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TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
TM 5-3805-294-10
WARNING SUMMARY
This warning summary contains general safety and hazardous materials warnings that must be understood and
applied during operation and maintenance of the machine. Failure to observe these precautions or operating this
machine without training or instruction may result in serious injury or death to personnel.
FIRST AID
First aid is defined as "urgent and immediate lifesaving and other measures, which may be performed for casualties
by nonmedical personnel when medical personnel are not immediately available."
FOR FIRST AID INFORMATION, REFER TO FM 4-25.11.
EXPLANATION OF SAFETY WARNING ICONS
AIR PRESSURE - Human hand blocking air gun shows the need to reduce air
pressure before use, or debris may injure user and/or damage equipment.
BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria
or viruses that present a danger to life or health.
EAR PROTECTION - Headphones over ears show that noise level will harm ears.
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.
TM 5-3805-294-10
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.
TM 5-3805-294-10
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 DESCRIPTIONS
TM 5-3805-294-10
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
TM 5-3805-294-10
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
TM 5-3805-294-10
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.
TM 5-3805-294-10
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.
TM 5-3805-294-10
WARNING SUMMARY
2. DO NOT idle engine without adequate ventilation.
3. DO NOT drive machine with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
Headache
Dizziness
Sleepiness
Notify a Medic
TM 5-3805-294-10
07 March 2011
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TM 5-3805-294-10
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.
i/ii blank
TM 5-3805-294-10
TABLE OF CONTENTS
Page No.
WP Sequence No.
How to Use this Manual
Chapter 1 - OPERATOR GENERAL INFORMATION
GENERAL INFORMATION.......................................................................................................................... WP 0001
Table 1.
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.
Table 1.
Figure 2.
Table 2.
Figure 3.
Table 3.
iii
TM 5-3805-294-10
Table 4.
Figure 5.
Table 5.
Figure 6.
Table 6.
Figure 7.
Table 7.
Figure 8.
Table 8.
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.
iv
TM 5-3805-294-10
Table 7.
Figure 11.
Table 8.
Figure 12.
Table 9.
Figure 13.
Table 10.
Figure 14.
Figure 1.
Monitor................................................................................................................................. 0005-1
Figure 2.
Figure 3.
Figure 4.
Table 2.
Figure 5.
Figure 6.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
TM 5-3805-294-10
Figure 8.
Figure 9.
Figure 10.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Counter-Rotate..................................................................................................................... 0008-5
Figure 2.
Figure 3.
Figure 4.
Figure 5.
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED................................................. WP 0010
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 2.
vi
TM 5-3805-294-10
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
vii
TM 5-3805-294-10
Figure 10.
Figure 11.
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Trenching............................................................................................................................. 0016-6
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 2.
Figure 3.
viii
TM 5-3805-294-10
Figure 2.
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.
Figure 2.
Figure 3.
ix
TM 5-3805-294-10
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.
Figure 2.
TM 5-3805-294-10
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 2.
Figure 3.
xi
TM 5-3805-294-10
Figure 5.
Figure 2.
Figure 3.
Figure 4.
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.
xii
TM 5-3805-294-10
Figure 21.
Figure 22.
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Counterweight...................................................................................................................... 0027-4
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Windshield............................................................................................................................ 0027-6
Figure 12.
Figure 13.
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
xiii
TM 5-3805-294-10
Figure 20.
Figure 21.
Figure 22.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Table 1.
Figure 10.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
xiv
TM 5-3805-294-10
Table 1.
Figure 10.
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................... WP 0033
Figure 1.
Figure 2.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 2.
Figure 3.
xv
TM 5-3805-294-10
xvi
TM 5-3805-294-10
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
xvii
TM 5-3805-294-10
Batteries............................................................................................................................. 0077-13
Figure 14.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Figure 19.
Figure 20.
Figure 21.
Figure 22.
Figure 23.
Monitor............................................................................................................................... 0077-21
Figure 24.
Figure 25.
Figure 26.
Breaker............................................................................................................................... 0077-23
Figure 27.
Compactor.......................................................................................................................... 0077-24
Figure 28.
Crush-All............................................................................................................................. 0077-25
Figure 29.
Figure 30.
Figure 31.
Figure 32.
Figure 33.
Figure 34.
Figure 35.
Figure 36.
Figure 37.
Figure 38.
Figure 39.
xviii
TM 5-3805-294-10
Figure 41.
Figure 42.
Figure 43.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
xix
TM 5-3805-294-10
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 2.
Figure 3.
Figure 2.
Figure 3.
xx
TM 5-3805-294-10
Figure 5.
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 3.
Figure 4.
Figure 2.
Figure 3.
Figure 4.
Table 2.
xxi
TM 5-3805-294-10
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.
xxii
TM 5-3805-294-10
Crush-All............................................................................................................................. 0100-18
Figure 24.
Compactor.......................................................................................................................... 0100-18
Figure 25.
Figure 26.
Figure 27.
Figure 28.
Figure 29.
Figure 30.
Figure 31.
Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.................... 0100-22
Figure 32.
Index
xxiii/xxiv blank
TM 5-3805-294-10
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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TM 5-3805-294-10
CHAPTER 1
OPERATOR GENERAL INFORMATION
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0001
OPERATOR MAINTENANCE
GENERAL INFORMATION
SCOPE
This manual contains instructions for operation, operator troubleshooting, and operator-performed maintenance on
the Hydraulic Excavator Type 1 (HYEX). The HYEX is used for construction operations.
MAINTENANCE FORMS AND RECORDS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094); or
AR 700-138, Army Logistics Readiness and Sustainability (WP 0094).
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your HYEX needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you 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).
0001-1
TM 5-3805-294-10
LIST OF ABBREVIATIONS/ACRONYMS
Table 1. List of Abbreviations/Acronyms.
Abbreviation/Acronym
Description
AAL
A/C
Air Conditioning
ACC
Accessory
AEPS
A/I or A.I.
Auto-Idle
AOAP
BII
CAGEC
cm
Centimeter
COEI
CPC
CTA
Economy
ECU
EDRS
EIR
FC
Full-Cool
FH
Full-Heat
ft
Feet
gal
Gallon
Hour
HET
hp
Horsepower
H/P
High Power
0001-2
0001
TM 5-3805-294-10
LIST OF ABBREVIATIONS/ACRONYMS - Continued
Table 1.
HYEX
Hydraulic Excavator
in.
Inch
INT
Intermittent
kg
Kilogram
kohm
Kilo ohm
Liter
L/h
Liter/hour
Meter
mm
Millimeter
Power
PMCS
P/N
Part Number
psi
QDR
TAMMS
0001-3/4 blank
0001
TM 5-3805-294-10
0002
OPERATOR MAINTENANCE
EQUIPMENT DESCRIPTION AND DATA
0002-1
TM 5-3805-294-10
0002
Attachments
The HYEX digging and loading attachments are as follows:
Heavy Duty Bucket (for general purpose excavating and in material, such as dense clay and light rock) with
heaped capacity of 1.5 sq yd (1.25 sq m), a 42 in. (107 cm) outside lip width, and five pick-shaped pointed
teeth.
Heavy Duty Bucket (for use with the deep digging attachment) with heaped capacity of 0.5 sq yd (0.41 sq
m), 30 in. (76 cm) outside lip width, and four pick-shaped pointed teeth.
Ditch Cleaning Bucket (Utility) with heaped capacity of 1.33 sq yd (1.11 sq m), 60 in. (152 cm) outside lip
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.
0002-2
TM 5-3805-294-10
0002
6
8
9
HYEX00104
Figure 1.
Table 1.
FUEL TANK. Contains JP-8, diesel, or other NATO-approved fuels for engine operation.
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.
ATTACHMENT CYLINDER. Curls the bucket while digging and allows for dumping.
0002-3
TM 5-3805-294-10
0002
20
17
10
16
11
19
12
16
18
15
13
Figure 2.
Table 2.
14
HYEX00105
10
11
12
BATTERIES. Two 12-volt batteries provide current for the electrical system.
13
CAB. All digging and travel functions are controlled by the operator.
14
TRAVEL MOTORS. Drives the machine forward or backward and provides turning capability.
15
16
17
HYDRAULIC THUMB. Used with the bucket attachment to clamp and lift.
18
19
20
HYDRAULIC HOSE REEL. Quick attach hose reel used to power hydraulic tools and accessories.
0002-4
TM 5-3805-294-10
0002
IDENTIFICATION PLATES
Maintain, in a secure location, an up-to-date inventory of all product and component serial numbers.
Regularly verify that identification plates have not been removed. Report any evidence of tampering to appropriate
agencies and order duplicate plates.
Mark your machine with your own numbering system and take color photographs from several angles of each plate.
22
21
HYEX01506
Figure 3.
Table 3.
Data Plates.
Data Plates.
21
IDENTIFICATION PLATE. The identification plate has the model, serial number, registration number,
manufacture's name and the warranty information on it.
22
0002-5
TM 5-3805-294-10
EQUIPMENT DATA
Table 4.
Equipment Data.
ENGINE:
Model
PowerTech
Manufacturer
John Deere
Number of Cylinders
Displacement
CAPACITIES:
Fuel Tank
Cooling System
Hydraulic Reservoir
Hydraulic System
74 gal (280 L)
Swing Gearbox
1.2 qt (1.1 L)
0002-6
0002
TM 5-3805-294-10
0002
12
3
7
1
8
2
10
11
HYEX00106
Figure 4.
Table 5.
HYEX Specifications.
HYEX Specification.
ITEM
DESCRIPTION
MEASUREMENT
SPECIFICATION
Distance
Undercarriage
Length
Counterweight Clearance
Distance
Distance
Distance
Cab
Height
Distance
Distance
Track Shoes
Width
10
Undercarriage
Width
11
Machine
Overall Length
12
Machine
Transport Height
13
Machine
Shipping Weight
0002-7
TM 5-3805-294-10
0002
2
6
HYEX00107
0002-8
TM 5-3805-294-10
0002
ITEM
DESCRIPTION
MEASUREMENT
SPECIFICATION
Distance
Distance
Radius
Height
Height
Depth
Depth
Depth
Radius
0002-9
TM 5-3805-294-10
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.
5 (1.52)
10 (3.05)
15 (4.57)
20 (6.10)
20 (6.10)
25 (7.62)
30 (9.14)
7.55 lb
(3.42 kg)*
15 (4.57)
8.52 lb
(3.86 kg)*
8.61 lb
(3.90 kg)*
6.26 lb
(2.84 kg)*
10 (3.05)
14.69 lb
(6.66 kg)*
11.56 lb
(5.24 kg)*
10.05 lb
(4.56 kg)*
8.09 lb
(3.66 kg)*
5 (1.25)
20.76 lb
(9.41 kg)*
14.49 lb
(6.57 kg)*
11.62 lb
(5.27 kg)*
9.68 lb
(4.39 kg)
Ground Line
24.56 lb
(11.14 kg)*
16.88 lb
(7.65 kg)*
12.79 lb
(5.80 kg)
9.46 lb
(4.29 kg)
13.06 lb
(5.92 kg)*
25.71 lb
(11.66 kg)*
17.90 lb
(8.11 kg)
12.48 lb
(5.66 kg)
9.31 lb
(4.22 kg)
22.51 lb
(10.21 kg)*
25.00 lb
(11.33 kg)*
17.77 lb
(8.06 kg)
12.39 lb
(5.62 kg)
29.63 lb
(13.43 kg)*
22.54 lb
(10.22 kg)*
16.71 lb
(7.57 kg)*
12.31 lb
(5.58 kg)
17.28 lb
(7.83 kg)*
12.10 lb
(5.48 kg)*
-5 (-1.52)
-10 (-3.05)
-15 (-4.57)
-20 (6.10)
15.60 lb
(7.07 kg)*
0002-10
TM 5-3805-294-10
0002
Table 8.
5 (1.52)
10 (3.05)
15 (4.57)
20 (6.10)
20 (6.10)
25 (7.62)
30 (9.14)
7.55 lb
(3.42 kg)*
15 (4.57)
8.52 lb
(3.86 kg)*
8.61 lb
(3.90 kg)*
6.26 lb
(2.84 kg)*
10 (3.05)
14.69 lb
(6.66 kg)*
11.56 lb
(5.24 kg)*
8.88 lb
(4.02 kg)
6.29 lb
(2.85 kg)
5 (1.52)
18.90 lb
(8.57 kg)
12.10 lb
(5.48 kg)
8.39 lb
(3.80 kg)
6.04 lb
(2.73 kg)
Ground Line
17.62 lb
(7.99 kg)
11.35 lb
(5.14 kg)
7.96 lb
(3.61 kg)
5.81 lb
(2.63 kg)
13.06 lb
(5.92 kg)*
17.16 lb
(7.78 kg)
10.92 lb
(4.95 kg)
7.68 lb
(3.48 kg)
5.67 lb
(2.57 kg)
22.51 lb
(10.21 kg)*
17.15 lb
(7.77 kg)
10.80 lb
(4.89 kg)
7.59 lb
(3.44 kg)
29.63 lb
(13.44 kg)*
17.46 lb
(7.91 kg)
10.96 lb
(4.97 kg)
7.77 lb
(3.52 kg)
17.28 lb
(7.83 kg)*
11.53 lb
(5.22 kg)
-5 (-1.52)
-10 (-3.05)
-15 (-4.57)
-20 (6.10)
15.60 lb
(7.07 kg)*
0002-11
TM 5-3805-294-10
0002
Machine Weight
Total weight
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
Total Weight
0002-12
TM 5-3805-294-10
0003
OPERATOR MAINTENANCE
THEORY OF OPERATION
SCOPE
This section explains how components of the HYEX work together. A functional description is given for the engine,
Electronic Control Unit (ECU), fuel system, cooling system, electrical system, and hydraulic system.
Engine
The engine is a John Deere 6068H PowerTech Plus, 6.8L, 6-cylinder diesel engine. The 6068H includes a
turbocharger, electronic control unit, 4-valve per cylinder head, electronic fuel injectors, and a high-pressure common
rail fuel system. The 6068H is air-to-air after cooled to help reduce exhaust emissions while maintaining low-speed
torque. The engine application includes a hydraulically-driven cool-on-demand fan system.
ECU
The electronic control system serves as an engine governor, controlling the engine speed by delivering fuel, in
precise amounts, and at precise time according to a given set of engine conditions in relation to piston position. In
order to achieve this, the control system performs the following functions:
Constantly monitors engine operating conditions
Performs system diagnosis
Notify operator of machine faults through the monitor
Can derate or shut down engine to prevent damage
0003-1
TM 5-3805-294-10
0003
ECU - Continued
Electrical System
5
1
HYEX01511
Batteries
The batteries provide power for the electrical circuits. Two 12-volt batteries are
connected in series to provide 24-volt starting power.
Alternator
The alternator provides 28-volt, 80-amp. current to charge the batteries and
operate the electrical system.
Starter Motor
Part of the starting circuit, the starter motor is used to turn the engine flywheel
fast enough to start the engine.
Slave Receptacle
The slave receptacle can be used to charge the batteries and slave start the
engine from an external power source. The slave receptacle can also be used
to charge and slave start other equipment.
Fuse Panel
The fuse panel provides centrally located fuses that will open the battery circuit
if there is a shorted, grounded wire or excessive current draw by a defective
component in the corresponding circuit. When the circuit is open, no current
will flow through the electrical system. Fuses are easily replaced. If a fuse
continually trips, the affected component or vehicle electrical system requires
repair.
0003-2
TM 5-3805-294-10
0003
Hydraulic System
10
11
14
13
15
9
16
12
17
HYEX01512
Figure 2.
Table 2.
Main Pumps
The HYEX has two main hydraulic pumps that supply hydraulic oil for all
functions including boom, arm, bucket, swing, and travel.
Pilot Pump
The pilot pump is a small gear pump that keeps oil moving through the pilot
system. It also provides the pressure to move the spools in the main hydraulic
valve and to release the spring-applied hydraulically-released swing and park
brakes.
Hydraulic Reservoir
The control valve consists of two monoblock valves referred to as the left control
valve and right control valve. There is a spool in each valve to control the boom,
arm, and travel functions. All other functions are supplied by a single spool in
one or the other of the valves. All spools are moved by pilot oil. Each valve
section controls the flow rate and direction for its hydraulic circuit.
0003-3
TM 5-3805-294-10
0003
10
11
14
13
15
9
16
12
17
HYEX01512
10
The pilot signal manifold is in the pilot system between the pilot control valves
and the control valve and regulators. The manifold receives a pilot signal from
the pilot control valves and sends the signal on multiple paths simultaneously
so there is little lag between operation of the pilot control valves, pump stroke,
and function movement.
11
Swing Motor
The swing motor uses hydraulic pressure supplied by the pumps to make the
upper structure rotate. It has a spring-applied hydraulically-released swing
brake. The swing brake engages as soon as the swing controls are released.
12
Rotary Manifold
The rotary manifold allows the upper structure of the machine to rotate relative
to the undercarriage while still supplying hydraulic oil to the travel motors.
13
Boom Cylinders
The boom cylinders are attached to the main frame and the boom. When
activated they raise and lower the boom.
14
Arm Cylinder
The arm cylinder is attached between the boom and the arm. When activated,
this cylinder moves the arm in and out.
0003-4
TM 5-3805-294-10
0003
15
Hydraulic Thumb
Cylinder
The hydraulic thumb cylinder is attached between the arm and the thumb.
When activated, this cylinder extends and retracts the hydraulic thumb. The
hydraulic thumb cylinder circuit can be closed to provide the hydraulic power
to operate the crush-all, breaker, compactor and deep dig arm accessories.
16
Bucket Cylinder
The bucket cylinder is attached between the arm and the quick latch. When
activated, this cylinder extends and curls the bucket or attachments.
17
Reduced leakage valves are used in the boom head-end circuit and arm rodend circuit. The function of a reduced leakage valve is to reduce cylinder drift
by stopping leakage from the cylinder back through the control valve.
Powertrain
21
18
20
19
HYEX01513
Figure 4.
Table 4.
Powertrain Components.
Powertrain Components.
18
The track chain adjuster is located between the frame and the track chain idler.
Grease is added or removed to adjust the track sag. The recoil spring is located
with the track chain adjuster and absorbs shocks to the tracks and track chain
idler.
19
Track
The track assembly consists of the chain and shoes. The travel motor drives
the track to move the machine.
20
Rollers
The machine has two carrier rollers and nine lower track rollers on each side
of the machine. The rollers guide the tracks and keep the tracks in contact with
the ground.
21
Travel Motor
The travel motors are located inside the tracks to prevent damage during
operation. The travel system has a spring-applied hydraulically-released
parking brake. The parking brake engages as soon as the travel controls are
released.
0003-5
TM 5-3805-294-10
0003
Fuel System
22
24
27
23
25
26
HYEX01514
28
Figure 5. Fuel System Components.
Table 5.
22
The fuel transfer pump pulls fuel from the fuel tank through the water separator
and sends it through the fuel filters to the high-pressure fuel injection pump.
23
Primary Fuel/Water
Separator
The primary water separator keeps large particles and contaminants from
entering the high-pressure fuel pump.
24
Secondary Fuel/Water
Separator
The secondary water separator keeps small particles and contaminants from
entering the pressure fuel pump.
25
Lubricity Canister
The lubricity canister is a spin-on canister with a lubricant that is slowly released
into the fuel. To enable use of all types of diesel fuels.
26
Fuel Tank
The fuel tank has 132 gal (500 liter) capacity and is equipped with a low fuel
level alarm and vented fill cap.
27
The strainer is designed to keep debris from entering the fuel system.
28
The drain valve is used to remove water and debris from the fuel tank.
0003-6
TM 5-3805-294-10
0003
30
29
HYEX01515
Figure 6.
Table 6.
29
High-Pressure Fuel
Pump
The high-pressure fuel pump increases the fuel pressure to send exact
amounts of fuel to the injector nozzles.
30
Fuel Injectors
The fuel injectors turn the stream of fuel into a fine spray, which permits good
combustion in the cylinder. There is one nozzle for each cylinder. The injectors
are located under the rocker arm cover.
0003-7
TM 5-3805-294-10
0003
31
33
32
34
HYEX01516
Figure 7.
Table 7.
Cooling Package.
Cooling Package.
31
Radiator
Coolant circulates through the radiator to be cooled after leaving the cylinder
block.
32
The hydraulic oil cooler uses air from the fan to cool the oil before returning it
to the reservoir.
33
The charge air cooler cools the air supplied to the engine to decrease fuel
consumption and emissions.
34
Fuel Cooler
0003-8
TM 5-3805-294-10
0003
Cooling - Continued
35
36
37
HYEX01517
Figure 8.
Table 8.
35
The coolant surge tank is where the coolant level is checked and added.
36
Coolant from the radiator passes through the engine oil cooler to maintain a
safe operating temperature.
37
Fan
The variable speed fan is located at the front of the engine and is driven by a
hydraulic motor. The speed of the fan is varied to provide the amount of airflow
that the engine coolant, charge air cooler, or hydraulic cooler need, ensuring
maximum fuel efficiency, reduced noise levels, and faster engine warm up. A
reversing function reverses the cooling fan to help clean the cooling package
of dirt and debris.
0003-9/10 blank
TM 5-3805-294-10
CHAPTER 2
OPERATOR INSTRUCTIONS
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0004
OPERATOR MAINTENANCE
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
INTRODUCTION
The following tables and illustrations provide the description and use of the controls and indicators pertaining to the
front switch panel, heater and air conditioner control panel, control pedals and levers, left console, left and right
control levers, seat controls and arm rest, coolant heater and cab door, and warning indicators and alarms.
Table 1.
4
5
1
Figure 1.
HYEX00867
Key
Control/Indicator
Function
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.
Operating Lights
Switch
This is a three-position switch. The first position turns on the drive light. Front
Switch panel will also illuminate. The second position turns on the boom work
lights, the front cab work lights, and the drive light. If the default screen on the
monitor is displayed, the background goes from white to black.
0004-1
TM 5-3805-294-10
0004
Control/Indicator
Function
4
5
1
Figure 2.
HYEX00867
Auto-Idle (A/I)
Switch
This is a two-position switch. In the ON position, it will reduce the engine speed
after 4 seconds when control levers are in the neutral position. In the OFF
position the operator can set the engine speed to improve machine control.
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.
Key Switch
This is a four-position switch. When in the OFF position, the key can be
removed. Moving the switch to the ACC position allows the radio to be turned
on or off. In the ON position, all electrical functions will operate. Move and
release the switch to the START position starts the machine.
0004-2
TM 5-3805-294-10
Table 2.
0004
15 14 13
10
12
11
HYEX00868
17
Control/Indicator
Function
Increases or decreases the speed of the blower fans. Turns on blower fans
when A/C is off.
Monitor Display
Displays blower fan speed, selected air vent, and temperature setting.
10
A/C Button
When pressed, it turns on the air conditioning (A/C) and illuminates the A/C
indicator.
11
AUTO Button
When pressed, it turns on the AUTO and A/C indicators. Air flow-in temperature
at the vent, blower fan speed, vent locations, and fresh air port are then
automatically controlled.
0004-3
TM 5-3805-294-10
0004
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
15 14 13
10
12
11
HYEX00868
17
Temperature
Control Buttons
Press buttons to set temperature from full-cool (FC) to full-heat (FH). The
monitor display will show FC or FH.
14
Recirculating Mode
Button
Press the recirculating mode button to close the fresh air vent and circulate air
already in the cab.
15
Press fresh air mode to route outside air into the cab.
16
Mode Button
Press to select air vent. Selected vent will display on the monitor display.
17
Radio Display
The radio display contains standard AM/FM radio tuning and volume controls.
0004-4
TM 5-3805-294-10
Table 3.
22
23
0004
21
20
18
19
HYEX00869
Figure 5.
Key
Control/Indicator
Function
18
Attachment Pedal
Primarily used to open and close the hydraulic thumb. When attachments are
connected, hydraulic valve selection will disable the hydraulic thumb and
enable this pedal to operate the attachment.
19
Attachment Pedal
Lock
Locks attachment pedal in the neutral position to disable the hydraulic thumb
or any attachments that are connected.
20
Controls the direction of travel and steers the machine. Pushing down on the
top of the pedal moves the machine forward. Pushing down on the bottom of
the pedal moves the machine backwards.
21
Use this hand lever to perform the same functions as the right travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.
0004-5
TM 5-3805-294-10
Table 3.
