mode Alarm Displays when work mode is abnormal. . Item 2). Item 4) to slide seat (Figure 1. 0006-1 .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. Item 2) and controls (Figure 1. Push down on handle (Figure 1. 2. Item 3) to set operator weight. 3. Push on lever (Figure 1. Pull up on handle (Figure 1. Item 1) to tilt seat (Figure 1. Item 5) to slide seat (Figure 1. Turn knob (Figure 1. 1. Item 6). HYEX00145 Operator's Seat Adjustments. 13 9 8 11 10 12 2 6 1 7 3 5 4 Figure 1. Item 2). 4. 8. Turn dial (Figure 1. Push button (Figure 1. END OF TASK END OF WORK PACKAGE 0006-2 0006 . Raise or lower headrest (Figure 1. Item 13) to adjust angle. Item 12) on underside of armrest (Figure 1. 7. Item 11) to desired height.TM 5-3805-294-10 ADJUSTMENT . 6. 10. Item 9) to unlock backrest (10). Tilt headrest (Figure 1.Continued 5. Squeeze bulb (Figure 1. Item 7) to increase lumbar support. Item 8) to decrease lumbar support. 9. Item 11) to desired angle. Pull up on handle (Figure 1. (WP 0006) STARTING THE ENGINE WARNING Perform a complete walk around the machine prior to starting the engine. Item 2) in LOCKED (up) position. Failure to comply may result in injury or death to personnel.TM 5-3805-294-10 0007 OPERATOR MAINTENANCE STARTING THE ENGINE INITIAL SETUP: Equipment Condition Before operations Preventive Maintenance Checks and Services performed. Seat Belt. Place pilot shutoff lever (Figure 2. Ensure sufficient clearance from personnel and equipment for safe operation of machine. 1 HYEX00090 Figure 1. Prior to starting engine sound horn to alert personnel. NOTE Engine will not start unless pilot shutoff lever is in the LOCKED (up) position. 2. Item 1). (WP 0077) Operators seat adjusted. Buckle the seat belt (Figure 1. 1. 0007-1 . Continued 2 HYEX00091 Figure 2. Item 4) to ON position. 3. Item 3) to slow idle position. 4. Turn key switch (Figure 4. Pilot Shutoff Lever. 0007-2 . Engine Speed Dial Slow Idle.TM 5-3805-294-10 0007 STARTING THE ENGINE . 3 HYEX00092 Figure 3. Turn engine speed dial (Figure 3. .. 5. 0007-3 . 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX00094 Figure 5. Item 5) to change to default screen (Figure 5. the pre-heat indicator will be displayed for up to 15 seconds depending on engine fuel temperature. Wait until engine preheat indicator (Figure 6. System Starting and Default Screen. 6 5 System Starting. 6. Key Switch ON. NOTE At approximately 32°F (0°C) or below. the "System Starting" screen will display for about 2 seconds.TM 5-3805-294-10 0007 STARTING THE ENGINE .Continued 4 HYEX00093 Figure 4. Item 6). Item 7) is no longer displayed. Wait for "System Starting" screen (Figure 5. The default screen will then be displayed. NOTE When the ignition key is turned to the ON position. wait until engine stops spinning before turning the key again.TM 5-3805-294-10 0007 STARTING THE ENGINE .7 h F1 F2 H F F3 F4 E 17. If engine fails to start. return key switch to OFF position and wait 2 minutes before attempting to start again. Turn key switch (Figure 7. 0007-4 .3 L/h C 8:01 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX00095 Figure 6. 7777. Failure to comply may result in damage to equipment. Key Switch to START. CAUTION • Never operate starter longer than 20 seconds at a time. NOTE Key switch will return to ON position when key is released.I.Continued 7 A. Item 4) to START position and release when engine starts. 7. 4 HYEX00099 Figure 7. Failure to comply may result in damage to equipment. Preheat Indicator. • After a false start. Item 8) are displayed. Alarm indicator. 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. 0007-5 . 8. Move engine speed dial (Figure 9. Turn engine speed dial (Figure 10.Continued CAUTION • If alarm indicators are still displayed after starting the engine. 8 HYEX00096 Figure 8. 3 HYEX00100 Figure 9. Item 3) right 1/3 and allow engine to idle for 30 seconds. 9. After the engine is started. Failure to comply may result in damage to equipment. Engine Speed Dial Turned to 1/3 Position. Item 3) to slow idle position until machine reaches normal operating temperature. ensure that no alarm indicators (Figure 8.TM 5-3805-294-10 0007 STARTING THE ENGINE . 10. Continued 3 HYEX00092 Figure 10. Return Engine Speed Dial to Slow Idle.TM 5-3805-294-10 0007 STARTING THE ENGINE . END OF TASK END OF WORK PACKAGE 0007-6 . the machine moves in opposite direction as described in these procedures. NOTE • If traveling long distances. 0008-1 . ensure that travel motors are at the back of the machine. 1 120 LOCK HYEX00146 Figure 1.TM 5-3805-294-10 0008 OPERATOR MAINTENANCE MOVING THE HYEX INITIAL SETUP: Equipment Condition Engine running. 1. • Keep personnel clear of the machine when traveling. • If travel motors are at the front of the machine. notify your supervisor prior to operating the boom. • When traveling down a slope. power lines. ensure that the boom has at least 10 ft (3 m) of clearance from overhead wires. (WP 0007) MOVING THE HYEX WARNING • Before moving the machine or operating the boom. Move pilot shutoff lever (Figure 1. Pilot Shutoff Lever Unlocked. If lines are near to your operating area. or structures. • When traveling up slopes. Failure to comply may result in injury or death to personnel. keep the bucket on the uphill side and just above the ground. Item 1) to the unlocked (down) position. Failure to comply may result in injury or death to personnel. operate control pedals or levers slowly. Item 3) off of ground to allow for sufficient visibility and to keep machine stable. NOTE If carrying a heavy load. Failure to comply may result in damage to equipment. Move travel mode switch (Figure 3. Boom and Arm Raised. 2 3 HYEX00147 Figure 2. Raise boom (Figure 2. 0008-2 . reduce travel speed to avoid undercarriage damage. Item 2) and arm (Figure 2. CAUTION When traveling over rough terrain. 4 HYEX00148 Figure 3.TM 5-3805-294-10 0008 MOVING THE HYEX .Continued 2. Item 4) to high position. NOTE Travel speed of machine is controlled by the foot pedals or travel levers. Travel Mode Switch. 3. keep travel mode switch in the low position for more control of the machine. Items 7 and 8) forward to move HYEX forward. or both travel levers (Figure 4. 5. Watch clearances. Push down on the rear of both foot pedals (Figure 4.Continued 4. • Use care when backing the machine.TM 5-3805-294-10 0008 MOVING THE HYEX . Items 5 and 6). Items 7 and 8) to move the HYEX backwards. Moving Forward and Backwards. Failure to comply may result in injury or death to personnel. Items 5 and 6). or push both travel levers (Figure 4. 7 8 5 6 HYEX01297 Figure 4. NOTE If travel motors are at the front of the machine. Allowing both foot pedals (Figure 4. Items 7 and 8) to return to center. Items 5 and 6) or pull both travel levers (Figure 4. END OF TASK STEERING THE HYEX WARNING • Keep personnel clear of the machine when traveling. 6. 0008-3 . Have an assistant direct you if you cannot see where you are going. Failure to comply may result in injury or death to personnel. the machine moves in opposite direction as described in these procedures. will stop the HYEX. Push down on the front of both foot pedals (Figure 4. 2. Item 8) back to counterrotate. Item 7) at center turns the HYEX left. Item 7) or pull right travel lever (Figure 7. 7 8 5 6 HYEX01296 Figure 5. Right Turn. Pushing front of left foot pedal (Figure 5. Item 6) or push right travel lever (Figure 6. Item 8) forward with left foot pedal (Figure 6. Item 7) forward with right foot pedal (Figure 5. 3. Left Turn. Item 6) and right travel lever (Figure 5. Pushing front of left foot pedal (Figure 7.Continued 1. 7 8 5 6 HYEX01295 Figure 6. Item 6). Item 5) and left travel lever (Figure 6. Item 5) or push left travel lever (Figure 5.TM 5-3805-294-10 0008 STEERING THE HYEX . Item 8) forward and push down on rear of right foot pedal (Figure 7. or push left travel lever (Figure 7. Pushing front of right foot pedal (Figure 6. Item 8) at center turns the HYEX right. 0008-4 . Items 5 and 6) or both travel levers (Figure 7. END OF TASK END OF WORK PACKAGE 0008-5/6 blank . Allowing both foot pedals (Figure 7. Counter-Rotate.Continued 7 8 5 6 HYEX01291 Figure 7. Items 7 and 8) to return to center will stop the HYEX.TM 5-3805-294-10 0008 STEERING THE HYEX . 4. . (WP 0004) END OF TASK SHUT DOWN ENGINE 1. 0009-1 . position flat side of bucket (Figure 1.) WP 0011 WP 0010 SAFELY PARK HYEX 1. Park machine (Figure 1. NOTE Do not force bucket on or in the ground. Item 2) and boom (Figure 1. Item 3). turn Auto-Idle (A/I) switch to the OFF position. Machine In Parked Position. 2. Item 5) is on. level surface. Bucket should be resting on the ground. Item 1) on solid. If Auto-Idle (A/I) switch (Figure 2.TM 5-3805-294-10 0009 OPERATOR MAINTENANCE SHUTTING DOWN THE HYEX INITIAL SETUP: References WP 0004 References (cont. Keeping angle between arm (Figure 1. 2 3 4 1 HYEX02418 Figure 1. Item 4) on the ground. TM 5-3805-294-10 0009 SHUT DOWN ENGINE . Auto-Idle Switch and Engine Speed Dial. Turn engine speed dial (Figure 3. NOTE Engine speed dial shown approximately at 1/3 position. 2. 0009-2 . Item 6) to slow idle position. Turn engine speed dial (Figure 2. Item 6) to 1/3 position for 2 minutes without a load. CAUTION Turbocharger may be damaged if engine is not shut down properly.Continued 6 5 HYEX00153 Figure 2. 3. Failure to comply may result in damage to equipment. Engine Speed Dial. 0009-3 . Item 8) to OFF position and remove key.TM 5-3805-294-10 0009 SHUT DOWN ENGINE . 4.Continued 6 HYEX00154 Figure 3. Pilot Shutoff Lever. Item 7) to LOCKED (up) position. 5. Move pilot shutoff lever (Figure 4. 7 HYEX00155 Figure 4. Turn key switch (Figure 5. TM 5-3805-294-10 0009 SHUT DOWN ENGINE . CAUTION Ensure all windows and doors are closed when machine is parked to prevent electrical system damage during inclement weather. 6. Key Switch Turned OFF.Continued 8 HYEX00157 Figure 5. (WP 0011) END OF TASK END OF WORK PACKAGE 0009-4 . Close windows. Failure to comply may result in damage to equipment. position flat side of bucket (Figure 1. Item 2) and arm (Figure 1. Bucket should be resting on the ground. 2 3 1 4 HYEX01637 Figure 1. (WP 0004) END OF TASK SHUT DOWN ENGINE 1. level surface. NOTE Do not force bucket on or in the ground. turn Auto-Idle (A/I) switch to the OFF position. Park machine (Figure 1. 0010-1 . Item 5) is on. Keeping angle between deep dig arm (Figure 1. 2. (WP 0007) SAFELY PARK MACHINE 1.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. Machine In Parked Position. Item 4) on the ground. Item 1) on solid. Item 3) at approximately 90 degrees. If Auto-Idle (A/I) switch (Figure 2. Auto-Idle Switch and Engine Speed Dial.TM 5-3805-294-10 0010 SHUT DOWN ENGINE . 2. Item 6) to slow idle position. 0010-2 . 3. Turn engine speed dial (Figure 2. Failure to comply may result in damage to equipment. NOTE Engine speed dial shown approximately at 1/3 position. CAUTION Turbocharger may be damaged if engine is not shut down properly. Turn engine speed dial (Figure 3.Continued 6 5 HYEX01507 Figure 2. Item 6) to 1/3 position for 2 minutes without a load. Continued 6 HYEX01508 Figure 3. 0010-3 . 5. 4. Move pilot shutoff lever (Figure 4. Turn key switch (Figure 5.TM 5-3805-294-10 0010 SHUT DOWN ENGINE . Item 8) to OFF position and remove key. Engine Speed Dial. Pilot Shutoff Lever. Item 7) to LOCKED (up) position. 7 HYEX01509 Figure 4. Key Switch Turned OFF. Close windows.Continued 8 HYEX01510 Figure 5. 6. (WP 0011) END OF TASK END OF WORK PACKAGE 0010-4 .TM 5-3805-294-10 0010 SHUT DOWN ENGINE . 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. 2 1 3 HYEX00160 Figure 1. Pull lock pin (Figure 1. 0011-1 . • The washer can operate with windshield open. 3. Item 2) to open windshield (Figure 1. 1. Item 3) until it latches open. Open Windshield. Item 1) inward and rotate into notch. Item 4) to raise windshield (Figure 2. Pull on latch release bar (Figure 1. Lift on handle (Figure 2.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. Item 3). 2. 5. Item 5) and rotate into notch.TM 5-3805-294-10 0011 WINDSHIELD . 4. pull lock pin (Figure 4. Item 1) from notch and slide into cab frame lock hole (Figure 3.Continued 4 3 HYEX00161 Figure 2. 0011-2 . 5 1 HYEX00162 Figure 3. Item 5). To close the windshield. Item 1) inward from cab frame lock hole (Figure 4. Failure to comply may result in injury or death to personnel. WARNING Lock pin must be used to secure upper front window in raised position. Raise Windshield. Release lock pin (Figure 3. Lock Windshield Open. Press glass (Figure 6. Release Windshield Latch.Continued 1 5 2 HYEX00163 Figure 4. Item 2).TM 5-3805-294-10 0011 WINDSHIELD . 8. Item 3) until bar (Figure 6. 7. 0011-3 . Use lower handle to prevent window from free falling. Item 3) until it is latched in the closed position. WARNING Window closes rapidly when released. Hold handle (Figure 5. Item 4) and lower windshield (Figure 5. Failure to comply may result in injury or death to personnel. 6. Pull on latch release bar (Figure 4. Close Windshield. Item 2) snaps into place. 4 3 HYEX00161 Figure 5. Item 7) to rear until latch (Figure 7. Latch Windshield. 2.Continued 2 1 3 HYEX00160 Figure 6. 6 7 HYEX01411 Figure 7. To close. END OF TASK 0011-4 . slide cab door window (Figure 7. Item 6) engages. release latch (Figure 7. Item 6) and slide cab door window (Figure 7. Open and Close Cab Door Window. Item 1) from notch. Item 7) forward. To open. Release lock pin (Figure 6. 9.TM 5-3805-294-10 0011 WINDSHIELD . END OF TASK CAB DOOR WINDOW 1. Open Access Cover. Item 10) and engage two latches (Figure 9. 2. 8 HYEX03377 Figure 8. To open.TM 5-3805-294-10 0011 SKYLIGHT WINDOW (SECONDARY EXIT) 1. pull down on handle (Figure 9. release two latches (Figure 9. Item 8) open. Item 8) closed. 0011-5 . Slide access cover (Figure 10. To close. Slide access cover (Figure 8. 4. 10 9 9 HYEX00167 Figure 9. Item 10). Item 9). 3. Item 9) and push up on handle (Figure 9. Open and Close Skylight Window. END OF TASK END OF WORK PACKAGE 0011-6 . Close Access Cover.TM 5-3805-294-10 0011 SKYLIGHT WINDOW (SECONDARY EXIT) .Continued 8 HYEX03377 Figure 10. 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. 1. M240B. Stow Weapon In Rear Bracket Place barrel of weapon in front mounting bracket (Figure 2. Place butt of weapon in rear mounting bracket (Figure 1. or M16 series weapon with and without M203 grenade launcher. 0012-1 . Item 2). 2. 1 HYEX00999 Figure 1. M249. Item 1). Remove butt of weapon from rear mounting bracket (Figure 4. Item 3). If necessary. 0012-2 . Item 3) and slide front mounting bracket (Figure 2.Continued 3 2 4 HYEX00998 Figure 2. Stow Weapon In Front Bracket 3. 3 2 4 HYEX00998 Figure 3. Item 2). Item 2) on two rails (Figure 2. Tighten two handles (Figure 2. Item 1). END OF TASK REMOVE 1. 4.TM 5-3805-294-10 0012 STOW . Remove Weapon From Front Bracket 2. loosen two handles (Figure 2. Item 4). Lift barrel of weapon from front mounting bracket (Figure 3. Remove Weapon From Rear Bracket END OF TASK END OF WORK PACKAGE 0012-3/4 blank .TM 5-3805-294-10 0012 REMOVE .Continued 1 HYEX00999 Figure 4. . 0013-1 . Press button 1 or button 2 until the Time Set menu is highlighted. Press menu button. Press select button to open Time Set menu. 3. 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. (WP 0007) TIME ADJUSTMENT NOTE After approximately 1 minute the monitor will return to the default screen.TM 5-3805-294-10 0013 OPERATOR MAINTENANCE GENERAL MONITOR OPERATION INITIAL SETUP: Equipment Condition Engine running. Select Time Set Menu. 1. 2. 2. END OF TASK DISPLAYING OPERATING CONDITIONS 1. Press select button and "Data is being applied" will display on the screen. 3. 5 BACK BUTTON MENU BUTTON Select Operating Conditions Menu. Press button 3 or button 4 to adjust date or time up or down. 6. Press button 1 or button 2 to select date or time. HYEX00058 Adjust Time. 7. 5. 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. Press menu button 1. Press select button.TM 5-3805-294-10 0013 TIME ADJUSTMENT . Press button 1 or button 2 until the Operating Conditions menu is highlighted.Continued 4. After desired date and time is achieved. Press back button until default screen is displayed. press button 1 or button 2 until the apply setting icon is highlighted. 0013-2 HYEX00059 . 8. 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. press select button. OK? is displayed.Continued 4. press back button. press back button until default screen is displayed. If reset is not desired. Reset Operating Conditions. The Reset Data.TM 5-3805-294-10 0013 DISPLAYING OPERATING CONDITIONS . To reset data. 6. When finished with menu. END OF TASK END OF WORK PACKAGE 0013-3/4 blank . Operating Conditions menu will be displayed. END OF TASK MAINTENANCE SETTINGS Maintenance settings are to be accessed only by the Field Level maintainer. 8. OK? SELECT BUTTON 1 2 6 3 4 5 7 8 9 0 F1 F2 F3 F4 BACK BUTTON HYEX00060 Figure 4. Operating Conditions Reset Data. 5. 7. . 42 inch rock bucket shown. Item 1). (WP 0007) 3. the bucket can fall off of the quick latch. NOTE The ditch cleaning bucket and 42 inch rock bucket are removed the same way. Item 3).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. 1 HYEX03379 Figure 1. Lift and rotate safety lock pin lever (Figure 1. 1. 2. 0014-1 . Item 2) to allow adequate ground clearance for bucket (Figure 2. Slowly retract or extend bucket cylinder when removing or installing bucket. Start engine. Ensure that personnel are clear of equipment when removing or installing bucket. (WP 0009) REMOVING BUCKET WARNING With quick latch wedges disengaged from bucket. Raise boom (Figure 2. Unlock Safety Lock Pin. Failure to comply may result in injury or death to personnel. Move Quick Latch Switch to Unlatch Position. Item 5) until quick latch wedges (Figure 4. 0014-2 . Fully extend bucket cylinder (Figure 4. Item 6) are fully retracted. Raise Boom. Item 4) to unlatch position. Move quick latch switch (Figure 3. 4. 4 HYEX00939 Figure 3.TM 5-3805-294-10 0014 REMOVING BUCKET . 5.Continued 2 3 HYEX03380 Figure 2. Slowly retract bucket cylinder (Figure 5.Continued 5 6 HYEX03387 Figure 4.TM 5-3805-294-10 0014 REMOVING BUCKET . Item 2) and place bucket (Figure 6. NOTE Ensure that arm is just past the vertical position prior to setting bucket on the ground. 6. Extend Bucket Cylinder. Slowly lower boom (Figure 6. WARNING With quick latch wedges disengaged from bucket. Item 5) and position quick latch (Figure 5. Ensure that personnel are clear of equipment when removing or installing bucket. 5 7 HYEX03384 Figure 5. Retract Bucket Cylinder. Item 3) on ground. Failure to comply may result in injury or death to personnel. 7. Item 7) in vertical position. the bucket can fall off of the quick latch. Slowly retract or extend bucket cylinder when removing or installing bucket. 0014-3 . Move quick latch switch (Figure 7. Item 4) in latch position. 0014-4 . Item 7) from bucket (Figure 8.Continued 2 3 HYEX03382 Figure 6. Position Quick Latch Switch to Latch position. Lower Boom. Item 3). Remove quick latch (Figure 8.TM 5-3805-294-10 0014 REMOVING BUCKET . 4 HYEX00939 Figure 7. 8. 9. Continued 7 3 HYEX03389 Figure 8. NOTE The ditch cleaning bucket and 42 inch rock bucket are installed the same way. Failure to comply may result in injury or death to personnel. the bucket can fall off of the quick latch. 1. 42 inch rock bucket shown. 0014-5 . END OF TASK INSTALLING BUCKET WARNING With quick latch wedges disengaged from bucket. Item 4) in the unlatch position. Remove Quick Latch.TM 5-3805-294-10 0014 REMOVING BUCKET . Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Move quick latch switch (Figure 9. Failure to comply may result in injury or death to personnel.TM 5-3805-294-10 0014 INSTALLING BUCKET . 0014-6 . Item 6) are fully retracted. 2 HYEX03385 Figure 10. 3. Slowly extend bucket cylinder (Figure 11. Position Quick Latch Switch to Unlatch position. the bucket can fall off of the quick latch.Continued 4 HYEX00939 Figure 9. WARNING With quick latch wedges disengaged from bucket. Ensure that personnel are clear of equipment when removing or installing bucket. Raise Boom for Clearance. Item 5) until quick latch wedges (Figure 11. Item 2) to allow for adequate ground clearance. Raise boom (Figure 10. 2. Slowly retract or extend bucket cylinder when removing or installing bucket. 7. Item 3).TM 5-3805-294-10 0014 INSTALLING BUCKET . Install Quick Latch. Extend bucket cylinder (Figure 12. 5 7 3 HYEX03381 Figure 12. Item 3). Move quick latch switch (Figure 13. Item 5) until quick latch (Figure 12. Item 7) is resting on bucket (Figure 12. Item 7) to bucket (Figure 12. Install quick latch (Figure 12. Item 7) in vertical position. Position quick latch (Figure 12.Continued 5 6 HYEX03383 Figure 11. 4. 0014-7 . Item 4) in latch position. 5. Retract Wedges. 6. TM 5-3805-294-10 0014 INSTALLING BUCKET . Raise boom (Figure 14. 2 5 6 HYEX03386 Figure 14. Fully extend bucket cylinder (Figure 14. Item 5) to ensure quick latch wedges (Figure 14. 0014-8 . 10.Continued 4 HYEX00939 Figure 13. Position Quick Latch Switch toLatch position. Item 2) to allow for ground clearance. 8. Position bucket (Figure 15. 9. Item 3) on ground. Item 6) are fully engaged. Raise Boom. END OF TASK END OF WORK PACKAGE 0014-9/10 blank . 11. Safety Pin Locked. Item 1) to lock position. Rotate safety lock pin lever (Figure 15.TM 5-3805-294-10 0014 INSTALLING BUCKET .Continued 1 3 HYEX03378 Figure 15. . (WP 0007) Personnel Required Horizontal Construction Engineer 12N (2) LIFTING WARNING LIFTING GUIDELINES: • Do not use machine to lift personnel. • Personnel must remain clear of lifted items. Failure to comply may result in injury or death to personnel. Do not allow lifted items to strike obstacles. Item 1) to load (Figure 1.TM 5-3805-294-10 OPERATOR MAINTENANCE LIFTING WITH HYEX INITIAL SETUP: Tools and Special Tools Suitable Lifting Device Equipment Condition Engine running. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 1. NOTE • Use a suitable lifting device and tether lines to guide load. Secure lifting device (Figure 1. Failure to comply may result in injury or death to personnel. • Do not hook lifting device to bucket teeth. • Coordinate hand signals with assistant prior to lifting. • Lift load only as high as necessary. • Ensure load does not exceed the capacity of machine or lifting device. 0015-1 0015 . • Move load slowly. Failure to comply may result in injury or death to personnel. Item 2). Failure to comply may result in injury or death to personnel. Item 1) to quick latch loop (Figure 1. Item 2) and verify stability of load and machine (Figure 1. END OF TASK END OF WORK PACKAGE 0015-2 .TM 5-3805-294-10 0015 LIFTING . Item 3) and retract arm (Figure 1. With the aid of an assistant. Attach lifting device (Figure 1. Item 4).Continued 4 6 5 3 1 2 HYEX00919 Figure 1. Curl bucket (Figure 1. raise load (Figure 1. Item 5). 4. Lifting with Quick Latch Loop. 3. 2. Item 6) before moving the machine. 2. If material is added. HYEX01484 Figure 2. Add or Remove Material. level surface optimizes machine stability. (WP 0007) LEVELING MACHINE NOTE Operating on a firm. Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material. drive over new material to compact it until the worksite feels stable. If necessary.TM 5-3805-294-10 0016 OPERATOR MAINTENANCE OPERATING TECHNIQUES INITIAL SETUP: Equipment Condition Engine running. Leveling Machine. 3. HYEX01483 Figure 1. use bucket to add or remove material to level the worksite. END OF TASK 0016-1 . 1. Failure to comply may result in damage to equipment. 1. with travel motors to the rear of the machine. (102-152 mm) deep. or attempt to shift rocks and break down walls using swing motion. use MINIMUM amount of force to prevent damage to the cylinders. CAUTION • When bucket cylinder is fully extended. • Do not dig under the machine. • If you clean the bucket by rapping it against the cylinder stops. NOTE • Initial cut should be approximately 4 ft (122 cm) long and 3-4 in. • Do not use the bucket as a hammer. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. • To prevent the spoil pile from caving in the excavation. Failure to comply may result in damage to equipment.TM 5-3805-294-10 ARM DIGGING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. Failure to comply may result in damage to equipment. Failure to comply may result in damage to equipment. swing bucket to level material. Clean the bucket by hand if rapping the bucket lightly does not work. • Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. • Remaining cuts should be approximately 4 ft (122 cm) long and 4-6 in. Position arm in a vertical position. do not strike the ground or use the bucket for tamping. spoil piles should be placed at least 3 ft (1 m) from trench. • Do not side load bucket. or strike objects from the side with the bucket. 0016-2 0016 . Failure to comply may result in injury or death to personnel. pile driver. (76-102 mm) deep. Failure to comply may result in damage to equipment. Arm Digging.Continued HYEX01486 Figure 3. 0016-3 . Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. • Do not side load bucket. 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. • Do not use the bucket as a hammer. 3. • Do not dig under the machine. Failure to comply may result in injury or death to personnel. pile driver. Move arm away from machine approximately 2 ft (61 cm).TM 5-3805-294-10 0016 ARM DIGGING . do not strike the ground or use the bucket for tamping. Failure to comply may result in damage to equipment. • Do not drive near the edge of an excavation or trench. with travel motors to the rear of the machine. 2. Failure to comply may result in injury or death to personnel. Failure to comply may result in damage to equipment. swing bucket to level material. • To prevent the spoil pile from caving in the excavation. or attempt to shift rocks and break down walls using swing motion. CAUTION • When bucket cylinder is fully extended. spoil piles should be placed at least 3 ft (1 m) from trench. or strike objects from the side with the bucket. Use boom to force bucket into ground. 4. Bucket Digging. 5. • Excavate in thin layers to fragment material and to ease in dumping material from the bucket. This especially applies to sticky materials. END OF TASK 0016-4 . • For power digging and for working in confined areas.Continued • If you clean the bucket by rapping it against the cylinder stops. HYEX01485 Figure 4. roll back bucket to break out. 2. 3. use MINIMUM amount of force to prevent damage to the cylinders. NOTE • Ensure that correct bucket is used for the type of material being excavated. 1. raise boom slightly then continue to curl bucket . Lower bucket to the digging area. If bucket stalls. If arm stalls. use the bucket cylinder for digging.TM 5-3805-294-10 0016 BUCKET DIGGING . Clean the bucket by hand if rapping the bucket lightly does not work. Retract arm and curl bucket at the same time until bucket is full. Failure to comply may result in damage to equipment. Failure to comply may result in injury or death to personnel. 2. Failure to comply may result in injury or death to personnel. • Do not drive near the edge of an excavation or trench. On slopes. Failure to comply may result in injury or death to personnel. If required. Failure to comply may result in injury or death to personnel. Planning Spoil Piles. with travel motors to the rear of the machine. place spoil piles on the upper side of the slope to improve machine stability and ease backfilling. • Do not dig under the machine. place spoil piles for convenient truck loading or backfilling. • To prevent the spoil pile from caving in the excavation. 1. spoil piles should be placed at least 3 ft (1 m) from trench.TM 5-3805-294-10 0016 PLANNING SPOIL PILES WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. 0016-5 . the further away the spoil pile should be placed. with travel motors to the rear of the machine. HYEX01487 Figure 5. END OF TASK TRENCHING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. The deeper the excavation. Failure to comply may result in injury or death to personnel. 3. Place spoil piles at least 3 ft (1 m) away from excavation. TM 5-3805-294-10 0016 TRENCHING . Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench. 2. • To prevent the spoil pile from caving in the excavation. HYEX01503 Figure 7.Continued • Do not drive near the edge of an excavation or trench. spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 3. 1. END OF TASK CLEANING A CAVE IN 1. DO NOT back over the trench. Cleaning Cave In. Drive the machine to the cave in. Failure to comply may result in injury or death to personnel. HYEX01504 Figure 6. 2. If you cannot clean a cave in from the machine's current position. Park the machine at a 90 degree angle to the trench with the travel motors to the rear of the machine. 3. and gas or oil pipelines. The deeper the trench. 0016-6 . • Do not dig under the machine. 4. pipes. Trenching. Check for buried utility lines. the further away the spoil pile should be placed. Before starting work. Failure to comply may result in injury or death to personnel. walk the site to uncover hazards and to plan the job. 2. • Do not dig under the machine.Continued 4. When trenching across a slope. with travel motors to the rear of the machine. 3.TM 5-3805-294-10 0016 CLEANING A CAVE IN . • Do not drive near the edge of an excavation or trench. Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling. spoil piles should be placed at least 3 ft (1 m) from trench. level the machine so that the bottom of the trench will be level. END OF TASK TRENCHING ON A SLOPE WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. END OF TASK 0016-7 . Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 1. NOTE The deeper the trench the further away the spoil pile should be. HYEX01488 Figure 8. • To prevent the spoil pile from caving in the excavation. Clean cave in from the side of the trench. Level machine by counter-rotating tracks or by digging a shelf. Failure to comply may result in injury or death to personnel. Trenching on a Slope. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. They are especially helpful when the machine is moved often. Failure to comply may result in injury or death to personnel. with travel motors to the rear of the machine. 0016-8 . 3. 1. HYEX01489 Figure 9.TM 5-3805-294-10 0016 STRAIGHT LINE TRENCHING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. • To prevent the spoil pile from caving in the excavation. Use stakes as a sight gauge. spoil piles should be placed at least 3 ft (1 m) from trench. Drive the second stake approximately 30 ft (9 m) behind the first stake. Failure to comply may result in injury or death to personnel. 2. NOTE The deeper the trench. