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TECHNICAL MANUAL OPERATOR'S MANUAL FOR

HYDRAULIC EXCAVATOR (HYEX) (JOHN DEERE 240D LCR) TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH NSN 3805-01-573-0677 (EIC : ALL)

DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

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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.

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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.

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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

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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

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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

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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.

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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.

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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.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the "Change No." column indicates an original page or work package. Date of issue for the original manual is: Original 07 March 2011

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 54 AND TOTAL NUMBER OF WORK PACKAGES IS 100 CONSISTING OF THE FOLLOWING: 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) 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 A CHANGE NO. PAGE/WP NO. 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) 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 CHANGE NO.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

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) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 CHANGE NO. PAGE/WP NO. 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 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 CHANGE NO.

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HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 07 MARCH 2011 TECHNICAL MANUAL OPERATORS MANUAL FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677 (EIC ALL) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is: tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726. A reply will be furnished to you.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS
Page No. WP Sequence No. How to Use this Manual Chapter 1 - OPERATOR GENERAL INFORMATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Table 1. Figure 2. Table 2. Figure 3. Table 3. Table 4. Figure 4. Table 5. Figure 5. Table 6. Table 7. Table 8. Table 9. Table 10. Right View of HYEX............................................................................................................. 0002-3 Right View of HYEX............................................................................................................. 0002-3 Left View of HYEX................................................................................................................ 0002-4 Left View of HYEX................................................................................................................ 0002-4 Data Plates........................................................................................................................... 0002-5 Data Plates........................................................................................................................... 0002-5 Equipment Data.................................................................................................................... 0002-6 HYEX Specifications............................................................................................................ 0002-7 HYEX Specification.............................................................................................................. 0002-7 HYEX Working Ranges........................................................................................................ 0002-8 HYEX Working Ranges........................................................................................................ 0002-9 Front Lift Capacities........................................................................................................... 0002-10 Side Lift Capacities............................................................................................................. 0002-11 HYEX Weights With Attachments...................................................................................... 0002-12 Deep Dig Arm Weights....................................................................................................... 0002-12

THEORY OF OPERATION.......................................................................................................................... WP 0003 Figure 1. Table 1. Figure 2. Table 2. Figure 3. Table 3. Electrical System Components............................................................................................ 0003-2 Electrical System Components............................................................................................ 0003-2 Hydraulic System Components............................................................................................ 0003-3 Hydraulic System Components............................................................................................ 0003-3 Hydraulic System Components Continued........................................................................... 0003-4 Hydraulic System Components Continued........................................................................... 0003-4

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 4. Table 4. Figure 5. Table 5. Figure 6. Table 6. Figure 7. Table 7. Figure 8. Table 8. Powertrain Components....................................................................................................... 0003-5 Powertrain Components....................................................................................................... 0003-5 Fuel System Components.................................................................................................... 0003-6 Fuel System Components.................................................................................................... 0003-6 High-Pressure Pump and Injectors...................................................................................... 0003-7 High-Pressure Pump and Injectors...................................................................................... 0003-7 Cooling Package.................................................................................................................. 0003-8 Cooling Package.................................................................................................................. 0003-8 Cooling System Components............................................................................................... 0003-9 Cooling System Components............................................................................................... 0003-9

Chapter 2 - OPERATOR INSTRUCTIONS DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........................................... WP 0004 Table 1. Figure 1. Figure 2. Table 2. Figure 3. Figure 4. Table 3. Figure 5. Figure 6. Table 4. Figure 7. Table 5. Figure 8. Figure 9. Table 6. Front Switch Panel............................................................................................................... 0004-1 Front Switch Panel............................................................................................................... 0004-1 Front Switch Panel Continued.............................................................................................. 0004-2 Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3 Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3 Heater/Air Conditioner (A/C) Controller and Radio Continued............................................. 0004-4 Control Pedals and Levers................................................................................................... 0004-5 Control Pedals and Levers................................................................................................... 0004-5 Control Pedals and Levers Continued.................................................................................. 0004-6 Left Console and Pilot Shutoff Lever.................................................................................... 0004-7 Left Console and Pilot Shutoff Lever.................................................................................... 0004-7 Right and Left Pilot Control Levers....................................................................................... 0004-8 Right Pilot Control Lever...................................................................................................... 0004-8 Left Pilot Control Lever......................................................................................................... 0004-9 Seat Controls...................................................................................................................... 0004-10

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 10. Table 7. Figure 11. Table 8. Figure 12. Table 9. Figure 13. Table 10. Figure 14. Seat Controls...................................................................................................................... 0004-10 Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12 Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12 Quick Latch Control............................................................................................................ 0004-13 Quick Latch Control............................................................................................................ 0004-13 Cab Light Switch................................................................................................................ 0004-14 Cab Light Switch................................................................................................................ 0004-14 Hydraulic Hose Reel........................................................................................................... 0004-15 Hydraulic Hose Reel........................................................................................................... 0004-15

DESCRIPTION AND USE OF MONITOR AND ALARMS........................................................................... WP 0005 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Table 2. Figure 5. Figure 6. Monitor Buttons and Indicators............................................................................................. 0005-1 Monitor................................................................................................................................. 0005-1 Monitor Buttons.................................................................................................................... 0005-2 Main Menu............................................................................................................................ 0005-3 Monitor Indicators................................................................................................................. 0005-4 Warning Indicators and Alarms............................................................................................ 0005-6 Warning Indicators and Alarms............................................................................................ 0005-6 Overload Alarm.................................................................................................................... 0005-7

ADJUSTING THE OPERATOR'S SEAT...................................................................................................... WP 0006 Figure 1. Operator's Seat Adjustments................................................................................................ 0006-1

STARTING THE ENGINE............................................................................................................................ WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Seat Belt............................................................................................................................... 0007-1 Pilot Shutoff Lever................................................................................................................ 0007-2 Engine Speed Dial Slow Idle................................................................................................ 0007-2 Key Switch ON..................................................................................................................... 0007-3 System Starting and Default Screen.................................................................................... 0007-3 Preheat Indicator.................................................................................................................. 0007-4

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Key Switch to START........................................................................................................... 0007-4 Alarm indicator..................................................................................................................... 0007-5 Engine Speed Dial Turned to 1/3 Position........................................................................... 0007-5 Return Engine Speed Dial to Slow Idle................................................................................ 0007-6

MOVING THE HYEX................................................................................................................................... WP 0008 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Pilot Shutoff Lever Unlocked................................................................................................ 0008-1 Boom and Arm Raised......................................................................................................... 0008-2 Travel Mode Switch.............................................................................................................. 0008-2 Moving Forward and Backwards.......................................................................................... 0008-3 Right Turn............................................................................................................................. 0008-4 Left Turn............................................................................................................................... 0008-4 Counter-Rotate..................................................................................................................... 0008-5

SHUTTING DOWN THE HYEX................................................................................................................... WP 0009 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Machine In Parked Position.................................................................................................. 0009-1 Auto-Idle Switch and Engine Speed Dial.............................................................................. 0009-2 Engine Speed Dial................................................................................................................ 0009-3 Pilot Shutoff Lever................................................................................................................ 0009-3 Key Switch Turned OFF....................................................................................................... 0009-4

SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED................................................. WP 0010 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Machine In Parked Position.................................................................................................. 0010-1 Auto-Idle Switch and Engine Speed Dial.............................................................................. 0010-2 Engine Speed Dial................................................................................................................ 0010-3 Pilot Shutoff Lever................................................................................................................ 0010-3 Key Switch Turned OFF....................................................................................................... 0010-4

OPENING AND CLOSING WINDOWS....................................................................................................... WP 0011 Figure 1. Figure 2. Open Windshield.................................................................................................................. 0011-1 Raise Windshield.................................................................................................................. 0011-2

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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Lock Windshield Open......................................................................................................... 0011-2 Release Windshield Latch.................................................................................................... 0011-3 Close Windshield.................................................................................................................. 0011-3 Latch Windshield.................................................................................................................. 0011-4 Open and Close Cab Door Window..................................................................................... 0011-4 Open Access Cover............................................................................................................. 0011-5 Open and Close Skylight Window........................................................................................ 0011-5 Close Access Cover............................................................................................................. 0011-6

USING THE RIFLE MOUNT........................................................................................................................ WP 0012 Figure 1. Figure 2. Figure 3. Figure 4. Stow Weapon In Rear Bracket............................................................................................. 0012-1 Stow Weapon In Front Bracket............................................................................................ 0012-2 Remove Weapon From Front Bracket.................................................................................. 0012-2 Remove Weapon From Rear Bracket.................................................................................. 0012-3

GENERAL MONITOR OPERATION............................................................................................................ WP 0013 Figure 1. Figure 2. Figure 3. Figure 4. Select Time Set Menu.......................................................................................................... 0013-1 Adjust Time.......................................................................................................................... 0013-2 Select Operating Conditions Menu....................................................................................... 0013-2 Reset Operating Conditions................................................................................................. 0013-3

REMOVING AND INSTALLING BUCKET................................................................................................... WP 0014 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Unlock Safety Lock Pin........................................................................................................ 0014-1 Raise Boom.......................................................................................................................... 0014-2 Move Quick Latch Switch to Unlatch Position...................................................................... 0014-2 Extend Bucket Cylinder........................................................................................................ 0014-3 Retract Bucket Cylinder........................................................................................................ 0014-3 Lower Boom......................................................................................................................... 0014-4 Position Quick Latch Switch to Latch position...................................................................... 0014-4 Remove Quick Latch............................................................................................................ 0014-5

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Page No. WP Sequence No. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Position Quick Latch Switch to Unlatch position.................................................................. 0014-6 Raise Boom for Clearance................................................................................................... 0014-6 Retract Wedges.................................................................................................................... 0014-7 Install Quick Latch................................................................................................................ 0014-7 Position Quick Latch Switch toLatch position....................................................................... 0014-8 Raise Boom.......................................................................................................................... 0014-8 Safety Pin Locked................................................................................................................ 0014-9

LIFTING WITH HYEX.................................................................................................................................. WP 0015 Figure 1. Lifting with Quick Latch Loop............................................................................................... 0015-2

OPERATING TECHNIQUES....................................................................................................................... WP 0016 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Leveling Machine................................................................................................................. 0016-1 Add or Remove Material....................................................................................................... 0016-1 Arm Digging.......................................................................................................................... 0016-3 Bucket Digging..................................................................................................................... 0016-4 Planning Spoil Piles.............................................................................................................. 0016-5 Trenching............................................................................................................................. 0016-6 Cleaning Cave In.................................................................................................................. 0016-6 Trenching on a Slope........................................................................................................... 0016-7 Straight Line Trenching........................................................................................................ 0016-8 Back Filling........................................................................................................................... 0016-9 Truck Loading..................................................................................................................... 0016-10

OPERATING THE HYDRAULIC THUMB.................................................................................................... WP 0017 Figure 1. Figure 2. Figure 3. Clamping With Bucket.......................................................................................................... 0017-1 Clamping With Hydraulic Thumb.......................................................................................... 0017-2 Releasing Objects................................................................................................................ 0017-3

SELECTING AN ATTACHMENT ON THE MONITOR................................................................................ WP 0018 Figure 1. Select Attachment................................................................................................................ 0018-1

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Page No. WP Sequence No. Table 1. Figure 2. Attachment Selection........................................................................................................... 0018-1 Attachment Specification Screen......................................................................................... 0018-2

INSTALLING AND OPERATING THE CRUSH-ALL.................................................................................... WP 0019 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Close Hydraulic Thumb Circuit............................................................................................. 0019-1 Move Quick Latch Switch to Unlatch Position...................................................................... 0019-2 Extend Bucket Cylinder........................................................................................................ 0019-3 Install Quick Latch................................................................................................................ 0019-3 Quick Latch Switch to Latch Position................................................................................... 0019-4 Position Crush-All................................................................................................................. 0019-4 Connect Auxiliary Supply Line.............................................................................................. 0019-5 Connect Auxiliary Return Line.............................................................................................. 0019-5 Crush-All Operation.............................................................................................................. 0019-7 Open Lid............................................................................................................................... 0019-9 Clearing Jam from Crush-All................................................................................................ 0019-9 Push Crush-All Rotor Backwards....................................................................................... 0019-10 Position Crush-All............................................................................................................... 0019-10 Disconnect Auxiliary Return Line....................................................................................... 0019-11 Disconnect Auxiliary Supply Line....................................................................................... 0019-12 Move Quick Latch Switch................................................................................................... 0019-12 Raise Boom........................................................................................................................ 0019-13 Remove Quick Latch.......................................................................................................... 0019-14 Move Quick Latch Switch................................................................................................... 0019-14 Open Hydraulic Thumb Circuit........................................................................................... 0019-15

INSTALLING AND OPERATING THE IMPACT BREAKER........................................................................ WP 0020 Figure 1. Figure 2. Figure 3. Close Hydraulic Thumb Circuit............................................................................................. 0020-1 Move Quick Latch Switch..................................................................................................... 0020-2 Raise Boom.......................................................................................................................... 0020-3

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Quick Latch Wedges Retracted............................................................................................ 0020-3 Install Quick Latch................................................................................................................ 0020-4 Extend Bucket Cylinder........................................................................................................ 0020-4 Move Quick Latch Switch to Latch Position......................................................................... 0020-5 Quick Latch Wedges Engaged............................................................................................. 0020-5 Safety Pin to Lock Position................................................................................................... 0020-6 Connect Auxiliary Supply Line.............................................................................................. 0020-6 Connect Auxiliary Return Line.............................................................................................. 0020-7 Breaker Tool Lock Bolt......................................................................................................... 0020-8 Insert Breaker Tool............................................................................................................... 0020-9 Lock Breaker Tool................................................................................................................ 0020-9 Breaker Operation.............................................................................................................. 0020-10 Tool Removal..................................................................................................................... 0020-10 Remove Breaker Tool........................................................................................................ 0020-11 Lock Breaker Tool.............................................................................................................. 0020-11 Disconnect Auxiliary Return Line....................................................................................... 0020-12 Disconnect Auxiliary Supply Line....................................................................................... 0020-12 Safety Pin to Unlock Position............................................................................................. 0020-13 Raise Boom for Clearance................................................................................................. 0020-13 Move Quick Latch Switch to Unlatch Position.................................................................... 0020-14 Quick Latch Wedges Retracted.......................................................................................... 0020-14 Impact Breaker Removal.................................................................................................... 0020-15 Quick Latch Switch to Latch Position................................................................................. 0020-15 Open Hydraulic Thumb Circuit........................................................................................... 0020-16

INSTALLING AND OPERATING THE COMPACTOR................................................................................. WP 0021 Figure 1. Figure 2. Close Hydraulic Thumb Circuit............................................................................................. 0021-2 Move Quick Latch Switch..................................................................................................... 0021-3

TM 5-3805-294-10

TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Raise Boom.......................................................................................................................... 0021-3 Quick Latch Wedges Retracted............................................................................................ 0021-4 Install Quick Latch................................................................................................................ 0021-4 Position Quick Latch............................................................................................................. 0021-5 Quick Latch Switch to Latch Position................................................................................... 0021-5 Raise Boom for Clearance................................................................................................... 0021-6 Engage Quick Latch Wedges............................................................................................... 0021-6 Lock Safety Lock.................................................................................................................. 0021-7 Connect Auxiliary Supply Line.............................................................................................. 0021-7 Connect Auxiliary Return Line.............................................................................................. 0021-8 Attachment Pedal Lock Release.......................................................................................... 0021-8 Disconnect Auxiliary Return Line......................................................................................... 0021-9 Connect Auxiliary Supply Line............................................................................................ 0021-10 Unlock Safety Lock............................................................................................................. 0021-10 Quick Latch Switch to Unlatch Position.............................................................................. 0021-11 Raise Boom........................................................................................................................ 0021-11 Disengage Quick Latch Wedges........................................................................................ 0021-12 Retract Bucket Cylinder...................................................................................................... 0021-12 Remove Quick Latch.......................................................................................................... 0021-13 Quick Latch Switch to Latch Position................................................................................. 0021-13 Close Hydraulic Thumb Circuit........................................................................................... 0021-14

OPERATING THE BARRIER GRAPPLE..................................................................................................... WP 0022 Figure 1. Lifting Barrier Grapple.......................................................................................................... 0022-2

OPERATING THE DEEP DIG ARM............................................................................................................ WP 0023 Figure 1. Figure 2. Figure 3. Deep Dig Control Pattern Switch.......................................................................................... 0023-1 Turn Auto Idle Switch On..................................................................................................... 0023-2 Pilot Shutoff Lever................................................................................................................ 0023-3

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 4. Figure 5. Turn RPM Dial...................................................................................................................... 0023-4 Cycle Deep Dig Arm Cylinders............................................................................................. 0023-5

MOVING MACHINE ON/OFF AN EMBANKMENT...................................................................................... WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Position Bucket..................................................................................................................... 0024-1 Upperstructure Rotated........................................................................................................ 0024-2 Position Bucket on Lower Level........................................................................................... 0024-3 Rotate Upperstructure to Upper Level.................................................................................. 0024-3

USING THE VANDAL PROTECTION KIT................................................................................................... WP 0025 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Right Side Rear Cover Installation....................................................................................... 0025-1 Right Side Center Cover Installation.................................................................................... 0025-1 Right Side Front Cover Installation....................................................................................... 0025-2 Lock Bar Installation............................................................................................................. 0025-2 Front Door Cover Installation............................................................................................... 0025-3 Center Door Cover Installation............................................................................................. 0025-3 Lower Door Cover Installation.............................................................................................. 0025-4 Side Upper Glass Cover Installation.................................................................................... 0025-4 Side Lower Glass Cover Installation.................................................................................... 0025-5 Right Rear Cab Cover Installation........................................................................................ 0025-5 Left Rear Cab Cover Installation.......................................................................................... 0025-6 Left Rear Cab Cover Removal............................................................................................. 0025-6 Right Rear Cab Cover Removal........................................................................................... 0025-7 Side Lower Glass Cover Removal....................................................................................... 0025-7 Side Upper Glass Cover Removal....................................................................................... 0025-8 Lower Door Cover Removal................................................................................................. 0025-8 Center Door Cover Removal................................................................................................ 0025-9 Front Door Cover Removal.................................................................................................. 0025-9 Lock Bar Removal.............................................................................................................. 0025-10

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 20. Figure 21. Figure 22. Right Side Front Cover Removal........................................................................................ 0025-10 Right Side Center Cover Removal..................................................................................... 0025-10 Right Side Rear Cover Removal........................................................................................ 0025-11

OPERATING THE HYDRAULIC HOSE REEL............................................................................................ WP 0026 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Tool Attachment................................................................................................... 0026-1 Turn On Hydraulic Tool........................................................................................................ 0026-2 Turn Off Hydraulic Tool........................................................................................................ 0026-2 Hydraulic Tool Removal....................................................................................................... 0026-3

DECAL LOCATION GUIDE......................................................................................................................... WP 0027 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Left Side, Rear Cab Window, and Top Decals..................................................................... 0027-1 Left Inside Door.................................................................................................................... 0027-2 Top Under Engine Cover...................................................................................................... 0027-2 Right Side on Hydraulic Reservoir....................................................................................... 0027-3 Right Side............................................................................................................................. 0027-3 Boom, Right Side, and Rear Cab Window........................................................................... 0027-4 Counterweight...................................................................................................................... 0027-4 Front and Rear Frame.......................................................................................................... 0027-5 Cab on Seat......................................................................................................................... 0027-5 Key Switch............................................................................................................................ 0027-5 Windshield............................................................................................................................ 0027-6 Side Window........................................................................................................................ 0027-6 Upper and Lower Right Side Window.................................................................................. 0027-7 Lower Right Side Window.................................................................................................... 0027-8 Vandal Protection Kit............................................................................................................ 0027-9 Upper Section Periodic Maintenance................................................................................. 0027-10 Lower Section Periodic Maintenance................................................................................. 0027-11 Ditch Cleaning Bucket........................................................................................................ 0027-12

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 19. Figure 20. Figure 21. Figure 22. Heavy Duty Bucket............................................................................................................. 0027-12 Right Side Crush-All........................................................................................................... 0027-13 Left Side Crush-All............................................................................................................. 0027-13 Output Side Crush-All......................................................................................................... 0027-14

TOWING THE HYEX................................................................................................................................... WP 0028 LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................... WP 0029 OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)..................................................................... WP 0030 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Table 1. Figure 10. Press and Hold Back Button................................................................................................ 0030-1 Key Switch to ON Position................................................................................................... 0030-2 Release Back Button............................................................................................................ 0030-2 Highlight Service Menu........................................................................................................ 0030-3 Select Monitoring.................................................................................................................. 0030-3 Temperatures Displayed...................................................................................................... 0030-4 Start Engine.......................................................................................................................... 0030-4 Engine Speed Dial................................................................................................................ 0030-5 Check Engine and Hydraulic Oil Temperatures................................................................... 0030-5 Machine Switch Selections................................................................................................... 0030-6 Raise Machine...................................................................................................................... 0030-6

OPERATING IN COLD WEATHER 5F (-15C) OR COLDER ................................................................... WP 0031 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Press and Hold Back Button................................................................................................ 0031-1 Key Switch to ON Position................................................................................................... 0031-2 Release Back Button............................................................................................................ 0031-2 Highlight Service Menu........................................................................................................ 0031-3 Select Monitoring.................................................................................................................. 0031-3 Temperatures Displayed...................................................................................................... 0031-4 Start Engine.......................................................................................................................... 0031-4 Engine Idle Speed................................................................................................................ 0031-5

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 9. Table 1. Figure 10. Monitor Temperatures Displayed......................................................................................... 0031-5 Machine Switch Selection.................................................................................................... 0031-6 Raise Machine...................................................................................................................... 0031-7

SLAVE STARTING...................................................................................................................................... WP 0032 Figure 1. Slave Receptacle................................................................................................................. 0032-2

SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................... WP 0033 Figure 1. Figure 2. Open and Close Roof Exit.................................................................................................... 0033-1 Emergency Exit Tool............................................................................................................ 0033-2

OPERATING THE COOLANT HEATER...................................................................................................... WP 0034 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Coolant Heater Control Panel.............................................................................................. 0034-2 Adjusting Time and Day....................................................................................................... 0034-2 Setting Program................................................................................................................... 0034-3 Adjusting Run Time.............................................................................................................. 0034-4 Manually Start Coolant Heater............................................................................................. 0034-4 Manually Start Coolant Heater Continued............................................................................ 0034-5

MOVING UP/DOWN STEEP OR SLIPPERY SLOPES............................................................................... WP 0035 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Buckle Seat Belt................................................................................................................... 0035-1 Pulling Machine Up.............................................................................................................. 0035-2 Buckle Seat Belt................................................................................................................... 0035-3 Pushing Machine.................................................................................................................. 0035-3 Traveling Down.................................................................................................................... 0035-4

FORDING THE HYEX................................................................................................................................. WP 0036 Figure 1. Figure 2. Figure 3. Fording Line......................................................................................................................... 0036-1 Pilot Shutoff Lever................................................................................................................ 0036-2 Check Monitor...................................................................................................................... 0036-2

Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE............................................... WP 0037

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. TRAVEL ALARM DOES NOT OPERATE.................................................................................................... WP 0038 WINDSHIELD WIPER AND WASHER DO NOT OPERATE....................................................................... WP 0039 CAB DOME LIGHT DOES NOT OPERATE................................................................................................ WP 0040 BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE............................................................................ WP 0041 CAB FRONT WORK LIGHTS DO NOT OPERATE..................................................................................... WP 0042 CAB REAR WORK LIGHTS DO NOT OPERATE....................................................................................... WP 0043 LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE..................................................................... WP 0044 AIR CONDITIONER DOES NOT OPERATE............................................................................................... WP 0045 ENGINE CRANKS BUT DOES NOT START OR HARD TO START.......................................................... WP 0046 ENGINE WILL NOT CRANK........................................................................................................................ WP 0047 ENGINE RUNS POORLY............................................................................................................................ WP 0048 EXCESSIVE FUEL CONSUMPTION.......................................................................................................... WP 0049 EXCESSIVE OIL CONSUMPTION.............................................................................................................. WP 0050 ENGINE IDLES POORLY............................................................................................................................ WP 0051 AUTO-IDLE DOES NOT WORK.................................................................................................................. WP 0052 ENGINE NOT DEVELOPING FULL POWER.............................................................................................. WP 0053 ENGINE OIL PRESSURE LOW.................................................................................................................. WP 0054 ENGINE COOLANT TEMPERATURE ABOVE NORMAL........................................................................... WP 0055 ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE....................................................... WP 0056 ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE......................................................................... WP 0057 NO HYDRAULIC FUNCTIONS.................................................................................................................... WP 0058 HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER............................................. WP 0059 POWER DIG DOES NOT WORK................................................................................................................ WP 0060 HYDRAULIC OIL OVERHEATS.................................................................................................................. WP 0061 HYDRAULIC OIL FOAMS............................................................................................................................ WP 0062 NO SWING FUNCTION............................................................................................................................... WP 0063 SWING FUNCTION IS JERKY.................................................................................................................... WP 0064

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. SLOW TRAVEL SPEED ONLY................................................................................................................... WP 0065 TRAVEL IS JERKY...................................................................................................................................... WP 0066 ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED..................................................... WP 0067 QUICK LATCH DOES NOT OPERATE....................................................................................................... WP 0068 COMPACTOR DOES NOT OPERATE........................................................................................................ WP 0069 BREAKER DOES NOT OPERATE.............................................................................................................. WP 0070 BREAKER OPERATES SLOWLY............................................................................................................... WP 0071 CRUSH-ALL DOES NOT OPERATE........................................................................................................... WP 0072 BARRIER GRAPPLE DOES NOT HOLD LOAD......................................................................................... WP 0073 DEEP DIG DOES NOT OPERATE.............................................................................................................. WP 0074 HYDRAULIC HOSE REEL DOES NOT OPERATE..................................................................................... WP 0075 Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................... WP 0076 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0077 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES.......................... 0077-1 Exterior of Machine.............................................................................................................. 0077-3 Exterior of Machine Continued............................................................................................. 0077-4 Coolant Level....................................................................................................................... 0077-5 Engine Oil............................................................................................................................. 0077-6 Exhaust Components........................................................................................................... 0077-7 Hydraulic Reservoir Cap...................................................................................................... 0077-7 Fuel Tank and Fuel Level..................................................................................................... 0077-8 Fuel Filters............................................................................................................................ 0077-9 Engine Oil Filter.................................................................................................................... 0077-9 Boom, Arm, Quick Latch, and Hydraulic Thumb................................................................ 0077-10 Bucket and Teeth............................................................................................................... 0077-11 Air Cleaner Housing and Hose Reel.................................................................................. 0077-12

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Batteries............................................................................................................................. 0077-13 Batteries Continued............................................................................................................ 0077-14 Cab Glass........................................................................................................................... 0077-15 Mirrors and Wiper Arm....................................................................................................... 0077-15 Cab Door, Hinges, and Latches......................................................................................... 0077-16 Fire Extinguisher................................................................................................................ 0077-17 Pedals and Levers.............................................................................................................. 0077-18 Pilot Control Levers............................................................................................................ 0077-19 Seat Belt............................................................................................................................. 0077-20 Ignition Switch.................................................................................................................... 0077-20 Monitor............................................................................................................................... 0077-21 Position Boom and Arm...................................................................................................... 0077-22 Hydraulic Oil Level Check.................................................................................................. 0077-22 Breaker............................................................................................................................... 0077-23 Compactor.......................................................................................................................... 0077-24 Crush-All............................................................................................................................. 0077-25 Barrier Grapple................................................................................................................... 0077-26 Deep Dig Arm and Bucket.................................................................................................. 0077-27 Deep Dig Bucket................................................................................................................ 0077-28 Ditch Cleaning Bucket........................................................................................................ 0077-29 Position Boom and Arm...................................................................................................... 0077-31 Hydraulic Oil Level Check.................................................................................................. 0077-31 Fuel Tank and Fuel Level Check........................................................................................ 0077-32 Engine Oil Check................................................................................................................ 0077-33 Engine Compartment......................................................................................................... 0077-33 Exterior of Machine Check................................................................................................. 0077-34 Swing Gearbox Oil Level Check......................................................................................... 0077-35

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 40. Figure 41. Figure 42. Figure 43. Hydraulic Pump Oil Level Check........................................................................................ 0077-36 Serpentine Belt Check........................................................................................................ 0077-37 Air Conditioner Belt Check................................................................................................. 0077-38 Fan Check.......................................................................................................................... 0077-39

Chapter 5 - OPERATOR MAINTENANCE INSTRUCTIONS GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0078 TAKING ENGINE OIL SAMPLE.................................................................................................................. WP 0079 Figure 1. Engine Oil Sampling Valve................................................................................................... 0079-1

TRACK SAG CHECK .................................................................................................................................. WP 0080 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Raise Machine...................................................................................................................... 0080-1 Rotate Track......................................................................................................................... 0080-2 Shut Machine Off.................................................................................................................. 0080-3 Measure Track Sag.............................................................................................................. 0080-4 Start Machine....................................................................................................................... 0080-5 Lower Machine..................................................................................................................... 0080-5

TIGHTENING TRACK TENSION................................................................................................................. WP 0081 Figure 1. Tighten Track....................................................................................................................... 0081-1

LOOSENING TRACK TENSION................................................................................................................. WP 0082 Figure 1. Loosen Track........................................................................................................................ 0082-1

TAKING HYDRAULIC OIL SAMPLE........................................................................................................... WP 0083 Figure 1. Hydraulic Oil Sampling Valve............................................................................................... 0083-1

CAB FUSE REPLACEMENT....................................................................................................................... WP 0084 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Fuse Box Access Cover Removal........................................................................................ 0084-2 Main Fuse Box Cover Removal............................................................................................ 0084-3 Fuse Removal...................................................................................................................... 0084-4 Fuse Installation................................................................................................................... 0084-5 Main Fuse Box Cover Installation......................................................................................... 0084-6

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 6. Fuse Box Access Cover Installation..................................................................................... 0084-7

BUCKET TEETH REPLACEMENT.............................................................................................................. WP 0085 Figure 1. Figure 2. Figure 3. Figure 4. Tooth Removal..................................................................................................................... 0085-1 Tooth Installation.................................................................................................................. 0085-2 Bucket Tooth Removal......................................................................................................... 0085-2 Bucket Tooth Installation...................................................................................................... 0085-3

PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................................. WP 0086 Figure 1. Figure 2. Drain Fuel Filter/Water Separators....................................................................................... 0086-1 Drain Fuel Filter/Water Separators Continued..................................................................... 0086-2

PRIMARY AND SECONDARY AIR CLEANER SERVICE.......................................................................... WP 0087 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Cover Removal..................................................................................................................... 0087-1 Primary Air Cleaner Removal............................................................................................... 0087-2 Secondary Air Cleaner Removal.......................................................................................... 0087-2 Primary Air Cleaner Service................................................................................................. 0087-3 Air Cleaner Housing Service................................................................................................ 0087-4 Cover and Dust Boot Service............................................................................................... 0087-4 Secondary Air Cleaner Installation....................................................................................... 0087-5 Primary Air Cleaner Installation............................................................................................ 0087-5 Cover Installation.................................................................................................................. 0087-6

HYDRAULIC RESERVOIR SERVICE......................................................................................................... WP 0088 Figure 1. Figure 2. Figure 3. Hydraulic Reservoir Cover Removal.................................................................................... 0088-1 Hydraulic Reservoir Sight Glass........................................................................................... 0088-2 Hydraulic Reservoir Cover Installation................................................................................. 0088-3

FRESH AIR FILTER SERVICE.................................................................................................................... WP 0089 Figure 1. Figure 2. Figure 3. Filter Removal...................................................................................................................... 0089-1 Inspect Seal.......................................................................................................................... 0089-2 Clean Filter........................................................................................................................... 0089-3

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 4. Figure 5. Clean Housing...................................................................................................................... 0089-3 Filter Installation................................................................................................................... 0089-4

AIR CONDITIONER/HEATER FILTER SERVICE....................................................................................... WP 0090 Figure 1. Figure 2. Figure 3. Figure 4. Filter Removal...................................................................................................................... 0090-1 Clean Filter........................................................................................................................... 0090-2 Clean Housing...................................................................................................................... 0090-3 Filter Installation................................................................................................................... 0090-3

DRAINING WATER AND SEDIMENT FROM FUEL TANK......................................................................... WP 0091 Figure 1. Figure 2. Figure 3. Figure 4. Remove Fuel Cap................................................................................................................ 0091-1 Drain Hose........................................................................................................................... 0091-2 Drain Valve........................................................................................................................... 0091-3 Install Fuel Cap.................................................................................................................... 0091-4

CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT..................................................................... WP 0092 Figure 1. Figure 2. Figure 3. Figure 4. Curtain Adjustment............................................................................................................... 0092-2 Clearance Check.................................................................................................................. 0092-3 Clamp Installation................................................................................................................. 0092-4 Spring Compression............................................................................................................. 0092-5

MAINTENANCE AFTER FORDING............................................................................................................ WP 0093 Figure 1. Draining Mud or Water......................................................................................................... 0093-1

Chapter 6 - OPERATOR SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0094 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................ WP 0095 Table 1. Table 2. COMPONENTS OF END ITEM........................................................................................... 0095-2 BASIC ISSUE ITEMS........................................................................................................... 0095-4

ADDITIONAL AUTHORIZATION LIST (AAL).............................................................................................. WP 0096 Table 1. Additional Authorization List................................................................................................. 0096-1

EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0097

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. SPECIAL PURPOSE KITS (SPK) LIST....................................................................................................... WP 0098 Table 1. Special Purpose Kits............................................................................................................ 0098-2

TROUBLESHOOTING NOTES................................................................................................................... WP 0099 HYEX TRANSPORTABILITY INSTRUCTIONS........................................................................................... WP 0100 Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Military Load Classification................................................................................................... 0100-1 HYEX Dimensions................................................................................................................ 0100-2 HYEX Transportation Data Plate.......................................................................................... 0100-3 HYEX Lifting and Tie Down Points....................................................................................... 0100-4 HYEX Lift and Tie Down Information.................................................................................... 0100-4 M870 Loading....................................................................................................................... 0100-5 M870A1 Loading.................................................................................................................. 0100-6 M870A3 Loading.................................................................................................................. 0100-7 GIC Rail Clearance.............................................................................................................. 0100-8 Standard Cab Clearance...................................................................................................... 0100-9 Armored Cab Clearance..................................................................................................... 0100-10 HTTX Railcar Loading Overhead View.............................................................................. 0100-10 HTTX Railcar Loading Side View....................................................................................... 0100-11 C-5 Aircraft Loading........................................................................................................... 0100-11 C-17 Aircraft Loading......................................................................................................... 0100-12 Marine Loading................................................................................................................... 0100-12 Standard Rock Bucket........................................................................................................ 0100-13 Standard Ditch Cleaning Bucket........................................................................................ 0100-14 Standard Buckets Loaded On M870A1.............................................................................. 0100-15 Standard Buckets Loaded On M870A3.............................................................................. 0100-15 Deep Dig Arm..................................................................................................................... 0100-16 Deep Dig Bucket................................................................................................................ 0100-16 Deep Dig Ditch Cleaning Bucket........................................................................................ 0100-17

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TABLE OF CONTENTS - Continued

Page No. WP Sequence No. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Index Crush-All............................................................................................................................. 0100-18 Compactor.......................................................................................................................... 0100-18 Impact Breaker................................................................................................................... 0100-19 Barrier Grapple................................................................................................................... 0100-19 Crush-All On M870A1........................................................................................................ 0100-20 Crush-All On M870A3........................................................................................................ 0100-20 Standard Buckets Loaded On HTTX Railcar...................................................................... 0100-21 Crush-All Loaded On HTTX Railcar................................................................................... 0100-21 Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.................... 0100-22 Deep Dig Arm and Buckets Loaded On HTTX Railcar....................................................... 0100-22

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HOW TO USE THIS MANUAL

This Technical Manual (TM) is designed to help you safely and efficiently operate and maintain the Hydraulic Excavator Type 1 (HYEX), NSN 3805-01-573-0677. Instructions are included to cover most circumstances. However, it is impossible to address every scenario you may encounter. If you are unsure of what to do after looking in this TM, always contact your direct supervisor. These instructions provide the user with a general knowledge of the equipment, characteristics, and operating procedures of the HYEX. Troubleshooting and maintenance procedures are provided at crew maintenance levels. Operating instructions for most circumstances will be provided, but the user's best guide will be knowledge of the machine and its operation. In an emergency, a quick instinctive response based on that knowledge is essential. This manual contains a "References" Work Package (WP). Occasionally a different Technical Manual (TM) will be referenced in the text of this manual. A link will appear in parenthesis along with the manual that is referenced. The link lists the references WP in the manual. This will allow the user to see the TM number and the title. TABLE OF CONTENTS The table of contents provides a quick reference of each WP by Title and WP number, and lists each Figure and Table within that WP to assist in finding the required information except blank pages. WORK PACKAGE NUMBERS The WP number is found in the upper right corner of each page. It is also found at the bottom center of every page. INITIAL SETUP BLOCK The initial setup block contains information vital for the completion of the WP. In some instances, it may contain the words "Not Applicable". The following is a list of what is found in the initial setup block. 1. TOOLS AND SPECIAL TOOLS: These are all of the tools required to complete the tasks in the WP. 2. MATERIALS/PARTS: Any part to include oil, grease, or rags to complete the tasks in the WP. 3. PERSONNEL REQUIRED: Lists the number and Military Occupation Skill (MOS) required to complete the WP. 4. REFERENCES: When the reference is in the same manual, it will only list the WP number. If the reference is in a different manual, it will list the title and the WP number and will link you to the References WP for additional information. 5. EQUIPMENT CONDITION: This is how the machine needs to be configured before starting the work. 6. TIME TO COMPLETE: Not all WP will have the time to complete listed. Normally, maintenance and servicing procedures will list the time it should take to complete that WP. WARNINGS, CAUTIONS, AND NOTES Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure. Abbreviated formatted warnings are recognized when a warning in a WP has a single word that will be printed in all caps and BOLD. The full warning is in the warning summary and should be read prior to continuing the WP. Warning, caution, and note headings and certain essential information are printed in BOLD type for clarity. This is critical data to ensure personal safety, prevent damage to the machine, and clarify unique data or procedures used on the HYEX.

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HOW TO USE THIS MANUAL - Continued

CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION Chapter 1 presents general information, as well as the characteristics, capabilities, and features of the HYEX. Also included in Chapter 1 is HYEX theory of operation. CHAPTER 2 OPERATOR INSTRUCTIONS Chapter 2 provides operator instructions for starting and shutting off the machine, operation of standard functions, and driving procedures. Chapter 2 also provides operator instructions for individual equipment items in the HYEX. Included are description and location of driver's controls, fire suppression system, and the coolant heater system. CHAPTER 3 TROUBLESHOOTING PROCEDURES Chapter 3 provides operator level troubleshooting procedures for various malfunctions that may occur during machine operation. The troubleshooting index is a quick reference by WP of the common malfunctions/symptoms which you may find during the operation or maintenance of the HYEX or its attachments. CHAPTER 4 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Chapter 4 lists operator level preventive maintenance checks and services (PMCS) that are performed before machine operation, while it is being operated, and after the mission is completed. The PMCS table lists the item to be checked or serviced, the check or service procedure, and the criteria for determining whether the equipment being checked is ready for its mission. CHAPTER 5 MAINTENANCE INSTRUCTIONS Chapter 5 lists maintenance instructions the crew can perform on the machine. CHAPTER 6 SUPPORTING INFORMATION Chapter 6 lists the regulations, forms, pamphlets, field manuals, technical bulletins, and technical manuals that apply to this manual. Chapter 6 also includes Components of End Item (COEI), Basic Issue Items (BII), Additional Authorization List (AAL), and Expendable/Durable supplies and materials lists.

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CHAPTER 1 OPERATOR GENERAL INFORMATION FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE GENERAL INFORMATION

0001

SCOPE This manual contains instructions for operation, operator troubleshooting, and operator-performed maintenance on the Hydraulic Excavator Type 1 (HYEX). The HYEX is used for construction operations. MAINTENANCE FORMS AND RECORDS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094); or AR 700-138, Army Logistics Readiness and Sustainability (WP 0094). REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your HYEX needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you dont like about your equipment. Let us know why you dont like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/ aespublic.cfm (scroll down and choose "Submit Quality Deficiency Report" bar). The internet form lets you choose to submit an EIR, a Product Quality Deficiency Report (PDQR) or a Warranty Claim Action (WCA). You may also submit your information using an SF Form 368 (Product Quality Deficiency Report). You can send your SF Form 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094), and mail it to us at: Department of the Army, U.S. Army Tank-Automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 38397-5000. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materials is a continuing concern. It is important that any corrosion problems with the HYEX be reported so that the problem can be corrected and improvements can be made to prevent the problem in the future. While corrosion is typically associated with rusting of metals, corrosion can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency report (WP 0094). Use of key words, such as corrosion, rust, deterioration, and cracking, will ensure that the information is identified as a CPC problem. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE For procedures to destroy the HYEX to prevent its use by the enemy, refer to TM 750-244-6, Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (WP 0094). PREPARATION FOR STORAGE OR SHIPMENT Contact Field Maintenance for instructions on preparation for storage or shipment. WARRANTY INFORMATION The HYEX is warranted by John Deere. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record (WP 0094). Refer to TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D LC (WP 0094).