0004
Key
Control/Indicator
Function
22
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
Use this hand lever to perform the same functions as the left travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.
0004-6
TM 5-3805-294-10
Table 4.
0004
24
25
26
27
28
HYEX00870
Control/Indicator
Function
24
Controls hydraulic functions on the machine. With the lever in the locked
position, hydraulic functions are not operational. In the unlocked position, all
hydraulic functions operate. The engine will not start with the lever in the
unlocked position.
25
After the initial 13-second alarm, depressing the right half of the switch will shut
the alarm off.
26
27
Auxiliary Control
Switch
Disables the right joystick left and right button auxiliary function.
28
Reversing Cooling
Fan Switch
This is a three position switch that controls the direction that the cooling fan is
moving. AUTO: Every 60 minutes the cooling fan will automatically reverse
direction for 15 seconds without intervention from the operator. OFF Fan
resumes normal operation. MANUAL: Fan will reverse direction for 15 seconds
when right portion of switch is pressed.
0004-7
TM 5-3805-294-10
Table 5.
0004
31
32
30
29
HYEX00871
Figure 8.
Key
Control/Indicator
Function
29
When pushed forward, the boom lowers. When pulled back, the boom raises.
When pulled left, the bucket will curl. When pushed right, the bucket will dump.
When released the lever will return to the neutral position.
30
Pressing the power dig button gives the operator an 8-second increase in
hydraulic power.
31
32
Right Button
Auxiliary Function
0004-8
TM 5-3805-294-10
0004
Control/Indicator
Function
33
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
0004-9
TM 5-3805-294-10
Table 6.
0004
Seat Controls.
39
40
35
38
37
36
41
HYEX00873
Figure 10.
Seat Controls.
Key
Control/Indicator
Function
35
36
Seat Adjustment
Handle
37
Seat Weight
Adjustment Knob
Turn knob to adjust seat suspension to the proper weight of the operator.
38
Lumbar Adjustment
Squeeze ball to add air for desired lumbar firmness. Press button next to ball
to release air.
0004-10
TM 5-3805-294-10
Table 6.
0004
Key
Control/Indicator
Function
39
Backrest
Adjustment Lever
Pull up lever to release backrest and adjust to desired position, then release
lever.
40
Armrest Angle
Adjustment
41
Seat Assembly
Adjustment Lever
Pull handle to slide entire seat to desired distance from travel pedals.
0004-11
TM 5-3805-294-10
Table 7.
0004
43
44
45
46
47
48
42
HYEX00874
Figure 11. Cab Door Release Lever and Coolant Heater Display.
Key
Control/Indicator
Function
42
Push down to release cab door from the locked open position.
43
Coolant Heater
Display
44
Clock Button
Pressing button displays date and time and allows to change date and time
settings.
45
Preset Button
Press the preset button to program the desired time to start cycle.
46
Heat Display
47
Lower Button
0004-12
TM 5-3805-294-10
Table 7.
0004
Key
Control/Indicator
Function
48
Raise Button
Table 8.
49
50
HYEX00875
Figure 12.
Key
Control/Indicator
Function
49
50
0004-13
TM 5-3805-294-10
Table 9.
0004
51
HYEX01316
Figure 13.
Key
Control/Indicator
Function
51
Cab light has a two-position switch that turns the light on and off. It will only
illuminate with the key switch turned on. (Not present when armored cab is
installed).
0004-14
TM 5-3805-294-10
Table 10.
0004
52
54
53
55
HYEX00876
Figure 14.
Key
Control/Indicator
Function
52
53
Hydraulic Tool
Circuit Switch
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.
0004-15/16 blank
TM 5-3805-294-10
0005
OPERATOR MAINTENANCE
DESCRIPTION AND USE OF MONITOR AND ALARMS
INTRODUCTION
The following tables and illustrations provide the description and use of the monitor buttons, indicators, and warning
indicators.
Table 1.
7777.7 h
F1
F2
F3
F4
17.3 L/h
8:01
1
F1
F2
F3
F4
Figure 1.
HYEX00858
Monitor.
Key
Control/Indicator
Function
Button 1
Button 2
Button 3
Button 4
Button 5
0005-1
TM 5-3805-294-10
Table 1.
0005
Key
Control/Indicator
Function
Button 6/Return to
Default Screen
Button
A.I.
7777.7 h
F1
F2
F3
F4
17.3 L/h
11
8:01
1
F1
F2
F3
F4
12
13
14
8
Figure 2.
10
HYEX00859
Monitor Buttons.
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.
10
Press button to key in the number 0 or to select the desired preset optional
function from any screen.
11
Select Button
12
Back Button
0005-2
TM 5-3805-294-10
Table 1.
0005
Key
Control/Indicator
Function
13
Without key inserted or with key switch OFF, press and hold button to display
default screen and hour meter.
14
Alarm Indicator
Light
Main Menu
Time Set
Attachment Adjustment
Operating Conditions
Maintenance Settings
F1
F2
F3
F4
15
HYEX01319
Figure 3.
15
Menu Button
Main Menu.
Press button to display main menu from any screen. Main menu includes time
set, attachment adjustment, operating conditions, and maintenance settings.
0005-3
TM 5-3805-294-10
Table 1.
0005
Key
Control/Indicator
Function
16
Coolant
Temperature Gauge
Indicates the engine coolant temperature. Needle should be around the center
of the scale during operation.
17
18
19 20 21 22
24
A.I.
7777.7 h
23
25
F1
F2
F3
F4
28
17.3 L/h
8:01
16
1
29
27
F1
F2
F3
F4
26
HYEX00860
30
Figure 4.
Monitor Indicators.
17
Work Mode
Indicator
18
Auto-Idle Indicator
When selecting auto-idle from the front switch panel, the auto-idle icon
displays.
19
Auxiliary Indicator
20
Auxiliary Indicator
21
Auxiliary Indicator
22
Engine Preheat
Indicator
23
Hour Meter
Total machine operation hours counted since the machine started working are
displayed in the unit of hour (h). One digit after the decimal point indicates
tenths of an hour (6 minutes).
0005-4
TM 5-3805-294-10
Table 1.
Key
Control/Indicator
Function
24
F1 Function Button
Indicator
25
F2 Function Button
Indicator
26
F3 Function Button
Indicator
27
F4 Function Button
Indicator
28
Fuel Gauge
29
30
Clock
0005-5
0005
TM 5-3805-294-10
Table 2.
31
0005
33
32
36
35
34
39
37
38
HYEX00861
Figure 5.
Key
Control/Indicator
Function
31
Engine Overheat
Alarm
32
Engine Warning
Alarm
33
34
Alternator Alarm
0005-6
TM 5-3805-294-10
0005
Control/Indicator
Function
35
Remaining Fuel
Alarm
36
37
38
39
40
HYEX00862
Figure 6.
40
Overload Alarm
Overload Alarm.
0005-7/8 blank
TM 5-3805-294-10
0006
OPERATOR MAINTENANCE
ADJUSTING THE OPERATOR'S SEAT
INITIAL SETUP:
Not Applicable
ADJUSTMENT
NOTE
Proper seat adjustment is achieved when operator can reach the foot control pedals and the
travel levers easily with the seat belt buckled.
1.
Push down on handle (Figure 1, Item 1) to tilt seat (Figure 1, Item 2).
13
11
10
12
2
6
1
7
3
4
Figure 1.
HYEX00145
2.
3.
4.
Push on lever (Figure 1, Item 5) to slide seat (Figure 1, Item 2) and controls (Figure 1, Item 6).
0006-1
TM 5-3805-294-10
ADJUSTMENT - Continued
5.
6.
7.
8.
9.
10.
Turn dial (Figure 1, Item 12) on underside of armrest (Figure 1, Item 13) to adjust angle.
END OF TASK
END OF WORK PACKAGE
0006-2
0006
TM 5-3805-294-10
0007
OPERATOR MAINTENANCE
STARTING THE ENGINE
INITIAL SETUP:
Equipment Condition
Before operations Preventive Maintenance Checks
and Services performed. (WP 0077)
Operators seat adjusted. (WP 0006)
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.
HYEX00090
Figure 1.
Seat Belt.
NOTE
Engine will not start unless pilot shutoff lever is in the LOCKED (up) position.
2.
0007-1
TM 5-3805-294-10
0007
HYEX00091
Figure 2.
3.
HYEX00092
Figure 3.
4.
0007-2
TM 5-3805-294-10
0007
HYEX00093
Figure 4.
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
F1
F2
F3
F4
HYEX00094
Figure 5.
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.
0007-3
TM 5-3805-294-10
0007
7777.7 h
F1
F2
F3
F4
17.3 L/h
8:01
1
F1
F2
F3
F4
HYEX00095
Figure 6.
Preheat Indicator.
CAUTION
Never operate starter longer than 20 seconds at a time. If engine fails to start, return key
switch to OFF position and wait 2 minutes before attempting to start again. Failure to
comply may result in damage to equipment.
After a false start, wait until engine stops spinning before turning the key again. Failure
to comply may result in damage to equipment.
NOTE
Key switch will return to ON position when key is released.
7.
Turn key switch (Figure 7, Item 4) to START position and release when engine starts.
HYEX00099
0007-4
TM 5-3805-294-10
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.
Turn engine speed dial (Figure 10, Item 3) to slow idle position until machine reaches normal operating
temperature.
0007-5
TM 5-3805-294-10
0007
HYEX00092
0007-6
TM 5-3805-294-10
0008
OPERATOR MAINTENANCE
MOVING THE HYEX
INITIAL SETUP:
Equipment Condition
Engine running. (WP 0007)
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.
0008-1
TM 5-3805-294-10
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.
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.
HYEX00148
NOTE
Travel speed of machine is controlled by the foot pedals or travel levers.
0008-2
TM 5-3805-294-10
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.
HYEX01297
Figure 4.
5.
Push down on the rear of both foot pedals (Figure 4, Items 5 and 6) or pull both travel levers (Figure 4, Items
7 and 8) to move the HYEX backwards.
6.
Allowing both foot pedals (Figure 4, Items 5 and 6), or both travel levers (Figure 4, Items 7 and 8) to return to
center, will stop the HYEX.
END OF TASK
STEERING THE HYEX
WARNING
Keep personnel clear of the machine when traveling. Failure to comply may result in injury
or death to personnel.
Use care when backing the machine. Watch clearances. Have an assistant direct you if
you cannot see where you are going. Failure to comply may result in injury or death to
personnel.
NOTE
If travel motors are at the front of the machine, the machine moves in opposite direction as
described in these procedures.
0008-3
TM 5-3805-294-10
0008
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.
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.
HYEX01295
Figure 6.
3.
Left Turn.
Pushing front of left foot pedal (Figure 7, Item 6), or push left travel lever (Figure 7, Item 8) forward and push
down on rear of right foot pedal (Figure 7, Item 7) or pull right travel lever (Figure 7, Item 8) back to counterrotate.
0008-4
TM 5-3805-294-10
0008
HYEX01291
Figure 7.
4.
Counter-Rotate.
Allowing both foot pedals (Figure 7, Items 5 and 6) or both travel levers (Figure 7, Items 7 and 8) to return to
center will stop the HYEX.
END OF TASK
END OF WORK PACKAGE
0008-5/6 blank
TM 5-3805-294-10
0009
OPERATOR MAINTENANCE
SHUTTING DOWN THE HYEX
INITIAL SETUP:
References
WP 0004
References (cont.)
WP 0011
WP 0010
4
1
HYEX02418
Figure 1.
NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2.
Keeping angle between arm (Figure 1, Item 2) and boom (Figure 1, Item 3), position flat side of bucket (Figure
1, Item 4) on the ground. (WP 0004)
END OF TASK
SHUT DOWN ENGINE
1.
If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.
0009-1
TM 5-3805-294-10
0009
HYEX00153
Figure 2.
CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may
result in damage to equipment.
NOTE
Engine speed dial shown approximately at 1/3 position.
2.
Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.
3.
0009-2
TM 5-3805-294-10
0009
HYEX00154
Figure 3.
4.
HYEX00155
Figure 4.
5.
Turn key switch (Figure 5, Item 8) to OFF position and remove key.
0009-3
TM 5-3805-294-10
0009
HYEX00157
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.
END OF TASK
END OF WORK PACKAGE
0009-4
TM 5-3805-294-10
0010
OPERATOR MAINTENANCE
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED
INITIAL SETUP:
References
WP 0004
WP 0011
Equipment Condition
Engine running. (WP 0007)
3
1
4
HYEX01637
Figure 1.
NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2.
Keeping angle between deep dig arm (Figure 1, Item 2) and arm (Figure 1, Item 3) at approximately 90 degrees,
position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004)
END OF TASK
SHUT DOWN ENGINE
1.
If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.
0010-1
TM 5-3805-294-10
0010
HYEX01507
Figure 2.
CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may
result in damage to equipment.
NOTE
Engine speed dial shown approximately at 1/3 position.
2.
Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.
3.
0010-2
TM 5-3805-294-10
0010
HYEX01508
Figure 3.
4.
HYEX01509
Figure 4.
5.
Turn key switch (Figure 5, Item 8) to OFF position and remove key.
0010-3
TM 5-3805-294-10
0010
HYEX01510
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.
END OF TASK
END OF WORK PACKAGE
0010-4
TM 5-3805-294-10
0011
OPERATOR MAINTENANCE
OPENING AND CLOSING WINDOWS
INITIAL SETUP:
Not Applicable
WINDSHIELD
NOTE
The wiper will not operate with windshield open.
The washer can operate with windshield open.
1.
Pull lock pin (Figure 1, Item 1) inward and rotate into notch.
HYEX00160
Figure 1.
Open Windshield.
2.
Pull on latch release bar (Figure 1, Item 2) to open windshield (Figure 1, Item 3).
3.
Lift on handle (Figure 2, Item 4) to raise windshield (Figure 2, Item 3) until it latches open.
0011-1
TM 5-3805-294-10
0011
WINDSHIELD - Continued
4
3
HYEX00161
Figure 2.
Raise Windshield.
WARNING
Lock pin must be used to secure upper front window in raised position. Failure to comply may
result in injury or death to personnel.
4.
Release lock pin (Figure 3, Item 1) from notch and slide into cab frame lock hole (Figure 3, Item 5).
HYEX00162
Figure 3.
5.
To close the windshield, pull lock pin (Figure 4, Item 1) inward from cab frame lock hole (Figure 4, Item 5) and
rotate into notch.
0011-2
TM 5-3805-294-10
0011
WINDSHIELD - Continued
5
2
HYEX00163
Figure 4.
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.
Hold handle (Figure 5, Item 4) and lower windshield (Figure 5, Item 3) until it is latched in the closed position.
4
3
HYEX00161
Figure 5.
8.
Close Windshield.
Press glass (Figure 6, Item 3) until bar (Figure 6, Item 2) snaps into place.
0011-3
TM 5-3805-294-10
0011
WINDSHIELD - Continued
HYEX00160
Figure 6.
9.
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.
To close, slide cab door window (Figure 7, Item 7) to rear until latch (Figure 7, Item 6) engages.
END OF TASK
0011-4
TM 5-3805-294-10
0011
HYEX03377
Figure 8.
2.
To open, release two latches (Figure 9, Item 9) and push up on handle (Figure 9, Item 10).
10
HYEX00167
Figure 9.
3.
To close, pull down on handle (Figure 9, Item 10) and engage two latches (Figure 9, Item 9).
4.
0011-5
TM 5-3805-294-10
0011
HYEX03377
Figure 10.
END OF TASK
END OF WORK PACKAGE
0011-6
TM 5-3805-294-10
0012
OPERATOR MAINTENANCE
USING THE RIFLE MOUNT
INITIAL SETUP:
Not Applicable
STOW
NOTE
Rifle mount is designed to store an M4 with optics, M240B, M249, or M16 series weapon with
and without M203 grenade launcher.
1.
HYEX00999
Figure 1.
2.
0012-1
TM 5-3805-294-10
0012
STOW - Continued
HYEX00998
If necessary, loosen two handles (Figure 2, Item 3) and slide front mounting bracket (Figure 2, Item 2) on two
rails (Figure 2, Item 4).
4.
END OF TASK
REMOVE
1.
Lift barrel of weapon from front mounting bracket (Figure 3, Item 2).
HYEX00998
Remove butt of weapon from rear mounting bracket (Figure 4, Item 1).
0012-2
TM 5-3805-294-10
0012
REMOVE - Continued
HYEX00999
0012-3/4 blank
TM 5-3805-294-10
0013
OPERATOR MAINTENANCE
GENERAL MONITOR OPERATION
INITIAL SETUP:
Equipment Condition
Engine running. (WP 0007)
TIME ADJUSTMENT
NOTE
After approximately 1 minute the monitor will return to the default screen.
1.
Main Menu
TIME SET
Time Set
Attachment Adjustment
Operating Conditions
SELECT
BUTTON
Maintenance Settings
BUTTON 1
BUTTON 2
F1
F2
F3
F4
MENU
BUTTON
HYEX00057
Figure 1.
2.
3.
0013-1
TM 5-3805-294-10
0013
12 /
12 :
BUTTON
1
23
23
SELECT
BUTTON
1
F1
F2
F3
F4
BACK
BUTTON
HYEX00058
Adjust Time.
5.
6.
After desired date and time is achieved, press button 1 or button 2 until the apply setting icon is highlighted.
7.
Press select button and "Data is being applied" will display on the screen.
8.
END OF TASK
DISPLAYING OPERATING CONDITIONS
1.
OPERATING
CONDITIONS
Attachment Adjustment
Operating Conditions
Maintenance Settings
SELECT
BUTTON
1
BUTTON
1
F1
F2
F3
F4
BUTTON
2
Figure 3.
BACK
BUTTON
MENU
BUTTON
2.
3.
0013-2
HYEX00059
TM 5-3805-294-10
0013
SELECT
BUTTON
1
F1
F2
F3
F4
BACK
BUTTON
HYEX00060
Figure 4.
5.
6.
7.
8.
When finished with menu, press back button until default screen is displayed.
END OF TASK
MAINTENANCE SETTINGS
Maintenance settings are to be accessed only by the Field Level maintainer.
END OF TASK
END OF WORK PACKAGE
0013-3/4 blank
TM 5-3805-294-10
0014
OPERATOR MAINTENANCE
REMOVING AND INSTALLING BUCKET
INITIAL SETUP:
References
WP 0007
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
REMOVING BUCKET
WARNING
With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch.
Ensure that personnel are clear of equipment when removing or installing bucket. Slowly
retract or extend bucket cylinder when removing or installing bucket. Failure to comply may
result in injury or death to personnel.
NOTE
The ditch cleaning bucket and 42 inch rock bucket are removed the same way. 42 inch rock
bucket shown.
1.
Lift and rotate safety lock pin lever (Figure 1, Item 1).
1
HYEX03379
Figure 1.
2.
3.
Raise boom (Figure 2, Item 2) to allow adequate ground clearance for bucket (Figure 2, Item 3).
0014-1
TM 5-3805-294-10
0014
3
HYEX03380
Figure 2.
4.
Raise Boom.
HYEX00939
Figure 3.
5.
Fully extend bucket cylinder (Figure 4, Item 5) until quick latch wedges (Figure 4, Item 6) are fully retracted.
0014-2
TM 5-3805-294-10
0014
6
HYEX03387
Figure 4.
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.
NOTE
Ensure that arm is just past the vertical position prior to setting bucket on the ground.
7.
Slowly lower boom (Figure 6, Item 2) and place bucket (Figure 6, Item 3) on ground.
0014-3
TM 5-3805-294-10
0014
3
HYEX03382
Figure 6.
8.
Lower Boom.
HYEX00939
Figure 7.
9.
Remove quick latch (Figure 8, Item 7) from bucket (Figure 8, Item 3).
0014-4
TM 5-3805-294-10
0014
3
HYEX03389
Figure 8.
END OF TASK
INSTALLING BUCKET
WARNING
With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch.
Ensure that personnel are clear of equipment when removing or installing bucket. Slowly
retract or extend bucket cylinder when removing or installing bucket. Failure to comply may
result in injury or death to personnel.
NOTE
The ditch cleaning bucket and 42 inch rock bucket are installed the same way. 42 inch rock
bucket shown.
1.
0014-5
TM 5-3805-294-10
0014
HYEX00939
Figure 9.
2.
Raise boom (Figure 10, Item 2) to allow for adequate ground clearance.
HYEX03385
Figure 10.
WARNING
With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch.
Ensure that personnel are clear of equipment when removing or installing bucket. Slowly
retract or extend bucket cylinder when removing or installing bucket. Failure to comply may
result in injury or death to personnel.
3.
Slowly extend bucket cylinder (Figure 11, Item 5) until quick latch wedges (Figure 11, Item 6) are fully retracted.
0014-6
TM 5-3805-294-10
0014
6
HYEX03383
Figure 11.
4.
Retract Wedges.
3
HYEX03381
Figure 12.
5.
Install quick latch (Figure 12, Item 7) to bucket (Figure 12, Item 3).
6.
Extend bucket cylinder (Figure 12, Item 5) until quick latch (Figure 12, Item 7) is resting on bucket (Figure 12,
Item 3).
7.
0014-7
TM 5-3805-294-10
0014
HYEX00939
6
HYEX03386
Figure 14.
Raise Boom.
9.
Fully extend bucket cylinder (Figure 14, Item 5) to ensure quick latch wedges (Figure 14, Item 6) are fully
engaged.
10.
0014-8
TM 5-3805-294-10
0014
HYEX03378
Figure 15.
11.
Rotate safety lock pin lever (Figure 15, Item 1) to lock position.
END OF TASK
END OF WORK PACKAGE
0014-9/10 blank
TM 5-3805-294-10
OPERATOR MAINTENANCE
LIFTING WITH HYEX
INITIAL SETUP:
Tools and Special Tools
Suitable Lifting Device
Equipment Condition
Engine running. (WP 0007)
Personnel Required
Horizontal Construction Engineer 12N (2)
LIFTING
WARNING
LIFTING GUIDELINES:
Do not use machine to lift personnel. Failure to comply may result in injury or death to
personnel.
Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death
to personnel.
Ensure load does not exceed the capacity of machine or lifting device. Failure to comply
may result in injury or death to personnel.
Lift load only as high as necessary. Failure to comply may result in injury or death to
personnel.
Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may
result in injury or death to personnel.
Personnel must remain clear of lifted items. Failure to comply may result in injury or death
to personnel.
NOTE
Use a suitable lifting device and tether lines to guide load.
Coordinate hand signals with assistant prior to lifting.
1.
0015-1
0015
TM 5-3805-294-10
0015
LIFTING - Continued
5
3
1
2
HYEX00919
Figure 1.
2.
Curl bucket (Figure 1, Item 3) and retract arm (Figure 1, Item 4).
3.
Attach lifting device (Figure 1, Item 1) to quick latch loop (Figure 1, Item 5).
4.
With the aid of an assistant, raise load (Figure 1, Item 2) and verify stability of load and machine (Figure 1,
Item 6) before moving the machine.
END OF TASK
END OF WORK PACKAGE
0015-2
TM 5-3805-294-10
0016
OPERATOR MAINTENANCE
OPERATING TECHNIQUES
INITIAL SETUP:
Equipment Condition
Engine running. (WP 0007)
LEVELING MACHINE
NOTE
Operating on a firm, level surface optimizes machine stability.
1.
Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material.
HYEX01483
Figure 1.
2.
Leveling Machine.
HYEX01484
Figure 2.
3.
If material is added, drive over new material to compact it until the worksite feels stable.
END OF TASK
0016-1
TM 5-3805-294-10
ARM DIGGING
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
CAUTION
When bucket cylinder is fully extended, do not strike the ground or use the bucket for
tamping. Failure to comply may result in damage to equipment.
Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down
walls using swing motion. Failure to comply may result in damage to equipment.
Do not side load bucket, swing bucket to level material, or strike objects from the side
with the bucket. Failure to comply may result in damage to equipment.
If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of
force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket
lightly does not work. Failure to comply may result in damage to equipment.
NOTE
Initial cut should be approximately 4 ft (122 cm) long and 3-4 in. (76-102 mm) deep.
Remaining cuts should be approximately 4 ft (122 cm) long and 4-6 in. (102-152 mm)
deep.
1.
0016-2
0016
TM 5-3805-294-10
0016
HYEX01486
Figure 3.
Arm Digging.
2.
3.