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. Drive the first stake immediately behind the start point of the trench. with travel motors to the rear of the machine. the further away the spoil pile should be. • Do not dig under the machine. • Do not drive near the edge of an excavation or trench. • Do not drive near the edge of an excavation or trench. Straight Line Trenching. Drive two stakes in the ground at the beginning of the trench. END OF TASK BACKFILLING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. CAUTION Do not use side of bucket to backfill. spoil piles should be placed at least 3 ft (1 m) from trench. • To prevent the spoil pile from caving in the excavation. Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine. 1. 2.TM 5-3805-294-10 0016 BACKFILLING . Failure to comply may result in damage to equipment. NOTE The bucket side can be used for finish grading.Continued • Do not dig under the machine. HYEX01490 Figure 10. Failure to comply may result in injury or death to personnel. Use material from spoil pile to backfill. Back Filling. Failure to comply may result in injury or death to personnel. END OF TASK 0016-9 . HYEX01491 Figure 11. 2. • Do not drive near the edge of an excavation or trench. 1. • Do not dig under the machine. Truck Loading. • To prevent the spoil pile from caving in the excavation. Continue to fill bed from front to rear. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. spoil piles should be placed at least 3 ft (1 m) from trench.TM 5-3805-294-10 0016 TRUCK LOADING WARNING PREVENTING CAVE IN • Work perpendicular to or at an angle to excavation. END OF TASK END OF WORK PACKAGE 0016-10 . Position bucket and slowly dump load in vehicle at the front center of the bed. with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. Medium duty land clearing/grubbing. 5. Bulky loose materials. 5. 4. Medium duty scrap handling. 0017-1 . Curl the bucket (Figure 1. Item 1). Clamping and lifting. Position hydraulic thumb (Figure 1. 6. Heavy land clearing. Clamping With Bucket. Breaking ledge rock. 2.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 WITH THE BUCKET 1. 1 2 HYEX01175 Figure 1. Logging. Heavy scrap handling. The hydraulic thumb was not designed and should not be used for the following: 1. 3. Ripping up concrete or asphalt. Item 1) near the object to be picked up. Item 2) until it begins to force the object to the hydraulic thumb (Figure 1. Demolition of wood and brick structures. Quarry applications. 6. 3. 2. 2. 4. Heavy grubbing. 3. 2. Move hydraulic thumb (Figure 2. Curl bucket (Figure 2. Item 2) and position it near or in contact with the object being picked up. Item 1) to grasp and clamp the object.TM 5-3805-294-10 0017 CLAMPING WITH THE BUCKET . 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. Clamping With Hydraulic Thumb. Gently move the bucket control to pick the object up without crushing it. 1 2 HYEX01174 Figure 2. END OF TASK 0017-2 .Continued 3. Position hydraulic thumb (Figure 2. Item 1) in the store position. Retract either the hydraulic thumb (Figure 3. Failure to comply may result in injury or death to personnel. the machine becomes unstable and could roll over. END OF TASK END OF WORK PACKAGE 0017-3/4 blank . Never release load while moving or turning. Failure to comply may result in injury or death to personnel. The possibility of the clamped object to fall always exists. • Always look before releasing a load. • Always keep object close to machine when lifting with the hydraulic thumb and bucket. 2. Move object to desired location. 1. Item 1) or bucket (Figure 3.TM 5-3805-294-10 0017 MOVING AND RELEASING CLAMPED OBJECTS WARNING • Never lift clamped objects over personnel. Failure to comply may result in injury or death to personnel. Item 2) to release object. Releasing Objects. 1 2 HYEX01174 Figure 3. When the object is moved away from the machine using the boom or arm. . 2. 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. (WP 0007) SELECTING ATTACHMENT 1. 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 . Table 1.TM 5-3805-294-10 0018 OPERATOR MAINTENANCE SELECTING AN ATTACHMENT ON THE MONITOR INITIAL SETUP: Equipment Condition Engine running. Use the following table to select attachment. Attachment Selection. HYEX00172 Select Attachment. Press F1 button and Work Mode screen will be displayed. The default screen will be displayed. 4. Verify the attachment specifications are the same as displayed on the monitor.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.TM 5-3805-294-10 0018 SELECTING ATTACHMENT . Press the select button. The attachment specification screen will be displayed. END OF TASK END OF WORK PACKAGE 0018-2 . 5.Continued 3. Attachment Specification Screen. Breaker 1 Maximum Pump Flow Rate 288. Table 2. Item 4). Item 14) Wrench. Table 2. Remove retaining clip (Figure 1. Item 3) from storage position (Figure 1.) WP 0009 WP 0018 WP 0092 Equipment Condition Safely park and shutdown machine.95 in. (WP 0014) Materials/Parts Rags.5 mm) (WP 0095. 0019-1 . Item 3). 3 4 2 6 1 5 3 HYEX03392 Figure 1. Wiping (WP 0097. Table 2. Remove pin (Figure 1. Item 1). Item 2) from pin (Figure 1. (WP 0007) 2. (63. Open End. Adjustable 0. Open End. (76 mm) (WP 0095. Retract hydraulic thumb cylinder (Figure 1. Start machine. Open End. 4. (24 mm) (WP 0095. Table 1. Item 15) References WP 0007 INSTALLING CRUSH-ALL 1. 3 in. Item 15) Wrench. 3. Close Hydraulic Thumb Circuit. 2 1/2 in.TM 5-3805-294-10 0019 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE CRUSH-ALL INITIAL SETUP: Tools and Special Tools Wrench. Item 19) References (cont. (WP 0009) Bucket removed. Item 3). 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. Item 3). 0019-2 . Only use prybar to push pin. Item 5). NOTE There are two auxiliary circuit shutoff valves. Using prybar to push pin (Figure 1. Item 7) to unlatch position. Move Quick Latch Switch to Unlatch Position. 7. 6. Move quick latch switch (Figure 2. Item 8) to ensure quick latch wedges (Figure 3. Item 2) on pin (Figure 1. Item 9) are fully retracted. Left side shown.TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL . install pin in thumb lock position (Figure 1. Item 6). There is one located on both sides of the arm.Continued WARNING Keep hands away from pin and alignment holes while thumb is being moved. Install retaining clip (Figure 1. Failure to comply may result in injury or death to personnel. Fully extend bucket cylinder (Figure 3. 8. 5. 9. Close two auxiliary circuit shut off valves (Figure 1. 7 HYEX03393 Figure 2. Install quick latch (Figure 4. Item 10) is in the vertical position. 11. Item 8) until quick latch (Figure 4. Retract bucket cylinder (Figure 4. Item 11). 12. Item 8) until quick latch (Figure 4. Item 10) to crush-all (Figure 4. Item 7) to latch position. 13. 0019-3 . Item 10) is resting on crush-all (Figure 4.Continued 8 9 HYEX03394 Figure 3. Extend Bucket Cylinder.TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL . 8 10 11 HYEX03397 Figure 4. Move quick latch switch (Figure 5. Item 11). 10. Extend bucket cylinder (Figure 4. Install Quick Latch. Continued 7 HYEX03393 Figure 5. 16. Item 12) to allow adequate ground clearance of crush-all (Figure 6. Rotate safety lock pin lever (Figure 6. Clean cap (Figure 7. Position Crush-All. Shutdown machine. Extend arm cylinder (Figure 6. Item 16) with rag. Item 15) and machine quick disconnect (Figure 7. Raise boom (Figure 6. 14. Curl crush-all (Figure 6. (WP 0009) 19. Item 9) are fully engaged to crush-all (Figure 6. 0019-4 . Item 14) and lower boom (Figure 6. Item 11). Item 11) on ground. 18. 15. Item 11). Quick Latch Switch to Latch Position. Item 11) as in Figure 6 until quick latch wedges (Figure 6. 17. 12 14 13 8 9 11 HYEX03395 Figure 6. Item 13) to lock position.TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL . Item 12) to position crush-all (Figure 6. Item 16). 23.Continued 18 16 17 15 HYEX01501 Figure 7. Remove plug (Figure 7. Item 26) with rag. Item 16). Clean plug (Figure 7. Item 19) and machine quick disconnect (Figure 8. Item 20) with rag. Item 15) from machine quick disconnect (Figure 7. 21 HYEX01502 Figure 8. 33. 27 28 29 26 24 22 20 23. Connect attachment quick disconnect (Figure 8. Item 20). 22. Item 19) from machine quick disconnect (Figure 8. Connect Auxiliary Return Line. Item 17) and attachment quick disconnect (Figure 7. Item 25) and attachment quick disconnect (Figure 8. 25. Item 26). Item 25). 21. Item 18) to machine quick disconnect (Figure 7. 32. Remove cap (Figure 8. Item 21). 27. Item 25) from attachment quick disconnect (Figure 8. Item 20) from attachment quick disconnect (Figure 8. 30. 0019-5 . Item 23) from machine quick disconnect Figure 8. Connect attachment quick disconnect (Figure 7. Item 22) with rag. Clean cap (Figure 8. Item 20). 26. Connect Auxiliary Supply Line. 29. Clean cap (Figure 8. Item 17) from attachment quick disconnect (Figure 7. Item 23) and machine quick disconnect (Figure 8. Item 21) and attachment quick disconnect (Figure 8. Item 22) to machine quick disconnect (Figure 8. Item 18) with rag.TM 5-3805-294-10 0019 INSTALLING CRUSH-ALL . Remove plug (Figure 8. 28. Clean plug (Figure 8. Item (24). 31. Remove cap (Figure 8. Item 24). 25 19. 20. 24. Remove cap (Figure 7. Item 26) to machine quick disconnect (Figure 8. Clean plug (Figure 8. Remove plug (Figure 8. Connect attachment quick disconnect (Figure 8. Item 18). (WP 0092) WARNING • Ensure operator protection guard is installed prior to operation.72 cm x 45. the maximum feed size is 15 in. strike objects or ground.72 cm). • Do not reach into machine to remove debris. limestone. (WP 0004) 4. Ensure personnel maintain distance of 150 ft (45. panels. wet down material prior to crushing. Remove cap (Figure 8. 5. CAUTION Do not overload Crush-All. (WP 0007) 2. Lift Crush-All (Figure 9. (WP 0004) 6. x 18 in. (WP 0018) 3.1 cm x 12. asphalt. or other materials with dirt. Item 28). Item 27) from connector (Figure 8. Turn on the Auxiliary Control Switch. NOTE • When crushing concrete. • To reduce dust output. Item 28). • Do not operate Crush-All with guards. Item 29) to connector (Figure 8. or softer stone. block. brick. Item 11) approximately 6 ft (182. the maximum feed size is 18 in. Failure to comply may result in injury or death to personnel. Start machine. or use sides of Crush-All to move material. Select the Pulverizer 1 on the monitor. 0019-6 0019 .72 m). Adjust discharge size as needed. Place engine at full speed while crushing.8 cm) off ground. Failure to comply may result in injury or death to personnel. or covers removed.Continued 34. Attach connector (Figure 8. (45. • Crush-All can throw objects at any time during operation. • When crushing slag. (38. x 5 in.TM 5-3805-294-10 INSTALLING CRUSH-ALL . END OF TASK OPERATION 1. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 35. Failure to comply may result in damage to equipment.7 cm). 8. 7. hold attachment pedal until all material has been discharged. Item 11) to vertical position. Item 11). Release attachment pedal (Figure 9. then boom up and curl as the Crush-All is elevated above material. Item 11) to vertical position. Item 31) and press button (Figure 9. 11. Press button (Figure 9. NOTE Scooping material is best performed by arming into the material. 14. Press attachment pedal (Figure 9. 9. Curl crush-all (Figure 9.Continued 34 31 30 32 33 11 HYEX01499 Figure 9. Item 32) to open lid (Figure 9. Item 30). Item 11) to run for 5 minutes with no load. 12. Allow all material to pass through crush-all (Figure 9. Item 11) away from material. 13. Allow Crush-All (Figure 9.TM 5-3805-294-10 0019 OPERATION . 15. Scoop material and raise Crush-All (Figure 9. Item 31) to turn off crush-all (Figure 9. Item 33). 10. Swing Crush-All (Figure 9. 0019-7 . 17. Curl Crush-All (Figure 9. Item 32). NOTE To avoid jamming. Item 11). Item 11). Release attachment pedal lock (Figure 9. Item 34) to close lid (Figure 9. Press attachment pedal (Figure 9. NOTE Reduce dust by keeping bottom of Crush-All close to stock pile. Crush-All Operation. 16. Item 11) over stock pile. Item 31) to turn on Crush-All (Figure 9. 72 m). Engage attachment pedal lock (Figure 9. Item 33). Ensure personnel maintain distance of 150 ft (45. • Do not reach into machine to remove debris. END OF TASK JAMMING WARNING • Ensure operator protection guard is installed prior to operation. 0019-8 . Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 1. • It may be necessary to shake Crush-All. NOTE • These steps may be used to clear uncrushable material from machine. Failure to comply may result in damage to equipment. Item 30). Item 31) and press button (Figure 10. • Crush-All can throw objects at any time during operation.TM 5-3805-294-10 0019 OPERATION . Failure to comply may result in injury or death to personnel. Item 32) to open lid (Figure 10. panels. or covers removed. Press attachment pedal (Figure 10. Failure to comply may result in injury or death to personnel. CAUTION Do not attempt to clear jam by striking Crush-All on ground.Continued 18. • Do not operate Crush-All with guards. 2. 3. Open Lid. Safely park and shutdown machine. 8 11 HYEX03148 Figure 11.Continued 31 32 33 HYEX03431 Figure 10.TM 5-3805-294-10 0019 JAMMING . Clearing Jam from Crush-All. Use a sturdy piece of lumber to push rotor (Figure 12. Retract bucket cylinder (Figure 11. (WP 0009) 4. Item 11) upside down and allow material to fall out. 0019-9 . Item 34) in reverse. Item 8) to dump crush-all (Figure 10. 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 Item 11). the impact breaker could fall off of the quick latch. Item 9) until quick latch (Figure 6. Install Quick Latch. 13. 0020-4 . With the aid of an assistant slowly raise boom (Figure 5.TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER . Item 11) is resting on impact breaker (Figure 6. Slowly retract or extend bucket cylinder when removing or installing impact breaker.Continued 9 8 11 12 HYEX03402 Figure 5. Item 8) to allow for adequate ground clearance of quick latch (Figure 5. Item 12) 9 12 11 HYEX03403 Figure 6. Ensure that personnel are clear of equipment when removing or installing impact breaker. Extend Bucket Cylinder. Item 12). Item 11) to impact breaker (Figure 5. WARNING With quick latch wedges disengaged from impact breaker. Extend bucket cylinder (Figure 6. 14. Install quick latch (Figure 5. Failure to comply may result in injury or death to personnel. 12. TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER . (WP 0009) 19. Extend bucket cylinder (Figure 8. 0020-5 . 17. Shutdown machine. 9 10 12 HYEX03401 Figure 8. Item 9) until quick latch wedges (Figure 8. Item 13) to lock position. Retract bucket cylinder (Figure 8. Item 9) and place impact breaker (Figure 8. Item 7) to LATCH position. 7 HYEX03398 Figure 7. 18. Rotate safety lock pin lever (Figure 9. Item 12). Item 12) on ground. Quick Latch Wedges Engaged. 16.Continued 15. Move quick latch switch (Figure 7. Item 10) are fully engaged to impact breaker (Figure 8. Move Quick Latch Switch to Latch Position. Item 17) to machine quick disconnect (Figure 10. Item 18) and machine quick disconnect (Figure 11. Item 14) from machine quick disconnect (Figure 10. 22. Clean plug (Figure 10.TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER . Item 17). 0020-6 . Connect Auxiliary Supply Line. Item 17) with rag. Safety Pin to Lock Position. 24. Remove plug (Figure 10. Item 15). Remove cap (Figure 10. Item 16) and attachment quick disconnect (Figure 10. Clean cap (Figure 10. 20.Continued HYEX03406 13 Figure 9. 23. 21. Item 19) with rag. Clean plug (Figure 11. Item 15) with rag. Item 16) from attachment quick disconnect (Figure 10. Connect attachment quick disconnect (Figure 10. 17 15 16 14 HYEX01322 Figure 10. Item 14) and machine quick disconnect (Figure 10. 25. Item 15). Press and turn lock bolt (Figure 12.TM 5-3805-294-10 0020 INSTALLING IMPACT BREAKER . Item 19). 28. Item 20) and attachment quick disconnect (Figure 11. • Blunt is for breaking large. 29. Remove plug (Figure 11.Continued 21 19 18 20 HYEX01323 Figure 11. • Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to medium hardness. medium hardness rocks into smaller pieces. Item 21) with rag. Connect attachment quick disconnect (Figure 11. Item 23) pointed to the tool end of breaker (Figure 12. 26. Item 22) to unlocked position with slot (Figure 12. Item 21). • Moil is for demolition of medium hardness rock or materials except layered rock. Item 20) from attachment quick disconnect (Figure 11. END OF TASK TOOL INSTALLATION NOTE • Select the proper tool before operation. Item 12). Clean cap (Figure 11. 0020-7 . Item 18) from machine quick disconnect (Figure 11. Remove cap (Figure 11. Connect Auxiliary Return Line. 27. 1. Item 19). Item 21) to machine quick disconnect (Figure 11. slide tool (Figure 13. Item 26) with grease. Lubricate bushing (Figure 12. WARNING Breaker tools weigh approximately 275 lb (102 kg). 3. 0020-8 . Item 25). NOTE Ensure cavity is free of debris and tool is properly lubricated. 2. Item 12) with side notches (Figure 13. Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. Item 29). With the aid of an assistant and suitable lifting device. Repeat Steps 1 and 2 for other retaining axle. 4. Failure to comply may result in injury or death to personnel.Continued 22 23 24 12 26 25 HYEX01326 Figure 12. Push the retaining axle (Figure 12. Item 24) out of the breaker (Figure 12. Breaker Tool Lock Bolt. Item 27) into breaker (Figure 13. Item 12) through hole (Figure 12. Item 28) in alignment with axle slots (Figure 13.TM 5-3805-294-10 0020 TOOL INSTALLATION . 5. (WP 0007) 2.TM 5-3805-294-10 0020 TOOL INSTALLATION . Repeat Steps (Figure 14. Item 22) to locked position with slot (Figure 14. Item 12). Failure to comply may result in damage to the attachment. Start the machine. 12 24 23 22 HYEX01328 Figure 14. • Keep machine close to work area. 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. Item 23) pointed to top of breaker (Figure 14. NOTE • Keep tool perpendicular to work surface. 0020-9 . even pressure as tool penetrates work surface. Insert Breaker Tool. Press and turn lock bolt (Figure 14.Continued 29 12 27 28 HYEX01327 Figure 13. END OF TASK OPERATING IMPACT BREAKER 1. • Maintain constant. Lock Breaker Tool. Item 24) to breaker (Figure 14. Item 6) and (Figure 14. Item 7) for other retaining axle. 7. Install retaining axle (Figure 14. Item 12). 8. 6. 6. 30 8 31 12 HYEX01520 Figure 15. Press attachment pedal (Figure 15. 5. Item 12) off ground and extend bucket cylinder (Figure 16. Item 31) to stop impact breaker (Figure 15. Item 30). Release attachment pedal (Figure 15. Item 12).TM 5-3805-294-10 0020 OPERATING IMPACT BREAKER . 0020-10 . Item 12) on work area. Item 12) before retracting from work area. Item 30). 7.Continued • Increase down pressure when strokes have a metallic sound. Breaker Operation. Item 31) to start impact breaker (Figure 15. Release attachment pedal lock (Figure 15. Item 8) down pressure to impact breaker (Figure 15. 3. END OF TASK TOOL REMOVAL 1. 9 24 12 23 25 22 HYEX03440 Figure 16. • Decrease down pressure when strokes cause strong vibrations in the machine. 4. Item 9) until breaker is horizontal. Raise breaker (Figure 16. Tool Removal. Engage attachment pedal lock (Figure 15. Apply boom (Figure 15. Item 12). Item 12). 7. Repeat Steps 2 and 3 for other retaining axle. WARNING Breaker tools weigh approximately 275 lb (102 kg). Item 23) pointed to the tool end of breaker (Figure 16. 6. Press and turn lock bolt (Figure 16.TM 5-3805-294-10 0020 TOOL REMOVAL . Item 23) pointed to top of breaker (Figure 18 . With the aid of an assistant and suitable lifting device. Press and turn lock bolt (Figure 18. Item 24) to breaker (Figure 18. Item 22) to unlocked position with slot (Figure 16. 4. Item 12) through hole (Figure 16. Item 22) to locked position with slot (Figure 18.Continued 2. Install retaining axle (Figure 18. slide tool (Figure 17. 12 27 HYEX03439 Figure 17. Item 12). Lock Breaker Tool. Item 25). Remove Breaker Tool. 5. 12 24 23 22 HYEX01328 Figure 18. Item 12). 0020-11 . Item 24) out of the breaker (Figure 16. 3. Push the retaining axle (Figure 16. Failure to comply may result in injury or death to personnel. Item 27) out of breaker (Figure 17. Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. 9. Item 17) from machine quick disconnect (Figure 20. Disconnect Auxiliary Return Line. 4. Item 17) with rag. Clean cap (Figure 20. END OF TASK REMOVING IMPACT BREAKER 1. Item 18) with rag. Remove attachment quick disconnect (Figure 19. Item 18) to machine quick disconnect (Figure 19. 6. Clean machine quick disconnect (Figure 20. Clean machine quick disconnect (Figure 19. Repeat Steps 6 and 7 for other retaining axle. Item 19). 5. 3. (WP 0009) 2. Disconnect Auxiliary Supply Line. Item 21). Install plug (Figure 19.TM 5-3805-294-10 0020 TOOL REMOVAL . 8. 17 15 16 14 HYEX01322 Figure 20. Item 21) with rag. Item 14) and plug (Figure 20. Item 15). Item 21) from machine quick disconnect (Figure 19.Continued 8. Item 16) with rag. Safely park and shut down machine. Item 20) to attachment quick disconnect (Figure 19. 7. Item 19) and attachment quick disconnect (Figure 19. Item 20) and plug (Figure 19. Item 19). Install cap (Figure 19. Remove attachment quick disconnect (Figure 20. Clean cap (Figure 19. 0020-12 . 21 19 18 20 HYEX01323 Figure 19. Item 15) and attachment quick disconnect (Figure 20. Item 8) to allow for adequate ground clearance. Install cap (Figure 20. Item 16) to attachment quick disconnect (Figure 20. Raise Boom for Clearance. Item 14) to machine quick disconnect (Figure 20. 13. 8 HYEX03399 Figure 22. Lift and rotate safety lock pin lever (Figure 21. Safety Pin to Unlock Position. Item 7) to UNLATCH position.Continued 10. Start the machine. 15. 0020-13 . 12. Item 17). HYEX03406 13 Figure 21.TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER . Install plug (Figure 20. Raise boom (Figure 22. 11. (WP 0007) 14. Move quick latch switch (Figure 23. Item 13) to unlock position. Item 15). Move Quick Latch Switch to Unlatch Position. Item 9) until tool end of impact breaker (Figure 25. Item 11) is in vertical position. 9 10 12 HYEX03401 Figure 24. Item 10) are fully retracted.TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER . Item 12) is resting on ground and quick latch (Figure 25. 16. Extend bucket cylinder (Figure 24. Item 9) until quick latch wedges (Figure 24. Retract bucket cylinder (Figure 25. Quick Latch Wedges Retracted.Continued 7 HYEX03398 Figure 23. 17. 0020-14 . 7 HYEX03398 Figure 26. Remove quick latch (Figure 25. Item 7) to LATCH position. 21. Left side shown. Open two auxiliary circuit shutoff valves (Figure 27. Quick Latch Switch to Latch Position. Lower boom (Figure 25. Item 11) from impact breaker (Figure 25. Item 12) is resting on ground. There is one located on both sides of the arm. Item 8) until impact breaker (Figure 25. 18. Item 6). NOTE There are two auxiliary circuit shutoff valves.TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER .Continued 9 8 11 12 HYEX03402 Figure 25. Move quick latch switch (Figure 26. 19. Impact Breaker Removal. 0020-15 . 20. Item 12). Item 4). 25. Failure to comply may result in injury or death to personnel. (WP 0009) END OF TASK END OF WORK PACKAGE 0020-16 . Open Hydraulic Thumb Circuit. while using prybar to remove pin (Figure 27. extend or retract thumb cylinder (Figure 27. Item 5). 23.TM 5-3805-294-10 0020 REMOVING IMPACT BREAKER . 22. Install pin (Figure 27. WARNING Keep hands away from pin and alignment holes while thumb is being moved.Continued 3 4 2 6 1 5 3 HYEX01321 Figure 27. Item 3). Item 2) to pin (Figure 27. Item 3) in storage position (Figure 27. Item 3). 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. 24. Remove retaining pin (Figure 27. Item 2) from pin (Figure 27. Only use prybar to push pin. 26. as needed. Item 1). Safely park and shut down machine. Install retaining pin (Figure 27. With the aid of an assistant. Item 3) from thumb lock position (Figure 27. Item 14) References (cont. Item 15) References WP 0007 INSTALLING COMPACTOR 1. Item 15) Wrench. Only use prybar to push pin. (304 mm) Long (WP 0095. (24 mm) (WP 0095. (63. 2. Open End. Adjustable 0. 0021-1 . (WP 0014) Materials/Parts Rags.5 mm) (WP 0095. Table 2. 12 in. 3 in.) WP 0009 WP 0018 Equipment Condition Safely park and shutdown machine. Pry Bar. Wiping (WP 0097. Item 11) Wrench.95 in. (76 mm) (WP 0095. Table 1. Retract hydraulic thumb cylinder (Figure 1.TM 5-3805-294-10 0021 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE COMPACTOR INITIAL SETUP: Tools and Special Tools Screwdriver. Item 1). 2 1/2 in. Open End. (WP 0009) Bucket removed. Start machine. Table 2. Open End. Failure to comply may result in injury or death to personnel. (WP 0007) WARNING Keep hands away from pin and alignment holes while thumb is being moved. Table 2. Table 2. Item 19) Wrench. Item 5). 4. as needed. Item 3) from storage position (Figure 1. Item 3) to thumb lock position (Figure 1. extend or retract thumb cylinder (Figure 1. 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. Close two auxiliary circuit shut off valves (Figure 1. 7. 6. Close Hydraulic Thumb Circuit. With the aid of an assistant.Continued 3 4 2 6 1 5 3 HYEX03411 Figure 1. WARNING Keep hands away from pin and alignment holes while thumb is being moved. Failure to comply may result in injury or death to personnel. Item 3). Only use prybar to push pin. Item 7) to UNLATCH position. Item 3).TM 5-3805-294-10 0021 INSTALLING COMPACTOR . Move quick latch switch (Figure 2. 3. 8. Item 4). 0021-2 . Item 2) on pin (Figure 1. Item 2) from pin (Figure 1. Item 1). Item 6). There is one located on both sides of the arm. while using prybar to install pin (Figure 1. Install retaining clip (Figure 1. NOTE There are two auxiliary circuit shutoff valves. 5. Remove pin (Figure 1. Remove retaining clip (Figure 1. Left side shown. Item 10) are fully retracted. 0021-3 . 10. 9. 8 HYEX03413 Figure 3.TM 5-3805-294-10 0021 INSTALLING COMPACTOR .Continued 7 HYEX03412 Figure 2. Fully extend bucket cylinder (Figure 4. Item 9) to ensure quick latch wedges (Figure 4. Raise Boom. Move Quick Latch Switch. Raise boom (Figure 3. Item 8) to allow for adequate ground clearance. 13. 11. Item 11) is resting on compactor (Figure 6. Item 12).TM 5-3805-294-10 0021 INSTALLING COMPACTOR . Item 11) is in the vertical position. Item 12). Item 11) to compactor (Figure 5. 12. Extend bucket cylinder (Figure 6. Retract bucket cylinder (Figure 5. Install Quick Latch. Item 9) until quick latch (Figure 6. Install quick latch (Figure 5. 0021-4 . 9 11 12 HYEX03415 Figure 5. Item 9) until quick latch (Figure 5.Continued 9 10 HYEX03414 Figure 4. Quick Latch Wedges Retracted. Item 7) to LATCH position. Quick Latch Switch to Latch Position. 14. Slowly retract or extend bucket cylinder when removing or installing compactor. 7 HYEX03412 Figure 7. Position Quick Latch. Move quick latch switch (Figure 7. the compactor could fall off of the quick latch.TM 5-3805-294-10 0021 INSTALLING COMPACTOR . 15. Failure to comply may result in injury or death to personnel.Continued 9 11 12 HYEX03416 Figure 6. Ensure that personnel are clear of equipment when removing or installing compactor. Raise boom (Figure 8. WARNING With quick latch wedges disengaged from compactor. 0021-5 . Item 8) to allow for adequate ground clearance. Rotate safety lock pin lever (Figure 10. 18. Item 9) and position compactor (Figure 9. 17. Retract bucket cylinder (Figure 9. 9 12 10 HYEX03417 Figure 9. 16.TM 5-3805-294-10 0021 INSTALLING COMPACTOR . Raise Boom for Clearance. Shutdown machine. Extend bucket cylinder (Figure 9. Item 13) to lock position. Item 12). Engage Quick Latch Wedges. 0021-6 . (WP 0009) 19. Item 10) are fully engaged to compactor (Figure 9. Item 9) until quick latch wedges (Figure 9.Continued 8 HYEX03413 Figure 8. Item 12) on ground. Clean cap (Figure 11. 20. Item 18) and machine quick disconnect (Figure 12. Clean plug (Figure 12. 21. Item 15). 25. Connect Auxiliary Supply Line. 17 15 16 14 HYEX03419 Figure 11. Item 16) and attachment quick disconnect (Figure 11. 23. Remove cap (Figure 11.TM 5-3805-294-10 0021 INSTALLING COMPACTOR . 24. Item 19) with rag. 0021-7 . Item 15). Lock Safety Lock. Item 14) from machine quick disconnect (Figure 11. Item 17). Item 17) to machine quick disconnect (Figure 11. Clean plug (Figure 11. Item 14) and machine quick disconnect (Figure 11. Remove plug (Figure 11. 22. Connect attachment quick disconnect (Figure 11. Item 15) with rag. Item 17) with rag. Item 16) from attachment quick disconnect (Figure 11.Continued 13 HYEX03418 Figure 10. Item 12). 29. Start the machine. Item 20) from attachment quick disconnect (Figure 12. Item 18) from machine quick disconnect (Figure 12. END OF TASK OPERATING THE COMPACTOR 1. (WP 0007) 2. Connect attachment quick disconnect (Figure 12. Connect Auxiliary Return Line. Item 19). Remove plug (Figure 12. Press attachment pedal (Figure 13. Item 20) and attachment quick disconnect (Figure 12. Item 21). 27. 5. 6. (WP 0018) 3. 0021-8 . Remove cap (Figure 12. Apply boom down pressure to deflect rubber isolators (Figure 13. Item 22). Select Breaker 2 on the monitor. Item 19). Item 23) to turn on compactor (Figure 13. Attachment Pedal Lock Release. Item 21) to machine quick disconnect (Figure 12. 26.TM 5-3805-294-10 0021 INSTALLING COMPACTOR . 22 23 12 24 HYEX01325 Figure 13. Item 24) approximately half way. 4. Item 12) on work surface. Item 21) with rag.Continued 21 19 18 20 HYEX03420 Figure 12. Release attachment pedal lock (Figure 13. Position compactor (Figure 13. 28. Clean cap (Figure 12. Item 15) with rag. Item 17) and machine quick disconnect (Figure 15. 7. Clean attachment quick disconnect (Figure 14. Disconnect Auxiliary Return Line. 9. Item 21). 8. 2.TM 5-3805-294-10 0021 OPERATING THE COMPACTOR . Item 21) and machine quick disconnect (Figure 14. Item 18) with rag. Item 18) to machine quick disconnect (Figure 14. 6. Item 12). Clean attachment quick disconnect (Figure 15. Item 20) with rag. Item 19). Item 23) to stop compactor (Figure 13. Safely park and shutdown machine. Item 19) with rag. 5. 3. Item 21) from machine quick disconnect (Figure 14. 21 19 18 20 HYEX03420 Figure 14. Item 12) over work surface while continuing to apply down pressure. Item 19). Item 20) to attachment quick disconnect (Figure 14. Remove attachment quick disconnect (Figure 14. Item 22). Install plug (Figure 14. 10. Install cap (Figure 14. (WP 0009) END OF TASK REMOVING THE COMPACTOR 1. 4. Engage attachment pedal lock (Figure 13. 0021-9 . Clean plug (Figure 14. Clean cap (Figure 14. Release attachment pedal (Figure 13. Move compactor (Figure 13.Continued 7. Clean cap (Figure 15. Item 15). 