You are on page 1of 536

TM 5-3805-294-10

TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR

HYDRAULIC EXCAVATOR (HYEX)


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

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

HEADQUARTERS, DEPARTMENT OF THE ARMY


0$5&+

TM 5-3805-294-10

WARNING SUMMARY
This warning summary contains general safety and hazardous materials warnings that must be understood and
applied during operation and maintenance of the machine. Failure to observe these precautions or operating this
machine without training or instruction may result in serious injury or death to personnel.
FIRST AID
First aid is defined as "urgent and immediate lifesaving and other measures, which may be performed for casualties
by nonmedical personnel when medical personnel are not immediately available."
FOR FIRST AID INFORMATION, REFER TO FM 4-25.11.
EXPLANATION OF SAFETY WARNING ICONS
AIR PRESSURE - Human hand blocking air gun shows the need to reduce air
pressure before use, or debris may injure user and/or damage equipment.

BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria
or viruses that present a danger to life or health.

EAR PROTECTION - Headphones over ears show that noise level will harm ears.

ELECTRICAL - Electrical wire to hand with electricity symbol running through


human hand shows that shock hazard is present.

EXPLOSION - Human figure in front of explosion symbol shows that the material
may explode if subjected to high temperatures, sources of ignition, or high pressure.

EXTREMELY COLD SURFACE - Hand touching object with ice formed on both
shows that surface is extremely cold and can damage human tissue.

EYE PROTECTION - Person with goggles shows that material will injure the eyes.

TM 5-3805-294-10

WARNING SUMMARY - Continued


EXPLANATION OF SAFETY WARNING ICONS - Continued
FIRE - Flame shows that material may ignite and cause burns.

FIRE EXTINGUISHER - Fire extinguisher shows that material may ignite and a fire
extinguisher should be within easy reach.

HEAVY OBJECT - Human figure stooping over heavy object shows physical injury
potential for improper lifting technique, and/or aid of assistant(s) and/or lifting device
(as required).

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush
and harm.

HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush
and harm.

HEAVY PARTS - Moving heavy object pinning human figure against stationary
object shows that heavy, moving parts/objects present a danger to life or limb.

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a
danger to life or limb.

HOT AREA - Hand over object radiating heats shows that part is hot and can burn.

MOVING PARTS - Hand with fingers caught between gears shows that the moving
parts of the equipment present a danger to life or limb.

TM 5-3805-294-10

WARNING SUMMARY - Continued


EXPLANATION OF SAFETY WARNING ICONS - Continued
POISON - Skull and crossbones symbol shows that dangerous gases, sprays,
vapors, liquids, or materials contain compounds that present a danger to life or
health.

PROJECTILE HAZARD - Human body with object passing through it shows that a
projectile hazard exists.

RADIATION - Three circular wedges show that the material emits radioactive
energy and can injure human tissue.

SEAT BELT USE - Human figure wearing seat belt indicates a seat belt must be
used to prevent injury or death in the event of a vehicle crash or rollover.

SKIN IRRITATION - Hand radiating shows that material can cause skin irritation.

SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents
a danger of falling.

STEAM HAZARD - Human engulfed in steam cloud shows steam hazard exists
that could injure/burn human tissue.

VAPOR - Human figure in a cloud shows that material vapors present a danger to
life or health.

WARNING - Triangle with exclamation point within shows that a WARNING is


present that indicates a potential hazard, which may cause injury or death to
personnel.

WARNING DESCRIPTIONS

TM 5-3805-294-10

WARNING SUMMARY - Continued


WARNING

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

WARNING

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

WARNING

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

WARNING

DIESEL FUEL
Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow
open flame or sparks in the vicinity while working on any part of fuel system. Keep fire

TM 5-3805-294-10

WARNING SUMMARY - Continued


extinguisher within easy reach when working with fuel. Failure to comply may result in
injury or death to personnel.
Spilled fuel is slippery and creates a hazardous condition. Clean up and properly dispose
of spilled fuel as soon as possible. Failure to comply may result in injury or death to
personnel.
Do not work on fuel system when engine is hot. Failure to comply may result in injury or
death to personnel.
Safety glasses must be worn when working on pressurized systems. Failure to comply
may result in injury or death to personnel.