END OF TASK
BUCKET DIGGING
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
CAUTION
When bucket cylinder is fully extended, do not strike the ground or use the bucket for
tamping. Failure to comply may result in damage to equipment.
Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down
walls using swing motion. Failure to comply may result in damage to equipment.
Do not side load bucket, swing bucket to level material, or strike objects from the side
with the bucket. Failure to comply may result in damage to equipment.
0016-3
TM 5-3805-294-10
0016
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.
HYEX01485
Figure 4.
Bucket Digging.
2.
3.
Retract arm and curl bucket at the same time until bucket is full.
4.
5.
END OF TASK
0016-4
TM 5-3805-294-10
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.
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.
On slopes, place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.
END OF TASK
TRENCHING
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
0016-5
TM 5-3805-294-10
0016
TRENCHING - Continued
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
1.
Before starting work, walk the site to uncover hazards and to plan the job.
HYEX01504
Figure 6.
Trenching.
2.
Check for buried utility lines, pipes, and gas or oil pipelines.
3.
Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench.
4.
The deeper the trench, the further away the spoil pile should be placed.
END OF TASK
CLEANING A CAVE IN
1.
If you cannot clean a cave in from the machine's current position, DO NOT back over the trench.
HYEX01503
Figure 7.
2.
3.
Park the machine at a 90 degree angle to the trench with the travel motors to the rear of the machine.
0016-6
TM 5-3805-294-10
0016
END OF TASK
TRENCHING ON A SLOPE
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
NOTE
The deeper the trench the further away the spoil pile should be.
1.
When trenching across a slope, level the machine so that the bottom of the trench will be level.
HYEX01488
Figure 8.
Trenching on a Slope.
2.
3.
Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.
END OF TASK
0016-7
TM 5-3805-294-10
0016
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.
HYEX01489
Figure 9.
2.
Drive the first stake immediately behind the start point of the trench. Drive the second stake approximately
30 ft (9 m) behind the first stake.
3.
Use stakes as a sight gauge. They are especially helpful when the machine is moved often.
END OF TASK
BACKFILLING
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
0016-8
TM 5-3805-294-10
0016
BACKFILLING - Continued
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
CAUTION
Do not use side of bucket to backfill. Failure to comply may result in damage to equipment.
NOTE
The bucket side can be used for finish grading.
1.
Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine.
HYEX01490
Figure 10.
2.
Back Filling.
END OF TASK
0016-9
TM 5-3805-294-10
0016
TRUCK LOADING
WARNING
PREVENTING CAVE IN
Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
1.
Position bucket and slowly dump load in vehicle at the front center of the bed.
HYEX01491
Figure 11.
2.
Truck Loading.
END OF TASK
END OF WORK PACKAGE
0016-10
TM 5-3805-294-10
0017
OPERATOR MAINTENANCE
OPERATING THE HYDRAULIC THUMB
INITIAL SETUP:
Not Applicable
Position hydraulic thumb (Figure 1, Item 1) near the object to be picked up.
HYEX01175
Figure 1.
2.
Curl the bucket (Figure 1, Item 2) until it begins to force the object to the hydraulic thumb (Figure 1, Item 1).
0017-1
TM 5-3805-294-10
0017
Gently move the bucket control to pick the object up without crushing it.
END OF TASK
CLAMPING WITH THE HYDRAULIC THUMB
NOTE
This method is less precise and should only be used when there is no concern about crushing
the object being lifted.
1.
1
2
HYEX01174
Curl bucket (Figure 2, Item 2) and position it near or in contact with the object being picked up.
3.
Move hydraulic thumb (Figure 2, Item 1) to grasp and clamp the object.
END OF TASK
0017-2
TM 5-3805-294-10
0017
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.
1
2
HYEX01174
Figure 3.
2.
Releasing Objects.
Retract either the hydraulic thumb (Figure 3, Item 1) or bucket (Figure 3, Item 2) to release object.
END OF TASK
END OF WORK PACKAGE
0017-3/4 blank
TM 5-3805-294-10
0018
OPERATOR MAINTENANCE
SELECTING AN ATTACHMENT ON THE MONITOR
INITIAL SETUP:
Equipment Condition
Engine running. (WP 0007)
SELECTING ATTACHMENT
1.
Breaker 1
Crusher 1
Pulverizer 1
BUTTON
1
1
F1
BUTTON
Breaker 2
F1
F2
F3
F4
BUTTON
5
2.
HYEX00172
Select Attachment.
Attachment Selection.
Attachment to be used
Bucket/Thumb
Dig
Breaker
Breaker 1
Compactor
Breaker 2
Crush-All
Pulverizer 1
Crusher 1
0018-1
TM 5-3805-294-10
0018
288.0 L/min
1800 min-1
Accumulator
OFF
SELECT
BUTTON
1
F1
F2
F3
F4
HYEX00173
Verify the attachment specifications are the same as displayed on the monitor.
5.
END OF TASK
END OF WORK PACKAGE
0018-2
TM 5-3805-294-10
0019
OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE CRUSH-ALL
INITIAL SETUP:
Tools and Special Tools
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)
References (cont.)
WP 0009
WP 0018
WP 0092
Equipment Condition
Safely park and shutdown machine. (WP 0009)
Bucket removed. (WP 0014)
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
References
WP 0007
INSTALLING CRUSH-ALL
1.
2.
3
4
2
6
5
3
HYEX03392
Figure 1.
3.
Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3).
4.
Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).
0019-1
TM 5-3805-294-10
0019
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.
Using prybar to push pin (Figure 1, Item 3), install pin in thumb lock position (Figure 1, Item 5).
6.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.
Close two auxiliary circuit shut off valves (Figure 1, Item 6).
8.
HYEX03393
Figure 2.
9.
Fully extend bucket cylinder (Figure 3, Item 8) to ensure quick latch wedges (Figure 3, Item 9) are fully retracted.
0019-2
TM 5-3805-294-10
0019
9
HYEX03394
Figure 3.
10.
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.
Install quick latch (Figure 4, Item 10) to crush-all (Figure 4, Item 11).
12.
Extend bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is resting on crush-all (Figure 4,
Item 11).
13.
0019-3
TM 5-3805-294-10
0019
HYEX03393
Raise boom (Figure 6, Item 12) to allow adequate ground clearance of crush-all (Figure 6, Item 11).
12
14
13
11
HYEX03395
Figure 6.
Position Crush-All.
15.
Curl crush-all (Figure 6, Item 11) as in Figure 6 until quick latch wedges (Figure 6, Item 9) are fully engaged
to crush-all (Figure 6, Item 11).
16.
Rotate safety lock pin lever (Figure 6, Item 13) to lock position.
17.
Extend arm cylinder (Figure 6, Item 14) and lower boom (Figure 6, Item 12) to position crush-all (Figure 6, Item
11) on ground.
18.
19.
Clean cap (Figure 7, Item 15) and machine quick disconnect (Figure 7, Item 16) with rag.
0019-4
TM 5-3805-294-10
0019
18
16
17
15
HYEX01501
Figure 7.
20.
Clean plug (Figure 7, Item 17) and attachment quick disconnect (Figure 7, Item 18) with rag.
21.
Remove cap (Figure 7, Item 15) from machine quick disconnect (Figure 7, Item 16).
22.
Remove plug (Figure 7, Item 17) from attachment quick disconnect (Figure 7, Item 18).
23.
Connect attachment quick disconnect (Figure 7, Item 18) to machine quick disconnect (Figure 7, Item 16).
24.
Clean plug (Figure 8, Item 19) and machine quick disconnect (Figure 8, Item 20) with rag.
27
28
29
26
24
22
20
23, 25
19, 21
HYEX01502
Figure 8.
25.
Clean cap (Figure 8, Item 21) and attachment quick disconnect (Figure 8, Item 22) with rag.
26.
Remove plug (Figure 8, Item 19) from machine quick disconnect (Figure 8, Item 20).
27.
Remove cap (Figure 8, Item 20) from attachment quick disconnect (Figure 8, Item 21).
28.
Connect attachment quick disconnect (Figure 8, Item 22) to machine quick disconnect (Figure 8, Item 20).
29.
Clean plug (Figure 8, Item 23) and machine quick disconnect (Figure 8, Item 24).
30.
Clean cap (Figure 8, Item 25) and attachment quick disconnect (Figure 8, Item 26) with rag.
31.
Remove plug (Figure 8, Item 23) from machine quick disconnect Figure 8, Item (24).
32.
Remove cap (Figure 8, Item 25) from attachment quick disconnect (Figure 8, Item 26).
33.
Connect attachment quick disconnect (Figure 8, Item 26) to machine quick disconnect (Figure 8, Item 25).
0019-5
TM 5-3805-294-10
INSTALLING CRUSH-ALL - Continued
34.
Remove cap (Figure 8, Item 27) from connector (Figure 8, Item 28).
35.
END OF TASK
OPERATION
1.
2.
3.
4.
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.
Lift Crush-All (Figure 9, Item 11) approximately 6 ft (182.8 cm) off ground.
0019-6
0019
TM 5-3805-294-10
0019
OPERATION - Continued
34
31
30
32
33
11
HYEX01499
Figure 9.
Crush-All Operation.
7.
8.
9.
Press attachment pedal (Figure 9, Item 31) to turn on Crush-All (Figure 9, Item 11).
10.
Allow Crush-All (Figure 9, Item 11) to run for 5 minutes with no load.
11.
Press attachment pedal (Figure 9, Item 31) and press button (Figure 9, Item 32) to open lid (Figure 9, Item
33).
NOTE
Scooping material is best performed by arming into the material, then boom up and curl as
the Crush-All is elevated above material.
12.
Scoop material and raise Crush-All (Figure 9, Item 11) away from material.
13.
NOTE
Reduce dust by keeping bottom of Crush-All close to stock pile.
14.
15.
Press button (Figure 9, Item 34) to close lid (Figure 9, Item 32).
16.
NOTE
To avoid jamming, hold attachment pedal until all material has been discharged.
17.
Release attachment pedal (Figure 9, Item 31) to turn off crush-all (Figure 9, Item 11).
0019-7
TM 5-3805-294-10
0019
OPERATION - Continued
18.
END OF TASK
JAMMING
WARNING
Ensure operator protection guard is installed prior to operation. Failure to comply may
result in injury or death to personnel.
Crush-All can throw objects at any time during operation. Ensure personnel maintain
distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel.
Do not reach into machine to remove debris. Failure to comply may result in injury or
death to personnel.
Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may
result in injury or death to personnel.
CAUTION
Do not attempt to clear jam by striking Crush-All on ground. Failure to comply may result in
damage to equipment.
NOTE
These steps may be used to clear uncrushable material from machine.
It may be necessary to shake Crush-All.
1.
Press attachment pedal (Figure 10, Item 31) and press button (Figure 10, Item 32) to open lid (Figure 10, Item
33).
0019-8
TM 5-3805-294-10
0019
JAMMING - Continued
31
32
33
HYEX03431
Figure 10.
2.
Open Lid.
Retract bucket cylinder (Figure 11, Item 8) to dump crush-all (Figure 10, Item 11) upside down and allow
material to fall out.
8
11
HYEX03148
Figure 11.
3.
4.
Use a sturdy piece of lumber to push rotor (Figure 12, Item 34) in reverse.
0019-9
TM 5-3805-294-10
0019
JAMMING - Continued
35
34
HYEX03149
If material is jammed between the curtain (Figure 12, Item 35) and rotor (Figure 12, Item 34), raise curtain.
(WP 0092)
6.
END OF TASK
REMOVING CRUSH-ALL
1.
Raise boom (Figure 13, Item 12) to allow adequate ground clearance of crush-all (Figure 13, Item 11).
12
14
11
HYEX03432
Figure 13.
Position Crush-All.
2.
Curl crush-all (Figure 13, Item 11) under as shown in Figure 13.
3.
Extend arm cylinder (Figure 13, Item 14), lower boom (Figure 13, Item 12), and position crush-all (Figure 13,
Item 11) on ground.
4.
0019-10
TM 5-3805-294-10
0019
Remove connector (Figure 14, Item 29) from connector (Figure 14, Item 28).
27
28
29
26
24
22
20
23, 25
19, 21
HYEX01502
Figure 14.
6.
Install cap (Figure 14, Item 27) to connector (Figure 14, Item 28).
7.
Clean attachment quick disconnect (Figure 14, Item 26) and machine quick disconnect (Figure 14, Item 24)
with rag.
8.
Clean cap (Figure 14, Item 25) and plug (Figure 14, Item 23) with rag.
9.
Remove attachment quick disconnect (Figure 14, Item 26) from machine quick disconnect (Figure 14, Item
24).
10.
Install cap (Figure 14, Item 25) to attachment quick disconnect (Figure 14, Item 26).
11.
Install plug (Figure 14, Item 23) to machine quick disconnect (Figure 14, Item 24).
12.
Clean attachment quick disconnect (Figure 14, Item 22) and machine quick disconnect (Figure 14, Item 20)
with rag.
13.
Clean cap (Figure 14, Item 21) and plug (Figure 14, Item 19) with rag.
14.
Remove attachment quick disconnect (Figure 14, Item 22) from machine quick disconnect (Figure 14, Item
20).
15.
Install cap (Figure 14, Item 21) to attachment quick disconnect (Figure 14, Item 22).
16.
Install plug (Figure 14, Item 19) to machine quick disconnect (Figure 14, Item 20).
17.
Clean attachment quick disconnect (Figure 15, Item 18) and machine quick disconnect (Figure 15, Item 16)
with rag.
0019-11
TM 5-3805-294-10
0019
18
16
17
15
HYEX01501
Clean cap (Figure 15, Item 15) and plug (Figure 15, Item 17) with rag.
19.
Remove attachment quick disconnect (Figure 15, Item 18) from machine quick disconnect (Figure 15, Item
16).
20.
Install plug (Figure 15, Item 17) to attachment quick disconnect (Figure 15, Item 18).
21.
Install cap (Figure 15, Item 15) to machine quick disconnect (Figure 15, Item 16).
22.
23.
HYEX03393
Raise boom (Figure 17, Item 12) to allow adequate ground clearance of crush-all (Figure 17, Item 11).
0019-12
TM 5-3805-294-10
0019
14
13
11
HYEX03433
Figure 17.
25.
Raise Boom.
Lift and rotate safety lock pin lever (Figure 17, Item 13) to unlock position.
WARNING
With quick latch wedges disengaged from crush-all, the crush-all could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing crush-all.
Slowly retract or extend bucket cylinder when removing or installing crush-all. Failure to
comply may result in injury or death to personnel.
26.
Fully extend bucket cylinder (Figure 17, Item 8) until quick latch wedges (Figure 17, Item 9) are fully retracted.
27.
Retract bucket cylinder (Figure 17, Item 8), arm cylinder (Figure 17, Item 14), and lower boom to position crushall (Figure 17, Item 11) on the ground.
28.
Retract bucket cylinder (Figure 18, Item 8) and position quick latch (Figure 18, Item10) in vertical position.
0019-13
TM 5-3805-294-10
0019
10
11
HYEX03397
Remove quick latch (Figure 18, Item 10) from crush-all (Figure 18, Item 11).
30.
HYEX03393
0019-14
TM 5-3805-294-10
0019
3
4
2
4
1
5
3
5
35
HYEX01500
Figure 20.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
32.
Open two auxiliary circuit shut off valves (Figure 20, Item 6).
33.
Remove retaining clip (Figure 20, Item 2) from pin (Figure 20, Item 3).
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
34.
Retract or extend thumb cylinder (Figure 20, Item 1) to remove pin (Figure 20, Item 3) from thumb lock position
(Figure 20, Item 5).
35.
Install pin (Figure 20, Item 3) in storage position (Figure 20, Item 4).
36.
Install retaining pin (Figure 20, Item 2) on pin (Figure 20, Item 3).
37.
END OF TASK
END OF WORK PACKAGE
0019-15/16 blank
TM 5-3805-294-10
0020
OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE IMPACT BREAKER
INITIAL SETUP:
Tools and Special Tools
Screwdriver, Pry Bar, 12 in. (304 mm) Long
(WP 0095, Table 2, Item 11)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)
Materials/Parts (cont.)
(WP 0097, Table 1, Item 10)
Rags, Wiping (WP 0097, Table 1, Item 15)
Materials/Parts
Grease, Automotive and Artillery, GAA
Equipment Condition
Machine safely parked and shutdown. (WP 0009)
Bucket removed. (WP 0014)
References
WP 0007
WP 0009
WP 0018
2.
3
4
2
6
5
3
HYEX01321
Figure 1.
3.
Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3).
4.
Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).
0020-1
TM 5-3805-294-10
0020
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.
With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).
6.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.
8.
HYEX03398
0020-2
TM 5-3805-294-10
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.
Retract bucket cylinder (Figure 5, Item 9) until quick latch (Figure 5, Item 11) is in the vertical position.
0020-3
TM 5-3805-294-10
0020
8
11
12
HYEX03402
Figure 5.
12.
Install quick latch (Figure 5, Item 11) to impact breaker (Figure 5, Item 12).
WARNING
With quick latch wedges disengaged from impact breaker, the impact breaker could fall off
of the quick latch. Ensure that personnel are clear of equipment when removing or installing
impact breaker. Slowly retract or extend bucket cylinder when removing or installing impact
breaker. Failure to comply may result in injury or death to personnel.
13.
With the aid of an assistant slowly raise boom (Figure 5, Item 8) to allow for adequate ground clearance of
quick latch (Figure 5, Item 11).
14.
Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on impact breaker
(Figure 6, Item 12)
12
11
HYEX03403
Figure 6.
0020-4
TM 5-3805-294-10
0020
HYEX03398
Figure 7.
16.
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.
Retract bucket cylinder (Figure 8, Item 9) and place impact breaker (Figure 8, Item 12) on ground.
18.
19.
Rotate safety lock pin lever (Figure 9, Item 13) to lock position.
0020-5
TM 5-3805-294-10
0020
HYEX03406
13
Figure 9.
20.
Clean cap (Figure 10, Item 14) and machine quick disconnect (Figure 10, Item 15) with rag.
17
15
16
14
HYEX01322
Clean plug (Figure 10, Item 16) and attachment quick disconnect (Figure 10, Item 17) with rag.
22.
Remove cap (Figure 10, Item 14) from machine quick disconnect (Figure 10, Item 15).
23.
Remove plug (Figure 10, Item 16) from attachment quick disconnect (Figure 10, Item 17).
24.
Connect attachment quick disconnect (Figure 10, Item 17) to machine quick disconnect (Figure 10, Item 15).
25.
Clean plug (Figure 11, Item 18) and machine quick disconnect (Figure 11, Item 19) with rag.
0020-6
TM 5-3805-294-10
0020
21
19
18
20
HYEX01323
Figure 11.
26.
Clean cap (Figure 11, Item 20) and attachment quick disconnect (Figure 11, Item 21) with rag.
27.
Remove plug (Figure 11, Item 18) from machine quick disconnect (Figure 11, Item 19).
28.
Remove cap (Figure 11, Item 20) from attachment quick disconnect (Figure 11, Item 21).
29.
Connect attachment quick disconnect (Figure 11, Item 21) to machine quick disconnect (Figure 11, Item 19).
END OF TASK
TOOL INSTALLATION
NOTE
Select the proper tool before operation.
Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to
medium hardness.
Moil is for demolition of medium hardness rock or materials except layered rock.
Blunt is for breaking large, medium hardness rocks into smaller pieces.
1.
Press and turn lock bolt (Figure 12, Item 22) to unlocked position with slot (Figure 12, Item 23) pointed to the
tool end of breaker (Figure 12, Item 12).
0020-7
TM 5-3805-294-10
0020
22
23
24
12
26
25
HYEX01326
Figure 12.
2.
Push the retaining axle (Figure 12, Item 24) out of the breaker (Figure 12, Item 12) through hole (Figure 12,
Item 25).
3.
4.
WARNING
Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without
the aid of an assistant and suitable lifting device. Failure to comply may result in injury or
death to personnel.
NOTE
Ensure cavity is free of debris and tool is properly lubricated.
5.
With the aid of an assistant and suitable lifting device, slide tool (Figure 13, Item 27) into breaker (Figure 13,
Item 12) with side notches (Figure 13, Item 28) in alignment with axle slots (Figure 13, Item 29).
0020-8
TM 5-3805-294-10
0020
29
12
27
28
HYEX01327
Figure 13.
6.
Install retaining axle (Figure 14, Item 24) to breaker (Figure 14, Item 12).
12
24
23
22
HYEX01328
Figure 14.
7.
Press and turn lock bolt (Figure 14, Item 22) to locked position with slot (Figure 14, Item 23) pointed to top of
breaker (Figure 14, Item 12).
8.
Repeat Steps (Figure 14, Item 6) and (Figure 14, Item 7) for other retaining axle.
END OF TASK
OPERATING IMPACT BREAKER
1.
2.
CAUTION
Breaker must be lubricated every 2 hours of use and every hour during dusty conditions.
Failure to comply may result in damage to the attachment.
NOTE
Keep tool perpendicular to work surface.
Keep machine close to work area.
Maintain constant, even pressure as tool penetrates work surface.
0020-9
TM 5-3805-294-10
0020
30
31
12
HYEX01520
Figure 15.
Breaker Operation.
4.
Apply boom (Figure 15, Item 8) down pressure to impact breaker (Figure 15, Item 12) on work area.
5.
Press attachment pedal (Figure 15, Item 31) to start impact breaker (Figure 15, Item 12).
6.
Release attachment pedal (Figure 15, Item 31) to stop impact breaker (Figure 15, Item 12) before retracting
from work area.
7.
END OF TASK
TOOL REMOVAL
1.
Raise breaker (Figure 16, Item 12) off ground and extend bucket cylinder (Figure 16, Item 9) until breaker is
horizontal.
9
24
12
23
25
22
HYEX03440
Figure 16.
Tool Removal.
0020-10
TM 5-3805-294-10
0020
Press and turn lock bolt (Figure 16, Item 22) to unlocked position with slot (Figure 16, Item 23) pointed to the
tool end of breaker (Figure 16, Item 12).
3.
Push the retaining axle (Figure 16, Item 24) out of the breaker (Figure 16, Item 12) through hole (Figure 16,
Item 25).
4.
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.
Install retaining axle (Figure 18, Item 24) to breaker (Figure 18, Item 12).
12
24
23
22
HYEX01328
Figure 18.
7.
Press and turn lock bolt (Figure 18, Item 22) to locked position with slot (Figure 18, Item 23) pointed to top of
breaker (Figure 18 , Item 12).
0020-11
TM 5-3805-294-10
0020
END OF TASK
REMOVING IMPACT BREAKER
1.
2.
Clean machine quick disconnect (Figure 19, Item 19) and attachment quick disconnect (Figure 19, Item 21)
with rag.
21
19
18
20
HYEX01323
Clean cap (Figure 19, Item 20) and plug (Figure 19, Item 18) with rag.
4.
Remove attachment quick disconnect (Figure 19, Item 21) from machine quick disconnect (Figure 19, Item
19).
5.
Install cap (Figure 19, Item 20) to attachment quick disconnect (Figure 19, Item 21).
6.
Install plug (Figure 19, Item 18) to machine quick disconnect (Figure 19, Item 19).
7.
Clean machine quick disconnect (Figure 20, Item 15) and attachment quick disconnect (Figure 20, Item 17)
with rag.
17
15
16
14
HYEX01322
Clean cap (Figure 20, Item 14) and plug (Figure 20, Item 16) with rag.
9.
Remove attachment quick disconnect (Figure 20, Item 17) from machine quick disconnect (Figure 20, Item
15).
0020-12
TM 5-3805-294-10
0020
Install plug (Figure 20, Item 16) to attachment quick disconnect (Figure 20, Item 17).
11.
Install cap (Figure 20, Item 14) to machine quick disconnect (Figure 20, Item 15).
12.
Lift and rotate safety lock pin lever (Figure 21, Item 13) to unlock position.
HYEX03406
13
Figure 21.
13.
14.
Raise boom (Figure 22, Item 8) to allow for adequate ground clearance.
HYEX03399
Figure 22.
15.
0020-13
TM 5-3805-294-10
0020
HYEX03398
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.
Retract bucket cylinder (Figure 25, Item 9) until tool end of impact breaker (Figure 25, Item 12) is resting on
ground and quick latch (Figure 25, Item 11) is in vertical position.
0020-14
TM 5-3805-294-10
0020
8
11
12
HYEX03402
Figure 25.
18.