8. Item 16) to attachment quick disconnect (Figure 15. 10.TM 5-3805-294-10 0021 REMOVING THE COMPACTOR . Start the machine.Continued 17 15 16 14 HYEX03419 Figure 15. Item 16) with rag. Install plug (Figure 15. (WP 0007) 15. Item 14) with rag. Connect Auxiliary Supply Line. 12. 9. Clean plug (Figure 15. Remove attachment quick disconnect (Figure 15. Item 17) from machine quick disconnect (Figure 15. Install cap (Figure 15. 11. Item 17). Move quick latch switch (Figure 17. 13. Rotate safety lock pin lever (Figure 16. Item 13) to unlock position. Item 14) to machine quick disconnect (Figure 15. Unlock Safety Lock. Item 7) to UNLATCH position. 13 HYEX03421 Figure 16. Item 15). 14. 0021-10 . Item 9) until quick latch wedges (Figure 19. WARNING With quick latch wedges disengaged from compactor. Slowly retract or extend bucket cylinder when removing or installing compactor. Raise boom (Figure 18.TM 5-3805-294-10 0021 REMOVING THE COMPACTOR . Quick Latch Switch to Unlatch Position. Raise Boom. Extend bucket cylinder (Figure 19. Item 8) to allow for adequate ground clearance. 0021-11 . the compactor could fall off of the quick latch. Failure to comply may result in injury or death to personnel. Item 10) are disengaged from compactor (Figure 19. 17. 16. Item 12).Continued 7 HYEX03412 Figure 17. Ensure that personnel are clear of equipment when removing or installing compactor. 8 HYEX03413 Figure 18. 0021-12 . Retract Bucket Cylinder. Item 9) until quick latch (Figure 20.TM 5-3805-294-10 0021 REMOVING THE COMPACTOR . Retract bucket cylinder (Figure 20. 19.Continued 9 12 10 HYEX03417 Figure 19. 18. Item 24). 9 11 HYEX03422 Figure 20. A combination of slow and smooth boom down and arm in movements is required. NOTE Removal of the arm/quick latch from the compactor is seldom done the same way twice. Disengage Quick Latch Wedges. Fully retract arm cylinder (Figure 21. Item 11) is in vertical position. 7 HYEX03412 Figure 22.TM 5-3805-294-10 0021 REMOVING THE COMPACTOR . Item 12).Continued 24 8 9 11 12 25 Figure 21. 20. Left side shown. ensure that the tracks do not begin to raise. 21. NOTE The compactor will likely become wedged between the ground the quick latch/arm until it "pops" out of the hooks. 22. Item 8) until compactor plate (Figure 21. then begin to boom down while continuing to arm in until quick latch (Figure 21. and try again. raise boom. Item 11) is removed from compactor. 0021-13 . Item 25) is just touching the ground. Quick Latch Switch to Latch Position. When this wedged situation occurs. HYEX03424 Remove Quick Latch. There is one located on both sides of the arm. Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure 21. Lower boom (Figure 21. NOTE There are two auxiliary circuit shutoff valves. Move quick latch switch (Figure 22. Item 7) to LATCH position. If tracks begin to raise: stop movements. Item 2) from pin (Figure 23. 27. Item 1). Item 2) to pin (Figure 23. Item 3) from thumb lock position (Figure 23. Failure to comply may result in injury or death to personnel. 25. WARNING Keep hands away from pin and alignment holes while thumb is being moved. With the aid of an assistant. 28. Install pin (Figure 23. Install retaining pin (Figure 23. Item 5). 3 4 2 6 1 5 3 HYEX03411 Figure 23.TM 5-3805-294-10 0021 REMOVING THE COMPACTOR . as needed. 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. Open two auxiliary circuit shutoff valves (Figure 23.Continued 23. Safely park and shutdown machine. while using prybar to remove pin (Figure 23. 26. Item 3). extend or retract thumb cylinder (Figure 23. Only use prybar to push pin. 24. Close Hydraulic Thumb Circuit. Remove retaining pin (Figure 23. (WP 0009) END OF TASK END OF WORK PACKAGE 0021-14 . Item 4). Item 6). Item 3). Item 3) in storage position (Figure 23. TM 5-3805-294-10 0022 OPERATOR MAINTENANCE OPERATING THE BARRIER GRAPPLE INITIAL SETUP: Tools and Special Tools Lifting Device. Item 1) to quick latch loop (Figure 1.000 lb (7257. (WP 0007) BARRIER GRAPPLE OPERATION WARNING LIFTING GUIDELINES: • Do not use machine to lift personnel. Item 2) with suitable lifting device (Figure 1.8 kg) Equipment Condition Engine running. Failure to comply may result in injury or death to personnel. Minimum Capacity 16. • Personnel must remain clear of lifted items. • Do not hook lifting device to bucket teeth. • Ensure load does not exceed the capacity of machine or lifting device. 0022-1 .48 kg). Attach barrier grapple (Figure 1. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. • Lift load only as high as necessary. • Move load slowly. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 1. NOTE Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16. Failure to comply may result in injury or death to personnel. Item 3). Do not allow lifted items to strike obstacles.000 lbs (72574. striking. and poor alignment with barriers. Slowly lower barrier grapple (Figure 1. Item 4). 6. Item 1) and barrier (Figure 1. 4. Item 4) until tension is released from lifting device (Figure 1.TM 5-3805-294-10 0022 BARRIER GRAPPLE OPERATION . Position barrier (Figure 1. Item 1) on to barrier (Figure 1. The barrier grapple will automatically latch open and release the barrier. Item 4) in desired location.Continued 2 3 1 4 HYEX02585 Figure 1. Position barrier grapple (Figure 1. Slowly raise barrier grapple (Figure 1. CAUTION Avoid jerky lifting. Failure to comply may result in damage to equipment. Item 3). Lifting Barrier Grapple. 3. 5. Item 4). Item 1) on to barrier (Figure 1. Item 3). 2. Item 4) until tension is released from lifting device (Figure 1. Slowly lower barrier grapple (Figure 1. Item 1) near center of barrier (Figure 1. The barrier grapple will automatically close on the barrier. 0022-2 . Continued 7.TM 5-3805-294-10 BARRIER GRAPPLE OPERATION . Item 1). Raise barrier grapple (Figure 1. END OF TASK END OF WORK PACKAGE 0022-3/4 blank 0022 . . NOTE After the Deep Dig Attachment has been installed on the machine. HYEX01519 3 Figure 1. WP 0007 DEEP DIG ARM OPERATION CAUTION Do not attempt to extend the arm cylinder with the deep dig arm attached. Item 4) to on position 0023-1 2 1 . Item 2). 3. Move switch (Figure 1. Switch A/I (Figure 2. Failure to comply may result in damage to equipment. Item 3) to ON position and install pin (Figure 1. Remove clip (Figure 1.TM 5-3805-294-10 0023 OPERATOR MAINTENANCE OPERATING THE DEEP DIG ARM INITIAL SETUP: References WP 0010 WP 0077 Equipment Condition Engine running. The deep dig arm can strike the machine. Deep Dig Control Pattern Switch. Item 1). Item 1) from switch bracket (Figure 1. 2. the following steps must be performed to enable Deep Dig Arm Operation. 1. Item 5) to unlocked position (down). Turn Auto Idle Switch On. 0023-2 .TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION . Move pilot shutoff lever (Figure 3.Continued 4 HYEX03404 Figure 2. 4. Continued 5 HYEX01518 Figure 3. 5.TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION . Pilot Shutoff Lever. Item 6) to max RPM setting. Turn RPM dial (Figure 4. 0023-3 . Item 5) and deep dig bucket cylinder (Figure 5. the pilot control levers operate in the same way. Turn RPM Dial. Slowly cycle bucket cylinder (Figure 5. 0023-4 . NOTE • When the deep dig control pattern switch is in the ON position. • The arm cylinder can only be retracted.Continued 6 HYEX03405 Figure 4.TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION . 6. • With the deep dig control pattern switch in the ON position. It is necessary to occasionally retract the arm cylinder due to the weight of the deep dig arm. the arm cylinder is controlled by the attachment pedal and can only be retracted. Item 6) until full smooth movement of each cylinder is obtained. Park and shut down machine. 7. Check hydraulic oil level.TM 5-3805-294-10 0023 DEEP DIG ARM OPERATION . (WP 0077) END OF TASK END OF WORK PACKAGE 0023-5/6 blank . Cycle Deep Dig Arm Cylinders.Continued 5 6 HYEX01636 Figure 5. (WP 0010) 8. . 1. Item 3) angle at 90 degrees. 3. 0024-1 . Item 2) is retracted. Item 1) on upper level of embankment with arm (Figure 1. Position flat surface of bucket (Figure 1. Lower boom (Figure 1.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. 3 5 2 4 1 HYEX01102 Figure 1. Item 3) until tracks (Figure 1. 2. 5. Position Bucket. Drive machine (Figure 1. Item 5) towards upper level as arm (Figure 1. Failure to comply may result in damage to equipment. Item 2) to boom (Figure 1. Rotate upper structure (Figure 2. Item 4) clear edge of embankment. Item 6) 180 degrees towards lower level of embankment. Item 4) are resting on upper level of embankment. Slowly raise boom (Figure 1. 4. Item 3) to raise undercarriage until front of tracks (Figure 1. Item 1) on lower level of embankment with arm (Figure 2. Item 2) until machine is completely on upper level of embankment. Item 3) angle at 90 degrees. 6. 7. Item 1) on lower level of embankment with arm (Figure 3.TM 5-3805-294-10 0024 MOVING MACHINE ON AN EMBANKMENT . Item 2) to boom (Figure 3. 1. END OF TASK MOVING MACHINE OFF AN EMBANKMENT CAUTION Do not allow machine to impact the ground with the bucket absorbing the force. Position flat surface of bucket (Figure 2. Position flat surface of bucket (Figure 3. 0024-2 . Failure to comply may result in damage to equipment. Item 5) towards upper level while extending arm (Figure 2. Item 3) angle at 90 degrees.Continued 6 5 3 2 4 1 HYEX01104 Figure 2. Item 2) to boom (Figure 2. Drive machine (Figure 2. Upperstructure Rotated. 0024-3 . Item 5) towards lower level while raising boom (Figure 3. Position flat surface of bucket (Figure 4. Item 1) off of the ground and rotate upper structure (Figure 4. Item 2) to boom (Figure 4. Item 6) 180 degrees towards upper level of embankment. 3.TM 5-3805-294-10 0024 MOVING MACHINE OFF AN EMBANKMENT . 2. Item 4) reach lower level of embankment. Item 3) angle at 90 degrees. Raise bucket (Figure 4. Item 2) until front of tracks (Figure 3. Drive machine (Figure 3.Continued 5 3 2 4 1 HYEX00689 Figure 3. 4. 6 3 2 5 1 4 HYEX01103 Figure 4. Position Bucket on Lower Level. Item 3) and retracting arm (Figure 3. Item 1) on upper level of embankment with arm (Figure 4. Rotate Upperstructure to Upper Level. When tracks (Figure 4. Item 3) until machine (Figure 4. Item 4) clear upper level of embankment. 6. slowly raise boom (Figure 4. END OF TASK END OF WORK PACKAGE 0024-4 . Lower boom (Figure 4. Item 5) is on lower level.Continued 5. Item 5) towards lower level as the arm (Figure 4. Item 3) slightly and drive machine (Figure 4. Item 2) is extended.TM 5-3805-294-10 0024 MOVING MACHINE OFF AN EMBANKMENT . Item 1) on cab hook (Figure 1. 2 1 3 HYEX01548 Figure 1. Item 4) on cab hook (Figure 2. Position cover (Figure 1. 5 4 6 HYEX01549 Figure 2. Right Side Center Cover Installation. Right Side Rear Cover Installation.TM 5-3805-294-10 0025 OPERATOR MAINTENANCE USING THE VANDAL PROTECTION KIT INITIAL SETUP: Not Applicable RIGHT SIDE CAB INSTALLATION 1. Item 3). Item 2) and behind brackets (Figure 1. Item 5) and behind brackets (Figure 2. 0025-1 . Item 6). Position cover (Figure 2. 2. Item 8) and behind brackets (Figure 3. 8 7 9 HYEX01550 Figure 3. END OF TASK LEFT SIDE CAB INSTALLATION 1. Item 9). 4.TM 5-3805-294-10 0025 RIGHT SIDE CAB INSTALLATION . Position cover (Figure 5.Continued 3. Item 11) and turn lock (Figure 4. Item 14) and behind brackets (Figure 5. Item 12) to lock in place. Item 13) over door hook (Figure 5. Position plate (Figure 4. Item 15). Lock Bar Installation. Right Side Front Cover Installation. 0025-2 . Item 7) on cab hook (Figure 3. Item 10) over tabs (Figure 4. 11 10 11 12 HYEX01551 Figure 4. Position cover (Figure 3. 0025-3 . Front Door Cover Installation. Item 18). Item 16) over cab hook (Figure 6. Item 21). 2. Item 19) over hooks (Figure 7. Item 20) and behind brackets (Figure 7. Center Door Cover Installation. Position cover (Figure 6. 17 16 18 HYEX01553 Figure 6.TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION .Continued 14 13 15 HYEX01552 Figure 5. Position cover (Figure 7. Item 17) and behind brackets (Figure 6. 3. Item 28) over hooks (Figure 9. 5. Position hinge (Figure 7. 19 HYEX01554 Lower Door Cover Installation. 26 26 25 27 HYEX01555 Figure 8. Position cover (Figure 8. 0025-4 . Side Upper Glass Cover Installation. Item 25) over cab hooks (Figure 8. 6. Item 27). Item 29) and behind brackets (Figure 9. Item 26) and behind bracket (Figure 8.TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION . Position cover (Figure 9. Item 24) to lock in place. Item 23) and turn lock (Figure 7.Continued 20 20 21 24 23 22 Figure 7. Item 22) over tab (Figure 7. Item 30). 4. Item 33) to lock in place. Item 39). Item 36). HYEX01557 Right Rear Cab Cover Installation. Item 32) and turn lock (Figure 9.Continued 29 30 28 33 32 31 HYEX01556 Figure 9. Item 38) and behind brackets (Figure 11. 34 35 36 Figure 10. Item 35) and behind brackets (Figure 10. Side Lower Glass Cover Installation. Place hinge (Figure 9. Position cover (Figure 11. 0025-5 . Position cover (Figure 10. Item 37) over tab (Figure 11. 7. 2.TM 5-3805-294-10 0025 LEFT SIDE CAB INSTALLATION . END OF TASK REAR CAB INSTALLATION 1. Item 31) over tab (Figure 9. Item 34) over cab hook (Figure 10. Turn lock (Figure 11.Continued 38 40 39 37 Figure 11. 2. Item 37) from behind brackets (Figure 12. Item 40) to unlock. 38 40 39 37 HYEX01558 Figure 12. Item 39) and from tab (Figure 12. END OF TASK REAR CAB REMOVAL 1. HYEX01558 Left Rear Cab Cover Installation. 0025-6 . 3. Turn lock (Figure 12. Item 38). Item 40) to lock in place. Left Rear Cab Cover Removal. Remove cover (Figure 12.TM 5-3805-294-10 0025 REAR CAB INSTALLATION . 34 35 36 Figure 13. Item 28) from behind brackets (Figure 14. Item 27) and cab hooks (Figure 15. Item 29). Item 33) to unlock and remove hinge (Figure 14.Continued 3. Side Lower Glass Cover Removal. 2. Remove cover (Figure 15. Turn lock (Figure 14. Remove cover (Figure 13. 0025-7 . 29 30 28 33 32 31 HYEX01556 Figure 14. Item 25) from behind bracket (Figure 15. Item 31) from tab (Figure 14. Item 35). Remove cover (Figure 14. Item 32). END OF TASK LEFT SIDE CAB REMOVAL 1. Item 26). HYEX01557 Right Rear Cab Cover Removal. Item 34) from behind brackets (Figure 13. Item 30) and hooks (Figure 14. 3.TM 5-3805-294-10 0025 REAR CAB REMOVAL . Item 36) and cab hook (Figure 13. Item 24) to unlock and remove hinge (Figure 16. 20 20 21 24 23 22 19 HYEX01554 Figure 16. Item 23). Item 16) from behind brackets (Figure 17. 0025-8 . 6. Item 17).TM 5-3805-294-10 0025 LEFT SIDE CAB REMOVAL . Side Upper Glass Cover Removal. Item 22) from tab (Figure 16. 5. 4. Remove cover (Figure 16. Item 18) and cab hooks (Figure 17. Item 19) from behind brackets (Figure 16.Continued 26 26 25 27 HYEX01555 Figure 15. Turn lock (Figure 16. Item 20). Remove cover (Figure 17. Item 21) and hooks (Figure 16. Lower Door Cover Removal. Item 12) to unlock and remove plate (Figure 19. Center Door Cover Removal. Item 15) and door hooks (Figure 18. Item 13) from behind brackets (Figure 18. END OF TASK RIGHT SIDE CAB REMOVAL 1. Remove cover (Figure 18.Continued 17 16 18 HYEX01553 Figure 17. 14 13 15 HYEX01552 Figure 18. Item 11).TM 5-3805-294-10 0025 LEFT SIDE CAB REMOVAL . Turn lock (Figure 19. 0025-9 . Item 10) from tabs (Figure 19. Front Door Cover Removal. Item 14). 7. Right Side Center Cover Removal. 5 4 6 HYEX01549 Figure 21. Remove cover (Figure 20.Continued 11 10 11 12 HYEX01551 Figure 19. 3. 2. Right Side Front Cover Removal. Item 5). Item 6) and cab hook (Figure 21. Lock Bar Removal.TM 5-3805-294-10 0025 RIGHT SIDE CAB REMOVAL . Item 8). 8 7 9 HYEX01550 Figure 20. Remove cover (Figure 21. 0025-10 . Item 9) and cab hook (Figure 20. Item 4) from behind brackets (Figure 21. Item 7) from behind brackets (Figure 20. END OF TASK END OF WORK PACKAGE 0025-11/12 blank . Right Side Rear Cover Removal. Remove cover (Figure 22. Item 1) from behind brackets (Figure 22. 2 1 3 HYEX01548 Figure 22. Item 3) and cab hook (Figure 22.TM 5-3805-294-10 0025 RIGHT SIDE CAB REMOVAL . Item 2).Continued 4. . 3. Item 3) from quick coupler (Figure 1. 6. Table 1. 5 6 2 4 1 3 HYEX01097 Figure 1. Item 6) to hydraulic tool. Using a clean rag. Connect quick coupler (Figure 1. Item 4). Remove cover (Figure 1.TM 5-3805-294-10 0026 OPERATOR MAINTENANCE OPERATING THE HYDRAULIC HOSE REEL INITIAL SETUP: Materials/Parts Rags. Item 2) and (Figure 1. Item 2) on return hose (Figure 1. Remove cover (Figure 1. Start engine. Item 2). (WP 0007) 0026-1 . Hydraulic Tool Attachment. 4. Item 4) on supply hose (Figure 1. Wiping (WP 0097. Connect quick coupler (Figure 1. 2. 5. Item 1) from quick coupler (Figure 1. Item 15) Equipment Condition Machine safely parked and shut down. Item 4) and couplers on tool to be connected. Item 5) to hydraulic tool. wipe quick coupler (Figure 1. (WP 0009) References WP 0007 WP 0009 CONNECTING HYDRAULIC TOOL 1. Turn On Hydraulic Tool.Continued 7. END OF TASK DISCONNECTING HYDRAULIC TOOL 1. Item 7) to OFF position. 2. Move hand held hydraulic tool circuit switch (Figure 2. Item 8) to tool specification. (WP 0009) 0026-2 . 8. 8 7 HYEX01096 Figure 2. 3. Move hand held hydraulic tool circuit switch (Figure 3. Item 8) to lowest setting. Move flow regulator (Figure 3. Turn Off Hydraulic Tool. 8 7 HYEX01096 Figure 3. Shut engine off.TM 5-3805-294-10 0026 CONNECTING HYDRAULIC TOOL . Item 7) to ON position. Adjust flow regulator (Figure 2. Disconnect quick coupler (Figure 4. Item 3) to quick coupler (Figure 4. 5 6 2 4 1 3 HYEX01097 Figure 4. END OF TASK END OF WORK PACKAGE 0026-3/4 blank .TM 5-3805-294-10 0026 DISCONNECTING HYDRAULIC TOOL . Item 2). Item 4) on supply hose (Figure 4. 7. Hydraulic Tool Removal. Operate hydraulic tool to relieve pressure from hoses. Item 1) to quick coupler (Figure 4. Item 6) from hydraulic tool. 8. Install cover (Figure 4. Item 5) from hydraulic tool. Item 2) on return hose (Figure 4. 5. Item 4). Disconnect quick coupler (Figure 4. 6.Continued 4. Install cover (Figure 4. . 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. Rear Cab Window. and Top Decals. Some are located inside access panels or under the engine cover. Left Side. 240D 24 VOLTS DC SLAVE RECEPTACLE LCR D DIESEL ONLY HYEX01457 Figure 1. 0027-1 . clear the primary element at the next refueling or daily service period if: a. DO NOT USE OIL HYEX01449 Figure 2. Stop engine before removing filter element. If equipped with safety air cleaner or safety element. Left Inside Door. If tractor is equipped with an air cleaner restriction indicator. 7. 2. Service according to instructions on primary element. or b. Indicator light on the instrument panel glows with the engine running. Top Under Engine Cover 0027-2 .Continued DRY AIR CLEANER 1.Manual indicator on the outlet of the air cleaner shows red. service daily. 6. replace yearly or ans required. periodically clear valve by squeezing or if equipped with dust cup.TM 5-3805-294-10 0027 DECALS . service the filter element every 250 hours or whem engine loses power or smokes excessively. 5. whichever occurs first. 4. DO NOT ATTEMPT TO CLEAN SAFETY CLEANER OR ELEMENT. Replace primary element yearly or if damaged or when if no longer responds to cleaning. HYEX01448 Figure 3. If equipped with automatic dust unloader vale. If tractor is not equipped with restriction indicator. 3. NO. Right Side.] 1212 MM [47. 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. Right Side on Hydraulic Reservoir.5 IN. FUEL TANK SUMP WATER DRAIN TRANSPORTATION DATA Drain water and sediment from fuel tank every 50 hours or weekly. 0027-3 .TM 5-3805-294-10 0027 DECALS .] HYEX01445 Figure 5.000 LB.Continued IMPORTANT OIL LEVEL Fully Retracted Fully Retracted 3’ Without Bucket Check oil level cold with excavator in position shown above. HYEX01447 Figure 4. GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD - 60. Drain water and sediment into container and dispose of properly. - EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS SWING CENTERLINE T247868 CENTER OF GRAVITY 44 MM [1. Allow water to settle to tank bottom before draining. OF SLINGS REQUIRED LENGTH OF SLINGS 4 12 FT.7 IN. HYEX01446 Figure 7.Continued LIFT ENGINE OIL SAMPLE VALVE HYD OIL SAMPLE VALVE HYEX01444 Figure 6.TM 5-3805-294-10 0027 DECALS . Counterweight. Right Side. Boom. and Rear Cab Window. 0027-4 . AC C ON S TA RT HYEX01530 Figure 10. Key Switch. Front and Rear Frame. LOCK HYEX01450 Figure 9.Continued TIEDOWN HYEX01442 Figure 8. 0027-5 .TM 5-3805-294-10 0027 DECALS . O FF Cab on Seat. 62 11.92 12.OVER THE FRONT BLACK .90 13.67 Always keep tool in machine.54* 16.90 12.77 17. 11 FT.39 9.68 6.69* 11.88* 12.62* 18.49* 11.61* 6.10 8.46 5.52* 8.88 8.04 24.29 20.80 12.60* 22.35 7.96 9.71* 17.71* 12. WITH 1920 LB.10* 17. T223082 Window handle will move with the front window.56* 8. 240DLC LIFT IN 1000 LBS.06* 17.96 7.79 17. T190393 29.61* 8.15 10.63* 22.09* 6.00* 17.52* 8. ARM AND 32 INCH SHOES 10' 15' 20' 25' IMPORTANT 30' 7.28* 12.39 7.06* 25.56* 10.51* 17. 10 IN.69* 11.68 15. HYEX01531 Figure 11.26* 14.Continued CAUTION FRONT WINDOW HANDLE Avoid injury from slip or fall.76* 14.16 10. 9. BUCKET. DO NOT use as a handhold.81 13.28* 11.05* 14.63* 17.55* 7.60* 22.56* 16.51* 25.26* 6.48 7.55* 8.OVER THE SIDE *HYDRAULICALLY LIMITED NOTE: SEE OPERATOR'S MANUAL FOR MORE ACCURATE INFORMATION HYEX01532 T218383 Figure 12.46 10.31 5.31 29. 0027-6 .77 15.59 SECONDARY EXIT Use tool to break window.53 RED . Windshield.TM 5-3805-294-10 0027 DECALS . Side Window. 5 WORK MODE SCREEN 3. 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. Upper and Lower Right Side Window. 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. 4. lock window in place with the lock pin. Always verify control response before operating.] plus twice the line insulator length. Attachment to be used Bucket or Thumb Attachment mode Key No. 2. 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. 0027-7 . 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. T201519 HYEX01533 Figure 13.Continued CAUTION ATTACHMENT MODE SELECTION PROCEDURE 1. Press Key F1 to display the work mode screen. While referring to the table below. Never move any part of unit or load closer to electric line than 3 M [10 FT. press the key corresponding to the attachment mode you are going to use. Press the CONFIRM.TM 5-3805-294-10 0027 DECALS . The screen is returned to the STANDARD screen and the attachment becomes operable. Select for light digging.Select for heavy digging. Stop engine.TM 5-3805-294-10 0027 DECALS .Reduce RPM's to low idle for 2 minutes with no load.Continued ENGINE OPERATION STARTING . Lower Right Side Window. A/I . Avoid tipping . maximum fuel economy. restart immediately. especially before moving boom. AUTOMATIC SPEED CHANGE OFF CAUTION Avoid contact between boom/attachments and overhead obstacles whenever operating. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged.READ AND UNDERSTAND THE OPERATOR'S MANUAL AND SAFETY MANUAL PRIOR TO OPERATING THIS MACHINE. T159887 WARNING • AVOID SERIOUS CRUSHING INJURY FROM BOOM • NEVER place any part of body beyond window bars or frame. DO NOT USE ETHER AS A STARTING AID. Keep bystanders clear of machine. STOPPING . if control levers are in Neutral for 4 seconds. swinging upperstructure or traveling. turn key to start and crank for 20 seconds maximum or less if required. Try control pattern before operating.Auto Idle Engine speed is temporarily reduced. replace immediately.Remove load. Always lower working tools to the ground and engage hydraulic control lockout lever before leaving operator's seat. POWER MODE H/P . turn key on and wait until glow plug warm-up indicator turns off. T219580 Avoid parking machine on an incline. maximum productivity. D3067125 S HYEX01536 Figure 14. If window is missing or broken.Select for standard digging E . traveling or transporting machine.Set RPM's (dial or throttle position) at low idle.Do not lift or move objects that exceed machine stability. P . ENGINE STALL . Upperstructure position affects travel direction. Controls may be changed for attachment or operator preference. Run 30 seconds at half speed before adding load. 0027-8 . Allow 2 minutes between cranking attempts. • DO NOT remove window bars. Keep riders off machine. 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 . Try pedals or levers to determine travel direction before moving machine. FRONT. Vandal Protection Kit.Continued 1. LEFT SIDE T218467 HYEX01538 Figure 15. FRONT 3 5 CAB. REAR CAB. 0027-9 . 2.TM 5-3805-294-10 0027 DECALS . 2 1 3 1 2 1 4 2 1 2 4 3 5 CAB. START THE COVER INSTALLATION AT THE REAR OF THE CAB. CONTINUE INSTALLATION IN THE ORDER SHOWN BELOW. LEFT SIDE) LOCK COVERS AFTER INSTALLATION. (RIGHT SIDE. COVERS ARE SHOWN BELOW TO AID IN DETERMINING LOCATION ON CAB. RIGHT SIDE CAB. 3. FOR BREAK-IN.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 . EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS. Upper Section Periodic Maintenance.ADJUST (A) 7 HYDRAULIC SYSTEM OIL LEVEL 1 16 20 ENGINE OIL LEVEL ENGINE COOLANT LEVEL 1 1 CHECK WITH EXTENDED BUCKET CYLINDER.Continued 240DLCR PERIODIC MAINTENANCE T260750 REFER TO OPERATOR'S MANUAL FOR DETAILED INFORMATION INTERVAL HOURS ITEM NO. FILL RADIATOR.CLEAN AND TIGHTEN TERMINALS CHECK . EVERY 10 HOURS DURING FIRST 30-100 HOURS. CHANGE EVERY 6 CLEANINGS GREASE .5 Kg] (A) (D) REPLACE (A) (C) REPLACE (A) REPLACE . FLUSH AND REFILL WITH PROPER COOLANT.TO BOTTOM OF FILLER NECK . CLEAN SUCTION SCREEN (A) REFER TO SERVICE MANUAL DRAIN.8 SHOTS EACH .ADD 1 LB.TM 5-3805-294-10 0027 DECALS .UNTIL IT ESCAPES AT JOINTS .UNTIL IT ESCAPES AT JOINTS . [0. CHANGE EVERY 6 CLEANINGS CLEAN ELEMENT. GREASE EVERY 4 HOURS FOR FIRST 20 HOURS. 0027-10 .500 HOURS OR AS REQUIRED (A) DRAIN AND REFILL (B) (C) CHECK FOR CRACKS AND LOOSE CONNECTIONS (A) CLEAN ELEMENT. GREASE DAILY WHEN WORKING IN WATER GREASE .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. 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. GREASE EVERY 4 HOURS FOR FIRST 20 HOURS.FOR BREAK-IN. 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 . 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 .CLEAN DUST VALVE AND/OR ELEMENT (A) CHECK . 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 . 9 L 24. 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.20%] WILL REDUCE THE ENGINE OIL AND FILTER CHANGE INTERVAL TO 250 HOURS WITH PREMIUM OILS. (C) USE OF JP8 JET FUEL OR DIESEL FUEL WITH SULFUR CONTENT GREATER THAN 2000 PPM [0.6 QT 26 QT (6.2 QT METRIC 500 L 29.Continued (A) SEE OPERATOR'S MANUAL. 0027-11 .22 -4 14 32 50 68 86 104 122 °C .40 .4 GAL 22 LB 7.6 L 147.40 . 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. (D) DRAIN WATER FROM GREASE SUMP WHEN IN WATER ABOVE TRACK.5 GAL) 39 GAL 63.5 QT 6. 0 OR 1 ARCTIC GREASE HYEX01535 Figure 17. 2 J.6 L 240 L 10 Kg 7L 6. SEE OPERATOR'S MANUAL.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 .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.20 .5 QT 1.10 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) .TM 5-3805-294-10 0027 DECALS . DRAIN AND REFILL CAPACITIES ITEM U.30 . (B) FOR BREAK IN OR REBUILD.S.D.2 L 1. Lower Section Periodic Maintenance. 0027-12 . HYEX01440 Figure 19. Ditch Cleaning Bucket. HYEX01441 Figure 18.TM 5-3805-294-10 0027 DECALS . Heavy Duty Bucket.Continued WARNING TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT. WARNING TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT. Left Side Crush-All. 0027-13 .Continued HYEX01437 Figure 20. HYEX01438 Figure 21. Right Side Crush-All.TM 5-3805-294-10 0027 DECALS . TM 5-3805-294-10 0027 DECALS . END OF TASK END OF WORK PACKAGE 0027-14 .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. Field Maintenance must prepare the travel motors before the HYEX can be towed. notify Field level maintenance.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. Failure to comply may result in damage to equipment. Do not attempt to tow the HYEX without Field Maintenance support. In the event during operation of the HYEX the machine becomes disabled and needs to be towed. END OF TASK END OF WORK PACKAGE 0028-1/2 blank . . END OF TASK END OF WORK PACKAGE 0029-1/2 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. . Press and hold back button. Turn key switch (Figure 2. an extended warm-up period will be necessary. Item 1) to ON position.) WP 0005 WP 0018 STARTING NOTE • In extreme cold conditions. • Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. BACK BUTTON HYEX01413 Figure 1. 0030-1 .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. 2. 1. Press and Hold Back Button. Continued 1 HYEX01414 Figure 2. BACK BUTTON MENU BUTTON Figure 3. Press button one or button two until service menu is highlighted. Release back button when monitor goes to default screen. Key Switch to ON Position. 5. 3.TM 5-3805-294-10 0030 STARTING . 0030-2 HYEX01415 . Release Back Button. Press menu button. 4. Highlight Service Menu. 8. Select Monitoring. (WP 0005) 0030-3 . Press button one or button two until monitoring is highlighted then press the select button. Service Menu Troubleshooting Monitoring Ver. 6. Press button 1 or 2 until the hydraulic oil temperature. Press the select button.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. 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. and actual engine speed are displayed. coolant temperature. 7. 0030-4 . Move engine idle speed switch (Figure 8. Start Engine. Turn key switch (Figure 7.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. Do not run at fast or slow idle. Temperatures Displayed. NOTE If hydraulic oil temperature is 32°F (0°C) or below. 10.TM 5-3805-294-10 0030 STARTING . 1 HYEX01419 Figure 7. 9. engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36°F (2°C). Release key when engine starts. Item 2) to half throttle and run engine for 5 minutes. Item 1) to start engine. 12. Engine Speed Dial. Lower the boom cylinders until the alarm is no longer displayed. Check Engine and Hydraulic Oil Temperatures. the overload alarm may sound even if the machine is not in an overload condition. 0030-5 . NOTE During warm-up procedures. 11. 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.Continued 2 HYEX01420 Figure 8. Ensure engine coolant and hydraulic oil temperatures are above 0°F (-18°C) before proceeding to Step 12. if the upper structure is over the side and the boom cylinders are fully raised. Set machine switch selections for temperatures between 5° and 32°F (-15° and 0°C) per Table 1.TM 5-3805-294-10 0030 STARTING . Operate swing. Item 7) off ground. Failure to comply may result in injury or death to personnel. Machine can move unexpectedly. 18. 0030-6 . 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. Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is obtained. Machine Switch Selections. 