WARNING

LUBRICATING OIL
Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing
immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure
to comply may result in injury or death to personnel.
Spilled oil is slippery and creates a hazardous condition. Clean up and properly dispose
of hydraulic oil. Failure to comply may result in injury or death to personnel.

WARNING

Ensure electrical power is off prior to working on all electrical connections. Remove all jewelry
such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools
can catch on equipment, contact positive electrical circuits, and cause a direct short, severe
burns, or electrical shock. Failure to comply may result in injury or death to personnel.

WARNING

LEAD-ACID BATTERIES
Avoid battery electrolyte contact with skin, eyes, and clothing. If battery electrolyte spills,
take the following immediate action to stop burning effects:
External - If battery electrolyte contacts skin, immediately flush affected area with cold
running water. Failure to comply may result in injury or death to personnel.
Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15
minutes and seek immediate medical attention. IMPORTANT - If only one eye is affected,
ensure the affected eye is always kept lower than the unaffected eye, during both flushing

TM 5-3805-294-10

WARNING SUMMARY - Continued


and transport. This will help keep the affected eye from draining into and contaminating
the unaffected eye. Failure to comply may result in injury or death to personnel.
Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Follow
with milk of magnesia, a beaten egg, or vegetable oil and seek immediate medical
attention. Failure to comply may result in injury or death to personnel.
Clothing or vehicle - Immediately flush area with cold water and neutralize battery
electrolyte with baking soda or household ammonia solution. Failure to comply may result
in injury or death to personnel.
Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do
not allow hot, sparking, or glowing objects near batteries. If batteries are giving off gases,
the presence of heat, flame, or spark may cause fire and/or explosion. Failure to comply
may result in injury or death to personnel.
Wear proper eye protection, gloves, and an apron when working near batteries. Failure
to comply may result in injury or death to personnel.

WARNING

Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating
to skin and respiratory system. High concentrations of isocyanate can produce symptoms of
itching and reddening of skin, a burning sensation in the throat and nose, and watering of the
eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain
during respiration, increased sputum production, and chest tightness. First aid for ingestion:
do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek
medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation
subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh
air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.
Failure to comply may result in injury or death to personnel.

WARNING

If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be
handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBC
NCO for appropriate handling or disposal instructions. Failure to comply may result in injury
or death to personnel.

TM 5-3805-294-10

WARNING SUMMARY - Continued


WARNING

Personnel hearing can be permanently damaged if exposed to constant high noise levels of
85 dB or greater. Failure to comply may result in injury to personnel.

WARNING

Unless otherwise specified, perform all maintenance procedures with all attachments lowered
to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may
result in injury or death to personnel.

WARNING

Do not operate bucket or any attachment if the quick attach wedge is not fully seated and the
safety lock pin is not in the locked position . The bucket or attachment may fall. One exception
to this rule is when specifically instructed to do so during the removing and installing of bucket
or attachment to and from machine. Failure to comply may result in injury or death to
personnel.

WARNING

CARBON MONOXIDE
Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives
the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide
produces symptoms of headache, dizziness, loss of muscular control, apparent
drowsiness, and coma. Permanent brain damage or death to personnel can result from
severe exposure.
Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also
occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon
monoxide can become dangerously concentrated under conditions of inadequate
ventilation. The following precautions must be observed to ensure safety of personnel
when engine of HYEX is operated:
1. DO NOT operate engine in enclosed areas without adequate ventilation.

TM 5-3805-294-10

WARNING SUMMARY
2. DO NOT idle engine without adequate ventilation.
3. DO NOT drive machine with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
Headache

Dizziness

Sleepiness

Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:


Remove person from area

Expose to fresh air

Keep person warm

DO NOT permit physical exercise

Administer cardiopulmonary resuscitation (CPR) if necessary

Notify a Medic

6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection


will NOT protect you from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD
VENTILATION. Failure to comply may result in injury or death to personnel.