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TM 5-3805-294-10 LIST OF ABBREVIATIONS/ACRONYMS Table 1. List of Abbreviations/Acronyms. Abbreviation/Acronym AAL A/C ACC AEPS A/I or A.I. AOAP BII CAGEC cm COEI CPC CTA E ECU EDRS EIR FC FH ft gal h HET hp H/P Description Additional Authorization List Air Conditioning Accessory Army Electronic Product Support Auto-Idle Army Oil Analysis Program Basic Issue Items Commercial and Government Entity Code Centimeter Components of End Item Corrosion Prevention and Control Common Table of Allowance Economy Engine Control Unit Electronic Deficiency Reports Equipment Improvement Record Full-Cool Full-Heat Feet Gallon Hour Heavy Equipment Transport Horsepower High Power

0001

0001-2

TM 5-3805-294-10 LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. HYEX in. INT kg kohm L L/h m mm P PMCS P/N psi QDR TAMMS END OF WORK PACKAGE List of Abbreviations/Acronyms - Continued. Hydraulic Excavator Inch Intermittent Kilogram Kilo ohm Liter Liter/hour Meter Millimeter Power Preventive Maintenance Checks and Services Part Number Pounds per Square Inch Quality Deficiency Report The Army Maintenance Management System

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TM 5-3805-294-10 OPERATOR MAINTENANCE EQUIPMENT DESCRIPTION AND DATA

0002

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 360degree 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 -25F to 120F (-31.6C to 48.8C) without restriction, and when required, down to -40F (-40C) 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.

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TM 5-3805-294-10

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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 Nm)), 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.

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TM 5-3805-294-10 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

5

0002

6 8

9
HYEX00104

Figure 1. Table 1. 1 2 3 4 5 6 7 8 9

Right View of HYEX.

Right View of HYEX.

FUEL TANK. Contains JP-8, diesel, or other NATO-approved fuels for engine operation. HYDRAULIC RESERVOIR. Contains hydraulic oil for the hydraulic system. HYDRAULIC PUMPS. Draws hydraulic fluid from the hydraulic reservoir and provides hydraulic pressure and control pressure to the rest of the hydraulic system. COUNTERWEIGHT. Adds stability to the machine during digging and lifting operations. ARM CYLINDER. Extends and retracts the arm. BOOM CYLINDERS. Raises and lowers the boom. ATTACHMENT CYLINDER. Curls the bucket while digging and allows for dumping. HYDRAULIC THUMB CYLINDER. Extends and retracts the hydraulic thumb. TOOL BOX. Used for storage of Basic Issue Items (BII).

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TM 5-3805-294-10 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

0002

20 17 16

10

11 12 19

16 18 15 13
Figure 2. Table 2. 10 11 12 13 14 15 16 17 18 19 20 Left View of HYEX.

14

HYEX00105

Left View of HYEX.

ENGINE. Drives the hydraulic pumps and the pilot pump. RADIATOR. Contains coolant which provides engine cooling. BATTERIES. Two 12-volt batteries provide current for the electrical system. CAB. All digging and travel functions are controlled by the operator. TRAVEL MOTORS. Drives the machine forward or backward and provides turning capability. BUCKET. Used for digging operations. ARM. Used to connect quick latch or different attachments depending on mission. HYDRAULIC THUMB. Used with the bucket attachment to clamp and lift. UNDERCARRIAGE. Consists of the lower structure and the track assemblies. UPPERSTRUCTURE. Consists of the upperstructure, engine/hydraulic pump compartment, cab, boom and arm, and accessories. HYDRAULIC HOSE REEL. Quick attach hose reel used to power hydraulic tools and accessories.

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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. 21 22

Data Plates.

Data Plates.

IDENTIFICATION PLATE. The identification plate has the model, serial number, registration number, manufacture's name and the warranty information on it. SERIAL NUMBER PLATE. Has the machine serial on it.

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TM 5-3805-294-10

0002

EQUIPMENT DATA Table 4. ENGINE: Model Manufacturer Horsepower (2,000 rpm) Number of Cylinders Displacement CAPACITIES: Fuel Tank Cooling System Engine Oil (including oil filter) Hydraulic Reservoir Hydraulic System Swing Gearbox Travel Gearbox (each) Pump Drive Gearbox 132 gal (500 L) 7.9 gal (29.9 L) 6.5 gal (24.6 L) 64.2 gal (243 L) 74 gal (280 L) 2.4 gal (9.1 L) 2.1 gal (7.9 L) 1.2 qt (1.1 L) PowerTech John Deere 177 hp (132 kW) 6 414 cu in. (6.8 L) Equipment Data.

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TM 5-3805-294-10 EQUIPMENT DATA - Continued

0002

12 3

9 8

7 1 2 10 11

HYEX00106

Figure 4. Table 5. ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION Sprocket Center to Idler Center Undercarriage Counterweight Clearance Rear End Swing Radius Upper Structure Width (excluding back mirrors) Cab Minimum Ground Clearance Center of Sprocket to Center of Sprocket Track Shoes Undercarriage Machine Machine Machine

HYEX Specifications.

HYEX Specification. MEASUREMENT Distance Length Distance Distance Distance Height Distance Distance Width Width Overall Length Transport Height Shipping Weight SPECIFICATION 12 ft 7 in. (3840 mm) 15 ft 3 in. (4640 mm) 3 ft 7 in. (1090 mm) 9 ft 8 in. (2940 mm) 9 ft 6 in. (2890 mm) 9 ft 11 in. (3020 mm) 1 ft 6 in. (460 mm) 8 ft 6 in. (2590 mm) 32 in. (800 mm) 133 in. (2780 mm) 399 in. (10134 mm) 122 in. (3099 mm) 66,000 lb (29937 kg)

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TM 5-3805-294-10 EQUIPMENT DATA - Continued

0002

1 2 6 7 8

HYEX00107

Figure 5. HYEX Working Ranges.

0002-8

TM 5-3805-294-10 EQUIPMENT DATA - Continued Table 6. ITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION Maximum Digging reach Maximum Digging reach at Ground Level Minimum Swing Radius Maximum Cutting Height Maximum Dumping Height Maximum Digging Depth Maximum Digging Depth (flat bottom) Maximum Vertical Wall Tail Swing Radius HYEX Working Ranges. MEASUREMENT Distance Distance Radius Height Height Depth Depth Depth Radius SPECIFICATION 35 ft 6 in. (10810 mm) 34 ft 11 in. (10640 mm) 11 ft 4 in. (3460 mm) 34 ft 6 in. (10520 mm) 24 ft 9 in. (7540 mm) 24 ft 7 in. (7490 mm) 24 ft 1 in. (7330 mm) 21 ft 9 in. (6630 mm) 9 ft 8 in. (2940 mm)

0002

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TM 5-3805-294-10 EQUIPMENT DATA - Continued

0002

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) 20 (6.10) 15 (4.57) 10 (3.05) 5 (1.25) Ground Line -5 (-1.52) -10 (-3.05) -15 (-4.57) -20 (6.10) 15.60 lb (7.07 kg)* 13.06 lb (5.92 kg)* 22.51 lb (10.21 kg)* 29.63 lb (13.43 kg)* 14.69 lb (6.66 kg)* 20.76 lb (9.41 kg)* 24.56 lb (11.14 kg)* 25.71 lb (11.66 kg)* 25.00 lb (11.33 kg)* 22.54 lb (10.22 kg)* 17.28 lb (7.83 kg)* 8.52 lb (3.86 kg)* 11.56 lb (5.24 kg)* 14.49 lb (6.57 kg)* 16.88 lb (7.65 kg)* 17.90 lb (8.11 kg) 17.77 lb (8.06 kg) 16.71 lb (7.57 kg)* 12.10 lb (5.48 kg)* 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 25 (7.62) 7.55 lb (3.42 kg)* 8.61 lb (3.90 kg)* 10.05 lb (4.56 kg)* 11.62 lb (5.27 kg)* 12.79 lb (5.80 kg) 12.48 lb (5.66 kg) 12.39 lb (5.62 kg) 12.31 lb (5.58 kg) 6.26 lb (2.84 kg)* 8.09 lb (3.66 kg)* 9.68 lb (4.39 kg) 9.46 lb (4.29 kg) 9.31 lb (4.22 kg) 30 (9.14)

* Hydraulically Limited Capacity

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TM 5-3805-294-10 EQUIPMENT DATA - Continued

0002

Table 8.

Side Lift Capacities.

LIFTING OVER SIDE IN 1,000 lb (454 kg) ft (m) 20 (6.10) 15 (4.57) 10 (3.05) 5 (1.52) Ground Line -5 (-1.52) -10 (-3.05) -15 (-4.57) -20 (6.10) 15.60 lb (7.07 kg)* 13.06 lb (5.92 kg)* 22.51 lb (10.21 kg)* 29.63 lb (13.44 kg)* 14.69 lb (6.66 kg)* 18.90 lb (8.57 kg) 17.62 lb (7.99 kg) 17.16 lb (7.78 kg) 17.15 lb (7.77 kg) 17.46 lb (7.91 kg) 17.28 lb (7.83 kg)* 8.52 lb (3.86 kg)* 11.56 lb (5.24 kg)* 12.10 lb (5.48 kg) 11.35 lb (5.14 kg) 10.92 lb (4.95 kg) 10.80 lb (4.89 kg) 10.96 lb (4.97 kg) 11.53 lb (5.22 kg) 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 25 (7.62) 7.55 lb (3.42 kg)* 8.61 lb (3.90 kg)* 8.88 lb (4.02 kg) 8.39 lb (3.80 kg) 7.96 lb (3.61 kg) 7.68 lb (3.48 kg) 7.59 lb (3.44 kg) 7.77 lb (3.52 kg) 6.26 lb (2.84 kg)* 6.29 lb (2.85 kg) 6.04 lb (2.73 kg) 5.81 lb (2.63 kg) 5.67 lb (2.57 kg) 30 (9.14)

* Hydraulically Limited Capacity

0002-11

TM 5-3805-294-10 EQUIPMENT DATA - Continued HYEX weights with attachments. Table 9. Machine Weight 66,000 (29937 kg) 66,000 (29937 kg) 66,000 (29937 kg) 66,000 (29937 kg) 66,000 (29937 kg) 66,000 (29937 kg) HYEX Weights With Attachments. Total weight 66,750 lb (30277 kg) 66,840 lb (30318 kg)

0002

Attachment and Weight Barrier Grappler 750 lb (341 kg) Compactor 840 lb (381 kg)

Heavy Duty Bucket 1,600 lb (726 kg). 67,600 lb (30663 kg) Ditching Bucket 1,600 lb (726 kg) Breaker 4,900 lb (2223 kg) Crush-All 5,800 lb (2631 kg) 67,600 lb (30663 kg) 70,900 lb (32160 kg) 71,800 lb (32568 kg)

Deep dig arm weighs 3,000 lb (1361 kg) and additional counterweight with four mounts and two spacer plates for deep dig arm operation weigh 1,550 lb (703 kg). Table 10. Deep Dig Arm Weights. Machine/Deep Dig Arm/ Counterweight 67,550 lb (30640 kg) 67,550 lb (30640 kg) Attachment and Weight Deep Dig Bucket 1,000 lb (454 kg) Total Weight 68,550 lb (31094 kg)

Deep Ditch Cleaning Bucket 1,000 lb 68,550 lb (31094 kg) (454 kg)

END OF WORK PACKAGE

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TM 5-3805-294-10 OPERATOR MAINTENANCE THEORY OF OPERATION

0003

SCOPE This section explains how components of the HYEX work together. A functional description is given for the engine, Electronic Control Unit (ECU), fuel system, cooling system, electrical system, and hydraulic system. Engine The engine is a John Deere 6068H PowerTech Plus, 6.8L, 6-cylinder diesel engine. The 6068H includes a turbocharger, electronic control unit, 4-valve per cylinder head, electronic fuel injectors, and a high-pressure common rail fuel system. The 6068H is air-to-air after cooled to help reduce exhaust emissions while maintaining low-speed torque. The engine application includes a hydraulically-driven cool-on-demand fan system. ECU The electronic control system serves as an engine governor, controlling the engine speed by delivering fuel, in precise amounts, and at precise time according to a given set of engine conditions in relation to piston position. In order to achieve this, the control system performs the following functions: Constantly monitors engine operating conditions Performs system diagnosis Notify operator of machine faults through the monitor Can derate or shut down engine to prevent damage

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TM 5-3805-294-10 ECU - Continued Electrical System

0003

5 1
HYEX01511

Figure 1. Electrical System Components. Table 1. 1 2 3 4 Batteries Alternator Starter Motor Slave Receptacle Electrical System Components.

The batteries provide power for the electrical circuits. Two 12-volt batteries are connected in series to provide 24-volt starting power. The alternator provides 28-volt, 80-amp. current to charge the batteries and operate the electrical system. Part of the starting circuit, the starter motor is used to turn the engine flywheel fast enough to start the engine. The slave receptacle can be used to charge the batteries and slave start the engine from an external power source. The slave receptacle can also be used to charge and slave start other equipment. The fuse panel provides centrally located fuses that will open the battery circuit if there is a shorted, grounded wire or excessive current draw by a defective component in the corresponding circuit. When the circuit is open, no current will flow through the electrical system. Fuses are easily replaced. If a fuse continually trips, the affected component or vehicle electrical system requires repair.

Fuse Panel

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TM 5-3805-294-10 Hydraulic System

10 11

0003

14

13 15 9 12 16

17 6
HYEX01512

Figure 2. Table 2. 6 7 Main Pumps Pilot Pump

Hydraulic System Components.

Hydraulic System Components.

The HYEX has two main hydraulic pumps that supply hydraulic oil for all functions including boom, arm, bucket, swing, and travel. The pilot pump is a small gear pump that keeps oil moving through the pilot system. It also provides the pressure to move the spools in the main hydraulic valve and to release the spring-applied hydraulically-released swing and park brakes. The hydraulic reservoir is pressurized ensuring that hydraulic oil is always supplied to the pumps. The control valve consists of two monoblock valves referred to as the left control valve and right control valve. There is a spool in each valve to control the boom, arm, and travel functions. All other functions are supplied by a single spool in one or the other of the valves. All spools are moved by pilot oil. Each valve section controls the flow rate and direction for its hydraulic circuit.

8 9

Hydraulic Reservoir Main Control Valve

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TM 5-3805-294-10 Hydraulic System - Continued

0003

10

11

14

13 15 9 12 16

17 6
HYEX01512

Figure 3. Hydraulic System Components Continued. Table 3. 10 Pilot Signal Manifold Hydraulic System Components Continued.

The pilot signal manifold is in the pilot system between the pilot control valves and the control valve and regulators. The manifold receives a pilot signal from the pilot control valves and sends the signal on multiple paths simultaneously so there is little lag between operation of the pilot control valves, pump stroke, and function movement. The swing motor uses hydraulic pressure supplied by the pumps to make the upper structure rotate. It has a spring-applied hydraulically-released swing brake. The swing brake engages as soon as the swing controls are released. 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. The boom cylinders are attached to the main frame and the boom. When activated they raise and lower the boom. The arm cylinder is attached between the boom and the arm. When activated, this cylinder moves the arm in and out.

11

Swing Motor

12 13 14

Rotary Manifold Boom Cylinders Arm Cylinder

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TM 5-3805-294-10 Hydraulic System - Continued Table 3. 15 Hydraulic Thumb Cylinder Hydraulic System Components Continued - Continued.

0003

The hydraulic thumb cylinder is attached between the arm and the thumb. When activated, this cylinder extends and retracts the hydraulic thumb. The hydraulic thumb cylinder circuit can be closed to provide the hydraulic power to operate the crush-all, breaker, compactor and deep dig arm accessories. The bucket cylinder is attached between the arm and the quick latch. When activated, this cylinder extends and curls the bucket or attachments. Reduced leakage valves are used in the boom head-end circuit and arm rodend circuit. The function of a reduced leakage valve is to reduce cylinder drift by stopping leakage from the cylinder back through the control valve.

16 17

Bucket Cylinder Load Holding Valves

Powertrain

21 18 20

19
HYEX01513

Figure 4. Table 4. 18 Track Chain Adjuster

Powertrain Components.

Powertrain Components.

The track chain adjuster is located between the frame and the track chain idler. Grease is added or removed to adjust the track sag. The recoil spring is located with the track chain adjuster and absorbs shocks to the tracks and track chain idler. The track assembly consists of the chain and shoes. The travel motor drives the track to move the machine. The machine has two carrier rollers and nine lower track rollers on each side of the machine. The rollers guide the tracks and keep the tracks in contact with the ground. The travel motors are located inside the tracks to prevent damage during operation. The travel system has a spring-applied hydraulically-released parking brake. The parking brake engages as soon as the travel controls are released.

19 20

Track Rollers

21

Travel Motor

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TM 5-3805-294-10 Fuel System

0003

22

24 27

23

25 28

26
HYEX01514

Figure 5. Fuel System Components. Table 5. 22 23 24 25 26 27 28 Fuel Transfer Pump Primary Fuel/Water Separator Secondary Fuel/Water Separator Lubricity Canister Fuel Tank Fuel Tank Strainer Fuel Tank Drain Valve Fuel System Components.

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. The primary water separator keeps large particles and contaminants from entering the high-pressure fuel pump. The secondary water separator keeps small particles and contaminants from entering the pressure fuel pump. The lubricity canister is a spin-on canister with a lubricant that is slowly released into the fuel. To enable use of all types of diesel fuels. The fuel tank has 132 gal (500 liter) capacity and is equipped with a low fuel level alarm and vented fill cap. The strainer is designed to keep debris from entering the fuel system. The drain valve is used to remove water and debris from the fuel tank.

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TM 5-3805-294-10 Fuel System - Continued

0003

30

29
Figure 6. Table 6. 29 30 High-Pressure Fuel Pump Fuel Injectors High-Pressure Pump and Injectors.

HYEX01515

High-Pressure Pump and Injectors.

The high-pressure fuel pump increases the fuel pressure to send exact amounts of fuel to the injector nozzles. The fuel injectors turn the stream of fuel into a fine spray, which permits good combustion in the cylinder. There is one nozzle for each cylinder. The injectors are located under the rocker arm cover.

0003-7

TM 5-3805-294-10 Fuel System - Continued Cooling

0003

31

33

32

34
HYEX01516

Figure 7. Table 7. 31 32 33 34 Radiator Hydraulic Oil Cooler Charge Air Cooler Fuel Cooler

Cooling Package. Cooling Package.

Coolant circulates through the radiator to be cooled after leaving the cylinder block. The hydraulic oil cooler uses air from the fan to cool the oil before returning it to the reservoir. The charge air cooler cools the air supplied to the engine to decrease fuel consumption and emissions. Fuel is circulated across the cooler to lower fuel temperature.

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TM 5-3805-294-10 Cooling - Continued

0003

35

36

37

HYEX01517

Figure 8. Table 8. 35 36 37 Coolant Surge Tank Engine Oil Cooler Fan

Cooling System Components.

Cooling System Components.

The coolant surge tank is where the coolant level is checked and added. Coolant from the radiator passes through the engine oil cooler to maintain a safe operating temperature. The variable speed fan is located at the front of the engine and is driven by a hydraulic motor. The speed of the fan is varied to provide the amount of airflow that the engine coolant, charge air cooler, or hydraulic cooler need, ensuring maximum fuel efficiency, reduced noise levels, and faster engine warm up. A reversing function reverses the cooling fan to help clean the cooling package of dirt and debris.

END OF WORK PACKAGE

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TM 5-3805-294-10

CHAPTER 2 OPERATOR INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

0004

INTRODUCTION The following tables and illustrations provide the description and use of the controls and indicators pertaining to the front switch panel, heater and air conditioner control panel, control pedals and levers, left console, left and right control levers, seat controls and arm rest, coolant heater and cab door, and warning indicators and alarms. Table 1. Front Switch Panel.

4 5

1
Figure 1. Key Control/Indicator Function Front Switch Panel.

HYEX00867

Washer/Wiper Switch

Wiper switch has several positions. The OFF position stops the wipers from operating and parks them. The INT position operates the wipers intermittently at the interval selected by the switch position. The ON position operates the wipers continuously. To operate the washer, push and hold switch down for no more than 20 seconds. Note that the wiper will not operate unless the windshield is completely closed. This is a three-position switch. The first position turns on the drive light. Front Switch panel will also illuminate. The second position turns on the boom work lights, the front cab work lights, and the drive light. If the default screen on the monitor is displayed, the background goes from white to black.

Operating Lights Switch

0004-1

TM 5-3805-294-10

0004

Table 1. Front Switch Panel - Continued. Key Control/Indicator Function

Engine Speed Dial

The dial is used to increase or decrease engine speed.

4 5

1
Figure 2. 4 Auto-Idle (A/I) Switch Front Switch Panel Continued.

HYEX00867

This is a two-position switch. In the ON position, it will reduce the engine speed after 4 seconds when control levers are in the neutral position. In the OFF position the operator can set the engine speed to improve machine control. This is a three-position switch. The H/P mode is used when more hydraulic power is desired for raising the boom and rolling the bucket during excavation work. The Power (P) mode is used when performing general digging operations. The Economy (E) mode is used to increase fuel efficiency and reduces noise level. This is a two-position switch. It is used to select fast or slow speed of travel. This is a four-position switch. When in the OFF position, the key can be removed. Moving the switch to the ACC position allows the radio to be turned on or off. In the ON position, all electrical functions will operate. Move and release the switch to the START position starts the machine.

Power Mode Switch

6 7

Travel Mode Switch Key Switch

0004-2

TM 5-3805-294-10

0004

Table 2.

Heater/Air Conditioner (A/C) Controller and Radio.

16 9 15 14 13 10 12 11

17

HYEX00868

Figure 3. Heater/Air Conditioner (A/C) Controller and Radio. Key Control/Indicator Function

Blower Fan Speed Buttons Monitor Display A/C Button

Increases or decreases the speed of the blower fans. Turns on blower fans when A/C is off. Displays blower fan speed, selected air vent, and temperature setting. When pressed, it turns on the air conditioning (A/C) and illuminates the A/C indicator. When pressed, it turns on the AUTO and A/C indicators. Air flow-in temperature at the vent, blower fan speed, vent locations, and fresh air port are then automatically controlled.

9 10

11

AUTO Button

0004-3

TM 5-3805-294-10

0004

Table 2. Heater/Air Conditioner (A/C) Controller and Radio - Continued. Key Control/Indicator Function

12

OFF Button

When pressed the A/C and blower fans will turn off. Blower fans will turn on if one of the blower fan speed buttons is pressed even if the OFF button is on or off.
16 9 15 14 13 10 12 11

17

HYEX00868

Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued. 13 Temperature Control Buttons Recirculating Mode Button Fresh Air Mode Button Mode Button Radio Display Press buttons to set temperature from full-cool (FC) to full-heat (FH). The monitor display will show FC or FH. Press the recirculating mode button to close the fresh air vent and circulate air already in the cab. Press fresh air mode to route outside air into the cab.

14

15

16 17

Press to select air vent. Selected vent will display on the monitor display. The radio display contains standard AM/FM radio tuning and volume controls.

0004-4

TM 5-3805-294-10

0004

Table 3.

Control Pedals and Levers.

22

23

21

20

18

19

HYEX00869

Figure 5. Key Control/Indicator Function

Control Pedals and Levers.

18

Attachment Pedal

Primarily used to open and close the hydraulic thumb. When attachments are connected, hydraulic valve selection will disable the hydraulic thumb and enable this pedal to operate the attachment. Locks attachment pedal in the neutral position to disable the hydraulic thumb or any attachments that are connected. Controls the direction of travel and steers the machine. Pushing down on the top of the pedal moves the machine forward. Pushing down on the bottom of the pedal moves the machine backwards. Use this hand lever to perform the same functions as the right travel pedal with increased control. Pushing forward on the lever moves the machine forward. Pulling the lever moves the machine backwards.

19

Attachment Pedal Lock Right Travel Pedal

20

21

Right Travel Lever

0004-5

TM 5-3805-294-10

0004

Table 3. Key Control/Indicator

Control Pedals and Levers - Continued.

Function

22

Left Travel Pedal

Controls the direction of travel and steers the machine. Pushing down on the top of the pedal moves the machine forward. Pushing down on the bottom of the pedal moves the machine backwards.

22

23

21

20

18

19

HYEX00869

Figure 6. Control Pedals and Levers Continued. 23 Left Travel Lever Use this hand lever to perform the same functions as the left travel pedal with increased control. Pushing forward on the lever moves the machine forward. Pulling the lever moves the machine backwards.

0004-6

TM 5-3805-294-10

0004

Table 4.

Left Console and Pilot Shutoff Lever.

24

25

26

27

28

HYEX00870

Figure 7. Left Console and Pilot Shutoff Lever. Key Control/Indicator Function

24

Pilot Shutoff Lever

Controls hydraulic functions on the machine. With the lever in the locked position, hydraulic functions are not operational. In the unlocked position, all hydraulic functions operate. The engine will not start with the lever in the unlocked position. After the initial 13-second alarm, depressing the right half of the switch will shut the alarm off. Turns the rear cab work lights on and off.

25

Travel Alarm Switch

26

Rear Cab Work Lights Switch Auxiliary Control Switch Reversing Cooling Fan Switch

27

Disables the right joystick left and right button auxiliary function.

28

This is a three position switch that controls the direction that the cooling fan is moving. AUTO: Every 60 minutes the cooling fan will automatically reverse direction for 15 seconds without intervention from the operator. OFF Fan resumes normal operation. MANUAL: Fan will reverse direction for 15 seconds when right portion of switch is pressed.

0004-7

TM 5-3805-294-10

0004

Table 5.

Right and Left Pilot Control Levers.

31 32

30

29

HYEX00871

Figure 8. Key Control/Indicator Function

Right Pilot Control Lever.

29

Right Pilot Control Lever

When pushed forward, the boom lowers. When pulled back, the boom raises. When pulled left, the bucket will curl. When pushed right, the bucket will dump. When released the lever will return to the neutral position. Pressing the power dig button gives the operator an 8-second increase in hydraulic power. Used to close crush-all lid if connected.

30

Power Dig Button

31

Left Button Auxiliary Function Right Button Auxiliary Function

32

Used to open crush-all lid if connected.

0004-8

TM 5-3805-294-10

0004

Table 5. Right and Left Pilot Control Levers - Continued. Key Control/Indicator Function

33

Left Pilot Control Lever

When pushed forward, the arm will go out. When pulled back, the arm will come in. When pushed left, machine swings left. When pulled right, machine swings right. When released, lever returns to the neutral position.

34

33

HYEX00872

Figure 9. 34 Horn Button

Left Pilot Control Lever.

When pressed the horn will sound.

0004-9

TM 5-3805-294-10

0004

Table 6.

Seat Controls.

39 40

35 38 37

41

36
Figure 10. Seat Controls.

HYEX00873

Key

Control/Indicator

Function

35 36

Seat Angle Lever Seat Adjustment Handle Seat Weight Adjustment Knob Lumbar Adjustment

Allows seat to be adjusted to a desired angle. Pull up handle to adjust the seat forward or backward.

37

Turn knob to adjust seat suspension to the proper weight of the operator.

38

Squeeze ball to add air for desired lumbar firmness. Press button next to ball to release air.

0004-10

TM 5-3805-294-10

0004

Table 6. Key Control/Indicator Function

Seat Controls - Continued.

39

Backrest Adjustment Lever Armrest Angle Adjustment Seat Assembly Adjustment Lever

Pull up lever to release backrest and adjust to desired position, then release lever. Turn dial to adjust armrest to desired angle.

40

41

Pull handle to slide entire seat to desired distance from travel pedals.

0004-11

TM 5-3805-294-10

0004

Table 7.

Cab Door Release Lever and Coolant Heater Display.

43

44

45

46

47

48

42

HYEX00874

Figure 11. Cab Door Release Lever and Coolant Heater Display. Key Control/Indicator Function

42

Cab Door Release Lever Coolant Heater Display Clock Button

Push down to release cab door from the locked open position.

43

Displays date and time.

44

Pressing button displays date and time and allows to change date and time settings. Press the preset button to program the desired time to start cycle. Display will flash when a program is activated or if the coolant heater is manually operated. Used to lower time, date, or operating time depending on current screen.

45 46

Preset Button Heat Display

47

Lower Button

0004-12

TM 5-3805-294-10

0004

Table 7. Key

Cab Door Release Lever and Coolant Heater Display - Continued. Function

Control/Indicator

48

Raise Button

Used to raise time, date, or operating time depending on current screen.

Table 8.

Quick Latch Control.

49

50

HYEX00875

Figure 12. Key Control/Indicator Function

Quick Latch Control.

49 50

Quick Latch Switch Quick Latch Light

Used to lock and unlock quick latch. Illuminates when switch is in unlatch position.

0004-13

TM 5-3805-294-10

0004

Table 9.

Cab Light Switch.

51

HYEX01316

Figure 13. Key Control/Indicator Function

Cab Light Switch.

51

Cab Light Switch

Cab light has a two-position switch that turns the light on and off. It will only illuminate with the key switch turned on. (Not present when armored cab is installed).

0004-14

TM 5-3805-294-10

0004

Table 10.

Hydraulic Hose Reel.

52 54 53

55
HYEX00876

Figure 14. Key Control/Indicator Function

Hydraulic Hose Reel.

52 53

Hydraulic Hose Reel Hydraulic Tool Circuit Switch Hydraulic Tool Flow Regulator Deep Dig Control Pattern Switch

Used for hydraulic tools. Moved to the on position when using hydraulic tools.

54

Used to regulate the flow of hydraulic fluid when using the hydraulic hose reel.

55

Moved to the on position when using deep dig arm to enable the deep dig control pattern.

END OF WORK PACKAGE

0004-15/16 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE DESCRIPTION AND USE OF MONITOR AND ALARMS

0005

INTRODUCTION The following tables and illustrations provide the description and use of the monitor buttons, indicators, and warning indicators. Table 1. Monitor Buttons and Indicators.
A.I.

7777.7 h
F1 F2

F3 F4

17.3 L/h

8:01
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX00858

Figure 1. Key Control/Indicator Function

Monitor.

Button 1

Press button to key in the number 1 or use as instructed depending on current screen. Press button to key in the number 2 or use as instructed depending on current screen. Press button to key in the number 3 or use as instructed depending on current screen. Press button to key in the number 4 or use as instructed depending on current screen. Press button to key in the number 5 or use as instructed depending on current screen.

Button 2

Button 3

Button 4

Button 5

0005-1

TM 5-3805-294-10

0005

Table 1. Key Control/Indicator

Monitor Buttons and Indicators - Continued.

Function

Button 6/Return to Default Screen Button

Press button to key in the number 6, or to return to the default screen.

A.I.

7777.7 h
F1 F2

F3 F4

17.3 L/h

11

8:01
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

12 13

14

8
Figure 2.

10

HYEX00859

Monitor Buttons.

Button 7/F1 function button Button 8/F2 function button Button 9/F3 function button Button 0/F4 function button Select Button Back Button

Press button to key in the number 7 or to select the desired preset optional function from any screen. Press button to key in the number 8 or to select the desired preset optional function from any screen. Press button to key in the number 9 or to select the desired preset optional function from any screen. Press button to key in the number 0 or to select the desired preset optional function from any screen. Use button as instructed depending on current screen. Use button as instructed depending on current screen.

10

11 12

0005-2

TM 5-3805-294-10

0005

Table 1. Key Control/Indicator

Monitor Buttons and Indicators - Continued.

Function

13

Hour Meter Button

Without key inserted or with key switch OFF, press and hold button to display default screen and hour meter. Lights when an abnormality has occurred.

14

Alarm Indicator Light

Main Menu
Time Set Attachment Adjustment Operating Conditions Maintenance Settings

15
6 7 F1 8 F2 9 F3 0 F4

HYEX01319

Figure 3. 15 Menu Button

Main Menu.

Press button to display main menu from any screen. Main menu includes time set, attachment adjustment, operating conditions, and maintenance settings.

0005-3

TM 5-3805-294-10

0005

Table 1. Key Control/Indicator

Monitor Buttons and Indicators - Continued.

Function

16

Coolant Temperature Gauge

Indicates the engine coolant temperature. Needle should be around the center of the scale during operation.

17

18
A.I.

19 20 21 22

24 23 25

7777.7 h
F1 F2

F3 F4

28

17.3 L/h

16
1 2 3

8:01
4 5

29 27
6 7 F1 8 F2 9 F3 0 F4

26 30
Figure 4. 17 Work Mode Indicator Auto-Idle Indicator Monitor Indicators.
HYEX00860

The icon for the current attachment being used is displayed.

18

When selecting auto-idle from the front switch panel, the auto-idle icon displays. Optional auxiliary data icon displays. Optional auxiliary data icon displays. Optional auxiliary data icon displays. If preheat is required, the preheat icon is displayed.

19 20 21 22

Auxiliary Indicator Auxiliary Indicator Auxiliary Indicator Engine Preheat Indicator Hour Meter

23

Total machine operation hours counted since the machine started working are displayed in the unit of hour (h). One digit after the decimal point indicates tenths of an hour (6 minutes).

0005-4

TM 5-3805-294-10

0005

Table 1. Key Control/Indicator

Monitor Buttons and Indicators - Continued.

Function

24

F1 Function Button Indicator F2 Function Button Indicator F3 Function Button Indicator F4 Function Button Indicator Fuel Gauge Fuel Rate Display Clock

Optional indicator icon is displayed.

25

Optional indicator icon is displayed.

26

Optional indicator icon is displayed.

27

Optional indicator icon is displayed.

28 29 30

Shows level of fuel in fuel tank. Fuel consumption in Liter/hour (L/h) is displayed. Indicates present time.

0005-5

TM 5-3805-294-10

0005

Table 2.

Warning Indicators and Alarms.

31

32

33

34

35

36

39 37 38
HYEX00861

Figure 5. Key Control/Indicator Function

Warning Indicators and Alarms.

31

Engine Overheat Alarm Engine Warning Alarm Engine Oil Pressure Alarm Alternator Alarm

Displays when engine coolant temperature has abnormally increased.

32

Displays when engine has an abnormal operating condition.

33

Displays when oil pressure has decreased.

34

Displays when an abnormality in the electrical system has occurred.

0005-6

TM 5-3805-294-10

0005

Table 2. Warning Indicators and Alarms - Continued. Key Control/Indicator Function

35

Remaining Fuel Alarm Hydraulic Oil Filter Alarm Air Cleaner Clogged Alarm Work Mode Alarm Pilot Shutoff Lever Alarm

Displays when fuel level is low.

36

Displays when hydraulic filter is clogged.

37

Displays when air cleaner are clogged.

38 39

Displays when work mode is abnormal. Displays when pilot shutoff system is abnormal.

40
HYEX00862

Figure 6. 40 Overload Alarm

Overload Alarm.

Illuminates when an overload condition exists when digging.

END OF WORK PACKAGE

0005-7/8 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ADJUSTING THE OPERATOR'S SEAT

0006

INITIAL SETUP: Not Applicable

ADJUSTMENT

NOTE
Proper seat adjustment is achieved when operator can reach the foot control pedals and the travel levers easily with the seat belt buckled. 1. Push down on handle (Figure 1, Item 1) to tilt seat (Figure 1, Item 2).

9 10 2 6

13 11 12

1 7 3

4
Figure 1. Operator's Seat Adjustments.

HYEX00145

2. 3. 4.

Turn knob (Figure 1, Item 3) to set operator weight. Pull up on handle (Figure 1, Item 4) to slide seat (Figure 1, Item 2). Push on lever (Figure 1, Item 5) to slide seat (Figure 1, Item 2) and controls (Figure 1, Item 6).

0006-1

TM 5-3805-294-10 ADJUSTMENT - Continued 5. 6. 7. 8. 9. 10. Squeeze bulb (Figure 1, Item 7) to increase lumbar support. Push button (Figure 1, Item 8) to decrease lumbar support. Pull up on handle (Figure 1, Item 9) to unlock backrest (10). Raise or lower headrest (Figure 1, Item 11) to desired height. Tilt headrest (Figure 1, Item 11) to desired angle. Turn dial (Figure 1, Item 12) on underside of armrest (Figure 1, Item 13) to adjust angle.

0006

END OF TASK END OF WORK PACKAGE

0006-2

TM 5-3805-294-10 OPERATOR MAINTENANCE STARTING THE ENGINE

0007

INITIAL SETUP: Equipment Condition Before operations Preventive Maintenance Checks and Services performed. (WP 0077) Operators seat adjusted. (WP 0006)

STARTING THE ENGINE

WARNING

Perform a complete walk around the machine prior to starting the engine. Ensure sufficient clearance from personnel and equipment for safe operation of machine. Prior to starting engine sound horn to alert personnel. Failure to comply may result in injury or death to personnel. 1. Buckle the seat belt (Figure 1, Item 1).

HYEX00090

Figure 1.

Seat Belt.

NOTE
Engine will not start unless pilot shutoff lever is in the LOCKED (up) position. 2. Place pilot shutoff lever (Figure 2, Item 2) in LOCKED (up) position.

0007-1

TM 5-3805-294-10 STARTING THE ENGINE - Continued

2

0007

HYEX00091

Figure 2. 3.

Pilot Shutoff Lever.

Turn engine speed dial (Figure 3, Item 3) to slow idle position.

HYEX00092

Figure 3. 4.

Engine Speed Dial Slow Idle.

Turn key switch (Figure 4, Item 4) to ON position.

0007-2

TM 5-3805-294-10 STARTING THE ENGINE - Continued

0007

HYEX00093

Figure 4.

Key Switch ON.

NOTE
When the ignition key is turned to the ON position, the "System Starting" screen will display for about 2 seconds. The default screen will then be displayed. 5. Wait for "System Starting" screen (Figure 5, Item 5) to change to default screen (Figure 5, Item 6).
6

System Starting...
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX00094

Figure 5.

System Starting and Default Screen.

NOTE
At approximately 32F (0C) or below, the pre-heat indicator will be displayed for up to 15 seconds depending on engine fuel temperature. 6. Wait until engine preheat indicator (Figure 6, Item 7) is no longer displayed.

0007-3

TM 5-3805-294-10 STARTING THE ENGINE - Continued

7
A.I.

0007

7777.7 h
F1 F2

F3 F4

17.3 L/h

8:01
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX00095

Figure 6.

Preheat Indicator.

CAUTION
Never operate starter longer than 20 seconds at a time. If engine fails to start, return key switch to OFF position and wait 2 minutes before attempting to start again. Failure to comply may result in damage to equipment. After a false start, wait until engine stops spinning before turning the key again. Failure to comply may result in damage to equipment.

NOTE
Key switch will return to ON position when key is released. 7. Turn key switch (Figure 7, Item 4) to START position and release when engine starts.

HYEX00099

Figure 7. Key Switch to START.

0007-4

TM 5-3805-294-10 STARTING THE ENGINE - Continued

0007

CAUTION
If alarm indicators are still displayed after starting the engine, immediately shut down the engine. Failure to comply may result in damage to equipment. Do not run engine at fast idle or rapidly accelerate engine until it has reached normal operating temperature. Failure to comply may result in damage to equipment. 8. After the engine is started, ensure that no alarm indicators (Figure 8, Item 8) are displayed.

HYEX00096

Figure 8. 9.

Alarm indicator.

Move engine speed dial (Figure 9, Item 3) right 1/3 and allow engine to idle for 30 seconds.

HYEX00100

Figure 9. 10.

Engine Speed Dial Turned to 1/3 Position.

Turn engine speed dial (Figure 10, Item 3) to slow idle position until machine reaches normal operating temperature.

0007-5

TM 5-3805-294-10 STARTING THE ENGINE - Continued

0007

HYEX00092

Figure 10. Return Engine Speed Dial to Slow Idle. END OF TASK END OF WORK PACKAGE

0007-6

TM 5-3805-294-10 OPERATOR MAINTENANCE MOVING THE HYEX

0008

INITIAL SETUP: Equipment Condition Engine running. (WP 0007)

MOVING THE HYEX

WARNING

Before moving the machine or operating the boom, ensure that the boom has at least 10 ft (3 m) of clearance from overhead wires, power lines, or structures. If lines are near to your operating area, notify your supervisor prior to operating the boom. Failure to comply may result in injury or death to personnel. Keep personnel clear of the machine when traveling. Failure to comply may result in injury or death to personnel.

NOTE
If traveling long distances, ensure that travel motors are at the back of the machine. If travel motors are at the front of the machine, the machine moves in opposite direction as described in these procedures. When traveling up slopes, keep the bucket on the uphill side and just above the ground. When traveling down a slope, operate control pedals or levers slowly. 1. Move pilot shutoff lever (Figure 1, Item 1) to the unlocked (down) position.

120

LOCK

HYEX00146

Figure 1.

Pilot Shutoff Lever Unlocked.

0008-1

TM 5-3805-294-10 MOVING THE HYEX - Continued 2.

0008

Raise boom (Figure 2, Item 2) and arm (Figure 2, Item 3) off of ground to allow for sufficient visibility and to keep machine stable.

HYEX00147

Figure 2.

Boom and Arm Raised.

CAUTION
When traveling over rough terrain, reduce travel speed to avoid undercarriage damage. Failure to comply may result in damage to equipment.

NOTE
If carrying a heavy load, keep travel mode switch in the low position for more control of the machine. 3. Move travel mode switch (Figure 3, Item 4) to high position.

HYEX00148

Figure 3. Travel Mode Switch.

NOTE
Travel speed of machine is controlled by the foot pedals or travel levers.

0008-2

TM 5-3805-294-10 MOVING THE HYEX - Continued 4.

0008

Push down on the front of both foot pedals (Figure 4, Items 5 and 6), or push both travel levers (Figure 4, Items 7 and 8) forward to move HYEX forward.

7 5

8 6

HYEX01297

Figure 4. 5. 6.

Moving Forward and Backwards.