Lower boom (Figure 25, Item 8) until impact breaker (Figure 25, Item 12) is resting on ground.
19.
Remove quick latch (Figure 25, Item 11) from impact breaker (Figure 25, Item 12).
20.
HYEX03398
Figure 26.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
21.
Open two auxiliary circuit shutoff valves (Figure 27, Item 6).
0020-15
TM 5-3805-294-10
0020
3
4
2
6
5
3
HYEX01321
Remove retaining pin (Figure 27, Item 2) from pin (Figure 27, Item 3).
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
23.
With the aid of an assistant, extend or retract thumb cylinder (Figure 27, Item 1), as needed, while using prybar
to remove pin (Figure 27, Item 3) from thumb lock position (Figure 27, Item 5).
24.
Install pin (Figure 27, Item 3) in storage position (Figure 27, Item 4).
25.
Install retaining pin (Figure 27, Item 2) to pin (Figure 27, Item 3).
26.
END OF TASK
END OF WORK PACKAGE
0020-16
TM 5-3805-294-10
0021
OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE COMPACTOR
INITIAL SETUP:
Tools and Special Tools
Screwdriver, Pry Bar, 12 in. (304 mm) Long
(WP 0095, Table 2, Item 11)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)
References (cont.)
WP 0009
WP 0018
Equipment Condition
Safely park and shutdown machine. (WP 0009)
Bucket removed. (WP 0014)
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
References
WP 0007
INSTALLING COMPACTOR
1.
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.
0021-1
TM 5-3805-294-10
0021
3
4
2
6
5
3
HYEX03411
Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3).
4.
Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.
With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).
6.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.
Close two auxiliary circuit shut off valves (Figure 1, Item 6).
8.
0021-2
TM 5-3805-294-10
0021
HYEX03412
Figure 2.
9.
HYEX03413
Figure 3.
10.
Raise Boom.
Fully extend bucket cylinder (Figure 4, Item 9) to ensure quick latch wedges (Figure 4, Item 10) are fully
retracted.
0021-3
TM 5-3805-294-10
0021
10
HYEX03414
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.
Install quick latch (Figure 5, Item 11) to compactor (Figure 5, Item 12).
13.
Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on compactor (Figure
6, Item 12).
0021-4
TM 5-3805-294-10
0021
11
12
HYEX03416
Figure 6.
14.
HYEX03412
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.
0021-5
TM 5-3805-294-10
0021
HYEX03413
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
Retract bucket cylinder (Figure 9, Item 9) and position compactor (Figure 9, Item 12) on ground.
18.
19.
Rotate safety lock pin lever (Figure 10, Item 13) to lock position.
0021-6
TM 5-3805-294-10
0021
HYEX03418
Figure 10.
20.
Clean cap (Figure 11, Item 14) and machine quick disconnect (Figure 11, Item 15) with rag.
17
15
16
14
HYEX03419
Figure 11.
21.
Clean plug (Figure 11, Item 16) and attachment quick disconnect (Figure 11, Item 17) with rag.
22.
Remove cap (Figure 11, Item 14) from machine quick disconnect (Figure 11, Item 15).
23.
Remove plug (Figure 11, Item 16) from attachment quick disconnect (Figure 11, Item 17).
24.
Connect attachment quick disconnect (Figure 11, Item 17) to machine quick disconnect (Figure 11, Item 15).
25.
Clean plug (Figure 12, Item 18) and machine quick disconnect (Figure 12, Item 19) with rag.
0021-7
TM 5-3805-294-10
0021
21
19
18
20
HYEX03420
Figure 12.
26.
Clean cap (Figure 12, Item 20) and attachment quick disconnect (Figure 12, Item 21) with rag.
27.
Remove plug (Figure 12, Item 18) from machine quick disconnect (Figure 12, Item 19).
28.
Remove cap (Figure 12, Item 20) from attachment quick disconnect (Figure 12, Item 21).
29.
Connect attachment quick disconnect (Figure 12, Item 21) to machine quick disconnect (Figure 12, Item 19).
END OF TASK
OPERATING THE COMPACTOR
1.
2.
3.
23
12
24
HYEX01325
Press attachment pedal (Figure 13, Item 23) to turn on compactor (Figure 13, Item 12).
5.
6.
Apply boom down pressure to deflect rubber isolators (Figure 13, Item 24) approximately half way.
0021-8
TM 5-3805-294-10
0021
Move compactor (Figure 13, Item 12) over work surface while continuing to apply down pressure.
8.
Release attachment pedal (Figure 13, Item 23) to stop compactor (Figure 13, Item 12).
9.
10.
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.
Remove attachment quick disconnect (Figure 14, Item 21) from machine quick disconnect (Figure 14, Item
19).
5.
Install cap (Figure 14, Item 20) to attachment quick disconnect (Figure 14, Item 21).
6.
Install plug (Figure 14, Item 18) to machine quick disconnect (Figure 14, Item 19).
7.
Clean attachment quick disconnect (Figure 15, Item 17) and machine quick disconnect (Figure 15, Item 15)
with rag.
0021-9
TM 5-3805-294-10
0021
17
15
16
14
HYEX03419
9.
10.
Remove attachment quick disconnect (Figure 15, Item 17) from machine quick disconnect (Figure 15, Item
15).
11.
Install plug (Figure 15, Item 16) to attachment quick disconnect (Figure 15, Item 17).
12.
Install cap (Figure 15, Item 14) to machine quick disconnect (Figure 15, Item 15).
13.
Rotate safety lock pin lever (Figure 16, Item 13) to unlock position.
13
HYEX03421
Figure 16.
14.
15.
0021-10
TM 5-3805-294-10
0021
HYEX03412
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
0021
12
10
HYEX03417
Retract bucket cylinder (Figure 20, Item 9) until quick latch (Figure 20, Item 11) is in vertical position.
9
11
HYEX03422
Figure 20.
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.
0021-12
TM 5-3805-294-10
0021
9
11
12
25
Figure 21.
20.
HYEX03424
Lower boom (Figure 21, Item 8) until compactor plate (Figure 21, Item 25) is just touching the ground.
NOTE
The compactor will likely become wedged between the ground the quick latch/arm until it
"pops" out of the hooks. When this wedged situation occurs, ensure that the tracks do not
begin to raise. If tracks begin to raise: stop movements, raise boom, and try again.
21.
Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure
21, Item 12), then begin to boom down while continuing to arm in until quick latch (Figure 21, Item 11) is
removed from compactor.
22.
HYEX03412
Figure 22.
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
0021-13
TM 5-3805-294-10
0021
Open two auxiliary circuit shutoff valves (Figure 23, Item 6).
3
4
2
6
5
3
HYEX03411
Remove retaining pin (Figure 23, Item 2) from pin (Figure 23, Item 3).
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
25.
With the aid of an assistant, extend or retract thumb cylinder (Figure 23, Item 1), as needed, while using prybar
to remove pin (Figure 23, Item 3) from thumb lock position (Figure 23, Item 5).
26.
Install pin (Figure 23, Item 3) in storage position (Figure 23, Item 4).
27.
Install retaining pin (Figure 23, Item 2) to pin (Figure 23, Item 3).
28.
END OF TASK
END OF WORK PACKAGE
0021-14
TM 5-3805-294-10
0022
OPERATOR MAINTENANCE
OPERATING THE BARRIER GRAPPLE
INITIAL SETUP:
Tools and Special Tools
Lifting Device, Minimum Capacity 16,000 lbs
(72574.8 kg)
Equipment Condition
Engine running. (WP 0007)
WARNING
LIFTING GUIDELINES:
Do not use machine to lift personnel. Failure to comply may result in injury or death to
personnel.
Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death
to personnel.
Ensure load does not exceed the capacity of machine or lifting device. Failure to comply
may result in injury or death to personnel.
Lift load only as high as necessary. Failure to comply may result in injury or death to
personnel.
Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may
result in injury or death to personnel.
Personnel must remain clear of lifted items. Failure to comply may result in injury or death
to personnel.
NOTE
Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16,000 lb (7257.48 kg).
1.
Attach barrier grapple (Figure 1, Item 1) to quick latch loop (Figure 1, Item 2) with suitable lifting device (Figure
1, Item 3).
0022-1
TM 5-3805-294-10
0022
HYEX02585
Position barrier grapple (Figure 1, Item 1) near center of barrier (Figure 1, Item 4).
3.
Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically close on the barrier.
CAUTION
Avoid jerky lifting, striking, and poor alignment with barriers. Failure to comply may result in
damage to equipment.
4.
Slowly raise barrier grapple (Figure 1, Item 1) and barrier (Figure 1, Item 4).
5.
6.
Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically latch open and release the barrier.
0022-2
TM 5-3805-294-10
BARRIER GRAPPLE OPERATION - Continued
7.
END OF TASK
END OF WORK PACKAGE
0022-3/4 blank
0022
TM 5-3805-294-10
0023
OPERATOR MAINTENANCE
OPERATING THE DEEP DIG ARM
INITIAL SETUP:
References
WP 0010
WP 0077
Equipment Condition
Engine running. WP 0007
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.
Move switch (Figure 1, Item 3) to ON position and install pin (Figure 1, Item 1).
3.
0023-1
TM 5-3805-294-10
0023
HYEX03404
0023-2
TM 5-3805-294-10
0023
5
HYEX01518
Figure 3.
5.
0023-3
TM 5-3805-294-10
0023
HYEX03405
Figure 4.
NOTE
When the deep dig control pattern switch is in the ON position, the arm cylinder is
controlled by the attachment pedal and can only be retracted.
The arm cylinder can only be retracted. It is necessary to occasionally retract the arm
cylinder due to the weight of the deep dig arm.
With the deep dig control pattern switch in the ON position, the pilot control levers operate
in the same way.
6.
Slowly cycle bucket cylinder (Figure 5, Item 5) and deep dig bucket cylinder (Figure 5, Item 6) until full smooth
movement of each cylinder is obtained.
0023-4
TM 5-3805-294-10
0023
HYEX01636
Figure 5.
7.
8.
END OF TASK
END OF WORK PACKAGE
0023-5/6 blank
TM 5-3805-294-10
0024
OPERATOR MAINTENANCE
MOVING MACHINE ON/OFF AN EMBANKMENT
INITIAL SETUP:
Not Applicable
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.
Position Bucket.
2.
Lower boom (Figure 1, Item 3) to raise undercarriage until front of tracks (Figure 1, Item 4) clear edge of
embankment.
3.
Drive machine (Figure 1, Item 5) towards upper level as arm (Figure 1, Item 2) is retracted.
4.
Slowly raise boom (Figure 1, Item 3) until tracks (Figure 1, Item 4) are resting on upper level of embankment.
5.
Rotate upper structure (Figure 2, Item 6) 180 degrees towards lower level of embankment.
0024-1
TM 5-3805-294-10
0024
6
5
3
2
4
1
HYEX01104
Figure 2.
Upperstructure Rotated.
6.
Position flat surface of bucket (Figure 2, Item 1) on lower level of embankment with arm (Figure 2, Item 2) to
boom (Figure 2, Item 3) angle at 90 degrees.
7.
Drive machine (Figure 2, Item 5) towards upper level while extending arm (Figure 2, Item 2) until machine is
completely on upper level of embankment.
END OF TASK
MOVING MACHINE OFF AN EMBANKMENT
CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to
comply may result in damage to equipment.
1.
Position flat surface of bucket (Figure 3, Item 1) on lower level of embankment with arm (Figure 3, Item 2) to
boom (Figure 3, Item 3) angle at 90 degrees.
0024-2
TM 5-3805-294-10
0024
5
3
2
4
1
HYEX00689
Figure 3.
2.
Drive machine (Figure 3, Item 5) towards lower level while raising boom (Figure 3, Item 3) and retracting arm
(Figure 3, Item 2) until front of tracks (Figure 3, Item 4) reach lower level of embankment.
3.
Raise bucket (Figure 4, Item 1) off of the ground and rotate upper structure (Figure 4, Item 6) 180 degrees
towards upper level of embankment.
3
2
5
1
4
HYEX01103
Figure 4.
4.
Position flat surface of bucket (Figure 4, Item 1) on upper level of embankment with arm (Figure 4, Item 2) to
boom (Figure 4, Item 3) angle at 90 degrees.
0024-3
TM 5-3805-294-10
0024
Lower boom (Figure 4, Item 3) slightly and drive machine (Figure 4, Item 5) towards lower level as the arm
(Figure 4, Item 2) is extended.
6.
When tracks (Figure 4, Item 4) clear upper level of embankment, slowly raise boom (Figure 4, Item 3) until
machine (Figure 4, Item 5) is on lower level.
END OF TASK
END OF WORK PACKAGE
0024-4
TM 5-3805-294-10
0025
OPERATOR MAINTENANCE
USING THE VANDAL PROTECTION KIT
INITIAL SETUP:
Not Applicable
Position cover (Figure 1, Item 1) on cab hook (Figure 1, Item 2) and behind brackets (Figure 1, Item 3).
2
HYEX01548
Figure 1.
2.
Position cover (Figure 2, Item 4) on cab hook (Figure 2, Item 5) and behind brackets (Figure 2, Item 6).
HYEX01549
Figure 2.
0025-1
TM 5-3805-294-10
0025
Position cover (Figure 3, Item 7) on cab hook (Figure 3, Item 8) and behind brackets (Figure 3, Item 9).
8
HYEX01550
Figure 3.
4.
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
Position cover (Figure 5, Item 13) over door hook (Figure 5, Item 14) and behind brackets (Figure 5, Item 15).
0025-2
TM 5-3805-294-10
0025
14
13
15
HYEX01552
Figure 5.
2.
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.
Position cover (Figure 7, Item 19) over hooks (Figure 7, Item 20) and behind brackets (Figure 7, Item 21).
0025-3
TM 5-3805-294-10
0025
20
20
21
24
23
22
Figure 7.
19
HYEX01554
4.
Position hinge (Figure 7, Item 22) over tab (Figure 7, Item 23) and turn lock (Figure 7, Item 24) to lock in place.
5.
Position cover (Figure 8, Item 25) over cab hooks (Figure 8, Item 26) and behind bracket (Figure 8, Item 27).
26
26
25
27
HYEX01555
Position cover (Figure 9, Item 28) over hooks (Figure 9, Item 29) and behind brackets (Figure 9, Item 30).
0025-4
TM 5-3805-294-10
0025
30
28
33
32
31
HYEX01556
Figure 9.
7.
Place hinge (Figure 9, Item 31) over tab (Figure 9, Item 32) and turn lock (Figure 9, Item 33) to lock in place.
END OF TASK
REAR CAB INSTALLATION
1.
Position cover (Figure 10, Item 34) over cab hook (Figure 10, Item 35) and behind brackets (Figure 10, Item
36).
34 35
36
Figure 10.
2.
HYEX01557
Position cover (Figure 11, Item 37) over tab (Figure 11, Item 38) and behind brackets (Figure 11, Item 39).
0025-5
TM 5-3805-294-10
0025
38
40
39
37
Figure 11.
3.
HYEX01558
END OF TASK
REAR CAB REMOVAL
1.
38
40
39
37
HYEX01558
Remove cover (Figure 12, Item 37) from behind brackets (Figure 12, Item 39) and from tab (Figure 12, Item
38).
0025-6
TM 5-3805-294-10
0025
Remove cover (Figure 13, Item 34) from behind brackets (Figure 13, Item 36) and cab hook (Figure 13, Item
35).
34 35
36
Figure 13.
HYEX01557
END OF TASK
LEFT SIDE CAB REMOVAL
1.
Turn lock (Figure 14, Item 33) to unlock and remove hinge (Figure 14, Item 31) from tab (Figure 14, Item 32).
29
30
28
33
32
31
HYEX01556
Figure 14.
2.
Remove cover (Figure 14, Item 28) from behind brackets (Figure 14, Item 30) and hooks (Figure 14, Item 29).
3.
Remove cover (Figure 15, Item 25) from behind bracket (Figure 15, Item 27) and cab hooks (Figure 15, Item
26).
0025-7
TM 5-3805-294-10
0025
26
26
25
27
HYEX01555
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
Remove cover (Figure 16, Item 19) from behind brackets (Figure 16, Item 21) and hooks (Figure 16, Item 20).
6.
Remove cover (Figure 17, Item 16) from behind brackets (Figure 17, Item 18) and cab hooks (Figure 17, Item
17).
0025-8
TM 5-3805-294-10
0025
16
18
HYEX01553
Figure 17.
7.
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.
Turn lock (Figure 19, Item 12) to unlock and remove plate (Figure 19, Item 10) from tabs (Figure 19, Item 11).
0025-9
TM 5-3805-294-10
0025
11
10
11
12
HYEX01551
Figure 19.
2.
Remove cover (Figure 20, Item 7) from behind brackets (Figure 20, Item 9) and cab hook (Figure 20, Item 8).
8
HYEX01550
Remove cover (Figure 21, Item 4) from behind brackets (Figure 21, Item 6) and cab hook (Figure 21, Item 5).
HYEX01549
0025-10
TM 5-3805-294-10
0025
Remove cover (Figure 22, Item 1) from behind brackets (Figure 22, Item 3) and cab hook (Figure 22, Item 2).
2
HYEX01548
Figure 22.
END OF TASK
END OF WORK PACKAGE
0025-11/12 blank
TM 5-3805-294-10
0026
OPERATOR MAINTENANCE
OPERATING THE HYDRAULIC HOSE REEL
INITIAL SETUP:
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
References
WP 0007
WP 0009
Remove cover (Figure 1, Item 1) from quick coupler (Figure 1, Item 2).
5
6
2
4
1
3
HYEX01097
Figure 1.
2.
Remove cover (Figure 1, Item 3) from quick coupler (Figure 1, Item 4).
3.
Using a clean rag, wipe quick coupler (Figure 1, Item 2) and (Figure 1, Item 4) and couplers on tool to be
connected.
4.
Connect quick coupler (Figure 1, Item 2) on return hose (Figure 1, Item 5) to hydraulic tool.
5.
Connect quick coupler (Figure 1, Item 4) on supply hose (Figure 1, Item 6) to hydraulic tool.
6.
0026-1
TM 5-3805-294-10
0026
Move hand held hydraulic tool circuit switch (Figure 2, Item 7) to ON position.
8
7
HYEX01096
Figure 2.
8.
END OF TASK
DISCONNECTING HYDRAULIC TOOL
1.
8
7
HYEX01096
Figure 3.
2.
Move hand held hydraulic tool circuit switch (Figure 3, Item 7) to OFF position.
3.
0026-2
TM 5-3805-294-10
0026
5.
Disconnect quick coupler (Figure 4, Item 4) on supply hose (Figure 4, Item 6) from hydraulic tool.
5
6
2
4
1
3
HYEX01097
Figure 4.
6.
Disconnect quick coupler (Figure 4, Item 2) on return hose (Figure 4, Item 5) from hydraulic tool.
7.
8.
END OF TASK
END OF WORK PACKAGE
0026-3/4 blank
TM 5-3805-294-10
0027
OPERATOR MAINTENANCE
DECAL LOCATION GUIDE
INITIAL SETUP:
Not Applicable
DECALS
This work package shows the typical location of all decals on the machine and attachments. Some are located inside
access panels or under the engine cover.
240D
24 VOLTS
DC SLAVE
RECEPTACLE
LCR
DIESEL
ONLY
HYEX01457
0027-1
TM 5-3805-294-10
0027
DECALS - Continued
Figure 2.
HYEX01448
0027-2
TM 5-3805-294-10
0027
DECALS - Continued
IMPORTANT
OIL
LEVEL
Fully
Retracted
Fully
Retracted
3 Without Bucket
HYEX01447
Figure 4.
TRANSPORTATION DATA
GROSS WEIGHT
EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD
-
60,000 LB.
4
12 FT.
T247868
CENTER OF
GRAVITY
44 MM [1.7 IN.]
HYEX01445
Figure 5.
Right Side.
0027-3
TM 5-3805-294-10
0027
DECALS - Continued
LIFT
ENGINE OIL
SAMPLE VALVE
HYD
OIL
SAMPLE
VALVE
HYEX01444
Figure 6.
HYEX01446
Figure 7.
Counterweight.
0027-4
TM 5-3805-294-10
0027
DECALS - Continued
TIEDOWN
HYEX01442
Figure 8.
LOCK
HYEX01450
Figure 9.
O FF
Cab on Seat.
AC
C
ON
S TA
RT
HYEX01530
Figure 10.
Key Switch.
0027-5
TM 5-3805-294-10
0027
DECALS - Continued
CAUTION
FRONT WINDOW
HANDLE
HYEX01531
Figure 11.
Windshield.
10'
15'
20'
25'
IMPORTANT
30'
7.55*
7.55*
8.52*
8.52*
8.61*
8.61*
6.26*
6.26*
8.09*
6.29
9.68
6.04
9.46
5.81
12.48
7.68
12.39
7.59
SECONDARY EXIT
Use tool to break window.
9.31
5.67
HYEX01532
T218383
Figure 12.
Side Window.
0027-6
TM 5-3805-294-10
0027
DECALS - Continued
CAUTION
Attachment mode
Key No.
to be selected
1
Excavation
Hammer/
Breaker
Alternative
Hammer/Breaker
Breaker 1
Breaker 2
Pulverizer
Pulverizer 1
Crusher
Crusher 1
Work Mode
Breaker 2
Dig
Breaker 1
Pulverizer 1
Crusher 1
F1
F2
F3
F4
DANGER
2
F1
Crusher 1
Maximum Pump Flow Rate
420 L/min
1900 min-1
Accumulator
2-Speed Selector ON
OFF
T146667
F1
F2
F3
F4
CONFIRM
ATTACHMENT SPECIFICATION SCREEN
T223619
CAUTION
Alternate control
patterns are
available for this
machine. Always
verify control
response before
operating.
T201519
HYEX01533
Figure 13.
0027-7
TM 5-3805-294-10
0027
DECALS - Continued
ENGINE OPERATION
STARTING - Set RPM's (dial or throttle position) at low idle, turn key on and wait
until glow plug warm-up indicator turns off; turn key to start and crank for 20
seconds maximum or less if required. Allow 2 minutes between cranking
attempts. DO NOT USE ETHER AS A STARTING AID.
STOPPING - Reduce RPM's to low idle for 2 minutes with no load. Stop engine.
ENGINE STALL - Remove load, restart immediately. Run 30 seconds at half
speed before adding load.
H
min1
A/I
H/P
P
E
CAUTION
POWER MODE
H/P - Select for heavy digging, maximum productivity.
Avoid tipping - Do not lift or move objects that exceed machine stability.
T219580
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
0027-8
TM 5-3805-294-10
0027
DECALS - Continued
1.
2.
3.
2
1
1
2
CAB, REAR
CAB, FRONT
HYEX01538
Figure 15.
0027-9
TM 5-3805-294-10
0027
DECALS - Continued
T260750
ITEM
NO.
AS
REQUIRED
4
23
24
26
1
1
1
2
16
20
1
1
5
12
1
1
29
3
6
10
12
14
16
19
20
21
22
24
1
1
1
1
1
1
1
1
2
2
1
CHECK DIPSTICK
DRAIN WATER SEDIMENT (A)
REPLACE (A) (C)
REPLACE (A)
CHECK DIPSTICK
DRAIN AND REFILL
CHECK AND ADJUST
CHECK - LEVEL IN BOTTLE BETWEEN "MAX COLD" AND "MIN COLD" MARKS (A)
CHECK - TO BOTTOM OF FILLER NECK - CLEAN AND TIGHTEN TERMINALS
CHECK - REMOVE PLUG
CLEAN ELEMENT
16
2
10
12
13
16
18
25
27
28
1
1
1
1
1
2
1
1
2
GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR
FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS.