TM 5-3805-294-10

LIST OF EFFECTIVE PAGES/WORK PACKAGES


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

07 March 2011

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

PAGE/WP NO.
Front Cover
Warning summary (10 pgs)
i-ii
iii-xxiv
How to use this manual (2 pgs)
Chapter 1 title page
Blank
WP0001 (4 pgs)
WP0002 (12 pgs)
WP0003 (10 pgs)
Chapter 2 title page
Blank
WP0004 (16 pgs)
WP0005 (8 pgs)
WP0006 (2 pgs)
WP0007 (6 pgs)
WP0008 (6 pgs)
WP0009 (4 pgs)
WP0010 (4 pgs)
WP0011 (6 pgs)
WP0012 (4 pgs)
WP0013 (4 pgs)
WP0014 (10 pgs)
WP0015 (2 pgs)
WP0016 (10 pgs)
WP0017 (4 pgs)
WP0018 (2 pgs)
WP0019 (16 pgs)
WP0020 (16 pgs)
WP0021 (14 pgs)
WP0022 (4 pgs)
WP0023 (6 pgs)
WP0024 (4 pgs)
WP0025 (12 pgs)
WP0026 (4 pgs)
WP0027 (14 pgs)
WP0028 (2 pgs)
WP0029 (2 pgs)
WP0030 (8 pgs)
WP0031 (8 pgs)
WP0032 (2 pgs)

CHANGE
NO.

PAGE/WP NO.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

WP0033 (2 pgs)
WP0034 (6 pgs)
WP0035 (6 pgs)
WP0036 (4 pgs)
Chapter 3 title page
Blank
WP0037 (2 pgs)
WP0038 (2 pgs)
WP0039 (2 pgs)
WP0040 (2 pgs)
WP0041 (2 pgs)
WP0042 (2 pgs)
WP0043 (2 pgs)
WP0044 (2 pgs)
WP0045 (2 pgs)
WP0046 (2 pgs)
WP0047 (4 pgs)
WP0048 (2 pgs)
WP0049 (2 pgs)
WP0050 (2 pgs)
WP0051 (2 pgs)
WP0052 (2 pgs)
WP0053 (2 pgs)
WP0054 (2 pgs)
WP0055 (2 pgs)
WP0056 (2 pgs)
WP0057 (2 pgs)
WP0058 (2 pgs)
WP0059 (2 pgs)
WP0060 (2 pgs)
WP0061 (2 pgs)
WP0062 (2 pgs)
WP0063 (2 pgs)
WP0064 (2 pgs)
WP0065 (2 pgs)
WP0066 (2 pgs)
WP0067 (2 pgs)
WP0068 (2 pgs)
WP0069 (2 pgs)
WP0070 (2 pgs)
WP0071 (2 pgs)
A

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

TM 5-3805-294-10

LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued


CHANGE
NO.

PAGE/WP NO.
WP0072 (2 pgs)
WP0073 (2 pgs)
WP0074 (2 pgs)
WP0075 (2 pgs)
Chapter 4 title page
Blank
WP0076 (4 pgs)
WP0077 (40 pgs)
Chapter 5 title page
Blank
WP0078 (2 pgs)
WP0079 (2 pgs)
WP0080 (6 pgs)
WP0081 (2 pgs)
WP0082 (2 pgs)
WP0083 (2 pgs)
WP0084 (8 pgs)
WP0085 (4 pgs)
WP0086 (2 pgs)

CHANGE
NO.

PAGE/WP NO.