Push down on the rear of both foot pedals (Figure 4, Items 5 and 6) or pull both travel levers (Figure 4, Items 7 and 8) to move the HYEX backwards. Allowing both foot pedals (Figure 4, Items 5 and 6), or both travel levers (Figure 4, Items 7 and 8) to return to center, will stop the HYEX.

END OF TASK STEERING THE HYEX

WARNING

Keep personnel clear of the machine when traveling. Failure to comply may result in injury or death to personnel. Use care when backing the machine. Watch clearances. Have an assistant direct you if you cannot see where you are going. Failure to comply may result in injury or death to personnel.

NOTE
If travel motors are at the front of the machine, the machine moves in opposite direction as described in these procedures.

0008-3

TM 5-3805-294-10 STEERING THE HYEX - Continued 1.

0008

Pushing front of left foot pedal (Figure 5, Item 5) or push left travel lever (Figure 5, Item 7) forward with right foot pedal (Figure 5, Item 6) and right travel lever (Figure 5, Item 8) at center turns the HYEX right.

7 5

8 6

HYEX01296

Figure 5. 2.

Right Turn.

Pushing front of right foot pedal (Figure 6, Item 6) or push right travel lever (Figure 6, Item 8) forward with left foot pedal (Figure 6, Item 5) and left travel lever (Figure 6, Item 7) at center turns the HYEX left.

7 5

8 6

HYEX01295

Figure 6. 3.

Left Turn.

Pushing front of left foot pedal (Figure 7, Item 6), or push left travel lever (Figure 7, Item 8) forward and push down on rear of right foot pedal (Figure 7, Item 7) or pull right travel lever (Figure 7, Item 8) back to counterrotate.

0008-4

TM 5-3805-294-10 STEERING THE HYEX - Continued

0008

7 5

8 6

HYEX01291

Figure 7. 4.

Counter-Rotate.

Allowing both foot pedals (Figure 7, Items 5 and 6) or both travel levers (Figure 7, Items 7 and 8) to return to center will stop the HYEX.

END OF TASK END OF WORK PACKAGE

0008-5/6 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE SHUTTING DOWN THE HYEX

0009

INITIAL SETUP: References WP 0004 References (cont.) WP 0011 WP 0010

SAFELY PARK HYEX 1. Park machine (Figure 1, Item 1) on solid, level surface.

4 1

HYEX02418

Figure 1.

Machine In Parked Position.

NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground. 2. Keeping angle between arm (Figure 1, Item 2) and boom (Figure 1, Item 3), position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004)

END OF TASK SHUT DOWN ENGINE 1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.

0009-1

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0009

HYEX00153

Figure 2.

Auto-Idle Switch and Engine Speed Dial.

CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may result in damage to equipment.

NOTE
Engine speed dial shown approximately at 1/3 position. 2. 3. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load. Turn engine speed dial (Figure 3, Item 6) to slow idle position.

0009-2

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0009

HYEX00154

Figure 3. 4.

Engine Speed Dial.

Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position.

HYEX00155

Figure 4. 5.

Pilot Shutoff Lever.

Turn key switch (Figure 5, Item 8) to OFF position and remove key.

0009-3

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0009

HYEX00157

Figure 5. Key Switch Turned OFF.

CAUTION
Ensure all windows and doors are closed when machine is parked to prevent electrical system damage during inclement weather. Failure to comply may result in damage to equipment. 6. Close windows. (WP 0011)

END OF TASK END OF WORK PACKAGE

0009-4

TM 5-3805-294-10 OPERATOR MAINTENANCE SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED

0010

INITIAL SETUP: References WP 0004 WP 0011 Equipment Condition Engine running. (WP 0007)

SAFELY PARK MACHINE 1. Park machine (Figure 1, Item 1) on solid, level surface.

3 1

4
HYEX01637

Figure 1.

Machine In Parked Position.

NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground. 2. Keeping angle between deep dig arm (Figure 1, Item 2) and arm (Figure 1, Item 3) at approximately 90 degrees, position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004)

END OF TASK SHUT DOWN ENGINE 1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.

0010-1

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0010

HYEX01507

Figure 2.

Auto-Idle Switch and Engine Speed Dial.

CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may result in damage to equipment.

NOTE
Engine speed dial shown approximately at 1/3 position. 2. 3. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load. Turn engine speed dial (Figure 3, Item 6) to slow idle position.

0010-2

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0010

HYEX01508

Figure 3. 4.

Engine Speed Dial.

Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position.

HYEX01509

Figure 4. 5.

Pilot Shutoff Lever.

Turn key switch (Figure 5, Item 8) to OFF position and remove key.

0010-3

TM 5-3805-294-10 SHUT DOWN ENGINE - Continued

0010

HYEX01510

Figure 5. Key Switch Turned OFF.

CAUTION
Ensure all windows and doors are closed when machine is parked to prevent electrical system damage during inclement weather. Failure to comply may result in damage to equipment. 6. Close windows. (WP 0011)

END OF TASK END OF WORK PACKAGE

0010-4

TM 5-3805-294-10 OPERATOR MAINTENANCE OPENING AND CLOSING WINDOWS

0011

INITIAL SETUP: Not Applicable

WINDSHIELD

NOTE
The wiper will not operate with windshield open. The washer can operate with windshield open. 1. Pull lock pin (Figure 1, Item 1) inward and rotate into notch.

2 3

HYEX00160

Figure 1. 2. 3.

Open Windshield.

Pull on latch release bar (Figure 1, Item 2) to open windshield (Figure 1, Item 3). Lift on handle (Figure 2, Item 4) to raise windshield (Figure 2, Item 3) until it latches open.

0011-1

TM 5-3805-294-10 WINDSHIELD - Continued

0011

4 3

HYEX00161

Figure 2.

Raise Windshield.

WARNING

Lock pin must be used to secure upper front window in raised position. Failure to comply may result in injury or death to personnel. 4. Release lock pin (Figure 3, Item 1) from notch and slide into cab frame lock hole (Figure 3, Item 5).

HYEX00162

Figure 3. 5.

Lock Windshield Open.

To close the windshield, pull lock pin (Figure 4, Item 1) inward from cab frame lock hole (Figure 4, Item 5) and rotate into notch.

0011-2

TM 5-3805-294-10 WINDSHIELD - Continued

0011

5 2

HYEX00163

Figure 4.

Release Windshield Latch.

WARNING

Window closes rapidly when released. Use lower handle to prevent window from free falling. Failure to comply may result in injury or death to personnel. 6. 7. Pull on latch release bar (Figure 4, Item 2). Hold handle (Figure 5, Item 4) and lower windshield (Figure 5, Item 3) until it is latched in the closed position.

4 3

HYEX00161

Figure 5. 8.

Close Windshield.

Press glass (Figure 6, Item 3) until bar (Figure 6, Item 2) snaps into place.

0011-3

TM 5-3805-294-10 WINDSHIELD - Continued

0011

2 3

HYEX00160

Figure 6. 9. Release lock pin (Figure 6, Item 1) from notch.

Latch Windshield.

END OF TASK CAB DOOR WINDOW 1. To open, release latch (Figure 7, Item 6) and slide cab door window (Figure 7, Item 7) forward.

6 7

HYEX01411

Figure 7. 2.

Open and Close Cab Door Window.

To close, slide cab door window (Figure 7, Item 7) to rear until latch (Figure 7, Item 6) engages.

END OF TASK

0011-4

TM 5-3805-294-10 SKYLIGHT WINDOW (SECONDARY EXIT) 1. Slide access cover (Figure 8, Item 8) open.

0011

HYEX03377

Figure 8. 2.

Open Access Cover.

To open, release two latches (Figure 9, Item 9) and push up on handle (Figure 9, Item 10).

10

HYEX00167

Figure 9. 3. 4.

Open and Close Skylight Window.

To close, pull down on handle (Figure 9, Item 10) and engage two latches (Figure 9, Item 9). Slide access cover (Figure 10, Item 8) closed.

0011-5

TM 5-3805-294-10 SKYLIGHT WINDOW (SECONDARY EXIT) - Continued

0011

HYEX03377

Figure 10. END OF TASK END OF WORK PACKAGE

Close Access Cover.

0011-6

TM 5-3805-294-10 OPERATOR MAINTENANCE USING THE RIFLE MOUNT

0012

INITIAL SETUP: Not Applicable

STOW

NOTE
Rifle mount is designed to store an M4 with optics, M240B, M249, or M16 series weapon with and without M203 grenade launcher. 1. Place butt of weapon in rear mounting bracket (Figure 1, Item 1).

HYEX00999

Figure 1. 2.

Stow Weapon In Rear Bracket

Place barrel of weapon in front mounting bracket (Figure 2, Item 2).

0012-1

TM 5-3805-294-10 STOW - Continued

0012

HYEX00998

Figure 2. Stow Weapon In Front Bracket 3. 4. If necessary, loosen two handles (Figure 2, Item 3) and slide front mounting bracket (Figure 2, Item 2) on two rails (Figure 2, Item 4). Tighten two handles (Figure 2, Item 3).

END OF TASK REMOVE 1. Lift barrel of weapon from front mounting bracket (Figure 3, Item 2).

HYEX00998

Figure 3. Remove Weapon From Front Bracket 2. Remove butt of weapon from rear mounting bracket (Figure 4, Item 1).

0012-2

TM 5-3805-294-10 REMOVE - Continued

0012

HYEX00999

Figure 4. Remove Weapon From Rear Bracket END OF TASK END OF WORK PACKAGE

0012-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE GENERAL MONITOR OPERATION

0013

INITIAL SETUP: Equipment Condition Engine running. (WP 0007)

TIME ADJUSTMENT

NOTE
After approximately 1 minute the monitor will return to the default screen. 1. Press menu button.

Main Menu

TIME SET

Time Set Attachment Adjustment Operating Conditions Maintenance Settings

SELECT BUTTON
5

BUTTON 1

7 F1

8 F2

9 F3

0 F4

BUTTON 2

MENU BUTTON
HYEX00057

Figure 1. 2. 3.

Select Time Set Menu.

Press button 1 or button 2 until the Time Set menu is highlighted. Press select button to open Time Set menu.

0013-1

TM 5-3805-294-10 TIME ADJUSTMENT - Continued 4. Press button 1 or button 2 to select date or time.
Time Set
2005 / 12 : 12 / 23 23

0013

BUTTON 1

SELECT BUTTON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

BACK BUTTON

BUTTON BUTTON BUTTON 2 3 4

Figure 2. 5. 6. 7. 8. Adjust Time.

HYEX00058

Press button 3 or button 4 to adjust date or time up or down. After desired date and time is achieved, press button 1 or button 2 until the apply setting icon is highlighted. Press select button and "Data is being applied" will display on the screen. Press back button until default screen is displayed.

END OF TASK DISPLAYING OPERATING CONDITIONS 1. Press menu button 1.

Main Menu
Time Set

OPERATING CONDITIONS

Attachment Adjustment Operating Conditions Maintenance Settings

SELECT BUTTON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

BUTTON 1

BACK BUTTON

BUTTON 2
Figure 3. 2. 3.

MENU BUTTON

HYEX00059

Select Operating Conditions Menu.

Press button 1 or button 2 until the Operating Conditions menu is highlighted. Press select button.

0013-2

TM 5-3805-294-10 DISPLAYING OPERATING CONDITIONS - Continued 4. Operating Conditions menu will be displayed.
Operating Conditions
Reset Data. OK?

0013

SELECT BUTTON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

BACK BUTTON
HYEX00060

Figure 4. 5. 6. 7. 8. To reset data, press select button. The Reset Data. OK? is displayed. If reset is not desired, press back button.

Reset Operating Conditions.

When finished with menu, press back button until default screen is displayed.

END OF TASK MAINTENANCE SETTINGS Maintenance settings are to be accessed only by the Field Level maintainer. END OF TASK END OF WORK PACKAGE

0013-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE REMOVING AND INSTALLING BUCKET

0014

INITIAL SETUP: References WP 0007 Equipment Condition Machine safely parked and shut down. (WP 0009)

REMOVING BUCKET

WARNING

With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel.

NOTE
The ditch cleaning bucket and 42 inch rock bucket are removed the same way. 42 inch rock bucket shown. 1. Lift and rotate safety lock pin lever (Figure 1, Item 1).
1

HYEX03379

Figure 1. 2. 3. Start engine. (WP 0007)

Unlock Safety Lock Pin.

Raise boom (Figure 2, Item 2) to allow adequate ground clearance for bucket (Figure 2, Item 3).

0014-1

TM 5-3805-294-10 REMOVING BUCKET - Continued

2

0014

3
HYEX03380

Figure 2. 4.

Raise Boom.

Move quick latch switch (Figure 3, Item 4) to unlatch position.

HYEX00939

Figure 3. 5.

Move Quick Latch Switch to Unlatch Position.

Fully extend bucket cylinder (Figure 4, Item 5) until quick latch wedges (Figure 4, Item 6) are fully retracted.

0014-2

TM 5-3805-294-10 REMOVING BUCKET - Continued

5

0014

6
HYEX03387

Figure 4.

Extend Bucket Cylinder.

WARNING

With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. 6. Slowly retract bucket cylinder (Figure 5, Item 5) and position quick latch (Figure 5, Item 7) in vertical position.

HYEX03384

Figure 5.

Retract Bucket Cylinder.

NOTE
Ensure that arm is just past the vertical position prior to setting bucket on the ground. 7. Slowly lower boom (Figure 6, Item 2) and place bucket (Figure 6, Item 3) on ground.

0014-3

TM 5-3805-294-10 REMOVING BUCKET - Continued

2

0014

3
HYEX03382

Figure 6. 8.

Lower Boom.

Move quick latch switch (Figure 7, Item 4) in latch position.

HYEX00939

Figure 7. 9.

Position Quick Latch Switch to Latch position.

Remove quick latch (Figure 8, Item 7) from bucket (Figure 8, Item 3).

0014-4

TM 5-3805-294-10 REMOVING BUCKET - Continued

0014

3
HYEX03389

Figure 8. END OF TASK INSTALLING BUCKET

Remove Quick Latch.

WARNING

With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel.

NOTE
The ditch cleaning bucket and 42 inch rock bucket are installed the same way. 42 inch rock bucket shown. 1. Move quick latch switch (Figure 9, Item 4) in the unlatch position.

0014-5

TM 5-3805-294-10 INSTALLING BUCKET - Continued

0014

HYEX00939

Figure 9. 2.

Position Quick Latch Switch to Unlatch position.

Raise boom (Figure 10, Item 2) to allow for adequate ground clearance.

HYEX03385

Figure 10.

Raise Boom for Clearance.

WARNING

With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing bucket. Slowly retract or extend bucket cylinder when removing or installing bucket. Failure to comply may result in injury or death to personnel. 3. Slowly extend bucket cylinder (Figure 11, Item 5) until quick latch wedges (Figure 11, Item 6) are fully retracted.

0014-6

TM 5-3805-294-10 INSTALLING BUCKET - Continued

5

0014

6
HYEX03383

Figure 11. 4.

Retract Wedges.

Position quick latch (Figure 12, Item 7) in vertical position.

5 7

3
HYEX03381

Figure 12. 5. 6. 7.

Install Quick Latch.

Install quick latch (Figure 12, Item 7) to bucket (Figure 12, Item 3). Extend bucket cylinder (Figure 12, Item 5) until quick latch (Figure 12, Item 7) is resting on bucket (Figure 12, Item 3). Move quick latch switch (Figure 13, Item 4) in latch position.

0014-7

TM 5-3805-294-10 INSTALLING BUCKET - Continued

0014

HYEX00939

Figure 13. Position Quick Latch Switch toLatch position. 8. Raise boom (Figure 14, Item 2) to allow for ground clearance.
2 5

6
HYEX03386

Figure 14. 9. 10.

Raise Boom.

Fully extend bucket cylinder (Figure 14, Item 5) to ensure quick latch wedges (Figure 14, Item 6) are fully engaged. Position bucket (Figure 15, Item 3) on ground.

0014-8

TM 5-3805-294-10 INSTALLING BUCKET - Continued

0014

HYEX03378

Figure 15. 11.

Safety Pin Locked.

Rotate safety lock pin lever (Figure 15, Item 1) to lock position.

END OF TASK END OF WORK PACKAGE

0014-9/10 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE LIFTING WITH HYEX

0015

INITIAL SETUP: Tools and Special Tools Suitable Lifting Device Personnel Required Horizontal Construction Engineer 12N (2) Equipment Condition Engine running. (WP 0007)

LIFTING

WARNING

LIFTING GUIDELINES: Do not use machine to lift personnel. Failure to comply may result in injury or death to personnel. Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death to personnel. Ensure load does not exceed the capacity of machine or lifting device. Failure to comply may result in injury or death to personnel. Lift load only as high as necessary. Failure to comply may result in injury or death to personnel. Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may result in injury or death to personnel. Personnel must remain clear of lifted items. Failure to comply may result in injury or death to personnel.

NOTE
Use a suitable lifting device and tether lines to guide load. Coordinate hand signals with assistant prior to lifting. 1. Secure lifting device (Figure 1, Item 1) to load (Figure 1, Item 2).

0015-1

TM 5-3805-294-10 LIFTING - Continued

0015

5 3 1

2
HYEX00919

Figure 1. 2. 3. 4.

Lifting with Quick Latch Loop.

Curl bucket (Figure 1, Item 3) and retract arm (Figure 1, Item 4). Attach lifting device (Figure 1, Item 1) to quick latch loop (Figure 1, Item 5). With the aid of an assistant, raise load (Figure 1, Item 2) and verify stability of load and machine (Figure 1, Item 6) before moving the machine.

END OF TASK END OF WORK PACKAGE

0015-2

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING TECHNIQUES

0016

INITIAL SETUP: Equipment Condition Engine running. (WP 0007)

LEVELING MACHINE

NOTE
Operating on a firm, level surface optimizes machine stability. 1. Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material.

HYEX01483

Figure 1. 2.

Leveling Machine.

If necessary, use bucket to add or remove material to level the worksite.

HYEX01484

Figure 2. 3.

Add or Remove Material.

If material is added, drive over new material to compact it until the worksite feels stable.

END OF TASK

0016-1

TM 5-3805-294-10 ARM DIGGING

0016

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

CAUTION
When bucket cylinder is fully extended, do not strike the ground or use the bucket for tamping. Failure to comply may result in damage to equipment. Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down walls using swing motion. Failure to comply may result in damage to equipment. Do not side load bucket, swing bucket to level material, or strike objects from the side with the bucket. Failure to comply may result in damage to equipment. If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket lightly does not work. Failure to comply may result in damage to equipment.

NOTE
Initial cut should be approximately 4 ft (122 cm) long and 3-4 in. (76-102 mm) deep. Remaining cuts should be approximately 4 ft (122 cm) long and 4-6 in. (102-152 mm) deep. 1. Position arm in a vertical position.

0016-2

TM 5-3805-294-10 ARM DIGGING - Continued

0016

HYEX01486

Figure 3. 2. 3.

Arm Digging.

Move arm away from machine approximately 2 ft (61 cm). While retracting arm curl bucket as bucket fills.

END OF TASK BUCKET DIGGING

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

CAUTION
When bucket cylinder is fully extended, do not strike the ground or use the bucket for tamping. Failure to comply may result in damage to equipment. Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down walls using swing motion. Failure to comply may result in damage to equipment. Do not side load bucket, swing bucket to level material, or strike objects from the side with the bucket. Failure to comply may result in damage to equipment.

0016-3

TM 5-3805-294-10 BUCKET DIGGING - Continued If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket lightly does not work. Failure to comply may result in damage to equipment.

0016

NOTE
Ensure that correct bucket is used for the type of material being excavated. Excavate in thin layers to fragment material and to ease in dumping material from the bucket. This especially applies to sticky materials. For power digging and for working in confined areas, use the bucket cylinder for digging. 1. Lower bucket to the digging area.

HYEX01485

Figure 4. 2. 3. 4. 5. Use boom to force bucket into ground.

Bucket Digging.

Retract arm and curl bucket at the same time until bucket is full. If bucket stalls, raise boom slightly then continue to curl bucket . If arm stalls, roll back bucket to break out.

END OF TASK

0016-4

TM 5-3805-294-10

0016

PLANNING SPOIL PILES

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Place spoil piles at least 3 ft (1 m) away from excavation. The deeper the excavation, the further away the spoil pile should be placed.

HYEX01487

Figure 5. 2. 3.

Planning Spoil Piles.

If required, place spoil piles for convenient truck loading or backfilling. On slopes, place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.

END OF TASK TRENCHING

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel.

0016-5

TM 5-3805-294-10 TRENCHING - Continued Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Before starting work, walk the site to uncover hazards and to plan the job.

0016

HYEX01504

Figure 6. 2. 3. 4.

Trenching.

Check for buried utility lines, pipes, and gas or oil pipelines. Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench. The deeper the trench, the further away the spoil pile should be placed.

END OF TASK CLEANING A CAVE IN 1. If you cannot clean a cave in from the machine's current position, DO NOT back over the trench.

HYEX01503

Figure 7. 2. 3. Drive the machine to the cave in.

Cleaning Cave In.

Park the machine at a 90 degree angle to the trench with the travel motors to the rear of the machine.

0016-6

TM 5-3805-294-10 CLEANING A CAVE IN - Continued 4. Clean cave in from the side of the trench.

0016

END OF TASK TRENCHING ON A SLOPE

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

NOTE
The deeper the trench the further away the spoil pile should be. 1. When trenching across a slope, level the machine so that the bottom of the trench will be level.

HYEX01488

Figure 8. 2. 3.

Trenching on a Slope.

Level machine by counter-rotating tracks or by digging a shelf. Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.

END OF TASK

0016-7

TM 5-3805-294-10 STRAIGHT LINE TRENCHING

0016

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

NOTE
The deeper the trench, the further away the spoil pile should be. 1. Drive two stakes in the ground at the beginning of the trench.

HYEX01489

Figure 9. 2. 3.

Straight Line Trenching.

Drive the first stake immediately behind the start point of the trench. Drive the second stake approximately 30 ft (9 m) behind the first stake. Use stakes as a sight gauge. They are especially helpful when the machine is moved often.

END OF TASK BACKFILLING

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel.

0016-8

TM 5-3805-294-10 BACKFILLING - Continued Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

0016

CAUTION
Do not use side of bucket to backfill. Failure to comply may result in damage to equipment.

NOTE
The bucket side can be used for finish grading. 1. Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine.

HYEX01490

Figure 10. 2. Use material from spoil pile to backfill.

Back Filling.

END OF TASK

0016-9

TM 5-3805-294-10

0016

TRUCK LOADING

WARNING

PREVENTING CAVE IN Work perpendicular to or at an angle to excavation, with travel motors to the rear of the machine. Failure to comply may result in injury or death to personnel. Do not drive near the edge of an excavation or trench. Failure to comply may result in injury or death to personnel. Do not dig under the machine. Failure to comply may result in injury or death to personnel. To prevent the spoil pile from caving in the excavation, spoil piles should be placed at least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel. 1. Position bucket and slowly dump load in vehicle at the front center of the bed.

HYEX01491

Figure 11. 2. Continue to fill bed from front to rear.

Truck Loading.

END OF TASK END OF WORK PACKAGE

0016-10

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING THE HYDRAULIC THUMB

0017

INITIAL SETUP: Not Applicable

GENERAL HYDRAULIC THUMB INFORMATION The hydraulic thumb was designed to be used for the following: 1. Clamping and lifting. 2. Medium duty scrap handling. 3. Demolition of wood and brick structures. 4. Medium duty land clearing/grubbing. 5. Bulky loose materials. 6. Logging. The hydraulic thumb was not designed and should not be used for the following: 1. Ripping up concrete or asphalt. 2. Quarry applications. 3. Heavy scrap handling. 4. Heavy land clearing. 5. Heavy grubbing. 6. Breaking ledge rock. CLAMPING WITH THE BUCKET 1. Position hydraulic thumb (Figure 1, Item 1) near the object to be picked up.

HYEX01175

Figure 1. 2.

Clamping With Bucket.

Curl the bucket (Figure 1, Item 2) until it begins to force the object to the hydraulic thumb (Figure 1, Item 1).

0017-1

TM 5-3805-294-10 CLAMPING WITH THE BUCKET - Continued 3. Gently move the bucket control to pick the object up without crushing it.

0017

END OF TASK CLAMPING WITH THE HYDRAULIC THUMB

NOTE
This method is less precise and should only be used when there is no concern about crushing the object being lifted. 1. Position hydraulic thumb (Figure 2, Item 1) in the store position.

1 2

HYEX01174

Figure 2. Clamping With Hydraulic Thumb. 2. 3. Curl bucket (Figure 2, Item 2) and position it near or in contact with the object being picked up. Move hydraulic thumb (Figure 2, Item 1) to grasp and clamp the object.

END OF TASK

0017-2

TM 5-3805-294-10 MOVING AND RELEASING CLAMPED OBJECTS

0017

WARNING

Never lift clamped objects over personnel. The possibility of the clamped object to fall always exists. Failure to comply may result in injury or death to personnel. Always keep object close to machine when lifting with the hydraulic thumb and bucket. When the object is moved away from the machine using the boom or arm, the machine becomes unstable and could roll over. Failure to comply may result in injury or death to personnel. Always look before releasing a load. Never release load while moving or turning. Failure to comply may result in injury or death to personnel. 1. Move object to desired location.

1 2

HYEX01174

Figure 3. 2.

Releasing Objects.

Retract either the hydraulic thumb (Figure 3, Item 1) or bucket (Figure 3, Item 2) to release object.

END OF TASK END OF WORK PACKAGE

0017-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE SELECTING AN ATTACHMENT ON THE MONITOR

0018

INITIAL SETUP: Equipment Condition Engine running. (WP 0007)

SELECTING ATTACHMENT 1. Press F1 button and Work Mode screen will be displayed.
Work Mode
Dig Breaker 2
2

Crusher 1
1

Breaker 1

Pulverizer 1
1

BUTTON 1
1

7 F1

8 F2

9 F3

0 F4

BUTTON 5
HYEX00172

F1 BUTTON

BUTTON BUTTON BUTTON 2 3 4

Figure 1. Select Attachment.

2.

Use the following table to select attachment. Table 1. Attachment Selection. Attachment mode to be selected Dig Breaker 1 Breaker 2 Pulverizer 1 Crusher 1

Attachment to be used Bucket/Thumb Breaker Compactor Crush-All Deep dig arm

Monitor key pad button 1 2 3 4 5

0018-1

TM 5-3805-294-10 SELECTING ATTACHMENT - Continued 3. The attachment specification screen will be displayed.
Breaker 1
Maximum Pump Flow Rate Maximum Engine Speed Valve Selector O/T 2-Speed Selector OFF 288.0 L/min 1800 min-1 OFF

0018

Accumulator

2ndary Hydraulic Relief Selector ON

SELECT BUTTON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX00173

Figure 2. Attachment Specification Screen. 4. 5. Verify the attachment specifications are the same as displayed on the monitor. Press the select button. The default screen will be displayed.

END OF TASK END OF WORK PACKAGE

0018-2

TM 5-3805-294-10 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE CRUSH-ALL

0019

INITIAL SETUP: Tools and Special Tools Wrench, Open End, 2 1/2 in. (63.5 mm) (WP 0095, Table 2, Item 15) Wrench, Open End, 3 in. (76 mm) (WP 0095, Table 2, Item 14) Wrench, Open End, Adjustable 0.95 in. (24 mm) (WP 0095, Table 2, Item 19) Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 References (cont.) WP 0009 WP 0018 WP 0092 Equipment Condition Safely park and shutdown machine. (WP 0009) Bucket removed. (WP 0014)

INSTALLING CRUSH-ALL 1. 2. Start machine. (WP 0007) Retract hydraulic thumb cylinder (Figure 1, Item 1).

3 4 2 6 1

5 3

HYEX03392

Figure 1. 3. 4.

Close Hydraulic Thumb Circuit.

Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).

0019-1

TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued

0019

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. 6. Using prybar to push pin (Figure 1, Item 3), install pin in thumb lock position (Figure 1, Item 5). Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 7. 8. Close two auxiliary circuit shut off valves (Figure 1, Item 6). Move quick latch switch (Figure 2, Item 7) to unlatch position.

HYEX03393

Figure 2. 9.

Move Quick Latch Switch to Unlatch Position.

Fully extend bucket cylinder (Figure 3, Item 8) to ensure quick latch wedges (Figure 3, Item 9) are fully retracted.

0019-2

TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued

8

0019

9
HYEX03394

Figure 3. 10.

Extend Bucket Cylinder.

Retract bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is in the vertical position.
8 10

11

HYEX03397

Figure 4. 11. 12. 13.

Install Quick Latch.

Install quick latch (Figure 4, Item 10) to crush-all (Figure 4, Item 11). Extend bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is resting on crush-all (Figure 4, Item 11). Move quick latch switch (Figure 5, Item 7) to latch position.

0019-3

TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued

0019

HYEX03393

Figure 5. Quick Latch Switch to Latch Position. 14. Raise boom (Figure 6, Item 12) to allow adequate ground clearance of crush-all (Figure 6, Item 11).
14 12 13

11
HYEX03395

Figure 6. 15. 16. 17. 18. 19.

Position Crush-All.

Curl crush-all (Figure 6, Item 11) as in Figure 6 until quick latch wedges (Figure 6, Item 9) are fully engaged to crush-all (Figure 6, Item 11). Rotate safety lock pin lever (Figure 6, Item 13) to lock position. Extend arm cylinder (Figure 6, Item 14) and lower boom (Figure 6, Item 12) to position crush-all (Figure 6, Item 11) on ground. Shutdown machine. (WP 0009) Clean cap (Figure 7, Item 15) and machine quick disconnect (Figure 7, Item 16) with rag.

0019-4

TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued

0019

18 16 17

15
HYEX01501

Figure 7. 20. 21. 22. 23. 24.

Connect Auxiliary Supply Line.

Clean plug (Figure 7, Item 17) and attachment quick disconnect (Figure 7, Item 18) with rag. Remove cap (Figure 7, Item 15) from machine quick disconnect (Figure 7, Item 16). Remove plug (Figure 7, Item 17) from attachment quick disconnect (Figure 7, Item 18). Connect attachment quick disconnect (Figure 7, Item 18) to machine quick disconnect (Figure 7, Item 16). Clean plug (Figure 8, Item 19) and machine quick disconnect (Figure 8, Item 20) with rag.

27 26

28 29

24 22 20 23, 25 19, 21
HYEX01502

Figure 8. 25. 26. 27. 28. 29. 30. 31. 32. 33.

Connect Auxiliary Return Line.

Clean cap (Figure 8, Item 21) and attachment quick disconnect (Figure 8, Item 22) with rag. Remove plug (Figure 8, Item 19) from machine quick disconnect (Figure 8, Item 20). Remove cap (Figure 8, Item 20) from attachment quick disconnect (Figure 8, Item 21). Connect attachment quick disconnect (Figure 8, Item 22) to machine quick disconnect (Figure 8, Item 20). Clean plug (Figure 8, Item 23) and machine quick disconnect (Figure 8, Item 24). Clean cap (Figure 8, Item 25) and attachment quick disconnect (Figure 8, Item 26) with rag. Remove plug (Figure 8, Item 23) from machine quick disconnect Figure 8, Item (24). Remove cap (Figure 8, Item 25) from attachment quick disconnect (Figure 8, Item 26). Connect attachment quick disconnect (Figure 8, Item 26) to machine quick disconnect (Figure 8, Item 25).

0019-5

TM 5-3805-294-10 INSTALLING CRUSH-ALL - Continued 34. 35. Remove cap (Figure 8, Item 27) from connector (Figure 8, Item 28). Attach connector (Figure 8, Item 29) to connector (Figure 8, Item 28).

0019

END OF TASK OPERATION 1. 2. 3. 4. Start machine. (WP 0007) Select the Pulverizer 1 on the monitor. (WP 0018) Turn on the Auxiliary Control Switch. (WP 0004) Adjust discharge size as needed. (WP 0092)

WARNING

Ensure operator protection guard is installed prior to operation. Failure to comply may result in injury or death to personnel. Crush-All can throw objects at any time during operation. Ensure personnel maintain distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel. Do not reach into machine to remove debris. Failure to comply may result in injury or death to personnel. Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may result in injury or death to personnel.

CAUTION
Do not overload Crush-All, strike objects or ground, or use sides of Crush-All to move material. Failure to comply may result in damage to equipment.

NOTE
When crushing concrete, asphalt, brick, block, or softer stone, the maximum feed size is 18 in. x 18 in. (45.72 cm x 45.72 cm). When crushing slag, limestone, or other materials with dirt, the maximum feed size is 15 in. x 5 in. (38.1 cm x 12.7 cm). To reduce dust output, wet down material prior to crushing. 5. 6. Place engine at full speed while crushing. (WP 0004) Lift Crush-All (Figure 9, Item 11) approximately 6 ft (182.8 cm) off ground.

0019-6

TM 5-3805-294-10 OPERATION - Continued

34 31 30 32

0019

33

11

HYEX01499

Figure 9. 7. 8. 9. 10. 11.

Crush-All Operation.

Curl crush-all (Figure 9, Item 11) to vertical position. Release attachment pedal lock (Figure 9, Item 30). Press attachment pedal (Figure 9, Item 31) to turn on Crush-All (Figure 9, Item 11). Allow Crush-All (Figure 9, Item 11) to run for 5 minutes with no load. Press attachment pedal (Figure 9, Item 31) and press button (Figure 9, Item 32) to open lid (Figure 9, Item 33).

NOTE
Scooping material is best performed by arming into the material, then boom up and curl as the Crush-All is elevated above material. 12. 13. Scoop material and raise Crush-All (Figure 9, Item 11) away from material. Curl Crush-All (Figure 9, Item 11) to vertical position.

NOTE
Reduce dust by keeping bottom of Crush-All close to stock pile. 14. 15. 16. Swing Crush-All (Figure 9, Item 11) over stock pile. Press button (Figure 9, Item 34) to close lid (Figure 9, Item 32). Allow all material to pass through crush-all (Figure 9, Item 11).

NOTE
To avoid jamming, hold attachment pedal until all material has been discharged. 17. Release attachment pedal (Figure 9, Item 31) to turn off crush-all (Figure 9, Item 11).

0019-7

TM 5-3805-294-10 OPERATION - Continued 18. Engage attachment pedal lock (Figure 9, Item 30).

0019

END OF TASK JAMMING

WARNING

Ensure operator protection guard is installed prior to operation. Failure to comply may result in injury or death to personnel. Crush-All can throw objects at any time during operation. Ensure personnel maintain distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel. Do not reach into machine to remove debris. Failure to comply may result in injury or death to personnel. Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may result in injury or death to personnel.

CAUTION
Do not attempt to clear jam by striking Crush-All on ground. Failure to comply may result in damage to equipment.

NOTE
These steps may be used to clear uncrushable material from machine. It may be necessary to shake Crush-All. 1. Press attachment pedal (Figure 10, Item 31) and press button (Figure 10, Item 32) to open lid (Figure 10, Item 33).

0019-8

TM 5-3805-294-10 JAMMING - Continued

0019

31 32

33

HYEX03431

Figure 10. 2.

Open Lid.

Retract bucket cylinder (Figure 11, Item 8) to dump crush-all (Figure 10, Item 11) upside down and allow material to fall out.
8

11

HYEX03148

Figure 11. 3. 4.

Clearing Jam from Crush-All.

Safely park and shutdown machine. (WP 0009) Use a sturdy piece of lumber to push rotor (Figure 12, Item 34) in reverse.

0019-9

TM 5-3805-294-10 JAMMING - Continued

35

0019

34

HYEX03149

Figure 12. Push Crush-All Rotor Backwards. 5. 6. If material is jammed between the curtain (Figure 12, Item 35) and rotor (Figure 12, Item 34), raise curtain. (WP 0092) 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).
14 12

11
HYEX03432

Figure 13. 2. 3. 4.

Position Crush-All.

Curl crush-all (Figure 13, Item 11) under as shown in Figure 13. Extend arm cylinder (Figure 13, Item 14), lower boom (Figure 13, Item 12), and position crush-all (Figure 13, Item 11) on ground. Shutdown machine. (WP 0009)

0019-10

TM 5-3805-294-10 REMOVING CRUSH-ALL - Continued 5. Remove connector (Figure 14, Item 29) from connector (Figure 14, Item 28).

0019

27 26

28 29

24 22 20 23, 25 19, 21
HYEX01502

Figure 14. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Disconnect Auxiliary Return Line.

Install cap (Figure 14, Item 27) to connector (Figure 14, Item 28). Clean attachment quick disconnect (Figure 14, Item 26) and machine quick disconnect (Figure 14, Item 24) with rag. Clean cap (Figure 14, Item 25) and plug (Figure 14, Item 23) with rag. Remove attachment quick disconnect (Figure 14, Item 26) from machine quick disconnect (Figure 14, Item 24). Install cap (Figure 14, Item 25) to attachment quick disconnect (Figure 14, Item 26). Install plug (Figure 14, Item 23) to machine quick disconnect (Figure 14, Item 24). Clean attachment quick disconnect (Figure 14, Item 22) and machine quick disconnect (Figure 14, Item 20) with rag. Clean cap (Figure 14, Item 21) and plug (Figure 14, Item 19) with rag. Remove attachment quick disconnect (Figure 14, Item 22) from machine quick disconnect (Figure 14, Item 20). Install cap (Figure 14, Item 21) to attachment quick disconnect (Figure 14, Item 22). Install plug (Figure 14, Item 19) to machine quick disconnect (Figure 14, Item 20). 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 REMOVING CRUSH-ALL - Continued

0019

18 16 17

15
HYEX01501

Figure 15. Disconnect Auxiliary Supply Line. 18. 19. 20. 21. 22. 23. Clean cap (Figure 15, Item 15) and plug (Figure 15, Item 17) with rag. Remove attachment quick disconnect (Figure 15, Item 18) from machine quick disconnect (Figure 15, Item 16). Install plug (Figure 15, Item 17) to attachment quick disconnect (Figure 15, Item 18). Install cap (Figure 15, Item 15) to machine quick disconnect (Figure 15, Item 16). Start machine. (WP 0007) Move quick latch switch (Figure 16, Item 7) to unlatch position.

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 REMOVING CRUSH-ALL - Continued

14 12 13

0019

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. 27. 28. Fully extend bucket cylinder (Figure 17, Item 8) until quick latch wedges (Figure 17, Item 9) are fully retracted. 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. Retract bucket cylinder (Figure 18, Item 8) and position quick latch (Figure 18, Item10) in vertical position.

0019-13

TM 5-3805-294-10 REMOVING CRUSH-ALL - Continued

8 10

0019

11

HYEX03397

Figure 18. Remove Quick Latch. 29. 30. Remove quick latch (Figure 18, Item 10) from crush-all (Figure 18, Item 11). Move quick latch switch (Figure 19, Item 7) to latch position.

HYEX03393

Figure 19. Move Quick Latch Switch. 31. Lower arm (Figure 20, Item 35) to ground.

0019-14

TM 5-3805-294-10 REMOVING CRUSH-ALL - Continued

0019

3 4 2 6 4 1

5 5 35 3

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. 33. Open two auxiliary circuit shut off valves (Figure 20, Item 6). 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. 35. 36. 37. Retract or extend thumb cylinder (Figure 20, Item 1) to remove pin (Figure 20, Item 3) from thumb lock position (Figure 20, Item 5). Install pin (Figure 20, Item 3) in storage position (Figure 20, Item 4). Install retaining pin (Figure 20, Item 2) on pin (Figure 20, Item 3). Shutdown machine. (WP 0009)

END OF TASK END OF WORK PACKAGE

0019-15/16 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE IMPACT BREAKER

0020

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 Grease, Automotive and Artillery, GAA Materials/Parts (cont.) (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 WP 0009 WP 0018 Equipment Condition Machine safely parked and shutdown. (WP 0009) Bucket removed. (WP 0014)

INSTALLING IMPACT BREAKER 1. 2. Start the machine. (WP 0007) Retract hydraulic thumb cylinder (Figure 1, Item 1).

3 4 2 6 1

5 3

HYEX01321

Figure 1. 3. 4.

Close Hydraulic Thumb Circuit.

Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).

0020-1

TM 5-3805-294-10 INSTALLING IMPACT BREAKER - Continued

0020

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. 6. 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). 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. 8. Close two auxiliary circuit shutoff valves (Figure 1, Item 6). Move quick latch switch (Figure 2, Item 7) to UNLATCH position.

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 INSTALLING IMPACT BREAKER - Continued

0020

HYEX03399

Figure 3. 10.

Raise Boom.

Fully extend bucket cylinder (Figure 4, Item 9) to ensure quick latch wedges (Figure 4, Item 10) are fully retracted.
9

10
HYEX03400

Figure 4. 11.

Quick Latch Wedges Retracted.

Retract bucket cylinder (Figure 5, Item 9) until quick latch (Figure 5, Item 11) is in the vertical position.

0020-3

TM 5-3805-294-10 INSTALLING IMPACT BREAKER - Continued

9

0020

8 11

12
HYEX03402

Figure 5. 12.

Install Quick Latch.

Install quick latch (Figure 5, Item 11) to impact breaker (Figure 5, Item 12).

WARNING

With quick latch wedges disengaged from impact breaker, the impact breaker could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing impact breaker. Slowly retract or extend bucket cylinder when removing or installing impact breaker. Failure to comply may result in injury or death to personnel. 13. 14. With the aid of an assistant slowly raise boom (Figure 5, Item 8) to allow for adequate ground clearance of quick latch (Figure 5, Item 11). Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on impact breaker (Figure 6, Item 12)

12

11
HYEX03403

Figure 6.

Extend Bucket Cylinder.

0020-4

TM 5-3805-294-10 INSTALLING IMPACT BREAKER - Continued 15. Move quick latch switch (Figure 7, Item 7) to LATCH position.