GREASE DAILY WHEN WORKING IN WATER
GREASE - ADD 1 LB. [0.5 Kg] (A) (D)
REPLACE (A) (C)
REPLACE (A)
REPLACE - 500 HOURS OR AS REQUIRED (A)
DRAIN AND REFILL (B) (C)
CHECK FOR CRACKS AND LOOSE CONNECTIONS (A)
CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS
CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS
GREASE - 8 SHOTS EACH - EVERY 45 FOR ONE REVOLUTION (A)
3
9
11
14
15
19
24
1
1
1
1
1
1
1
MPL-SEE LUBRICANTS
JD FILTER
JD FILTER
EO-SEE LUBRICANTS
8
17
20
1
1
1
HYDO-SEE LUBRICANTS
22
DRAIN AND REFILL EVERY 2000 HOURS. CLEAN SUCTION SCREEN (A)
REFER TO SERVICE MANUAL
DRAIN, FLUSH AND REFILL WITH PROPER COOLANT. FILL RADIATOR, FILL BOTTLE
TO ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD (A)
DRAIN AND REFILL EACH (A)
10
OR
DAILY
50
OR WEEKLY
MAINTENANCE
POINTS
ITEM
100
250
500
1000
2000
DESCRIPTION
APPROVED MATERIAL
MPGM-SEE LUBRICANTS
HYDO-SEE LUBRICANTS
EO-SEE LUBRICANTS
PROPER COOLANT (A)
MPGM-SEE LUBRICANTS
JD FILTER
JD ELEMENT
EO-SEE LUBRICANTS
EO-SEE LUBRICANTS
PROPER COOLANT (A)
DISTILLED WATER
MPL-SEE LUBRICANTS
MPGM-SEE LUBRICANTS
JD FILTER
JD FILTER
JD FILTER
EO-SEE LUBRICANTS
JD FILTER
JD FILTER
MPGM-SEE LUBRICANTS
HYEX01534
0027-10
TM 5-3805-294-10
0027
DECALS - Continued
U.S. MEASURE
FUEL TANK
COOLING SYSTEM
ENGINE CRANKCASE
(INCLUDING FILTER)
HYDRAULIC RESERVOIR
HYDRAULIC SYSTEM
SWING BEARING GEAR
SWING GEAR REDUCTION
TRAVEL GEARBOX (EACH)
PUMP DRIVE GEARBOX
132 GAL
31.6 QT
26 QT
(6.5 GAL)
39 GAL
63.4 GAL
22 LB
7.5 QT
6.5 QT
1.2 QT
METRIC
500 L
29.9 L
24.6 L
147.6 L
240 L
10 Kg
7L
6.2 L
1.1 L
10 11 12 13
14
15
16
17
18
19
20
29
28
27 26
25 24 23 22
21
LUBRICANTS
AIR TEMPERATURE RANGE DURING FILL PERIOD
RECOMMENDED LUBRICANTS
- 40
- 22
-4
14
32
50
68
86
104
122
- 40
- 30
- 20
- 10
10
20
30
40
50
SAE 15W40
SAE 10W30
SAE 5W30
SAE 0W40
SAE 30
(1) ARCTIC OIL
SAE 10W30
SAE 5W30
SAE 15W40
MIL-46167
MIL-32073-GR1
MIL-32073-GR5
SAE 90: 85W140
SAE 80W90
SAE 75W
ARCTIC OIL
NLGI NO. 0 OR 1
ARCTIC GREASE
HYEX01535
Figure 17.
TM 5-3805-294-10
0027
DECALS - Continued
WARNING
TOP OF WEDGE MUST BE
ENGAGED TO THIS AREA
BEFORE OPERATING
ATTACHMENT.
HYEX01441
WARNING
TOP OF WEDGE MUST BE
ENGAGED TO THIS AREA
BEFORE OPERATING
ATTACHMENT.
HYEX01440
Figure 19.
0027-12
TM 5-3805-294-10
0027
DECALS - Continued
HYEX01437
Figure 20.
HYEX01438
Figure 21.
0027-13
TM 5-3805-294-10
0027
DECALS - Continued
DANGER
DANGER
SHUT OFF
EXCAVATOR PRIOR
TO MAINTENANCE
ALL PERSONNEL
STAND CLEAR
FLYING DEBRIS
DANGER
DANGER
HIGH PRESSURE
HYDRAULIC
SYSTEM
DO NOT OPERATE
WITHOUT GUARDS
HYEX01439
0027-14
TM 5-3805-294-10
0028
OPERATOR MAINTENANCE
TOWING THE HYEX
INITIAL SETUP:
Not Applicable
TOWING
CAUTION
The travel motors require hydraulic pressure to release the parking brakes. Do not attempt
to tow the HYEX without Field Maintenance support. Field Maintenance must prepare the
travel motors before the HYEX can be towed. Failure to comply may result in damage to
equipment.
In the event during operation of the HYEX the machine becomes disabled and needs to be towed, notify Field level
maintenance.
END OF TASK
END OF WORK PACKAGE
0028-1/2 blank
TM 5-3805-294-10
0029
OPERATOR MAINTENANCE
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE
INITIAL SETUP:
Not Applicable
LOWERING BOOM
In the event during operation of the HYEX the machine becomes disabled and the boom needs to be lowered, notify
Field level maintenance.
END OF TASK
END OF WORK PACKAGE
0029-1/2 blank
TM 5-3805-294-10
0030
OPERATOR MAINTENANCE
OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)
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.
BACK BUTTON
HYEX01413
Figure 1.
2.
0030-1
TM 5-3805-294-10
0030
STARTING - Continued
HYEX01414
Figure 2.
3.
4.
BACK
BUTTON
MENU
BUTTON
Figure 3.
5.
0030-2
HYEX01415
TM 5-3805-294-10
0030
STARTING - Continued
Main Menu
Fuel Rate Display/No Display
Back Monitor Settings
SERVICE
MENU
Language/
Service Menu
SELECT
BUTTON
1
BUTTON 1
F1
F2
F3
F4
BUTTON 2
HYEX01416
Figure 4.
6.
7.
Press button one or button two until monitoring is highlighted then press the select button.
Service Menu
Troubleshooting
Monitoring
Ver. Controller Version
MONITORING
SELECT
BUTTON
BUTTON 2
1
BUTTON 1
6
F1
F2
F3
F4
HYEX01417
Figure 5.
8.
Select Monitoring.
Press button 1 or 2 until the hydraulic oil temperature, coolant temperature, and actual engine speed are
displayed. (WP 0005)
0030-3
TM 5-3805-294-10
0030
STARTING - Continued
Monitoring
Hydraulic Oil Temperature
0 oC
0 oC
Fuel Temperature
0 oC
ON
1
F1
F2
F3
F4
HYEX01418
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
0030
STARTING - Continued
HYEX01420
Figure 8.
11.
Ensure engine coolant and hydraulic oil temperatures are above 0F (-18C) before proceeding to Step 12.
Monitoring
Hydraulic Oil Temperature
0 oC
0 oC
Fuel Temperature
0 oC
ON
1
F1
F2
F3
F4
HYEX01418
Figure 9.
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
0030
STARTING - Continued
Table 1.
Engine Speed
OFF
Slow (Turtle)
13.
WARNING
Clear the area of all personnel during machine warm up procedures. Machine can move
unexpectedly. Failure to comply may result in injury or death to personnel.
CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
14.
Operate swing, boom, arm, hydraulic thumb, and bucket functions slowly and short distances initially in each
direction. (WP 0004)
15.
Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is
obtained.
16.
5
6
3
7
Figure 10.
HYEX01421
Raise Machine.
17.
18.
Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees,
slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.
0030-6
TM 5-3805-294-10
0030
STARTING - Continued
19.
Operate travel lever for raised track for approximately 5 minutes. (WP 0004)
20.
Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.
21.
END OF TASK
END OF WORK PACKAGE
0030-7/8 blank
TM 5-3805-294-10
0031
OPERATOR MAINTENANCE
OPERATING IN COLD WEATHER 5F (-15C) OR COLDER
INITIAL SETUP:
References
WP 0004
References (cont.)
WP 0018
WP 0034
STARTING
NOTE
Contact Field Maintenance to ensure that all fluids meet the requirements for the current
operating conditions.
In extreme cold conditions, an extended warm-up period will be necessary.
Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly
warm.
1.
If temperature is 5F (-15C) or below, operate coolant heater for 30 minutes. (WP 0034)
2.
BACK
BUTTON
HYEX01423
Figure 1.
0031-1
TM 5-3805-294-10
0031
STARTING - Continued
3.
HYEX01424
Figure 2.
4.
BACK
BUTTON
MENU
BUTTON
Figure 3.
5.
6.
0031-2
HYEX01415
TM 5-3805-294-10
0031
STARTING - Continued
Main Menu
Fuel Rate Display/No Display
Back Monitor Settings
SERVICE
MENU
Language/
Service Menu
SELECT
BUTTON
1
BUTTON 1
F1
F2
F3
F4
BUTTON 2
HYEX01430
Figure 4.
7.
8.
Press button one or button two until monitoring is highlighted, then press the select button.
MONITORING
Service Menu
Troubleshooting
Monitoring
Ver. Controller Version
SELECT
BUTTON
1
BUTTON 1
6
F1
F2
F3
F4
BUTTON 2
HYEX01431
Figure 5.
Select Monitoring.
0031-3
TM 5-3805-294-10
0031
STARTING - Continued
9.
Ensure the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed.
Monitoring
Hydraulic Oil Temperature
0 oC
0 oC
Fuel Temperature
0 oC
ON
1
F1
F2
F3
F4
HYEX01432
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
0031
STARTING - Continued
HYEX01434
Figure 8.
12.
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
0 oC
Fuel Temperature
0 oC
ON
1
F1
F2
F3
F4
HYEX01432
Figure 9.
0031-5
TM 5-3805-294-10
0031
STARTING - Continued
NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders
are fully raised, the overload alarm may sound even if the machine is not in an overload
condition. Lower the boom cylinders until the alarm is no longer displayed.
13.
Set machine switch selections for temperatures between 5F (-15C) and below per Table 1.
Table 1.
Machine Specification
Temperatures 5 to 0F (-15 to
-18C)
Engine Speed
OFF
OFF
Slow (Turtle)
Slow (Turtle)
14.
WARNING
Clear the area of all personnel during machine warm up procedures. Machine can move
unexpectedly. Failure to comply may result in injury or death to personnel.
CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
15.
Operate swing, boom, arm, and bucket functions slowly and short distances initially in each direction.
(WP 0004)
16.
Continue cycling cylinders by increasing travel each cycle until full smooth movement of function is obtained.
17.
0031-6
TM 5-3805-294-10
0031
STARTING - Continued
5
6
3
7
Figure 10.
HYEX01435
Raise Machine.
18.
19.
Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees,
slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.
20.
Operate travel lever for raised track for approximately 5 minutes. (WP 0004)
21.
Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.
22.
END OF TASK
END OF WORK PACKAGE
0031-7/8 blank
TM 5-3805-294-10
OPERATOR MAINTENANCE
SLAVE STARTING
INITIAL SETUP:
References
WP 0007
SLAVE STARTING
WARNING
An explosive gas is produced while batteries are in use or being charged. Keep flames and
sparks away from battery area. Ensure batteries are charged in a well-ventilated area. Failure
to comply may result in injury or death to personnel.
NOTE
Ensure that booster vehicle is equipped with a slave receptacle.
1.
2.
3.
Remove cap (Figure 1, Item 1) from slave receptacle (Figure 1, Item 2).
0032-1
0032
TM 5-3805-294-10
0032
HYEX00866
Figure 1.
Slave Receptacle.
4.
5.
Run booster vehicle at a speed just above idle. Refer to booster vehicle Operator's Manual.
6.
7.
After starting machine, return booster vehicle to idle. Refer to booster vehicle Operator's Manual.
8.
Remove the slave cable from slave receptacle (Figure 1, Item 2).
9.
10.
END OF TASK
END OF WORK PACKAGE
0032-2
TM 5-3805-294-10
0033
OPERATOR MAINTENANCE
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)
INITIAL SETUP:
Not Applicable
2.
HYEX00943
Figure 1.
3.
END OF TASK
REAR WINDOW (EMERGENCY EXIT)
1.
Remove emergency exit tool (Figure 2, Item 3) from holder (Figure 2, Item 4).
0033-1
TM 5-3805-294-10
0033
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.
Using emergency exit tool (Figure 2, Item 3) smash rear window (Figure 2, Item 5). One or two strikes with
emergency exit tool (Figure 2, Item 3) should shatter glass.
3.
END OF TASK
END OF WORK PACKAGE
0033-2
TM 5-3805-294-10
OPERATOR MAINTENANCE
OPERATING THE COOLANT HEATER
INITIAL SETUP:
Not Applicable
WARNING
The coolant heater must be switched off while the fuel tank on the machine is being filled.
Failure to comply may result in injury or death to personnel.
DO NOT operate engine or coolant heater in a closed place without proper ventilation.
Failure to comply may result in injury or death to personnel.
CAUTION
If a fault arises during coolant heater operation, the heat symbol will flash on the control panel
display and a three-digit fault code will be displayed. Shut down the coolant heater and notify
field maintenance. Failure to comply may result in damage to equipment.
NOTE
Coolant heater is only required to be used when temperature is -25 F (-32 C) or colder.
The timer can control operation of the coolant heater for up to 7 days in advance.
The default timer setting is for the coolant heater to operate for 120 minutes before
automatically turning off.
0034-1
0034
TM 5-3805-294-10
0034
The coolant heater control panel (Figure 1, Item 1) is located on left outer console of operator's seat.
2
1
M0
20:30
HYEX00023
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
Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust time up or down.
3.
When time is correct wait approximately 5 seconds and day (Figure 2, Item 7) will begin to flash.
4.
Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust day (Figure 2,
Item 7) up or down.
5.
When day (Figure 2, Item 7) is correct wait approximately 5 seconds and day will stop flashing.
0034-2
TM 5-3805-294-10
0034
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
Figure 3.
HYEX01315
Setting Program.
2.
Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust start time (Figure
3, Item 4) up or down.
3.
When start time (Figure 3, Item 4) is set, wait approximately 5 seconds and day (Figure 3, Item 7) will begin
to flash.
4.
Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust day (Figure 3,
Item 7) up or down.
5.
When day (Figure 3, Item 7) is set, wait approximately 5 seconds and day will stop flashing.
6.
7.
8.
END OF TASK
ADJUSTING COOLANT HEATER RUN TIME
NOTE
The maximum amount of time for the coolant heater will run is 120 minutes.
0034-3
TM 5-3805-294-10
0034
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
Press the left arrow button (Figure 4, Item 5) or right arrow button (Figure 4, Item 6) to adjust run time (Figure
4, Item 11) up or down.
3.
After desired run time (Figure 4, Item 11) is selected, wait approximately 5 seconds and run time is set.
END OF TASK
USING COOLANT HEATER MANUALLY
1.
Press heater button (Figure 5, Item 10) and the coolant heater will start and run.
11
120
10
Figure 5.
HYEX00020
2.
If desired, press the left arrow button (Figure 5, Item 5) or right arrow button (Figure 5, Item 6) to adjust run
time (Figure 5, Item 11) up or down.
3.
To manually shut coolant heater off press the heater button (Figure 6, Item 10). The coolant heater will do a
normal cool-down cycle and then turn itself off.
0034-4
TM 5-3805-294-10
0034
11
120
10
Figure 6.
HYEX00020
END OF TASK
END OF WORK PACKAGE
0034-5/6 blank
TM 5-3805-294-10
0035
OPERATOR MAINTENANCE
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES
INITIAL SETUP:
Not Applicable
PULLING MACHINE UP
WARNING
This procedure should only be used on a short slope of no more than 35 degrees to prevent
machine rollover. The machine depends on support of the boom, arm, and bucket during
entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to
reposition the bucket or swing upperstructure during the procedure because the machine will
become unstable. Failure to comply may result in injury or death to personnel.
1.
HYEX00687
Figure 1.
2.
Position undercarriage so travel motors (Figure 2, Item 2) will be on the uphill end of machine (Figure 2, Item
3).
0035-1
TM 5-3805-294-10
0035
4
5
HYEX00674
Push bucket (Figure 2, Item 4) into the ground on the top of the slope.
4.
While using travel pedals pull the machine using the boom (Figure 2, Item 5) and arm cylinder (Figure 2, Item
6) to assist the travel motors (Figure 2, Item 2).
END OF TASK
PUSHING MACHINE UP
WARNING
This procedure should only be used on a short slope of no more than 35 degrees to prevent
machine rollover. The machine depends on support of the boom, arm, and bucket during
entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to
reposition the bucket or swing upperstructure during the procedure because the machine will
become unstable. Failure to comply may result in injury or death to personnel.
1.
0035-2
TM 5-3805-294-10
0035
HYEX00687
Figure 3.
2.
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
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.
END OF TASK
END OF WORK PACKAGE
0035-5/6 blank
0035
TM 5-3805-294-10
0036
OPERATOR MAINTENANCE
FORDING THE HYEX
INITIAL SETUP:
References
WP 0093
FORDING
CAUTION
Do not ford water unless depth is known. Water deeper than 40.0 in. (1.0 m) may enter
machine systems and damage operating components. Failure to comply may result in
damage to equipment.
NOTE
Use travel control levers during fording operations to maintain better control of machine
speed.
1.
Ensure bottom at fording site is firm enough that 40 in. (1 m) maximum fording depth will not be exceeded and
machine will not become mired.
HYEX01311
Figure 1.
Fording Line.
2.
3.
0036-1
TM 5-3805-294-10
0036
FORDING - Continued
Figure 2.
4.
HYEX00367
Ensure that there are no alarms indicated on monitor (Figure 3, Item 2).
5
2
Figure 3.
HYEX00368
Check Monitor.
5.
6.
7.
8.
Enter the water slowly to minimize surges of backwash into the upperstructure.
9.
If machine accidently enters water deeper than 40 in. (1.0 m), move travel levers (Figure 3, Item 5) back 1/4
travel and slowly back machine out of deep water.
0036-2
TM 5-3805-294-10
FORDING - Continued
10.
END OF TASK
END OF WORK PACKAGE
0036-3/4 blank
0036
TM 5-3805-294-10
CHAPTER 3
OPERATOR TROUBLESHOOTING PROCEDURES
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0037
OPERATOR MAINTENANCE
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE
Troubleshooting Procedure
ELECTRICAL SYSTEM
1.
2.
3.
4.
5.
6.
7.
Low Note and High Note Horns Do Not Operate ............................................................................. WP 0044
8.
ENGINE
1.
Engine Cranks But Will Not Start Or Hard To Start .......................................................................... WP 0046
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
HYDRAULICS SYSTEM
1.
2.
3.
4.
5.
0037-1
TM 5-3805-294-10
0037
Troubleshooting Procedure
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
0037-2
TM 5-3805-294-10
0038
OPERATOR MAINTENANCE
TRAVEL ALARM DOES NOT OPERATE
INITIAL SETUP:
References
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Travel Alarm Does Not Operate.
Malfunction
Travel Alarm Fuse
Blown.
Test or Inspection
1.
2.
0038-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0039
OPERATOR MAINTENANCE
WINDSHIELD WIPER AND WASHER DO NOT OPERATE
INITIAL SETUP:
References
WP 0009
WP 0011
WP 0084
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Windshield Wiper and Washer Do Not Operate.
Malfunction
1.
2.
Upper Front
Window Not Fully
Closed.
Windshield Wiper
and Washer Fuse
Blown.
Test or Inspection
1.
2.
1.
2.
3.
0039-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0040
OPERATOR MAINTENANCE
CAB DOME LIGHT DOES NOT OPERATE
INITIAL SETUP:
References
WP 0004
WP 0009
WP 0084
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Cab Dome Light Does Not Operate.
Malfunction
1.
2.
Test or Inspection
1.
2.
3.
0040-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0041
OPERATOR MAINTENANCE
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE
INITIAL SETUP:
References
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Boom, Cab, And Drive Lights Do Not Operate.
Malfunction
Work and Drive
Lights Fuse Blown.
Test or Inspection
1.
2.
0041-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0042
OPERATOR MAINTENANCE
CAB FRONT WORK LIGHTS DO NOT OPERATE
INITIAL SETUP:
References
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Cab Front Work Lights Do Not Operate.
Malfunction
Cab Front Work
Lights Fuse Blown.
Test or Inspection
1.
2.
0042-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0043
OPERATOR MAINTENANCE
CAB REAR WORK LIGHTS DO NOT OPERATE
INITIAL SETUP:
References
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Cab Rear Work Lights Do Not Operate.
Malfunction
Cab Rear Work
Lights Fuse Blown.
Test or Inspection
1.
2.
0043-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0044
OPERATOR MAINTENANCE
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE
INITIAL SETUP:
References
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Low Note And High Note Horns Do Not Operate.
Malfunction
Horn Fuse Blown.
Test or Inspection
1.
2.
0044-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0045
OPERATOR MAINTENANCE
AIR CONDITIONER DOES NOT OPERATE
INITIAL SETUP:
References
WP 0077
WP 0084
WP 0089
WP 0090
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Air Conditioner Does Not Operate.
Malfunction
1.
2.
3.
Test or Inspection
1.
2.
1.
2.
1.
2.
0045-1
Corrective Action
1.
2.
1.
2.
1.
2.
3.
TM 5-3805-294-10
0045
5.
6.
Air Conditioner/
Heater Filter
Clogged or
Damaged.
Air Conditioner
Condenser Dirty or
Damaged.
Test or Inspection
1.
2.
0045-2
Corrective Action
1.
2.
3.
1.
2.
3.
1.
2.
TM 5-3805-294-10
0046
OPERATOR MAINTENANCE
ENGINE CRANKS BUT DOES NOT START OR HARD TO START
INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077
References (cont.)
WP 0086
WP 0087
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Cranks But Does Not Start or Hard to Start.
Malfunction
1.
2.
3.
Test or Inspection
Engine Cranks
Slowly.
1.
2.
3.
1.
2.
0046-1
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0046
Table 1. Engine Cranks But Does Not Start or Hard to Start - Continued.
Malfunction
Test or Inspection
3.
4.
5.
Fuel Filter/Water
Separators Contain
Water or Sediment.
1.
2.
0046-2
Corrective Action
1.
2.
1.
2.
1.
2.
TM 5-3805-294-10
0047
OPERATOR MAINTENANCE
ENGINE WILL NOT CRANK
INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
References (cont.)
WP 0077
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Will Not Crank.
Malfunction
1.
2.
Discharged
Batteries.
Test or Inspection
1.
2.
1.
2.
3.
0047-1
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0047
Blown Fuses.
Test or Inspection
1.
Corrective Action
2.
4.
Corroded or Loose
Battery
Connections.
0047-2
1.
2.
1.
2.
TM 5-3805-294-10
0048
OPERATOR MAINTENANCE
ENGINE RUNS POORLY
INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077
WP 0086
References (cont.)
WP 0087
WP 0091
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Runs Poorly.
Malfunction
1.
2.
Fuel Filter/Water
Separators Contain
Water or Sediment.
Test or Inspection
1.
2.
1.
2.
0048-1
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0048
Fuel Tank is
Contaminated.
Test or Inspection
1.
2.
3.
4.
0048-2
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0049
OPERATOR MAINTENANCE
EXCESSIVE FUEL CONSUMPTION
INITIAL SETUP:
References
WP 0005
WP 0009
References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Excessive Fuel Consumption.
Malfunction
1.
2.
Test or Inspection
1.
2.
0049-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0050
OPERATOR MAINTENANCE
EXCESSIVE OIL CONSUMPTION
INITIAL SETUP:
References
WP 0005
WP 0009
References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Excessive Oil Consumption.
Malfunction
1.
2.
Test or Inspection
1.
2.
0050-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0051
OPERATOR MAINTENANCE
ENGINE IDLES POORLY
INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077
References (cont.)
WP 0086
WP 0087
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Idles Poorly.
Malfunction
1.
2.
Fuel Filter/Water
Separators Contain
Water or Sediment.
Test or Inspection
1.
2.
3.
1.
2.
0051-1
Corrective Action
1.
2.
3.
1.
2.
TM 5-3805-294-10
0051
Test or Inspection
1.
2.
0051-2
Corrective Action
1.
2.
TM 5-3805-294-10
0052
OPERATOR MAINTENANCE
AUTO-IDLE DOES NOT WORK
INITIAL SETUP:
References
WP 0004
WP 0005
WP 0009
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Auto-Idle Does Not Work.
Malfunction
1.
2.
3.
Hydraulic
Operations Being
Performed.
Test or Inspection
1.
2.
0052-1
Corrective Action
1.
2.
1.
2.
If A. I. indicator is displayed on
monitor, proceed to
Malfunction 3.
1.
TM 5-3805-294-10
0052
4.
Test or Inspection
0052-2
Corrective Action
2.
1.
2.
TM 5-3805-294-10
0053
OPERATOR MAINTENANCE
ENGINE NOT DEVELOPING FULL POWER
INITIAL SETUP:
References
WP 0005
WP 0009
References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Not Developing Full Power.