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

WP0087 (6 pgs)
WP0088 (4 pgs)
WP0089 (4 pgs)
WP0090 (4 pgs)
WP0091 (4 pgs)
WP0092 (6 pgs)
WP0093 (2 pgs)
Chapter 6 title page
Blank
WP0094 (4 pgs)
WP0095 (6 pgs)
WP0096 (2 pgs)
WP0097 (2 pgs)
WP0098 (4 pgs)
WP0099 (2 pgs)
WP0100 (22 pgs)
INDEX-1 - INDEX-4
Inside back cover
Back cover

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

TM 5-3805-294-10

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

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.+($'48$57(56

i/ii blank

TM 5-3805-294-10

TABLE OF CONTENTS
Page No.
WP Sequence No.
How to Use this Manual
Chapter 1 - OPERATOR GENERAL INFORMATION
GENERAL INFORMATION.......................................................................................................................... WP 0001
Table 1.

List of Abbreviations/Acronyms............................................................................................ 0001-2

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002


Figure 1.

Right View of HYEX............................................................................................................. 0002-3

Table 1.

Right View of HYEX............................................................................................................. 0002-3

Figure 2.

Left View of HYEX................................................................................................................ 0002-4

Table 2.

Left View of HYEX................................................................................................................ 0002-4

Figure 3.

Data Plates........................................................................................................................... 0002-5

Table 3.

Data Plates........................................................................................................................... 0002-5

Table 4.

Equipment Data.................................................................................................................... 0002-6

Figure 4.

HYEX Specifications............................................................................................................ 0002-7

Table 5.

HYEX Specification.............................................................................................................. 0002-7

Figure 5.

HYEX Working Ranges........................................................................................................ 0002-8

Table 6.

HYEX Working Ranges........................................................................................................ 0002-9

Table 7.

Front Lift Capacities........................................................................................................... 0002-10

Table 8.

Side Lift Capacities............................................................................................................. 0002-11

Table 9.

HYEX Weights With Attachments...................................................................................... 0002-12

Table 10.

Deep Dig Arm Weights....................................................................................................... 0002-12

THEORY OF OPERATION.......................................................................................................................... WP 0003


Figure 1.

Electrical System Components............................................................................................ 0003-2

Table 1.

Electrical System Components............................................................................................ 0003-2

Figure 2.

Hydraulic System Components............................................................................................ 0003-3

Table 2.

Hydraulic System Components............................................................................................ 0003-3

Figure 3.

Hydraulic System Components Continued........................................................................... 0003-4

Table 3.

Hydraulic System Components Continued........................................................................... 0003-4

iii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 4.

Powertrain Components....................................................................................................... 0003-5

Table 4.

Powertrain Components....................................................................................................... 0003-5

Figure 5.

Fuel System Components.................................................................................................... 0003-6

Table 5.

Fuel System Components.................................................................................................... 0003-6

Figure 6.

High-Pressure Pump and Injectors...................................................................................... 0003-7

Table 6.

High-Pressure Pump and Injectors...................................................................................... 0003-7

Figure 7.

Cooling Package.................................................................................................................. 0003-8

Table 7.

Cooling Package.................................................................................................................. 0003-8

Figure 8.

Cooling System Components............................................................................................... 0003-9

Table 8.

Cooling System Components............................................................................................... 0003-9

Chapter 2 - OPERATOR INSTRUCTIONS


DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........................................... WP 0004
Table 1.

Front Switch Panel............................................................................................................... 0004-1

Figure 1.

Front Switch Panel............................................................................................................... 0004-1

Figure 2.

Front Switch Panel Continued.............................................................................................. 0004-2

Table 2.

Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3

Figure 3.

Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3

Figure 4.

Heater/Air Conditioner (A/C) Controller and Radio Continued............................................. 0004-4

Table 3.

Control Pedals and Levers................................................................................................... 0004-5

Figure 5.

Control Pedals and Levers................................................................................................... 0004-5

Figure 6.

Control Pedals and Levers Continued.................................................................................. 0004-6

Table 4.

Left Console and Pilot Shutoff Lever.................................................................................... 0004-7

Figure 7.

Left Console and Pilot Shutoff Lever.................................................................................... 0004-7

Table 5.

Right and Left Pilot Control Levers....................................................................................... 0004-8

Figure 8.

Right Pilot Control Lever...................................................................................................... 0004-8

Figure 9.

Left Pilot Control Lever......................................................................................................... 0004-9

Table 6.