0020

HYEX03398

Figure 7. 16.

Move Quick Latch Switch to Latch Position.

Extend bucket cylinder (Figure 8, Item 9) until quick latch wedges (Figure 8, Item 10) are fully engaged to impact breaker (Figure 8, Item 12).
9

10

12
HYEX03401

Figure 8. 17. 18. 19.

Quick Latch Wedges Engaged.

Retract bucket cylinder (Figure 8, Item 9) and place impact breaker (Figure 8, Item 12) on ground. Shutdown machine. (WP 0009) Rotate safety lock pin lever (Figure 9, Item 13) to lock position.

0020-5

TM 5-3805-294-10 INSTALLING IMPACT BREAKER - Continued

0020

13

HYEX03406

Figure 9. 20.

Safety Pin to Lock Position.

Clean cap (Figure 10, Item 14) and machine quick disconnect (Figure 10, Item 15) with rag.

17 15 16

14
HYEX01322

Figure 10. Connect Auxiliary Supply Line. 21. 22. 23. 24. 25. Clean plug (Figure 10, Item 16) and attachment quick disconnect (Figure 10, Item 17) with rag. Remove cap (Figure 10, Item 14) from machine quick disconnect (Figure 10, Item 15). Remove plug (Figure 10, Item 16) from attachment quick disconnect (Figure 10, Item 17). Connect attachment quick disconnect (Figure 10, Item 17) to machine quick disconnect (Figure 10, Item 15). Clean plug (Figure 11, Item 18) and machine quick disconnect (Figure 11, Item 19) with rag.

0020-6

TM 5-3805-294-10 INSTALLING IMPACT BREAKER - Continued

0020

21 19 18 20
HYEX01323

Figure 11. 26. 27. 28. 29.

Connect Auxiliary Return Line.

Clean cap (Figure 11, Item 20) and attachment quick disconnect (Figure 11, Item 21) with rag. Remove plug (Figure 11, Item 18) from machine quick disconnect (Figure 11, Item 19). Remove cap (Figure 11, Item 20) from attachment quick disconnect (Figure 11, Item 21). Connect attachment quick disconnect (Figure 11, Item 21) to machine quick disconnect (Figure 11, Item 19).

END OF TASK TOOL INSTALLATION

NOTE
Select the proper tool before operation. Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to medium hardness. Moil is for demolition of medium hardness rock or materials except layered rock. Blunt is for breaking large, medium hardness rocks into smaller pieces. 1. Press and turn lock bolt (Figure 12, Item 22) to unlocked position with slot (Figure 12, Item 23) pointed to the tool end of breaker (Figure 12, Item 12).

0020-7

TM 5-3805-294-10 TOOL INSTALLATION - Continued

0020

22

23 24

12

26 25

HYEX01326

Figure 12. 2. 3. 4.

Breaker Tool Lock Bolt.

Push the retaining axle (Figure 12, Item 24) out of the breaker (Figure 12, Item 12) through hole (Figure 12, Item 25). Repeat Steps 1 and 2 for other retaining axle. Lubricate bushing (Figure 12, Item 26) with grease.

WARNING

Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. Failure to comply may result in injury or death to personnel.

NOTE
Ensure cavity is free of debris and tool is properly lubricated. 5. With the aid of an assistant and suitable lifting device, slide tool (Figure 13, Item 27) into breaker (Figure 13, Item 12) with side notches (Figure 13, Item 28) in alignment with axle slots (Figure 13, Item 29).

0020-8

TM 5-3805-294-10 TOOL INSTALLATION - Continued

0020

12

29

27 28
HYEX01327

Figure 13. 6.

Insert Breaker Tool.

Install retaining axle (Figure 14, Item 24) to breaker (Figure 14, Item 12).

12 24

23

22

HYEX01328

Figure 14. 7. 8.

Lock Breaker Tool.

Press and turn lock bolt (Figure 14, Item 22) to locked position with slot (Figure 14, Item 23) pointed to top of breaker (Figure 14, Item 12). Repeat Steps (Figure 14, Item 6) and (Figure 14, Item 7) for other retaining axle.

END OF TASK OPERATING IMPACT BREAKER 1. 2. Start the machine. (WP 0007) Select work mode BREAKER 1 on the monitor. (WP 0018)

CAUTION
Breaker must be lubricated every 2 hours of use and every hour during dusty conditions. Failure to comply may result in damage to the attachment.

NOTE
Keep tool perpendicular to work surface. Keep machine close to work area. Maintain constant, even pressure as tool penetrates work surface.

0020-9

TM 5-3805-294-10 OPERATING IMPACT BREAKER - Continued Increase down pressure when strokes have a metallic sound. Decrease down pressure when strokes cause strong vibrations in the machine. 3. Release attachment pedal lock (Figure 15, Item 30).

0020

30

12

31

HYEX01520

Figure 15. 4. 5. 6. 7.

Breaker Operation.

Apply boom (Figure 15, Item 8) down pressure to impact breaker (Figure 15, Item 12) on work area. Press attachment pedal (Figure 15, Item 31) to start impact breaker (Figure 15, Item 12). Release attachment pedal (Figure 15, Item 31) to stop impact breaker (Figure 15, Item 12) before retracting from work area. Engage attachment pedal lock (Figure 15, Item 30).

END OF TASK TOOL REMOVAL 1. Raise breaker (Figure 16, Item 12) off ground and extend bucket cylinder (Figure 16, Item 9) until breaker is horizontal.
9 12 24

23

25 22
HYEX03440

Figure 16.

Tool Removal.

0020-10

TM 5-3805-294-10 TOOL REMOVAL - Continued 2. 3. 4.

0020

Press and turn lock bolt (Figure 16, Item 22) to unlocked position with slot (Figure 16, Item 23) pointed to the tool end of breaker (Figure 16, Item 12). Push the retaining axle (Figure 16, Item 24) out of the breaker (Figure 16, Item 12) through hole (Figure 16, Item 25). Repeat Steps 2 and 3 for other retaining axle.

WARNING

Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without the aid of an assistant and suitable lifting device. Failure to comply may result in injury or death to personnel. 5. With the aid of an assistant and suitable lifting device, slide tool (Figure 17, Item 27) out of breaker (Figure 17, Item 12).

12

27

HYEX03439

Figure 17. 6.

Remove Breaker Tool.

Install retaining axle (Figure 18, Item 24) to breaker (Figure 18, Item 12).

12 24

23

22

HYEX01328

Figure 18. 7.

Lock Breaker Tool.

Press and turn lock bolt (Figure 18, Item 22) to locked position with slot (Figure 18, Item 23) pointed to top of breaker (Figure 18 , Item 12).

0020-11

TM 5-3805-294-10 TOOL REMOVAL - Continued 8. Repeat Steps 6 and 7 for other retaining axle.

0020

END OF TASK REMOVING IMPACT BREAKER 1. 2. Safely park and shut down machine. (WP 0009) Clean machine quick disconnect (Figure 19, Item 19) and attachment quick disconnect (Figure 19, Item 21) with rag.

21 19 18 20
HYEX01323

Figure 19. Disconnect Auxiliary Return Line. 3. 4. 5. 6. 7. Clean cap (Figure 19, Item 20) and plug (Figure 19, Item 18) with rag. Remove attachment quick disconnect (Figure 19, Item 21) from machine quick disconnect (Figure 19, Item 19). Install cap (Figure 19, Item 20) to attachment quick disconnect (Figure 19, Item 21). Install plug (Figure 19, Item 18) to machine quick disconnect (Figure 19, Item 19). Clean machine quick disconnect (Figure 20, Item 15) and attachment quick disconnect (Figure 20, Item 17) with rag.

17 15 16

14
HYEX01322

Figure 20. Disconnect Auxiliary Supply Line. 8. 9. Clean cap (Figure 20, Item 14) and plug (Figure 20, Item 16) with rag. Remove attachment quick disconnect (Figure 20, Item 17) from machine quick disconnect (Figure 20, Item 15).

0020-12

TM 5-3805-294-10 REMOVING IMPACT BREAKER - Continued 10. 11. 12. Install plug (Figure 20, Item 16) to attachment quick disconnect (Figure 20, Item 17). Install cap (Figure 20, Item 14) to machine quick disconnect (Figure 20, Item 15). Lift and rotate safety lock pin lever (Figure 21, Item 13) to unlock position.

0020

13

HYEX03406

Figure 21. 13. 14. Start the machine. (WP 0007)

Safety Pin to Unlock Position.

Raise boom (Figure 22, Item 8) to allow for adequate ground clearance.

HYEX03399

Figure 22. 15.

Raise Boom for Clearance.

Move quick latch switch (Figure 23, Item 7) to UNLATCH position.

0020-13

TM 5-3805-294-10 REMOVING IMPACT BREAKER - Continued

0020

HYEX03398

Figure 23. Move Quick Latch Switch to Unlatch Position. 16. Extend bucket cylinder (Figure 24, Item 9) until quick latch wedges (Figure 24, Item 10) are fully retracted.
9

10

12
HYEX03401

Figure 24. 17.

Quick Latch Wedges Retracted.

Retract bucket cylinder (Figure 25, Item 9) until tool end of impact breaker (Figure 25, Item 12) is resting on ground and quick latch (Figure 25, Item 11) is in vertical position.

0020-14

TM 5-3805-294-10 REMOVING IMPACT BREAKER - Continued

9

0020

8 11

12
HYEX03402

Figure 25. 18. 19. 20.

Impact Breaker Removal.

Lower boom (Figure 25, Item 8) until impact breaker (Figure 25, Item 12) is resting on ground. Remove quick latch (Figure 25, Item 11) from impact breaker (Figure 25, Item 12). Move quick latch switch (Figure 26, Item 7) to LATCH position.

HYEX03398

Figure 26.

Quick Latch Switch to Latch Position.

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 21. Open two auxiliary circuit shutoff valves (Figure 27, Item 6).

0020-15

TM 5-3805-294-10 REMOVING IMPACT BREAKER - Continued

0020

3 4 2 6 1

5 3

HYEX01321

Figure 27. Open Hydraulic Thumb Circuit. 22. Remove retaining pin (Figure 27, Item 2) from pin (Figure 27, Item 3).

WARNING

Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel.

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 23. 24. 25. 26. With the aid of an assistant, extend or retract thumb cylinder (Figure 27, Item 1), as needed, while using prybar to remove pin (Figure 27, Item 3) from thumb lock position (Figure 27, Item 5). Install pin (Figure 27, Item 3) in storage position (Figure 27, Item 4). Install retaining pin (Figure 27, Item 2) to pin (Figure 27, Item 3). Safely park and shut down machine. (WP 0009)

END OF TASK END OF WORK PACKAGE

0020-16

TM 5-3805-294-10 OPERATOR MAINTENANCE INSTALLING AND OPERATING THE COMPACTOR

0021

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 Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 References (cont.) WP 0009 WP 0018 Equipment Condition Safely park and shutdown machine. (WP 0009) Bucket removed. (WP 0014)

INSTALLING COMPACTOR 1. Start machine. (WP 0007)

WARNING

Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel. 2. Retract hydraulic thumb cylinder (Figure 1, Item 1).

0021-1

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

0021

3 4 2 6 1

5 3

HYEX03411

Figure 1. Close Hydraulic Thumb Circuit. 3. 4. Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3). Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).

WARNING

Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel.

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 5. 6. 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). Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown. 7. 8. Close two auxiliary circuit shut off valves (Figure 1, Item 6). Move quick latch switch (Figure 2, Item 7) to UNLATCH position.

0021-2

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

0021

HYEX03412

Figure 2. 9.

Move Quick Latch Switch.

Raise boom (Figure 3, Item 8) to allow for adequate ground clearance.

HYEX03413

Figure 3. 10.

Raise Boom.

Fully extend bucket cylinder (Figure 4, Item 9) to ensure quick latch wedges (Figure 4, Item 10) are fully retracted.

0021-3

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

9

0021

10
HYEX03414

Figure 4. Quick Latch Wedges Retracted. 11. Retract bucket cylinder (Figure 5, Item 9) until quick latch (Figure 5, Item 11) is in the vertical position.
9 11

12

HYEX03415

Figure 5. 12. 13.

Install Quick Latch.

Install quick latch (Figure 5, Item 11) to compactor (Figure 5, Item 12). Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on compactor (Figure 6, Item 12).

0021-4

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

9

0021

11

12
HYEX03416

Figure 6. 14.

Position Quick Latch.

Move quick latch switch (Figure 7, Item 7) to LATCH position.

HYEX03412

Figure 7. Quick Latch Switch to Latch Position.

WARNING

With quick latch wedges disengaged from compactor, the compactor could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing compactor. Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to comply may result in injury or death to personnel. 15. Raise boom (Figure 8, Item 8) to allow for adequate ground clearance.

0021-5

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

0021

HYEX03413

Figure 8. Raise Boom for Clearance. 16. Extend bucket cylinder (Figure 9, Item 9) until quick latch wedges (Figure 9, Item 10) are fully engaged to compactor (Figure 9, Item 12).

12 10
HYEX03417

Figure 9. Engage Quick Latch Wedges. 17. 18. 19. Retract bucket cylinder (Figure 9, Item 9) and position compactor (Figure 9, Item 12) on ground. Shutdown machine. (WP 0009) Rotate safety lock pin lever (Figure 10, Item 13) to lock position.

0021-6

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

13

0021

HYEX03418

Figure 10. 20.

Lock Safety Lock.

Clean cap (Figure 11, Item 14) and machine quick disconnect (Figure 11, Item 15) with rag.

17 15 16

14
HYEX03419

Figure 11. 21. 22. 23. 24. 25.

Connect Auxiliary Supply Line.

Clean plug (Figure 11, Item 16) and attachment quick disconnect (Figure 11, Item 17) with rag. Remove cap (Figure 11, Item 14) from machine quick disconnect (Figure 11, Item 15). Remove plug (Figure 11, Item 16) from attachment quick disconnect (Figure 11, Item 17). Connect attachment quick disconnect (Figure 11, Item 17) to machine quick disconnect (Figure 11, Item 15). Clean plug (Figure 12, Item 18) and machine quick disconnect (Figure 12, Item 19) with rag.

0021-7

TM 5-3805-294-10 INSTALLING COMPACTOR - Continued

0021

21 19 18 20
HYEX03420

Figure 12. 26. 27. 28. 29.

Connect Auxiliary Return Line.

Clean cap (Figure 12, Item 20) and attachment quick disconnect (Figure 12, Item 21) with rag. Remove plug (Figure 12, Item 18) from machine quick disconnect (Figure 12, Item 19). Remove cap (Figure 12, Item 20) from attachment quick disconnect (Figure 12, Item 21). Connect attachment quick disconnect (Figure 12, Item 21) to machine quick disconnect (Figure 12, Item 19).

END OF TASK OPERATING THE COMPACTOR 1. 2. 3. Start the machine. (WP 0007) Select Breaker 2 on the monitor. (WP 0018) Release attachment pedal lock (Figure 13, Item 22).
22

23 12

24
HYEX01325

Figure 13. Attachment Pedal Lock Release. 4. 5. 6. Press attachment pedal (Figure 13, Item 23) to turn on compactor (Figure 13, Item 12). Position compactor (Figure 13, Item 12) on work surface. Apply boom down pressure to deflect rubber isolators (Figure 13, Item 24) approximately half way.

0021-8

TM 5-3805-294-10 OPERATING THE COMPACTOR - Continued 7. 8. 9. 10. Move compactor (Figure 13, Item 12) over work surface while continuing to apply down pressure. Release attachment pedal (Figure 13, Item 23) to stop compactor (Figure 13, Item 12). Engage attachment pedal lock (Figure 13, Item 22). Safely park and shutdown machine. (WP 0009)

0021

END OF TASK REMOVING THE COMPACTOR 1. Clean attachment quick disconnect (Figure 14, Item 21) and machine quick disconnect (Figure 14, Item 19) with rag.

21 19 18 20
HYEX03420

Figure 14. 2. 3. 4. 5. 6. 7. Clean cap (Figure 14, Item 20) with rag. Clean plug (Figure 14, Item 18) with rag.

Disconnect Auxiliary Return Line.

Remove attachment quick disconnect (Figure 14, Item 21) from machine quick disconnect (Figure 14, Item 19). Install cap (Figure 14, Item 20) to attachment quick disconnect (Figure 14, Item 21). Install plug (Figure 14, Item 18) to machine quick disconnect (Figure 14, Item 19). Clean attachment quick disconnect (Figure 15, Item 17) and machine quick disconnect (Figure 15, Item 15) with rag.

0021-9

TM 5-3805-294-10 REMOVING THE COMPACTOR - Continued

0021

17 15 16

14
HYEX03419

Figure 15. Connect Auxiliary Supply Line. 8. 9. 10. 11. 12. 13. Clean plug (Figure 15, Item 16) with rag. Clean cap (Figure 15, Item 14) with rag. Remove attachment quick disconnect (Figure 15, Item 17) from machine quick disconnect (Figure 15, Item 15). Install plug (Figure 15, Item 16) to attachment quick disconnect (Figure 15, Item 17). Install cap (Figure 15, Item 14) to machine quick disconnect (Figure 15, Item 15). Rotate safety lock pin lever (Figure 16, Item 13) to unlock position.
13

HYEX03421

Figure 16. 14. 15. Start the machine. (WP 0007)

Unlock Safety Lock.

Move quick latch switch (Figure 17, Item 7) to UNLATCH position.

0021-10

TM 5-3805-294-10 REMOVING THE COMPACTOR - Continued

0021

HYEX03412

Figure 17. Quick Latch Switch to Unlatch Position. 16. Raise boom (Figure 18, Item 8) to allow for adequate ground clearance.

HYEX03413

Figure 18.

Raise Boom.

WARNING

With quick latch wedges disengaged from compactor, the compactor could fall off of the quick latch. Ensure that personnel are clear of equipment when removing or installing compactor. Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to comply may result in injury or death to personnel. 17. Extend bucket cylinder (Figure 19, Item 9) until quick latch wedges (Figure 19, Item 10) are disengaged from compactor (Figure 19, Item 12).

0021-11

TM 5-3805-294-10 REMOVING THE COMPACTOR - Continued

0021

12 10
HYEX03417

Figure 19. Disengage Quick Latch Wedges. 18. Retract bucket cylinder (Figure 20, Item 9) until quick latch (Figure 20, Item 11) is in vertical position.
9 11

HYEX03422

Figure 20.

Retract Bucket Cylinder.

NOTE
Removal of the arm/quick latch from the compactor is seldom done the same way twice. A combination of slow and smooth boom down and arm in movements is required. 19. Fully retract arm cylinder (Figure 21, Item 24).

0021-12

TM 5-3805-294-10 REMOVING THE COMPACTOR - Continued

24 8

0021

9 11

12 25
HYEX03424

Figure 21. 20.

Remove Quick Latch.

Lower boom (Figure 21, Item 8) until compactor plate (Figure 21, Item 25) is just touching the ground.

NOTE
The compactor will likely become wedged between the ground the quick latch/arm until it "pops" out of the hooks. When this wedged situation occurs, ensure that the tracks do not begin to raise. If tracks begin to raise: stop movements, raise boom, and try again. 21. Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure 21, Item 12), then begin to boom down while continuing to arm in until quick latch (Figure 21, Item 11) is removed from compactor. Move quick latch switch (Figure 22, Item 7) to LATCH position.

22.

HYEX03412

Figure 22.

Quick Latch Switch to Latch Position.

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm. Left side shown.

0021-13

TM 5-3805-294-10 REMOVING THE COMPACTOR - Continued 23. Open two auxiliary circuit shutoff valves (Figure 23, Item 6).

0021

3 4 2 6 1

5 3

HYEX03411

Figure 23. Close Hydraulic Thumb Circuit. 24. Remove retaining pin (Figure 23, Item 2) from pin (Figure 23, Item 3).

WARNING

Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar to push pin. Failure to comply may result in injury or death to personnel.

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until proper alignment of thumb to arm is achieved in order for pin to slide completely through. 25. 26. 27. 28. With the aid of an assistant, extend or retract thumb cylinder (Figure 23, Item 1), as needed, while using prybar to remove pin (Figure 23, Item 3) from thumb lock position (Figure 23, Item 5). Install pin (Figure 23, Item 3) in storage position (Figure 23, Item 4). Install retaining pin (Figure 23, Item 2) to pin (Figure 23, Item 3). Safely park and shutdown machine. (WP 0009)

END OF TASK END OF WORK PACKAGE

0021-14

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING THE BARRIER GRAPPLE

0022

INITIAL SETUP: Tools and Special Tools Lifting Device, Minimum Capacity 16,000 lbs (72574.8 kg) Equipment Condition Engine running. (WP 0007)

BARRIER GRAPPLE OPERATION

WARNING

LIFTING GUIDELINES: Do not use machine to lift personnel. Failure to comply may result in injury or death to personnel. Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death to personnel. Ensure load does not exceed the capacity of machine or lifting device. Failure to comply may result in injury or death to personnel. Lift load only as high as necessary. Failure to comply may result in injury or death to personnel. Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may result in injury or death to personnel. Personnel must remain clear of lifted items. Failure to comply may result in injury or death to personnel.

NOTE
Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16,000 lb (7257.48 kg). 1. Attach barrier grapple (Figure 1, Item 1) to quick latch loop (Figure 1, Item 2) with suitable lifting device (Figure 1, Item 3).

0022-1

TM 5-3805-294-10 BARRIER GRAPPLE OPERATION - Continued

0022

HYEX02585

Figure 1. Lifting Barrier Grapple. 2. 3. Position barrier grapple (Figure 1, Item 1) near center of barrier (Figure 1, Item 4). Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from lifting device (Figure 1, Item 3). The barrier grapple will automatically close on the barrier.

CAUTION
Avoid jerky lifting, striking, and poor alignment with barriers. Failure to comply may result in damage to equipment. 4. 5. 6. Slowly raise barrier grapple (Figure 1, Item 1) and barrier (Figure 1, Item 4). Position barrier (Figure 1, Item 4) in desired location. Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from lifting device (Figure 1, Item 3). The barrier grapple will automatically latch open and release the barrier.

0022-2

TM 5-3805-294-10 BARRIER GRAPPLE OPERATION - Continued 7. Raise barrier grapple (Figure 1, Item 1).

0022

END OF TASK END OF WORK PACKAGE

0022-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING THE DEEP DIG ARM

0023

INITIAL SETUP: References WP 0010 WP 0077 Equipment Condition Engine running. WP 0007

DEEP DIG ARM OPERATION

CAUTION
Do not attempt to extend the arm cylinder with the deep dig arm attached. The deep dig arm can strike the machine. Failure to comply may result in damage to equipment.

NOTE
After the Deep Dig Attachment has been installed on the machine, the following steps must be performed to enable Deep Dig Arm Operation. 1. Remove clip (Figure 1, Item 1) from switch bracket (Figure 1, Item 2).

HYEX01519

Figure 1. 2. 3.

Deep Dig Control Pattern Switch.

Move switch (Figure 1, Item 3) to ON position and install pin (Figure 1, Item 1). Switch A/I (Figure 2, Item 4) to on position

0023-1

TM 5-3805-294-10 DEEP DIG ARM OPERATION - Continued

0023

HYEX03404

Figure 2. Turn Auto Idle Switch On. 4. Move pilot shutoff lever (Figure 3, Item 5) to unlocked position (down).

0023-2

TM 5-3805-294-10 DEEP DIG ARM OPERATION - Continued

0023

5
HYEX01518

Figure 3. 5.

Pilot Shutoff Lever.

Turn RPM dial (Figure 4, Item 6) to max RPM setting.

0023-3

TM 5-3805-294-10 DEEP DIG ARM OPERATION - Continued

0023

HYEX03405

Figure 4.

Turn RPM Dial.

NOTE
When the deep dig control pattern switch is in the ON position, the arm cylinder is controlled by the attachment pedal and can only be retracted. The arm cylinder can only be retracted. It is necessary to occasionally retract the arm cylinder due to the weight of the deep dig arm. With the deep dig control pattern switch in the ON position, the pilot control levers operate in the same way. 6. Slowly cycle bucket cylinder (Figure 5, Item 5) and deep dig bucket cylinder (Figure 5, Item 6) until full smooth movement of each cylinder is obtained.

0023-4

TM 5-3805-294-10 DEEP DIG ARM OPERATION - Continued

0023

HYEX01636

Figure 5. 7. 8.

Cycle Deep Dig Arm Cylinders.

Park and shut down machine. (WP 0010) Check hydraulic oil level. (WP 0077)

END OF TASK END OF WORK PACKAGE

0023-5/6 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE MOVING MACHINE ON/OFF AN EMBANKMENT

0024

INITIAL SETUP: Not Applicable

MOVING MACHINE ON AN EMBANKMENT

CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to comply may result in damage to equipment. 1. Position flat surface of bucket (Figure 1, Item 1) on upper level of embankment with arm (Figure 1, Item 2) to boom (Figure 1, Item 3) angle at 90 degrees.

3 5 2 4

HYEX01102

Figure 1. 2. 3. 4. 5.

Position Bucket.

Lower boom (Figure 1, Item 3) to raise undercarriage until front of tracks (Figure 1, Item 4) clear edge of embankment. Drive machine (Figure 1, Item 5) towards upper level as arm (Figure 1, Item 2) is retracted. Slowly raise boom (Figure 1, Item 3) until tracks (Figure 1, Item 4) are resting on upper level of embankment. Rotate upper structure (Figure 2, Item 6) 180 degrees towards lower level of embankment.

0024-1

TM 5-3805-294-10 MOVING MACHINE ON AN EMBANKMENT - Continued

0024

6 5 3 2

4 1

HYEX01104

Figure 2. 6. 7.

Upperstructure Rotated.

Position flat surface of bucket (Figure 2, Item 1) on lower level of embankment with arm (Figure 2, Item 2) to boom (Figure 2, Item 3) angle at 90 degrees. Drive machine (Figure 2, Item 5) towards upper level while extending arm (Figure 2, Item 2) until machine is completely on upper level of embankment.

END OF TASK MOVING MACHINE OFF AN EMBANKMENT

CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to comply may result in damage to equipment. 1. Position flat surface of bucket (Figure 3, Item 1) on lower level of embankment with arm (Figure 3, Item 2) to boom (Figure 3, Item 3) angle at 90 degrees.

0024-2

TM 5-3805-294-10 MOVING MACHINE OFF AN EMBANKMENT - Continued

0024

5 3 2

4 1

HYEX00689

Figure 3. 2. 3.

Position Bucket on Lower Level.

Drive machine (Figure 3, Item 5) towards lower level while raising boom (Figure 3, Item 3) and retracting arm (Figure 3, Item 2) until front of tracks (Figure 3, Item 4) reach lower level of embankment. Raise bucket (Figure 4, Item 1) off of the ground and rotate upper structure (Figure 4, Item 6) 180 degrees towards upper level of embankment.

3 2 5

1 4

HYEX01103

Figure 4. 4.

Rotate Upperstructure to Upper Level.

Position flat surface of bucket (Figure 4, Item 1) on upper level of embankment with arm (Figure 4, Item 2) to boom (Figure 4, Item 3) angle at 90 degrees. 0024-3

TM 5-3805-294-10 MOVING MACHINE OFF AN EMBANKMENT - Continued 5. 6.

0024

Lower boom (Figure 4, Item 3) slightly and drive machine (Figure 4, Item 5) towards lower level as the arm (Figure 4, Item 2) is extended. When tracks (Figure 4, Item 4) clear upper level of embankment, slowly raise boom (Figure 4, Item 3) until machine (Figure 4, Item 5) is on lower level.

END OF TASK END OF WORK PACKAGE

0024-4

TM 5-3805-294-10 OPERATOR MAINTENANCE USING THE VANDAL PROTECTION KIT

0025

INITIAL SETUP: Not Applicable

RIGHT SIDE CAB INSTALLATION 1. Position cover (Figure 1, Item 1) on cab hook (Figure 1, Item 2) and behind brackets (Figure 1, Item 3).
2 1

HYEX01548

Figure 1. 2.

Right Side Rear Cover Installation.

Position cover (Figure 2, Item 4) on cab hook (Figure 2, Item 5) and behind brackets (Figure 2, Item 6).

HYEX01549

Figure 2.

Right Side Center Cover Installation.

0025-1

TM 5-3805-294-10 RIGHT SIDE CAB INSTALLATION - Continued 3. Position cover (Figure 3, Item 7) on cab hook (Figure 3, Item 8) and behind brackets (Figure 3, Item 9).
8 7

0025

HYEX01550

Figure 3. 4.

Right Side Front Cover Installation.

Position plate (Figure 4, Item 10) over tabs (Figure 4, Item 11) and turn lock (Figure 4, Item 12) to lock in place.

11

10 11

12

HYEX01551

Figure 4. Lock Bar Installation. END OF TASK LEFT SIDE CAB INSTALLATION 1. Position cover (Figure 5, Item 13) over door hook (Figure 5, Item 14) and behind brackets (Figure 5, Item 15).

0025-2

TM 5-3805-294-10 LEFT SIDE CAB INSTALLATION - Continued

0025

14

13

15

HYEX01552

Figure 5. 2.

Front Door Cover Installation.

Position cover (Figure 6, Item 16) over cab hook (Figure 6, Item 17) and behind brackets (Figure 6, Item 18).
17 16

18

HYEX01553

Figure 6. 3.

Center Door Cover Installation.

Position cover (Figure 7, Item 19) over hooks (Figure 7, Item 20) and behind brackets (Figure 7, Item 21).

0025-3

TM 5-3805-294-10 LEFT SIDE CAB INSTALLATION - Continued

0025

20

20

21

24 23

22
Figure 7. 4. 5.

19

HYEX01554

Lower Door Cover Installation.

Position hinge (Figure 7, Item 22) over tab (Figure 7, Item 23) and turn lock (Figure 7, Item 24) to lock in place. Position cover (Figure 8, Item 25) over cab hooks (Figure 8, Item 26) and behind bracket (Figure 8, Item 27).

26

26

25

27

HYEX01555

Figure 8. Side Upper Glass Cover Installation. 6. Position cover (Figure 9, Item 28) over hooks (Figure 9, Item 29) and behind brackets (Figure 9, Item 30).

0025-4

TM 5-3805-294-10 LEFT SIDE CAB INSTALLATION - Continued

29

0025

30 28

33 32 31

HYEX01556

Figure 9. 7.

Side Lower Glass Cover Installation.

Place hinge (Figure 9, Item 31) over tab (Figure 9, Item 32) and turn lock (Figure 9, Item 33) to lock in place.

END OF TASK REAR CAB INSTALLATION 1. Position cover (Figure 10, Item 34) over cab hook (Figure 10, Item 35) and behind brackets (Figure 10, Item 36).
34 35

36

HYEX01557

Figure 10. 2.

Right Rear Cab Cover Installation.

Position cover (Figure 11, Item 37) over tab (Figure 11, Item 38) and behind brackets (Figure 11, Item 39).

0025-5

TM 5-3805-294-10 REAR CAB INSTALLATION - Continued

0025

38

40

39

37
Figure 11. 3.

HYEX01558

Left Rear Cab Cover Installation.

Turn lock (Figure 11, Item 40) to lock in place.

END OF TASK REAR CAB REMOVAL 1. Turn lock (Figure 12, Item 40) to unlock.

38

40

39

37

HYEX01558

Figure 12. Left Rear Cab Cover Removal. 2. Remove cover (Figure 12, Item 37) from behind brackets (Figure 12, Item 39) and from tab (Figure 12, Item 38).

0025-6

TM 5-3805-294-10 REAR CAB REMOVAL - Continued 3.

0025

Remove cover (Figure 13, Item 34) from behind brackets (Figure 13, Item 36) and cab hook (Figure 13, Item 35).
34 35

36

HYEX01557

Figure 13. END OF TASK LEFT SIDE CAB REMOVAL 1.

Right Rear Cab Cover Removal.

Turn lock (Figure 14, Item 33) to unlock and remove hinge (Figure 14, Item 31) from tab (Figure 14, Item 32).
29

30 28

33 32 31
HYEX01556

Figure 14. 2. 3.

Side Lower Glass Cover Removal.

Remove cover (Figure 14, Item 28) from behind brackets (Figure 14, Item 30) and hooks (Figure 14, Item 29). Remove cover (Figure 15, Item 25) from behind bracket (Figure 15, Item 27) and cab hooks (Figure 15, Item 26).

0025-7

TM 5-3805-294-10 LEFT SIDE CAB REMOVAL - Continued

0025

26

26

25

27

HYEX01555

Figure 15. Side Upper Glass Cover Removal. 4. Turn lock (Figure 16, Item 24) to unlock and remove hinge (Figure 16, Item 22) from tab (Figure 16, Item 23).

20

20

21

24 23

22

19

HYEX01554

Figure 16. Lower Door Cover Removal. 5. 6. Remove cover (Figure 16, Item 19) from behind brackets (Figure 16, Item 21) and hooks (Figure 16, Item 20). Remove cover (Figure 17, Item 16) from behind brackets (Figure 17, Item 18) and cab hooks (Figure 17, Item 17).

0025-8

TM 5-3805-294-10 LEFT SIDE CAB REMOVAL - Continued

17 16

0025

18

HYEX01553

Figure 17. 7.

Center Door Cover Removal.

Remove cover (Figure 18, Item 13) from behind brackets (Figure 18, Item 15) and door hooks (Figure 18, Item 14).

14

13

15

HYEX01552

Figure 18. END OF TASK RIGHT SIDE CAB REMOVAL 1.

Front Door Cover Removal.

Turn lock (Figure 19, Item 12) to unlock and remove plate (Figure 19, Item 10) from tabs (Figure 19, Item 11).

0025-9

TM 5-3805-294-10 RIGHT SIDE CAB REMOVAL - Continued

0025

11

10 11

12

HYEX01551

Figure 19. 2.

Lock Bar Removal.

Remove cover (Figure 20, Item 7) from behind brackets (Figure 20, Item 9) and cab hook (Figure 20, Item 8).
8 7

HYEX01550

Figure 20. Right Side Front Cover Removal. 3. Remove cover (Figure 21, Item 4) from behind brackets (Figure 21, Item 6) and cab hook (Figure 21, Item 5).

HYEX01549

Figure 21. Right Side Center Cover Removal.

0025-10

TM 5-3805-294-10 RIGHT SIDE CAB REMOVAL - Continued 4.

0025

Remove cover (Figure 22, Item 1) from behind brackets (Figure 22, Item 3) and cab hook (Figure 22, Item 2).
2 1

HYEX01548

Figure 22. END OF TASK END OF WORK PACKAGE

Right Side Rear Cover Removal.

0025-11/12 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING THE HYDRAULIC HOSE REEL

0026

INITIAL SETUP: Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) References WP 0007 WP 0009 Equipment Condition Machine safely parked and shut down. (WP 0009)

CONNECTING HYDRAULIC TOOL 1. Remove cover (Figure 1, Item 1) from quick coupler (Figure 1, Item 2).

5 6

2 4 1 3
HYEX01097

Figure 1. 2. 3. 4. 5. 6.

Hydraulic Tool Attachment.

Remove cover (Figure 1, Item 3) from quick coupler (Figure 1, Item 4). Using a clean rag, wipe quick coupler (Figure 1, Item 2) and (Figure 1, Item 4) and couplers on tool to be connected. Connect quick coupler (Figure 1, Item 2) on return hose (Figure 1, Item 5) to hydraulic tool. Connect quick coupler (Figure 1, Item 4) on supply hose (Figure 1, Item 6) to hydraulic tool. Start engine. (WP 0007)

0026-1

TM 5-3805-294-10 CONNECTING HYDRAULIC TOOL - Continued 7. Move hand held hydraulic tool circuit switch (Figure 2, Item 7) to ON position.

0026

8 7
HYEX01096

Figure 2. 8.

Turn On Hydraulic Tool.

Adjust flow regulator (Figure 2, Item 8) to tool specification.

END OF TASK DISCONNECTING HYDRAULIC TOOL 1. Move flow regulator (Figure 3, Item 8) to lowest setting.

8 7
HYEX01096

Figure 3. 2. 3. Shut engine off. (WP 0009)

Turn Off Hydraulic Tool.

Move hand held hydraulic tool circuit switch (Figure 3, Item 7) to OFF position.

0026-2

TM 5-3805-294-10 DISCONNECTING HYDRAULIC TOOL - Continued 4. 5. Operate hydraulic tool to relieve pressure from hoses. Disconnect quick coupler (Figure 4, Item 4) on supply hose (Figure 4, Item 6) from hydraulic tool.

0026

5 6

2 4 1 3
HYEX01097

Figure 4. 6. 7. 8.

Hydraulic Tool Removal.

Disconnect quick coupler (Figure 4, Item 2) on return hose (Figure 4, Item 5) from hydraulic tool. Install cover (Figure 4, Item 3) to quick coupler (Figure 4, Item 4). Install cover (Figure 4, Item 1) to quick coupler (Figure 4, Item 2).

END OF TASK END OF WORK PACKAGE

0026-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE DECAL LOCATION GUIDE

0027

INITIAL SETUP: Not Applicable

DECALS This work package shows the typical location of all decals on the machine and attachments. Some are located inside access panels or under the engine cover.
24 VOLTS DC SLAVE RECEPTACLE

240D
LCR

DIESEL ONLY

HYEX01457

Figure 1. Left Side, Rear Cab Window, and Top Decals.

0027-1

TM 5-3805-294-10 DECALS - Continued

0027

DRY AIR CLEANER

1. If equipped with automatic dust unloader vale, periodically clear valve by squeezing or if equipped with dust cup, service daily. 2. If tractor is equipped with an air cleaner restriction indicator, clear the primary element at the next refueling or daily service period if: a. Indicator light on the instrument panel glows with the engine running, or b.Manual indicator on the outlet of the air cleaner shows red. 3. If tractor is not equipped with restriction indicator, service the filter element every 250 hours or whem engine loses power or smokes excessively. 4. Stop engine before removing filter element. 5. Service according to instructions on primary element. 6. Replace primary element yearly or if damaged or when if no longer responds to cleaning, whichever occurs first. 7. If equipped with safety air cleaner or safety element, replace yearly or ans required. DO NOT ATTEMPT TO CLEAN SAFETY CLEANER OR ELEMENT.

DO NOT USE OIL

HYEX01449

Figure 2.

Left Inside Door.

HYEX01448

Figure 3. Top Under Engine Cover

0027-2

TM 5-3805-294-10 DECALS - Continued

0027

IMPORTANT
OIL LEVEL
Fully Retracted Fully Retracted

3 Without Bucket

Check oil level cold with excavator in position shown above.

HYEX01447

Figure 4.

Right Side on Hydraulic Reservoir.

FUEL TANK SUMP WATER DRAIN

Drain water and sediment from fuel tank every 50 hours or weekly. Allow water to settle to tank bottom before draining. It may be possible when valve is opened that fuel may drain out at first. Wait several seconds to allow enough time for water to drain through hose. Drain water and sediment into container and dispose of properly.
T247868

TRANSPORTATION DATA
GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD NO. OF SLINGS REQUIRED LENGTH OF SLINGS EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS
SWING CENTERLINE

60,000 LB.

4 12 FT.

CENTER OF GRAVITY

44 MM [1.7 IN.]

1212 MM [47.5 IN.]

HYEX01445

Figure 5.

Right Side.

0027-3

TM 5-3805-294-10 DECALS - Continued

0027

LIFT
ENGINE OIL SAMPLE VALVE HYD OIL SAMPLE VALVE

HYEX01444

Figure 6.

Boom, Right Side, and Rear Cab Window.

HYEX01446

Figure 7.

Counterweight.

0027-4

TM 5-3805-294-10 DECALS - Continued

0027

TIEDOWN
HYEX01442

Figure 8.

Front and Rear Frame.

LOCK

HYEX01450

Figure 9.
O FF

Cab on Seat.

AC C

ON

S TA
RT
HYEX01530

Figure 10.

Key Switch.

0027-5

TM 5-3805-294-10 DECALS - Continued

0027

CAUTION

FRONT WINDOW HANDLE

Avoid injury from slip or fall. DO NOT use as a handhold. T223082 Window handle will move with the front window.

HYEX01531

Figure 11.
240DLC LIFT IN 1000 LBS.
WITH 1920 LB. BUCKET, 11 FT. 10 IN. ARM AND 32 INCH SHOES

Windshield.

10'

15'

20'

25' 7.55* 7.55*

30'

IMPORTANT
SECONDARY EXIT
Use tool to break window.

8.52* 8.52*

8.61* 8.61*

6.26* 6.26* 8.09* 6.29 9.68 6.04 9.46 5.81 9.31 5.67

14.69* 11.56* 10.05* 14.69* 11.56* 8.88 20.76* 14.49* 11.62* 18.90 12.10 8.39 24.56* 16.88* 12.79 17.62 11.35 7.96 13.06* 25.71* 17.90 13.06* 17.16 10.92 15.60* 22.51* 25.00* 17.77 15.60* 22.51* 17.15 10.80 12.48 7.68 12.39 7.59

Always keep tool in machine.

T190393

29.63* 22.54* 16.71* 12.31 29.63* 17.46 10.96 7.77 17.28* 12.10* 17.28* 11.53 RED - OVER THE FRONT BLACK - OVER THE SIDE *HYDRAULICALLY LIMITED NOTE: SEE OPERATOR'S MANUAL FOR MORE ACCURATE INFORMATION
T218383

HYEX01532

Figure 12.

Side Window.