Malfunction
1.
2.
3.
Exhaust Pipes
Dented or
Restricted.
Test or Inspection
1.
2.
0053-1/2 blank
Corrective Action
1.
2.
1.
2.
1.
2.
TM 5-3805-294-10
0054
OPERATOR MAINTENANCE
ENGINE OIL PRESSURE LOW
INITIAL SETUP:
References
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Oil Pressure Low.
Malfunction
Low Engine Oil
Level.
Test or Inspection
Check engine oil level.
(WP 0077)
0054-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0055
OPERATOR MAINTENANCE
ENGINE COOLANT TEMPERATURE ABOVE NORMAL
INITIAL SETUP:
References
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Coolant Temperature Above Normal.
Malfunction
1.
2.
3.
4.
Engine Coolant
Level Low.
Radiator Damaged
or Has Foreign
Objects/Debris.
Test or Inspection
Visually inspect engine coolant
level. (WP 0077)
0055-1/2 blank
Corrective Action
1.
2.
1.
2.
1.
2.
3.
1.
2.
3.
TM 5-3805-294-10
0056
OPERATOR MAINTENANCE
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE
INITIAL SETUP:
References
WP 0005
WP 0009
WP 0087
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Emits Excessive Black Or Gray Exhaust Smoke.
Malfunction
Air Cleaners Dirty
or Clogged.
Test or Inspection
1.
2.
0056-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0057
OPERATOR MAINTENANCE
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE
INITIAL SETUP:
References
WP 0007
WP 0009
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Emits Excessive White Exhaust Smoke.
Malfunction
1.
2.
Test or Inspection
White Exhaust
Smoke Excessive at
Normal Operating
Temperature.
2.
3.
0057-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0058
OPERATOR MAINTENANCE
NO HYDRAULIC FUNCTIONS
INITIAL SETUP:
References
WP 0004
WP 0009
References (cont.)
WP 0077
WP 0088
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. No Hydraulic Functions.
Malfunction
1.
2.
Test or Inspection
1.
2.
3.
0058-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0059
OPERATOR MAINTENANCE
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER
INITIAL SETUP:
References
WP 0030
WP 0031
WP 0077
WP 0088
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Functions Are Slow or Have Little or No Power.
Malfunction
1.
2.
3.
Hydraulic Reservoir
Fill Cap is Damaged
or Missing
Hardware.
Test or Inspection
Check hydraulic oil level.
(WP 0077)
Corrective Action
1.
2.
1.
2.
1.
If damaged or missing
hardware, notify Field
Maintenance.
2.
0059-1/2 blank
TM 5-3805-294-10
0060
OPERATOR MAINTENANCE
POWER DIG DOES NOT WORK
INITIAL SETUP:
References
WP 0077
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Power Dig Does Not Work.
Malfunction
1.
2.
Solenoid Fuse
Blown.
Test or Inspection
1.
2.
Visually inspect F4
SOLENOID 10A fuse for blown
fuse.
0060-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0061
OPERATOR MAINTENANCE
HYDRAULIC OIL OVERHEATS
INITIAL SETUP:
References
WP 0077
WP 0088
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Oil Overheats.
Malfunction
1.
2.
Cooling Package
Has Damage,
Foreign Objects/
Debris.
Test or Inspection
Visually inspect cooling
package for damage, foreign
objects/debris. (WP 0077)
0061-1/2 blank
Corrective Action
1.
2.
3.
1.
2.
TM 5-3805-294-10
0062
OPERATOR MAINTENANCE
HYDRAULIC OIL FOAMS
INITIAL SETUP:
References
WP 0077
WP 0088
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Oil Foams.
Malfunction
1.
2.
Test or Inspection
Check hydraulic oil level.
(WP 0077)
0062-1/2 blank
Corrective Action
1.
2.
3.
1.
2.
TM 5-3805-294-10
0063
OPERATOR MAINTENANCE
NO SWING FUNCTION
INITIAL SETUP:
References
WP 0077
WP 0088
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. No Swing Function.
Malfunction
Hydraulic Oil Level
Low.
Test or Inspection
Check hydraulic oil level.
(WP 0077)
0063-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0064
OPERATOR MAINTENANCE
SWING FUNCTION IS JERKY
INITIAL SETUP:
References
LO 5-3805-294-13 (WP 0094)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Swing Function Is Jerky.
Malfunction
Lack of Grease in
Swing Bearing.
Test or Inspection
Visually inspect swing bearing
grease fittings (LO
5-3805-294-13). (WP 0094)
0064-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0065
OPERATOR MAINTENANCE
SLOW TRAVEL SPEED ONLY
INITIAL SETUP:
References
WP 0077
WP 0084
WP 0088
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Slow Travel Speed Only.
Malfunction
1.
2.
Solenoid Fuse
Blown.
Test or Inspection
1.
2.
Visually inspect F4
SOLENOID 10A fuse for blown
fuse.
0065-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0066
OPERATOR MAINTENANCE
TRAVEL IS JERKY
INITIAL SETUP:
References
WP 0077
WP 0080
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Travel is Jerky.
Malfunction
1.
2.
Incorrect Track
Chain Tension.
Debris in Track
Frame.
Test or Inspection
Check track chain sag.
(WP 0080)
0066-1/2 blank
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0067
OPERATOR MAINTENANCE
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED
INITIAL SETUP:
References
WP 0007
WP 0008
WP 0086
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Engine Stops When Travel or Control Lever Actuated.
Malfunction
Fuel Filter/Water
Separators Contain
Water or Sediment.
Test or Inspection
1.
2.
3.
0067-1/2 blank
Corrective Action
1.
2.
3.
TM 5-3805-294-10
0068
OPERATOR MAINTENANCE
QUICK LATCH DOES NOT OPERATE
INITIAL SETUP:
References
WP 0009
WP 0014
References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Quick Latch Does Not Operate.
Malfunction
1.
2.
3.
Test or Inspection
1.
2.
3.
1.
2.
3.
0068-1
Corrective Action
1.
2.
1.
2.
1.
2.
TM 5-3805-294-10
0068
Test or Inspection
Visually inspect quick latch for
jammed debris. (WP 0077)
0068-2
Corrective Action
1.
2.
TM 5-3805-294-10
0069
OPERATOR MAINTENANCE
COMPACTOR DOES NOT OPERATE
INITIAL SETUP:
References
WP 0077
WP 0020
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Compactor Does Not Operate.
Malfunction
1.
2.
3.
Hydraulic Supply
Quick Disconnect
Not Fully Seated.
Hydraulic Return
Quick Disconnect
Not Fully Seated.
Compactor Has
Jammed Debris.
Test or Inspection
Visually inspect hydraulic
supply quick disconnect.
(WP 0077)
0069-1/2 blank
Corrective Action
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
1.
2.
TM 5-3805-294-10
0070
OPERATOR MAINTENANCE
BREAKER DOES NOT OPERATE
INITIAL SETUP:
References
WP 0020
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Breaker Does Not Operate.
Malfunction
1.
2.
3.
Hydraulic Supply
Quick Disconnect
Not Fully Seated.
Hydraulic Return
Quick Disconnect
Not Fully Seated.
Breaker Has
Jammed Debris.
Test or Inspection
Visually inspect hydraulic
supply quick disconnect.
(WP 0077)
0070-1/2 blank
Corrective Action
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
1.
2.
TM 5-3805-294-10
0071
OPERATOR MAINTENANCE
BREAKER OPERATES SLOWLY
INITIAL SETUP:
References
WP 0009
WP 0018
References (cont.)
WP 0077
WP 0088
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Breaker Operates Slowly.
Malfunction
1.
2.
3.
Test or Inspection
Breaker
Attachment Not
Selected.
Hydraulic Supply
Hose is Damaged or
Has Leaks.
Hydraulic Return
Hose is Damaged or
Has Leaks.
1.
2.
0071-1
Corrective Action
1.
If breaker attachment is
selected, proceed to
Malfunction 2.
2.
1.
2.
1.
2.
TM 5-3805-294-10
0071
Test or Inspection
Check hydraulic oil level.
(WP 0077)
0071-2
Corrective Action
1.
2.
TM 5-3805-294-10
0072
OPERATOR MAINTENANCE
CRUSH-ALL DOES NOT OPERATE
INITIAL SETUP:
References
WP 0020
WP 0077
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Crush-All Does Not Operate.
Malfunction
1.
2.
3.
12-Volt Power
Outlet Fuse Blown.
Hydraulic Supply
Quick Disconnect
Not Fully Seated.
Hydraulic Return
Quick Disconnect
Not Fully Seated.
Test or Inspection
1.
2.
0072-1
Corrective Action
1.
2.
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
TM 5-3805-294-10
0072
Crush-All Has
Jammed Debris.
Test or Inspection
Visually inspect crush-all for
jammed debris. (WP 0077)
0072-2
Corrective Action
1.
2.
TM 5-3805-294-10
0073
OPERATOR MAINTENANCE
BARRIER GRAPPLE DOES NOT HOLD LOAD
INITIAL SETUP:
References
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Barrier Grapple Does Not Hold Load.
Malfunction
Grip pads worn.
Test or Inspection
Visually inspect grip pads.
(WP 0077)
0073-1/2 blank
Corrective Action
1.
2.
TM 5-3805-294-10
0074
OPERATOR MAINTENANCE
DEEP DIG DOES NOT OPERATE
INITIAL SETUP:
References
WP 0009
WP 0023
References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Deep Dig Does Not Operate.
Malfunction
1.
2.
3.
Test or Inspection
Cab Auxiliary
Power Connector
One Fuse Blown.
Hydraulic Supply
Quick Disconnect
Not Fully Seated.
1.
2.
3.
1.
2.
3.
0074-1
Corrective Action
1.
2.
1.
2.
TM 5-3805-294-10
0074
Test or Inspection
4.
0074-2
Corrective Action
1.
2.
If quick disconnect(s) is
damaged, notify Field
Maintenance.
3.
4.
TM 5-3805-294-10
0075
OPERATOR MAINTENANCE
HYDRAULIC HOSE REEL DOES NOT OPERATE
INITIAL SETUP:
References
WP 0009
WP 0026
References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)
TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Hose Reel Does Not Operate.
Malfunction
1.
2.
3.
Test or Inspection
Hand Held
Hydraulic Tool
Circuit Switch is
OFF.
Cab Auxiliary
Power Connector
One Fuse Blown.
Hydraulic Supply
Quick Disconnect
Not Fully Seated.
1.
2.
3.
0075-1
Corrective Action
1.
2.
1.
2.
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
TM 5-3805-294-10
0075
5.
6.
Hydraulic Return
Quick Disconnect
Not Fully Seated.
Test or Inspection
Visually inspect hydraulic
return quick disconnect.
(WP 0077)
Corrective Action
1.
2.
3.
If quick disconnect is
damaged, notify Field
Maintenance.
Hydraulic Tool
Supply Hose Has
Damage.
1.
2.
Hydraulic Tool
Return Hose Has
Damage.
1.
2.
0075-2
TM 5-3805-294-10
CHAPTER 4
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (PMCS)
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0076
OPERATOR MAINTENANCE
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
NOTE
If the machine has reached the initial 250 hours of operation, contact field level
maintenance to perform the initial 250 hour service.
Tools supplied on the machine are to be used for Preventive Maintenance Checks and
Services (PMCS). Rags are also required for removing dirt and grease.
PMCS intervals should be performed more frequently when operating under unusual
conditions.
Perform PMCS on attachments only if they are to be used for the current mission.
This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The PMCS tables
contain checks and services necessary to ensure that the machine is ready for operation. Maintenance is performed
at specified intervals using the PMCS tables.
Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable.
Components in good condition are: not bent or twisted, chafed or burned, broken, or cracked. There should be no
signs of wear, fraying, dents, collapsing, tears, cuts, or deterioration.
Damage is any condition that affects safety or prevents a part or assembly from functioning normally or would render
the machine unserviceable for mission requirements.
MAINTENANCE RECORDS AND FORMS
Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The completed forms
and records have several uses. They are a permanent record of services, repairs, and modifications made to the
machine. They are reports to maintenance personnel, and to the Commander. They serve as a checklist to track
previous machine malfunctions and repair actions. Record results of PMCS on DA Form 2404, Equipment Inspection
and Maintenance Worksheet, or DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet.
For the information needed on forms and records, refer to DA PAM 750-8 The Army Maintenance Management
System (TAMMS) Users Manual.
GENERAL MAINTENANCE PROCEDURES
Cleanliness: Dirt, grease, oil, and debris can conceal serious problems. Use solvent cleaning compound
on all metal surfaces and soapy water on rubber or plastic surfaces.
Bolts, Nuts, and Screws: Check for loose bolts, nuts, and screws, as well as for those that are missing,
bent, or broken. Tighten or replace as necessary. If parts cannot be checked with a tool, look for signs of
chipped paint, bare metal, or rust around bolt heads.
Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a damaged weld
is discovered, notify Field Level Maintenance.
Electric Wires and Connectors: Look for cracked or broken insulation, exposed wires, and loose or broken
connectors. Tighten loose connectors and ensure wires are in good shape.
Fluid Hoses, Tubes, and Fittings: Look for wear, damage, or leaks. Ensure clamps and fittings are tight.
Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If connectors or
fittings are loose or if hoses, tubes, or fittings are broken or worn out, notify Field Level Maintenance.
0076-1
TM 5-3805-294-10
0076
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).
0076-2
TM 5-3805-294-10
0076
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.
0076-3/4 blank
TM 5-3805-294-10
0077
OPERATOR MAINTENANCE
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP:
Materials/Parts
Antifreeze, Arctic Type
(WP 0097, Table 1, Item 1)
Antifreeze (WP 0097, Table 1, Item 2)
Engine Oil (WP 0097, Table 1, Item 13)
Gloves (WP 0097, Table 1, Item 10)
Goggles (WP 0097, Table 1, Item 10)
Grease (WP 0097, Table 1, Item 10)
Penetrating Oil (WP 0097, Table 1, Item 14)
Rags, Wiping (WP 0097, Table 1, Item 15)
References
LO 5-3805-294-13 (WP 0094)
Table 1.
ITEM
NO.
INTERVAL
References (cont.)
TM 5-3805-295-13&P (WP 0094)
WP 0007
WP 0009
WP 0034
WP 0080
WP 0085
WP 0087
WP 0088
WP 0089
WP 0090
WP 0091
WP 0094
PROCEDURE
WARNING
WARNING
0077-1
EQUIPMENT NOT
READY/
AVAILABLE IF:
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
the up position, and engine
shut off. Failure to comply
may result in injury or death
to personnel.
WARNING
CAUTION
New machine break-in
maintenance is required at
250 hours. Contact Field
Maintenance to avoid early
wear or damage to the machine. Failure to comply may
result in voidance of warranty and damage to the machine.
NOTE
Perform Operator's Before
PMCS checks if:
You are the assigned
operator but have not
operated the machine
since the last PMCS
was performed.
0077-2
EQUIPMENT NOT
READY/
AVAILABLE IF:
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
You are operating the
machine for the first
time.
Only perform PMCS on
attachments if they are
to be operated for
current mission.
The lubrication order is
to be used in
conjunction with the
PMCS.
For Armored Cab
PMCS, refer to
TM 5-3805-295-13&P.
Before
Exterior of Machine
Damage that
would impair
operation is evident.
3
1
4
Figure 1.
Exterior of Machine.
0077-3
HYEX01001
TM 5-3805-294-10
Table 1.
ITEM
NO.
2
0077
INTERVAL
Before
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
Check for loose or missing track
shoe (Figure 2, Item 2) and track
bolts.
3
1
HYEX01001
Before
Coolant level
below MIN
COLD level.
0077-4
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
6
Figure 3.
HYEX01002
Coolant Level.
If coolant is low, remove surge tank
cap (Figure 3, Item 7) and fill as
required.
Before
Cap is missing
or is unserviceable.
0077-5
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
8
9
HYEX01003
Figure 4.
Engine Oil.
If engine oil is low, remove cap
(Figure 4, Item 9) and add oil as
required (LO 5-3805-294-13).
(WP 0094)
Before
Engine Compartment
Any damage
that would impair safe operation of the machine.
Before
Exhaust Components
Loose, leaking,
or damaged
components.
0077-6
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
HYEX03409
Exhaust Components.
Figure 5.
7
Before
11
10
HYEX01004
Figure 6.
8
Before
Fuel Tank
0077-7
Any signs of
leaks from fuel
tank.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
14
13
12
HYEX01005
Figure 7.
Before
Fuel Filters
0077-8
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
16
15
18
17
HYEX01006
Figure 8.
Fuel Filters.
10
Before
11
Before
Hydraulic Pump
Compartment
Any damage
that would impair safe operation of machine.
12
Before
19
HYEX01007
Figure 9.
0077-9
TM 5-3805-294-10
Table 1.
ITEM
NO.
13
INTERVAL
Before
0077
ITEM TO BE CHECKED
OR SERVICED
Boom, Arm, Quick Latch,
Hydraulic Thumb
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
Check boom (Figure 10, Item 20),
arm (Figure 10, Item 21), quick
latch (Figure 10, Item 22), and
hydraulic thumb (Figure 10, Item
23) for damage that would impair
operation.
24
Damage that
impairs proper
operation.
27
20
25
26
23
21
24
26
24
22
24
HYEX01008
Before
NOTE
Bucket
0077-10
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
28
HYEX01009
Figure 11.
15
Before
Loose, broken,
or missing hardware or mounting bracket is
cracked.
Primary and
secondary air
cleaner housing
cracked or cover missing.
0077-11
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
29
30
33
32
31
HYEX01395
Figure 12.
16
Before
0077-12
TM 5-3805-294-10
Table 1.
ITEM
NO.
17
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
Before
Batteries
WARNING
EQUIPMENT NOT
READY/
AVAILABLE IF:
LEAD-ACID BATTERIES
Remove four wing nuts (Figure 13,
Item 34), washers (Figure 13, Item
35), and two covers (Figure 13,
Item 36) from batteries (Figure 13,
Item 37).
Check batteries (Figure 13, Item
37) for leaks or cracks.
Batteries show
signs of leaking
or have cracks.
40
41
36
34, 35
37
38
Figure 13.
39
HYEX01011
Batteries.
0077-13
Battery cables
are loose.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
Before
Cooling Package
19
Before
Fuel Cooler
40
41
36
34, 35
37
Figure 14.
38
39
HYEX01011
Batteries Continued.
Check windshield washer reservoir
(Figure 14, Item 41) for fluid and
damage. Fill as required.
20
Before
Cab Glass
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.
0077-14
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
42
42
42
42
HYEX01012
Figure 15.
21
Before
Cab Glass.
43
43
45
44
HYEX01396
Figure 16.
0077-15
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
Check that wiper arm and blade
(Figure 16, Item 45) are
serviceable.
22
Before
46
Door is difficult
to open or close.
47
48
48
46
HYEX03430
Figure 17.
23
Before
Fire Extinguisher
Door fails to
latch or latches
fail to release.
0077-16
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
49
HYEX01013
Figure 18.
24
Before
Fire Extinguisher.
Check that left and right travel pedal
and lever (Figure 19, Item 50) move
freely through their full range of
travel.
0077-17
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
50
ITEM TO BE CHECKED
OR SERVICED
50
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
50
50
51
52
HYEX01399
Figure 19.
25
Before
Attachment
pedal does not
move freely or
attachment
pedal lock does
not operate.
0077-18
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
54
53
HYEX01397
Figure 20.
26
Before
Horn
27
Before
Seat Belt
Seat belt is
frayed or will not
fasten together.
0077-19
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
55
HYEX01398
Figure 21.
28
Before
Monitor
Seat Belt.
56
HYEX01014
Figure 22.
Ignition Switch.
0077-20
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
NOTE
If default screen is not displayed after start up screen,
wait 10 seconds to ensure
default screen will be displayed.
Check that monitor (Figure 23, Item
57) comes on, then goes to default
screen.
Monitor does
not come on.
Monitor does
not go to default
screen.
57
System Starting...
1
F1
F2
F3
F4
HYEX01015
Figure 23.
Monitor.
29
Before
Starter
30
Before
Lights
Lights do not
operate.
31
Before
Wipers do not
operate.
32
Before
0077-21
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
60
58
59
Figure 24.
HYEX01016
61
HYEX01017
0077-22
Reservoir is
empty.
Sight glass is
broken or damaged.
Any Class III
leaks.
TM 5-3805-294-10
Table 1.
ITEM
NO.
33
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
Before
Breaker
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
NOTE
Only perform PMCS on attachments that are required
for current mission.
Check breaker (Figure 26, Item 62)
for loose, broken, or missing
hardware or mounting bracket
damage.
Loose, broken,
or missing hardware or mounting bracket is
cracked.
63
HYEX01018
62
Figure 26.
34
Before
Compactor
Breaker.
Loose, broken,
or missing hardware or mounting bracket is
cracked.
0077-23
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
65
64
HYEX01019
Figure 27.
35
Before
Crush-All
Compactor.
Loose, broken,
or missing hardware or mounting bracket is
cracked.
0077-24
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
66
Figure 28.
67
EQUIPMENT NOT
READY/
AVAILABLE IF:
HYEX01020
Crush-All.
Before
Lubricate
37
Before
Barrier Grapple
0077-25
Loose, broken,
or missing hardware or mounting bracket is
cracked.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
69
68
HYEX02987
Figure 29.
Barrier Grapple.
Check barrier grapple for missing or
damaged pads.
Barrier grapple
pad missing or
damaged.
Barrier grapple
cable is kinked
or three or more
strands are broken.
38
Before
39
Before
0077-26
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
72
71
70
HYEX01306
Figure 30.
40
Before
Loose, broken,
or missing hardware or mounting bracket is
cracked.
0077-27
TM 5-3805-294-10
Table 1.
ITEM
NO.
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
73
Before
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
HYEX01307
Figure 31.
41
0077
Loose, broken,
or missing hardware or mounting bracket is
cracked.
Loose, broken,
or missing hardware or mounting bracket is
cracked.
0077-28
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
74
HYEX01308
Figure 32.
42
During
Monitor
Any alarm
sounds or is displayed on monitor.
43
During
Engine speed
dial does not operate.
44
During
Right-Hand Console
Switches
Switches do not
operate.
45
During
Hydraulic Cylinders
46
During
If machine
doesn't travel in
a straight line.
Machine does
not steer left or
right.
Track chain
makes unusual
0077-29
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
When travel levers or
pedals are released
machine stops.
Travel levers and pedals
return to center when
released.
EQUIPMENT NOT
READY/
AVAILABLE IF:
or popping
noises.
Machine does
not stop when
travel levers or
pedals are released.
Travel levers or
pedals do not
return to center
when released.
47
During
Travel Alarm
Travel alarm
does not operate.
48
During
Upperstructure
does not stop or
drifts.
49
During
Air Conditioner/Heater
Blower motor
does not operate when turned
on.
50
During
Breaker
CAUTION
Breaker must be lubricated
every 2 hours of use and every hour during dusty conditions. Failure to comply may
result in damage to the attachment.
During extreme dusty conditions,
lubricate breaker after every hour of
use LO 5-3805-294-13.
(WP 0094)
51
After
0077-30
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
60
58
59
Figure 33.
HYEX01016
61
HYEX01017
Figure 34.
52
After
0077-31
Any signs of
leaks or damage to fuel tank
or strainer, or
strainer is missing.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
14
13
12
HYEX01005
After
CAUTION
0077-32
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
8
9
HYEX01003
Figure 36.
54
After
Engine Compartment,
Belts, and Hoses
HYEX03410
Figure 37.
Engine Compartment.
0077-33
Any damage
that would impair safe operation of the machine.
TM 5-3805-294-10
Table 1.
ITEM
NO.
55
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
After
Exterior of Machine
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
Perform walk-around inspection of
the machine exterior. Check on
ground under machine (Figure 38,
Item 1) for evidence of fluid leakage
such as oil, coolant, or fuel.
Damage that
would impair
operation is evident.
2
Figure 38.
HYEX01400
56
Monthly
CAUTION
0077-34
Any missing
track shoes or
mounting hardware.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
Check that swing gearbox oil is
between marks on dipstick (Figure
39, Item 75).
76
EQUIPMENT NOT
READY/
AVAILABLE IF:
Oil level is not
on dipstick.
75
HYEX01410
Figure 39.
57
Monthly
0077-35
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
78
77
HYEX01409
Figure 40.