Seat Controls...................................................................................................................... 0004-10

iv

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 10.

Seat Controls...................................................................................................................... 0004-10

Table 7.

Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12

Figure 11.

Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12

Table 8.

Quick Latch Control............................................................................................................ 0004-13

Figure 12.

Quick Latch Control............................................................................................................ 0004-13

Table 9.

Cab Light Switch................................................................................................................ 0004-14

Figure 13.

Cab Light Switch................................................................................................................ 0004-14

Table 10.

Hydraulic Hose Reel........................................................................................................... 0004-15

Figure 14.

Hydraulic Hose Reel........................................................................................................... 0004-15

DESCRIPTION AND USE OF MONITOR AND ALARMS........................................................................... WP 0005


Table 1.

Monitor Buttons and Indicators............................................................................................. 0005-1

Figure 1.

Monitor................................................................................................................................. 0005-1

Figure 2.

Monitor Buttons.................................................................................................................... 0005-2

Figure 3.

Main Menu............................................................................................................................ 0005-3

Figure 4.

Monitor Indicators................................................................................................................. 0005-4

Table 2.

Warning Indicators and Alarms............................................................................................ 0005-6

Figure 5.

Warning Indicators and Alarms............................................................................................ 0005-6

Figure 6.

Overload Alarm.................................................................................................................... 0005-7

ADJUSTING THE OPERATOR'S SEAT...................................................................................................... WP 0006


Figure 1.

Operator's Seat Adjustments................................................................................................ 0006-1

STARTING THE ENGINE............................................................................................................................ WP 0007


Figure 1.

Seat Belt............................................................................................................................... 0007-1

Figure 2.

Pilot Shutoff Lever................................................................................................................ 0007-2

Figure 3.

Engine Speed Dial Slow Idle................................................................................................ 0007-2

Figure 4.

Key Switch ON..................................................................................................................... 0007-3

Figure 5.

System Starting and Default Screen.................................................................................... 0007-3

Figure 6.

Preheat Indicator.................................................................................................................. 0007-4

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 7.

Key Switch to START........................................................................................................... 0007-4

Figure 8.

Alarm indicator..................................................................................................................... 0007-5

Figure 9.

Engine Speed Dial Turned to 1/3 Position........................................................................... 0007-5

Figure 10.

Return Engine Speed Dial to Slow Idle................................................................................ 0007-6

MOVING THE HYEX................................................................................................................................... WP 0008


Figure 1.

Pilot Shutoff Lever Unlocked................................................................................................ 0008-1

Figure 2.

Boom and Arm Raised......................................................................................................... 0008-2

Figure 3.

Travel Mode Switch.............................................................................................................. 0008-2

Figure 4.

Moving Forward and Backwards.......................................................................................... 0008-3

Figure 5.

Right Turn............................................................................................................................. 0008-4

Figure 6.

Left Turn............................................................................................................................... 0008-4

Figure 7.

Counter-Rotate..................................................................................................................... 0008-5

SHUTTING DOWN THE HYEX................................................................................................................... WP 0009


Figure 1.

Machine In Parked Position.................................................................................................. 0009-1

Figure 2.

Auto-Idle Switch and Engine Speed Dial.............................................................................. 0009-2

Figure 3.

Engine Speed Dial................................................................................................................ 0009-3

Figure 4.

Pilot Shutoff Lever................................................................................................................ 0009-3

Figure 5.

Key Switch Turned OFF....................................................................................................... 0009-4

SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED................................................. WP 0010
Figure 1.

Machine In Parked Position.................................................................................................. 0010-1

Figure 2.

Auto-Idle Switch and Engine Speed Dial.............................................................................. 0010-2

Figure 3.

Engine Speed Dial................................................................................................................ 0010-3

Figure 4.

Pilot Shutoff Lever................................................................................................................ 0010-3

Figure 5.

Key Switch Turned OFF....................................................................................................... 0010-4

OPENING AND CLOSING WINDOWS....................................................................................................... WP 0011


Figure 1.

Open Windshield.................................................................................................................. 0011-1

Figure 2.