0027-6

TM 5-3805-294-10 DECALS - Continued

ATTACHMENT MODE SELECTION PROCEDURE
1. Press Key F1 to display the work mode screen. 2. While referring to the table below, press the key corresponding to the attachment mode you are going to use. Attachment to be used Bucket or Thumb Hammer/ Breaker Alternative Hammer/Breaker Pulverizer Crusher Attachment mode Key No. to be selected 1 2 3 4 5 Excavation Breaker 1 Breaker 2 Pulverizer 1 Crusher 1 2 F1 3 4 5
Work Mode
Dig Breaker 2
2

0027

CAUTION
To prevent injury from the front window falling, lock window in place with the lock pin. T187353

Crusher 1
1

Breaker 1
1

Pulverizer 1
1

7 F1

8 F2

9 F3

0 F4

DANGER
Serious injury or death can result from contact with electric lines. Never move any part of unit or load closer to electric line than 3 M [10 FT.] plus twice the line insulator length.
T146667

WORK MODE SCREEN

Crusher 1
Maximum Pump Flow Rate Maximum Engine Speed Valve Selector C/V 2-Speed Selector ON 420 L/min 1900 min-1 OFF

Accumulator

2ndary Hydraulic Relief Selector OFF

3. The specifications of the selected attachment mode are displayed on the screen and the attachment hydraulic circuit is shifted to match operation of the selected attachment. 4. Press the CONFIRM. The screen is returned to the STANDARD screen and the attachment becomes operable.

7 F1

8 F2

9 F3

0 F4

CONFIRM
ATTACHMENT SPECIFICATION SCREEN

Affix this label to interior glass of operator's cab

T223619

CAUTION
Alternate control patterns are available for this machine. Always verify control response before operating. T201519

HYEX01533

Figure 13.

Upper and Lower Right Side Window.

0027-7

TM 5-3805-294-10 DECALS - Continued

ENGINE OPERATION
STARTING - Set RPM's (dial or throttle position) at low idle, turn key on and wait until glow plug warm-up indicator turns off; turn key to start and crank for 20 seconds maximum or less if required. Allow 2 minutes between cranking attempts. DO NOT USE ETHER AS A STARTING AID. STOPPING - Reduce RPM's to low idle for 2 minutes with no load. Stop engine. ENGINE STALL - Remove load, restart immediately. Run 30 seconds at half speed before adding load.
min1

0027

CAUTION
AVOID DEATH OR SERIOUS INJURY - READ AND UNDERSTAND THE OPERATOR'S MANUAL AND SAFETY MANUAL PRIOR TO OPERATING THIS MACHINE. Controls may be changed for attachment or operator preference. Try control pattern before operating. Always lower working tools to the ground and engage hydraulic control lockout lever before leaving operator's seat. Keep riders off machine. Avoid contact between boom/attachments and overhead obstacles whenever operating, traveling or transporting machine. Keep bystanders clear of machine; especially before moving boom, swinging upperstructure or traveling. Upperstructure position affects travel direction. Try pedals or levers to determine travel direction before moving machine. Avoid tipping - Do not lift or move objects that exceed machine stability.

ENGINE RPM CONTROL Turn CW to increase Turn CCW to decrease

AUTOMATIC SPEED CHANGE

OFF A/I

H/P P E

A/I - Auto Idle Engine speed is temporarily reduced, if control levers are in Neutral for 4 seconds. POWER MODE H/P - Select for heavy digging, maximum productivity.
P - Select for standard digging E - Select for light digging, maximum fuel economy.
T219580

Avoid parking machine on an incline.

T159887

WARNING
AVOID SERIOUS CRUSHING INJURY FROM BOOM NEVER place any part of body beyond window bars or frame. It could be crushed by the boom if boom control lever is accidentally bumped or otherwise engaged. DO NOT remove window bars. If window is missing or broken, replace immediately. D3067125 S HYEX01536

Figure 14. Lower Right Side Window.

0027-8

TM 5-3805-294-10 DECALS - Continued

0027

1. 2.

3.

COVERS ARE SHOWN BELOW TO AID IN DETERMINING LOCATION ON CAB. START THE COVER INSTALLATION AT THE REAR OF THE CAB. CONTINUE INSTALLATION IN THE ORDER SHOWN BELOW. (RIGHT SIDE, FRONT, LEFT SIDE) LOCK COVERS AFTER INSTALLATION.

2 1 2 4

1 2 3 4

CAB, REAR

CAB, RIGHT SIDE

CAB, FRONT

CAB, LEFT SIDE

T218467

HYEX01538

Figure 15.

Vandal Protection Kit.

0027-9

TM 5-3805-294-10 DECALS - Continued

0027

240DLCR PERIODIC MAINTENANCE

REFER TO OPERATOR'S MANUAL FOR DETAILED INFORMATION
INTERVAL HOURS ITEM NO. ITEM MAINTENANCE POINTS DESCRIPTION AS REQUIRED 4 23 24 26 7 16 20 5 12 29 100 FUEL TANK INLET SCREEN WINDSHIELD WASHER FLUID AIR CLEANER TRACK SAG HYDRAULIC SYSTEM OIL LEVEL ENGINE OIL LEVEL ENGINE COOLANT LEVEL FUEL TANK SUMP WATER SEPARATOR WORKING TOOL PIVOTS 1 1 1 2 1 1 1 1 1 4 REMOVE AND CLEAN (A) ADD AS REQUIRED CHECK - CLEAN DUST VALVE AND/OR ELEMENT (A) CHECK - ADJUST (A) CHECK WITH EXTENDED BUCKET CYLINDER, RETRACTED ARM CYLINDER AND BUCKET ON GROUND (A) CHECK (A) COOLANT LEVEL TO BE ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD DRAIN WATER AND SEDIMENT (A) DRAIN WATER GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS. GREASE DAILY WHEN WORKING IN WATER CHECK DIPSTICK DRAIN WATER SEDIMENT (A) REPLACE (A) (C) REPLACE (A) CHECK DIPSTICK DRAIN AND REFILL CHECK AND ADJUST CHECK - LEVEL IN BOTTLE BETWEEN "MAX COLD" AND "MIN COLD" MARKS (A) CHECK - TO BOTTOM OF FILLER NECK - CLEAN AND TIGHTEN TERMINALS CHECK - REMOVE PLUG CLEAN ELEMENT GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS. GREASE DAILY WHEN WORKING IN WATER GREASE - ADD 1 LB. [0.5 Kg] (A) (D) REPLACE (A) (C) REPLACE (A) REPLACE - 500 HOURS OR AS REQUIRED (A) DRAIN AND REFILL (B) (C) CHECK FOR CRACKS AND LOOSE CONNECTIONS (A) CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS GREASE - 8 SHOTS EACH - EVERY 45 FOR ONE REVOLUTION (A) 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 DRAIN AND REFILL EVERY 2000 HOURS. CLEAN SUCTION SCREEN (A) REFER TO SERVICE MANUAL DRAIN, FLUSH AND REFILL WITH PROPER COOLANT. FILL RADIATOR, FILL BOTTLE TO ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD (A) DRAIN AND REFILL EACH (A)

T260750

APPROVED MATERIAL

MPGM-SEE LUBRICANTS HYDO-SEE LUBRICANTS EO-SEE LUBRICANTS PROPER COOLANT (A)

10 OR DAILY 50 OR WEEKLY

MPGM-SEE LUBRICANTS

250

3 6 10 12 14 16 19 20 21 22 24 1

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 FRONT END PIN JOINTS

1 1 1 1 1 1 1 1 2 2 1 16

JD FILTER JD ELEMENT EO-SEE LUBRICANTS EO-SEE LUBRICANTS PROPER COOLANT (A) DISTILLED WATER MPL-SEE LUBRICANTS

MPGM-SEE LUBRICANTS

500

2 10 12 13 16 18 25 27 28 3 9 11 14 15 19 24 8 17 20 22

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 SWING GEAR BOX OIL HYDRAULIC OIL FILTER PILOT CONTROL OIL FILTER PUMP DRIVE GEARBOX ENGINE CRANKCASE VENT TUBE SERPENTINE BELT AIR CLEANER HYDRAULIC SYSTEM OIL ENGINE VALVE LASH RADIATOR TRAVEL GEARBOX OIL

1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 2

JD FILTER JD FILTER JD FILTER EO-SEE LUBRICANTS JD FILTER JD FILTER MPGM-SEE LUBRICANTS MPL-SEE LUBRICANTS JD FILTER JD FILTER EO-SEE LUBRICANTS

1000

JD FILTER AND VALVE HYDO-SEE LUBRICANTS PROPER COOLANT (A) MPL-SEE LUBRICANTS

2000

HYEX01534

Figure 16. Upper Section Periodic Maintenance.

0027-10

TM 5-3805-294-10 DECALS - Continued

0027

DRAIN AND REFILL CAPACITIES ITEM FUEL TANK COOLING SYSTEM ENGINE CRANKCASE (INCLUDING FILTER) HYDRAULIC RESERVOIR HYDRAULIC SYSTEM SWING BEARING GEAR SWING GEAR REDUCTION TRAVEL GEARBOX (EACH) PUMP DRIVE GEARBOX U.S. MEASURE 132 GAL 31.6 QT 26 QT (6.5 GAL) 39 GAL 63.4 GAL 22 LB 7.5 QT 6.5 QT 1.2 QT METRIC 500 L 29.9 L 24.6 L 147.6 L 240 L 10 Kg 7L 6.2 L 1.1 L

(A) SEE OPERATOR'S MANUAL. (B) FOR BREAK IN OR REBUILD, SEE OPERATOR'S MANUAL. (C) USE OF JP8 JET FUEL OR DIESEL FUEL WITH SULFUR CONTENT GREATER THAN 2000 PPM [0.20%] WILL REDUCE THE ENGINE OIL AND FILTER CHANGE INTERVAL TO 250 HOURS WITH PREMIUM OILS. (D) DRAIN WATER FROM GREASE SUMP WHEN IN WATER ABOVE TRACK.

10 11 12 13 14 15

16 17 18 19 20 29
LUBRICANTS AIR TEMPERATURE RANGE DURING FILL PERIOD F - 40 - 40 - 22 - 30 -4 - 20 14 - 10 32 0 50 10 68 20 86 30 104 40 122 50

28

27 26

25 24 23 22

21

RECOMMENDED LUBRICANTS
[EO] ENGINE OIL
USE JOHN DEERE PLUS 50 ENGINE OILS MEETING: MILITARY SPECIFICATIONS MIL-PRF-2104 VISCOSITY GRADE SAE 15W40 IS PREFERRED (1) - MAY USE MIL-PRF-46167 ARCTIC OIL BUT DRAIN INTERVAL IS REDUCED TO ONE-HALF OF NORMAL

SAE 15W40 SAE 10W30 SAE 5W30 SAE 0W40 SAE 30 (1) ARCTIC OIL

[HYDO] HYDRAULIC OIL

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 10W30 SAE 5W30 SAE 15W40 MIL-46167 MIL-32073-GR1 MIL-32073-GR5

[MPL] MULTIPURPOSE LUBRICANT

USE JOHN DEERE API GL-5 GEAR OIL OILS MEETING API GL-5 OR MILITARY SPECIFICATIONS MIL-L-2105B OR MIL-L-2105C

SAE 90: 85W140 SAE 80W90 SAE 75W ARCTIC OIL NLGI NO. 2 J.D. HIGH TEMP/EP NLGI NO. 0 OR 1 ARCTIC GREASE

[MPGM] MULTIPURPOSE GREASE WITH MOLYBDENUM DISULFIDE

USE JOHN DEERE MOLY HIGH-TEMPERATURE EXTREME PRESSURE (EP) GREASE SAE MULTIPURPOSE EP GREASE CONTAINING 3 TO 5% MOLYBDENUM DISULFIDE

HYEX01535

Figure 17.

Lower Section Periodic Maintenance. 0027-11

TM 5-3805-294-10 DECALS - Continued

0027

WARNING
TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT.

HYEX01441

Figure 18. Ditch Cleaning Bucket.

WARNING
TOP OF WEDGE MUST BE ENGAGED TO THIS AREA BEFORE OPERATING ATTACHMENT.

HYEX01440

Figure 19.

Heavy Duty Bucket.

0027-12

TM 5-3805-294-10 DECALS - Continued

0027

HYEX01437

Figure 20.

Right Side Crush-All.

HYEX01438

Figure 21.

Left Side Crush-All.

0027-13

TM 5-3805-294-10 DECALS - Continued

0027

DANGER
SHUT OFF EXCAVATOR PRIOR TO MAINTENANCE

DANGER
ALL PERSONNEL STAND CLEAR FLYING DEBRIS

DANGER
DO NOT OPERATE WITHOUT GUARDS

DANGER
HIGH PRESSURE HYDRAULIC SYSTEM

HYEX01439

Figure 22. Output Side Crush-All. END OF TASK END OF WORK PACKAGE

0027-14

TM 5-3805-294-10 OPERATOR MAINTENANCE TOWING THE HYEX

0028

INITIAL SETUP: Not Applicable

TOWING

CAUTION
The travel motors require hydraulic pressure to release the parking brakes. Do not attempt to tow the HYEX without Field Maintenance support. Field Maintenance must prepare the travel motors before the HYEX can be towed. Failure to comply may result in damage to equipment. In the event during operation of the HYEX the machine becomes disabled and needs to be towed, notify Field level maintenance. END OF TASK END OF WORK PACKAGE

0028-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE LOWERING BOOM WITHOUT HYDRAULIC PRESSURE

0029

INITIAL SETUP: Not Applicable

LOWERING BOOM In the event during operation of the HYEX the machine becomes disabled and the boom needs to be lowered, notify Field level maintenance. END OF TASK END OF WORK PACKAGE

0029-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)

0030

INITIAL SETUP: References WP 0004 References (cont.) WP 0005 WP 0018

STARTING

NOTE
In extreme cold conditions, an extended warm-up period will be necessary. Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. 1. Press and hold back button.

BACK BUTTON

HYEX01413

Figure 1. 2.

Press and Hold Back Button.

Turn key switch (Figure 2, Item 1) to ON position.

0030-1

TM 5-3805-294-10 STARTING - Continued

0030

HYEX01414

Figure 2. 3. 4.

Key Switch to ON Position.

Release back button when monitor goes to default screen. Press menu button.

BACK BUTTON

MENU BUTTON

HYEX01415

Figure 3. 5.

Release Back Button.

Press button one or button two until service menu is highlighted.

0030-2

TM 5-3805-294-10 STARTING - Continued

Main Menu
Fuel Rate Display/No Display

0030

SERVICE MENU

Back Monitor Settings Language/ Service Menu

SELECT BUTTON
1 2 3 4 5

BUTTON 1 BUTTON 2

7 F1

8 F2

9 F3

0 F4

HYEX01416

Figure 4. 6. 7. Press the select button.

Highlight Service Menu.

Press button one or button two until monitoring is highlighted then press the select button.
Service Menu Troubleshooting Monitoring Ver. Controller Version

MONITORING

BUTTON 2
1 2 3 4 5

SELECT BUTTON
6 7 F1 8 F2 9 F3 0 F4

BUTTON 1
HYEX01417

Figure 5. 8.

Select Monitoring.

Press button 1 or 2 until the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed. (WP 0005)

0030-3

TM 5-3805-294-10 STARTING - Continued

0030

Monitoring
Hydraulic Oil Temperature
0 oC

Coolant Temperature (E) Actual Engine Speed Fuel Temperature

0 oC 0 0 oC

ON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX01418

Figure 6. Temperatures Displayed.

NOTE
If hydraulic oil temperature is 32F (0C) or below, engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36F (2C). 9. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.

HYEX01419

Figure 7. 10.

Start Engine.

Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at fast or slow idle.

0030-4

TM 5-3805-294-10 STARTING - Continued

0030

HYEX01420

Figure 8. 11.

Engine Speed Dial.

Ensure engine coolant and hydraulic oil temperatures are above 0F (-18C) before proceeding to Step 12.

Monitoring
Hydraulic Oil Temperature
0 oC

Coolant Temperature (E) Actual Engine Speed Fuel Temperature

0 oC 0 0 oC

ON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX01418

Figure 9.

Check Engine and Hydraulic Oil Temperatures.

NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders are fully raised, the overload alarm may sound even if the machine is not in an overload condition. Lower the boom cylinders until the alarm is no longer displayed. 12. Set machine switch selections for temperatures between 5 and 32F (-15 and 0C) per Table 1.

0030-5

TM 5-3805-294-10 STARTING - Continued Table 1. Engine Speed Power Mode Switch Position Auto-Idle (A/I) Switch Position Travel Speed Switch 13. Select dig mode on monitor. (WP 0018) Machine Switch Selections. Speed Dial to Half Speed High Power (HP) Mode OFF Slow (Turtle)

0030

WARNING

Clear the area of all personnel during machine warm up procedures. Machine can move unexpectedly. Failure to comply may result in injury or death to personnel.

CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot spots in the control valve. Failure to comply may result in damage to equipment. 14. 15. 16. Operate swing, boom, arm, hydraulic thumb, and bucket functions slowly and short distances initially in each direction. (WP 0004) Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is obtained. Swing upperstructure (Figure 10, Item 3) 90 degrees.

5 6

3 7 4
HYEX01421

Figure 10. 17. 18.

Raise Machine.

Place round side of bucket (Figure 10, Item 4) on ground. Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees, slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.

0030-6

TM 5-3805-294-10 STARTING - Continued 19. 20. 21. Operate travel lever for raised track for approximately 5 minutes. (WP 0004)

0030

Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure back 90 degrees. Repeat Steps 14 to 18 for opposite track.

END OF TASK END OF WORK PACKAGE

0030-7/8 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE OPERATING IN COLD WEATHER 5F (-15C) OR COLDER

0031

INITIAL SETUP: References WP 0004 References (cont.) WP 0018 WP 0034

STARTING

NOTE
Contact Field Maintenance to ensure that all fluids meet the requirements for the current operating conditions. In extreme cold conditions, an extended warm-up period will be necessary. Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly warm. 1. 2. If temperature is 5F (-15C) or below, operate coolant heater for 30 minutes. (WP 0034) Press and hold back button.

BACK BUTTON

HYEX01423

Figure 1.

Press and Hold Back Button.

0031-1

TM 5-3805-294-10 STARTING - Continued 3. Turn key switch (Figure 2, Item 1) to ON position.

0031

HYEX01424

Figure 2. 4.

Key Switch to ON Position.

Release back button when monitor goes to default screen.

BACK BUTTON

MENU BUTTON

HYEX01415

Figure 3. 5. 6. Press menu button.

Release Back Button.

Press button one or button two until service menu is highlighted.

0031-2

TM 5-3805-294-10 STARTING - Continued

Main Menu
Fuel Rate Display/No Display

0031

SERVICE MENU

Back Monitor Settings Language/ Service Menu

SELECT BUTTON
1 2 3 4 5

BUTTON 1 BUTTON 2

7 F1

8 F2

9 F3

0 F4

HYEX01430

Figure 4. 7. 8. Press the select button.

Highlight Service Menu.

Press button one or button two until monitoring is highlighted, then press the select button.
Service Menu Troubleshooting Monitoring Ver. Controller Version

MONITORING

SELECT BUTTON
1 2 3 4 5

BUTTON 1
6 7 F1 8 F2 9 F3 0 F4

BUTTON 2
HYEX01431

Figure 5.

Select Monitoring.

0031-3

TM 5-3805-294-10 STARTING - Continued 9. Ensure the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed.

0031

Monitoring
Hydraulic Oil Temperature
0 oC

Coolant Temperature (E) Actual Engine Speed Fuel Temperature

0 oC 0 0 oC

ON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX01432

Figure 6. Temperatures Displayed.

NOTE
If hydraulic oil temperature is 32F (0C) or below, engine will run at 1400 rpm for 15 minutes or until hydraulic oil temperature reaches 36F (2C). 10. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.

HYEX01433

Figure 7. 11.

Start Engine.

Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at fast or slow idle.

0031-4

TM 5-3805-294-10 STARTING - Continued

0031

HYEX01434

Figure 8. 12.

Engine Idle Speed.

Monitor engine coolant and hydraulic oil. Once the oil temperatures reach 0F (-18C) the High Power (HP) mode can be selected.

Monitoring
Hydraulic Oil Temperature
0 oC

Coolant Temperature (E) Actual Engine Speed Fuel Temperature

0 oC 0 0 oC

ON
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX01432

Figure 9.

Monitor Temperatures Displayed.

0031-5

TM 5-3805-294-10 STARTING - Continued

0031

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 5F (-15C) and below per Table 1. Table 1. Machine Specification Engine Speed Power Mode Switch Position Auto-Idle (A/I) Switch Position Travel Speed Switch 14. Machine Switch Selection. Temperature Below 0F (-18C) Speed Dial to Half Speed Economy (E) Mode OFF Slow (Turtle)

Temperatures 5 to 0F (-15 to -18C) Speed Dial to Half Speed High Power (HP) Mode OFF Slow (Turtle)

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. 16. 17. Operate swing, boom, arm, and bucket functions slowly and short distances initially in each direction. (WP 0004) Continue cycling cylinders by increasing travel each cycle until full smooth movement of function is obtained. Swing upperstructure (Figure 10, Item 3) 90 degrees.

0031-6

TM 5-3805-294-10 STARTING - Continued

0031

5 6

3 7 4
HYEX01435

Figure 10. 18. 19. 20. 21. 22.

Raise Machine.

Place round side of bucket (Figure 10, Item 4) on ground. 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. Operate travel lever for raised track for approximately 5 minutes. (WP 0004) Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure back 90 degrees. 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

0032

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. 2. 3. Contact Field Maintenance to get a slave cable. Connect the slave cable to booster vehicle slave receptacle. Remove cap (Figure 1, Item 1) from slave receptacle (Figure 1, Item 2).

0032-1

TM 5-3805-294-10 SLAVE STARTING - Continued

0032

HYEX00866

Figure 1. 4. 5. 6. 7. 8. 9. 10.

Slave Receptacle.

Connect slave cable to slave receptacle (Figure 1, Item 2). Run booster vehicle at a speed just above idle. Refer to booster vehicle Operator's Manual. Start engine. (WP 0007) After starting machine, return booster vehicle to idle. Refer to booster vehicle Operator's Manual. Remove the slave cable from slave receptacle (Figure 1, Item 2). Install cap (Figure 1, Item 1) to slave receptacle (Figure 1, Item 2). Remove slave cable from booster vehicle.

END OF TASK END OF WORK PACKAGE

0032-2

TM 5-3805-294-10 OPERATOR MAINTENANCE SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)

0033

INITIAL SETUP: Not Applicable

SKYLIGHT WINDOW (SECONDARY EXIT) 1. 2. Slide back liner. Release two latches (Figure 1, Item 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 REAR WINDOW (EMERGENCY EXIT) - Continued

0033

3
Figure 2. Emergency Exit Tool.

HYEX00944

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. 3. 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. 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

0034

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

TM 5-3805-294-10 COOLANT HEATER OPERATION - Continued 1. The coolant heater control panel (Figure 1, Item 1) is located on left outer console of operator's seat.

0034

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.

M0

3 20:30

HYEX00022

Figure 2. Adjusting Time and Day. 2. 3. 4. 5. Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust time up or down. When time is correct wait approximately 5 seconds and day (Figure 2, Item 7) will begin to flash. 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. When day (Figure 2, Item 7) is correct wait approximately 5 seconds and day will stop flashing.

0034-2

TM 5-3805-294-10 ADJUSTING COOLANT HEATER TIME AND DAY - Continued 6. Time (Figure 2, Item 4) and day (Figure 2, Item 7) is set.

0034

END OF TASK SETTING AND SELECTING COOLANT HEATER PROGRAM

NOTE
The coolant heater control panel can program three start cycle times within a 24-hour period or one start cycle per day for 7 days. Only one program can be activated at one time. Pressing the preset button (Figure 3, Item 8) until memory display is blank will delete programs in memory. 1. Press the preset button (Figure 3, Item 8) until the desired program number (Figure 3, Item 9) begins to flash.

M0

9
3 20:30

HYEX01315

Figure 3. 2. 3. 4. 5. 6. 7. 8.

Setting Program.

Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust start time (Figure 3, Item 4) up or down. When start time (Figure 3, Item 4) is set, wait approximately 5 seconds and day (Figure 3, Item 7) will begin to flash. Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust day (Figure 3, Item 7) up or down. When day (Figure 3, Item 7) is set, wait approximately 5 seconds and day will stop flashing. Start time (Figure 3, Item 4) and day (Figure 3, Item 7) is set. Program number (Figure 3, Item 9) will be displayed. Repeat Steps 1 through 7 if additional days of programing is desired.

END OF TASK ADJUSTING COOLANT HEATER RUN TIME

NOTE
The maximum amount of time for the coolant heater will run is 120 minutes.

0034-3

TM 5-3805-294-10 ADJUSTING COOLANT HEATER RUN TIME - Continued Adjusting the run time must be performed every time a start program is selected. 1.

0034

Press the heater button (Figure 4, Item 10) and the preselected run time (Figure 4, Item 11) will appear on the display (Figure 4, Item 2).
2 11

120

10

HYEX00021

Figure 4. Adjusting Run Time. 2. 3. Press the left arrow button (Figure 4, Item 5) or right arrow button (Figure 4, Item 6) to adjust run time (Figure 4, Item 11) up or down. After desired run time (Figure 4, Item 11) is selected, wait approximately 5 seconds and run time is set.

END OF TASK USING COOLANT HEATER MANUALLY 1. Press heater button (Figure 5, Item 10) and the coolant heater will start and run.

11

120

10
Figure 5. 2. 3.

HYEX00020

Manually Start Coolant Heater.

If desired, press the left arrow button (Figure 5, Item 5) or right arrow button (Figure 5, Item 6) to adjust run time (Figure 5, Item 11) up or down. To manually shut coolant heater off press the heater button (Figure 6, Item 10). The coolant heater will do a normal cool-down cycle and then turn itself off.

0034-4

TM 5-3805-294-10 USING COOLANT HEATER MANUALLY - Continued

0034

11

120

10
Figure 6. END OF TASK END OF WORK PACKAGE

HYEX00020

Manually Start Coolant Heater Continued.

0034-5/6 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE MOVING UP/DOWN STEEP OR SLIPPERY SLOPES

0035

INITIAL SETUP: Not Applicable

PULLING MACHINE UP

WARNING

This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Buckle seat belt (Figure 1, Item 1).

HYEX00687

Figure 1. 2.

Buckle Seat Belt.

Position undercarriage so travel motors (Figure 2, Item 2) will be on the uphill end of machine (Figure 2, Item 3).

0035-1

TM 5-3805-294-10 PULLING MACHINE UP - Continued

0035

4 5

HYEX00674

Figure 2. Pulling Machine Up. 3. 4. Push bucket (Figure 2, Item 4) into the ground on the top of the slope. While using travel pedals pull the machine using the boom (Figure 2, Item 5) and arm cylinder (Figure 2, Item 6) to assist the travel motors (Figure 2, Item 2).

END OF TASK PUSHING MACHINE UP

WARNING

This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Buckle seat belt (Figure 3, Item 1).

0035-2

TM 5-3805-294-10 PUSHING MACHINE UP - Continued

0035

HYEX00687

Figure 3. 2.

Buckle Seat Belt.

Position undercarriage so travel motors (Figure 4, Item 2) will be on the uphill end of machine (Figure 4, Item 3).

3 6

HYEX00677

Figure 4. 3.

Pushing Machine.

Push bucket (Figure 4, Item 4) into the ground at the base of the slope.

0035-3

TM 5-3805-294-10 PUSHING MACHINE UP - Continued 4.

0035

While using travel pedals push the machine using the boom (Figure 4, Item 5) and arm cylinder (Figure 4, Item 6) to assist the travel motors (Figure 4, Item 2).

END OF TASK TRAVELING DOWN

WARNING

This procedure should only be used on a short slope of no more than 35 degrees to prevent machine rollover. The machine depends on support of the boom, arm, and bucket during entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to reposition the bucket or swing upperstructure during the procedure because the machine will become unstable. Failure to comply may result in injury or death to personnel. 1. Position undercarriage so travel motors (Figure 5, Item 2) will be on the uphill end of machine (Figure 5, Item 3).

3 6

HYEX00677

Figure 5. 2.

Traveling Down.

Using the boom (Figure 5, Item 5) and arm cylinder (Figure 5, Item 6) position bucket (Figure 5, Item 4) so it will drag the ground while traveling down the slope.

0035-4

TM 5-3805-294-10 TRAVELING DOWN - Continued 3. Slowly travel down the slope.

0035

END OF TASK END OF WORK PACKAGE

0035-5/6 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE FORDING THE HYEX

0036

INITIAL SETUP: References WP 0093

FORDING

CAUTION
Do not ford water unless depth is known. Water deeper than 40.0 in. (1.0 m) may enter machine systems and damage operating components. Failure to comply may result in damage to equipment.

NOTE
Use travel control levers during fording operations to maintain better control of machine speed. 1. Ensure bottom at fording site is firm enough that 40 in. (1 m) maximum fording depth will not be exceeded and machine will not become mired.

HYEX01311

Figure 1. 2. 3.

Fording Line.

Ensure that engine is operating normally and is at normal operating temperature. Move pilot shutoff lever (Figure 2, Item 1) to unlocked (down) position.

0036-1

TM 5-3805-294-10 FORDING - Continued

0036

HYEX00367

Figure 2. 4.

Pilot Shutoff Lever.

Ensure that there are no alarms indicated on monitor (Figure 3, Item 2).

5 2

HYEX00368

Figure 3. 5. 6. 7. 8. 9.

Check Monitor.

Position travel speed selector (Figure 3, Item 3) in slow position. Raise engine speed dial (Figure 3, Item 4) to 1/3 throttle position. Move travel levers (Figure 3, Item 5) forward 1/4 travel. Enter the water slowly to minimize surges of backwash into the upperstructure. If machine accidently enters water deeper than 40 in. (1.0 m), move travel levers (Figure 3, Item 5) back 1/4 travel and slowly back machine out of deep water.

0036-2

TM 5-3805-294-10 FORDING - Continued 10. After fording perform, maintenance after fording. (WP 0093)

0036

END OF TASK END OF WORK PACKAGE

0036-3/4 blank

TM 5-3805-294-10

CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE

0037

TROUBLESHOOTING SYMPTOM INDEX Malfunction/Symptom ELECTRICAL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. Travel Alarm Does Not Operate ....................................................................................................... WP 0038 Windshield Wiper and Washer Do Not Operate ............................................................................... WP 0039 Cab Dome Light Does Not Operate ................................................................................................. WP 0040 Boom, Cab, And Drive Lights Do Not Operate ................................................................................. WP 0041 Cab Front Work Lights Do Not Operate ........................................................................................... WP 0042 Cab Rear Work Lights Do Not Operate ............................................................................................ WP 0043 Low Note and High Note Horns Do Not Operate ............................................................................. WP 0044 Air Conditioner Does Not Operate ................................................................................................... WP 0045 Troubleshooting Procedure

ENGINE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Engine Cranks But Will Not Start Or Hard To Start .......................................................................... WP 0046 Engine Will Not Crank ...................................................................................................................... WP 0047 Engine Runs Poorly ......................................................................................................................... WP 0048 Excessive Fuel Consumption ........................................................................................................... WP 0049 Excessive Oil Consumption .............................................................................................................. WP 0050 Engine Idles Poorly .......................................................................................................................... WP 0051 Auto-Idle Does Not Work ................................................................................................................. WP 0052 Engine Not Developing Full Power .................................................................................................. WP 0053 Engine Oil Pressure Low .................................................................................................................. WP 0054 Engine Coolant Temperature Above Normal ................................................................................... WP 0055 Engine Emits Excessive Black Or Gray Exhaust Smoke ................................................................. WP 0056 Engine Emits Excessive White Exhaust Smoke ............................................................................... WP 0057

HYDRAULICS SYSTEM 1. 2. 3. 4. 5. No Hydraulic Functions .................................................................................................................... WP 0058 Hydraulic Functions Are Slow Or Have Little Or No Power .............................................................. WP 0059 Power Dig Does Not Work ............................................................................................................... WP 0060 Hydraulic Oil Overheats ................................................................................................................... WP 0061 Hydraulic Oil Foams ......................................................................................................................... WP 0062

0037-1

TM 5-3805-294-10 TROUBLESHOOTING SYMPTOM INDEX - Continued Malfunction/Symptom 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

0037

Troubleshooting Procedure

No Swing Function ........................................................................................................................... WP 0063 Swing Function Is Jerky ................................................................................................................... WP 0064 Slow Travel Speed Only ................................................................................................................... WP 0065 Travel Is Jerky .................................................................................................................................. WP 0066 Engine Stops When Travel Or Control Lever Actuated .................................................................... WP 0067 Quick Latch Does Not Operate ........................................................................................................ WP 0068 Compactor Does Not Operate .......................................................................................................... WP 0069 Breaker Does Not Operate ............................................................................................................... WP 0070 Breaker Operates Slowly ................................................................................................................. WP 0071 Crush-All Does Not Operate ............................................................................................................ WP 0072 Barrier Grapple Does Not Hold Load ............................................................................................... WP 0073 Deep Dig Does Not Operate ............................................................................................................ WP 0074 Hydraulic Hose Reel Does Not Operate ........................................................................................... WP 0075

END OF WORK PACKAGE

0037-2

TM 5-3805-294-10 OPERATOR MAINTENANCE TRAVEL ALARM DOES NOT OPERATE

0038

INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Travel Alarm Does Not Operate. Malfunction Travel Alarm Fuse Blown. 1. 2. Test or Inspection Remove F5 OPT.1 (ALT) 5A fuse. (WP 0084) Visually inspect F5 OPT.1 (ALT) 5A fuse for blown fuse. 1. 2. If fuse blown, replace F5 OPT. 1 (ALT) 5A fuse. (WP 0084) If fuse not blown, notify Field Maintenance. Corrective Action

END OF WORK PACKAGE

0038-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE WINDSHIELD WIPER AND WASHER DO NOT OPERATE

0039

INITIAL SETUP: References WP 0009 WP 0011 WP 0084 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Windshield Wiper and Washer Do Not Operate. Malfunction 1. Upper Front Window Not Fully Closed. 1. Test or Inspection If machine is equipped with a Supplemental Armor Set, proceed to Malfunction 2. Check upper front window to ensure window is fully closed. (WP 0011) 1. 2. If fully closed, proceed to Malfunction 2. If not fully closed, readjust and close upper front window. (WP 0011) Corrective Action

2.

2.

Windshield Wiper and Washer Fuse Blown.

1.

Shut engine off. (WP 0009)

2. 3.

Remove F2 WIPER 10A fuse. (WP 0084) Visually inspect F2 WIPER 10A fuse for blown fuse. 1. 2. If fuse blown, replace F2 WIPER 10A fuse. (WP 0084) If fuse not blown, notify Field Maintenance.

END OF WORK PACKAGE

0039-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE CAB DOME LIGHT DOES NOT OPERATE

0040

INITIAL SETUP: References WP 0004 WP 0009 WP 0084 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Cab Dome Light Does Not Operate. Malfunction 1. Cab Dome Light Switch is OFF (up). Test or Inspection Check cab dome light switch position. (WP 0004) 1. 2. Corrective Action If switch is ON (down), proceed to Malfunction 2. If switch is OFF (up), position cab dome light switch ON (down). (WP 0004)

2.

Radio and Dome Light Fuse Blown.

1. 2. 3.

Shut engine off. (WP 0009) Remove F11 RADIO 5A fuse. (WP 0084) Visually inspect F11 RADIO 5A fuse for blown fuse. 1. 2. If fuse blown, replace F11 RADIO 5A fuse. (WP 0084) If fuse not blown, notify Field Maintenance.

END OF WORK PACKAGE

0040-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE

0041

INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Boom, Cab, And Drive Lights Do Not Operate. Malfunction Work and Drive Lights Fuse Blown. 1. 2. Test or Inspection Remove F1 LAMP 20A fuse. (WP 0084) Visually inspect F1 LAMP 20A fuse for blown fuse. 1. 2. If fuse blown, replace F1 LAMP 20A fuse. (WP 0084) If fuse not blown, notify Field Maintenance. Corrective Action

END OF WORK PACKAGE

0041-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE CAB FRONT WORK LIGHTS DO NOT OPERATE

0042

INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Cab Front Work Lights Do Not Operate. Malfunction Cab Front Work Lights Fuse Blown. 1. 2. Test or Inspection Remove F22 CAB LAMP FRONT 10A fuse. (WP 0084) Visually inspect F22 CAB LAMP FRONT 10A fuse for blown fuse. 1. If fuse blown, replace F22 CAB LAMP FRONT 10A fuse. (WP 0084) If fuse not blown, notify Field Maintenance. Corrective Action

2.

END OF WORK PACKAGE

0042-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE CAB REAR WORK LIGHTS DO NOT OPERATE

0043

INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Cab Rear Work Lights Do Not Operate. Malfunction Cab Rear Work Lights Fuse Blown. 1. 2. Test or Inspection Remove F23 CAB LAMP REAR 10A fuse. (WP 0084) Visually inspect F23 CAB LAMP REAR 10A fuse for blown fuse. 1. If fuse blown, replace F23 CAB LAMP REAR 10A fuse. (WP 0084) If fuse not blown, notify Field Maintenance. Corrective Action

2.

END OF WORK PACKAGE

0043-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE

0044

INITIAL SETUP: References WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Low Note And High Note Horns Do Not Operate. Malfunction Horn Fuse Blown. 1. 2. Test or Inspection Remove F17 HORN 10A fuse. (WP 0084) Visually inspect F17 HORN 10A fuse for blown fuse. 1. 2. If fuse blown, replace F17 HORN 10A fuse. (WP 0084) If fuse not blown, notify Field Maintenance. Corrective Action

END OF WORK PACKAGE

0044-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE AIR CONDITIONER DOES NOT OPERATE

0045

INITIAL SETUP: References WP 0077 WP 0084 WP 0089 WP 0090 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Air Conditioner Does Not Operate. Malfunction 1. Air Conditioner and Heater 5A Fuse Blown. 1. Test or Inspection Remove F15 AIRCON 5A fuse. (WP 0084) Visually inspect F15 AIRCON 5A fuse for blown fuse. 1. 2. 2. Air Conditioner and Heater 20A Fuse Blown. 1. Remove F3 HEATER 20A fuse. (WP 0084) Visually inspect F3 HEATER 20A fuse for blown fuse. 1. If fuse blown, replace F3 HEATER 20A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 3. If fuse blown, replace F15 AIRCON 5A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 2. Corrective Action

2.

2.

2. 3. Fresh Air Filter Clogged or Damaged. 1. Remove fresh air filter. (WP 0089) Visually inspect fresh air filter and housing for clog and damage. 1. 2. 3.

2.

If clogged, service fresh air filter and housing. (WP 0089) If damaged, notify Field Maintenance. If not clogged and not damaged, proceed to Malfunction 4.

0045-1

TM 5-3805-294-10

0045

Table 1. Air Conditioner Does Not Operate - Continued. Malfunction 4. Air Conditioner/ Heater Filter Clogged or Damaged. 1. Test or Inspection Remove air conditioner/heater filter. (WP 0090) Corrective Action

2.

Visually inspect air conditioner/heater filter and housing for clog and damage.

1.

If clogged, service air conditioner/heater filter and housing. (WP 0090) If damaged, notify Field Maintenance. If not clogged and not damaged, proceed to Malfunction 5. If dirty, clean air conditioner condenser. (WP 0077) If damaged, notify Field Maintenance. If not dirty and not damaged, proceed to Malfunction 6. If worn or damaged, notify Field Maintenance. If not worn and not damaged, notify Field Maintenance.

2. 3.

5.

Air Conditioner Condenser Dirty or Damaged.

Visually inspect air conditioner/heater condenser for dirt and damage. (WP 0077)

1. 2. 3.

6.

Air Conditioner Belt Worn or Damaged.

Visually inspect air conditioner belt for wear and damage. (WP 0077)

1. 2.

END OF WORK PACKAGE

0045-2

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE CRANKS BUT DOES NOT START OR HARD TO START

0046

INITIAL SETUP: References WP 0005 WP 0007 WP 0009 WP 0077 References (cont.) WP 0086 WP 0087 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Engine Cranks But Does Not Start or Hard to Start. Malfunction 1. Engine Cranks Slowly. Test or Inspection Crank engine. (WP 0007) 1. 2. Corrective Action If engine cranks slowly, notify Field Maintenance. If engine does not crank slowly, proceed to Malfunction 2.

2.

Fuel Level Low.

1.

Turn key switch to ON position, but DO NOT START ENGINE. (WP 0007) Visually inspect monitor to verify at least 1/4 tank of fuel is available. (WP 0005) Turn key switch to OFF position. (WP 0009) 1. 2. If fuel level is low, service machine. (WP 0077) If fuel level is OK, proceed to Malfunction 3.

2.

3.

3.

Air Cleaners Dirty or Clogged.

1. 2.

Start engine. (WP 0007) Observe monitor for air cleaner clogged alarm. (WP 0005)

0046-1

TM 5-3805-294-10

0046

Table 1. Engine Cranks But Does Not Start or Hard to Start - Continued. Malfunction 3. Test or Inspection Shut down engine. (WP 0009) 1. Corrective Action If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaner. (WP 0087) If air cleaner clogged alarm is not displayed, proceed to Malfunction 4. If fuel lines and fittings are leaking, notify Field Maintenance. If fuel lines and fittings are not leaking, proceed to Malfunction 5.

2.

4.

Leaking Fuel Lines and Fittings.

Visually inspect fuel lines and fittings for leakage. (WP 0077)

1.

2.

5.

Fuel Filter/Water Separators Contain Water or Sediment.

1.

Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) Start engine. (WP 0007) 1. 2. If engine starts, malfunction corrected. If engine does not start, notify Field Maintenance.

2.