17. 14. 4 HYEX01421 Raise Machine. Swing upperstructure (Figure 10. (WP 0018) WARNING Clear the area of all personnel during machine warm up procedures. Item 3) 90 degrees. Place round side of bucket (Figure 10. slowly lower boom (Figure 10. (WP 0004) 15. arm.TM 5-3805-294-10 0030 STARTING . hydraulic thumb. Item 5) to raise track (Figure 10. and bucket functions slowly and short distances initially in each direction. Select dig mode on monitor.Continued Table 1. Item 6) between 90 and 110 degrees. Item 4) on ground. Item 5) and arm (Figure 10. 16. Keeping angle between boom (Figure 10. boom. Failure to comply may result in damage to equipment. CAUTION Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot spots in the control valve. 5 6 3 7 Figure 10. Slowly raise boom (Figure 10. (WP 0004) 20. Repeat Steps 14 to 18 for opposite track. Item 7) to ground and swing upperstructure back 90 degrees. 21. Operate travel lever for raised track for approximately 5 minutes. Item 5) to lower track (Figure 10.Continued 19. END OF TASK END OF WORK PACKAGE 0030-7/8 blank .TM 5-3805-294-10 0030 STARTING . . • In extreme cold conditions. Press and Hold Back Button. (WP 0034) 2. Press and hold back button. 0031-1 . 1. an extended warm-up period will be necessary. BACK BUTTON HYEX01423 Figure 1.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. • Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. operate coolant heater for 30 minutes. If temperature is 5°F (-15°C) or below.) WP 0018 WP 0034 STARTING NOTE • Contact Field Maintenance to ensure that all fluids meet the requirements for the current operating conditions. 5. Press menu button. Turn key switch (Figure 2. 6. Key Switch to ON Position. 4. Item 1) to ON position. 1 HYEX01424 Figure 2. Press button one or button two until service menu is highlighted. Release back button when monitor goes to default screen.Continued 3.TM 5-3805-294-10 0031 STARTING . Release Back Button. 0031-2 HYEX01415 . BACK BUTTON MENU BUTTON Figure 3. 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.TM 5-3805-294-10 0031 STARTING . MONITORING Service Menu Troubleshooting Monitoring Ver. Press the select button.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. 8. 0031-3 . Highlight Service Menu. 7. Select Monitoring. then press the select button. Press button one or button two until monitoring is highlighted. Item 1) to start engine. 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. 0031-4 . Release key when engine starts. 1 HYEX01433 Figure 7. 10. Move engine idle speed switch (Figure 8. 11. Ensure the hydraulic oil temperature. engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36°F (2°C). coolant temperature. Do not run at fast or slow idle. Turn key switch (Figure 7.TM 5-3805-294-10 0031 STARTING . and actual engine speed are displayed. Item 2) to half throttle and run engine for 5 minutes.Continued 9. Temperatures Displayed. NOTE If hydraulic oil temperature is 32°F (0°C) or below. Start Engine. 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 Item 6) to adjust start time (Figure 3. When start time (Figure 3. 5. 4 7 M0 9 3 20:30 8 Figure 3. Item 8) until the desired program number (Figure 3. 8. Press the left arrow button (Figure 3. When day (Figure 3. 6. 7.TM 5-3805-294-10 0034 ADJUSTING COOLANT HEATER TIME AND DAY . Press the preset button (Figure 3. Start time (Figure 3. 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. wait approximately 5 seconds and day will stop flashing. 5 6 HYEX01315 Setting Program. Item 7) will begin to flash. Press the left arrow button (Figure 3. Repeat Steps 1 through 7 if additional days of programing is desired. Only one program can be activated at one time. Item 5) or right arrow button (Figure 3. Program number (Figure 3. Item 7) is set. • Pressing the preset button (Figure 3. Item 9) will be displayed. 3. 4.Continued 6. Item 9) begins to flash. Item 8) until memory display is blank will delete programs in memory. 2. Item 4) and day (Figure 2. Item 5) or right arrow button (Figure 3. Item 4) and day (Figure 3. Item 7) up or down. Item 4) up or down. Item 6) to adjust day (Figure 3. 0034-3 . Time (Figure 2. Item 7) is set. END OF TASK ADJUSTING COOLANT HEATER RUN TIME NOTE • The maximum amount of time for the coolant heater will run is 120 minutes. wait approximately 5 seconds and day (Figure 3. 1. Item 4) is set. 0034-4 . Item 10) and the coolant heater will start and run. Item 6) to adjust run time (Figure 4. press the left arrow button (Figure 5. 1. Item 2). Item 11) up or down. 2. 11 120 10 Figure 5. wait approximately 5 seconds and run time is set. Item 11) up or down. After desired run time (Figure 4. Press heater button (Figure 5. Press the heater button (Figure 4. 2 11 120 10 5 6 HYEX00021 Figure 4. Press the left arrow button (Figure 4. 3. END OF TASK USING COOLANT HEATER MANUALLY 1. If desired. 2. Item 10) and the preselected run time (Figure 4. Item 11) is selected.TM 5-3805-294-10 0034 ADJUSTING COOLANT HEATER RUN TIME . The coolant heater will do a normal cool-down cycle and then turn itself off.Continued • Adjusting the run time must be performed every time a start program is selected. Item 5) or right arrow button (Figure 5. To manually shut coolant heater off press the heater button (Figure 6. Item 5) or right arrow button (Figure 4. Item 11) will appear on the display (Figure 4. Adjusting Run Time. Item 10). Item 6) to adjust run time (Figure 5. 3. 5 6 HYEX00020 Manually Start Coolant Heater. TM 5-3805-294-10 0034 USING COOLANT HEATER MANUALLY .Continued 11 120 10 Figure 6. END OF TASK END OF WORK PACKAGE 0034-5/6 blank . 5 6 HYEX00020 Manually Start Coolant Heater Continued. . Buckle seat belt (Figure 1. 1 HYEX00687 Figure 1. Item 2) will be on the uphill end of machine (Figure 2. and bucket during entire procedure until the machine reaches the top or bottom of the slope. 0035-1 . Item 3). Buckle Seat Belt. 1.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. Failure to comply may result in injury or death to personnel. arm. Item 1). 2. Position undercarriage so travel motors (Figure 2. The machine depends on support of the boom. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. 0035-2 . Push bucket (Figure 2. Item 4) into the ground on the top of the slope. 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. Item 5) and arm cylinder (Figure 2. arm. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. 3. Buckle seat belt (Figure 3.TM 5-3805-294-10 0035 PULLING MACHINE UP . Item 6) to assist the travel motors (Figure 2. 1. The machine depends on support of the boom. Failure to comply may result in injury or death to personnel.Continued 6 4 5 3 2 HYEX00674 Figure 2. While using travel pedals pull the machine using the boom (Figure 2. and bucket during entire procedure until the machine reaches the top or bottom of the slope. Pulling Machine Up. 4. Item 2). Item 1). Item 4) into the ground at the base of the slope. Buckle Seat Belt. Pushing Machine. 2.TM 5-3805-294-10 0035 PUSHING MACHINE UP . 3.Continued 1 HYEX00687 Figure 3. Item 2) will be on the uphill end of machine (Figure 4. 3 6 5 2 4 HYEX00677 Figure 4. Push bucket (Figure 4. Item 3). Position undercarriage so travel motors (Figure 4. 0035-3 . and bucket during entire procedure until the machine reaches the top or bottom of the slope. Item 3). The machine depends on support of the boom. Traveling Down. Item 6) position bucket (Figure 5. Item 2) will be on the uphill end of machine (Figure 5. Failure to comply may result in injury or death to personnel. 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. Item 5) and arm cylinder (Figure 5. Using the boom (Figure 5. 0035-4 . Position undercarriage so travel motors (Figure 5. 2.TM 5-3805-294-10 0035 PUSHING MACHINE UP . Item 6) to assist the travel motors (Figure 4.Continued 4. 1. arm. Item 2). Item 4) so it will drag the ground while traveling down the slope. While using travel pedals push the machine using the boom (Figure 4. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. 3 6 5 2 4 HYEX00677 Figure 5. Item 5) and arm cylinder (Figure 4. END OF TASK END OF WORK PACKAGE 0035-5/6 blank 0035 .Continued 3.TM 5-3805-294-10 TRAVELING DOWN . Slowly travel down the slope. . NOTE Use travel control levers during fording operations to maintain better control of machine speed. (1 m) maximum fording depth will not be exceeded and machine will not become mired. (1. HYEX01311 Figure 1. 0036-1 . Move pilot shutoff lever (Figure 2. Failure to comply may result in damage to equipment. 3. Fording Line.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. 2.0 m) may enter machine systems and damage operating components. Item 1) to unlocked (down) position. Ensure bottom at fording site is firm enough that 40 in. Ensure that engine is operating normally and is at normal operating temperature.0 in. 1. Water deeper than 40. Item 5) back 1/4 travel and slowly back machine out of deep water. 7. HYEX00368 Check Monitor. 6. move travel levers (Figure 3. Ensure that there are no alarms indicated on monitor (Figure 3.0 m). 4.TM 5-3805-294-10 0036 FORDING . Enter the water slowly to minimize surges of backwash into the upperstructure. Move travel levers (Figure 3. Item 2). Position travel speed selector (Figure 3. 5 2 4 3 Figure 3. Item 5) forward 1/4 travel. Raise engine speed dial (Figure 3. Item 3) in slow position. Item 4) to 1/3 throttle position.Continued 1 Figure 2. If machine accidently enters water deeper than 40 in. 9. 5. 8. 0036-2 . HYEX00367 Pilot Shutoff Lever. (1. (WP 0093) END OF TASK END OF WORK PACKAGE 0036-3/4 blank 0036 . maintenance after fording.Continued 10.TM 5-3805-294-10 FORDING . After fording perform. . TM 5-3805-294-10 CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 . . .................................................................. WP 0060 4.............. Engine Emits Excessive White Exhaust Smoke ............................. WP 0045 ENGINE 1...................... Power Dig Does Not Work ............................................... Air Conditioner Does Not Operate .................................... Hydraulic Oil Overheats .......................................... WP 0042 6................................................................................................ WP 0059 3................................................................................................ WP 0039 3.... Travel Alarm Does Not Operate ........................... WP 0050 6............. WP 0052 8.................................................................................................... Low Note and High Note Horns Do Not Operate ....... WP 0049 5.............................................................................. Engine Oil Pressure Low ................................ Engine Cranks But Will Not Start Or Hard To Start ..................... WP 0055 11.................................... WP 0058 2.................................................. And Drive Lights Do Not Operate ............. WP 0040 4............................. Cab Front Work Lights Do Not Operate . Engine Idles Poorly ...................................................................................... Auto-Idle Does Not Work .................. WP 0048 4.................. WP 0053 9.......................................................................... Cab........................................ Hydraulic Functions Are Slow Or Have Little Or No Power ............. WP 0046 2..... WP 0047 3...................... Engine Emits Excessive Black Or Gray Exhaust Smoke ............................................................................................................................................................................ Hydraulic Oil Foams .................................. WP 0057 HYDRAULICS SYSTEM 1.................................................................... WP 0051 7.................................................................................. WP 0041 5............................................................. Excessive Oil Consumption ................................................................................................................................ WP 0043 7...................................................................... Excessive Fuel Consumption ............. Engine Not Developing Full Power . Engine Runs Poorly ........................ No Hydraulic Functions ......... WP 0062 0037-1 ................................................................... Boom........... Cab Rear Work Lights Do Not Operate .................................................................................................................................................................................. WP 0056 12.............................................. WP 0061 5.................... WP 0038 2....................... Engine Will Not Crank ................................................................OPERATOR MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure ELECTRICAL SYSTEM 1................................................................. WP 0054 10............. Windshield Wiper and Washer Do Not Operate ..................................... WP 0044 8.........TM 5-3805-294-10 0037 OPERATOR MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX ........................................................................................................... Cab Dome Light Does Not Operate ............. Engine Coolant Temperature Above Normal ........................... WP 0065 9.... Swing Function Is Jerky ........................................................... Breaker Operates Slowly .................................................................. WP 0067 11...... Slow Travel Speed Only ............................................................ WP 0069 13....... Engine Stops When Travel Or Control Lever Actuated ............................................. Deep Dig Does Not Operate .................................................................................................................................................... Travel Is Jerky . WP 0074 18......... WP 0064 8.. Barrier Grapple Does Not Hold Load ....... WP 0071 15..... Hydraulic Hose Reel Does Not Operate ................... WP 0066 10........................................................................................... WP 0075 END OF WORK PACKAGE 0037-2 ....................Continued Malfunction/Symptom Troubleshooting Procedure 6......................................................................................................................................... Breaker Does Not Operate . WP 0068 12....................... WP 0072 16........................................TM 5-3805-294-10 0037 TROUBLESHOOTING SYMPTOM INDEX ........................ Crush-All Does Not Operate ............................................................................ WP 0073 17...... WP 0063 7........................... Compactor Does Not Operate .............................................................................................................................................................................................................................................................................................................................. No Swing Function .................................................. WP 0070 14.. Quick Latch Does Not Operate ..................................................................................................................................................... replace F5 OPT. Travel Alarm Does Not Operate.1 (ALT) 5A fuse. notify Field Maintenance. If fuse not blown. Malfunction Travel Alarm Fuse Blown. . END OF WORK PACKAGE 0038-1/2 blank Corrective Action 1. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1.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. Test or Inspection 1.1 (ALT) 5A fuse for blown fuse. 1 (ALT) 5A fuse. Remove F5 OPT. If fuse blown. (WP 0084) 2. (WP 0084) 2. Visually inspect F5 OPT. . (WP 0009) 2. Upper Front Window Not Fully Closed. Malfunction 1. proceed to Malfunction 2. (WP 0084) 2. Check upper front window to ensure window is fully closed. If fuse blown. . (WP 0011) 1. Visually inspect F2 WIPER 10A fuse for blown fuse. replace F2 WIPER 10A fuse. (WP 0084) 3. proceed to Malfunction 2. Shut engine off. END OF WORK PACKAGE 0039-1/2 blank Corrective Action 1. 2. If fully closed.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. readjust and close upper front window. Windshield Wiper and Washer Do Not Operate. Windshield Wiper and Washer Fuse Blown. (WP 0011) 1. Test or Inspection 1. 2. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. If not fully closed. If machine is equipped with a Supplemental Armor Set. If fuse not blown. notify Field Maintenance. Remove F2 WIPER 10A fuse. 2. . notify Field Maintenance. 2.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. Radio and Dome Light Fuse Blown. Check cab dome light switch position. Cab Dome Light Does Not Operate. position cab dome light switch ON (down). replace F11 RADIO 5A fuse. Visually inspect F11 RADIO 5A fuse for blown fuse. Malfunction 1. (WP 0004) 1. . END OF WORK PACKAGE 0040-1/2 blank Corrective Action 1. Remove F11 RADIO 5A fuse. If switch is OFF (up). proceed to Malfunction 2. If switch is ON (down). (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. 2. (WP 0084) 3. (WP 0004) 1. If fuse not blown. Shut engine off. If fuse blown. (WP 0009) 2. (WP 0084) 2. Test or Inspection Cab Dome Light Switch is OFF (up). . replace F1 LAMP 20A fuse. AND DRIVE LIGHTS DO NOT OPERATE INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. Cab. notify Field Maintenance. Visually inspect F1 LAMP 20A fuse for blown fuse. If fuse blown. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. . If fuse not blown.TM 5-3805-294-10 0041 OPERATOR MAINTENANCE BOOM. Test or Inspection 1. CAB. (WP 0084) 2. Malfunction Work and Drive Lights Fuse Blown. END OF WORK PACKAGE 0041-1/2 blank Corrective Action 1. Boom. And Drive Lights Do Not Operate. Remove F1 LAMP 20A fuse. (WP 0084) 2. . If fuse not blown. .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. replace F22 CAB LAMP FRONT 10A fuse. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Remove F22 CAB LAMP FRONT 10A fuse. Visually inspect F22 CAB LAMP FRONT 10A fuse for blown fuse. Test or Inspection 1. notify Field Maintenance. If fuse blown. (WP 0084) 2. (WP 0084) 2. Cab Front Work Lights Do Not Operate. END OF WORK PACKAGE 0042-1/2 blank Corrective Action 1. Malfunction Cab Front Work Lights Fuse Blown. . Malfunction Cab Rear Work Lights Fuse Blown. Visually inspect F23 CAB LAMP REAR 10A fuse for blown fuse. . Cab Rear Work Lights Do Not Operate. (WP 0084) 2. replace F23 CAB LAMP REAR 10A fuse. notify Field Maintenance. Remove F23 CAB LAMP REAR 10A fuse. (WP 0084) 2. If fuse blown. END OF WORK PACKAGE 0043-1/2 blank Corrective Action 1.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. Test or Inspection 1. If fuse not blown. . (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Low Note And High Note Horns Do Not Operate. Visually inspect F17 HORN 10A fuse for blown fuse. (WP 0084) 2. If fuse blown.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. If fuse not blown. Malfunction Horn Fuse Blown. notify Field Maintenance. Test or Inspection 1. END OF WORK PACKAGE 0044-1/2 blank Corrective Action 1. Remove F17 HORN 10A fuse. (WP 0084) 2. . replace F17 HORN 10A fuse. . 1. replace F3 HEATER 20A fuse. (WP 0084) 2. proceed to Malfunction 3. . 3. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. 0045-1 Corrective Action 1. proceed to Malfunction 2. Remove fresh air filter. service fresh air filter and housing. 2. Remove F3 HEATER 20A fuse. (WP 0084) 2. Visually inspect F15 AIRCON 5A fuse for blown fuse. If damaged. 3. (WP 0089) 2. If fuse blown. notify Field Maintenance. proceed to Malfunction 4. (WP 0084) 2. If fuse not blown. If fuse not blown. (WP 0084) 2. Visually inspect fresh air filter and housing for clog and damage. Visually inspect F3 HEATER 20A fuse for blown fuse. 1. If fuse blown. Test or Inspection 1. Fresh Air Filter Clogged or Damaged.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. Air Conditioner Does Not Operate. If not clogged and not damaged. Air Conditioner and Heater 20A Fuse Blown. Malfunction 1. (WP 0089) 2. Remove F15 AIRCON 5A fuse. 1. Air Conditioner and Heater 5A Fuse Blown. replace F15 AIRCON 5A fuse. If clogged. 1. 2. If dirty. Air Conditioner Does Not Operate . Test or Inspection 1. notify Field Maintenance. Malfunction 4. Air Conditioner Belt Worn or Damaged. (WP 0077) Visually inspect air conditioner belt for wear and damage. 1. notify Field Maintenance.TM 5-3805-294-10 0045 Table 1. 1. proceed to Malfunction 5. service air conditioner/heater filter and housing. clean air conditioner condenser. proceed to Malfunction 6. If worn or damaged. (WP 0077) END OF WORK PACKAGE 0045-2 Corrective Action 1. If not clogged and not damaged. 6. 5. notify Field Maintenance. (WP 0090) 2. If damaged.Continued. If damaged. Visually inspect air conditioner/heater condenser for dirt and damage. . 3. Visually inspect air conditioner/heater filter and housing for clog and damage. notify Field Maintenance. 3. Remove air conditioner/heater filter. Air Conditioner Condenser Dirty or Damaged. If not worn and not damaged. (WP 0090) 2. If clogged. If not dirty and not damaged. Air Conditioner/ Heater Filter Clogged or Damaged. (WP 0077) 2. (WP 0077) 2. If engine cranks slowly. (WP 0005) 3. Start engine. (WP 0005) 0046-1 Corrective Action 1. service machine. notify Field Maintenance. If fuel level is OK. Visually inspect monitor to verify at least 1/4 tank of fuel is available. Observe monitor for air cleaner clogged alarm. (WP 0007) 2. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Air Cleaners Dirty or Clogged. proceed to Malfunction 3. 2. Fuel Level Low. (WP 0007) 2. 3. Malfunction 1.) WP 0086 WP 0087 Equipment Condition Machine safely parked and shut down. If fuel level is low. Turn key switch to ON position. 2. but DO NOT START ENGINE. . (WP 0009) 1. 1. Engine Cranks But Does Not Start or Hard to Start. If engine does not crank slowly. Turn key switch to OFF position. proceed to Malfunction 2.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 0007) 1. Test or Inspection Engine Cranks Slowly. Crank engine. If fuel lines and fittings are leaking. 1. If fuel lines and fittings are not leaking. 5. (WP 0007) END OF WORK PACKAGE 0046-2 Corrective Action 1. (WP 0086) 2. If engine starts. Fuel Filter/Water Separators Contain Water or Sediment. Malfunction Test or Inspection 3. 1. 2. 2. proceed to Malfunction 4. notify Field Maintenance. Shut down engine.Continued. If air cleaner clogged alarm is not displayed. If air cleaner clogged alarm is displayed. . (WP 0009) Visually inspect fuel lines and fittings for leakage. Engine Cranks But Does Not Start or Hard to Start . If engine does not start. Start engine. notify Field Maintenance. malfunction corrected. 4. (WP 0077) 1. (WP 0087) 2. Leaking Fuel Lines and Fittings.TM 5-3805-294-10 0046 Table 1. remove foreign objects/debris or replace air cleaner. Drain primary and final fuel filter/water separators of water or sediment. proceed to Malfunction 5. 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. (WP 0004) If engine speed does not adjust to A. 3.I. Auto-Idle (A. cease any hydraulic operations being performed. I.I. Hydraulic Operations Being Performed.) Indicator Not Displayed On Monitor. proceed to Malfunction 3. (WP 0009) Notify Field Maintenance. I. (WP 0009) Notify Field Maintenance.I. (WP 0005) Verify if hydraulic operations are being performed. I. If A. 2. Turn A.6 seconds. 2. indicator is displayed on monitor. If engine speed lowers in 4 . 1. If engine speed does not lower in 4 . I. switch to ON position. If hydraulic operations are being performed.6 seconds. speed within 4 . 2. indicator is not displayed on monitor with A. shut down engine. speed within 4 . If A. Engine Speed Does Not Lower With Auto-Idle (A. shut down engine.6 seconds. Test or Inspection 1. proceed to Malfunction 4.6 seconds. proceed to Malfunction 2. I.) Turned ON. (WP 0004) 0052-1 Corrective Action 1. (WP 0004) 2. (WP 0004) Verify A. indicator is displayed on monitor. Malfunction 1. Turn engine speed dial to high idle position (H). Auto-Idle Does Not Work. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. . I. verify engine speed adjusts to A. 1. switch in ON position.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. shut down engine.TM 5-3805-294-10 0052 Table 1. I. (WP 0009) Notify Field Maintenance. (WP 0009) 2. Test or Inspection Operate hydraulic functions. (WP 0009) Notify Field Maintenance. If hydraulic operations are not being performed. If engine speed does not raise.Continued. Malfunction 4. no fault at this time.) Turned ON and Hydraulic Functions Being Performed. (WP 0004) END OF WORK PACKAGE 0052-2 Corrective Action 2. Engine Speed Does Not Raise With Auto-Idle (A. 1. Shut down engine. Auto-Idle Does Not Work . . If engine speed raises. shut down engine. Air Cleaners Dirty or Clogged.) WP 0077 WP 0087 Equipment Condition Engine running. If air cleaner clogged alarm is not displayed. notify Field Maintenance. proceed to Malfunction 3. 1. notify Field Maintenance. (WP 0077) END OF WORK PACKAGE 0053-1/2 blank Corrective Action 1. (WP 0009) Visually inspect exhaust pipes and muffler for dents and restrictions. . If fuel lines and fittings are not leaking. Malfunction 1. Leaking Fuel Lines or Fittings. (WP 0077) Visually inspect fuel lines and fittings for leakage. If exhaust pipes are not dented or restricted. Shut down engine. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1.TM 5-3805-294-10 0053 OPERATOR MAINTENANCE ENGINE NOT DEVELOPING FULL POWER INITIAL SETUP: References WP 0005 WP 0009 References (cont. Test or Inspection 1. 2. Engine Not Developing Full Power. (WP 0005) 2. notify Field Maintenance. 2. (WP 0087) 2. 1. If fuel lines and fittings are leaking. 3. proceed to Malfunction 2. 2. If exhaust pipes are dented or restricted. If air cleaner clogged alarm is displayed. Observe monitor for air cleaner clogged alarm. remove foreign objects/debris or replace air cleaners. Exhaust Pipes Dented or Restricted. . notify Field Maintenance. Malfunction Low Engine Oil Level. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. (WP 0077) 2. If engine oil level is low. Engine Oil Pressure Low. If engine oil level is full. . Test or Inspection Check engine oil level.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. service machine. (WP 0077) END OF WORK PACKAGE 0054-1/2 blank Corrective Action 1. . (WP 0077) Visually inspect engine oil level. 2. If radiator does not have foreign objects/debris or does not have damage. 2. 2. (WP 0077) 2. notify Field Maintenance. notify Field Maintenance. proceed to Malfunction 2. 1. If level is low. notify Field Maintenance. If level is low. 3. 3. 1. Malfunction 1. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. (WP 0077) Visually inspect radiator for damage. (WP 0077) Visually inspect surge tank cap for looseness or damage. secure cap. Test or Inspection Visually inspect engine coolant level. If radiator is damaged. Engine Coolant Temperature Above Normal. 4. If level is not low. If cap is damaged. (WP 0077) 2. proceed to Malfunction 4. Radiator Damaged or Has Foreign Objects/Debris. If radiator has foreign objects/ debris. If cap is not damaged or loose. foreign objects and debris.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. service radiator. remove foreign objects/ debris. Engine Oil Level Low. If level is not low. (WP 0077) END OF WORK PACKAGE 0055-1/2 blank Corrective Action 1. proceed to Malfunction 3. Engine Coolant Level Low. 3. Surge Tank Cap is Loose. service engine. 1. . If cap is loose. . Test or Inspection 1. (WP 0005) 2. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Observe monitor for air cleaner clogged alarm. (WP 0009) END OF WORK PACKAGE 0056-1/2 blank Corrective Action 1.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. remove foreign objects/debris or replace air cleaners. notify Field Maintenance. (WP 0087) 2. Engine Emits Excessive Black Or Gray Exhaust Smoke. Shut down engine. . If air cleaner clogged alarm is displayed. If air cleaner clogged alarm is not displayed. Malfunction Air Cleaners Dirty or Clogged. . 2. (WP 0009) END OF WORK PACKAGE 0057-1/2 blank Corrective Action 1. 1. White Exhaust Smoke Excessive at Normal Operating Temperature. Observe engine exhaust. If engine does not emit white exhaust. Malfunction 2. (WP 0007) 2. 1. 2. If engine emits white exhaust. Test or Inspection Oil Shows Signs Of Contamination. Malfunction 1. (WP 0077) Oil containing coolant will have a creamy brown appearance or oil containing fuel will be diluted and smell like fuel. Operate engine to normal operating temperature. 3. notify Field Maintenance. Engine Emits Excessive White Exhaust Smoke. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Shut down engine. Visually inspect engine oil dipstick for coolant or fuel contaminants. no fault at this time. notify Field Maintenance. 2. .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. If oil dipstick shows no signs of contaminants. If oil dipstick shows signs of contaminants. . fill oil to proper level. Malfunction 1. If hydraulic oil level is correct. 2. If hydraulic functions operate. No Hydraulic Functions. 1. Pilot Shutoff Lever in LOCK (up) Position. (WP 0004) 2. (WP 0088) . malfunction corrected. Shut engine off.) WP 0077 WP 0088 Equipment Condition Engine running. notify Field Maintenance. (WP 0009) Check hydraulic oil level. proceed to Malfunction 2. If hydraulic oil level is not correct. (WP 0004) 3. Test or Inspection 1. 2. 2. (WP 0077) END OF WORK PACKAGE 0058-1/2 blank Corrective Action 1. Operate control pedals and levers.TM 5-3805-294-10 0058 OPERATOR MAINTENANCE NO HYDRAULIC FUNCTIONS INITIAL SETUP: References WP 0004 WP 0009 References (cont. Hydraulic Oil Level Low. Place pilot shutoff lever in UNLOCKED (down) position. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. If hydraulic functions do not operate. . If damaged or missing hardware.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. 2. If hydraulic functions operate properly. If hydraulic oil level is not correct. (WP 0030) 1. Hydraulic Reservoir Fill Cap is Damaged or Missing Hardware. malfunction corrected. 2. notify Field Maintenance. proceed to Malfunction 2. Malfunction 1. 