Raise Windshield.................................................................................................................. 0011-2

vi

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 3.

Lock Windshield Open......................................................................................................... 0011-2

Figure 4.

Release Windshield Latch.................................................................................................... 0011-3

Figure 5.

Close Windshield.................................................................................................................. 0011-3

Figure 6.

Latch Windshield.................................................................................................................. 0011-4

Figure 7.

Open and Close Cab Door Window..................................................................................... 0011-4

Figure 8.

Open Access Cover............................................................................................................. 0011-5

Figure 9.

Open and Close Skylight Window........................................................................................ 0011-5

Figure 10.

Close Access Cover............................................................................................................. 0011-6

USING THE RIFLE MOUNT........................................................................................................................ WP 0012


Figure 1.

Stow Weapon In Rear Bracket............................................................................................. 0012-1

Figure 2.

Stow Weapon In Front Bracket............................................................................................ 0012-2

Figure 3.

Remove Weapon From Front Bracket.................................................................................. 0012-2

Figure 4.

Remove Weapon From Rear Bracket.................................................................................. 0012-3

GENERAL MONITOR OPERATION............................................................................................................ WP 0013


Figure 1.

Select Time Set Menu.......................................................................................................... 0013-1

Figure 2.

Adjust Time.......................................................................................................................... 0013-2

Figure 3.

Select Operating Conditions Menu....................................................................................... 0013-2

Figure 4.

Reset Operating Conditions................................................................................................. 0013-3

REMOVING AND INSTALLING BUCKET................................................................................................... WP 0014


Figure 1.

Unlock Safety Lock Pin........................................................................................................ 0014-1

Figure 2.

Raise Boom.......................................................................................................................... 0014-2

Figure 3.

Move Quick Latch Switch to Unlatch Position...................................................................... 0014-2

Figure 4.

Extend Bucket Cylinder........................................................................................................ 0014-3

Figure 5.

Retract Bucket Cylinder........................................................................................................ 0014-3

Figure 6.

Lower Boom......................................................................................................................... 0014-4

Figure 7.

Position Quick Latch Switch to Latch position...................................................................... 0014-4

Figure 8.

Remove Quick Latch............................................................................................................ 0014-5

vii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 9.

Position Quick Latch Switch to Unlatch position.................................................................. 0014-6

Figure 10.

Raise Boom for Clearance................................................................................................... 0014-6

Figure 11.

Retract Wedges.................................................................................................................... 0014-7

Figure 12.

Install Quick Latch................................................................................................................ 0014-7

Figure 13.

Position Quick Latch Switch toLatch position....................................................................... 0014-8

Figure 14.

Raise Boom.......................................................................................................................... 0014-8

Figure 15.

Safety Pin Locked................................................................................................................ 0014-9

LIFTING WITH HYEX.................................................................................................................................. WP 0015


Figure 1.

Lifting with Quick Latch Loop............................................................................................... 0015-2

OPERATING TECHNIQUES....................................................................................................................... WP 0016


Figure 1.

Leveling Machine................................................................................................................. 0016-1

Figure 2.

Add or Remove Material....................................................................................................... 0016-1

Figure 3.

Arm Digging.......................................................................................................................... 0016-3

Figure 4.

Bucket Digging..................................................................................................................... 0016-4

Figure 5.

Planning Spoil Piles.............................................................................................................. 0016-5

Figure 6.

Trenching............................................................................................................................. 0016-6

Figure 7.

Cleaning Cave In.................................................................................................................. 0016-6

Figure 8.

Trenching on a Slope........................................................................................................... 0016-7

Figure 9.

Straight Line Trenching........................................................................................................ 0016-8

Figure 10.

Back Filling........................................................................................................................... 0016-9

Figure 11.

Truck Loading..................................................................................................................... 0016-10

OPERATING THE HYDRAULIC THUMB.................................................................................................... WP 0017


Figure 1.

Clamping With Bucket.......................................................................................................... 0017-1

Figure 2.