END OF WORK PACKAGE

0046-2

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE WILL NOT CRANK

0047

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. Pilot Shutoff Lever in UNLOCKED (down) Position. 1. Test or Inspection Place pilot shutoff lever in LOCK (up) position. (WP 0007) Start engine. (WP 0007) 1. 2. 2. Discharged Batteries. 1. Turn key switch to ON position, but DO NOT START ENGINE. (WP 0007) Observe monitor for battery warning alarm. (WP 0005) Turn key switch to OFF position. (WP 0009) 1. If monitor displays battery warning alarm, notify Field Maintenance. If monitor does not display battery warning alarm, proceed to Malfunction 3. If engine starts, malfunction corrected. If engine does not crank, proceed to Malfunction 2. Corrective Action

2.

2. 3.

2.

0047-1

TM 5-3805-294-10

0047

Table 1. Engine Will Not Crank - Continued. Malfunction 3. Blown Fuses. 1. Test or Inspection Remove the following fuses: F8 ECM 20A fuse. (WP 0084) F10 CONTROLLER 5A fuse. (WP 0084) F16 POWER ON 5A fuse. (WP 0084) 2. Visually inspect fuses for blown fuse. 1. 2. 4. Corroded or Loose Battery Connections. Visually inspect batteries for corroded or loose connections. (WP 0077) 1. If fuse blown, replace fuse. (WP 0084) If no fuse blown, proceed to Malfunction 4. If battery connections are corroded or loose, notify Field Maintenance. If battery connections are not corroded or loose, notify Field Maintenance that engine does not crank. Corrective Action

2.

END OF WORK PACKAGE

0047-2

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE RUNS POORLY

0048

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. Air Cleaners Dirty or Clogged. 1. 2. Test or Inspection Observe monitor for air cleaner clogged alarm. (WP 0005) Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. Corrective Action

2.

2.

Fuel Filter/Water Separators Contain Water or Sediment.

1.

Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) Start engine. (WP 0007) 1. 2. If engine runs properly, malfunction corrected. If engine runs poorly, Malfunction 3.

2.

0048-1

TM 5-3805-294-10

0048

Table 1. Engine Runs Poorly - Continued. Malfunction 3. Fuel Tank is Contaminated. 1. 2. Test or Inspection Shut down engine. (WP 0009) Drain water and sediment from fuel tank. (WP 0091) 1. If clean fuel does not become present, Notify Field Maintenance. If clean fuel becomes present, proceed to Step 3. Corrective Action

2. 3. 4. Clean fuel strainer. (WP 0077) Start engine. (WP 0007) 1. 2.

If engine runs properly, malfunction corrected. If engine runs poorly, shut down engine. (WP 0009) Notify Field Maintenance.

END OF WORK PACKAGE

0048-2

TM 5-3805-294-10 OPERATOR MAINTENANCE EXCESSIVE FUEL CONSUMPTION

0049

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. Air Cleaners Dirty or Clogged. 1. 2. Test or Inspection Observe monitor for air cleaner clogged alarm. (WP 0005) Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. If fuel lines or fittings are leaking, notify Field Maintenance. If fuel lines or fittings are not leaking, notify Field Maintenance. Corrective Action

2.

2.

Leaking Fuel Lines and Fittings.

Visually inspect fuel lines and fittings for leakage. (WP 0077)

1.

2.

END OF WORK PACKAGE

0049-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE EXCESSIVE OIL CONSUMPTION

0050

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. Air Cleaners Dirty or Clogged. 1. 2. Test or Inspection Observe monitor for air cleaner clogged alarm. (WP 0005) Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. If oil dipstick shows signs of contaminants, notify Field Maintenance. If oil dipstick shows no signs of contaminants, notify Field Maintenance. Corrective Action

2.

2.

Oil Shows Signs Of Contamination.

Visually inspect engine oil dipstick for coolant or fuel contaminants. (WP 0077) Oil containing coolant will have a creamy brown appearance or oil containing fuel will be diluted and smell like fuel.

1.

2.

END OF WORK PACKAGE

0050-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE IDLES POORLY

0051

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. Warning Lights and Alarms are Present. 1. Test or Inspection Start engine. (WP 0007) If engine does not immediately idle poorly, allow engine to run until engine starts to exhibit poor idle symptoms. Observe monitor (WP 0005) for warning lights and alarms. Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If any other warning lights and alarms are present, notify Field Maintenance. If no warning lights and alarms are present, proceed to Malfunction 2. Corrective Action

2. 3.

2.

3.

2.

Fuel Filter/Water Separators Contain Water or Sediment.

1.

Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) Start engine. (WP 0007) 1. 2. If engine idles properly, malfunction corrected. If engine idles poorly, proceed to Malfunction 3.

2.

0051-1

TM 5-3805-294-10

0051

Table 1. Engine Idles Poorly - Continued. Malfunction 3. Leaking Fuel Lines and Fittings. 1. 2. Test or Inspection Shut down engine. (WP 0009) Visually inspect fuel lines and fittings for leakage. (WP 0077) 1. If fuel lines and fittings are leaking, notify Field Maintenance. If fuel lines and fittings are not leaking, notify Field Maintenance. Corrective Action

2.

END OF WORK PACKAGE

0051-2

TM 5-3805-294-10 OPERATOR MAINTENANCE AUTO-IDLE DOES NOT WORK

0052

INITIAL SETUP: References WP 0004 WP 0005 WP 0009 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Auto-Idle Does Not Work. Malfunction 1. Engine Speed Does Not Lower With Auto-Idle (A. I.) Turned ON. 1. Test or Inspection Turn engine speed dial to high idle position (H). (WP 0004) Corrective Action

2.

Turn A.I. switch to ON position. (WP 0004)

1.

If engine speed lowers in 4 - 6 seconds, proceed to Malfunction 4. If engine speed does not lower in 4 - 6 seconds, proceed to Malfunction 2. If A. I. indicator is not displayed on monitor with A. I. switch in ON position, shut down engine. (WP 0009) Notify Field Maintenance. If A. I. indicator is displayed on monitor, proceed to Malfunction 3. If hydraulic operations are being performed, cease any hydraulic operations being performed, verify engine speed adjusts to A. I. speed within 4 - 6 seconds. (WP 0004) If engine speed does not adjust to A.I. speed within 4 - 6 seconds, shut down engine. (WP 0009) Notify Field Maintenance.

2.

2.

Auto-Idle (A. I.) Indicator Not Displayed On Monitor.

Verify A.I. indicator is displayed on monitor. (WP 0005)

1.

2.

3.

Hydraulic Operations Being Performed.

Verify if hydraulic operations are being performed. (WP 0004)

1.

0052-1

TM 5-3805-294-10

0052

Table 1. Auto-Idle Does Not Work - Continued. Malfunction Test or Inspection 2. Corrective Action If hydraulic operations are not being performed, shut down engine. (WP 0009) Notify Field Maintenance. If engine speed raises, no fault at this time. Shut down engine. (WP 0009) If engine speed does not raise, shut down engine. (WP 0009) Notify Field Maintenance.

4.

Engine Speed Does Not Raise With Auto-Idle (A. I.) Turned ON and Hydraulic Functions Being Performed.

Operate hydraulic functions. (WP 0004)

1.

2.

END OF WORK PACKAGE

0052-2

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE NOT DEVELOPING FULL POWER

0053

INITIAL SETUP: References WP 0005 WP 0009 References (cont.) WP 0077 WP 0087 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Engine Not Developing Full Power. Malfunction 1. Air Cleaners Dirty or Clogged. 1. 2. Test or Inspection Observe monitor for air cleaner clogged alarm. (WP 0005) Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If air cleaner clogged alarm is not displayed, proceed to Malfunction 2. If exhaust pipes are dented or restricted, notify Field Maintenance. If exhaust pipes are not dented or restricted, proceed to Malfunction 3. If fuel lines and fittings are leaking, notify Field Maintenance. If fuel lines and fittings are not leaking, notify Field Maintenance. Corrective Action

2.

2.

Exhaust Pipes Dented or Restricted.

Visually inspect exhaust pipes and muffler for dents and restrictions. (WP 0077)

1.

2.

3.

Leaking Fuel Lines or Fittings.

Visually inspect fuel lines and fittings for leakage. (WP 0077)

1.

2.

END OF WORK PACKAGE

0053-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE OIL PRESSURE LOW

0054

INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Engine Oil Pressure Low. Malfunction Low Engine Oil Level. Test or Inspection Check engine oil level. (WP 0077) 1. 2. Corrective Action If engine oil level is low, service machine. (WP 0077) If engine oil level is full, notify Field Maintenance.

END OF WORK PACKAGE

0054-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE COOLANT TEMPERATURE ABOVE NORMAL

0055

INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Engine Coolant Temperature Above Normal. Malfunction 1. Engine Coolant Level Low. Test or Inspection Visually inspect engine coolant level. (WP 0077) 1. 2. 2. Engine Oil Level Low. Visually inspect engine oil level. (WP 0077) 1. 2. 3. Radiator Damaged or Has Foreign Objects/Debris. Visually inspect radiator for damage, foreign objects and debris. (WP 0077) 1. Corrective Action If level is low, service radiator. (WP 0077) If level is not low, proceed to Malfunction 2. If level is low, service engine. (WP 0077) If level is not low, proceed to Malfunction 3. If radiator has foreign objects/ debris, remove foreign objects/ debris. If radiator is damaged, notify Field Maintenance. If radiator does not have foreign objects/debris or does not have damage, proceed to Malfunction 4. If cap is loose, secure cap. If cap is damaged, notify Field Maintenance. If cap is not damaged or loose, notify Field Maintenance.

2. 3.

4.

Surge Tank Cap is Loose.

Visually inspect surge tank cap for looseness or damage. (WP 0077)

1. 2. 3.

END OF WORK PACKAGE

0055-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE

0056

INITIAL SETUP: References WP 0005 WP 0009 WP 0087 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Engine Emits Excessive Black Or Gray Exhaust Smoke. Malfunction Air Cleaners Dirty or Clogged. 1. 2. Test or Inspection Observe monitor for air cleaner clogged alarm. (WP 0005) Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is displayed, remove foreign objects/debris or replace air cleaners. (WP 0087) If air cleaner clogged alarm is not displayed, notify Field Maintenance. Corrective Action

2.

END OF WORK PACKAGE

0056-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE

0057

INITIAL SETUP: References WP 0007 WP 0009 WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Engine Emits Excessive White Exhaust Smoke. Malfunction 1. Oil Shows Signs Of Contamination. Test or Inspection Visually inspect engine oil dipstick for coolant or fuel contaminants. (WP 0077) Oil containing coolant will have a creamy brown appearance or oil containing fuel will be diluted and smell like fuel. 1. Operate engine to normal operating temperature. (WP 0007) Observe engine exhaust. Shut down engine. (WP 0009) 1. 2. If engine emits white exhaust, notify Field Maintenance. If engine does not emit white exhaust, no fault at this time. 1. Corrective Action If oil dipstick shows signs of contaminants, notify Field Maintenance. If oil dipstick shows no signs of contaminants, Malfunction 2.

2.

2.

White Exhaust Smoke Excessive at Normal Operating Temperature.

2. 3.

END OF WORK PACKAGE

0057-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE NO HYDRAULIC FUNCTIONS

0058

INITIAL SETUP: References WP 0004 WP 0009 References (cont.) WP 0077 WP 0088 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. No Hydraulic Functions. Malfunction 1. Pilot Shutoff Lever in LOCK (up) Position. 1. Test or Inspection Place pilot shutoff lever in UNLOCKED (down) position. (WP 0004) Operate control pedals and levers. (WP 0004) Shut engine off. (WP 0009) 1. 2. If hydraulic functions operate, malfunction corrected. If hydraulic functions do not operate, proceed to Malfunction 2. If hydraulic oil level is correct, notify Field Maintenance. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) Corrective Action

2. 3.

2.

Hydraulic Oil Level Low.

Check hydraulic oil level. (WP 0077)

1. 2.

END OF WORK PACKAGE

0058-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER

0059

INITIAL SETUP: References WP 0030 WP 0031 WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Functions Are Slow or Have Little or No Power. Malfunction 1. Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) 1. 2. Corrective Action If hydraulic oil level is correct, proceed to Malfunction 2. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) If hydraulic functions operate properly, malfunction corrected. If hydraulic functions do not operate properly, proceed to Malfunction 3. If damaged or missing hardware, notify Field Maintenance. if not damaged or missing hardware, notify Field Maintenance.

2.

Hydraulic Oil Cold.

Perform operating in cold weather below 5F (-15C) (WP 0031) or operating in cold weather 32 to 5F (0 to -15C). (WP 0030)

1.

2.

3.

Hydraulic Reservoir Fill Cap is Damaged or Missing Hardware.

Visually inspect hydraulic reservoir fill cap for damage or missing hardware. (WP 0077)

1.

2.

END OF WORK PACKAGE

0059-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE POWER DIG DOES NOT WORK

0060

INITIAL SETUP: References WP 0077 WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Power Dig Does Not Work. Malfunction 1. Solenoid Fuse Blown. 1. 2. Test or Inspection Remove F4 SOLENOID 10A fuse. (WP 0084) Visually inspect F4 SOLENOID 10A fuse for blown fuse. 1. If fuse blown, replace F4 SOLENOID 10A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 2. If damaged or leaking, notify Field Maintenance. If not damaged or leaking, notify Field Maintenance. Corrective Action

2. 2. Hydraulic Oil Hoses Damaged or Has Leaks. Visually inspect hydraulic oil hoses for damage and leaks. (WP 0077) 1. 2.

END OF WORK PACKAGE

0060-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE HYDRAULIC OIL OVERHEATS

0061

INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Oil Overheats. Malfunction 1. Cooling Package Has Damage, Foreign Objects/ Debris. Test or Inspection Visually inspect cooling package for damage, foreign objects/debris. (WP 0077) 1. 2. Corrective Action If damaged, notify Field Maintenance. If not damaged but has foreign objects/debris, remove foreign objects/debris. If not damaged and does not have foreign objects/debris, proceed to Malfunction 2. If hydraulic oil level is correct, notify Field Maintenance. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088)

3.

2.

Hydraulic Oil Level Low.

Check hydraulic oil level. (WP 0077)

1. 2.

END OF WORK PACKAGE

0061-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE HYDRAULIC OIL FOAMS

0062

INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Oil Foams. Malfunction 1. Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) 1. 2. 3. 2. Hydraulic Oil Hoses are Damaged. Visually inspect hydraulic oil hoses for damage. (WP 0077) 1. Corrective Action If hydraulic oil level is correct, proceed to Malfunction 2. If hydraulic oil level is low, fill oil to proper level. (WP 0088) If hydraulic oil level is high, notify Field Maintenance. If hydraulic oil hoses are damaged, notify Field Maintenance. If hydraulic oil hoses are not damaged, notify Field Maintenance.

2.

END OF WORK PACKAGE

0062-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE NO SWING FUNCTION

0063

INITIAL SETUP: References WP 0077 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. No Swing Function. Malfunction Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) 1. 2. Corrective Action If hydraulic oil level is correct, notify Field Maintenance. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088)

END OF WORK PACKAGE

0063-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE SWING FUNCTION IS JERKY

0064

INITIAL SETUP: References LO 5-3805-294-13 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Swing Function Is Jerky. Malfunction Lack of Grease in Swing Bearing. Test or Inspection Visually inspect swing bearing grease fittings (LO 5-3805-294-13). (WP 0094) 1. Corrective Action If swing bearing lacks grease, lubricate swing bearing grease fittings (LO 5-3805-294-13). (WP 0094) If swing bearing does not lack grease, notify Field Maintenance.

2.

END OF WORK PACKAGE

0064-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE SLOW TRAVEL SPEED ONLY

0065

INITIAL SETUP: References WP 0077 WP 0084 WP 0088 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Slow Travel Speed Only. Malfunction 1. Solenoid Fuse Blown. 1. 2. Test or Inspection Remove F4 SOLENOID 10A fuse. (WP 0084) Visually inspect F4 SOLENOID 10A fuse for blown fuse. 1. If fuse blown, replace F4 SOLENOID 10A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 2. If hydraulic oil level is correct, notify Field Maintenance. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088) Corrective Action

2. 2. Hydraulic Oil Level Low. Check hydraulic oil level. (WP 0077) 1. 2.

END OF WORK PACKAGE

0065-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE TRAVEL IS JERKY

0066

INITIAL SETUP: References WP 0077 WP 0080 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Travel is Jerky. Malfunction 1. Incorrect Track Chain Tension. Test or Inspection Check track chain sag. (WP 0080) 1. Corrective Action If track chain sag is within specification, proceed to Malfunction 2. If track chain sag is not within specification, adjust track chain tension. (WP 0080) If jammed with debris, remove debris. If not jammed with debris, notify Field Maintenance.

2.

2.

Debris in Track Frame.

Visually inspect track frame for jammed debris. (WP 0077)

1. 2.

END OF WORK PACKAGE

0066-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED

0067

INITIAL SETUP: References WP 0007 WP 0008 WP 0086 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Engine Stops When Travel or Control Lever Actuated. Malfunction Fuel Filter/Water Separators Contain Water or Sediment. 1. Test or Inspection Drain primary and final fuel filter/water separators of water or sediment. (WP 0086) Start engine. (WP 0007) Move HYEX. (WP 0008) 1. If engine stops when either control lever is actuated, notify Field Maintenance. If engine stops when travel is actuated, notify Field Maintenance. If engine does not stop while moving, malfunction corrected. Corrective Action

2. 3.

2.

3.

END OF WORK PACKAGE

0067-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE QUICK LATCH DOES NOT OPERATE

0068

INITIAL SETUP: References WP 0009 WP 0014 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Quick Latch Does Not Operate. Malfunction 1. Quick Latch Switch Does not Operate. 1. Test or Inspection Set quick latch switch to UNLATCH position. (WP 0014) Observe quick latch warning light and alarm. Observe quick latch for movement. 1. 2. 2. Safety Lock Pin Lever in Locked Position. Check quick latch safety lock pin lever position. (WP 0014) 1. If warning light and alarm are off, notify Field Maintenance. If warning light and alarm is on, proceed to Malfunction 2. If in locked position, place quick latch safety lock pin lever in unlocked position. (WP 0014) If in unlocked position, proceed to Malfunction 3. Corrective Action

2. 3.

2. 3. Quick Hitch Fuse Blown. 1. 2. 3. Shut down engine. (WP 0009) Remove F26 QUICK HITCH 5A fuse. (WP 0084) Visually inspect F26 QUICK HITCH 5A fuse for blown fuse. 1.

If fuse blown, replace F26 QUICK HITCH 5A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 4.

2.

0068-1

TM 5-3805-294-10

0068

Table 1. Quick Latch Does Not Operate - Continued. Malfunction 4. Quick Latch Has Jammed Debris. Test or Inspection Visually inspect quick latch for jammed debris. (WP 0077) 1. Corrective Action If quick latch does have jammed debris, remove jammed debris. (WP 0077) If quick latch does not have jammed debris, notify Field Maintenance.

2.

END OF WORK PACKAGE

0068-2

TM 5-3805-294-10 OPERATOR MAINTENANCE COMPACTOR DOES NOT OPERATE

0069

INITIAL SETUP: References WP 0077 WP 0020 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Compactor Does Not Operate. Malfunction 1. Hydraulic Supply Quick Disconnect Not Fully Seated. Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0077) 1. Corrective Action If quick disconnect is fully seated, proceed to Malfunction 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. If quick disconnect is fully seated, proceed to Malfunction 3. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. If compactor does have jammed debris, remove jammed debris. (WP 0077) If compactor does not have jammed debris, notify Field Maintenance.

2.

3.

2.

Hydraulic Return Quick Disconnect Not Fully Seated.

Visually inspect hydraulic return quick disconnect. (WP 0077)

1.

2.

3.

3.

Compactor Has Jammed Debris.

Visually inspect compactor for jammed debris. (WP 0077)

1.

2.

END OF WORK PACKAGE

0069-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE BREAKER DOES NOT OPERATE

0070

INITIAL SETUP: References WP 0020 WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Breaker Does Not Operate. Malfunction 1. Hydraulic Supply Quick Disconnect Not Fully Seated. Test or Inspection Visually inspect hydraulic supply quick disconnect. (WP 0077) 1. Corrective Action If quick disconnect is fully seated, proceed to Malfunction 2. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. If quick disconnect is fully seated, proceed to Malfunction 3. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. If breaker does have jammed debris, remove jammed debris. (WP 0077) If breaker does not have jammed debris, notify Field Maintenance.

2.

3.

2.

Hydraulic Return Quick Disconnect Not Fully Seated.

Visually inspect hydraulic return quick disconnect. (WP 0077)

1.

2.

3.

3.

Breaker Has Jammed Debris.

Visually inspect breaker for jammed debris. (WP 0077)

1.

2.

END OF WORK PACKAGE

0070-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE BREAKER OPERATES SLOWLY

0071

INITIAL SETUP: References WP 0009 WP 0018 References (cont.) WP 0077 WP 0088 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Breaker Operates Slowly. Malfunction 1. Breaker Attachment Not Selected. Test or Inspection Check attachment selection on monitor. (WP 0018) 1. Corrective Action If breaker attachment is selected, proceed to Malfunction 2. If breaker attachment is not selected, select breaker attachment on monitor. (WP 0018)

2.

2.

Hydraulic Supply Hose is Damaged or Has Leaks.

1.

Shut down engine. (WP 0009)

2.

Visually inspect hydraulic supply hose. (WP 0077)

1.

If hydraulic supply hose is damaged or leaking, notify Field Maintenance. If hydraulic supply hose is not damaged or leaking, proceed to Malfunction 3. If hydraulic return hose is damaged or leaking, notify Field Maintenance. If hydraulic return hose is not damaged or leaking, proceed to Malfunction 4.

2.

3.

Hydraulic Return Hose is Damaged or Has Leaks.

Visually inspect hydraulic return hose. (WP 0077)

1.

2.

0071-1

TM 5-3805-294-10

0071

Table 1. Breaker Operates Slowly - Continued. Malfunction 4. Hydraulic Oil Level Low. Test or Inspection Check hydraulic oil level. (WP 0077) 1. 2. Corrective Action If hydraulic oil level is correct, notify Field Maintenance. If hydraulic oil level is not correct, fill oil to proper level. (WP 0088)

END OF WORK PACKAGE

0071-2

TM 5-3805-294-10 OPERATOR MAINTENANCE CRUSH-ALL DOES NOT OPERATE

0072

INITIAL SETUP: References WP 0020 WP 0077 WP 0084 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Crush-All Does Not Operate. Malfunction 1. 12-Volt Power Outlet Fuse Blown. 1. 2. Test or Inspection Remove F6 OPT.2 (ALT) 10A fuse. (WP 0084) Visually inspect F6 OPT.2 (ALT) 10A fuse for blown fuse. 1. 2. 2. Hydraulic Supply Quick Disconnect Not Fully Seated. Visually inspect hydraulic supply quick disconnect. (WP 0077) 1. If fuse blown, replace F6 OPT. 2 (ALT) 10A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 2. If quick disconnect is fully seated, proceed to Malfunction 3. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. If quick disconnect is fully seated, proceed to Malfunction 4. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0020) If quick disconnect is damaged, notify Field Maintenance. Corrective Action

2.

3.

3.

Hydraulic Return Quick Disconnect Not Fully Seated.

Visually inspect hydraulic return quick disconnect. (WP 0077)

1.

2.

3.

0072-1

TM 5-3805-294-10

0072

Table 1. Crush-All Does Not Operate - Continued. Malfunction 4. Crush-All Has Jammed Debris. Test or Inspection Visually inspect crush-all for jammed debris. (WP 0077) 1. Corrective Action If crush-all does have jammed debris, remove jammed debris. (WP 0077) If crush-all does not have jammed debris, notify Field Maintenance.

2.

END OF WORK PACKAGE

0072-2

TM 5-3805-294-10 OPERATOR MAINTENANCE BARRIER GRAPPLE DOES NOT HOLD LOAD

0073

INITIAL SETUP: References WP 0077 Equipment Condition Machine safely parked and shut down. (WP 0009)

TROUBLESHOOTING PROCEDURE Table 1. Barrier Grapple Does Not Hold Load. Malfunction Grip pads worn. Test or Inspection Visually inspect grip pads. (WP 0077) 1. 2. Corrective Action If grip pads worn, notify Field Maintenance. If grip pads not worn, notify Field Maintenance.

END OF WORK PACKAGE

0073-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE DEEP DIG DOES NOT OPERATE

0074

INITIAL SETUP: References WP 0009 WP 0023 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Deep Dig Does Not Operate. Malfunction 1. Deep Dig Control Pattern Switch is OFF. Test or Inspection Check deep dig control pattern switch position. (WP 0023) 1. Corrective Action If switch is OFF, set deep dig control pattern switch to ON. (WP 0023) If switch is ON, proceed to Malfunction 2.

2. 2. Cab Auxiliary Power Connector One Fuse Blown. 1. Shut down engine. (WP 0009)

2. 3.

Remove F13 AUX 10A fuse. (WP 0084) Visually inspect F13 AUX 10A fuse for blown fuse. 1. 2. If fuse blown, replace F13 AUX 10A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 3.

3.

Hydraulic Supply Quick Disconnect Not Fully Seated.

1.

Visually inspect hydraulic supply quick disconnect. (WP 0077) Visually inspect hydraulic return quick disconnect. (WP 0077) Visually inspect hydraulic supply hose for damage. (WP 0077)

2.

3.

0074-1

TM 5-3805-294-10

0074

Table 1. Deep Dig Does Not Operate - Continued. Malfunction 4. Test or Inspection Visually inspect hydraulic return hose for damage. (WP 0077) 1. Corrective Action If quick disconnect(s) is not fully seated, reconnect quick disconnect properly. (WP 0023) If quick disconnect(s) is damaged, notify Field Maintenance. If hose(s) is damaged, notify Field Maintenance. If quick disconnects are fully seated and hoses are not damaged, notify Field Maintenance.

2.

3. 4.

END OF WORK PACKAGE

0074-2

TM 5-3805-294-10 OPERATOR MAINTENANCE HYDRAULIC HOSE REEL DOES NOT OPERATE

0075

INITIAL SETUP: References WP 0009 WP 0026 References (cont.) WP 0077 WP 0084 Equipment Condition Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE Table 1. Hydraulic Hose Reel Does Not Operate. Malfunction 1. Hand Held Hydraulic Tool Circuit Switch is OFF. Test or Inspection Check hand held hydraulic tool circuit switch position. (WP 0026) 1. Corrective Action If switch is OFF, set hand held hydraulic tool circuit switch to ON. (WP 0026) If switch is ON, proceed to Malfunction 2.

2. 1. Shut down engine. (WP 0009)

2.

Cab Auxiliary Power Connector One Fuse Blown.

2. 3.

Remove F13 AUX 10A fuse. (WP 0084) Visually inspect F13 AUX 10A fuse for blown fuse. 1. 2. If fuse blown, replace F13 AUX 10A fuse. (WP 0084) If fuse not blown, proceed to Malfunction 3. If quick disconnect is fully seated, proceed to Malfunction 4. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0026) If quick disconnect is damaged, notify Field Maintenance.

3.

Hydraulic Supply Quick Disconnect Not Fully Seated.

Visually inspect hydraulic supply quick disconnect. (WP 0077)

1.

2.

3.

0075-1

TM 5-3805-294-10

0075

Table 1. Hydraulic Hose Reel Does Not Operate - Continued. Malfunction 4. Hydraulic Return Quick Disconnect Not Fully Seated. Test or Inspection Visually inspect hydraulic return quick disconnect. (WP 0077) 1. Corrective Action If quick disconnect is fully seated, proceed to Malfunction 5. If quick disconnect is not fully seated, reconnect quick disconnect properly. (WP 0026) If quick disconnect is damaged, notify Field Maintenance. If hose is not damaged, proceed to Malfunction 6. If hose is damaged, notify Field Maintenance. If hose is not damaged, notify Field Maintenance. If hose is damaged, notify Field Maintenance.

2.

3.

5.

Hydraulic Tool Supply Hose Has Damage.

Visually inspect hydraulic tool supply hose for damage. (WP 0077)

1. 2. 1. 2.

6.

Hydraulic Tool Return Hose Has Damage.

Visually inspect hydraulic tool return hose for damage. (WP 0077)

END OF WORK PACKAGE

0075-2

TM 5-3805-294-10

CHAPTER 4 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

0076

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

NOTE
If the machine has reached the initial 250 hours of operation, contact field level maintenance to perform the initial 250 hour service. Tools supplied on the machine are to be used for Preventive Maintenance Checks and Services (PMCS). Rags are also required for removing dirt and grease. PMCS intervals should be performed more frequently when operating under unusual conditions. Perform PMCS on attachments only if they are to be used for the current mission. This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The PMCS tables contain checks and services necessary to ensure that the machine is ready for operation. Maintenance is performed at specified intervals using the PMCS tables. Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable. Components in good condition are: not bent or twisted, chafed or burned, broken, or cracked. There should be no signs of wear, fraying, dents, collapsing, tears, cuts, or deterioration. Damage is any condition that affects safety or prevents a part or assembly from functioning normally or would render the machine unserviceable for mission requirements. MAINTENANCE RECORDS AND FORMS Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The completed forms and records have several uses. They are a permanent record of services, repairs, and modifications made to the machine. They are reports to maintenance personnel, and to the Commander. They serve as a checklist to track previous machine malfunctions and repair actions. Record results of PMCS on DA Form 2404, Equipment Inspection and Maintenance Worksheet, or DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet. For the information needed on forms and records, refer to DA PAM 750-8 The Army Maintenance Management System (TAMMS) Users Manual. GENERAL MAINTENANCE PROCEDURES Cleanliness: Dirt, grease, oil, and debris can conceal serious problems. Use solvent cleaning compound on all metal surfaces and soapy water on rubber or plastic surfaces. Bolts, Nuts, and Screws: Check for loose bolts, nuts, and screws, as well as for those that are missing, bent, or broken. Tighten or replace as necessary. If parts cannot be checked with a tool, look for signs of chipped paint, bare metal, or rust around bolt heads. Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a damaged weld is discovered, notify Field Level Maintenance. Electric Wires and Connectors: Look for cracked or broken insulation, exposed wires, and loose or broken connectors. Tighten loose connectors and ensure wires are in good shape. Fluid Hoses, Tubes, and Fittings: Look for wear, damage, or leaks. Ensure clamps and fittings are tight. Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If connectors or fittings are loose or if hoses, tubes, or fittings are broken or worn out, notify Field Level Maintenance.

0076-1

TM 5-3805-294-10 WARNINGS AND CAUTIONS

0076

Always observe the warnings and cautions appearing in your PMCS table. Warnings and cautions appear before the applicable procedure. You must observe these warnings and cautions to prevent serious injury to personnel or to prevent damage to the equipment. ARMY OIL ANALYSIS PROGRAM (AOAP) The engine and hydraulic oil and filters replacement are governed by the AOAP program. Samples for the engine are taken every 90 days and once yearly for the hydraulic system. If sampling is not feasible due to mission, then hard time intervals apply for oil and filter changes. LUBRICATION INSTRUCTIONS During adverse weather or unusually dusty conditions, lubrication may be required on a daily basis. After fording operations, lubricate all lubrication points below fording line. For detailed lubrication instructions, refer to: LO 5-3805-294-13 Lubrication Instructions for the Hydraulic Excavator (HYEX).

PMCS COLUMN DESCRIPTION The PMCS table columns are described as follows: Item Number The order that the PMCS should be performed. Use the item number when recording results on the DA Form 2404, Equipment Inspection and Maintenance Worksheet or the DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet. Interval Lists the interval at which the check or service is to be performed. Item to be Inspected Lists the item being checked or serviced. Procedures Describes the procedure for the check or service. Equipment Not Ready or Available If Describes a condition that renders the machine not mission capable.

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Types of Preventive Maintenance Checks and Services (PMCS) For each service interval, perform all checks and services listed and all checks and services associated with any lower service interval. Before: Do the Before (B) PMCS before operating the machine. Pay attention to the WARNINGS and CAUTIONS. During: Do the During (D) PMCS while machine or its components are in operation. Pay attention to the WARNINGS and CAUTIONS. After: Do the After (A) PMCS after operating the machine. Pay attention to the WARNINGS and CAUTIONS. Monthly: Do the Monthly (M) PMCS once a month on the machine. Pay attention to the WARNINGS and CAUTIONS.

Always perform PMCS in the same order, every time. Once practiced, problems can be spotted quickly. If an item or component being inspected is inoperable or damaged, either troubleshoot by following instructions in the Troubleshooting Section of this manual or repair and/or replace as described in the related maintenance task. If there appears to be a malfunction that cannot be repaired immediately, complete either DA Form 2404,or DA Form 5988-E. FLUID LEAKAGE Class I: Seepage of fluid (as indicated by wetness or discoloration) not sufficient enough to form drops. Class II: Leakage of fluid sufficient enough to form drops, but not sufficient enough to cause the drops to drip from the item being inspected. Class III: Leakage of fluid sufficient enough to form drops that fall from the item being inspected.

END OF WORK PACKAGE

0076-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

0077

INITIAL SETUP: Materials/Parts Antifreeze, Arctic Type (WP 0097, Table 1, Item 1) Antifreeze (WP 0097, Table 1, Item 2) Engine Oil (WP 0097, Table 1, Item 13) Gloves (WP 0097, Table 1, Item 10) Goggles (WP 0097, Table 1, Item 10) Grease (WP 0097, Table 1, Item 10) Penetrating Oil (WP 0097, Table 1, Item 14) Rags, Wiping (WP 0097, Table 1, Item 15) References LO 5-3805-294-13 (WP 0094) References (cont.) TM 5-3805-295-13&P (WP 0094) WP 0007 WP 0009 WP 0034 WP 0080 WP 0085 WP 0087 WP 0088 WP 0089 WP 0090 WP 0091 WP 0094

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

WARNING

Personnel hearing can be permanently damaged if exposed to constant high noise levels of 85 dB or greater. Failure to comply may result in injury to personnel.

WARNING

Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in

0077-1

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE the up position, and engine shut off. Failure to comply may result in injury or death to personnel.

WARNING

Ensure electrical power is off prior to working on all electrical connections. Remove all jewelry such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools can catch on equipment, contact positive electrical circuits, and cause a direct short, severe burns, or electrical shock. Failure to comply may result in injury or death to personnel.

CAUTION
New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine.

NOTE
Perform Operator's Before PMCS checks if: You are the assigned operator but have not operated the machine since the last PMCS was performed.

0077-2

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE You are operating the machine for the first time. Only perform PMCS on attachments if they are to be operated for current mission. The lubrication order is to be used in conjunction with the PMCS. For Armored Cab PMCS, refer to TM 5-3805-295-13&P.

Before

Exterior of Machine

Perform walk-around inspection of the machine exterior. Check on ground under machine (Figure 1, Item 1) for evidence of fluid leakage such as oil, coolant, or fuel. Check machine (Figure 1, Item 1) for obvious damage that would impair operation.

Class III oil or coolant leaks. Any fuel leakage is evident. Damage that would impair operation is evident.

3 1

4
Figure 1.

HYEX01001

Exterior of Machine.

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0077

Table 1. ITEM NO. 2

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Left and Right Track Chain and Rollers EQUIPMENT NOT READY/ AVAILABLE IF: Loose or missing track shoe. One or more bolts missing from track shoe.

INTERVAL Before

PROCEDURE Check for loose or missing track shoe (Figure 2, Item 2) and track bolts.

3 1

HYEX01001

Figure 2. Exterior of Machine Continued. Check for oil leakage from carrier roller (Figure 2, Item 3) or support rollers (Figure 2, Item 4). 3 Before Coolant Surge Tank Check that coolant is at the MIN COLD line (Figure 3, Item 5) on the surge tank (Figure 3, Item 6). Oil leaking from carrier roller or support roller. Coolant level below MIN COLD level.

0077-4

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Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

6
Figure 3. Coolant Level.

HYEX01002

If coolant is low, remove surge tank cap (Figure 3, Item 7) and fill as required. Check that the surge tank (Figure 3, Item 6) is not damaged. Check that surge tank cap (Figure 3, Item 7) is present and is not broken or cracked. 4 Before Engine Oil Level Check oil level on the dipstick (Figure 4, Item 8) and ensure that it is between the ADD and FULL marks. Surge tank has a Class III leak. Cap is missing or is unserviceable. Engine oil level below the ADD mark or engine oil is overfull.

0077-5

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Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

8 9

HYEX01003

Figure 4.

Engine Oil. If engine oil is low, remove cap (Figure 4, Item 9) and add oil as required (LO 5-3805-294-13). (WP 0094)

Before

Engine Compartment

Check engine compartment for obvious damage or leaks in hoses or lines.

Any damage that would impair safe operation of the machine. Loose, leaking, or damaged components.

Before

Exhaust Components

Check exhaust components for leaks, loose parts, dents, or damage.

0077-6

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

HYEX03409

Figure 5. 7 Before Hydraulic Reservoir Cap

Exhaust Components. Press button (Figure 6, Item 10) on hydraulic reservoir cap (Figure 6, Item 11) to ensure that it is operational and that cap is not broken. Hydraulic reservoir cap is broken, missing, or button cannot be pressed.

11

10

HYEX01004

Figure 6. 8 Before Fuel Tank

Hydraulic Reservoir Cap. Check fuel tank (Figure 7, Item 12) for evidence of leaks. Any signs of leaks from fuel tank.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

14

13

12

HYEX01005

Figure 7.

Fuel Tank and Fuel Level. Ensure fuel tank is full. To fill fuel tank: Remove fuel cap (Figure 7, Item 13). Fill fuel tank (Figure 7, Item 12) until band (Figure 7, Item 14) is visible. Install fuel cap (Figure 7, Item 13).

Before

Fuel Filters

Check primary fuel filter (Figure 8, Item 15), fuel/water separator (Figure 8, Item 16), and fuel lubricity filter (Figure 8, Item 17) for evidence of leaks.

Any fuel leak.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

16

15

18

17

HYEX01006

Figure 8. 10 11 Before Before Hydraulic Oil Filter Hydraulic Pump Compartment

Fuel Filters. Check hydraulic oil filter (Figure 8, Item 18) for evidence of leaks. Check hydraulic pump compartment for obvious damage or leaks in lines or hoses. Check engine oil filter (Figure 9, Item 19) for evidence of leaks. Any Class III leak. Any damage that would impair safe operation of machine. Any Class III leak.

12

Before

Engine Oil Filter

19

HYEX01007

Figure 9.

Engine Oil Filter.

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0077

Table 1. ITEM NO. 13

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Boom, Arm, Quick Latch, Hydraulic Thumb EQUIPMENT NOT READY/ AVAILABLE IF: Damage that impairs proper operation.

INTERVAL Before

PROCEDURE Check boom (Figure 10, Item 20), arm (Figure 10, Item 21), quick latch (Figure 10, Item 22), and hydraulic thumb (Figure 10, Item 23) for damage that would impair operation.
24 27

20 25 26 23

21 24 26 24 24 22
HYEX01008

Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb. Check cylinders (Figure 10, Item 24) for leaks. Check hydraulic lines (Figure 10, Item 25) and hoses (Figure 10, Item 26) for leaks. Check for presence of hydraulic thumb pin (Figure 10, Item 27). 14 Before Bucket Any Class III leak. Any Class III leak.

NOTE
Only check bucket or attachment to be used for current mission. Check bucket (Figure 11, Item 28) for cracks and missing teeth.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE Replace teeth as required. (WP 0085)

28

HYEX01009

Figure 11.

Bucket and Teeth. Check bucket for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. Primary and secondary air cleaner housing cracked or cover missing.

15

Before

Primary and Secondary Air Cleaner Housing

Inspect and clean primary and secondary air cleaner housing (Figure 12, Item 29) for damage or missing parts. (WP 0087)

0077-11

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

29

30

33 32

31
HYEX01395

Figure 12.

Air Cleaner Housing and Hose Reel. Squeeze ejector (Figure 12, Item 30) to remove dust.

16

Before

Hose Reel, Hoses, Deep Dig Control Switch, and Hand Held Hydraulic Switch

Check deep dig control pattern switch (Figure 12, Item 31) to ensure it is in the OFF position. If deep dig arm is installed, ensure that deep dig control pattern switch (Figure 12, Item 31) is in the ON position. Check hydraulic hand held tool circuit switch (Figure 12, Item 32) to ensure it is in the OFF position. Check hydraulic hose reel and hoses (Figure 12, Item 33) for damage and leaks.

Any lines are cracked, frayed, or broken.

Any class III leak.

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0077

Table 1. ITEM NO. 17

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Batteries EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL Before

PROCEDURE

WARNING

LEAD-ACID BATTERIES Remove four wing nuts (Figure 13, Item 34), washers (Figure 13, Item 35), and two covers (Figure 13, Item 36) from batteries (Figure 13, Item 37). Check batteries (Figure 13, Item 37) for leaks or cracks. Batteries show signs of leaking or have cracks.

40

41

36

34, 35

37
Figure 13.

38
Batteries.

39

HYEX01011

Check battery cables (Figure 13, Item 38) for looseness. Install two covers (Figure 13, Item 36) to batteries (Figure 13, Item 37) with four wing nuts (Figure 13, Item

Battery cables are loose.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE 34) and washers (Figure 13, Item 35).

18 19

Before Before

Cooling Package Fuel Cooler

Check cooling package (Figure 13, Item 39) for leaks and damage. Check fuel cooler (Figure 14, Item 40) and fuel lines for leaks.

Any Class III coolant leak. Any fuel leak.

40

41

36

34, 35

37

38

39

HYEX01011

Figure 14.

Batteries Continued. Check windshield washer reservoir (Figure 14, Item 41) for fluid and damage. Fill as required. Check cooling compartment for obvious damage or leaks. Any damage that would impair safe operation of the machine. Any fuel leak or class III fluid leaks. Any broken glass that impairs the operators vision. Any glass missing.