2. If hydraulic oil level is correct. END OF WORK PACKAGE 0059-1/2 blank . (WP 0077) Corrective Action 1. Hydraulic Functions Are Slow or Have Little or No Power. if not damaged or missing hardware. Test or Inspection Check hydraulic oil level. fill oil to proper level. Visually inspect hydraulic reservoir fill cap for damage or missing hardware. proceed to Malfunction 3. notify Field Maintenance. Hydraulic Oil Level Low. If hydraulic functions do not operate properly. (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). 3. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Oil Cold. 2. (WP 0077) 1. . Test or Inspection 1. Visually inspect F4 SOLENOID 10A fuse for blown fuse. Solenoid Fuse Blown. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. proceed to Malfunction 2. Hydraulic Oil Hoses Damaged or Has Leaks. If not damaged or leaking. (WP 0084) 2. If fuse not blown. (WP 0077) END OF WORK PACKAGE 0060-1/2 blank Corrective Action 1. 2. Remove F4 SOLENOID 10A fuse. notify Field Maintenance. notify Field Maintenance.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 0084) 2. 2. Visually inspect hydraulic oil hoses for damage and leaks. Malfunction 1. . replace F4 SOLENOID 10A fuse. Power Dig Does Not Work. If damaged or leaking. If fuse blown. 1. . (WP 0088) . Test or Inspection Visually inspect cooling package for damage. fill oil to proper level. 3. notify Field Maintenance. Malfunction 1. Hydraulic Oil Level Low. remove foreign objects/debris.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. Cooling Package Has Damage. If not damaged and does not have foreign objects/debris. notify Field Maintenance. Hydraulic Oil Overheats. 1. (WP 0077) END OF WORK PACKAGE 0061-1/2 blank Corrective Action 1. (WP 0077) Check hydraulic oil level. 2. If hydraulic oil level is not correct. proceed to Malfunction 2. If damaged. If not damaged but has foreign objects/debris. 2. If hydraulic oil level is correct. 2. Foreign Objects/ Debris. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. foreign objects/debris. . Hydraulic Oil Level Low. proceed to Malfunction 2. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. If hydraulic oil hoses are not damaged. notify Field Maintenance. (WP 0077) END OF WORK PACKAGE 0062-1/2 blank Corrective Action 1. If hydraulic oil level is correct. . notify Field Maintenance. If hydraulic oil level is high. Test or Inspection Check hydraulic oil level.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 0088) 3. If hydraulic oil hoses are damaged. If hydraulic oil level is low. Hydraulic Oil Hoses are Damaged. notify Field Maintenance. fill oil to proper level. 1. (WP 0077) Visually inspect hydraulic oil hoses for damage. 2. 2. Hydraulic Oil Foams. Malfunction 1. 2. . (WP 0088) . (WP 0077) END OF WORK PACKAGE 0063-1/2 blank Corrective Action 1. fill oil to proper level. If hydraulic oil level is not correct. 2. Malfunction Hydraulic Oil Level Low. notify Field Maintenance. No Swing Function.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. Test or Inspection Check hydraulic oil level. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. If hydraulic oil level is correct. . (WP 0094) 2. notify Field Maintenance. Swing Function Is Jerky.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 0094) END OF WORK PACKAGE 0064-1/2 blank Corrective Action 1. If swing bearing does not lack grease. lubricate swing bearing grease fittings (LO 5-3805-294-13). Malfunction Lack of Grease in Swing Bearing. . (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. If swing bearing lacks grease. Test or Inspection Visually inspect swing bearing grease fittings (LO 5-3805-294-13). . Check hydraulic oil level. Remove F4 SOLENOID 10A fuse. Hydraulic Oil Level Low. Solenoid Fuse Blown. fill oil to proper level. Slow Travel Speed Only. If fuse blown. 1. (WP 0077) END OF WORK PACKAGE 0065-1/2 blank Corrective Action 1. proceed to Malfunction 2. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. If fuse not blown. 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. Visually inspect F4 SOLENOID 10A fuse for blown fuse. Test or Inspection 1. If hydraulic oil level is not correct. If hydraulic oil level is correct. (WP 0084) 2. (WP 0084) 2. (WP 0088) . 2. 2. replace F4 SOLENOID 10A fuse. Malfunction 1. . Test or Inspection Check track chain sag. If jammed with debris. If track chain sag is not within specification. adjust track chain tension. Incorrect Track Chain Tension. 2. (WP 0080) 1. If not jammed with debris. Debris in Track Frame. notify Field Maintenance. proceed to Malfunction 2. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. Travel is Jerky. . remove debris.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. 2. Malfunction 1. If track chain sag is within specification. 2. (WP 0077) END OF WORK PACKAGE 0066-1/2 blank Corrective Action 1. (WP 0080) Visually inspect track frame for jammed debris. . 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. Engine Stops When Travel or Control Lever Actuated. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. (WP 0007) 3. . Test or Inspection 1. Move HYEX. malfunction corrected. If engine stops when travel is actuated. notify Field Maintenance. If engine stops when either control lever is actuated. (WP 0008) END OF WORK PACKAGE 0067-1/2 blank Corrective Action 1. 3. Malfunction Fuel Filter/Water Separators Contain Water or Sediment. If engine does not stop while moving. 2. (WP 0086) 2. Drain primary and final fuel filter/water separators of water or sediment. notify Field Maintenance. Start engine. . Observe quick latch for movement. notify Field Maintenance. Quick Latch Switch Does not Operate. If fuse blown. (WP 0014) 1. 0068-1 Corrective Action 1.) WP 0077 WP 0084 Equipment Condition Engine running. Safety Lock Pin Lever in Locked Position. Observe quick latch warning light and alarm. Quick Hitch Fuse Blown. (WP 0084) 2. If in unlocked position. 1. Check quick latch safety lock pin lever position.TM 5-3805-294-10 0068 OPERATOR MAINTENANCE QUICK LATCH DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0014 References (cont. proceed to Malfunction 4. 2. proceed to Malfunction 3. Set quick latch switch to UNLATCH position. proceed to Malfunction 2. 1. (WP 0009) 2. Test or Inspection 1. 3. If fuse not blown. Malfunction 1. If warning light and alarm is on. (WP 0084) 3. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. (WP 0014) 2. . place quick latch safety lock pin lever in unlocked position. Visually inspect F26 QUICK HITCH 5A fuse for blown fuse. If warning light and alarm are off. Quick Latch Does Not Operate. 3. replace F26 QUICK HITCH 5A fuse. (WP 0014) 2. Shut down engine. 2. Remove F26 QUICK HITCH 5A fuse. If in locked position. (WP 0077) END OF WORK PACKAGE 0068-2 Corrective Action 1. notify Field Maintenance. If quick latch does have jammed debris. Test or Inspection Visually inspect quick latch for jammed debris. . remove jammed debris.TM 5-3805-294-10 0068 Table 1. Quick Latch Does Not Operate . Malfunction 4. (WP 0077) 2. Quick Latch Has Jammed Debris. If quick latch does not have jammed debris.Continued. Compactor Has Jammed Debris. If quick disconnect is damaged. (WP 0077) END OF WORK PACKAGE 0069-1/2 blank Corrective Action 1. (WP 0020) 3. Hydraulic Return Quick Disconnect Not Fully Seated. (WP 0020) 3. If quick disconnect is not fully seated. If quick disconnect is fully seated. notify Field Maintenance. . Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0077) 2. proceed to Malfunction 2. If compactor does have jammed debris. notify Field Maintenance. Malfunction 1. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. If quick disconnect is not fully seated. reconnect quick disconnect properly. remove jammed debris. If compactor does not have jammed debris. 1. proceed to Malfunction 3. If quick disconnect is fully seated. 2. Hydraulic Supply Quick Disconnect Not Fully Seated. 2. If quick disconnect is damaged. 2. (WP 0077) Visually inspect compactor for jammed debris. reconnect quick disconnect properly. (WP 0077) Visually inspect hydraulic return quick disconnect. 3. 1. notify Field Maintenance. Compactor Does Not Operate.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. . proceed to Malfunction 3. (WP 0077) Visually inspect hydraulic return quick disconnect. If breaker does not have jammed debris. 2. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. (WP 0020) 3. . 1. Malfunction 1. (WP 0077) Visually inspect breaker for jammed debris. Hydraulic Supply Quick Disconnect Not Fully Seated. reconnect quick disconnect properly. If quick disconnect is not fully seated. remove jammed debris. proceed to Malfunction 2. Breaker Has Jammed Debris. reconnect quick disconnect properly. Hydraulic Return Quick Disconnect Not Fully Seated.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 0077) END OF WORK PACKAGE 0070-1/2 blank Corrective Action 1. 2. If quick disconnect is not fully seated. If quick disconnect is fully seated. If quick disconnect is damaged. 2. notify Field Maintenance. notify Field Maintenance. Breaker Does Not Operate. 3. If quick disconnect is fully seated. If quick disconnect is damaged. 1. (WP 0077) 2. If breaker does have jammed debris. notify Field Maintenance. Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0020) 3. . If hydraulic supply hose is not damaged or leaking. 2. proceed to Malfunction 2. proceed to Malfunction 3. proceed to Malfunction 4. If hydraulic return hose is damaged or leaking. notify Field Maintenance. If breaker attachment is not selected. Hydraulic Return Hose is Damaged or Has Leaks. Visually inspect hydraulic supply hose. 2. .TM 5-3805-294-10 0071 OPERATOR MAINTENANCE BREAKER OPERATES SLOWLY INITIAL SETUP: References WP 0009 WP 0018 References (cont. (WP 0009) 2. Malfunction 1. If breaker attachment is selected. 3. (WP 0077) Visually inspect hydraulic return hose. If hydraulic supply hose is damaged or leaking. Breaker Operates Slowly. Test or Inspection Breaker Attachment Not Selected. 2.) WP 0077 WP 0088 Equipment Condition Engine running. notify Field Maintenance. If hydraulic return hose is not damaged or leaking. 1. (WP 0018) 1. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Check attachment selection on monitor. select breaker attachment on monitor. (WP 0018) 1. Shut down engine. 2. (WP 0077) 0071-1 Corrective Action 1. Hydraulic Supply Hose is Damaged or Has Leaks. Hydraulic Oil Level Low. If hydraulic oil level is not correct.Continued. 2. (WP 0088) .TM 5-3805-294-10 0071 Table 1. Malfunction 4. notify Field Maintenance. (WP 0077) END OF WORK PACKAGE 0071-2 Corrective Action 1. fill oil to proper level. Test or Inspection Check hydraulic oil level. If hydraulic oil level is correct. Breaker Operates Slowly . Test or Inspection 1. If quick disconnect is not fully seated.2 (ALT) 10A fuse. Visually inspect hydraulic supply quick disconnect.2 (ALT) 10A fuse for blown fuse. 2. 1. proceed to Malfunction 4. 12-Volt Power Outlet Fuse Blown. If quick disconnect is damaged. 2 (ALT) 10A fuse. . (WP 0077) Visually inspect hydraulic return quick disconnect. notify Field Maintenance. 2. replace F6 OPT. 2. If fuse not blown. Remove F6 OPT. Hydraulic Supply Quick Disconnect Not Fully Seated. 1. (WP 0020) 3. (WP 0084) 2. proceed to Malfunction 2. If fuse blown. Visually inspect F6 OPT. Malfunction 1. (WP 0084) 2. notify Field Maintenance. 3. proceed to Malfunction 3.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. Crush-All Does Not Operate. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1. reconnect quick disconnect properly. reconnect quick disconnect properly. If quick disconnect is fully seated. (WP 0020) 3. (WP 0077) 0072-1 Corrective Action 1. If quick disconnect is not fully seated. Hydraulic Return Quick Disconnect Not Fully Seated. If quick disconnect is damaged. If quick disconnect is fully seated. (WP 0077) 2. If crush-all does have jammed debris. notify Field Maintenance. remove jammed debris. Malfunction 4. (WP 0077) END OF WORK PACKAGE 0072-2 Corrective Action 1. . Test or Inspection Visually inspect crush-all for jammed debris. Crush-All Does Not Operate .Continued.TM 5-3805-294-10 0072 Table 1. Crush-All Has Jammed Debris. If crush-all does not have jammed debris. (WP 0077) END OF WORK PACKAGE 0073-1/2 blank Corrective Action 1. Malfunction Grip pads worn. If grip pads not worn. . notify Field Maintenance. 2. If grip pads worn. (WP 0009) TROUBLESHOOTING PROCEDURE Table 1.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. notify Field Maintenance. Barrier Grapple Does Not Hold Load. Test or Inspection Visually inspect grip pads. . Visually inspect hydraulic supply quick disconnect. If switch is ON. (WP 0077) 3. (WP 0084) 3. Check deep dig control pattern switch position. Shut down engine. proceed to Malfunction 2. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. 1. If fuse blown. Test or Inspection Deep Dig Control Pattern Switch is OFF. If switch is OFF. Remove F13 AUX 10A fuse. Visually inspect hydraulic supply hose for damage. (WP 0009) 2. Deep Dig Does Not Operate. Visually inspect F13 AUX 10A fuse for blown fuse. Cab Auxiliary Power Connector One Fuse Blown. 2. Hydraulic Supply Quick Disconnect Not Fully Seated. (WP 0077) 0074-1 Corrective Action 1. (WP 0023) 1. 3. (WP 0077) 2. set deep dig control pattern switch to ON. replace F13 AUX 10A fuse.TM 5-3805-294-10 0074 OPERATOR MAINTENANCE DEEP DIG DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0023 References (cont. 1. Visually inspect hydraulic return quick disconnect.) WP 0077 WP 0084 Equipment Condition Engine running. If fuse not blown. proceed to Malfunction 3. (WP 0084) 2. (WP 0023) 2. . Malfunction 1. (WP 0077) END OF WORK PACKAGE 0074-2 Corrective Action 1. notify Field Maintenance. 4. Malfunction Test or Inspection 4. notify Field Maintenance. Visually inspect hydraulic return hose for damage. If quick disconnects are fully seated and hoses are not damaged. Deep Dig Does Not Operate . If hose(s) is damaged.Continued.TM 5-3805-294-10 0074 Table 1. 3. . reconnect quick disconnect properly. notify Field Maintenance. (WP 0023) 2. If quick disconnect(s) is damaged. If quick disconnect(s) is not fully seated. (WP 0026) 2. If fuse not blown. (WP 0084) 2. Remove F13 AUX 10A fuse. Cab Auxiliary Power Connector One Fuse Blown. Shut down engine.TM 5-3805-294-10 0075 OPERATOR MAINTENANCE HYDRAULIC HOSE REEL DOES NOT OPERATE INITIAL SETUP: References WP 0009 WP 0026 References (cont. If quick disconnect is damaged. reconnect quick disconnect properly. Visually inspect F13 AUX 10A fuse for blown fuse. (WP 0084) 3. Hydraulic Hose Reel Does Not Operate. 3. (WP 0007) TROUBLESHOOTING PROCEDURE Table 1. Malfunction 1. If switch is ON. (WP 0026) 3. proceed to Malfunction 4. set hand held hydraulic tool circuit switch to ON. (WP 0077) 0075-1 Corrective Action 1. Check hand held hydraulic tool circuit switch position. notify Field Maintenance. (WP 0026) 1. If switch is OFF. . 1. 1. Hydraulic Supply Quick Disconnect Not Fully Seated. proceed to Malfunction 3.) WP 0077 WP 0084 Equipment Condition Engine running. replace F13 AUX 10A fuse. Visually inspect hydraulic supply quick disconnect. (WP 0009) 2. Test or Inspection Hand Held Hydraulic Tool Circuit Switch is OFF. If fuse blown. 2. 2. If quick disconnect is fully seated. If quick disconnect is not fully seated. proceed to Malfunction 2. Visually inspect hydraulic tool supply hose for damage. If hose is damaged. (WP 0077) Corrective Action 1. notify Field Maintenance. 2. END OF WORK PACKAGE 0075-2 . Hydraulic Tool Return Hose Has Damage. 6. (WP 0026) 3. proceed to Malfunction 5.Continued. proceed to Malfunction 6. 2. Hydraulic Hose Reel Does Not Operate .TM 5-3805-294-10 0075 Table 1. Malfunction 4. Visually inspect hydraulic tool return hose for damage. If hose is damaged. notify Field Maintenance. If quick disconnect is damaged. Hydraulic Tool Supply Hose Has Damage. notify Field Maintenance. If quick disconnect is not fully seated. 5. (WP 0077) 1. Hydraulic Return Quick Disconnect Not Fully Seated. (WP 0077) 1. Test or Inspection Visually inspect hydraulic return quick disconnect. If hose is not damaged. 2. notify Field Maintenance. If quick disconnect is fully seated. If hose is not damaged. reconnect quick disconnect properly. 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 . . and to the Commander. or DA Form 5988-E. but a stain around a fitting or connector may also indicate a leak. They are a permanent record of services. and Fittings: Look for wear. There should be no signs of wear. as well as for those that are missing. There is not much of it. nuts. Nuts. or broken. fraying. exposed wires. This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The completed forms and records have several uses. • Electric Wires and Connectors: Look for cracked or broken insulation. Rags are also required for removing dirt and grease. The PMCS tables contain checks and services necessary to ensure that the machine is ready for operation. Tighten loose connectors and ensure wires are in good shape. Use solvent cleaning compound on all metal surfaces and soapy water on rubber or plastic surfaces. and screws. MAINTENANCE RECORDS AND FORMS Every mission begins and ends with paperwork. or gaps where parts are welded together. • Welds: Look for loose or chipped paint. collapsing. or leaks. or rust around bolt heads. • Tools supplied on the machine are to be used for Preventive Maintenance Checks and Services (PMCS). • PMCS intervals should be performed more frequently when operating under unusual conditions. notify Field Level Maintenance. Equipment Inspection and Maintenance (Electronic) Worksheet. They serve as a checklist to track previous machine malfunctions and repair actions. 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. and modifications made to the machine. broken. chafed or burned. For the information needed on forms and records. • Perform PMCS on attachments only if they are to be used for the current mission. GENERAL MAINTENANCE PROCEDURES • Cleanliness: Dirt. Record results of PMCS on DA Form 2404. repairs. or cracked. 0076-1 . Tighten or replace as necessary. grease. and loose or broken connectors. but it must be kept up. bare metal. or fittings are broken or worn out. damage. Wet spots show leaks. cuts. Equipment Inspection and Maintenance Worksheet. refer to DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual. and Screws: Check for loose bolts. notify Field Level Maintenance. and debris can conceal serious problems. dents. Tubes. tubes. oil. • Fluid Hoses. Ensure clamps and fittings are tight. If connectors or fittings are loose or if hoses. or deterioration. • Bolts. Maintenance is performed at specified intervals using the PMCS tables. bent. look for signs of chipped paint. tears.TM 5-3805-294-10 0076 OPERATOR MAINTENANCE INTRODUCTION . rust.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. If parts cannot be checked with a tool. Components in good condition are: not bent or twisted. Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable. They are reports to maintenance personnel. If a damaged weld is discovered. then hard time intervals apply for oil and filter changes. Equipment Inspection and Maintenance (Electronic) Worksheet. LUBRICATION INSTRUCTIONS • During adverse weather or unusually dusty conditions. • After fording operations. Warnings and cautions appear before the applicable procedure. Use the item number when recording results on the DA Form 2404. lubricate all lubrication points below fording line. Item to be Inspected Lists the item being checked or serviced.TM 5-3805-294-10 0076 WARNINGS AND CAUTIONS Always observe the warnings and cautions appearing in your PMCS table. Samples for the engine are taken every 90 days and once yearly for the hydraulic system. Equipment Not Ready or Available If Describes a condition that renders the machine not mission capable. • For detailed lubrication instructions. 0076-2 . Procedures Describes the procedure for the check or service. Equipment Inspection and Maintenance Worksheet or the DA Form 5988-E. ARMY OIL ANALYSIS PROGRAM (AOAP) The engine and hydraulic oil and filters replacement are governed by the AOAP program. PMCS COLUMN DESCRIPTION The PMCS table columns are described as follows: Item Number The order that the PMCS should be performed. If sampling is not feasible due to mission. lubrication may be required on a daily basis. Interval Lists the interval at which the check or service is to be performed. You must observe these warnings and cautions to prevent serious injury to personnel or to prevent damage to the equipment. refer to: LO 5-3805-294-13 Lubrication Instructions for the Hydraulic Excavator (HYEX). END OF WORK PACKAGE 0076-3/4 blank . FLUID LEAKAGE • Class I: Seepage of fluid (as indicated by wetness or discoloration) not 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. • Class II: Leakage of fluid sufficient enough to form drops. perform all checks and services listed and all checks and services associated with any lower service interval. • After: Do the After (A) PMCS after operating the machine. Pay attention to the WARNINGS and CAUTIONS. Pay attention to the WARNINGS and CAUTIONS. Pay attention to the WARNINGS and CAUTIONS.or DA Form 5988-E. Always perform PMCS in the same order. • Monthly: Do the Monthly (M) PMCS once a month on the machine. • Before: Do the Before (B) PMCS before operating the machine. • During: Do the During (D) PMCS while machine or its components are in operation. either troubleshoot by following instructions in the Troubleshooting Section of this manual or repair and/or replace as described in the related maintenance task. problems can be spotted quickly.TM 5-3805-294-10 0076 Types of Preventive Maintenance Checks and Services (PMCS) For each service interval. complete either DA Form 2404. If there appears to be a malfunction that cannot be repaired immediately. If an item or component being inspected is inoperable or damaged. every time. Once practiced. Pay attention to the WARNINGS and CAUTIONS. . ITEM NO. INTERVAL References (cont. Item 2) Engine Oil (WP 0097. pilot shutoff lever in 0077-1 EQUIPMENT NOT READY/ AVAILABLE IF: . Table 1. Item 15) References LO 5-3805-294-13 (WP 0094) Table 1. Arctic Type (WP 0097. Table 1. Item 10) Goggles (WP 0097. Item 13) Gloves (WP 0097. Item 1) Antifreeze (WP 0097. WARNING Unless otherwise specified.TM 5-3805-294-10 0077 OPERATOR MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INITIAL SETUP: Materials/Parts Antifreeze.) 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. Table 1. Item 10) Grease (WP 0097. Table 1. Item 10) Penetrating Oil (WP 0097. Table 1. Table 1. Table 1. Wiping (WP 0097. Item 14) Rags. perform all maintenance procedures with all attachments lowered to the ground. Failure to comply may result in injury to personnel. Table 1. Jewelry and tools can catch on equipment. and cause a direct short. severe burns.. CAUTION New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. etc. prior to working on or around vehicle.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE the up position. ITEM NO. ID tags. 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. Remove all jewelry such as rings. Failure to comply may result in injury or death to personnel. Failure to comply may result in injury or death to personnel. 0077-2 EQUIPMENT NOT READY/ AVAILABLE IF: . 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . or electrical shock. bracelets. contact positive electrical circuits. WARNING Ensure electrical power is off prior to working on all electrical connections. and engine shut off.TM 5-3805-294-10 Table 1. 0077-3 HYEX01001 . Item 1) for evidence of fluid leakage such as oil. 2 Exterior of Machine. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Check machine (Figure 1. refer to TM 5-3805-295-13&P. • Only perform PMCS on attachments if they are to be operated for current mission. Check on ground under machine (Figure 1.Continued ITEM TO BE CHECKED OR SERVICED INTERVAL EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE • You are operating the machine for the first time. Item 1) for obvious damage that would impair operation. Class III oil or coolant leaks. • For Armored Cab PMCS. Damage that would impair operation is evident. ITEM NO. coolant. 1 Before Exterior of Machine Perform walk-around inspection of the machine exterior.TM 5-3805-294-10 Table 1. or fuel. 3 1 4 Figure 1. Any fuel leakage is evident. • The lubrication order is to be used in conjunction with the PMCS. 2 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 0077-4 . One or more bolts missing from track shoe. Item 3) or support rollers (Figure 2. Item 4). 3 Before Coolant Surge Tank Check for oil leakage from carrier roller (Figure 2.TM 5-3805-294-10 Table 1. Item 2) and track bolts.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. Oil leaking from carrier roller or support roller. 3 1 4 2 HYEX01001 Figure 2. Exterior of Machine Continued. Loose or missing track shoe. ITEM NO. Check that coolant is at the MIN COLD line (Figure 3. Coolant level below MIN COLD level. Item 6). Item 5) on the surge tank (Figure 3. 4 Before Engine Oil Level Check that the surge tank (Figure 3. Check that surge tank cap (Figure 3. Item 7) is present and is not broken or cracked. 0077-5 . remove surge tank cap (Figure 3.TM 5-3805-294-10 Table 1. Item 6) is not damaged. Check oil level on the dipstick (Figure 4. Item 7) and fill as required.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 7 6 Figure 3. ITEM NO. Cap is missing or is unserviceable. Engine oil level below the ADD mark or engine oil is overfull. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 8) and ensure that it is between the ADD and FULL marks. Surge tank has a Class III leak. If coolant is low. 5 HYEX01002 Coolant Level. 0077-6 . ITEM NO. or damaged components. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . dents. loose parts. Any damage that would impair safe operation of the machine. Loose. Engine Oil. leaking. (WP 0094) 5 Before Engine Compartment Check engine compartment for obvious damage or leaks in hoses or lines. remove cap (Figure 4.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 8 9 HYEX01003 Figure 4.TM 5-3805-294-10 Table 1. or damage. 6 Before Exhaust Components Check exhaust components for leaks. Item 9) and add oil as required (LO 5-3805-294-13). If engine oil is low. missing. 8 Before Fuel Tank Hydraulic Reservoir Cap. 10 HYEX01004 Figure 6. Figure 5. Hydraulic reservoir cap is broken.TM 5-3805-294-10 Table 1. . Item 11) to ensure that it is operational and that cap is not broken. Item 10) on hydraulic reservoir cap (Figure 6. ITEM NO.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE HYEX03409 Exhaust Components. 0077-7 Any signs of leaks from fuel tank. Check fuel tank (Figure 7. or button cannot be pressed. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 7 Before Hydraulic Reservoir Cap 11 Press button (Figure 6. Item 12) for evidence of leaks. and fuel lubricity filter (Figure 8. Item 12) until band (Figure 7. Ensure fuel tank is full.TM 5-3805-294-10 Table 1. • Install fuel cap (Figure 7. Item 17) for evidence of leaks. Item 14) is visible. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 13). fuel/water separator (Figure 8. Item 16). Fuel Tank and Fuel Level. 9 Before Fuel Filters Check primary fuel filter (Figure 8. Item 13). ITEM NO. • Fill fuel tank (Figure 7.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 14 13 12 HYEX01005 Figure 7. To fill fuel tank: • Remove fuel cap (Figure 7. Item 15). . 0077-8 Any fuel leak. 19 HYEX01007 Figure 9. Fuel Filters. 10 Before Hydraulic Oil Filter Check hydraulic oil filter (Figure 8. Any Class III leak. Any Class III leak. Any damage that would impair safe operation of machine. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES .TM 5-3805-294-10 Table 1. ITEM NO. Item 19) for evidence of leaks. 12 Before Engine Oil Filter Check engine oil filter (Figure 9. 0077-9 .Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 16 15 18 17 HYEX01006 Figure 8. 11 Before Hydraulic Pump Compartment Check hydraulic pump compartment for obvious damage or leaks in lines or hoses. Engine Oil Filter. Item 18) for evidence of leaks. Check for presence of hydraulic thumb pin (Figure 10. Check bucket (Figure 11. Any Class III leak. and hydraulic thumb (Figure 10. 0077-10 . 13 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Any Class III leak. ITEM NO. Item 21). Check hydraulic lines (Figure 10. Item 27). Arm. quick latch (Figure 10. Item 28) for cracks and missing teeth. Boom. Quick Latch.Continued INTERVAL Before 0077 ITEM TO BE CHECKED OR SERVICED Boom. Item 22). and Hydraulic Thumb. Item 26) for leaks. Check cylinders (Figure 10. Item 24) for leaks. Item 20). 27 20 25 26 23 21 24 26 24 22 24 HYEX01008 Figure 10. Arm. Quick Latch. Item 25) and hoses (Figure 10.TM 5-3805-294-10 Table 1. Item 23) for damage that would impair operation. arm (Figure 10. 24 Damage that impairs proper operation. 14 Before NOTE Bucket Only check bucket or attachment to be used for current mission. Hydraulic Thumb EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Check boom (Figure 10. Item 29) for damage or missing parts. 15 Before Primary and Secondary Air Cleaner Housing Bucket and Teeth. (WP 0087) Primary and secondary air cleaner housing cracked or cover missing. Loose. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . (WP 0085) 28 HYEX01009 Figure 11. broken. 0077-11 .TM 5-3805-294-10 Table 1. or missing hardware or mounting bracket damage. or missing hardware or mounting bracket is cracked. Inspect and clean primary and secondary air cleaner housing (Figure 12.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: Replace teeth as required. Check bucket for loose. ITEM NO. broken. Check hydraulic hand held tool circuit switch (Figure 12. frayed. or broken. Air Cleaner Housing and Hose Reel. Any lines are cracked.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 29 30 33 32 31 HYEX01395 Figure 12. If deep dig arm is installed. Deep Dig Control Switch. ITEM NO. Hoses. Item 31) to ensure it is in the OFF position. Item 30) to remove dust. Check hydraulic hose reel and hoses (Figure 12. Item 31) is in the ON position. and Hand Held Hydraulic Switch Check deep dig control pattern switch (Figure 12. Item 32) to ensure it is in the OFF position.TM 5-3805-294-10 Table 1. Item 33) for damage and leaks. 0077-12 Any class III leak. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . ensure that deep dig control pattern switch (Figure 12. Squeeze ejector (Figure 12. . 16 Before Hose Reel. Item 37) with four wing nuts (Figure 13. 40 41 36 34. 35 37 38 Figure 13. Item 36) to batteries (Figure 13. Check batteries (Figure 13. ITEM NO. . Item 37) for leaks or cracks. Install two covers (Figure 13.