58
Monthly
59
Monthly
Fuel Tank
60
Monthly
Coolant Heater
0077-36
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
EQUIPMENT NOT
READY/
AVAILABLE IF:
PROCEDURE
61
Monthly
62
Monthly
Serpentine Belt
Serpentine belt
is cut, broken, or
frayed.
79
HYEX01401
Figure 41.
63
Monthly
0077-37
Air conditioner
belt is cut or broken.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
80
HYEX01402
Figure 42.
64
Monthly
Fan
0077-38
Any damage
that would impair safe operation of machine.
Any debris that
would block air
flow through radiator.
Any class III hydraulic leak.
TM 5-3805-294-10
Table 1.
ITEM
NO.
0077
INTERVAL
ITEM TO BE CHECKED
OR SERVICED
PROCEDURE
EQUIPMENT NOT
READY/
AVAILABLE IF:
81
HYEX01403
Figure 43.
Fan Check.
65
Monthly
Track Sag
66
Monthly
67
Monthly
Air Conditioner/Heater
Filter Service
68
Monthly
Lubrication
END OF TASK
END OF WORK PACKAGE
0077-39/40 blank
TM 5-3805-294-10
CHAPTER 5
OPERATOR MAINTENANCE INSTRUCTIONS
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0078
OPERATOR MAINTENANCE
GENERAL MAINTENANCE INSTRUCTIONS
INITIAL SETUP:
Not Applicable
GENERAL MAINTENANCE
NOTE
Instructions in this section provide general procedures to be followed for maintenance
authorized at the operator level. Specific instructions are found in the operator maintenance
section of this manual.
This section covers general maintenance instructions for the machine. Read all CAUTIONS and WARNINGS that
apply to all maintenance instructions.
Follow these maintenance practices when working on the machine.
Prior to starting any inspection or maintenance procedure, ensure that machine is safely parked and shut down.
INSPECTION
Electrical Parts. Inspect wiring harnesses for cracked, broken, chafed, bare, and burned insulation, or bare wires.
Inspect all terminal connectors for loose connections and broken parts. Inspect connectors for corrosion or signs of
sparking. This is an indication of a malfunction within the terminal. Notify Field Level maintenance of any part found
to be defective.
Tubing and Hosing. Check all hose surfaces for wear, damage, broken, or frayed coverings, and leaks. Check for
breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. Wet spots show
leaks, but a stain around a fitting or connector may also indicate a leak. If a connector or fitting is loose, broken, or
worn out, notify Field Level maintenance.
Metal Parts. Check bolts, nuts, and screws for obvious looseness. Also check for missing, bent, or broken pieces.
They cannot all be checked with a tool, but look for chipped paint, bare metal, or rust around bolt heads. Look for
loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Visually
inspect all castings and weldments for cracks.
0078-1
TM 5-3805-294-10
0078
CLEANING
WARNING
Never use fuel to clean parts. Fuel is highly flammable. Failure to comply may result in injury
or death to personnel.
Rubber Parts. Do not clean rubber parts in solvent cleaning compound. Wipe parts clean with a dry, cleaning
cloth.
Machine Exterior. Steam clean all exterior parts thoroughly. If pressurized water is not available, wash
painted surfaces of machine with solution of 1/4 cup of soap chips, to 1 gallon (4 L) of water.
Electrical Parts. Electrical parts such as coils, junction blocks, switches, and electrical parts that contain
insulation materials should not be soaked or sprayed with cleaning solutions. Clean these parts with a
cleaning cloth moistened with cleaning compound. Clean rubber parts with hot, soapy water and soft cloths.
Do not clean with solvents.
END OF TASK
END OF WORK PACKAGE
0078-2
TM 5-3805-294-10
0079
OPERATOR MAINTENANCE
TAKING ENGINE OIL SAMPLE
INITIAL SETUP:
Materials/Parts
Bottle, Oil Sample (WP 0097, Table 1, Item 3)
Rags, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Engine running. (WP 0007)
Time to Complete
0.2 Hour(s)
Personnel Required
Horizontal Construction Engineer 12N (1)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
SAMPLING ENGINE
1.
1
3
HYEX00909
Figure 1.
2.
Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).
3.
Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.
4.
5.
END OF TASK
END OF WORK PACKAGE
0079-1/2 blank
TM 5-3805-294-10
0080
OPERATOR MAINTENANCE
TRACK SAG CHECK
INITIAL SETUP:
References (cont.)
WP 0007
WP 0009
WP 0081
WP 0082
Equipment Condition
Engine running. (WP 0007)
Personnel Required
Horizontal Construction Engineer 12N (2)
Time to Complete
0.5 Hour(s)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
RAISING MACHINE
NOTE
Sag for left and right side tracks is checked the same way.
1.
3
4
1
5
Figure 1.
HYEX00383
Raise Machine.
2.
3.
Keeping angle between boom (Figure 1, Item 3) and arm (Figure 1, Item 4) between 90 and 110 degrees,
slowly lower boom (Figure 1, Item 3) to raise track (Figure 1, Item 5) off ground.
END OF TASK
0080-1
TM 5-3805-294-10
0080
Mark track (Figure 2, Item 5) to measure two full rotations of track in each direction.
Figure 2.
Rotate Track.
2.
Rotate track (Figure 2, Item 5) forward two full rotations and in reverse two full rotations.
3.
0080-2
HYEX00491
TM 5-3805-294-10
0080
6
Figure 3.
HYEX01309
4.
5.
Measure for a distance of 11.8-13.2 in. (300-335 mm) between surface of track (Figure 4, Item 5) and bottom
of track frame (Figure 4, Item 8) at middle track roller (Figure 4, Item 9).
0080-3
TM 5-3805-294-10
0080
HYEX00838
Figure 4.
6.
If track sag is more than 13.2 in. (335 mm), Tighten Track Tension. (WP 0081)
7.
If track sag is less than 11.8 in. (300 mm), Loosen Track Tension. (WP 0082)
8.
If track sag is within limits, go to Lowering Machine task in this work package.
END OF TASK
LOWERING MACHINE
1.
0080-4
TM 5-3805-294-10
0080
HYEX01309
6
Figure 5.
Start Machine.
2.
3.
Slowly raise boom (Figure 6, Item 3) until track (Figure 6, Item 5) is resting on ground.
3
4
1
5
Figure 6.
Lower Machine.
0080-5
HYEX00383
TM 5-3805-294-10
LOWERING MACHINE - Continued
4.
Raise boom (Figure 6, Item 3), arm (Figure 6, Item 4), and bucket (Figure 6, Item 2) off ground.
5.
6.
END OF TASK
END OF WORK PACKAGE
0080-6
0080
TM 5-3805-294-10
0081
OPERATOR MAINTENANCE
TIGHTENING TRACK TENSION
INITIAL SETUP:
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
WP 0080
Equipment Condition
Track sag checked. (WP 0080)
Personnel Required
Horizontal Construction Engineer 12N
Time to Complete
0.1 Hour(s)
TIGHTENING TRACK
1.
1
Figure 1.
2.
Tighten Track.
END OF TASK
END OF WORK PACKAGE
0081-1/2 blank
HYEX00384
TM 5-3805-294-10
0082
OPERATOR MAINTENANCE
LOOSENING TRACK TENSION
INITIAL SETUP:
Tools and Special Tools
Wrench, Open End, 24 mm
(WP 0095, Table 2, Item 4)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
WP 0007
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Track sag checked. (WP 0080)
Personnel Required
Horizontal Construction Engineer 12N
Time to Complete
0.1 Hour(s)
Loosen nut (Figure 1, Item 1) and allow a small amount of grease to escape.
HYEX00385
Figure 1.
2.
3.
Loosen Track.
END OF TASK
END OF WORK PACKAGE
0082-1/2 blank
TM 5-3805-294-10
0083
OPERATOR MAINTENANCE
TAKING HYDRAULIC OIL SAMPLE
INITIAL SETUP:
Materials/Parts
Bottle, Oil Sample (WP 0097, Table 1, Item 3)
Rags, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Engine running. (WP 0007)
Time to Complete
0.2 Hour(s)
Personnel Required
Horizontal Construction Engineer 12N (1)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
HYEX00908
Figure 1.
2.
Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).
3.
Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.
4.
5.
END OF TASK
END OF WORK PACKAGE
0083-1/2 blank
TM 5-3805-294-10
OPERATOR MAINTENANCE
CAB FUSE REPLACEMENT
INITIAL SETUP:
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.2 Hour(s)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
REMOVAL
NOTE
All fuses from both main and auxiliary fuse boxes are removed the same way. Main fuse
box shown.
Spare fuses are located in the fuse box. After using a spare fuse, notify Field maintenance
to get a replacement fuse.
1.
Remove fuse box access cover (Figure 1, Item 1) from cab rear tray (Figure 1, Item 2).
0084-1
0084
TM 5-3805-294-10
0084
REMOVAL - Continued
2
1
HYEX00089
Figure 1.
2.
Remove main fuse box cover (Figure 2, Item 3) from main fuse box (Figure 2, Item 4).
0084-2
TM 5-3805-294-10
0084
REMOVAL - Continued
3
4
HYEX00097
Figure 2.
3.
Locate fuse in question using key found on fuse box cover (Figure 2, Item 3).
4.
Remove fuse (Figure 3, Item 5) from main fuse box (Figure 3, Item 4).
0084-3
TM 5-3805-294-10
0084
REMOVAL - Continued
HYEX00098
Figure 3.
Fuse Removal.
END OF TASK
INSTALLATION
CAUTION
Use only a fuse having the same amperage as noted on fuse box cover. Using a fuse with
higher amperage than specified could cause damage to the electrical system. Failure to
comply may result in damage to equipment.
NOTE
All fuses from both main and auxiliary fuse boxes are installed the same way. Main fuse box
shown.
1.
Install fuse (Figure 4, Item 5) to main fuse box (Figure 4, Item 4).
0084-4
TM 5-3805-294-10
0084
INSTALLATION - Continued
HYEX00098
Figure 4.
2.
Fuse Installation.
Install main fuse box cover (Figure 5, Item 3) to main fuse box (Figure 5, Item 4).
0084-5
TM 5-3805-294-10
0084
INSTALLATION - Continued
3
4
HYEX00097
Figure 5.
3.
Install fuse box access cover (Figure 6, Item 1) to cab rear tray (Figure 6, Item 2).
0084-6
TM 5-3805-294-10
0084
INSTALLATION - Continued
2
1
HYEX00089
Figure 6.
END OF TASK
END OF WORK PACKAGE
0084-7/8 blank
TM 5-3805-294-10
0085
OPERATOR MAINTENANCE
BUCKET TEETH REPLACEMENT
INITIAL SETUP:
Tools and Special Tools
Hammer, Hand, 3 lb (WP 0095, Table 2, Item 5)
Punch, Pin (WP 0095, Table 2, Item 9)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.2 Hour(s)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
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.
2.
2
Tooth Removal.
END OF TASK
0085-1
HYEX01282
TM 5-3805-294-10
0085
1
Figure 2.
2.
HYEX01282
Tooth Installation.
Using hammer, drive pin (Figure 2, Item 1) to tooth (Figure 2, Item 2) and shank (Figure 2, Item 3) until seated.
END OF TASK
DEEP DIG BUCKET TOOTH REMOVAL
1.
Using hammer and pin punch, drive out pin (Figure 3, Item 4) from tooth (Figure 3, Item 5) and shank (Figure
3, Item 6).
4
5
6
HYEX01281
0085-2
TM 5-3805-294-10
0085
END OF TASK
DEEP DIG BUCKET TOOTH INSTALLATION
1.
4
5
6
HYEX01281
Figure 4.
2.
Using hammer, drive pin (Figure 4, Item 4) to tooth (Figure 4, Item 5) and shank (Figure 4, Item 6) until seated.
END OF TASK
END OF WORK PACKAGE
0085-3/4 blank
TM 5-3805-294-10
0086
OPERATOR MAINTENANCE
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE
INITIAL SETUP:
Tools and Special Tools
Pan, Drain
Equipment Condition
Machine safely parked and shut down (WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.1 Hour(s)
WARNING
DIESEL FUEL
1.
Disconnect wiring harness connector D01 (Figure 1, Item 1) from water in fuel (WIF) sensor (Figure 1, Item
2).
5
HYEX00103
Figure 1.
0086-1
TM 5-3805-294-10
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
4.
Connect wiring harness connector D01 (Figure 2, Item 1) to WIF sensor (Figure 2, Item 2).
5.
Loosen, but do not remove valve (Figure 2, Item 4), and drain water/sediment from final fuel filter/water
separator (Figure 2, Item 5) for approximately 30 seconds.
6.
END OF TASK
END OF WORK PACKAGE
0086-2
TM 5-3805-294-10
0087
OPERATOR MAINTENANCE
PRIMARY AND SECONDARY AIR CLEANER SERVICE
INITIAL SETUP:
Materials/Parts
Rag, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Engine off. (WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.4 Hour(s)
REMOVAL
1.
Lift lever (Figure 1, Item 1) and rotate cover (Figure 1, Item 2) counterclockwise.
2
HYEX00073
Figure 1.
Cover Removal.
2.
Remove cover (Figure 1, Item 2) from air cleaner housing (Figure 1, Item 3).
3.
Remove primary air cleaner (Figure 2, Item 4) from air cleaner housing (Figure 2, Item 3).
0087-1
TM 5-3805-294-10
0087
REMOVAL - Continued
HYEX00074
Remove secondary air cleaner (Figure 3, Item 5) from air cleaner housing (Figure 3, Item 3).
HYEX00075
Figure 3.
END OF TASK
0087-2
TM 5-3805-294-10
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.
Start from inside, top of primary air cleaner (Figure 4, Item 4), blow remainder of debris out of primary air
cleaner.
3.
Work around and inward of primary air cleaner (Figure 4, Item 4) until primary air cleaner has been completely
blown out.
4.
Wipe out air cleaner housing (Figure 5, Item 3) with a clean rag.
0087-3
TM 5-3805-294-10
0087
HYEX00077
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
NOTE
Dust valve will be at the 6 O'clock position when air cleaner cover is installed.
1.
Install secondary air cleaner (Figure 7, Item 5) to air cleaner housing (Figure 7, Item 3).
0087-4
TM 5-3805-294-10
0087
INSTALLATION - Continued
3
HYEX00084
Figure 7.
2.
Install primary air cleaner (Figure 8, Item 4) to air cleaner housing (Figure 8, Item 3).
HYEX00074
Figure 8.
3.
Position cover (Figure 9, Item 2) on air cleaner housing (Figure 9, Item 3).
0087-5
TM 5-3805-294-10
0087
INSTALLATION - Continued
3
1
HYEX00083
Figure 9.
4.
Cover Installation.
Rotate cover (Figure 9, Item 2) clockwise until lever (Figure 9, Item 1) locks.
END OF TASK
END OF WORK PACKAGE
0087-6
TM 5-3805-294-10
0088
OPERATOR MAINTENANCE
HYDRAULIC RESERVOIR SERVICE
INITIAL SETUP:
Tools and Special Tools
Wrench, Allen 5 mm (0.196 in.)
(WP 0095, Table 2, Item 16)
References
LO 5-3805-294-13 (WP 0094)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
Materials/Parts
Lubricating Oil, Engine
(WP 0097, Table 1, Item 13)
Time to Complete
0.4 Hour(s)
Personnel Required
Horizontal Construction Engineer 12N (1)
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
2
HYEX00085
Remove four screws (Figure 1, Item 3) and hydraulic reservoir cover (Figure 1, Item 4) from hydraulic reservoir
(Figure 1, Item 2).
0088-1
TM 5-3805-294-10
0088
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
Ensure O-ring (Figure 3, Item 7) is present and is not damaged. If O-ring is missing or damaged, notify field
maintenance.
0088-2
TM 5-3805-294-10
0088
HYEX00087
Install hydraulic reservoir cover (Figure 3, Item 4) to hydraulic reservoir (Figure 3, Item 2) with four screws
(Figure 3, Item 3).
END OF TASK
END OF WORK PACKAGE
0088-3/4 blank
TM 5-3805-294-10
0089
OPERATOR MAINTENANCE
FRESH AIR FILTER SERVICE
INITIAL SETUP:
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
Materials/Parts
Rag, Wiping (WP 0097, Table 1, Item 15)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.2 Hour(s)
References
TM 5-3805-295-13&P (WP 0094)
DA FORM 5988-E or DA FORM 2404 (WP 0094)
REMOVAL
NOTE
After the fresh air filter has been serviced three times, it must be replaced by Field
Maintenance.
1.
Move two tabs (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).
Figure 1.
2.
Filter Removal.
0089-1
HYEX00168
TM 5-3805-294-10
0089
REMOVAL - Continued
Figure 2.
3.
HYEX00169
Inspect Seal.
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.
0089-2
TM 5-3805-294-10
0089
SERVICE - Continued
HYEX00170
Figure 3.
Clean Filter.
CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
to comply may result in damage to equipment.
2.
3.
HYEX00171
Figure 4.
Clean Housing.
END OF TASK
0089-3
TM 5-3805-294-10
0089
INSTALLATION
1.
Figure 5.
2.
Filter Installation.
END OF TASK
END OF WORK PACKAGE
0089-4
HYEX00168
TM 5-3805-294-10
0090
OPERATOR MAINTENANCE
AIR CONDITIONER/HEATER FILTER SERVICE
INITIAL SETUP:
Materials/Parts
Rag, Wiping (WP 0097, Table 1, Item 15)
Equipment Condition
Engine OFF. (WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.2 Hour(s)
REMOVAL
NOTE
After air conditioner/heater has been serviced three times it must be replaced by Field
Maintenance.
1.
Move tab (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).
Figure 1.
2.
HYEX00187
Filter Removal.
Check tab (Figure 1, Item 1) on filter (Figure 1, Item 2) and replace filter if tab broken.
END OF TASK
SERVICE
NOTE
Contact Field level maintenance for an air hose and air nozzle to service the air cleaner.
1.
0090-1
TM 5-3805-294-10
0090
SERVICE - Continued
HYEX00188
2
Figure 2.
Clean Filter.
WARNING
Particles blown by compressed air are hazardous. Ensure air stream is directed away from
user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed
air is used to clean parts. Always wear safety glasses when using compressed air. Failure to
comply may result in injury or death to personnel.
CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
to comply may result in damage to equipment.
2.
3.
0090-2
TM 5-3805-294-10
0090
SERVICE - Continued
HYEX00190
Figure 3.
Clean Housing.
END OF TASK
INSTALLATION
1.
Figure 4.
2.
Filter Installation.
END OF TASK
END OF WORK PACKAGE
0090-3/4 blank
HYEX00187
TM 5-3805-294-10
0091
OPERATOR MAINTENANCE
DRAINING WATER AND SEDIMENT FROM FUEL TANK
INITIAL SETUP:
Tools and Special Tools
Pan, Drain
Equipment Condition
Machine safely parked and shut down
(WP 0009)
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
Time to Complete
0.2 Hour(s)
Personnel Required
Horizontal Construction Engineer 12N (1)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
NOTE
Contact Field Maintenance for drain pan.
1.
1
HYEX01298
Figure 1.
2.
0091-1
TM 5-3805-294-10
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
0091
HYEX00915
Figure 3.
4.
5.
6.
Drain Valve.
0091-3
TM 5-3805-294-10
0091
1
HYEX01298
Figure 4.
END OF TASK
END OF WORK PACKAGE
0091-4
TM 5-3805-294-10
OPERATOR MAINTENANCE
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT
INITIAL SETUP:
Tools and Special Tools
Wrench 2-1/4
Wrench 2-1/2 (WP 0095, Table 2, Item 15)
Equipment Condition
Machine safely parked and shut down
(WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.3 Hour(s)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
DISCHARGE ADJUSTMENT
WARNING
Unless otherwise specified, perform all maintenance procedures with all attachments lowered
to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may
result in injury or death to personnel.
NOTE
Ensure curtain is set to desired discharge size before Crush-All operation.
There are no disassembly requirements to perform discharge adjustments. Adjustment
points are on the outside of the machine.
There are two adjustment points for lower curtain. Adjustment procedure is identical for
both points and must be adjusted at same time.
Raise curtain to increase discharge size.
Lower curtain to decrease discharge size.
To reduce dust, increase discharge size.
Repeat steps for opposite side.
1.
Loosen nut (Figure 1, Item 1) on nut (Figure 1, Item 2) and rod (Figure 1, Item 3).
0092-1
0092
TM 5-3805-294-10
0092
3
5
6
7, 8, 9
10
11
2
1
HYEX03092
Figure 1.
Curtain Adjustment.
2.
Loosen nut (Figure 1, Item 2) on rod (Figure 1, Item 3) to release tension from spring (Figure 1, Item 4).
3.
Using wrench provided with crush-all loosen nut (Figure 1, Item 5) on nut (Figure 1, Item 6) and rod (Figure 1,
Item 3).
4.
Remove bolt (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and washer (Figure 1, Item 9) from clamp (Figure
1, Item 10) and plate (Figure 1, Item 11).
5.
Remove clamp (Figure 1, Item 10) from nut (Figure 1, Item 6) and plate (Figure 1, Item 11).
6.
Turn nut (Figure 2, Item 6) to raise or lower curtain (Figure 2, Item 12).
0092-2
TM 5-3805-294-10
0092
12
14
13
HYEX03093
Figure 2.
Clearance Check.
CAUTION
Ensure surface of blow bar does not touch curtain. Failure to comply may result in damage
to equipment.
7.
Turn rotor (Figure 2, Item 13) manually. Verify curtain (Figure 2, Item 12) does not touch rotor (Figure 2, Item
13) or blow bars (Figure 2, Item 14).
8.
Position clamp (Figure 3, Item 10) on nut (Figure 3, Item 6) and plate (Figure 3, Item 11).
0092-3
TM 5-3805-294-10
0092
11
7, 8, 9
10
HYEX03094
Figure 3.
Clamp Installation.
9.
Install clamp (Figure 3, Item 10) on plate (Figure 3, Item 11) with bolt (Figure 3, Item 7), lockwasher (Figure 3,
Item 8), and washer (Figure 3, Item 9).
10.
Using wrench provided with crush-all tighten nut (Figure 3, Item 5) against nut (Figure 3, Item 6) on rod (Figure
3, Item 3).
11.
Tighten nut (Figure 4, Item 2) and compress spring (Figure 4, Item 4) to align marks (Figure 4, Item 15) and
(Figure 4, Item 16).
0092-4
TM 5-3805-294-10
0092
16
15
2
1
HYEX03095
Figure 4.
12.
Spring Compression.
Tighten nut (Figure 4, Item 1) against nut (Figure 4, Item 2) on rod (Figure 4, Item 3).
END OF TASK
END OF WORK PACKAGE
0092-5/6 blank
TM 5-3805-294-10
0093
OPERATOR MAINTENANCE
MAINTENANCE AFTER FORDING
INITIAL SETUP:
Tools and Special Tools
Grease Gun (WP 0095, Table 2, Item 4)
Wrench 17 mm (WP 0095, Table 2, Item 17)
References
LO 5-3805-294-13 (WP 0094)
DA FORM 5988-E or DA FORM 2404 (WP 0094)
Materials/Parts
Grease, Automotive and Artillery
(WP 0097, Table 1, Item 10)
Equipment Condition
Machine safely parked and shut down.
(WP 0094)
Personnel Required
Horizontal Construction Engineer 12N (1)
Time to Complete
0.5 Hour(s)
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.
Remove cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from machine (Figure 1, Item 5) and allow mud
or water to completely drain.
3.
4.
Install cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) to machine (Figure 1, Item 5) with two bolts (Figure
1, Item 1) and washers (Figure 1, Item 2).
0093-1
TM 5-3805-294-10
DRAINING MUD OR WATER - Continued
5.
If grease was removed, notify field level maintenance to service swing gear and swing bearing.
END OF TASK
END OF WORK PACKAGE
0093-2
0093
TM 5-3805-294-10
CHAPTER 6
OPERATOR SUPPORTING INFORMATION
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677
TM 5-3805-294-10
0094
OPERATOR MAINTENANCE
REFERENCES
SCOPE
This work package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in
this manual.