20

Before

Cab Glass

Check cab glass (Figure 15, Item 42) for cracks or chips.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

42

42 42

42
HYEX01012

Figure 15. 21 Before Mirrors, Wiper, and Operator Protection Guard

Cab Glass.

Check that mirrors (Figure 16, Item 43) are present and serviceable.

43

43 45 44

HYEX01396

Figure 16.

Mirrors and Wiper Arm. Check that operator protection guard (Figure 16, Item 44) is present and serviceable. Operator protection guard missing.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE Check that wiper arm and blade (Figure 16, Item 45) are serviceable.

22

Before

Door, Door Hinges, and Latches

Check that hinges (Figure 17, Item 46) allow door (Figure 17, Item 47) to swing freely.

Door is difficult to open or close.

46

47

48 48

46
Figure 17. Cab Door, Hinges, and Latches.

HYEX03430

Check that door (Figure 17, Item 47) and latches (Figure 17, Item 48) lock and release in open and closed positions. 23 Before Fire Extinguisher Check that fire extinguisher (Figure 18, Item 49) is present and is fully charged.

Door fails to latch or latches fail to release. Fire extinguisher is missing, has been discharged, or has an expired date of service.

0077-16

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

49

HYEX01013

Figure 18. 24 Before Cab Pedals and Levers

Fire Extinguisher. Check that left and right travel pedal and lever (Figure 19, Item 50) move freely through their full range of travel. Left or right travel pedal or lever are binding or do not move freely through full range of travel.

0077-17

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

50

50

50

50

51

52

HYEX01399

Figure 19.

Pedals and Levers. Check that attachment pedal (Figure 19, Item 51) moves freely through range of travel and attachment pedal lock (Figure 19, Item 52) is operational. Attachment pedal does not move freely or attachment pedal lock does not operate. Left or right pilot control lever binds or will not move through full range of motion.

25

Before

Pilot Control Levers

Check left (Figure 20, Item 53) and right (Figure 20, Item 54) pilot control levers to ensure that they move freely through full range of motion.

0077-18

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

54

53

HYEX01397

Figure 20. 26 27 Before Before Horn Seat Belt

Pilot Control Levers. Press horn button to ensure horn sounds. Check that seat belt (Figure 21, Item 55) is not frayed and fastens together. Horn does not sound. Seat belt is frayed or will not fasten together.

0077-19

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

55

HYEX01398

Figure 21. 28 Before Monitor

Seat Belt.

Turn ignition switch (Figure 22, Item 56) to ON position.

56

HYEX01014

Figure 22.

Ignition Switch.

0077-20

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

NOTE
If default screen is not displayed after start up screen, wait 10 seconds to ensure default screen will be displayed. Check that monitor (Figure 23, Item 57) comes on, then goes to default screen. Monitor does not come on. Monitor does not go to default screen.

57

System Starting...
1 2 3 4 5

7 F1

8 F2

9 F3

0 F4

HYEX01015

Figure 23. 29 Before Starter

Monitor. Engine does not start or starter makes unusual noises. Lights do not operate. Wipers do not operate. Sight glass has class III leak.

Start engine. (WP 0007)

30 31 32

Before Before Before

Lights Wipers and Washer Fluid Hydraulic Oil Level

Check that all lights operate. Check that wipers and washer pump works and has fluid. To check hydraulic oil level: Fully extend arm (Figure 24, Item 58).

0077-21

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE Curl bucket (Figure 24, Item 59). Lower boom (Figure 24, Item 60) until bucket is resting on the ground.

60 58 59
HYEX01016

Figure 24.

Position Boom and Arm.

61

HYEX01017

Figure 25. Hydraulic Oil Level Check. To fill hydraulic reservoir: Open right door and ensure that hydraulic oil is between marks on sight glass (Figure 25, Item 61). Fill as required. Shut down engine. (WP 0009) Service hydraulic reservoir. (WP 0088) Reservoir is empty. Sight glass is broken or damaged. Any Class III leaks.

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0077

Table 1. ITEM NO. 33

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Breaker EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL Before

PROCEDURE

NOTE
Only perform PMCS on attachments that are required for current mission. Check breaker (Figure 26, Item 62) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked.

63

HYEX01018

62

Figure 26.

Breaker. Any class III leak.

Check breaker hydraulic hoses (Figure 26, Item 63) for leaks and breaker for problems that would impair operation. 34 Before Compactor Check compactor (Figure 27, Item 64) for loose, broken, or missing hardware or mounting bracket damage.

Loose, broken, or missing hardware or mounting bracket is cracked.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED
65

INTERVAL

PROCEDURE

EQUIPMENT NOT READY/ AVAILABLE IF:

64
HYEX01019

Figure 27.

Compactor. Any class III leak.

Check compactor hydraulic hoses (Figure 27, Item 65) for leaks and compactor for problems that would impair operation. 35 Before Crush-All Check crush-all (Figure 28, Item 66) for loose, broken, or missing hardware or mounting bracket damage.

Loose, broken, or missing hardware or mounting bracket is cracked.

0077-24

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

66
Figure 28.

67
Crush-All.

HYEX01020

Check hydraulic hoses (Figure 28, Item 67) for leaks and crush-all for problems that would impair operation. 36 Before Lubricate Lubricate crush-all daily before each use (LO 5-3805-294-13). (WP 0094) Check barrier grapple (Figure 29, Item 68) for loose, broken, or missing hardware or mounting bracket damage.

Any class III leak.

37

Before

Barrier Grapple

Loose, broken, or missing hardware or mounting bracket is cracked.

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

69

68
HYEX02987

Figure 29.

Barrier Grapple. Check barrier grapple for missing or damaged pads. Check that barrier grapple lifting device (Figure 29, Item 69) does not have broken strands. Barrier grapple pad missing or damaged. Barrier grapple cable is kinked or three or more strands are broken.

38 39

Before Before

Barrier Grapple Actuator Deep Dig Arm

Lubricate actuator before use with penetrating oil. Check deep dig arm (Figure 30, Item 70) for loose, broken, or missing hardware or damage. Any loose, broken, or missing hardware or damage.

0077-26

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0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

72

71

70

HYEX01306

Figure 30.

Deep Dig Arm and Bucket. Check deep dig arm hydraulic hoses (Figure 30, Item 71) for leaks, damage, or fraying. Check deep dig ditch cleaning bucket (Figure 30, Item 72) for loose, broken, or missing hardware or mounting bracket damage. Any class III leak. Loose, broken, or missing hardware or mounting bracket is cracked.

40

Before

Deep Dig Bucket

Check bucket (Figure 31, Item 73) for cracks and missing teeth. Replace teeth as required. (WP 0085)

0077-27

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

73

HYEX01307

Figure 31.

Deep Dig Bucket. Check bucket (Figure 31, Item 73) for loose, broken, or missing hardware or mounting bracket damage. Loose, broken, or missing hardware or mounting bracket is cracked. Loose, broken, or missing hardware or mounting bracket is cracked.

41

Before

Ditch Cleaning Bucket

Check bucket (Figure 32, Item 74) for loose, broken, or missing hardware or mounting bracket damage.

0077-28

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

74
HYEX01308

Figure 32. 42 During Monitor

Ditch Cleaning Bucket. Check monitor during operation for any alarm. If alarm sounds or is displayed on monitor, perform corrective procedures as needed or shut down engine. (WP 0009) Turn engine speed dial and ensure engine speed increases. Operate right-hand console switches. Check that all hydraulic cylinders operate smoothly and through full range of travel. Any alarm sounds or is displayed on monitor. Engine speed dial does not operate. Switches do not operate. Hydraulic cylinders do not operate normally or have class III leak. If machine doesn't travel in a straight line. Machine does not steer left or right. Track chain makes unusual

43

During

Engine speed Dial

44 45

During During

Right-Hand Console Switches Hydraulic Cylinders

46

During

Travel Motor, Steering, and Brakes

Travel machine forward a short distance and ensure that: Machine travels in a straight line. Steers left and right. Track chain does not make any unusual or popping noises.

0077-29

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: or popping noises. Machine does not stop when travel levers or pedals are released. Travel levers or pedals do not return to center when released. Travel alarm does not operate. Upperstructure does not stop or drifts. Blower motor does not operate when turned on.

INTERVAL

PROCEDURE When travel levers or pedals are released machine stops. Travel levers and pedals return to center when released.

47

During

Travel Alarm

Ensure travel alarm operates when machine is moved. Swing upperstructure left or right approximately 90 degrees then release pilot control levers and ensure upperstructure stops. Ensure air conditioner/heater blower motor operates.

48

During

Swing Motor and Swing Brake

49

During

Air Conditioner/Heater

50

During

Breaker

CAUTION
Breaker must be lubricated every 2 hours of use and every hour during dusty conditions. Failure to comply may result in damage to the attachment. During extreme dusty conditions, lubricate breaker after every hour of use LO 5-3805-294-13. (WP 0094)

51

After

Hydraulic Oil Level

To check hydraulic oil level: Fully extend arm (Figure 33, Item 58). Curl bucket (Figure 33, Item 59). Lower boom (Figure 33, Item 60) until bucket is resting on the ground. Open right door and ensure that hydraulic oil is

Sight glass has class III leak.

0077-30

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE between marks on sight glass (Figure 34, Item 61). Fill as required.

60 58 59
HYEX01016

Figure 33.

Position Boom and Arm.

61

HYEX01017

Figure 34.

Hydraulic Oil Level Check. To fill hydraulic reservoir: Shut down engine. (WP 0009) Service hydraulic reservoir. (WP 0088) Start engine. (WP 0007) Safely park and shut down engine. (WP 0009)

52

After

Fuel Tank and Strainer

Check fuel tank and strainer (Figure 35, Item 12) for evidence of leaks or damage.

Any signs of leaks or damage to fuel tank or strainer, or strainer is missing.

0077-31

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

14

13

12

HYEX01005

Figure 35. Fuel Tank and Fuel Level Check. Ensure fuel tank is full. To fill fuel tank: Remove fuel cap (Figure 35, Item 13). Fill fuel tank (Figure 35, Item 12) until band (Figure 35, Item 14) is visible. Install fuel cap (Figure 35, Item 13). 53 After Engine Oil Level

CAUTION
New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine. Check oil level on the dipstick (Figure 36, Item 8) and ensure that it is between the ADD and FULL marks.

0077-32

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

8 9

HYEX01003

Figure 36.

Engine Oil Check. If engine oil is low, remove cap (Figure 36, Item 9) and add oil as required.

54

After

Engine Compartment, Belts, and Hoses

Check engine compartment for obvious damage or leaks in hoses or lines. Check belts for cuts or frays.

Any damage that would impair safe operation of the machine.

HYEX03410

Figure 37.

Engine Compartment.

0077-33

TM 5-3805-294-10

0077

Table 1. ITEM NO. 55

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Exterior of Machine EQUIPMENT NOT READY/ AVAILABLE IF: Class III oil or coolant leaks. Any fuel leakage is evident. Damage that would impair operation is evident.

INTERVAL After

PROCEDURE Perform walk-around inspection of the machine exterior. Check on ground under machine (Figure 38, Item 1) for evidence of fluid leakage such as oil, coolant, or fuel. Check machine (Figure 38, Item 1) for obvious damage that would impair operation.

2
Figure 38. Exterior of Machine Check.

HYEX01400

Check left and right track chains (Figure 38, Item 2) for missing shoes and mounting hardware. 56 Monthly Swing Gearbox Oil

Any missing track shoes or mounting hardware.

CAUTION
New machine break-in maintenance is required at 250 hours. Contact Field Maintenance to avoid early wear or damage to the machine. Failure to comply may result in voidance of warranty and damage to the machine.

0077-34

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF: Oil level is not on dipstick.

INTERVAL

PROCEDURE Check that swing gearbox oil is between marks on dipstick (Figure 39, Item 75).
76

75

HYEX01410

Figure 39.

Swing Gearbox Oil Level Check. To add oil: Remove cap (Figure 39, Item 76). Add oil until it is between the marks on the dipstick (Figure 39, Item 75). Install cap (Figure 39, Item 76).

57

Monthly

Hydraulic Pump Gearbox Oil

Check hydraulic pump gearbox oil level on dipstick (Figure 40, Item 77).

Oil level is below the "L" mark.

0077-35

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

78

77

HYEX01409

Figure 40.

Hydraulic Pump Oil Level Check. To add oil: Remove cap (Figure 40, Item 78). Add oil until it reaches the "H" mark on the dipstick (Figure 40, Item 77). Install cap (Figure 40, Item 78).

58 59 60

Monthly Monthly Monthly

Primary and Final Fuel Filter/Water Separators Fuel Tank Coolant Heater

Service primary and final fuel filter/ water separators. (WP 0086) Drain sediment from fuel tank. (WP 0091) Run coolant heater (WP 0034) for 5 minutes to keep water pump from seizing.

0077-36

TM 5-3805-294-10

0077

Table 1. ITEM NO. 61 62

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED Primary and Secondary Air Cleaner Serpentine Belt EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL Monthly Monthly

PROCEDURE Service primary and secondary air cleaner. (WP 0087) Check serpentine belt (Figure 41, Item 79) for cracks, cuts and frays.

Serpentine belt is cut, broken, or frayed.

79

HYEX01401

Figure 41. 63 Monthly Air Conditioner Belt

Serpentine Belt Check. Check air conditioner belt (Figure 42, Item 80) for cracks and cuts. Air conditioner belt is cut or broken.

0077-37

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

80

HYEX01402

Figure 42. 64 Monthly Fan

Air Conditioner Belt Check. Check fan (Figure 43, Item 81) for damage, debris, and hydraulic leaks. Any damage that would impair safe operation of machine. Any debris that would block air flow through radiator. Any class III hydraulic leak.

0077-38

TM 5-3805-294-10

0077

Table 1. ITEM NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/ AVAILABLE IF:

INTERVAL

PROCEDURE

81
HYEX01403

Figure 43. 65 66 67 68 Monthly Monthly Monthly Monthly Track Sag Fresh Air Filter Air Conditioner/Heater Filter Service Lubrication

Fan Check.

Check track sag. (WP 0080) Service fresh air filter. (WP 0089) Service air conditioner/heater filter. (WP 0090) Perform 100 lubrication in accordance with, LO 5-3805-294-13. (WP 0094)

END OF TASK END OF WORK PACKAGE

0077-39/40 blank

TM 5-3805-294-10

CHAPTER 5 OPERATOR MAINTENANCE INSTRUCTIONS FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE GENERAL MAINTENANCE INSTRUCTIONS

0078

INITIAL SETUP: Not Applicable

GENERAL MAINTENANCE

NOTE
Instructions in this section provide general procedures to be followed for maintenance authorized at the operator level. Specific instructions are found in the operator maintenance section of this manual. This section covers general maintenance instructions for the machine. Read all CAUTIONS and WARNINGS that apply to all maintenance instructions. Follow these maintenance practices when working on the machine. Prior to starting any inspection or maintenance procedure, ensure that machine is safely parked and shut down. INSPECTION Electrical Parts. Inspect wiring harnesses for cracked, broken, chafed, bare, and burned insulation, or bare wires. Inspect all terminal connectors for loose connections and broken parts. Inspect connectors for corrosion or signs of sparking. This is an indication of a malfunction within the terminal. Notify Field Level maintenance of any part found to be defective. Tubing and Hosing. Check all hose surfaces for wear, damage, broken, or frayed coverings, and leaks. Check for breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If a connector or fitting is loose, broken, or worn out, notify Field Level maintenance. Metal Parts. Check bolts, nuts, and screws for obvious looseness. Also check for missing, bent, or broken pieces. They cannot all be checked with a tool, but look for chipped paint, bare metal, or rust around bolt heads. Look for loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Visually inspect all castings and weldments for cracks.

0078-1

TM 5-3805-294-10

0078

CLEANING

WARNING

Never use fuel to clean parts. Fuel is highly flammable. Failure to comply may result in injury or death to personnel. Rubber Parts. Do not clean rubber parts in solvent cleaning compound. Wipe parts clean with a dry, cleaning cloth. Machine Exterior. Steam clean all exterior parts thoroughly. If pressurized water is not available, wash painted surfaces of machine with solution of 1/4 cup of soap chips, to 1 gallon (4 L) of water. Electrical Parts. Electrical parts such as coils, junction blocks, switches, and electrical parts that contain insulation materials should not be soaked or sprayed with cleaning solutions. Clean these parts with a cleaning cloth moistened with cleaning compound. Clean rubber parts with hot, soapy water and soft cloths. Do not clean with solvents. END OF TASK END OF WORK PACKAGE

0078-2

TM 5-3805-294-10 OPERATOR MAINTENANCE TAKING ENGINE OIL SAMPLE

0079

INITIAL SETUP: Materials/Parts Bottle, Oil Sample (WP 0097, Table 1, Item 3) Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Engine running. (WP 0007) Time to Complete 0.2 Hour(s)

SAMPLING ENGINE 1. Clean dirt from around cap (Figure 1, Item 1).

1 3

HYEX00909

Figure 1. 2. 3. 4. 5.

Engine Oil Sampling Valve.

Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2). Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full. Release valve (Figure 1, Item 3). Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).

END OF TASK END OF WORK PACKAGE

0079-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE TRACK SAG CHECK

0080

INITIAL SETUP: Tools and Special Tools Measuring Tape (WP 0095, Table 2, Item 10) Materials/Parts Grease (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (2) References DA FORM 5988-E or DA FORM 2404 (WP 0094) References (cont.) WP 0007 WP 0009 WP 0081 WP 0082 Equipment Condition Engine running. (WP 0007) Time to Complete 0.5 Hour(s)

RAISING MACHINE

NOTE
Sag for left and right side tracks is checked the same way. 1. Swing upperstructure (Figure 1, Item 1) 90 degrees.

3 4

1 5 2
HYEX00383

Figure 1. 2. 3.

Raise Machine.

Place round side of bucket (Figure 1, Item 2) on ground. Keeping angle between boom (Figure 1, Item 3) and arm (Figure 1, Item 4) between 90 and 110 degrees, slowly lower boom (Figure 1, Item 3) to raise track (Figure 1, Item 5) off ground.

END OF TASK

0080-1

TM 5-3805-294-10 TRACK SAG CHECK 1. Mark track (Figure 2, Item 5) to measure two full rotations of track in each direction.

0080

HYEX00491

Figure 2. 2. 3.

Rotate Track.

Rotate track (Figure 2, Item 5) forward two full rotations and in reverse two full rotations. Move pilot shutoff lever (Figure 3, Item 6) to locked (up) position.

0080-2

TM 5-3805-294-10 TRACK SAG CHECK - Continued

0080

6
Figure 3. 4. 5. Shut Machine Off.

HYEX01309

Turn key switch (Figure 3, Item 7) to OFF position. Measure for a distance of 11.8-13.2 in. (300-335 mm) between surface of track (Figure 4, Item 5) and bottom of track frame (Figure 4, Item 8) at middle track roller (Figure 4, Item 9).

0080-3

TM 5-3805-294-10 TRACK SAG CHECK - Continued

0080

HYEX00838

Figure 4. 6. 7. 8.

Measure Track Sag.

If track sag is more than 13.2 in. (335 mm), Tighten Track Tension. (WP 0081) If track sag is less than 11.8 in. (300 mm), Loosen Track Tension. (WP 0082) If track sag is within limits, go to Lowering Machine task in this work package.

END OF TASK LOWERING MACHINE 1. Turn key switch (Figure 5, Item 7) to ON position and start engine.

0080-4

TM 5-3805-294-10 LOWERING MACHINE - Continued

0080

6
Figure 5. 2. 3. Start Machine.

HYEX01309

Move pilot shutoff lever (Figure 5, Item 6) to unlocked (down) position. Slowly raise boom (Figure 6, Item 3) until track (Figure 6, Item 5) is resting on ground.

3 4

1 5 2
HYEX00383

Figure 6.

Lower Machine.

0080-5

TM 5-3805-294-10 LOWERING MACHINE - Continued 4. 5. 6. Raise boom (Figure 6, Item 3), arm (Figure 6, Item 4), and bucket (Figure 6, Item 2) off ground. Swing upperstructure (Figure 6, Item 1) 90 degrees. Safely park and shutdown machine. (WP 0009)

0080

END OF TASK END OF WORK PACKAGE

0080-6

TM 5-3805-294-10 OPERATOR MAINTENANCE TIGHTENING TRACK TENSION

0081

INITIAL SETUP: Tools and Special Tools Grease Gun (WP 0095, Table 2, Item 4) Materials/Parts Grease (WP 0097, Table 1, Item 10) Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N References DA FORM 5988-E or DA FORM 2404 (WP 0094) WP 0080 Equipment Condition Track sag checked. (WP 0080) Time to Complete 0.1 Hour(s)

TIGHTENING TRACK 1. Add a small amount of grease to grease fitting (Figure 1, Item 1).

1
Figure 1. 2. Check track sag. (WP 0080) Tighten Track.

HYEX00384

END OF TASK END OF WORK PACKAGE

0081-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE LOOSENING TRACK TENSION

0082

INITIAL SETUP: Tools and Special Tools Wrench, Open End, 24 mm (WP 0095, Table 2, Item 4) Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N References DA FORM 5988-E or DA FORM 2404 (WP 0094) WP 0007 Equipment Condition Track sag checked. (WP 0080) Time to Complete 0.1 Hour(s)

LOOSENING TRACK TENSION 1. Loosen nut (Figure 1, Item 1) and allow a small amount of grease to escape.

HYEX00385

Figure 1. 2. 3. Tighten nut (Figure 1, Item 1). Check track sag. (WP 0080)

Loosen Track.

END OF TASK END OF WORK PACKAGE

0082-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE TAKING HYDRAULIC OIL SAMPLE

0083

INITIAL SETUP: Materials/Parts Bottle, Oil Sample (WP 0097, Table 1, Item 3) Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Engine running. (WP 0007) Time to Complete 0.2 Hour(s)

SAMPLING HYDRAULIC OIL 1. Clean dirt from around cap (Figure 1, Item 1).
3 1

HYEX00908

Figure 1. 2. 3. 4. 5.

Hydraulic Oil Sampling Valve.

Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2). Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full. Release valve (Figure 1, Item 3). Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).

END OF TASK END OF WORK PACKAGE

0083-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE CAB FUSE REPLACEMENT

0084

INITIAL SETUP: Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) Time to Complete 0.2 Hour(s)

REMOVAL

NOTE
All fuses from both main and auxiliary fuse boxes are removed the same way. Main fuse box shown. Spare fuses are located in the fuse box. After using a spare fuse, notify Field maintenance to get a replacement fuse. 1. Remove fuse box access cover (Figure 1, Item 1) from cab rear tray (Figure 1, Item 2).

0084-1

TM 5-3805-294-10 REMOVAL - Continued

0084

2 1

HYEX00089

Figure 1. 2.

Fuse Box Access Cover Removal.

Remove main fuse box cover (Figure 2, Item 3) from main fuse box (Figure 2, Item 4).

0084-2

TM 5-3805-294-10 REMOVAL - Continued

0084

3 4
HYEX00097

Figure 2. 3. 4.

Main Fuse Box Cover Removal.

Locate fuse in question using key found on fuse box cover (Figure 2, Item 3). Remove fuse (Figure 3, Item 5) from main fuse box (Figure 3, Item 4).

0084-3

TM 5-3805-294-10 REMOVAL - Continued

0084

HYEX00098

Figure 3. END OF TASK INSTALLATION

Fuse Removal.

CAUTION
Use only a fuse having the same amperage as noted on fuse box cover. Using a fuse with higher amperage than specified could cause damage to the electrical system. Failure to comply may result in damage to equipment.

NOTE
All fuses from both main and auxiliary fuse boxes are installed the same way. Main fuse box shown. 1. Install fuse (Figure 4, Item 5) to main fuse box (Figure 4, Item 4).

0084-4

TM 5-3805-294-10 INSTALLATION - Continued

0084

HYEX00098

Figure 4. 2.

Fuse Installation.

Install main fuse box cover (Figure 5, Item 3) to main fuse box (Figure 5, Item 4).

0084-5

TM 5-3805-294-10 INSTALLATION - Continued

0084

3 4
HYEX00097

Figure 5. 3.

Main Fuse Box Cover Installation.

Install fuse box access cover (Figure 6, Item 1) to cab rear tray (Figure 6, Item 2).

0084-6

TM 5-3805-294-10 INSTALLATION - Continued

0084

2 1

HYEX00089

Figure 6. END OF TASK END OF WORK PACKAGE

Fuse Box Access Cover Installation.

0084-7/8 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE BUCKET TEETH REPLACEMENT

0085

INITIAL SETUP: Tools and Special Tools Hammer, Hand, 3 lb (WP 0095, Table 2, Item 5) Punch, Pin (WP 0095, Table 2, Item 9) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) Time to Complete 0.2 Hour(s)

HEAVY DUTY BUCKET TOOTH REMOVAL 1. Using hammer and pin punch, drive out pin (Figure 1, Item 1) from tooth (Figure 1, Item 2) and shank (Figure 1, Item 3).

1
Figure 1. Tooth Removal.

HYEX01282

2.

Remove tooth (Figure 1, Item 2) from shank (Figure 1, Item 3).

END OF TASK

0085-1

TM 5-3805-294-10 HEAVY DUTY BUCKET TOOTH INSTALLATION 1. Position tooth (Figure 2, Item 2) on shank (Figure 2, Item 3).

0085

1
Figure 2. Tooth Installation.

HYEX01282

2.

Using hammer, drive pin (Figure 2, Item 1) to tooth (Figure 2, Item 2) and shank (Figure 2, Item 3) until seated.

END OF TASK DEEP DIG BUCKET TOOTH REMOVAL 1. Using hammer and pin punch, drive out pin (Figure 3, Item 4) from tooth (Figure 3, Item 5) and shank (Figure 3, Item 6).

4 5

6
HYEX01281

Figure 3. Bucket Tooth Removal.

0085-2

TM 5-3805-294-10 DEEP DIG BUCKET TOOTH REMOVAL - Continued 2. Remove tooth (Figure 3, Item 5) from shank (Figure 3, Item 6).

0085

END OF TASK DEEP DIG BUCKET TOOTH INSTALLATION 1. Position tooth (Figure 4, Item 5) on shank (Figure 4, Item 6).

4 5

6
HYEX01281

Figure 4. 2.

Bucket Tooth Installation.

Using hammer, drive pin (Figure 4, Item 4) to tooth (Figure 4, Item 5) and shank (Figure 4, Item 6) until seated.

END OF TASK END OF WORK PACKAGE

0085-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE

0086

INITIAL SETUP: Tools and Special Tools Pan, Drain Personnel Required Horizontal Construction Engineer 12N (1) Equipment Condition Machine safely parked and shut down (WP 0009) Time to Complete 0.1 Hour(s)

DRAIN FUEL FILTER/WATER SEPARATORS

WARNING

DIESEL FUEL 1. Disconnect wiring harness connector D01 (Figure 1, Item 1) from water in fuel (WIF) sensor (Figure 1, Item 2).

1
Figure 1. Drain Fuel Filter/Water Separators.

5
HYEX00103

0086-1

TM 5-3805-294-10 DRAIN FUEL FILTER/WATER SEPARATORS - Continued

0086

NOTE
Place drain pan under fuel/water separators prior to draining. 2. Loosen, but do not remove WIF sensor (Figure 2, Item 2), and drain water/sediment from primary fuel filter/ water separator (Figure 2, Item 3) for approximately 30 seconds.

5
HYEX00103

Figure 2. Drain Fuel Filter/Water Separators Continued. 3. 4. 5. 6. Tighten WIF sensor (Figure 2, Item 2). Connect wiring harness connector D01 (Figure 2, Item 1) to WIF sensor (Figure 2, Item 2). Loosen, but do not remove valve (Figure 2, Item 4), and drain water/sediment from final fuel filter/water separator (Figure 2, Item 5) for approximately 30 seconds. Tighten valve (Figure 2, Item 4).

END OF TASK END OF WORK PACKAGE

0086-2

TM 5-3805-294-10 OPERATOR MAINTENANCE PRIMARY AND SECONDARY AIR CLEANER SERVICE

0087

INITIAL SETUP: Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) Equipment Condition Engine off. (WP 0009) Time to Complete 0.4 Hour(s)

REMOVAL 1. Lift lever (Figure 1, Item 1) and rotate cover (Figure 1, Item 2) counterclockwise.

2
HYEX00073

Figure 1. 2. 3.

Cover Removal.

Remove cover (Figure 1, Item 2) from air cleaner housing (Figure 1, Item 3). Remove primary air cleaner (Figure 2, Item 4) from air cleaner housing (Figure 2, Item 3).

0087-1

TM 5-3805-294-10 REMOVAL - Continued

0087

HYEX00074

Figure 2. Primary Air Cleaner Removal. 4. Remove secondary air cleaner (Figure 3, Item 5) from air cleaner housing (Figure 3, Item 3).

HYEX00075

Figure 3. END OF TASK

Secondary Air Cleaner Removal.

0087-2

TM 5-3805-294-10 SERVICING AIR CLEANERS

0087

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel.

NOTE
Contact field level maintenance for an air hose and air nozzle to service the air cleaner. Secondary air cleaner does not require servicing, only replacement. 1. Lightly tap primary air cleaner (Figure 4, Item 4) to remove major amount of dirt from primary air cleaner.

HYEX00076

Figure 4. 2. 3. 4.

Primary Air Cleaner Service.

Start from inside, top of primary air cleaner (Figure 4, Item 4), blow remainder of debris out of primary air cleaner. Work around and inward of primary air cleaner (Figure 4, Item 4) until primary air cleaner has been completely blown out. Wipe out air cleaner housing (Figure 5, Item 3) with a clean rag.

0087-3

TM 5-3805-294-10 SERVICING AIR CLEANERS - Continued

3

0087

HYEX00077

Figure 5. Air Cleaner Housing Service. 5. Wipe inside of cover (Figure 6, Item 2) with a clean rag and squeeze dust boot (Figure 6, Item 6) to remove dust.

2
HYEX00078

Figure 6. END OF TASK INSTALLATION

Cover and Dust Boot Service.

NOTE
Dust valve will be at the 6 O'clock position when air cleaner cover is installed. 1. Install secondary air cleaner (Figure 7, Item 5) to air cleaner housing (Figure 7, Item 3).

0087-4

TM 5-3805-294-10 INSTALLATION - Continued

3 5

0087

HYEX00084

Figure 7. 2.

Secondary Air Cleaner Installation.

Install primary air cleaner (Figure 8, Item 4) to air cleaner housing (Figure 8, Item 3).

HYEX00074

Figure 8. 3.

Primary Air Cleaner Installation.

Position cover (Figure 9, Item 2) on air cleaner housing (Figure 9, Item 3).

0087-5

TM 5-3805-294-10 INSTALLATION - Continued

3

0087

1
HYEX00083

Figure 9. 4.

Cover Installation.

Rotate cover (Figure 9, Item 2) clockwise until lever (Figure 9, Item 1) locks.

END OF TASK END OF WORK PACKAGE

0087-6

TM 5-3805-294-10 OPERATOR MAINTENANCE HYDRAULIC RESERVOIR SERVICE

0088

INITIAL SETUP: Tools and Special Tools Wrench, Allen 5 mm (0.196 in.) (WP 0095, Table 2, Item 16) Materials/Parts Lubricating Oil, Engine (WP 0097, Table 1, Item 13) Personnel Required Horizontal Construction Engineer 12N (1) References LO 5-3805-294-13 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) Time to Complete 0.4 Hour(s)

FILLING HYDRAULIC RESERVOIR

WARNING

Hydraulic system operates at high pressures and temperatures. Always allow hydraulic oil to cool and relieve pressure in hydraulic reservoir before working on hydraulic system. Wear eye protection and gloves to prevent injury. Open lines and hoses slowly and wait for any residual pressure to relieve before continuing to open lines and hoses. Failure to comply may result in injury or death to personnel. 1. Press button (Figure 1, Item 1) to relieve pressure from hydraulic reservoir (Figure 1, Item 2).
1 4 3

2
HYEX00085

Figure 1. Hydraulic Reservoir Cover Removal. 2. Remove four screws (Figure 1, Item 3) and hydraulic reservoir cover (Figure 1, Item 4) from hydraulic reservoir (Figure 1, Item 2).

0088-1

TM 5-3805-294-10 FILLING HYDRAULIC RESERVOIR - Continued

0088

WARNING

LUBRICATING OIL 3. Fill hydraulic reservoir (Figure 2, Item 2) until oil is between marks (Figure 2, Item 5) on sight glass (Figure 2, Item 6). LO 5-3805-294-13 (WP 0094)

5 2 6

HYEX00086

Figure 2. Hydraulic Reservoir Sight Glass. 4. Ensure O-ring (Figure 3, Item 7) is present and is not damaged. If O-ring is missing or damaged, notify field maintenance.

0088-2

TM 5-3805-294-10 FILLING HYDRAULIC RESERVOIR - Continued

4 3

0088

HYEX00087

Figure 3. Hydraulic Reservoir Cover Installation. 5. Install hydraulic reservoir cover (Figure 3, Item 4) to hydraulic reservoir (Figure 3, Item 2) with four screws (Figure 3, Item 3).

END OF TASK END OF WORK PACKAGE

0088-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE FRESH AIR FILTER SERVICE

0089

INITIAL SETUP: Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) References TM 5-3805-295-13&P (WP 0094) DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0009) Time to Complete 0.2 Hour(s)

REMOVAL

NOTE
After the fresh air filter has been serviced three times, it must be replaced by Field Maintenance. 1. Move two tabs (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).

HYEX00168

Figure 1. 2.

Filter Removal.

Inspect seal (Figure 2, Item 4) on filter (Figure 2, Item 2).

0089-1

TM 5-3805-294-10 REMOVAL - Continued

0089

HYEX00169

Figure 2. 3.

Inspect Seal.

If seal (Figure 2, Item 4) is damaged, contact field maintenance.

END OF TASK SERVICE

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel.

NOTE
Contact field level maintenance for an air hose and air nozzle to service the air filter. If HYEX is equipped with a Supplemental Armor Set, refer to and use procedure found in TM 5-3805-295-13&P. 1. Lightly tap filter (Figure 3, Item 2) with hand.

0089-2

TM 5-3805-294-10 SERVICE - Continued

0089

2
Figure 3. Clean Filter.

HYEX00170

CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing. Blowing compressed air from the outside to the inside could damage the air cleaner. Failure to comply may result in damage to equipment. 2. 3. Blow remainder of debris from filter (Figure 3, Item 2). Wipe inside of housing (Figure 4, Item 3) with clean rag.

HYEX00171

Figure 4. END OF TASK

Clean Housing.

0089-3

TM 5-3805-294-10 INSTALLATION 1. Install filter (Figure 5, Item 2) to housing (Figure 5, Item 3).

0089

HYEX00168

Figure 5. 2. Ensure tabs (Figure 5, Item 1) lock.

Filter Installation.

END OF TASK END OF WORK PACKAGE

0089-4

TM 5-3805-294-10 OPERATOR MAINTENANCE AIR CONDITIONER/HEATER FILTER SERVICE

0090

INITIAL SETUP: Materials/Parts Rag, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) Equipment Condition Engine OFF. (WP 0009) Time to Complete 0.2 Hour(s)

REMOVAL

NOTE
After air conditioner/heater has been serviced three times it must be replaced by Field Maintenance. 1. Move tab (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).

HYEX00187

Figure 1. 2.

Filter Removal.

Check tab (Figure 1, Item 1) on filter (Figure 1, Item 2) and replace filter if tab broken.

END OF TASK SERVICE

NOTE
Contact Field level maintenance for an air hose and air nozzle to service the air cleaner. 1. Lightly tap filter (Figure 2, Item 2) with hand.

0090-1

TM 5-3805-294-10 SERVICE - Continued

0090

HYEX00188

2
Figure 2. Clean Filter.

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel.

CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing. Blowing compressed air from the outside to the inside could damage the air cleaner. Failure to comply may result in damage to equipment. 2. 3. Blow remainder of debris from filter (Figure 2, Item 2). Wipe inside of housing (Figure 3, Item 3) with clean rag.

0090-2

TM 5-3805-294-10 SERVICE - Continued

0090

HYEX00190

Figure 3. END OF TASK INSTALLATION 1.

Clean Housing.

Install filter (Figure 4, Item 2) to housing (Figure 4, Item 3).

HYEX00187

Figure 4. 2. Ensure tab (Figure 4, Item 1) locks.

Filter Installation.

END OF TASK END OF WORK PACKAGE

0090-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE DRAINING WATER AND SEDIMENT FROM FUEL TANK

0091

INITIAL SETUP: Tools and Special Tools Pan, Drain Materials/Parts Rags, Wiping (WP 0097, Table 1, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down (WP 0009) Time to Complete 0.2 Hour(s)

DRAINING WATER AND SEDIMENT

NOTE
Contact Field Maintenance for drain pan. 1. Remove fuel tank fill cap (Figure 1, Item 1).

1
HYEX01298

Figure 1. 2.

Remove Fuel Cap.

Position drain pan under drain hose (Figure 2, Item 2).

0091-1

TM 5-3805-294-10 DRAINING WATER AND SEDIMENT - Continued

0091

HYEX00914

Figure 2. 3.

Drain Hose.

Open drain valve (Figure 3, Item 3) and drain water and sediment until a clear stream of fuel comes out.

0091-2

TM 5-3805-294-10 DRAINING WATER AND SEDIMENT - Continued

0091

HYEX00915

Figure 3. 4. 5. 6. Close drain valve (Figure 3, Item 3). Dispose of waste properly. Install fuel tank fill cap (Figure 4, Item 1).

Drain Valve.

0091-3

TM 5-3805-294-10 DRAINING WATER AND SEDIMENT - Continued

0091

1
HYEX01298

Figure 4. END OF TASK END OF WORK PACKAGE

Install Fuel Cap.

0091-4

TM 5-3805-294-10 OPERATOR MAINTENANCE CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT

0092

INITIAL SETUP: Tools and Special Tools Wrench 2-1/4 Wrench 2-1/2 (WP 0095, Table 2, Item 15) Personnel Required Horizontal Construction Engineer 12N (1) References DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down (WP 0009) Time to Complete 0.3 Hour(s)

DISCHARGE ADJUSTMENT

WARNING

Unless otherwise specified, perform all maintenance procedures with all attachments lowered to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may result in injury or death to personnel.

NOTE
Ensure curtain is set to desired discharge size before Crush-All operation. There are no disassembly requirements to perform discharge adjustments. Adjustment points are on the outside of the machine. There are two adjustment points for lower curtain. Adjustment procedure is identical for both points and must be adjusted at same time. Raise curtain to increase discharge size. Lower curtain to decrease discharge size. To reduce dust, increase discharge size. Repeat steps for opposite side. 1. Loosen nut (Figure 1, Item 1) on nut (Figure 1, Item 2) and rod (Figure 1, Item 3).

0092-1

TM 5-3805-294-10 DISCHARGE ADJUSTMENT - Continued

0092

3 5 6 7, 8, 9 10 11

2 1

HYEX03092

Figure 1. 2. 3. 4. 5. 6.

Curtain Adjustment.

Loosen nut (Figure 1, Item 2) on rod (Figure 1, Item 3) to release tension from spring (Figure 1, Item 4). Using wrench provided with crush-all loosen nut (Figure 1, Item 5) on nut (Figure 1, Item 6) and rod (Figure 1, Item 3). Remove bolt (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and washer (Figure 1, Item 9) from clamp (Figure 1, Item 10) and plate (Figure 1, Item 11). Remove clamp (Figure 1, Item 10) from nut (Figure 1, Item 6) and plate (Figure 1, Item 11). Turn nut (Figure 2, Item 6) to raise or lower curtain (Figure 2, Item 12).

0092-2

TM 5-3805-294-10 DISCHARGE ADJUSTMENT - Continued

0092

12

14 13

HYEX03093

Figure 2.

Clearance Check.

CAUTION
Ensure surface of blow bar does not touch curtain. Failure to comply may result in damage to equipment. 7. 8. Turn rotor (Figure 2, Item 13) manually. Verify curtain (Figure 2, Item 12) does not touch rotor (Figure 2, Item 13) or blow bars (Figure 2, Item 14). Position clamp (Figure 3, Item 10) on nut (Figure 3, Item 6) and plate (Figure 3, Item 11).

0092-3

TM 5-3805-294-10 DISCHARGE ADJUSTMENT - Continued

0092

7, 8, 9

11 10

HYEX03094

Figure 3. 9. 10. 11.

Clamp Installation.

Install clamp (Figure 3, Item 10) on plate (Figure 3, Item 11) with bolt (Figure 3, Item 7), lockwasher (Figure 3, Item 8), and washer (Figure 3, Item 9). Using wrench provided with crush-all tighten nut (Figure 3, Item 5) against nut (Figure 3, Item 6) on rod (Figure 3, Item 3). Tighten nut (Figure 4, Item 2) and compress spring (Figure 4, Item 4) to align marks (Figure 4, Item 15) and (Figure 4, Item 16).

0092-4

TM 5-3805-294-10 DISCHARGE ADJUSTMENT - Continued

3

0092

16

15

2 1

HYEX03095

Figure 4. 12.

Spring Compression.

Tighten nut (Figure 4, Item 1) against nut (Figure 4, Item 2) on rod (Figure 4, Item 3).