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. washers (Figure 13. Item 0077-13 Battery cables are loose. 17 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . and two covers (Figure 13. Batteries show signs of leaking or have cracks. Item 38) for looseness. Item 37). Item 34). 39 HYEX01011 Batteries. Check battery cables (Figure 13.TM 5-3805-294-10 Table 1. Item 35). Item 36) from batteries (Figure 13. Item 42) for cracks or chips. 40 41 36 34.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 34) and washers (Figure 13. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 39) for leaks and damage. Check cab glass (Figure 15. Any fuel leak. Any broken glass that impairs the operators vision. ITEM NO. Any fuel leak or class III fluid leaks. Check windshield washer reservoir (Figure 14. 0077-14 . 38 39 HYEX01011 Batteries Continued. 35 37 Figure 14. 20 Before Cab Glass Check cooling compartment for obvious damage or leaks. Fill as required. Item 41) for fluid and damage. 18 Before Cooling Package Check cooling package (Figure 13. Any glass missing. Any Class III coolant leak. 19 Before Fuel Cooler Check fuel cooler (Figure 14. Any damage that would impair safe operation of the machine. Item 40) and fuel lines for leaks. Item 35).TM 5-3805-294-10 Table 1. Mirrors and Wiper Arm. 21 Before Mirrors. Wiper. Item 44) is present and serviceable. ITEM NO.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 42 42 42 42 HYEX01012 Figure 15. 0077-15 Operator protection guard missing. . Check that operator protection guard (Figure 16. Item 43) are present and serviceable. 43 43 45 44 HYEX01396 Figure 16. and Operator Protection Guard Cab Glass. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES .TM 5-3805-294-10 Table 1. Check that mirrors (Figure 16. 47 48 48 46 HYEX03430 Figure 17. Fire extinguisher is missing. Item 47) to swing freely. ITEM NO. 23 Before Fire Extinguisher Cab Door. Check that door (Figure 17. or has an expired date of service. Item 46) allow door (Figure 17. Item 47) and latches (Figure 17.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE Check that wiper arm and blade (Figure 16. Item 49) is present and is fully charged. 22 Before Door. Item 45) are serviceable. Item 48) lock and release in open and closed positions. and Latches Check that hinges (Figure 17. has been discharged.TM 5-3805-294-10 Table 1. and Latches. 0077-16 . 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Hinges. Door fails to latch or latches fail to release. Check that fire extinguisher (Figure 18. 46 Door is difficult to open or close. Door Hinges. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 50) move freely through their full range of travel. 24 Before Cab Pedals and Levers Fire Extinguisher. . Check that left and right travel pedal and lever (Figure 19.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 49 HYEX01013 Figure 18.TM 5-3805-294-10 Table 1. 0077-17 Left or right travel pedal or lever are binding or do not move freely through full range of travel. Item 53) and right (Figure 20.Continued INTERVAL 50 ITEM TO BE CHECKED OR SERVICED 50 EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 50 50 51 52 HYEX01399 Figure 19. Check that attachment pedal (Figure 19. Left or right pilot control lever binds or will not move through full range of motion. Item 52) is operational. Item 54) pilot control levers to ensure that they move freely through full range of motion. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . ITEM NO. 0077-18 . Attachment pedal does not move freely or attachment pedal lock does not operate.TM 5-3805-294-10 Table 1. Item 51) moves freely through range of travel and attachment pedal lock (Figure 19. Check left (Figure 20. 25 Before Pilot Control Levers Pedals and Levers. Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 54 53 HYEX01397 Figure 20. ITEM NO. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 27 Before Seat Belt Check that seat belt (Figure 21. Seat belt is frayed or will not fasten together.TM 5-3805-294-10 Table 1. Item 55) is not frayed and fastens together. 0077-19 . Pilot Control Levers. 26 Before Horn Press horn button to ensure horn sounds. Horn does not sound. TM 5-3805-294-10 Table 1. Ignition Switch. 28 Before Monitor Seat Belt. 0077-20 . Turn ignition switch (Figure 22. Item 56) to ON position.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 55 HYEX01398 Figure 21. ITEM NO. 56 HYEX01014 Figure 22. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . . ITEM NO. 1 6 2 3 4 5 7 8 9 0 F1 F2 F3 F4 HYEX01015 Figure 23.TM 5-3805-294-10 Table 1. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Monitor. Sight glass has class III leak. Check that monitor (Figure 23. 57 System Starting. 32 Before Hydraulic Oil Level To check hydraulic oil level: • Fully extend arm (Figure 24. Monitor does not come on. (WP 0007) Engine does not start or starter makes unusual noises. wait 10 seconds to ensure default screen will be displayed. Item 58). Monitor does not go to default screen. Item 57) comes on. 31 Before Wipers and Washer Fluid Check that wipers and washer pump works and has fluid. Wipers do not operate. Lights do not operate.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. 0077-21 . 30 Before Lights Check that all lights operate. then goes to default screen.. 29 Before Starter Start engine. (WP 0088) 0077-22 Reservoir is empty. To fill hydraulic reservoir: • Open right door and ensure that hydraulic oil is between marks on sight glass (Figure 25. Item 59).TM 5-3805-294-10 Table 1. Hydraulic Oil Level Check.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: • Curl bucket (Figure 24. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Sight glass is broken or damaged. Item 60) until bucket is resting on the ground. 61 HYEX01017 Figure 25. (WP 0009) •Service hydraulic reservoir. 60 58 59 Figure 24. •Shut down engine. • Lower boom (Figure 24. . ITEM NO. HYEX01016 Position Boom and Arm. Any Class III leaks. Fill as required. Item 61). Item 62) for loose. Item 64) for loose. Item 63) for leaks and breaker for problems that would impair operation. 33 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Loose. ITEM NO. broken. Check breaker (Figure 26.TM 5-3805-294-10 Table 1. broken. or missing hardware or mounting bracket is cracked. Check compactor (Figure 27. Check breaker hydraulic hoses (Figure 26.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. Loose. or missing hardware or mounting bracket damage. 0077-23 . or missing hardware or mounting bracket is cracked. 34 Before Compactor Breaker. broken. broken. 63 HYEX01018 62 Figure 26. Any class III leak. or missing hardware or mounting bracket damage. 35 Before Crush-All Compactor.TM 5-3805-294-10 Table 1. 0077-24 . 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 66) for loose.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 65 64 HYEX01019 Figure 27. Check crush-all (Figure 28. broken. broken. ITEM NO. Check compactor hydraulic hoses (Figure 27. Loose. or missing hardware or mounting bracket damage. or missing hardware or mounting bracket is cracked. Any class III leak. Item 65) for leaks and compactor for problems that would impair operation. Item 68) for loose. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 36 Before Lubricate Lubricate crush-all daily before each use (LO 5-3805-294-13).Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE 66 Figure 28. or missing hardware or mounting bracket is cracked.TM 5-3805-294-10 Table 1. Check hydraulic hoses (Figure 28. Item 67) for leaks and crush-all for problems that would impair operation. or missing hardware or mounting bracket damage. . (WP 0094) 37 Before Barrier Grapple Check barrier grapple (Figure 29. ITEM NO. 67 EQUIPMENT NOT READY/ AVAILABLE IF: HYEX01020 Crush-All. broken. Loose. broken. 0077-25 Any class III leak. broken. 0077-26 Any loose. ITEM NO. . broken. Check barrier grapple for missing or damaged pads. Barrier grapple pad missing or damaged. or missing hardware or damage. 38 Before Barrier Grapple Actuator Lubricate actuator before use with penetrating oil. Check that barrier grapple lifting device (Figure 29. Barrier grapple cable is kinked or three or more strands are broken. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 70) for loose. Barrier Grapple. Item 69) does not have broken strands.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 69 68 HYEX02987 Figure 29. or missing hardware or damage. 39 Before Deep Dig Arm Check deep dig arm (Figure 30.TM 5-3805-294-10 Table 1. damage. 40 Before Deep Dig Bucket Deep Dig Arm and Bucket. (WP 0085) 0077-27 . Check deep dig arm hydraulic hoses (Figure 30.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 72 71 70 HYEX01306 Figure 30. Loose. Check deep dig ditch cleaning bucket (Figure 30. or missing hardware or mounting bracket is cracked. Replace teeth as required. Item 72) for loose. Check bucket (Figure 31. ITEM NO. broken. Any class III leak. or fraying.TM 5-3805-294-10 Table 1. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . or missing hardware or mounting bracket damage. Item 73) for cracks and missing teeth. Item 71) for leaks. broken. 0077-28 . Item 73) for loose. Check bucket (Figure 32. broken. broken. Check bucket (Figure 31. broken. ITEM NO. or missing hardware or mounting bracket damage. Loose. Item 74) for loose. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Loose. or missing hardware or mounting bracket is cracked. or missing hardware or mounting bracket is cracked.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED 73 Before PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: HYEX01307 Figure 31. broken. or missing hardware or mounting bracket damage. 41 0077 Ditch Cleaning Bucket Deep Dig Bucket.TM 5-3805-294-10 Table 1. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . and Brakes Travel machine forward a short distance and ensure that: • Machine travels in a straight line. •Steers left and right. 43 During Engine speed Dial Turn engine speed dial and ensure engine speed increases. Steering. Ditch Cleaning Bucket. Hydraulic cylinders do not operate normally or have class III leak.TM 5-3805-294-10 Table 1. 46 During Travel Motor. Engine speed dial does not operate. If machine doesn't travel in a straight line. 44 During Right-Hand Console Switches Operate right-hand console switches. perform corrective procedures as needed or shut down engine. (WP 0009) Any alarm sounds or is displayed on monitor. ITEM NO. 42 During Monitor Check monitor during operation for any alarm. Machine does not steer left or right. 45 During Hydraulic Cylinders Check that all hydraulic cylinders operate smoothly and through full range of travel. •Track chain does not make any unusual or popping noises. Switches do not operate.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 74 HYEX01308 Figure 32. Track chain makes unusual 0077-29 . If alarm sounds or is displayed on monitor. lubricate breaker after every hour of use LO 5-3805-294-13. Machine does not stop when travel levers or pedals are released. Failure to comply may result in damage to the attachment. EQUIPMENT NOT READY/ AVAILABLE IF: or popping noises. ITEM NO. Item 59). 50 During Breaker CAUTION Breaker must be lubricated every 2 hours of use and every hour during dusty conditions.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE •When travel levers or pedals are released machine stops. Blower motor does not operate when turned on. Travel alarm does not operate. Item 60) until bucket is resting on the ground. 49 During Air Conditioner/Heater Ensure air conditioner/heater blower motor operates. 48 During Swing Motor and Swing Brake Swing upperstructure left or right approximately 90 degrees then release pilot control levers and ensure upperstructure stops. • 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 58). •Travel levers and pedals return to center when released. During extreme dusty conditions. Travel levers or pedals do not return to center when released. Upperstructure does not stop or drifts. • Lower boom (Figure 33. (WP 0094) 51 After Hydraulic Oil Level To check hydraulic oil level: • Fully extend arm (Figure 33. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . . • Curl bucket (Figure 33. 47 During Travel Alarm Ensure travel alarm operates when machine is moved. (WP 0007) •Safely park and shut down engine. Item 12) for evidence of leaks or damage. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Hydraulic Oil Level Check. 0077-31 Any signs of leaks or damage to fuel tank or strainer. 60 58 59 Figure 33. Fill as required. ITEM NO. To fill hydraulic reservoir: •Shut down engine. Item 61).Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: between marks on sight glass (Figure 34. . or strainer is missing. (WP 0009) •Service hydraulic reservoir. HYEX01016 Position Boom and Arm. (WP 0009) 52 After Fuel Tank and Strainer Check fuel tank and strainer (Figure 35. 61 HYEX01017 Figure 34. (WP 0088) •Start engine.TM 5-3805-294-10 Table 1. Contact Field Maintenance to avoid early wear or damage to the machine. Item 13). Ensure fuel tank is full. Item 12) until band (Figure 35. ITEM NO. • Install fuel cap (Figure 35. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 13). 0077-32 . • Fill fuel tank (Figure 35. 53 After CAUTION Engine Oil Level New machine break-in maintenance is required at 250 hours. To fill fuel tank: • Remove fuel cap (Figure 35. Check oil level on the dipstick (Figure 36. Item 14) is visible.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. Failure to comply may result in voidance of warranty and damage to the machine. Item 8) and ensure that it is between the ADD and FULL marks.TM 5-3805-294-10 Table 1. Engine Oil Check. 0077-33 Any damage that would impair safe operation of the machine.TM 5-3805-294-10 Table 1. Belts. Check belts for cuts or frays. HYEX03410 Figure 37. 54 After Engine Compartment.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: PROCEDURE 8 9 HYEX01003 Figure 36. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Engine Compartment. and Hoses Check engine compartment for obvious damage or leaks in hoses or lines. . If engine oil is low. Item 9) and add oil as required. remove cap (Figure 36. ITEM NO. coolant. . Check machine (Figure 38.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. Damage that would impair operation is evident. Item 1) for obvious damage that would impair operation. or fuel. ITEM NO. Class III oil or coolant leaks. 1 2 Figure 38. Item 2) for missing shoes and mounting hardware. HYEX01400 Exterior of Machine Check. 56 Monthly CAUTION Swing Gearbox Oil New machine break-in maintenance is required at 250 hours.TM 5-3805-294-10 Table 1. Item 1) for evidence of fluid leakage such as oil. 0077-34 Any missing track shoes or mounting hardware. Failure to comply may result in voidance of warranty and damage to the machine. Check left and right track chains (Figure 38. Any fuel leakage is evident. Contact Field Maintenance to avoid early wear or damage to the machine. 55 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Check on ground under machine (Figure 38. 57 Monthly Hydraulic Pump Gearbox Oil Check hydraulic pump gearbox oil level on dipstick (Figure 40. . Item 76). 0077-35 Oil level is below the "L" mark. Swing Gearbox Oil Level Check. 76 EQUIPMENT NOT READY/ AVAILABLE IF: Oil level is not on dipstick. • Add oil until it is between the marks on the dipstick (Figure 39. Item 75). ITEM NO.TM 5-3805-294-10 Table 1. 75 HYEX01410 Figure 39. • Install cap (Figure 39. To add oil: • Remove cap (Figure 39.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE Check that swing gearbox oil is between marks on dipstick (Figure 39. Item 75). Item 76). 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . Item 77). Item 78). • Install cap (Figure 40. • Add oil until it reaches the "H" mark on the dipstick (Figure 40. (WP 0086) 59 Monthly Fuel Tank Drain sediment from fuel tank. To add oil: • Remove cap (Figure 40.TM 5-3805-294-10 Table 1. ITEM NO. 58 Monthly Primary and Final Fuel Filter/Water Separators Service primary and final fuel filter/ water separators.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 78 L H 77 2 HYEX01409 Figure 40. Item 77). (WP 0091) 60 Monthly Coolant Heater Run coolant heater (WP 0034) for 5 minutes to keep water pump from seizing. Hydraulic Pump Oil Level Check. Item 78). 0077-36 . 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . 79 HYEX01401 Figure 41. Serpentine belt is cut.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. ITEM NO. 0077-37 Air conditioner belt is cut or broken.TM 5-3805-294-10 Table 1. Item 80) for cracks and cuts. . or frayed. Check air conditioner belt (Figure 42. 63 Monthly Air Conditioner Belt Serpentine Belt Check. (WP 0087) 62 Monthly Serpentine Belt Check serpentine belt (Figure 41. broken. cuts and frays. Item 79) for cracks. 64 Monthly Fan Air Conditioner Belt Check. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . . Check fan (Figure 43. Item 81) for damage. 0077-38 Any damage that would impair safe operation of machine. Any debris that would block air flow through radiator.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 80 HYEX01402 Figure 42. ITEM NO. and hydraulic leaks. Any class III hydraulic leak.TM 5-3805-294-10 Table 1. debris. (WP 0090) 68 Monthly Lubrication Perform 100 lubrication in accordance with. (WP 0080) 66 Monthly Fresh Air Filter Service fresh air filter. 0077 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES . (WP 0089) 67 Monthly Air Conditioner/Heater Filter Service Service air conditioner/heater filter.TM 5-3805-294-10 Table 1. 65 Monthly Track Sag Check track sag. Fan Check. (WP 0094) END OF TASK END OF WORK PACKAGE 0077-39/40 blank . LO 5-3805-294-13.Continued INTERVAL ITEM TO BE CHECKED OR SERVICED PROCEDURE EQUIPMENT NOT READY/ AVAILABLE IF: 81 HYEX01403 Figure 43. ITEM NO. . TM 5-3805-294-10 CHAPTER 5 OPERATOR MAINTENANCE INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 . . or bare wires.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. Check all hose surfaces for wear. and leaks. Wet spots show leaks. Prior to starting any inspection or maintenance procedure. INSPECTION Electrical Parts. nuts. ensure that machine is safely parked and shut down. bent. chafed. or worn out. or gaps where parts are welded together. Notify Field Level maintenance of any part found to be defective. and screws for obvious looseness. and burned insulation. broken. but look for chipped paint. Also check for missing. Check bolts. broken. Visually inspect all castings and weldments for cracks. They cannot all be checked with a tool. notify Field Level maintenance. or frayed coverings. Read all CAUTIONS and WARNINGS that apply to all maintenance instructions. Follow these maintenance practices when working on the machine. Look for loose or chipped paint. Metal Parts. 0078-1 . Check for breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. This section covers general maintenance instructions for the machine. Inspect connectors for corrosion or signs of sparking. rust. Tubing and Hosing. damage. Inspect all terminal connectors for loose connections and broken parts. or rust around bolt heads. Specific instructions are found in the operator maintenance section of this manual. or broken pieces. broken. bare. If a connector or fitting is loose. have it repaired. This is an indication of a malfunction within the terminal. Inspect wiring harnesses for cracked. bare metal. If a bad weld is found. but a stain around a fitting or connector may also indicate a leak. junction blocks. cleaning cloth. END OF TASK END OF WORK PACKAGE 0078-2 . Do not clean with solvents. Steam clean all exterior parts thoroughly. wash painted surfaces of machine with solution of 1/4 cup of soap chips. If pressurized water is not available. Rubber Parts. Failure to comply may result in injury or death to personnel. Clean these parts with a cleaning cloth moistened with cleaning compound. Do not clean rubber parts in solvent cleaning compound. switches. Clean rubber parts with hot. Electrical Parts. to 1 gallon (4 L) of water. Fuel is highly flammable.TM 5-3805-294-10 0078 CLEANING WARNING Never use fuel to clean parts. Wipe parts clean with a dry. soapy water and soft cloths. Electrical parts such as coils. Machine Exterior. and electrical parts that contain insulation materials should not be soaked or sprayed with cleaning solutions. END OF TASK END OF WORK PACKAGE 0079-1/2 blank . 3. Table 1.TM 5-3805-294-10 0079 OPERATOR MAINTENANCE TAKING ENGINE OIL SAMPLE INITIAL SETUP: Materials/Parts Bottle. (WP 0007) Time to Complete 0. Oil Sample (WP 0097. Clean dirt from around cap (Figure 1. Release valve (Figure 1. Item 3) and fill sampling bottle until it is at least 3/4 full. Turn valve (Figure 1. 4. Item 15) Equipment Condition Engine running. Item 2). Item 2). Item 1) from sampling valve (Figure 1. 2. 5. Item 3) Rags. Engine Oil Sampling Valve. Wiping (WP 0097. Install cap (Figure 1. Item 3).2 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) SAMPLING ENGINE 1. Item 1) to sampling valve (Figure 1. Item 1). Table 1. 1 3 2 HYEX00909 Figure 1. Remove cap (Figure 1. . 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.) WP 0007 WP 0009 WP 0081 WP 0082 Tools and Special Tools Measuring Tape (WP 0095. 2 HYEX00383 Raise Machine. Item 3) to raise track (Figure 1. Table 1. Table 1. END OF TASK 0080-1 . Keeping angle between boom (Figure 1. 2. Item 5) off ground. Item 10) Materials/Parts Grease (WP 0097. Item 4) between 90 and 110 degrees. Place round side of bucket (Figure 1.TM 5-3805-294-10 0080 OPERATOR MAINTENANCE TRACK SAG CHECK INITIAL SETUP: References (cont. 3. Table 2. Item 15) Equipment Condition Engine running. 3 4 1 5 Figure 1. Item 1) 90 degrees. slowly lower boom (Figure 1. Item 10) Rags. Wiping (WP 0097. (WP 0007) Personnel Required Horizontal Construction Engineer 12N (2) Time to Complete 0. Item 2) on ground. Item 3) and arm (Figure 1. Swing upperstructure (Figure 1. 1. Rotate track (Figure 2.TM 5-3805-294-10 0080 TRACK SAG CHECK 1. Item 6) to locked (up) position. Move pilot shutoff lever (Figure 3. Item 5) to measure two full rotations of track in each direction. Mark track (Figure 2. Item 5) forward two full rotations and in reverse two full rotations. Rotate Track. 0080-2 HYEX00491 . 2. 3. 5 Figure 2. Continued 7 6 Figure 3.TM 5-3805-294-10 0080 TRACK SAG CHECK . Item 8) at middle track roller (Figure 4. (300-335 mm) between surface of track (Figure 4. Item 5) and bottom of track frame (Figure 4. Item 7) to OFF position. Item 9). Turn key switch (Figure 3. HYEX01309 Shut Machine Off.8-13. 4. Measure for a distance of 11. 0080-3 .2 in. 5. If track sag is more than 13.TM 5-3805-294-10 0080 TRACK SAG CHECK . Loosen Track Tension.2 in. END OF TASK LOWERING MACHINE 1. If track sag is less than 11. If track sag is within limits.Continued 8 9 HYEX00838 5 Figure 4. 0080-4 . (300 mm). Measure Track Sag. (335 mm). Turn key switch (Figure 5. Tighten Track Tension. 6. (WP 0082) 8.8 in. Item 7) to ON position and start engine. (WP 0081) 7. go to Lowering Machine task in this work package. 3 4 1 5 Figure 6. Start Machine. 2. 0080-5 2 HYEX00383 . Item 3) until track (Figure 6.TM 5-3805-294-10 0080 LOWERING MACHINE . Item 5) is resting on ground. 3. Lower Machine.Continued 7 HYEX01309 6 Figure 5. Slowly raise boom (Figure 6. Move pilot shutoff lever (Figure 5. Item 6) to unlocked (down) position. and bucket (Figure 6. Swing upperstructure (Figure 6. Raise boom (Figure 6. Item 2) off ground.Continued 4. 6. arm (Figure 6. Item 4). Item 1) 90 degrees. 5. Item 3). Safely park and shutdown machine.TM 5-3805-294-10 LOWERING MACHINE . (WP 0009) END OF TASK END OF WORK PACKAGE 0080-6 0080 . Item 4) Materials/Parts Grease (WP 0097. Table 2. Add a small amount of grease to grease fitting (Figure 1. Item 15) Equipment Condition Track sag checked. (WP 0080) Personnel Required Horizontal Construction Engineer 12N Time to Complete 0. Item 10) Rags. 2. 1 Figure 1.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. Check track sag.1 Hour(s) TIGHTENING TRACK 1. (WP 0080) END OF TASK END OF WORK PACKAGE 0081-1/2 blank HYEX00384 . Item 1). Wiping (WP 0097. Table 1. Tighten Track. Table 1. . Tighten nut (Figure 1. Loosen nut (Figure 1. END OF TASK END OF WORK PACKAGE 0082-1/2 blank .1 Hour(s) LOOSENING TRACK TENSION 1. (WP 0080) Loosen Track. 2. Table 2. Table 1. 1 HYEX00385 Figure 1.TM 5-3805-294-10 0082 OPERATOR MAINTENANCE LOOSENING TRACK TENSION INITIAL SETUP: Tools and Special Tools Wrench. Item 15) Equipment Condition Track sag checked. Item 1). (WP 0080) Personnel Required Horizontal Construction Engineer 12N Time to Complete 0. Check track sag. Item 4) References DA FORM 5988-E or DA FORM 2404 (WP 0094) WP 0007 Materials/Parts Rags. 24 mm (WP 0095. Item 1) and allow a small amount of grease to escape. Open End. 3. Wiping (WP 0097. . Oil Sample (WP 0097. 2. Item 15) Equipment Condition Engine running. 3. 4. Wiping (WP 0097. Remove cap (Figure 1. Clean dirt from around cap (Figure 1.TM 5-3805-294-10 0083 OPERATOR MAINTENANCE TAKING HYDRAULIC OIL SAMPLE INITIAL SETUP: Materials/Parts Bottle. Item 2). Item 1). 5. END OF TASK END OF WORK PACKAGE 0083-1/2 blank . Item 3) and fill sampling bottle until it is at least 3/4 full. Install cap (Figure 1. Turn valve (Figure 1. Item 2). (WP 0007) Time to Complete 0. Item 1) from sampling valve (Figure 1. Table 1. Release valve (Figure 1. 3 1 2 HYEX00908 Figure 1.2 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) SAMPLING HYDRAULIC OIL 1. Hydraulic Oil Sampling Valve. Item 1) to sampling valve (Figure 1. Item 3) Rags. Item 3). Table 1. . Item 2). • Spare fuses are located in the fuse box. Item 1) from cab rear tray (Figure 1.TM 5-3805-294-10 OPERATOR MAINTENANCE CAB FUSE REPLACEMENT INITIAL SETUP: Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. notify Field maintenance to get a replacement fuse. (WP 0009) REMOVAL NOTE • All fuses from both main and auxiliary fuse boxes are removed the same way. 0084-1 0084 . Main fuse box shown. Remove fuse box access cover (Figure 1. 1. After using a spare fuse.2 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. Item 3) from main fuse box (Figure 2. 0084-2 .TM 5-3805-294-10 0084 REMOVAL . 2. Remove main fuse box cover (Figure 2.Continued 2 1 HYEX00089 Figure 1. Fuse Box Access Cover Removal. Item 4). Locate fuse in question using key found on fuse box cover (Figure 2. Item 4). Item 5) from main fuse box (Figure 3.Continued 3 4 HYEX00097 Figure 2. Item 3). 3. 4. Remove fuse (Figure 3.TM 5-3805-294-10 0084 REMOVAL . 0084-3 . Main Fuse Box Cover Removal. 0084-4 . Fuse Removal. Item 5) to main fuse box (Figure 4.Continued 5 4 HYEX00098 Figure 3. 1. NOTE All fuses from both main and auxiliary fuse boxes are installed the same way.TM 5-3805-294-10 0084 REMOVAL . Install fuse (Figure 4. Item 4). Using a fuse with higher amperage than specified could cause damage to the electrical system. Main fuse box shown. Failure to comply may result in damage to equipment. END OF TASK INSTALLATION CAUTION Use only a fuse having the same amperage as noted on fuse box cover. TM 5-3805-294-10 0084 INSTALLATION . Install main fuse box cover (Figure 5.Continued 5 4 HYEX00098 Figure 4. Item 3) to main fuse box (Figure 5. 2. Item 4). Fuse Installation. 0084-5 . 3. Install fuse box access cover (Figure 6. Item 1) to cab rear tray (Figure 6.Continued 3 4 HYEX00097 Figure 5.TM 5-3805-294-10 0084 INSTALLATION . Item 2). Main Fuse Box Cover Installation. 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 . . Item 9) Equipment Condition Machine safely parked and shut down. Item 3). Item 1) from tooth (Figure 1. Remove tooth (Figure 1. Pin (WP 0095. 2 Tooth Removal. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. Table 2.2 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 3). 3 lb (WP 0095.TM 5-3805-294-10 0085 OPERATOR MAINTENANCE BUCKET TEETH REPLACEMENT INITIAL SETUP: Tools and Special Tools Hammer. 2. Item 5) Punch. Table 2. Item 2) from shank (Figure 1. Hand. Item 2) and shank (Figure 1. END OF TASK 0085-1 HYEX01282 . 3 1 Figure 1. Item 3) until seated. 4 5 6 HYEX01281 Figure 3. Bucket Tooth Removal. drive out pin (Figure 3. Item 3). Position tooth (Figure 2. Item 2) and shank (Figure 2. Item 2) on shank (Figure 2. Item 4) from tooth (Figure 3. Using hammer. Item 6). 2 HYEX01282 Tooth Installation. 2.TM 5-3805-294-10 0085 HEAVY DUTY BUCKET TOOTH INSTALLATION 1. 3 1 Figure 2. drive pin (Figure 2. END OF TASK DEEP DIG BUCKET TOOTH REMOVAL 1. Item 1) to tooth (Figure 2. Item 5) and shank (Figure 3. Using hammer and pin punch. 0085-2 . Remove tooth (Figure 3. Using hammer. Item 6). Item 6). Item 4) to tooth (Figure 4.Continued 2. Position tooth (Figure 4. Item 6) until seated. 4 5 6 HYEX01281 Figure 4. END OF TASK END OF WORK PACKAGE 0085-3/4 blank . END OF TASK DEEP DIG BUCKET TOOTH INSTALLATION 1. drive pin (Figure 4.TM 5-3805-294-10 0085 DEEP DIG BUCKET TOOTH REMOVAL . Bucket Tooth Installation. Item 5) on shank (Figure 4. Item 5) from shank (Figure 3. 2. Item 5) and shank (Figure 4. . 0086-1 .1 Hour(s) DRAIN FUEL FILTER/WATER SEPARATORS WARNING DIESEL FUEL 1. Drain Equipment Condition Machine safely parked and shut down (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. Item 1) from water in fuel (WIF) sensor (Figure 1. Disconnect wiring harness connector D01 (Figure 1. 3 2 1 4 5 HYEX00103 Figure 1. Item 2). Drain Fuel Filter/Water Separators.TM 5-3805-294-10 0086 OPERATOR MAINTENANCE PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE INITIAL SETUP: Tools and Special Tools Pan. but do not remove WIF sensor (Figure 2. Item 2). and drain water/sediment from primary fuel filter/ water separator (Figure 2. Loosen. 3. and drain water/sediment from final fuel filter/water separator (Figure 2. Item 4). Item 2). 6.Continued NOTE Place drain pan under fuel/water separators prior to draining. 2. Item 5) for approximately 30 seconds. Tighten WIF sensor (Figure 2. 5. Item 4). Item 3) for approximately 30 seconds. 4. END OF TASK END OF WORK PACKAGE 0086-2 . Tighten valve (Figure 2. Loosen. Connect wiring harness connector D01 (Figure 2. Item 2). 3 2 1 4 5 HYEX00103 Figure 2. Item 1) to WIF sensor (Figure 2. but do not remove valve (Figure 2.TM 5-3805-294-10 0086 DRAIN FUEL FILTER/WATER SEPARATORS . Drain Fuel Filter/Water Separators Continued. 3. 3 1 2 HYEX00073 Figure 1. 2. Table 1. Lift lever (Figure 1. Item 4) from air cleaner housing (Figure 2. Item 2) from air cleaner housing (Figure 1. Item 15) Equipment Condition Engine off. Remove cover (Figure 1. Item 1) and rotate cover (Figure 1.4 Hour(s) REMOVAL 1. Wiping (WP 0097. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. 