ARMY REGULATIONS
AR 25-52
AR 310-25
AR 385-40
AR 385-55
AR 700-138
DA PAM 750-8
FIELD MANUALS
FM 1-02
Military Symbols
FM 3-11.5
FM 3-97.6
Mountain Operations
FM 4-25.11
First Aid
FM 7-1
FM 9-207
FM 20-3
Camouflage
FM 21-305
FM 31-70
FM 31-71
Northern Operations
FM 55-15
FM 90-3
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
MIL-STD-1366
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
TECHNICAL MANUALS
LO 5-3805-294-13
TM 5-3805-295-13&P
0094-2
TM 5-3805-294-10
0094
TM 21-40
TM 38-250/AFR 71-4
TM 55-2200-001-12
TM 750-244-6
0094-3/4 blank
TM 5-3805-294-10
0095
OPERATOR MAINTENANCE
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
INTRODUCTION
Scope
This work package lists COEI and BII for the Hydraulic Excavator (HYEX) to help you inventory items for safe
operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components of End Item (COEI). This list is for information purposes only and is not authority to requisition
replacements. These items are part of the HYEX. As part of the end item, these items must be with the end item
whenever it is issued or transferred between property accounts. Items of COEI are removed and separately
packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify
the items.
Basic Issue Items (BII). These essential items are required to place the (HYEX) in operation, operate it, and to do
emergency repairs. Although shipped separately packaged, BII must be with the Hydraulic Excavator during
operation and when it is transferred between property accounts. Listing these items is your authority to request/
requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished
to help you find and identify the items.
Explanation of Columns in the COEI List and BII List
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.
0095-1
TM 5-3805-294-10
Table 1.
0095
(1)
(2)
(3)
(4)
(5)
(6)
ITEM
NUMBER
DESCRIPTION, PART
NUMBER/(CAGEC)
USABLE
ON CODE
U/I
QTY
RQR
EA
Quick Latch
C909332(1J955)
EA
EA
Hydraulic Thumb
70N0013(3PSD7)
EA
HYEX01340
2540-01-478-1207
HYEX01359
HYEX01341
HYEX01360
0095-2
TM 5-3805-294-10
Table 1.
0095
(1)
(2)
(3)
(4)
(5)
(6)
ITEM
NUMBER
DESCRIPTION, PART
NUMBER/(CAGEC)
USABLE
ON CODE
U/I
QTY
RQR
EA
2590-01-474-7812
HYEX01342
0095-3
TM 5-3805-294-10
Table 2.
0095
(1)
(2)
(3)
(4)
(5)
(6)
ITEM
NUMBER
DESCRIPTION, PART
NUMBER/(CAGEC)
USABLE
ON CODE
U/I
QTY
RQR
Bag, Mason
204900 (3PSD7)
EA
Cap
811438500 (1BVQ2)
EA
Cap, Pin
U42984 (3PSD7)
EA
EA
EA
Operator's Manual TM
5-3805-294-10
EA
EA
EA
HYEX03287
HYEX03288
HYEX03289
4
HYEX01349
5
HYEX03327
6
TM 5-3805-294-10
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
HYEX01339
HYEX03290
8
HYEX03291
0095-4
TM 5-3805-294-10
Table 2.
0095
(1)
(2)
(3)
(4)
(5)
(6)
ITEM
NUMBER
DESCRIPTION, PART
NUMBER/(CAGEC)
USABLE
ON CODE
U/I
QTY
RQR
Punch, Drift
70-195(08292)
EA
Tape, Measuring 25 FT
68-445 (08292)
EA
EA
EA
Vice Grips
67-460 (08292)
EA
EA
5120 -01-434-9835
HYEX03325
10
5210-01-434-9515
HYEX03326
11
5120 -01-434-9171
HYEX01348
12
3815-01-475-0710
HYEX03292
13
HYEX01355
14
HYEX01346
0095-5
TM 5-3805-294-10
Table 2.
0095
(1)
(2)
(3)
(4)
(5)
(6)
ITEM
NUMBER
DESCRIPTION, PART
NUMBER/(CAGEC)
USABLE
ON CODE
U/I
QTY
RQR
EA
EA
EA
EA
EA
15
HYEX01345
16
5120-01-045-4889
HYEX01344
17
HYEX01356
18
5120 - 01-581-3318
HYEX01356
19
5120-00-240-5328
HYEX01343
0095-6
TM 5-3805-294-10
0096
OPERATOR MAINTENANCE
ADDITIONAL AUTHORIZATION LIST (AAL)
INTRODUCTION
SCOPE
This work package lists additional items you are authorized for the support of the Hydraulic Excavator (HYEX).
GENERAL
This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it. These
items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (2) - Description, Part Number/(CAGEC). Identifies the Federal item name (in Initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Column (4) - Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (1).
Column (5) - Quantity Recommended (Qty Recom). Indicates the quantity recommended.
Table 1.
(1)
(2)
(3)
(4)
(5)
NATIONAL STOCK
NUMBER (NSN)
USABLE ON
CODE
U/I
QTY RECOM
EA
Compactor
IHC 00130FT (1N0L6)
END OF WORK PACKAGE
0096-1/2 blank
TM 5-3805-294-10
0097
OPERATOR MAINTENANCE
EXPENDABLE AND DURABLE ITEMS LIST
Introduction
Scope
This work package lists expendable/durable supplies and materials you will need to operate and maintain the
Hydraulic Excavator (HYEX). This list is for information only and is not authority to requisition the listed items. These
items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and
Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical
Department Expendable/Durable Items.
Explanation of Columns in the Expandable/Durable Items List
Column (1) - Item Number
This number is assigned to the entry in the listing and is referenced in the initial setup narrative instructions to identify
the material.
Column (2) - Level
This column identifies the lowest level of maintenance that requires the listed item.
C -- Operator/Crew
F -- Field
H -- Below Depot
D -- Depot
(1)
(2)
(3)
(4)
(5)
ITEM
NO.
LEVEL
NATIONAL STOCK
NUMBER (NSN)
U/I
6850-01-441-3248
0097-1
DR
TM 5-3805-294-10
Table 1.
0097
(1)
(2)
(3)
(4)
(5)
ITEM
NO.
LEVEL
NATIONAL STOCK
NUMBER (NSN)
U/I
6850-01-441-3257
CO
8125-01-193-3440
BX
6850-00-926-2275
BX
9130-01-031-5816
GL
9140-01-413-7511
GL
9140-00-286-5294
GL
9140-01-412-1311
GL
9140-00-286-5286
GL
10
9150-01-197-7688
TU
11
9150-00-111-6256
QT
12
9150-00-111-6255
GL
13
9150-01-438-6076
QT
14
9150-00-973-9504
CN
15
7920-00-148-9666
Rag, Wiping
7920-00-148-9666 (80244)
BE
0097-2
TM 5-3805-294-10
0098
OPERATOR MAINTENANCE
SPECIAL PURPOSE KITS (SPK) LIST
SCOPE
This work package lists the Special Purpose Kits (SPKs) for support of the Hydraulic Excavator (HYEX) Type 1.
Where to find operation instructions and troubleshooting procedures for the SPKs are also provided.
OPERATION INSTRUCTIONS FOR SPKS
For instructions on how to select the SPKs on the operators monitor, go to Selecting an Attachment On the
Monitor (WP 0018).
To operate the SPKs go to Operating the Barrier Grapple (WP 0022), Installing and Operating the Compactor and
Breaker (WP 0020), or Installing and Operating the Crush-All (WP 0019).
The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX
Type 1 by Field Maintenance. To operate the Deep Dig Arm, go to Operating the Deep Dig Arm (WP 0023).
TROUBLESHOOTING PROCEDURES FOR SPKS
To find troubleshooting procedures for the SPK items, go to the Troubleshooting Index (WP 0037).
INTRODUCTION TO THE SPECIAL PURPOSE KITS LIST
Special Purpose Kits (SPK) listed in Table 1 are for information purposes only and are not the authority to requisition
replacements. These items are part of the HYEX Type 1, but they are removed and separately packaged for
transportation or shipment. As part of the end item, these items must be with the end item whenever it is issued or
transferred between property accounts. Illustrations are furnished to help you find and identify the items.
EXPLANATION OF COLUMNS IN TABLE 1
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name followed by a minimum description
when needed. The last line below the description is the part number and the Commercial and Government Entity
Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (2).
Column (6) QTY RQD. Indicates the quantity required.
0098-1
TM 5-3805-294-10
0098
SCOPE - Continued
SPECIAL PURPOSE KITS
Table 1.
(1)
ITEM
NO.
(2)
NATIONAL STOCK NUMBER
(4)
USABLE
ON CODE
(5)
U/I
(6)
QTY
RQD
EA
Barrier Grapple
KL16000-1 (1V7ZO)
EA
Breaker, Impact
205146 (1BVQ2)
EA
Counterweight
305156 (1BVQ2)
EA
HYEX02525
HYEX02522
3830-01-585-2734
HYEX02520
HYEX02526
0098-2
TM 5-3805-294-10
0098
SCOPE - Continued
Table 1.
5
EA
EA
EA
HYEX02521
HYEX02523
HYEX02524
0098-3/4 blank
TM 5-3805-294-10
0099
OPERATOR MAINTENANCE
TROUBLESHOOTING NOTES
Troubleshooting Notes
This paragraph contains troubleshooting information for locating and correcting some operating troubles which may
develop in the HYEX. This manual cannot list all possible malfunctions that may occur, nor can it include all tests,
inspections, and corrective actions. Notify field maintenance personnel if a malfunction is not listed, unless a
malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed.
Procedures. The troubleshooting symptom index lists possible malfunctions that may be experienced during
operation of machine or components. Each malfunction for an individual component, unit, or system is followed by
a list of tests or inspections and corrective actions.
Lubrication. When instructions to lubricate, grease, oil, or add oil appear in the troubleshooting table, refer to Operator
Preventive Maintenance Checks and Services. (WP 0077)
END OF WORK PACKAGE
0099-1/2 blank
TM 5-3805-294-10
0100
OPERATOR MAINTENANCE
HYEX TRANSPORTABILITY INSTRUCTIONS
HYEX03197
Figure 1.
0100-1
TM 5-3805-294-10
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.
HYEX01365
Figure 2.
HYEX Dimensions.
0100-2
TM 5-3805-294-10
0100
TRANSPORTATION DATA
GROSS WEIGHT
EQUIPMENT TIEDOWN DESIGN LIMIT LOAD
LIFTING DESIGN LIMIT LOAD
-
60,000 LB.
4
12 FT.
44 MM [1.7 IN.]
CENTER OF
GRAVITY
Figure 3.
0100-3
TM 5-3805-294-10
0100
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
QTY
1 - Tie Down
39 in. forward
30 in. below
56 in.
2 - Tie Down
26 in. forward
25 in. below
7 in.
3 - Tie Down
43 in. aft
30 in. below
56 in.
4 - Tie Down
30 in. aft
25 in. below
7 in.
Lift Points
5 in. below
15 in.
0100-4
Lateral
TM 5-3805-294-10
0100
HIGHWAY:
Figure (5) shows the HYEX on an M870 semi trailer. The top view also shows a possible M870 tie down configuration.
The front view shows the HYEX is at or below the maximum height restriction for highway transport.
1 FOOT EXTENSION
BOTH SIDES
M870
TRAILER
SECTION A-A
HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I
JOHN DEERE MODEL 240D LCR
Figure 5.
M870 Loading.
0100-5
HYEX03073
TM 5-3805-294-10
0100
HIGHWAY: - Continued
Figure (6) shows the HYEX on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down
configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.
1 FOOT EXTENSION
BOTH SIDES
A
13 FT. 6 IN. HEIGHT CLEARANCE LINE
M870A1
TRAILER
SECTION A-A
HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I
JOHN DEERE MODEL 250D LCR
Figure 6.
M870A1 Loading.
0100-6
HYEX03072
TM 5-3805-294-10
0100
HIGHWAY: - Continued
Figure (7) shows the HYEX on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down
configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.
A
13 FT. 6 IN. HEIGHT CLEARANCE LINE
M870A3
TRAILER
SECTION A-A
HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I
JOHN DEERE MODEL 240D LCR
Figure 7.
M870A3 Loading.
0100-7
HYEX03069
TM 5-3805-294-10
0100
RAIL:
HYEX is equipped with 30 inch track shoes, which require the HYEX to have special rail routing. The armored HYEX
has the same exterior dimensions as the standard cab model, so the armored cab version was not shown in the GIC
envelope. The HYEX requires special routing for rail systems requiring the GIC dimensions. Figures (8), (9), and
(10) show the HYEX modeled in various rail envelopes.
51.4 INCH
HIGH
RAILCAR
HYEX03078
0100-8
TM 5-3805-294-10
0100
RAIL: - Continued
Figure 9.
0100-9
TM 5-3805-294-10
0100
RAIL: - Continued
HYEX01370
0100-10
TM 5-3805-294-10
0100
RAIL: - Continued
HYEX01371
Figure 12.
AIR:
The HYEX meets the requirements of MIL-HDBK-1791, Designing for Internal Aerial Delivery in Fixed Winged
Aircraft (WP 0094) for transport on C-17 and C-5 aircraft.
Figure (13) shows model of the HYEX, both standard and armored cab, inside the C-5 aircraft design envelope. The
model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft.
ARMORED CAB
GROUND
PLANE
0100-11
TM 5-3805-294-10
0100
AIR: - Continued
Figure (14) shows model of the HYEX, both standard and armored cab, inside the C-17 aircraft design envelope.
The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft.
STANDARD CAB
ARMORED CAB
GROUND
PLANE
HYEX01372
Figure 15.
Marine Loading.
0100-12
TM 5-3805-294-10
0100
HYEX03083
Figure 16.
0100-13
TM 5-3805-294-10
0100
Figure 17.
HYEX03087
HIGHWAY:
Figure (18) shows the Standard Buckets on an M870A1 semi trailer. The top view also shows a possible M870A1
tie down configuration.
0100-14
TM 5-3805-294-10
0100
HIGHWAY: - Continued
HYEX03071
HYEX03068
0100-15
TM 5-3805-294-10
0100
Figure 20.
Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions.
Figure 21.
HYEX03086
Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions.
0100-16
TM 5-3805-294-10
0100
SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
TIE DOWN PROVISIONS
HYEX03085
Figure 22.
0100-17
TM 5-3805-294-10
0100
SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
Figure (23) shows the Crush-All lifting and tie-down provisions.
TIE DOWN PROVISIONS
HYEX03084
Figure 23.
Crush-All.
Compactor.
0100-18
HYEX03082
TM 5-3805-294-10
0100
SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
Figure (25) shows the Impact Breaker lifting and tie-down provisions.
HYEX03081
Impact Breaker.
Figure (26) shows the Barrier Grapple lifting and tie-down provisions.
HYEX03147
Figure 26.
Barrier Grapple.
0100-19
TM 5-3805-294-10
0100
HYEX03070
HYEX CRUSH-ALL
ON M870A3 TRAILER
HYEX03067
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.
HYEX03076
Figure 30.
0100-21
TM 5-3805-294-10
0100
HYEX03074
Figure 31.
HYEX03075
Figure 32.
0100-22
TM 5-3805-294-10
INDEX
Subject
A
ADDITIONAL AUTHORIZATION LIST (AAL)..........................................................................
ADJUSTING THE OPERATOR'S SEAT.................................................................................
AIR CONDITIONER DOES NOT OPERATE..........................................................................
AIR CONDITIONER/HEATER FILTER SERVICE...................................................................
AUTO-IDLE DOES NOT WORK.............................................................................................
WP 0096-1
WP 0006-1
WP 0045-1
WP 0090-1
WP 0052-1
B
BARRIER GRAPPLE DOES NOT HOLD LOAD.....................................................................
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE.......................................................
BREAKER DOES NOT OPERATE.........................................................................................
BREAKER OPERATES SLOWLY...........................................................................................
BUCKET TEETH REPLACEMENT.........................................................................................
WP 0073-1
WP 0041-1
WP 0070-1
WP 0071-1
WP 0085-1
C
CAB DOME LIGHT DOES NOT OPERATE............................................................................
CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................
CAB FUSE REPLACEMENT...................................................................................................
CAB REAR WORK LIGHTS DO NOT OPERATE...................................................................
COMPACTOR DOES NOT OPERATE...................................................................................
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS...................
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT.................................................
CRUSH-ALL DOES NOT OPERATE......................................................................................
WP 0040-1
WP 0042-1
WP 0084-1
WP 0043-1
WP 0069-1
WP 0095-1
WP 0092-1
WP 0072-1
D
DECAL LOCATION GUIDE.....................................................................................................
DEEP DIG DOES NOT OPERATE.........................................................................................
DESCRIPTION AND USE OF MONITOR AND ALARMS.......................................................
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.......................
DRAINING WATER AND SEDIMENT FROM FUEL TANK....................................................
WP 0027-1
WP 0074-1
WP 0005-1
WP 0004-1
WP 0091-1
E
ENGINE COOLANT TEMPERATURE ABOVE NORMAL......................................................
ENGINE CRANKS BUT DOES NOT START OR HARD TO START......................................
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE...................................
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE.....................................................
ENGINE IDLES POORLY.......................................................................................................
ENGINE NOT DEVELOPING FULL POWER.........................................................................
ENGINE OIL PRESSURE LOW..............................................................................................
ENGINE RUNS POORLY........................................................................................................
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED................................
ENGINE WILL NOT CRANK...................................................................................................
EQUIPMENT DESCRIPTION AND DATA..............................................................................
EXCESSIVE FUEL CONSUMPTION......................................................................................
EXCESSIVE OIL CONSUMPTION.........................................................................................
EXPENDABLE AND DURABLE ITEMS LIST.........................................................................
Index-1
WP 0055-1
WP 0046-1
WP 0056-1
WP 0057-1
WP 0051-1
WP 0053-1
WP 0054-1
WP 0048-1
WP 0067-1
WP 0047-1
WP 0002-1
WP 0049-1
WP 0050-1
WP 0097-1
TM 5-3805-294-10
INDEX - Continued
Subject
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........................................................................................
Index-2
WP 0011-1
WP 0030-1
WP 0031-1
WP 0016-1
WP 0022-1
WP 0034-1
WP 0023-1
TM 5-3805-294-10
INDEX - Continued
Subject
O
OPERATING THE HYDRAULIC HOSE REEL........................................................................
OPERATING THE HYDRAULIC THUMB................................................................................
WP 0026-1
WP 0017-1
P
POWER DIG DOES NOT WORK............................................................................................
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).....................................
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE............................
PRIMARY AND SECONDARY AIR CLEANER SERVICE......................................................
WP 0060-1
WP 0077-1
WP 0086-1
WP 0087-1
Q
QUICK LATCH DOES NOT OPERATE..................................................................................
WP 0068-1
R
REFERENCES........................................................................................................................
REMOVING AND INSTALLING BUCKET...............................................................................
WP 0094-1
WP 0014-1
S
SELECTING AN ATTACHMENT ON THE MONITOR............................................................
SHUTTING DOWN THE HYEX...............................................................................................
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED.............................
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY
EXIT).......................................................................................................................................
SLAVE STARTING..................................................................................................................
SLOW TRAVEL SPEED ONLY...............................................................................................
SPECIAL PURPOSE KITS (SPK) LIST...................................................................................
STARTING THE ENGINE.......................................................................................................
SWING FUNCTION IS JERKY................................................................................................
WP 0018-1
WP 0009-1
WP 0010-1
WP 0033-1
WP 0032-1
WP 0065-1
WP 0098-1
WP 0007-1
WP 0064-1
T
TAKING ENGINE OIL SAMPLE..............................................................................................
TAKING HYDRAULIC OIL SAMPLE.......................................................................................
THEORY OF OPERATION.....................................................................................................
TIGHTENING TRACK TENSION............................................................................................
TOWING THE HYEX...............................................................................................................
TRACK SAG CHECK .............................................................................................................
TRAVEL ALARM DOES NOT OPERATE...............................................................................
TRAVEL IS JERKY..................................................................................................................
TROUBLESHOOTING NOTES...............................................................................................
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE...........................
WP 0079-1
WP 0083-1
WP 0003-1
WP 0081-1
WP 0028-1
WP 0080-1
WP 0038-1
WP 0066-1
WP 0099-1
WP 0037-1
U
USING THE RIFLE MOUNT....................................................................................................
USING THE VANDAL PROTECTION KIT..............................................................................
WP 0012-1
WP 0025-1
W
WINDSHIELD WIPER AND WASHER DO NOT OPERATE...................................................
Index-3/4 blank
WP 0039-1
DATE
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
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1103409
Distribution:
To be distributed in accordance with the Initial Distribution Number (IDN) 257856
requirements for TM 5-3805-294-10.
SQUARE MEASURE
1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles
WEIGHTS
1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces
1 Kilogram = 1000 Grams = 2.2 Lb
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
CUBIC MEASURE
1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches
1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
TEMPERATURE
5/9 ( F - 32) = C
212 Fahrenheit is equivalent to 100 Celsius
90 Fahrenheit is equivalent to 32.2 Celsius
32 Fahrenheit is equivalent to 0 Celsius
9/5 C + 32 = F
LIQUID MEASURE
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces
1 CM 2
3
4
5
6
7
2.540
0.305
0.914
1.609
6.451
0.093
0.836
2.590
0.405
0.028
0.765
29.573
0.473
0.946
3.785
28.349
0.454
0.907
1.356
6.895
0.425
1.609
Centimeters . . . . . . . . . . . . . . . . . .
Meters . . . . . . . . . . . . . . . . . . . . . . .
Meters . . . . . . . . . . . . . . . . . . . . . . .
Kilometers . . . . . . . . . . . . . . . . . . . .
Square Centimeters . . . . . . . . . . .
Square Meters . . . . . . . . . . . . . . . .
Square Meters . . . . . . . . . . . . . . . .
Square Kilometers . . . . . . . . . . . . .
Square Hectometers . . . . . . . . . . .
Cubic Meters . . . . . . . . . . . . . . . . .
Cubic Meters . . . . . . . . . . . . . . . . .
Milliliters. . . . . . . . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . . . . . . . .
Grams . . . . . . . . . . . . . . . . . . . . . . .
Kilograms . . . . . . . . . . . . . . . . . . . .
Metric Tons . . . . . . . . . . . . . . . . . . .
Newton-Meters . . . . . . . . . . . . . . . .
Kilopascals . . . . . . . . . . . . . . . . . . .
Kilometers per Liter . . . . . . . . . . . .
Kilometers per Hour . . . . . . . . . . .
INCHES
Inches . . . . . . . . . . . . . . . . .
Feet . . . . . . . . . . . . . . . . . . .
Yards . . . . . . . . . . . . . . . . . .
Miles . . . . . . . . . . . . . . . . . .
Square Inches . . . . . . . . . .
Square Feet . . . . . . . . . . . .
Square Yards . . . . . . . . . . .
Square Miles . . . . . . . . . . .
Acres . . . . . . . . . . . . . . . . . .
Cubic Feet . . . . . . . . . . . . .
Cubic Yards . . . . . . . . . . . .
Fluid Ounces . . . . . . . . . . .
Pints . . . . . . . . . . . . . . . . . .
Quarts . . . . . . . . . . . . . . . . .
Gallons. . . . . . . . . . . . . . . . .
Ounces . . . . . . . . . . . . . . . .
Pounds . . . . . . . . . . . . . . . .
Short Tons . . . . . . . . . . . . .
Pound-Feet . . . . . . . . . . . .
Pounds/Sq Inch . . . . . . . . .
Miles per Gallon . . . . . . . .
Miles per Hour . . . . . . . . . .
TO
TO CHANGE
3
8
TO CHANGE
TO
MULTIPLY BY
9
10
11
12
13
14
15
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
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 . . . . . . . . . . . . . . . .
Centimeters . . . . . . . . . . . .
Meters . . . . . . . . . . . . . . . . .
Meters. . . . . . . . . . . . . . . . . .
Kilometers . . . . . . . . . . . . .
Sq Centimeters . . . . . . . . .
Square Meters . . . . . . . . . .
Square Meters . . . . . . . . . .
Square Kilometers . . . . . .
Sq Hectometers . . . . . . . .
Cubic Meters
.............
Cubic Meters . . . . . . . . . . .
Milliliters . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . .
Liters . . . . . . . . . . . . . . . . . .
Grams . . . . . . . . . . . . . . . . .
Kilograms . . . . . . . . . . . . . .
Metrication . . . . . . . . . . . . .
Newton-Meters . . . . . . . . .
Kilopascals . . . . . . . . . . . . .
Km per Liter . . . . . . . . . . . .
Km per Hour. . . . . . . . . . . .
PIN 086698-000