END OF TASK END OF WORK PACKAGE

0092-5/6 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE MAINTENANCE AFTER FORDING

0093

INITIAL SETUP: Tools and Special Tools Grease Gun (WP 0095, Table 2, Item 4) Wrench 17 mm (WP 0095, Table 2, Item 17) Materials/Parts Grease, Automotive and Artillery (WP 0097, Table 1, Item 10) Personnel Required Horizontal Construction Engineer 12N (1) References LO 5-3805-294-13 (WP 0094) DA FORM 5988-E or DA FORM 2404 (WP 0094) Equipment Condition Machine safely parked and shut down. (WP 0094) Time to Complete 0.5 Hour(s)

DRAINING MUD OR WATER 1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from cover (Figure 1, Item 3).
1, 2 3, 4 5

HYEX03286

Figure 1. 2. 3. 4.

Draining Mud or Water.

Remove cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from machine (Figure 1, Item 5) and allow mud or water to completely drain. Remove any contaminated grease. Install cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) to machine (Figure 1, Item 5) with two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2).

0093-1

TM 5-3805-294-10 DRAINING MUD OR WATER - Continued 5. If grease was removed, notify field level maintenance to service swing gear and swing bearing.

0093

END OF TASK END OF WORK PACKAGE

0093-2

TM 5-3805-294-10

CHAPTER 6 OPERATOR SUPPORTING INFORMATION FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX) NSN 3805-01-573-0677

TM 5-3805-294-10 OPERATOR MAINTENANCE REFERENCES

0094

SCOPE This work package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in this manual. ARMY REGULATIONS AR 25-52 AR 310-25 AR 385-40 AR 385-55 AR 700-138 Authorized Abbreviations and Brevity Codes Dictionary of United States Army Terms Accident Reporting and Records Prevention of Motor Vehicle Accidents Army Logistics Readiness and Sustainability

DEPARTMENT OF ARMY PAMPHLETS (DA PAM) DA PAM 25-30 DA PAM 750-8 Consolidated Index of Army Publications and Blank Forms The Army Maintenance Management System (TAMMS) Users Manual

FIELD MANUALS FM 1-02 FM 3-11.5 FM 3-97.6 FM 4-25.11 FM 7-1 FM 9-207 FM 20-3 FM 21-305 FM 31-70 FM 31-71 FM 38-700 & 701 FM 55-15 FM 90-3 Military Symbols Chemical, Biological, Radiological, and Nuclear Decontamination Mountain Operations First Aid Military Training Management Operation and Maintenance of Ordnance Material in Cold Weather (0F to -65F) Camouflage Manual for Wheeled Vehicle Driver Basic Cold Weather Northern Operations Preservation and Packing of Military Supplies and Equipment Transportation Reference Data Desert Operations

0094-1

TM 5-3805-294-10

0094

FORMS DA Form 2404 DA Form 2408-9 DA Form 5988-E DD Form 1149 DD Form 1266 DD Form 250 SF 368 Equipment Inspection and Maintenance Worksheet Equipment Control Record Equipment Inspection and Maintenance (Electronic) Worksheet Requisition and Invoice/Shipping Document Request for Special Hauling Permit Material Inspection and Receiving Report 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 MIL-STD-1366 Enviromental Test Methods and Engineering Guidelines Interface Standard for Transportability Criteria

TECHNICAL BULLLITENS TB 5-3805-294-13 TB 9-2300-281-35 TB 43-0209 TB 43-0216 TB 55-45 TB 740-97-2 Warranty Program for Hydraulic Excavator 240D LC Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials Handling Equipment Safety and Hazard Warnings for Operation and Maintenance of TACOM Equipment Certification of Military Equipment for Transport in AMC/ CRAF Aircraft Preservation of USAMECOM Mechanical Equipment for Shipment and Storage

TECHNICAL MANUALS LO 5-3805-294-13 TM 5-3805-295-13&P Lubrication Instructions for the Hydraulic Excavator (HYEX) Operator's and Field Level Maintenance Manual for Supplemental Armor Set for Hydraulic Excavator (HYEX) (John Deere 240D LCR)

0094-2

TM 5-3805-294-10

0094

TECHNICAL MANUALS - Continued TM 9-2330-381-13 TM 21-40 TM 38-250/AFR 71-4 TM 55-2200-001-12 TM 750-244-6 Operator and Field Maintenance Manual for the Semitrailer, Transporter, Heavy Equipment Chemical, Biological, Radiological, and Nuclear Defense Preparation of Hazardous Materials for Military Air Shipment Transportability Guidance for Application of Blocking, Bracing and Tiedown Materiels for Rail Transport Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use

END OF WORK PACKAGE

0094-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

0095

INTRODUCTION Scope This work package lists COEI and BII for the Hydraulic Excavator (HYEX) to help you inventory items for safe operation of the equipment. General The COEI and BII information is divided into the following lists: Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the HYEX. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Basic Issue Items (BII). These essential items are required to place the (HYEX) in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the Hydraulic Excavator during operation and when it is transferred between property accounts. Listing these items is your authority to request/ requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items. Explanation of Columns in the COEI List and BII List Column (1) Item Number. Gives you the reference number of the item listed. Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in initial capital letters) followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. There are no usable on codes for this equipment. Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (2). Column (6) Qty Rqr. Indicates the quantity required.

0095-1

TM 5-3805-294-10

0095

Table 1. (1) ITEM NUMBER 1 (2)

COMPONENTS OF END ITEM (3) DESCRIPTION, PART NUMBER/(CAGEC) Ditch Cleaning Bucket C909323-623315 (8U941) (4) USABLE ON CODE (5) (6) QTY RQR 1

NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION

U/I EA

HYEX01340

2540-01-478-1207

Quick Latch C909332(1J955)

EA

HYEX01359

Rock Bucket, 42 in. 909325-623327(8U941)

EA

HYEX01341

Hydraulic Thumb 70N0013(3PSD7)

EA

HYEX01360

0095-2

TM 5-3805-294-10

0095

Table 1. (1) ITEM NUMBER 5 (2)

COMPONENTS OF END ITEM - Continued (3) DESCRIPTION, PART NUMBER/(CAGEC) Vandal Protection Kit AP33356 (75755) (4) USABLE ON CODE (5) (6) QTY RQR 1

NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION 2590-01-474-7812

U/I EA

HYEX01342

0095-3

TM 5-3805-294-10

0095

Table 2. (1) ITEM NUMBER 1 (2) NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION

BASIC ISSUE ITEMS (3) DESCRIPTION, PART NUMBER/(CAGEC) Bag, Mason 204900 (3PSD7) (4) USABLE ON CODE (5) (6) QTY RQR 1

U/I EA

HYEX03287

Cap 811438500 (1BVQ2)

EA

HYEX03288

Cap, Pin U42984 (3PSD7)

HYEX03289

EA

4
HYEX01349

Gun, Grease, Lever Action, 12 in. (304.8 mm) 7Y26518 (3PSD7) Hammer, Hand, 3 lb (1.36 kg) B3-3LB(72987)

EA

5
HYEX03327

EA

6
TM 5-3805-294-10
TECHNICAL MANUAL OPERATOR'S MANUAL FOR

Operator's Manual TM 5-3805-294-10

EA

HYDRAULIC EXCAVATOR (HYEX) (JOHN DEERE 240D LCR) TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH NSN 3805-01-573-0677 (EIC : ALL)

DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY XXXX XXXX

HYEX01339

Plug, Hex 37 Degree Flare, -12 205324(1BVQ2)

HYEX03290

EA

8
HYEX03291

Plug, Hex 37 Degree Flare, -6 R39783 (3PSD7)

EA

0095-4

TM 5-3805-294-10

0095

Table 2. (1) ITEM NUMBER 9 (2)

BASIC ISSUE ITEMS - Continued (3) DESCRIPTION, PART NUMBER/(CAGEC) Punch, Drift 70-195(08292) (4) USABLE ON CODE (5) (6) QTY RQR 1

NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION 5120 -01-434-9835

U/I EA

HYEX03325

10

5210-01-434-9515

Tape, Measuring 25 FT 68-445 (08292)

EA

HYEX03326

11

5120 -01-434-9171

Screwdriver, Pry Bar, 12 in. (305 mm) Long B107.60 (05047)

EA

HYEX01348

12

3815-01-475-0710

Tooth, Surface Ripping TX400 (1J955)

EA

HYEX03292

13

Vice Grips 67-460 (08292)

EA

HYEX01355

14

Wrench, Open End, 3 in. (76 mm) T183966 (75755)

HYEX01346

EA

0095-5

TM 5-3805-294-10

0095

Table 2. (1) ITEM NUMBER 15 (2)

BASIC ISSUE ITEMS - Continued (3) DESCRIPTION, PART NUMBER/(CAGEC) Wrench, Open End, 2 1/2 in. (63.5 mm) AT189507 (75755) (4) USABLE ON CODE (5) (6) QTY RQR 2

NATIONAL STOCK NUMBER (NSN) AND ILLUSTRATION

U/I EA

HYEX01345

16

5120-01-045-4889

Wrench, Allen, 5 mm (0.196 in.) B18.3.2M (05047)

EA

HYEX01344

17

Wrench, Open End, 17 mm 52-217 (08292)

EA

HYEX01356

18

5120 - 01-581-3318

Wrench, Open End, 24 mm 52-224 (08292)

EA

HYEX01356

19

5120-00-240-5328

Wrench, Open End, Adjustable, 0.95 in. (24 mm) Jaw Opening, 15 in. (381 mm) Long 11655778-3 (19207)

EA

HYEX01343

END OF WORK PACKAGE

0095-6

TM 5-3805-294-10 OPERATOR MAINTENANCE ADDITIONAL AUTHORIZATION LIST (AAL)

0096

INTRODUCTION SCOPE This work package lists additional items you are authorized for the support of the Hydraulic Excavator (HYEX). GENERAL This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it. These items are all authorized to you by CTA, MTOE, TDA, or JTA. Explanation of Columns in the AAL Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (2) - Description, Part Number/(CAGEC). Identifies the Federal item name (in Initial capital letters) followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. Column (4) - Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (1). Column (5) - Quantity Recommended (Qty Recom). Indicates the quantity recommended. Table 1. (1) NATIONAL STOCK NUMBER (NSN) Additional Authorization List. (3) USABLE ON CODE (4) U/I EA (5) QTY RECOM 1

(2) DESCRIPTION, PART NUMBER/ (CAGEC) Compactor IHC 00130FT (1N0L6)

END OF WORK PACKAGE

0096-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE EXPENDABLE AND DURABLE ITEMS LIST

0097

Introduction Scope This work package lists expendable/durable supplies and materials you will need to operate and maintain the Hydraulic Excavator (HYEX). This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expandable/Durable Items List Column (1) - Item Number This number is assigned to the entry in the listing and is referenced in the initial setup narrative instructions to identify the material. Column (2) - Level This column identifies the lowest level of maintenance that requires the listed item. C -- Operator/Crew F -- Field H -- Below Depot D -- Depot

Column (3) - National Stock Number (NSN) This is the NSN assigned to the item which you can use to requisition it. Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number (P/N) This column provides the other information you need to identify the item. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (5) - Unit of Issue (U/I) Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc. Table 1. (1) ITEM NO. 1 (2) LEVEL C (3) NATIONAL STOCK NUMBER (NSN) 6850-01-441-3248 Expendable and Durable Items List (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Antifreeze, Permanent, Type: Arctic Grade 55-Gallon Drum A-A-52624 (58536) (5) U/I DR

0097-1

TM 5-3805-294-10

0097

Table 1. (1) ITEM NO. 2 (2) LEVEL C (3)

Expendable and Durable Items List - Continued (4) ITEM NAME, DESCRIPTION, PART NUMBER/ (CAGEC) Antifreeze, Permanent, Ethylene Glycol, Inhibited 5Gallon Can A-A-52624 (58536) Bottle, Oil Sample M44054 TYPE III (81349) Cleaning Compound, Windshield 1-pt Can 0854-000 (0FTT5) Fuel, JP8 Bulk MILT83133 GR JP8 (81349) Fuel, DF-2, Regular Bulk W-F-800 (81348) Fuel, DF-2, Regular Bulk ASTM D 975 (58536) Fuel, DF-1, Winter Bulk W-F-800 (81348) Fuel, DF-1, Winter Bulk AA52557-1 (58536) Grease, Automotive and Artillery, GAA 2-1/4-oz Tube M-10924-A (81349) Lubricating Oil, OEA Ice, Subzero 1-qt Can MIL-PRF-46170 (81349) Lubricating Oil, OEA Ice, Subzero 5-gal Can MIL-PRF-46170 (81349) Lubricating Oil, Engine OE/HDO 15W-40 1-qt Can MIL-PRF-2104 (81349) Penetrating Oil Can, 8 oz Can L3 (77628) Rag, Wiping 7920-00-148-9666 (80244) (5) U/I CO

NATIONAL STOCK NUMBER (NSN) 6850-01-441-3257

3 4 5 6 7 8 9 10 11 12 13 14 15

C C C C C C C C C C C C C

8125-01-193-3440 6850-00-926-2275 9130-01-031-5816 9140-01-413-7511 9140-00-286-5294 9140-01-412-1311 9140-00-286-5286 9150-01-197-7688 9150-00-111-6256 9150-00-111-6255 9150-01-438-6076 9150-00-973-9504 7920-00-148-9666

BX BX GL GL GL GL GL TU QT GL QT CN BE

END OF WORK PACKAGE

0097-2

TM 5-3805-294-10 OPERATOR MAINTENANCE SPECIAL PURPOSE KITS (SPK) LIST

0098

SCOPE This work package lists the Special Purpose Kits (SPKs) for support of the Hydraulic Excavator (HYEX) Type 1. Where to find operation instructions and troubleshooting procedures for the SPKs are also provided. OPERATION INSTRUCTIONS FOR SPKS For instructions on how to select the SPKs on the operators monitor, go to Selecting an Attachment On the Monitor (WP 0018). To operate the SPKs go to Operating the Barrier Grapple (WP 0022), Installing and Operating the Compactor and Breaker (WP 0020), or Installing and Operating the Crush-All (WP 0019). The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX Type 1 by Field Maintenance. To operate the Deep Dig Arm, go to Operating the Deep Dig Arm (WP 0023). TROUBLESHOOTING PROCEDURES FOR SPKS To find troubleshooting procedures for the SPK items, go to the Troubleshooting Index (WP 0037). INTRODUCTION TO THE SPECIAL PURPOSE KITS LIST Special Purpose Kits (SPK) listed in Table 1 are for information purposes only and are not the authority to requisition replacements. These items are part of the HYEX Type 1, but they are removed and separately packaged for transportation or shipment. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Illustrations are furnished to help you find and identify the items. EXPLANATION OF COLUMNS IN TABLE 1 Column (1) Item Number. Gives you the reference number of the item listed. Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name followed by a minimum description when needed. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. There are no usable on codes for this equipment. Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National Stock Number shown in column (2). Column (6) QTY RQD. Indicates the quantity required.

0098-1

TM 5-3805-294-10 SCOPE - Continued SPECIAL PURPOSE KITS Table 1. (1) ITEM NO. 1 (2) NATIONAL STOCK NUMBER Special Purpose Kits. (3) DESCRIPTION, PART NUMBER/(CAGEC) Arm, Long Reach 502113 (1BVQ2) (4) USABLE ON CODE (5) U/I EA

0098

(6) QTY RQD 1

HYEX02525

Barrier Grapple KL16000-1 (1V7ZO)

EA

HYEX02522

3830-01-585-2734

Breaker, Impact 205146 (1BVQ2)

EA

HYEX02520

Counterweight 305156 (1BVQ2)

EA

HYEX02526

0098-2

TM 5-3805-294-10 SCOPE - Continued Table 1. 5 Special Purpose Kits - Continued. Crush-All 502063 (1BVQ2) EA

0098

HYEX02521

Excavator Bucket (Deep Dig) 70G0001 (3PSD7)

EA

HYEX02523

Bucket, Scoop Loader (Deep Dig) 70G0002 (3PSD7)

EA

HYEX02524

END OF WORK PACKAGE

0098-3/4 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE TROUBLESHOOTING NOTES

0099

Troubleshooting Notes This paragraph contains troubleshooting information for locating and correcting some operating troubles which may develop in the HYEX. This manual cannot list all possible malfunctions that may occur, nor can it include all tests, inspections, and corrective actions. Notify field maintenance personnel if a malfunction is not listed, unless a malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed. Procedures. The troubleshooting symptom index lists possible malfunctions that may be experienced during operation of machine or components. Each malfunction for an individual component, unit, or system is followed by a list of tests or inspections and corrective actions. Lubrication. When instructions to lubricate, grease, oil, or add oil appear in the troubleshooting table, refer to Operator Preventive Maintenance Checks and Services. (WP 0077) END OF WORK PACKAGE

0099-1/2 blank

TM 5-3805-294-10 OPERATOR MAINTENANCE HYEX TRANSPORTABILITY INSTRUCTIONS

0100

HYEX TRANSPORTABILITY INSTRUCTIONS. The HYEX can be transported via highway, rail, marine, C-5, and C-17 air transport and meets all weight and dimensional requirements while in its standard configuration with no reduction or sectionalization required. TRANSPORTABILITY RELATED PUBLICATIONS. Additional information on transport procedures can be found in: 1. TB 9-2300-281-35, Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles WP 0094. 2. TM 38-250/AFR 71-4, Preparation of Hazardous Materials for Military Air Shipment WP 0094. TRANSPORTABILITY RELATED DEFINITIONS. Technical terms that may be helpful while preparing the HYEX for transportation are: 1. Center of Gravity (CG). The balance point of a suspended item. The HYEX counterweight is used to shift CG to the rear. 2. Curb Weight (CW). Total weight of operational HYEX including fuel, all system fluids, and on-vehicle Basic Issue Items (BII). CW does not include crew weight, which in this case, is less than one percent of the gross vehicle weight. 3. Gross Vehicle Weight (GVW). CW plus payload. For transport purposes, there is no payload. Therefore, the GVW equals the CW. MILITARY LOAD CLASSIFICATION. The Military Load Classifications (MLC) for the HYEX are as follows: 1. HYEX Standard Cab System - MLC 32 2. HYEX Armored Cab System - MLC 34

HYEX03197

Figure 1.

Military Load Classification.

0100-1

TM 5-3805-294-10 HYEX SHIPPING WEIGHT. 1. HYEX with Standard Cab shipping weight, without bucket or attachment = 58,900 lbs 2. HYEX with Armored Cab shipping weight without bucket or attachment = 63,000 lbs HYEX HIGHWAY TRANSPORTABILITY.

0100

NOTE
The HYEX is self-propelled at speeds up to 3.4 mph. The unit transportation officer must contact local authorities to ensure the HYEX is not required to have special permits prior to highway transporting. The HYEX transport height is 10 feet 1 inch so it is capable of normal highway transport on trailers that have a bed height of 40 inches or less. HYEX is transportable on common military trailers, especially the M870A1 and M870A3. The HYEX is outfitted with a hydraulic quick latch for rapid exchange of attachments. HYEX can normally be transported over the road with any of the standard buckets attached. Attaching the Crush-All for shipment may cause the HYEX to exceed the 13 feet 6 inches transport height requirement.

33 FT. 4 IN. [10.15 M] 11 FT. 1 IN. [3.39 M]

10 FT. 1 IN. [3.07 M]

HYEX01365

Figure 2. HYEX RAIL TRANSPORTABILITY.

HYEX Dimensions.

Due to the 30 inch track shoe requirement, the HYEX will have to be subjected to restrictive routes for rail movements. The HYEX may easily be rail transported via routes subjected to DOD clearance diagrams. HYEX can be transported via rail with any of the standard buckets attached. HYEX MARINE TRANSPORTABILITY. The HYEX can be shipped as roll-on/roll-off, LASH, SEABEE, water-way barge, or boat. On deck storage is permissible with some protection for cylinder rods. The HYEX height of 10 feet 1 inch allows the sea shipment within the LASH lighter.

0100-2

TM 5-3805-294-10 HYEX LIFTING AND TIE DOWN PROVISIONS.

0100

HYEX Transportation Data Plate shows location of the lifting points, tie down points, and machine center of gravity (CG).

TRANSPORTATION DATA GROSS WEIGHT EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD NO. OF SLINGS REQUIRED LENGTH OF SLINGS -

60,000 LB.

4 12 FT.

EQUIPMENT TIEDOW PROVISIONS LIFTING PROVISIONS SWING CENTERLINE CENTER OF GRAVITY

44 MM [1.7 IN.]

1212 MM [47.5 IN.]

HYEX03192

Figure 3.

HYEX Transportation Data Plate.

The following values are the HYEX Design Load Capabilities: 1. TieDown Provisions 1 and 2; a. Longitudinal = 92,250 lbs b. Vertical = 124,200 lbs 2. Tie Down Provisions 3 and 4; a. Longitudinal = 110.250 lbs b. Vertical = 110,250 lbs 3. Lift Provisions; a. Rated design limit = 60,000 lbs, each shackle b. Ultimate design factor 5:1

0100-3

TM 5-3805-294-10 HYEX LIFTING AND TIE DOWN PROVISIONS - Continued.

0100

HYEX LIFT AND TIE DOWN PROVISIONS

TIE DOWN 2

TIE DOWN 4

TIE DOWN 3

CAB

TIE DOWN 1

LIFT POINTS =TIE DOWN 1 =TIE DOWN 2 =TIE DOWN 3 =TIE DOWN 4
HYEX03063

Figure 4. HYEX Lifting and Tie Down Points. Table 1. HYEX Lift and Tie Down Information. Provision 1 - Tie Down 2 - Tie Down 3 - Tie Down 4 - Tie Down Lift Points QTY 2 2 2 2 4 Location (Relative to CG) 39 in. forward 26 in. forward 43 in. aft 30 in. aft 120 in. aft 30 in. below 25 in. below 30 in. below 25 in. below 5 in. below Lateral 56 in. 7 in. 56 in. 7 in. 15 in.

0100-4

TM 5-3805-294-10

0100

HIGHWAY: Figure (5) shows the HYEX on an M870 semi trailer. The top view also shows a possible M870 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.

1 FOOT EXTENSION BOTH SIDES

13 FT. 6 IN. HEIGHT CLEARANCE LINE

M870 TRAILER SECTION A-A HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 240D LCR
Figure 5. M870 Loading.

HYEX03073

0100-5

TM 5-3805-294-10 HIGHWAY: - Continued

0100

Figure (6) shows the HYEX on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.

1 FOOT EXTENSION BOTH SIDES

A 13 FT. 6 IN. HEIGHT CLEARANCE LINE

M870A1 TRAILER SECTION A-A

HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 250D LCR

HYEX03072

Figure 6.

M870A1 Loading.

0100-6

TM 5-3805-294-10 HIGHWAY: - Continued

0100

Figure (7) shows the HYEX on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.

A 13 FT. 6 IN. HEIGHT CLEARANCE LINE

M870A3 TRAILER
SECTION A-A HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I JOHN DEERE MODEL 240D LCR

HYEX03069

Figure 7.

M870A3 Loading.

0100-7

TM 5-3805-294-10

0100

RAIL: HYEX is equipped with 30 inch track shoes, which require the HYEX to have special rail routing. The armored HYEX has the same exterior dimensions as the standard cab model, so the armored cab version was not shown in the GIC envelope. The HYEX requires special routing for rail systems requiring the GIC dimensions. Figures (8), (9), and (10) show the HYEX modeled in various rail envelopes.

HYEX RAIL DIAGRAM

51.4 INCH HIGH RAILCAR

GIC RAIL CLEARANCE WITH STANDARD CAB

Figure 8. GIC Rail Clearance.

HYEX03078

0100-8

TM 5-3805-294-10 RAIL: - Continued

0100

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 RAIL: - Continued

0100

HYEX RAIL DIAGRAMS

AAR RAIL CLEARANCE WITH ARMORED CAB

DOD RAIL CLEARANCE WITH ARMORED CAB

HYEX03064

Figure 10. Armored Cab Clearance. Figures (11) and (12) show the proposed HYEX tie down configurations on the HTTX railcar.

HYEX01370

Figure 11. HTTX Railcar Loading Overhead View.

0100-10

TM 5-3805-294-10 RAIL: - Continued

0100

HYEX01371

Figure 12. AIR:

HTTX Railcar Loading Side View.

The HYEX meets the requirements of MIL-HDBK-1791, Designing for Internal Aerial Delivery in Fixed Winged Aircraft (WP 0094) for transport on C-17 and C-5 aircraft. Figure (13) shows model of the HYEX, both standard and armored cab, inside the C-5 aircraft design envelope. The model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft.

HYEX DIAGRAMS INSIDE C-5 AIRCRAFT STANDARD CAB

LOAD RAMP CLEARANCE

ARMORED CAB

GROUND PLANE

BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE

Figure 13.

BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE HYEX03066

C-5 Aircraft Loading.

0100-11

TM 5-3805-294-10 AIR: - Continued

0100

Figure (14) shows model of the HYEX, both standard and armored cab, inside the C-17 aircraft design envelope. The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft.

HYEX DIAGRAMS INSIDE C-17 AIRCRAFT

STANDARD CAB
LOAD RAMP CLEARANCE

ARMORED CAB
LOAD RAMP CLEARANCE

GROUND PLANE

BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE

BOOM RAISED 152.4mm (6 inches) ABOVE GROUND PLANE

HYEX03065

Figure 14. C-17 Aircraft Loading. MARINE: Marine tie-down restraint depends on the size of the ship (decreasing on larger vessels), the expected sea state to be encountered, and the stow location of a given ship. Generally, the restraint required will increase for locations high and forward (or aft) in the ship. The most severe conditions will occur on exposed "weather decks," where strong wind and wet conditions add to the problem. A ships crew may require additional lashing on exposed decks. Belowdeck locations that are closer to the vessels center of gravity and rotation will experience less severe motion.

HYEX01372

Figure 15.

Marine Loading.

0100-12

TM 5-3805-294-10

0100

HYEX STANDARD BUCKET AND SPECIAL PURPOSE KITS (SPK) TRANSPORTABILITY. All HYEX attachments have lifting and tie-down provisions included for ease in preparing for transport. The standard HYEX quick latch system enables ease in changing attachments. The HYEX attachments can be directly chained down to railcar/trailer for transport. HYEX Attachments Weights are as follows: 1. Standard Rock Bucket, 42 in. = 3,000 lb (1361 kg) 2. Standard Ditch Cleaning Bucket = 2,337 lb (1060 kg) 3. Impact Breaker = 4,970 lb (2254 kg) 4. Crush-All = 7,450 lb (3379 kg) 5. Barrier Grapple = 870 lb (395 kg) 6. Plate Compactor = 2,200 lb (998 kg) 7. Deep Dig Arm = 3,440 lb (1560 kg) STANDARD BUCKET TIE DOWN PROVISIONS. Figure (16) shows the Standard Rock Bucket lifting and tie-down provisions.
TIE DOWN PROVISIONS

HYEX03083

Figure 16.

Standard Rock Bucket.

0100-13

TM 5-3805-294-10 STANDARD BUCKET TIE DOWN PROVISIONS - Continued. Figure (17) shows the Standard Ditch Cleaning Bucket lifting and tie-down provisions.

0100

TIE DOWN PROVISIONS

HYEX03087

Figure 17. HIGHWAY:

Standard Ditch Cleaning Bucket.

Figure (18) shows the Standard Buckets on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down configuration.

0100-14

TM 5-3805-294-10 HIGHWAY: - Continued

0100

HYEX STANDARD BUCKETS ON M870A1 TRAILER

HYEX03071

Figure 18. Standard Buckets Loaded On M870A1. Figure (19) shows the Standard Buckets on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down configuration.
HYEX STANDARD BUCKETS ON M870A3 TRAILER

HYEX03068

Figure 19. Standard Buckets Loaded On M870A3.

0100-15

TM 5-3805-294-10 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS. Figure (20) shows the Deep Dig Arm lifting and tie-down provisions.

0100

TIE DOWN PROVISIONS

HYEX03089

Figure 20.

Deep Dig Arm.

Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions.

TIE DOWN PROVISIONS

HYEX03086

Figure 21.

Deep Dig Bucket.

Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions.

0100-16

TM 5-3805-294-10 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
TIE DOWN PROVISIONS

0100

HYEX03085

Figure 22.

Deep Dig Ditch Cleaning Bucket.

0100-17

TM 5-3805-294-10 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued. Figure (23) shows the Crush-All lifting and tie-down provisions.
TIE DOWN PROVISIONS

0100

HYEX03084

Figure 23.

Crush-All.

Figure (24) shows the Compactor lifting and tie-down provisions.

TIE DOWN PROVISIONS

Figure 24. Compactor.

HYEX03082

0100-18

TM 5-3805-294-10 SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued. Figure (25) shows the Impact Breaker lifting and tie-down provisions.

0100

TIE DOWN PROVISIONS

Figure 25. Impact Breaker.

HYEX03081

Figure (26) shows the Barrier Grapple lifting and tie-down provisions.

TIE DOWN PROVISIONS

HYEX03147

Figure 26.

Barrier Grapple.

0100-19

TM 5-3805-294-10

0100

CRUSH-ALL TIE DOWNS FOR HIGHWAY TRANSPORT. Figure (27) shows the Crush-All loaded on M870A1 semi trailer. The top view also shows possible M870A1 tie down configuration.
HYEX CRUSH-ALL ATTACHMENTS ON M870A1 TRAILER

HYEX03070

Figure 27. Crush-All On M870A1. Figure (28) shows the Crush-All loaded on M870A3 semi trailer. The top view also shows possible M870A3 tie down configuration.

HYEX CRUSH-ALL ON M870A3 TRAILER

HYEX03067

Figure 28. Crush-All On M870A3.

0100-20

TM 5-3805-294-10

0100

TRANSPORTING ON RAIL. Figures (29) through (32) shows the Standard Buckets and Special Purpose Kits loading and tie downs on a HTTX railcar. The top view also shows possible HTTX railcar tie down configurations.

BUCKETS ON HTTX RAILCAR

HYEX03077

Figure 29.

Standard Buckets Loaded On HTTX Railcar.

HYEX CRUSH-ALL ATTACHMENT ON HTTX RAILCAR

HYEX03076

Figure 30.

Crush-All Loaded On HTTX Railcar.

0100-21

TM 5-3805-294-10 TRANSPORTING ON RAIL - Continued.

0100

HYEX IMPACT BREAKER, COMPACTOR, AND BARRIER GRAPPLE ON HTTX RAILCAR

HYEX03074

Figure 31.

Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.

HYEX DEEP DIG ATTACHMENTS ON HTTX RAILCAR

HYEX03075

Figure 32. END OF WORK PACKAGE

Deep Dig Arm and Buckets Loaded On HTTX Railcar.

0100-22

TM 5-3805-294-10

INDEX
Subject WP Sequence No.-Page No.

A
ADDITIONAL AUTHORIZATION LIST (AAL).......................................................................... ADJUSTING THE OPERATOR'S SEAT................................................................................. AIR CONDITIONER DOES NOT OPERATE.......................................................................... AIR CONDITIONER/HEATER FILTER SERVICE................................................................... AUTO-IDLE DOES NOT WORK............................................................................................. WP 0096-1 WP 0006-1 WP 0045-1 WP 0090-1 WP 0052-1

B
BARRIER GRAPPLE DOES NOT HOLD LOAD..................................................................... BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE....................................................... BREAKER DOES NOT OPERATE......................................................................................... BREAKER OPERATES SLOWLY........................................................................................... BUCKET TEETH REPLACEMENT......................................................................................... WP 0073-1 WP 0041-1 WP 0070-1 WP 0071-1 WP 0085-1

C
CAB DOME LIGHT DOES NOT OPERATE............................................................................ CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................ CAB FUSE REPLACEMENT................................................................................................... CAB REAR WORK LIGHTS DO NOT OPERATE................................................................... COMPACTOR DOES NOT OPERATE................................................................................... COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS................... CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT................................................. CRUSH-ALL DOES NOT OPERATE...................................................................................... WP 0040-1 WP 0042-1 WP 0084-1 WP 0043-1 WP 0069-1 WP 0095-1 WP 0092-1 WP 0072-1

D
DECAL LOCATION GUIDE..................................................................................................... DEEP DIG DOES NOT OPERATE......................................................................................... DESCRIPTION AND USE OF MONITOR AND ALARMS....................................................... DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS....................... DRAINING WATER AND SEDIMENT FROM FUEL TANK.................................................... WP 0027-1 WP 0074-1 WP 0005-1 WP 0004-1 WP 0091-1

E
ENGINE COOLANT TEMPERATURE ABOVE NORMAL...................................................... ENGINE CRANKS BUT DOES NOT START OR HARD TO START...................................... ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE................................... ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE..................................................... ENGINE IDLES POORLY....................................................................................................... ENGINE NOT DEVELOPING FULL POWER......................................................................... ENGINE OIL PRESSURE LOW.............................................................................................. ENGINE RUNS POORLY........................................................................................................ ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED................................ ENGINE WILL NOT CRANK................................................................................................... EQUIPMENT DESCRIPTION AND DATA.............................................................................. EXCESSIVE FUEL CONSUMPTION...................................................................................... EXCESSIVE OIL CONSUMPTION......................................................................................... EXPENDABLE AND DURABLE ITEMS LIST......................................................................... 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

Index-1

TM 5-3805-294-10

INDEX - Continued
Subject WP Sequence No.-Page No.

F
FORDING THE HYEX............................................................................................................. FRESH AIR FILTER SERVICE............................................................................................... WP 0036-1 WP 0089-1

G
GENERAL INFORMATION..................................................................................................... GENERAL MAINTENANCE INSTRUCTIONS........................................................................ GENERAL MONITOR OPERATION....................................................................................... WP 0001-1 WP 0078-1 WP 0013-1

H
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER........................ HYDRAULIC HOSE REEL DOES NOT OPERATE................................................................ HYDRAULIC OIL FOAMS....................................................................................................... HYDRAULIC OIL OVERHEATS.............................................................................................. HYDRAULIC RESERVOIR SERVICE..................................................................................... HYEX TRANSPORTABILITY INSTRUCTIONS...................................................................... WP 0059-1 WP 0075-1 WP 0062-1 WP 0061-1 WP 0088-1 WP 0100-1

I
INSTALLING AND OPERATING THE COMPACTOR............................................................ INSTALLING AND OPERATING THE CRUSH-ALL............................................................... INSTALLING AND OPERATING THE IMPACT BREAKER.................................................... INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...... WP 0021-1 WP 0019-1 WP 0020-1 WP 0076-1

L
LIFTING WITH HYEX.............................................................................................................. LOOSENING TRACK TENSION............................................................................................. LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE................................................. LOWERING BOOM WITHOUT HYDRAULIC PRESSURE..................................................... WP 0015-1 WP 0082-1 WP 0044-1 WP 0029-1

M
MAINTENANCE AFTER FORDING........................................................................................ MOVING MACHINE ON/OFF AN EMBANKMENT................................................................. MOVING THE HYEX............................................................................................................... MOVING UP/DOWN STEEP OR SLIPPERY SLOPES.......................................................... WP 0093-1 WP 0024-1 WP 0008-1 WP 0035-1

N
NO HYDRAULIC FUNCTIONS............................................................................................... NO SWING FUNCTION.......................................................................................................... WP 0058-1 WP 0063-1

O
OPENING AND CLOSING WINDOWS................................................................................... OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)................................................. OPERATING IN COLD WEATHER 5F (-15C) OR COLDER .............................................. OPERATING TECHNIQUES................................................................................................... OPERATING THE BARRIER GRAPPLE................................................................................ OPERATING THE COOLANT HEATER................................................................................. OPERATING THE DEEP DIG ARM........................................................................................ WP 0011-1 WP 0030-1 WP 0031-1 WP 0016-1 WP 0022-1 WP 0034-1 WP 0023-1

Index-2

TM 5-3805-294-10

INDEX - Continued
Subject WP Sequence No.-Page No.

O
OPERATING THE HYDRAULIC HOSE REEL........................................................................ OPERATING THE HYDRAULIC THUMB................................................................................ WP 0026-1 WP 0017-1

P
POWER DIG DOES NOT WORK............................................................................................ PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)..................................... PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE............................ PRIMARY AND SECONDARY AIR CLEANER SERVICE...................................................... WP 0060-1 WP 0077-1 WP 0086-1 WP 0087-1

Q
QUICK LATCH DOES NOT OPERATE.................................................................................. WP 0068-1

R
REFERENCES........................................................................................................................ REMOVING AND INSTALLING BUCKET............................................................................... WP 0094-1 WP 0014-1

S
SELECTING AN ATTACHMENT ON THE MONITOR............................................................ SHUTTING DOWN THE HYEX............................................................................................... SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED............................. SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................................................................................................................................... SLAVE STARTING.................................................................................................................. SLOW TRAVEL SPEED ONLY............................................................................................... SPECIAL PURPOSE KITS (SPK) LIST................................................................................... STARTING THE ENGINE....................................................................................................... SWING FUNCTION IS JERKY................................................................................................ WP 0018-1 WP 0009-1 WP 0010-1 WP 0033-1 WP 0032-1 WP 0065-1 WP 0098-1 WP 0007-1 WP 0064-1

T
TAKING ENGINE OIL SAMPLE.............................................................................................. TAKING HYDRAULIC OIL SAMPLE....................................................................................... THEORY OF OPERATION..................................................................................................... TIGHTENING TRACK TENSION............................................................................................ TOWING THE HYEX............................................................................................................... TRACK SAG CHECK ............................................................................................................. TRAVEL ALARM DOES NOT OPERATE............................................................................... TRAVEL IS JERKY.................................................................................................................. TROUBLESHOOTING NOTES............................................................................................... TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE........................... WP 0079-1 WP 0083-1 WP 0003-1 WP 0081-1 WP 0028-1 WP 0080-1 WP 0038-1 WP 0066-1 WP 0099-1 WP 0037-1

U
USING THE RIFLE MOUNT.................................................................................................... USING THE VANDAL PROTECTION KIT.............................................................................. WP 0012-1 WP 0025-1

W
WINDSHIELD WIPER AND WASHER DO NOT OPERATE................................................... WP 0039-1

Index-3/4 blank

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

Date you filled out this form.

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000

Your mailing address

PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS Title PUBLICATION/FORM NUMBER DATE

TM
ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE TABLE NO. NO. RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

TYPED NAME, GRADE OR TITLE

*Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Name DA FORM 2028, FEB 74

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

Your address

DATE Date you filled out this form

TM

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE DATE

0 Mar

PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Name

Your Signature
USAPPC V3.00

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

DATE

TO: (Forward to proponent of publication or form)(Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER TM ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE TABLE NO. NO. DATE 0 Mar RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). TITLE

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

TM

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE DATE

0 Mar

PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

ITEM NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

DATE

TO: (Forward to proponent of publication or form)(Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER TM ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE TABLE NO. NO. DATE 0 Mar RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). TITLE

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

TM

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE DATE

0 Mar

PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

ITEM NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

DATE

TO: (Forward to proponent of publication or form)(Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER TM ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE TABLE NO. NO. DATE 0 Mar RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). TITLE

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

TM

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE DATE

0 Mar

PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

ITEM NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

DATE

TO: (Forward to proponent of publication or form)(Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER TM ITEM NO. PAGE NO. PARAGRAPH LINE NO. * FIGURE TABLE NO. NO. DATE 0 Mar RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible). TITLE

*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE
TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

FROM: (Activity and location) (Include ZIP Code)

DATE

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

TM

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE DATE

0 Mar

PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER

ITEM NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

By Order of the Secretary of the Army:

Official:

GEORGE W. CASEY, JR. General, United States Army Chief of Staff

JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1103409 Distribution: To be distributed in accordance with the Initial Distribution Number (IDN) 257856 requirements for TM 5-3805-294-10.

THE METRIC SYSTEM AND EQUIVALENTS LINEAR MEASURE 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles WEIGHTS 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Lb 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons LIQUID MEASURE 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces SQUARE MEASURE 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles CUBIC MEASURE 1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet TEMPERATURE 5/9 ( F - 32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius 9/5 C + 32 = F

APPROXIMATE CONVERSION FACTORS

TO CHANGE

TO

MULTIPLY BY

INCHES

1 CM 2

Inches . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . Miles . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . Square Feet . . . . . . . . . . . . Square Yards . . . . . . . . . . . Square Miles . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . Pounds . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . Pounds/Sq Inch . . . . . . . . . Miles per Gallon . . . . . . . . Miles per Hour . . . . . . . . . .

Centimeters . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . . . Square Centimeters . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . Square Kilometers . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . . . Kilometers per Liter . . . . . . . . . . . . Kilometers per Hour . . . . . . . . . . .

2.540 0.305 0.914 1.609 6.451 0.093 0.836 2.590 0.405 0.028 0.765 29.573 0.473 0.946 3.785 28.349 0.454 0.907 1.356 6.895 0.425 1.609

1 3 4 5 2 3 8 6 7

TO CHANGE

TO

MULTIPLY BY

Centimeters . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . Sq Centimeters . . . . . . . . . Square Meters . . . . . . . . . . Square Meters . . . . . . . . . . Square Kilometers . . . . . . Sq Hectometers . . . . . . . . Cubic Meters . . . . . . . . . . . .. Cubic Meters . . . . . . . . . . . Milliliters . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . Metrication . . . . . . . . . . . . . Newton-Meters . . . . . . . . . Kilopascals . . . . . . . . . . . . . Km per Liter . . . . . . . . . . . . Km per Hour. . . . . . . . . . . .

Inches . . . . . . . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . . . Miles. . . . . . . . . . . . . . . . . . . . . . . . . Square Inches . . . . . . . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . . Square Miles . . . . . . . . . . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . . . Cubic Feet . . . . . . . . . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . . . Pounds. . . . . . . . . . . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . .

0.394 3.280 1.094 0.621 0.155 10.764 1.196 0.386 2.471 35.315 1.308 0.034 2.113 1.057 0.264 0.035 2.205 1.102 0.738 0.145 2.354 0.621

10

4 5 6

11 12 13 14 15

PIN 086698-000