0087-1 .TM 5-3805-294-10 0087 OPERATOR MAINTENANCE PRIMARY AND SECONDARY AIR CLEANER SERVICE INITIAL SETUP: Materials/Parts Rag. Cover Removal. Item 3). Item 3). Remove primary air cleaner (Figure 2. Item 2) counterclockwise. Continued 3 4 HYEX00074 Figure 2.TM 5-3805-294-10 0087 REMOVAL . Item 5) from air cleaner housing (Figure 3. END OF TASK 0087-2 . Item 3). Primary Air Cleaner Removal. Remove secondary air cleaner (Figure 3. 4. Secondary Air Cleaner Removal. 5 3 HYEX00075 Figure 3. TM 5-3805-294-10 0087 SERVICING AIR CLEANERS WARNING Particles blown by compressed air are hazardous. Work around and inward of primary air cleaner (Figure 4. 2. 4. Always wear safety glasses when using compressed air. Ensure air stream is directed away from user and any personnel in the area. • Secondary air cleaner does not require servicing. Use a maximum of 30 psi (2. Item 4) to remove major amount of dirt from primary air cleaner. Primary Air Cleaner Service. Failure to comply may result in injury or death to personnel. top of primary air cleaner (Figure 4. 4 HYEX00076 Figure 4. only replacement.0 bar) when compressed air is used to clean parts. Lightly tap primary air cleaner (Figure 4. 3. blow remainder of debris out of primary air cleaner. Item 4). Item 4) until primary air cleaner has been completely blown out. 1. Start from inside. 0087-3 . NOTE • Contact field level maintenance for an air hose and air nozzle to service the air cleaner. Item 3) with a clean rag. Wipe out air cleaner housing (Figure 5. 0087-4 . Item 6) to remove dust. Cover and Dust Boot Service. Item 3). Item 5) to air cleaner housing (Figure 7.Continued 3 HYEX00077 Figure 5. Item 2) with a clean rag and squeeze dust boot (Figure 6. 2 HYEX00078 6 Figure 6. Air Cleaner Housing Service. 1. END OF TASK INSTALLATION NOTE Dust valve will be at the 6 O'clock position when air cleaner cover is installed. 5.TM 5-3805-294-10 0087 SERVICING AIR CLEANERS . Install secondary air cleaner (Figure 7. Wipe inside of cover (Figure 6. Install primary air cleaner (Figure 8. Item 4) to air cleaner housing (Figure 8.Continued 3 5 HYEX00084 Figure 7. 3 4 HYEX00074 Figure 8. Item 2) on air cleaner housing (Figure 9. 3. 2. Primary Air Cleaner Installation. Item 3). Secondary Air Cleaner Installation. 0087-5 . Position cover (Figure 9. Item 3).TM 5-3805-294-10 0087 INSTALLATION . Item 2) clockwise until lever (Figure 9. Rotate cover (Figure 9. Item 1) locks. Cover Installation. END OF TASK END OF WORK PACKAGE 0087-6 .Continued 3 2 1 HYEX00083 Figure 9. 4.TM 5-3805-294-10 0087 INSTALLATION . Remove four screws (Figure 1. Item 16) References LO 5-3805-294-13 (WP 0094) Equipment Condition Machine safely parked and shut down. 2. Press button (Figure 1. Failure to comply may result in injury or death to personnel. Wear eye protection and gloves to prevent injury. Allen 5 mm (0. Table 2. 1. 0088-1 .196 in. Engine (WP 0097. Always allow hydraulic oil to cool and relieve pressure in hydraulic reservoir before working on hydraulic system. Item 13) Time to Complete 0. Item 1) to relieve pressure from hydraulic reservoir (Figure 1. Item 3) and hydraulic reservoir cover (Figure 1. 1 3 4 2 HYEX00085 Figure 1. Table 1. Open lines and hoses slowly and wait for any residual pressure to relieve before continuing to open lines and hoses. Item 4) from hydraulic reservoir (Figure 1. Hydraulic Reservoir Cover Removal. (WP 0009) Materials/Parts Lubricating Oil. Item 2).) (WP 0095. Item 2).TM 5-3805-294-10 0088 OPERATOR MAINTENANCE HYDRAULIC RESERVOIR SERVICE INITIAL SETUP: Tools and Special Tools Wrench.4 Hour(s) Personnel Required Horizontal Construction Engineer 12N (1) FILLING HYDRAULIC RESERVOIR WARNING Hydraulic system operates at high pressures and temperatures. LO 5-3805-294-13 (WP 0094) 5 2 6 HYEX00086 Figure 2.TM 5-3805-294-10 0088 FILLING HYDRAULIC RESERVOIR . Item 6). Hydraulic Reservoir Sight Glass. Ensure O-ring (Figure 3. If O-ring is missing or damaged. Item 7) is present and is not damaged. Fill hydraulic reservoir (Figure 2. 0088-2 . 4. Item 5) on sight glass (Figure 2.Continued WARNING LUBRICATING OIL 3. notify field maintenance. Item 2) until oil is between marks (Figure 2. Item 4) to hydraulic reservoir (Figure 3. Hydraulic Reservoir Cover Installation. 5. END OF TASK END OF WORK PACKAGE 0088-3/4 blank .TM 5-3805-294-10 0088 FILLING HYDRAULIC RESERVOIR . Item 2) with four screws (Figure 3.Continued 4 3 7 2 HYEX00087 Figure 3. Item 3). Install hydraulic reservoir cover (Figure 3. . Item 2). (WP 0009) Materials/Parts Rag.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. Wiping (WP 0097. Inspect seal (Figure 2. 2. 1 1 3 Figure 1. Table 1. Move two tabs (Figure 1. Item 1) inward and remove filter (Figure 1. 1. Item 3). Item 15) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. it must be replaced by Field Maintenance. 0089-1 2 HYEX00168 . Item 4) on filter (Figure 2. Filter Removal. Item 2) from housing (Figure 1.TM 5-3805-294-10 0089 OPERATOR MAINTENANCE FRESH AIR FILTER SERVICE INITIAL SETUP: Equipment Condition Machine safely parked and shut down. 3. HYEX00169 Inspect Seal. NOTE • Contact field level maintenance for an air hose and air nozzle to service the air filter. Use a maximum of 30 psi (2. 1. contact field maintenance. Item 2) with hand. refer to and use procedure found in TM 5-3805-295-13&P. 0089-2 .TM 5-3805-294-10 0089 REMOVAL . Failure to comply may result in injury or death to personnel.0 bar) when compressed air is used to clean parts. If seal (Figure 2. Always wear safety glasses when using compressed air. • If HYEX is equipped with a Supplemental Armor Set. Item 4) is damaged.Continued 4 2 Figure 2. Lightly tap filter (Figure 3. Ensure air stream is directed away from user and any personnel in the area. END OF TASK SERVICE WARNING Particles blown by compressed air are hazardous. Clean Housing. CAUTION Always blow compressed air from the inside to the outside of the air cleaner when servicing. Item 2). Item 3) with clean rag. Failure to comply may result in damage to equipment.TM 5-3805-294-10 0089 SERVICE . Clean Filter.Continued 2 HYEX00170 Figure 3. Blow remainder of debris from filter (Figure 3. Blowing compressed air from the outside to the inside could damage the air cleaner. Wipe inside of housing (Figure 4. 3 HYEX00171 Figure 4. END OF TASK 0089-3 . 3. 2. Ensure tabs (Figure 5. Install filter (Figure 5. Item 3). 2. 1 1 3 Figure 5. Item 1) lock. Filter Installation. Item 2) to housing (Figure 5. END OF TASK END OF WORK PACKAGE 0089-4 2 HYEX00168 .TM 5-3805-294-10 0089 INSTALLATION 1. 3 1 HYEX00187 Filter Removal. 0090-1 . 1. Item 3). Item 2) with hand.2 Hour(s) REMOVAL NOTE After air conditioner/heater has been serviced three times it must be replaced by Field Maintenance. 2 Figure 1. Table 1. Check tab (Figure 1. 2. 1. Item 1) inward and remove filter (Figure 1. Wiping (WP 0097.TM 5-3805-294-10 0090 OPERATOR MAINTENANCE AIR CONDITIONER/HEATER FILTER SERVICE INITIAL SETUP: Materials/Parts Rag. Lightly tap filter (Figure 2. Item 2) from housing (Figure 1. Item 15) Equipment Condition Engine OFF. Item 1) on filter (Figure 1. Move tab (Figure 1. Item 2) and replace filter if tab broken. (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. END OF TASK SERVICE NOTE Contact Field level maintenance for an air hose and air nozzle to service the air cleaner. WARNING Particles blown by compressed air are hazardous. 2. Wipe inside of housing (Figure 3. 0090-2 . Item 2). 3. CAUTION Always blow compressed air from the inside to the outside of the air cleaner when servicing. Item 3) with clean rag. Blow remainder of debris from filter (Figure 2. Clean Filter. Blowing compressed air from the outside to the inside could damage the air cleaner. Use a maximum of 30 psi (2.TM 5-3805-294-10 0090 SERVICE .Continued HYEX00188 2 Figure 2. Failure to comply may result in damage to equipment. Ensure air stream is directed away from user and any personnel in the area.0 bar) when compressed air is used to clean parts. Failure to comply may result in injury or death to personnel. Always wear safety glasses when using compressed air. Install filter (Figure 4. Filter Installation. Clean Housing. Item 2) to housing (Figure 4. 2. 2 Figure 4.Continued HYEX00190 3 Figure 3. Ensure tab (Figure 4. END OF TASK END OF WORK PACKAGE 0090-3/4 blank 3 1 HYEX00187 .TM 5-3805-294-10 0090 SERVICE . Item 3). END OF TASK INSTALLATION 1. Item 1) locks. . Item 1). 2.TM 5-3805-294-10 0091 OPERATOR MAINTENANCE DRAINING WATER AND SEDIMENT FROM FUEL TANK INITIAL SETUP: Tools and Special Tools Pan. 1. 0091-1 . Remove Fuel Cap. Position drain pan under drain hose (Figure 2. Item 2). Drain Equipment Condition Machine safely parked and shut down (WP 0009) Materials/Parts Rags. Remove fuel tank fill cap (Figure 1. 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. Wiping (WP 0097. 1 HYEX01298 Figure 1. Drain Hose. 3. Item 3) and drain water and sediment until a clear stream of fuel comes out.Continued 2 HYEX00914 Figure 2. Open drain valve (Figure 3. 0091-2 .TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT . 4. Dispose of waste properly.Continued 3 HYEX00915 Figure 3. Item 3). Item 1). Close drain valve (Figure 3. 5. 6. Drain Valve. Install fuel tank fill cap (Figure 4. 0091-3 .TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT . Continued 1 HYEX01298 Figure 4. END OF TASK END OF WORK PACKAGE 0091-4 . Install Fuel Cap.TM 5-3805-294-10 0091 DRAINING WATER AND SEDIMENT . • There are two adjustment points for lower curtain. Table 2. • Repeat steps for opposite side. pilot shutoff lever in the up position. • There are no disassembly requirements to perform discharge adjustments. increase discharge size. Loosen nut (Figure 1. and engine shut off. • To reduce dust. NOTE • Ensure curtain is set to desired discharge size before Crush-All operation. perform all maintenance procedures with all attachments lowered to the ground. Item 3). 1.3 Hour(s) References DA FORM 5988-E or DA FORM 2404 (WP 0094) DISCHARGE ADJUSTMENT WARNING Unless otherwise specified. Adjustment procedure is identical for both points and must be adjusted at same time. Failure to comply may result in injury or death to personnel. • Raise curtain to increase discharge size. • Lower curtain to decrease discharge size. Item 2) and rod (Figure 1. Item 15) Equipment Condition Machine safely parked and shut down (WP 0009) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. Adjustment points are on the outside of the machine. 0092-1 0092 . Item 1) on nut (Figure 1.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. Turn nut (Figure 2. 5. lockwasher (Figure 1. 9 10 11 4 2 1 HYEX03092 Figure 1. 6. Remove clamp (Figure 1. Item 8). Item 3). Item 11). Item 4). Item 5) on nut (Figure 1. 4.TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT . Item 6) and rod (Figure 1. Using wrench provided with crush-all loosen nut (Figure 1. 8. 0092-2 . Item 11). Curtain Adjustment. Item 3) to release tension from spring (Figure 1. Item 10) and plate (Figure 1. Item 10) from nut (Figure 1. 3. 2. Item 9) from clamp (Figure 1.Continued 3 5 6 7. Item 12). Remove bolt (Figure 1. Item 7). and washer (Figure 1. Loosen nut (Figure 1. Item 6) to raise or lower curtain (Figure 2. Item 2) on rod (Figure 1. Item 6) and plate (Figure 1. Item 12) does not touch rotor (Figure 2.TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT . Item 13) manually. Item 10) on nut (Figure 3. Verify curtain (Figure 2. Item 6) and plate (Figure 3. CAUTION Ensure surface of blow bar does not touch curtain. Position clamp (Figure 3. Item 11). Turn rotor (Figure 2. 0092-3 . 8. Failure to comply may result in damage to equipment. Clearance Check.Continued 6 12 14 13 HYEX03093 Figure 2. Item 13) or blow bars (Figure 2. Item 14). 7. Item 16). 10. Clamp Installation.Continued 3 5 6 11 7. Item 4) to align marks (Figure 4. Item 11) with bolt (Figure 3. Item 2) and compress spring (Figure 4. Tighten nut (Figure 4. 8. Item 3). Item 9). Item 7). 0092-4 . Item 5) against nut (Figure 3. lockwasher (Figure 3. 9 10 HYEX03094 Figure 3.TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT . Install clamp (Figure 3. 9. Using wrench provided with crush-all tighten nut (Figure 3. Item 6) on rod (Figure 3. Item 10) on plate (Figure 3. 11. and washer (Figure 3. Item 15) and (Figure 4. Item 8). Item 2) on rod (Figure 4.TM 5-3805-294-10 0092 DISCHARGE ADJUSTMENT . Item 1) against nut (Figure 4. END OF TASK END OF WORK PACKAGE 0092-5/6 blank .Continued 3 4 16 15 2 1 HYEX03095 Figure 4. Spring Compression. Item 3). Tighten nut (Figure 4. 12. . Item 5) with two bolts (Figure 1. 3. 2 3. Remove cover (Figure 1. 4 5 HYEX03286 Figure 1. Item 2). Item 3) and gasket (Figure 1. 4. Table 2. Item 4) to machine (Figure 1. Item 4) Wrench 17 mm (WP 0095. Automotive and Artillery (WP 0097. Item 3) and gasket (Figure 1.TM 5-3805-294-10 0093 OPERATOR MAINTENANCE MAINTENANCE AFTER FORDING INITIAL SETUP: Tools and Special Tools Grease Gun (WP 0095. Item 4) from machine (Figure 1. Remove two bolts (Figure 1. 1. Item 17) References LO 5-3805-294-13 (WP 0094) DA FORM 5988-E or DA FORM 2404 (WP 0094) Materials/Parts Grease. Install cover (Figure 1. Item 1) and washers (Figure 1. Table 2. Item 10) Equipment Condition Machine safely parked and shut down. Item 3). Item 5) and allow mud or water to completely drain. (WP 0094) Personnel Required Horizontal Construction Engineer 12N (1) Time to Complete 0. Table 1. Item 1) and washers (Figure 1. 0093-1 . Item 2) from cover (Figure 1. Remove any contaminated grease.5 Hour(s) DRAINING MUD OR WATER 1. Draining Mud or Water. 2. If grease was removed.Continued 5. notify field level maintenance to service swing gear and swing bearing.TM 5-3805-294-10 DRAINING MUD OR WATER . 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 . . Biological. Radiological. and Nuclear Decontamination FM 3-97. 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.TM 5-3805-294-10 0094 OPERATOR MAINTENANCE REFERENCES SCOPE This work package lists all field manuals.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 . technical manuals. forms. and miscellaneous publications referenced in this manual.5 Chemical.6 Mountain Operations FM 4-25. and Camouflage Painting of Military Vehicles. Construction Equipment. Marking. 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 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. Heavy Equipment TM 21-40 Chemical. Transporter.TM 5-3805-294-10 0094 TECHNICAL MANUALS .Continued TM 9-2330-381-13 Operator and Field Maintenance Manual for the Semitrailer. 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 . 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. . General The COEI and BII information is divided into the following lists: Components of End Item (COEI). Illustrations are furnished to help you find and identify the items. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Listing these items is your authority to request/ requisition them for replacement based on authorization of the end item by the TOE/MTOE. When applicable. Column (5) U/I. Part Number/(CAGEC). Column (3) Description. Illustrations are furnished to help you find and identify the items. Column (2) National Stock Number (NSN) and Illustration. 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). These items are part of the HYEX. Column (6) Qty Rqr. These essential items are required to place the (HYEX) in operation. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Explanation of Columns in the COEI List and BII List Column (1) Item Number. This list is for information purposes only and is not authority to requisition replacements. and to do emergency repairs.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. Column (4) Usable On Code. Gives you the reference number of the item listed. these items must be with the end item whenever it is issued or transferred between property accounts. 0095-1 . Identifies the Federal item name (in initial capital letters) followed by a minimum description when needed. Basic Issue Items (BII). There are no usable on codes for this equipment. BII must be with the Hydraulic Excavator during operation and when it is transferred between property accounts. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). As part of the end item. operate it. Indicates the quantity required. gives you a code if the item you need is not the same for different models of equipment. Although shipped separately packaged. TM 5-3805-294-10 Table 1. 42 in. 0095 COMPONENTS OF END ITEM (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION. 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 . 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. 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 1. PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Bag. Lever Action. 0095 BASIC ISSUE ITEMS (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION.Approved for public release. Mason 204900 (3PSD7) EA 1 Cap 811438500 (1BVQ2) EA 4 Cap. 3 lb (1. Hand. DEPARTMENT OF THE ARMY XXXX XXXX HYEX01339 7 HYEX03290 8 HYEX03291 0095-4 . -12 205324(1BVQ2) EA 4 Plug.36 kg) B3-3LB(72987) EA 1 Operator's Manual TM 5-3805-294-10 EA 1 Plug. (304. HEADQUARTERS.8 mm) 7Y26518 (3PSD7) EA 1 Hammer. Pin U42984 (3PSD7) EA 4 Gun. Grease. Hex 37 Degree Flare. 12 in. -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: .TM 5-3805-294-10 Table 2. distribution is unlimited. Hex 37 Degree Flare. (305 mm) Long B107. PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Punch. (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 . 12 in. Open End. 0095 BASIC ISSUE ITEMS .Continued (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION. Measuring 25 FT 68-445 (08292) EA 1 Screwdriver. Pry Bar.TM 5-3805-294-10 Table 2. Drift 70-195(08292) EA 1 Tape. Surface Ripping TX400 (1J955) EA 5 Vice Grips 67-460 (08292) EA 1 Wrench.60 (05047) EA 1 Tooth. 3 in. ) B18.95 in. PART NUMBER/(CAGEC) USABLE ON CODE U/I QTY RQR Wrench. Open End.2M (05047) EA 1 Wrench. 0095 BASIC ISSUE ITEMS . 15 in.196 in. 5 mm (0. Allen. Open End. 24 mm 52-224 (08292) EA 1 Wrench. Adjustable. 17 mm 52-217 (08292) EA 1 Wrench. Open End. 0.01-581-3318 HYEX01356 19 5120-00-240-5328 HYEX01343 END OF WORK PACKAGE 0095-6 . Open End. 2 1/2 in.Continued (1) (2) (3) (4) (5) (6) ITEM NUMBER NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION DESCRIPTION.3.TM 5-3805-294-10 Table 2. (63. (24 mm) Jaw Opening.5 mm) AT189507 (75755) EA 2 Wrench. (381 mm) Long 11655778-3 (19207) EA 1 15 HYEX01345 16 5120-01-045-4889 HYEX01344 17 HYEX01356 18 5120 . (1) (2) (3) (4) (5) NATIONAL STOCK NUMBER (NSN) DESCRIPTION.Description.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 (4) . Column (5) . Column (3) . or JTA. Column (2) . GENERAL This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it.Usable On Code. PART NUMBER/ (CAGEC) USABLE ON CODE U/I QTY RECOM EA 1 Compactor IHC 00130FT (1N0L6) END OF WORK PACKAGE 0096-1/2 blank . Identifies the stock number of the item to be used for requisitioning purposes. Part Number/(CAGEC). When applicable. Indicates the quantity recommended.Quantity Recommended (Qty Recom). These items are all authorized to you by CTA. gives you a code if the item you need is not the same for different models of equipment. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).National Stock Number (NSN). Additional Authorization List. Table 1. Identifies the Federal item name (in Initial capital letters) followed by a minimum description when needed. MTOE. Explanation of Columns in the AAL Column (1) .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). TDA. . • C -. Permanent.Level This column identifies the lowest level of maintenance that requires the listed item. and Part Number (P/N) This column provides the other information you need to identify the item. Expendable and Durable Items List (1) (2) (3) (4) (5) ITEM NO. Explanation of Columns in the Expandable/Durable Items List Column (1) .Depot Column (3) . Type: Arctic Grade 55-Gallon Drum A-A-52624 (58536) 0097-1 DR . Commercial and Government Entity Code (CAGEC).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). Expendable/Durable Items (Except Medical. PART NUMBER/ (CAGEC) U/I 1 C 6850-01-441-3248 Antifreeze.Field • H -. This list is for information only and is not authority to requisition the listed items. such as gallon. Field and Garrison Furnishings and Equipment or CTA 8-100.National Stock Number (NSN) This is the NSN assigned to the item which you can use to requisition it. and Heraldic Items). CTA 50-909. Table 1. Column (2) .Below Depot • D -. These items are authorized to you by CTA 50-970.Operator/Crew • F -.Unit of Issue (U/I) Unit of Issue (U/I) code shows the physical measurement or count of an item. etc. gross. Description. LEVEL NATIONAL STOCK NUMBER (NSN) ITEM NAME. dozen. Class V Repair Parts. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).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. Army Medical Department Expendable/Durable Items. Column (5) . DESCRIPTION. Column (4) Item Name. 8 oz Can L3 (77628) CN 15 C 7920-00-148-9666 Rag. Engine OE/HDO 15W-40 1-qt Can MIL-PRF-2104 (81349) QT 14 C 9150-00-973-9504 Penetrating Oil Can. DESCRIPTION. Oil Sample M44054 TYPE III (81349) BX 4 C 6850-00-926-2275 Cleaning Compound. Winter Bulk W-F-800 (81348) GL 9 C 9140-00-286-5286 Fuel.TM 5-3805-294-10 Table 1. Inhibited 5Gallon Can A-A-52624 (58536) CO 3 C 8125-01-193-3440 Bottle. Wiping 7920-00-148-9666 (80244) BE END OF WORK PACKAGE 0097-2 . OEA Ice. DF-1. PART NUMBER/ (CAGEC) U/I 2 C 6850-01-441-3257 Antifreeze. DF-2. Windshield 1-pt Can 0854-000 (0FTT5) BX 5 C 9130-01-031-5816 Fuel. DF-1. Subzero 5-gal Can MIL-PRF-46170 (81349) GL 13 C 9150-01-438-6076 Lubricating Oil. 0097 Expendable and Durable Items List . GAA 2-1/4-oz Tube M-10924-A (81349) TU 11 C 9150-00-111-6256 Lubricating Oil.Continued (1) (2) (3) (4) (5) ITEM NO. Winter Bulk AA52557-1 (58536) GL 10 C 9150-01-197-7688 Grease. DF-2. Permanent. Regular Bulk ASTM D 975 (58536) GL 8 C 9140-01-412-1311 Fuel. Ethylene Glycol. Subzero 1-qt Can MIL-PRF-46170 (81349) QT 12 C 9150-00-111-6255 Lubricating Oil. LEVEL NATIONAL STOCK NUMBER (NSN) ITEM NAME. OEA Ice. Regular Bulk W-F-800 (81348) GL 7 C 9140-00-286-5294 Fuel. JP8 Bulk MILT83133 GR JP8 (81349) GL 6 C 9140-01-413-7511 Fuel. Automotive and Artillery. TROUBLESHOOTING PROCEDURES FOR SPKS To find troubleshooting procedures for the SPK items. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Installing and Operating the Compactor and Breaker (WP 0020). As part of the end item. 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. go to the Troubleshooting Index (WP 0037). Column (2) National Stock Number (NSN) and Illustration. these items must be with the end item whenever it is issued or transferred between property accounts. Column (6) QTY RQD. When applicable. To operate the Deep Dig Arm. go to Selecting an Attachment On the Monitor (WP 0018). OPERATION INSTRUCTIONS FOR SPKS For instructions on how to select the SPKs on the operators monitor. Indicates the quantity required. Illustrations are furnished to help you find and identify the items. Column (3) Description. Gives you the reference number of the item listed. but they are removed and separately packaged for transportation or shipment.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. 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). go to Operating the Deep Dig Arm (WP 0023). EXPLANATION OF COLUMNS IN TABLE 1 Column (1) Item Number. or Installing and Operating the Crush-All (WP 0019). 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). The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX Type 1 by Field Maintenance. Where to find operation instructions and troubleshooting procedures for the SPKs are also provided. These items are part of the HYEX Type 1. Part Number/(CAGEC). Column (5) U/I. There are no usable on codes for this equipment. gives you a code if the item you need is not the same for different models of equipment. To operate the SPKs go to Operating the Barrier Grapple (WP 0022). 0098-1 . Column (4) Usable On Code. Continued SPECIAL PURPOSE KITS Table 1. (1) ITEM NO. Impact 205146 (1BVQ2) EA 1 Counterweight 305156 (1BVQ2) EA 1 HYEX02525 2 HYEX02522 3 3830-01-585-2734 HYEX02520 4 HYEX02526 0098-2 . Long Reach 502113 (1BVQ2) EA 1 Barrier Grapple KL16000-1 (1V7ZO) EA 1 Breaker. (3) DESCRIPTION.TM 5-3805-294-10 0098 SCOPE . (2) NATIONAL STOCK NUMBER 1 Special Purpose Kits. PART NUMBER/(CAGEC) (4) USABLE ON CODE (5) U/I (6) QTY RQD Arm. Scoop Loader (Deep Dig) 70G0002 (3PSD7) EA 1 HYEX02521 6 HYEX02523 7 HYEX02524 END OF WORK PACKAGE 0098-3/4 blank .Continued. Crush-All 502063 (1BVQ2) EA 1 Excavator Bucket (Deep Dig) 70G0001 (3PSD7) EA 1 Bucket. 5 Special Purpose Kits .TM 5-3805-294-10 0098 SCOPE .Continued Table 1. . unit. The troubleshooting symptom index lists possible malfunctions that may be experienced during operation of machine or components. or system is followed by a list of tests or inspections and corrective actions. refer to Operator Preventive Maintenance Checks and Services. nor can it include all tests. or add oil appear in the troubleshooting table. Lubrication. When instructions to lubricate. Notify field maintenance personnel if a malfunction is not listed. grease. (WP 0077) END OF WORK PACKAGE 0099-1/2 blank . Procedures. oil. Each malfunction for an individual component. unless a malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed. and corrective actions.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. inspections. This manual cannot list all possible malfunctions that may occur. . C-5. The HYEX counterweight is used to shift CG to the rear. Gross Vehicle Weight (GVW). Additional information on transport procedures can be found in: 1. The Military Load Classifications (MLC) for the HYEX are as follows: 1. TB 9-2300-281-35. the GVW equals the CW. all system fluids. 2. Center of Gravity (CG). For transport purposes. is less than one percent of the gross vehicle weight. Technical terms that may be helpful while preparing the HYEX for transportation are: 1. The balance point of a suspended item. Military Load Classification. HYEX Armored Cab System . Therefore.MLC 34 HYEX03197 Figure 1. which in this case. 3. TRANSPORTABILITY RELATED PUBLICATIONS. 2.TM 5-3805-294-10 0100 OPERATOR MAINTENANCE HYEX TRANSPORTABILITY INSTRUCTIONS HYEX TRANSPORTABILITY INSTRUCTIONS. HYEX Standard Cab System . and C-17 air transport and meets all weight and dimensional requirements while in its standard configuration with no reduction or sectionalization required. CW plus payload. Total weight of operational HYEX including fuel. and on-vehicle Basic Issue Items (BII). Curb Weight (CW).MLC 32 2. TM 38-250/AFR 71-4. Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles WP 0094. The HYEX can be transported via highway. 0100-1 . Preparation of Hazardous Materials for Military Air Shipment WP 0094. marine. there is no payload. CW does not include crew weight. MILITARY LOAD CLASSIFICATION. TRANSPORTABILITY RELATED DEFINITIONS. rail. 15 M] 11 FT. HYEX with Standard Cab shipping weight.39 M] 10 FT. HYEX can normally be transported over the road with any of the standard buckets attached. HYEX is transportable on common military trailers. • The unit transportation officer must contact local authorities to ensure the HYEX is not required to have special permits prior to highway transporting. NOTE • The HYEX is self-propelled at speeds up to 3. HYEX MARINE TRANSPORTABILITY. On deck storage is permissible with some protection for cylinder rods. 4 IN. Attaching the Crush-All for shipment may cause the HYEX to exceed the 13 feet 6 inches transport height requirement. [3. the HYEX will have to be subjected to restrictive routes for rail movements. HYEX RAIL TRANSPORTABILITY. The HYEX can be shipped as roll-on/roll-off. without bucket or attachment = 58. The HYEX may easily be rail transported via routes subjected to DOD clearance diagrams. 1 IN. HYEX can be transported via rail with any of the standard buckets attached. The HYEX height of 10 feet 1 inch allows the sea shipment within the LASH lighter. The HYEX is outfitted with a hydraulic quick latch for rapid exchange of attachments.000 lbs HYEX HIGHWAY TRANSPORTABILITY. especially the M870A1 and M870A3. LASH. 0100-2 . [10. 33 FT.900 lbs 2.4 mph. HYEX Dimensions. Due to the 30 inch track shoe requirement. 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.07 M] HYEX01365 Figure 2. [3. 1.TM 5-3805-294-10 0100 HYEX SHIPPING WEIGHT. 1 IN. water-way barge. or boat. SEABEE. HYEX with Armored Cab shipping weight without bucket or attachment = 63. Ultimate design factor 5:1 0100-3 .5 IN. a. The following values are the HYEX Design Load Capabilities: 1. HYEX Transportation Data Plate. HYEX Transportation Data Plate shows location of the lifting points. and machine center of gravity (CG). Vertical = 124. each shackle b.250 lbs b. Longitudinal = 92.] HYEX03192 Figure 3. Longitudinal = 110.TM 5-3805-294-10 0100 HYEX LIFTING AND TIE DOWN PROVISIONS. TieDown Provisions 1 and 2.000 lbs.250 lbs b. tie down points. a. NO.7 IN. Rated design limit = 60. Lift Provisions.000 LB. TRANSPORTATION DATA GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD - 60. OF SLINGS REQUIRED LENGTH OF SLINGS 4 12 FT. Vertical = 110. - EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS SWING CENTERLINE 44 MM [1.200 lbs 2.250 lbs 3.] CENTER OF GRAVITY 1212 MM [47. Tie Down Provisions 3 and 4. a. Tie Down 2 26 in. Provision QTY Location (Relative to CG) 1 . 4 .Tie Down 2 39 in. below 7 in. below 15 in.TM 5-3805-294-10 0100 HYEX LIFTING AND TIE DOWN PROVISIONS .Tie Down 2 43 in. Lift Points 4 120 in. aft 5 in. aft 30 in. Table 1. forward 25 in. HYEX Lift and Tie Down Information. forward 30 in. 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. below 56 in. below 56 in. 3 .Tie Down 2 30 in. aft 25 in. 2 . 0100-4 Lateral . below 7 in.Continued. HYEX Lifting and Tie Down Points. 6 IN. M870 Loading. The front view shows the HYEX is at or below the maximum height restriction for highway transport. HEIGHT CLEARANCE LINE M870 TRAILER SECTION A-A HYDRAULIC EXCAVATOR. The top view also shows a possible M870 tie down configuration. 1 FOOT EXTENSION BOTH SIDES A A 13 FT.TM 5-3805-294-10 0100 HIGHWAY: Figure (5) shows the HYEX on an M870 semi trailer. 0100-5 HYEX03073 . TYPE I JOHN DEERE MODEL 240D LCR Figure 5. CRAWLER MOUNTED. HEIGHT CLEARANCE LINE M870A1 TRAILER SECTION A-A HYDRAULIC EXCAVATOR.Continued Figure (6) shows the HYEX on an M870A1 semi trailer. 1 FOOT EXTENSION BOTH SIDES A A 13 FT. 0100-6 HYEX03072 . CRAWLER MOUNTED. M870A1 Loading.TM 5-3805-294-10 0100 HIGHWAY: . TYPE I JOHN DEERE MODEL 250D LCR Figure 6. The front view shows the HYEX is at or below the maximum height restriction for highway transport. 6 IN. The top view also shows a possible M870A1 tie down configuration. HEIGHT CLEARANCE LINE M870A3 TRAILER SECTION A-A HYDRAULIC EXCAVATOR. 6 IN. M870A3 Loading. CRAWLER MOUNTED.Continued Figure (7) shows the HYEX on an M870A3 semi trailer. The front view shows the HYEX is at or below the maximum height restriction for highway transport. The top view also shows a possible M870A3 tie down configuration. A A 13 FT. TYPE I JOHN DEERE MODEL 240D LCR Figure 7.TM 5-3805-294-10 0100 HIGHWAY: . 0100-7 HYEX03069 . The armored HYEX has the same exterior dimensions as the standard cab model. and (10) show the HYEX modeled in various rail envelopes. which require the HYEX to have special rail routing. 0100-8 .TM 5-3805-294-10 0100 RAIL: HYEX is equipped with 30 inch track shoes. (9). Figures (8).4 INCH HIGH RAILCAR GIC RAIL CLEARANCE WITH STANDARD CAB HYEX03078 Figure 8. so the armored cab version was not shown in the GIC envelope. HYEX RAIL DIAGRAM 51. GIC Rail Clearance. The HYEX requires special routing for rail systems requiring the GIC dimensions. 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: . 0100-10 . HTTX Railcar Loading Overhead View. Armored Cab Clearance. HYEX01370 Figure 11.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. Figures (11) and (12) show the proposed HYEX tie down configurations on the HTTX railcar. Continued HYEX01371 Figure 12. HTTX Railcar Loading Side View.TM 5-3805-294-10 0100 RAIL: .4mm (6 inches) ABOVE GROUND PLANE Figure 13. both standard and armored cab. inside the C-5 aircraft design envelope. HYEX DIAGRAMS INSIDE C-5 AIRCRAFT STANDARD CAB ARMORED CAB LOAD RAMP CLEARANCE GROUND PLANE BOOM RAISED 152. BOOM RAISED 152. Designing for Internal Aerial Delivery in Fixed Winged Aircraft (WP 0094) for transport on C-17 and C-5 aircraft. 0100-11 . Figure (13) shows model of the HYEX. The model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft. AIR: The HYEX meets the requirements of MIL-HDBK-1791.4mm (6 inches) ABOVE GROUND PLANE HYEX03066 C-5 Aircraft Loading. HYEX DIAGRAMS INSIDE C-17 AIRCRAFT STANDARD CAB ARMORED CAB LOAD RAMP CLEARANCE LOAD RAMP CLEARANCE GROUND PLANE BOOM RAISED 152. HYEX01372 Figure 15. and the stow location of a given ship. Generally. Belowdeck locations that are closer to the vessel’s center of gravity and rotation will experience less severe motion. the expected sea state to be encountered.4mm (6 inches) ABOVE GROUND PLANE HYEX03065 Figure 14. The most severe conditions will occur on exposed "weather decks.4mm (6 inches) ABOVE GROUND PLANE BOOM RAISED 152. The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft. Marine Loading. MARINE: Marine tie-down restraint depends on the size of the ship (decreasing on larger vessels). 0100-12 . C-17 Aircraft Loading.Continued Figure (14) shows model of the HYEX. the restraint required will increase for locations high and forward (or aft) in the ship.TM 5-3805-294-10 0100 AIR: . both standard and armored cab." where strong wind and wet conditions add to the problem. A ship’s crew may require additional lashing on exposed decks. inside the C-17 aircraft design envelope. The HYEX attachments can be directly chained down to railcar/trailer for transport. All HYEX attachments have lifting and tie-down provisions included for ease in preparing for transport. Plate Compactor = 2.200 lb (998 kg) 7.TM 5-3805-294-10 0100 HYEX STANDARD BUCKET AND SPECIAL PURPOSE KITS (SPK) TRANSPORTABILITY. Deep Dig Arm = 3. Figure (16) shows the Standard Rock Bucket lifting and tie-down provisions. 0100-13 . Crush-All = 7. 42 in. Impact Breaker = 4.000 lb (1361 kg) 2. Barrier Grapple = 870 lb (395 kg) 6. TIE DOWN PROVISIONS HYEX03083 Figure 16.337 lb (1060 kg) 3.450 lb (3379 kg) 5. Standard Rock Bucket.970 lb (2254 kg) 4. Standard Rock Bucket.440 lb (1560 kg) STANDARD BUCKET TIE DOWN PROVISIONS. The standard HYEX quick latch system enables ease in changing attachments. Standard Ditch Cleaning Bucket = 2. = 3. HYEX Attachments Weights are as follows: 1. 0100-14 . HIGHWAY: Figure (18) shows the Standard Buckets on an M870A1 semi trailer. Figure (17) shows the Standard Ditch Cleaning Bucket lifting and tie-down provisions. The top view also shows a possible M870A1 tie down configuration. HYEX03087 Standard Ditch Cleaning Bucket.TM 5-3805-294-10 0100 STANDARD BUCKET TIE DOWN PROVISIONS .Continued. TIE DOWN PROVISIONS Figure 17. HYEX STANDARD BUCKETS ON M870A3 TRAILER HYEX03068 Figure 19. The top view also shows a possible M870A3 tie down configuration. Figure (19) shows the Standard Buckets on an M870A3 semi trailer.Continued HYEX STANDARD BUCKETS ON M870A1 TRAILER HYEX03071 Figure 18.TM 5-3805-294-10 0100 HIGHWAY: . Standard Buckets Loaded On M870A1. 0100-15 . Standard Buckets Loaded On M870A3. Deep Dig Arm. 0100-16 . Figure (20) shows the Deep Dig Arm lifting and tie-down provisions. Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions.TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS. Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03089 Figure 20. HYEX03086 Deep Dig Bucket. TIE DOWN PROVISIONS Figure 21. 0100-17 . Deep Dig Ditch Cleaning Bucket. TIE DOWN PROVISIONS HYEX03085 Figure 22.Continued.TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS . TIE DOWN PROVISIONS HYEX03084 Figure 23. TIE DOWN PROVISIONS Figure 24. Compactor. 0100-18 HYEX03082 . Figure (24) shows the Compactor lifting and tie-down provisions.Continued.TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS . Crush-All. Figure (23) shows the Crush-All lifting and tie-down provisions. TIE DOWN PROVISIONS HYEX03147 Figure 26.Continued. TIE DOWN PROVISIONS Figure 25. 0100-19 . Figure (26) shows the Barrier Grapple lifting and tie-down provisions.TM 5-3805-294-10 0100 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS . HYEX03081 Impact Breaker. Barrier Grapple. Figure (25) shows the Impact Breaker lifting and tie-down provisions. Crush-All On M870A1. HYEX CRUSH-ALL ATTACHMENTS ON M870A1 TRAILER HYEX03070 Figure 27. The top view also shows possible M870A3 tie down configuration. Figure (27) shows the Crush-All loaded on M870A1 semi trailer. HYEX CRUSH-ALL ON M870A3 TRAILER HYEX03067 Figure 28. The top view also shows possible M870A1 tie down configuration. Figure (28) shows the Crush-All loaded on M870A3 semi trailer.TM 5-3805-294-10 0100 CRUSH-ALL TIE DOWNS FOR HIGHWAY TRANSPORT. Crush-All On M870A3. 0100-20 . HYEX CRUSH-ALL ATTACHMENT ON HTTX RAILCAR HYEX03076 Figure 30. Crush-All Loaded On HTTX Railcar. The top view also shows possible HTTX railcar tie down configurations.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. Standard Buckets Loaded On HTTX Railcar. BUCKETS ON HTTX RAILCAR HYEX03077 Figure 29. 0100-21 . HYEX DEEP DIG ATTACHMENTS ON HTTX RAILCAR HYEX03075 Figure 32.Continued. COMPACTOR. Deep Dig Arm and Buckets Loaded On HTTX Railcar. END OF WORK PACKAGE 0100-22 . Impact Breaker. AND BARRIER GRAPPLE ON HTTX RAILCAR HYEX03074 Figure 31. HYEX IMPACT BREAKER. and Barrier Grapple Loaded On HTTX Railcar.TM 5-3805-294-10 0100 TRANSPORTING ON RAIL . Compactor. ................. A ADDITIONAL AUTHORIZATION LIST (AAL)............................................................................ ENGINE OIL PRESSURE LOW................................................................... BUCKET TEETH REPLACEMENT.................... DESCRIPTION AND USE OF MONITOR AND ALARMS..................................................... ENGINE IDLES POORLY..... DRAINING WATER AND SEDIMENT FROM FUEL TANK......... EXPENDABLE AND DURABLE ITEMS LIST........................................................................................................................................................................................................................................................................................................ CRUSH-ALL DOES NOT OPERATE...... ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE..... DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........ WP 0027-1 WP 0074-1 WP 0005-1 WP 0004-1 WP 0091-1 E ENGINE COOLANT TEMPERATURE ABOVE NORMAL............................................................ WP 0073-1 WP 0041-1 WP 0070-1 WP 0071-1 WP 0085-1 C CAB DOME LIGHT DOES NOT OPERATE............................................................................ BREAKER DOES NOT OPERATE................................... ENGINE WILL NOT CRANK........... ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED....................................................................................................................................... ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE................................................ AND DRIVE LIGHTS DO NOT OPERATE................................ AIR CONDITIONER/HEATER FILTER SERVICE...................................................................................................................................................... DEEP DIG 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...................................... EXCESSIVE FUEL CONSUMPTION................ ENGINE CRANKS BUT DOES NOT START OR HARD TO START..................................................................................... CAB FUSE REPLACEMENT.... ENGINE RUNS POORLY................................................................................................................................................................................ WP 0096-1 WP 0006-1 WP 0045-1 WP 0090-1 WP 0052-1 B BARRIER GRAPPLE DOES NOT HOLD LOAD.TM 5-3805-294-10 INDEX Subject WP Sequence No................................................................................................ CAB REAR WORK LIGHTS DO NOT OPERATE...... EQUIPMENT DESCRIPTION AND DATA................................................................................................................................................ COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................................................................................................................................................................................................................ AUTO-IDLE DOES NOT WORK................................ AIR CONDITIONER DOES NOT OPERATE...................................................................................................................................... CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................... COMPACTOR DOES NOT OPERATE.......................... CAB......................................................................................................................................................... CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT......... BOOM....................... ENGINE NOT DEVELOPING FULL POWER.......-Page No........................................................................................... BREAKER OPERATES SLOWLY...................... 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 ............................................................................................................... ADJUSTING THE OPERATOR'S SEAT................... EXCESSIVE OIL CONSUMPTION.................... ........................................................... OPERATING TECHNIQUES................................................................................................... INSTALLING AND OPERATING THE CRUSH-ALL.................. FRESH AIR FILTER SERVICE............... GENERAL MAINTENANCE INSTRUCTIONS................................................................................................................. HYDRAULIC OIL OVERHEATS................................................................. GENERAL MONITOR OPERATION.............................................................................. INSTALLING AND OPERATING THE IMPACT BREAKER.............. F FORDING THE HYEX........................................................................................... 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..................................................................................... OPERATING THE COOLANT HEATER........... WP 0058-1 WP 0063-1 O OPENING AND CLOSING WINDOWS. MOVING UP/DOWN STEEP OR SLIPPERY SLOPES......... OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER ................................................................................................................................................................. HYDRAULIC RESERVOIR SERVICE....................................... OPERATING THE DEEP DIG ARM............................................................................ MOVING MACHINE ON/OFF AN EMBANKMENT................................................................................................................................................... HYEX TRANSPORTABILITY INSTRUCTIONS................ MOVING THE HYEX...................................................PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)............................................................... OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)................................. HYDRAULIC OIL FOAMS........................ WP 0093-1 WP 0024-1 WP 0008-1 WP 0035-1 N NO HYDRAULIC FUNCTIONS............................TM 5-3805-294-10 INDEX ..................................................................................................................................................................... WP 0015-1 WP 0082-1 WP 0044-1 WP 0029-1 M MAINTENANCE AFTER FORDING................................................................................................................................................................................................................................................................................................................. WP 0059-1 WP 0075-1 WP 0062-1 WP 0061-1 WP 0088-1 WP 0100-1 I INSTALLING AND OPERATING THE COMPACTOR.... LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE................................................................................................ OPERATING THE BARRIER GRAPPLE....................................................................... WP 0036-1 WP 0089-1 G GENERAL INFORMATION........................................................-Page No.................. WP 0021-1 WP 0019-1 WP 0020-1 WP 0076-1 L LIFTING WITH HYEX.................................................... LOOSENING TRACK TENSION................................. INTRODUCTION ....................... NO SWING FUNCTION........................................... Index-2 WP 0011-1 WP 0030-1 WP 0031-1 WP 0016-1 WP 0022-1 WP 0034-1 WP 0023-1 ...................................................................................................................Continued Subject WP Sequence No.......................................................................................................................................... LOWERING BOOM WITHOUT HYDRAULIC PRESSURE...................... ..............................................................TM 5-3805-294-10 INDEX ............................................................................................................................................................. STARTING THE ENGINE.................................................................................................................................................................................. SLAVE STARTING..................................... WP 0060-1 WP 0077-1 WP 0086-1 WP 0087-1 Q QUICK LATCH DOES NOT OPERATE.......................................................................................-Page No........ WP 0012-1 WP 0025-1 W WINDSHIELD WIPER AND WASHER DO NOT OPERATE................................................................... TROUBLESHOOTING SYMPTOM INDEX ............................................................................................ TRAVEL ALARM DOES NOT OPERATE.......... TROUBLESHOOTING NOTES.................................................................................................................................................................. WP 0094-1 WP 0014-1 S SELECTING AN ATTACHMENT ON THE MONITOR........................................ TOWING THE HYEX............................................................................................................................................................................................. OPERATING THE HYDRAULIC THUMB...................... USING THE VANDAL PROTECTION KIT............................................. 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........................................................ Index-3/4 blank WP 0039-1 .......... SPECIAL PURPOSE KITS (SPK) LIST........ WP 0026-1 WP 0017-1 P POWER DIG DOES NOT WORK............................... SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED......................................................OPERATOR MAINTENANCE................. SHUTTING DOWN THE HYEX................................... TRACK SAG CHECK .......................................................................................................................................................................................... O OPERATING THE HYDRAULIC HOSE REEL................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................... SLOW TRAVEL SPEED ONLY............................................................................. 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..................................................................................................................................... PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................................ TRAVEL IS JERKY................................. WP 0068-1 R REFERENCES............................................... THEORY OF OPERATION.... TAKING HYDRAULIC OIL SAMPLE............................................................................................... SWING FUNCTION IS JERKY...................................................................... TIGHTENING TRACK TENSION.............Continued Subject WP Sequence No....................................................... SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT).............................................................................................................................................. REMOVING AND INSTALLING BUCKET................................................................................................................................................................................................................ PRIMARY AND SECONDARY AIR CLEANER SERVICE......................................................................... . PAGE NO. MI 48397-5000 Your mailing address DATE Date you filled out this form.RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form.S. TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code) U. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. PARAGRAPH LINE NO. FEB 74 0DUFK +<(. GRADE OR TITLE Your Name DA FORM 2028. Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). the proponent agency is ODISC4. 11 Mile Road. * TYPED NAME. Warren. 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. see AR 25-30. if possible). 1 DEC 68. RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes. TELEPHONE EXCHANGE/AUTOVON. *Reference to line numbers within the paragraph or subparagraph. NO. PLUS EXTENSION Signature Your Signature REPLACES DA FORM 2028.7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK FIGURE TABLE NO. USAPPC V3.00 . WHICH WILL BE USED. TO: (Forward direct to addressee listed in publication) U. 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  +<(. 11 Mile Road. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. Warren. S. NO. LINE NO. GRADE OR TITLE Your Name TELEPHONE EXCHANGE/AUTOVON. NUMBER TOTAL NO.00 .) TYPED NAME. COLM NO. NO. PLUS EXTENSION SIGNATURE Your Signature USAPPC V3.7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK PUBLICATION NUMBER TM PAGE NO. Additional blank sheets may be used if more space is needed. NATIONAL STOCK REFERENCE FIGURE ITEM 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. For use of this form. Warren.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). * 0 MarFK FIGURE TABLE NO. see AR 25-30.S. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. PARAGRAPH LINE NO. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U. the proponent agency is ODISC4. MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. NO. USAPPC V3. 1 DEC 68. TYPED NAME. PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028. WHICH WILL BE USED. FEB 74 TELEPHONE EXCHANGE/AUTOVON. *Reference to line numbers within the paragraph or subparagraph. GRADE OR TITLE DA FORM 2028. if possible). 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes.00 . 11 Mile Road. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(.TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. Warren. S. Additional blank sheets may be used if more space is needed. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (Any general remarks or recommendations. LINE NO. NATIONAL STOCK REFERENCE FIGURE NO. NUMBER PART III – REMARKS TYPED NAME.) TELEPHONE EXCHANGE/AUTOVON. PLUS EXTENSION SIGNATURE USAPPC V3. COLM NO. NO. TOTAL NO. DATE TM  PAGE NO. GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. or suggestions for improvement of publications and blank forms.00 . PARAGRAPH LINE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. For use of this form. Warren. see AR 25-30.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). * 0 MarFK FIGURE TABLE NO. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U. the proponent agency is ODISC4. MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. PAGE NO. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road.S. *Reference to line numbers within the paragraph or subparagraph. USAPPC V3. 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes. FEB 74 TELEPHONE EXCHANGE/AUTOVON. GRADE OR TITLE DA FORM 2028. 1 DEC 68. WHICH WILL BE USED. if possible).00 . TYPED NAME. PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(.TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. 11 Mile Road. S. Warren. ) TELEPHONE EXCHANGE/AUTOVON. DATE TM  PAGE NO. Additional blank sheets may be used if more space is needed. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (Any general remarks or recommendations. TOTAL NO. NO. NATIONAL STOCK REFERENCE FIGURE NO. COLM NO. GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO.00 . LINE NO. PLUS EXTENSION SIGNATURE USAPPC V3. or suggestions for improvement of publications and blank forms. NUMBER PART III – REMARKS TYPED NAME. * 0 MarFK FIGURE TABLE NO. see AR 25-30.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). NO. PARAGRAPH LINE NO. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U. Warren. PAGE NO.S. For use of this form. MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road. the proponent agency is ODISC4. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. 1 DEC 68. GRADE OR TITLE DA FORM 2028. FEB 74 TELEPHONE EXCHANGE/AUTOVON. TYPED NAME. if possible). 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes. WHICH WILL BE USED.00 . PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028. *Reference to line numbers within the paragraph or subparagraph. USAPPC V3. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E.TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. 11 Mile Road. Warren. S. MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. or suggestions for improvement of publications and blank forms. TOTAL NO. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (Any general remarks or recommendations. NATIONAL STOCK REFERENCE FIGURE NO.) TELEPHONE EXCHANGE/AUTOVON. COLM NO.00 . GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. PLUS EXTENSION SIGNATURE USAPPC V3. NUMBER PART III – REMARKS TYPED NAME. LINE NO. Additional blank sheets may be used if more space is needed. NO. DATE TM  PAGE NO. NO. TITLE 2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. PAGE NO.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. PARAGRAPH LINE NO.S. MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TM  ITEM NO. the proponent agency is ODISC4. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road. see AR 25-30. * 0 MarFK FIGURE TABLE NO. Warren. TO: (Forward to proponent of publication or form)(Include ZIP Code) DATE FROM: (Activity and location) (Include ZIP Code) U. *Reference to line numbers within the paragraph or subparagraph. 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes.00 . TYPED NAME. WHICH WILL BE USED. 1 DEC 68. if possible). USAPPC V3. PLUS EXTENSION SIGNATURE REPLACES DA FORM 2028. FEB 74 TELEPHONE EXCHANGE/AUTOVON. GRADE OR TITLE DA FORM 2028. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E.TO: (Forward direct to addressee listed in publication) DATE FROM: (Activity and location) (Include ZIP Code) U. 11 Mile Road. Warren. S. MI 48397-5000 PUBLICATION NUMBER PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE2SHUDWRU V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(. NUMBER PART III – REMARKS TYPED NAME. Additional blank sheets may be used if more space is needed. NO.00 . NATIONAL STOCK REFERENCE FIGURE NO. or suggestions for improvement of publications and blank forms. LINE NO. TOTAL NO. COLM NO.) TELEPHONE EXCHANGE/AUTOVON. OF MAJOR ITEMS SUPPORTED RECOMMENDED ACTION (Any general remarks or recommendations. DATE TM  PAGE NO. GRADE OR TITLE 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK 0 MarFK 0 ITEM NO. PLUS EXTENSION SIGNATURE USAPPC V3. United States Army Chief of Staff Official: JOYCE E. General. CASEY. 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.By Order of the Secretary of the Army: GEORGE W. JR. . . . . . . . . . . .196 0. . .. . .454 0. . . . . . . . .113 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Square Miles . . Liters . . . . . .386 2. . .. . . . . . . . . . .914 1. . .609 6. . .305 0. .621 Miles SQUARE MEASURE 1 Sq Centimeter = 100 Sq Millimeters = 0. . . . . . . . Yards . . . Fluid Ounces . . . . . . . . . . . . . . . . . . .425 1. . . . . . . . .354 0. . . . . . . . . . . . .145 2. . . . . . . . . . Kilograms . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .946 3. . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . . . . . . .034 2. .356 6. . . . . .093 0. . . . . . . . . Square Meters .000.82 Fluid Ounces APPROXIMATE CONVERSION FACTORS MULTIPLY BY 1 CM 2 3 4 5 2 6 7 2. . . . . . . . . . . . . . Yards . . Miles per Hour . . . . . Short Tons . Milliliters. . . . . . . Pounds. . . Kilometers per Liter . . . .349 0. . . . . . . . . . . . . Sq Centimeters . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . .621 0. . . . . . . . . . . . . . .102 0. . . . Fluid Ounces . . . . . . Gallons . . . . . . . . . . Square Kilometers . . . . . . . . . . . . . . . . . .386 Sq Miles WEIGHTS 1 Gram = 0. . . . . . . . . . . . . .. . . . .. . Kilometers . . . . . .405 0. . . . . . . . . . . . . . . . . . . .76 Sq Feet 1 Sq Kilometer = 1. . . . . . . . . . . . .31 Cu Feet TEMPERATURE 5/9 ( F . . . . . . . . . . . . . . . . . . . . . .37 Inches 1 Kilometer = 1000 Meters = 0. . Kilopascals . . .836 2. .0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33. . . . . . . . . . . . . . . . . .. . . . . . . . . . . Gallons. . .. . . . . Liters . . . . Cubic Meters . . . . . . . . Feet . .451 0. . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . Meters . . . . Feet . . . . . .621 5 Inches . . . Kilograms . . . . . . . Square Inches . . Acres . . . . Square Meters . Square Miles . . . . . . . . . . . . . . . . . . . . . . . . .057 0. .. . Cubic Meters . . . . .473 0. . . . .2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9/5 C + 32 = F LIQUID MEASURE 1 Milliliter = 0. . . . . . Short Tons . . . . . . . . . . . . . . . . . . . . . Miles . . . . . . . Cubic Yards . . . . . . . Km per Liter . . . . . .155 Sq Inches 1 Sq Meter = 10. . . . Quarts . . . . . . . Grams . . . . . . Square Centimeters . . . . . . . . . . . . . . . . . .471 35. .32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32. . . . . . . . . Square Yards .205 1. . . . . INCHES Inches . . . . .2 Lb 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1. . . . .000. . Km per Hour. . . . . . . . . . . . . . . . . . . . . .094 0. . Meters. .573 0. . . Square Kilometers . . . . . . . . . . . . . Cubic Feet . . . . . .000 Sq Centimeters = 10. . . . . Miles per Gallon . . . . .1 Short Tons CUBIC MEASURE 1 Cu Centimeter = 1000 Cu Millimeters = 0. . . . . . . . . . . . .001 Liters = 0. . . . . . . . .738 0. .. . . . . . . . . . . Square Feet . . . . . . Milliliters . . . . . . . . . . . . . . . . . Square Hectometers . Liters . . . . . . . . Acres . . . . . . .035 2. Miles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 10.001 Kilograms = 1000 Milligrams = 0. . . . . Grams . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . Cubic Yards .028 0. . . . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . .06 Cu Inches 1 Cu Meter = 1. . . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . Liters . . . . . . . . . . .. . . . . . . . . Liters . .394 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . Pounds/Sq Inch .264 0. . . . . . .308 0. . . . . . . . . . . . . . . . . Kilometers per Hour . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609 1 Centimeters . . .540 0. . . . . Newton-Meters . . TO 0 TO CHANGE 3 8 TO CHANGE TO MULTIPLY BY 9 10 11 12 13 14 15 6 0. . .895 0. . . . . . . Quarts . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . .765 29. . . . . . . . . .01 Meters = 0. . . . . . . . Pound-Feet . . . . . . Miles per Gallon . .. . . . .280 1. . . . . . . . . . . . . . . . . . Liters . .907 1. . . . . Square Feet .000 Sq Meters = 0. Ounces . . . . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . Metrication . . Pound-Feet . . . . . . . . . . . . . . .590 0. . . . . . . . . . . . . . 4 Centimeters .035 Ounces 1 Kilogram = 1000 Grams = 2. . . Sq Hectometers . . . . . . . . . . . . . . . . . . . . . .THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE 1 Centimeter = 10 Millimeters = 0. . . . . . Cubic Meters . . .3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39. . . . . . . . . . . . . . . . . . . . . . . . Kilopascals . .764 1. . . .000 Cu Centimeters = 35. . Newton-Meters . . . . . . . . . . . . .. . . .315 1. . . . . . . . . Meters . . .785 28. . . . . . . . . . Square Inches . . . . . . . . . PIN 086698-000 .


Comments

Copyright © 2024 UPDOCS Inc.