Clamping With Hydraulic Thumb.......................................................................................... 0017-2

Figure 3.

Releasing Objects................................................................................................................ 0017-3

SELECTING AN ATTACHMENT ON THE MONITOR................................................................................ WP 0018


Figure 1.

Select Attachment................................................................................................................ 0018-1

viii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Table 1.

Attachment Selection........................................................................................................... 0018-1

Figure 2.

Attachment Specification Screen......................................................................................... 0018-2

INSTALLING AND OPERATING THE CRUSH-ALL.................................................................................... WP 0019


Figure 1.

Close Hydraulic Thumb Circuit............................................................................................. 0019-1

Figure 2.

Move Quick Latch Switch to Unlatch Position...................................................................... 0019-2

Figure 3.

Extend Bucket Cylinder........................................................................................................ 0019-3

Figure 4.

Install Quick Latch................................................................................................................ 0019-3

Figure 5.

Quick Latch Switch to Latch Position................................................................................... 0019-4

Figure 6.

Position Crush-All................................................................................................................. 0019-4

Figure 7.

Connect Auxiliary Supply Line.............................................................................................. 0019-5

Figure 8.

Connect Auxiliary Return Line.............................................................................................. 0019-5

Figure 9.

Crush-All Operation.............................................................................................................. 0019-7

Figure 10.

Open Lid............................................................................................................................... 0019-9

Figure 11.

Clearing Jam from Crush-All................................................................................................ 0019-9

Figure 12.

Push Crush-All Rotor Backwards....................................................................................... 0019-10

Figure 13.

Position Crush-All............................................................................................................... 0019-10

Figure 14.

Disconnect Auxiliary Return Line....................................................................................... 0019-11

Figure 15.

Disconnect Auxiliary Supply Line....................................................................................... 0019-12

Figure 16.

Move Quick Latch Switch................................................................................................... 0019-12

Figure 17.

Raise Boom........................................................................................................................ 0019-13

Figure 18.

Remove Quick Latch.......................................................................................................... 0019-14

Figure 19.

Move Quick Latch Switch................................................................................................... 0019-14

Figure 20.

Open Hydraulic Thumb Circuit........................................................................................... 0019-15

INSTALLING AND OPERATING THE IMPACT BREAKER........................................................................ WP 0020


Figure 1.

Close Hydraulic Thumb Circuit............................................................................................. 0020-1

Figure 2.

Move Quick Latch Switch..................................................................................................... 0020-2

Figure 3.

Raise Boom.......................................................................................................................... 0020-3

ix

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 4.

Quick Latch Wedges Retracted............................................................................................ 0020-3

Figure 5.

Install Quick Latch................................................................................................................ 0020-4

Figure 6.

Extend Bucket Cylinder........................................................................................................ 0020-4

Figure 7.

Move Quick Latch Switch to Latch Position......................................................................... 0020-5

Figure 8.

Quick Latch Wedges Engaged............................................................................................. 0020-5

Figure 9.

Safety Pin to Lock Position................................................................................................... 0020-6

Figure 10.

Connect Auxiliary Supply Line.............................................................................................. 0020-6

Figure 11.

Connect Auxiliary Return Line.............................................................................................. 0020-7

Figure 12.

Breaker Tool Lock Bolt......................................................................................................... 0020-8

Figure 13.

Insert Breaker Tool............................................................................................................... 0020-9

Figure 14.

Lock Breaker Tool................................................................................................................ 0020-9

Figure 15.

Breaker Operation.............................................................................................................. 0020-10

Figure 16.

Tool Removal..................................................................................................................... 0020-10

Figure 17.

Remove Breaker Tool........................................................................................................ 0020-11

Figure 18.

Lock Breaker Tool.............................................................................................................. 0020-11

Figure 19.

Disconnect Auxiliary Return Line....................................................................................... 0020-12

Figure 20.

Disconnect Auxiliary Supply Line....................................................................................... 0020-12

Figure 21.

Safety Pin to Unlock Position............................................................................................. 0020-13

Figure 22.

Raise Boom for Clearance................................................................................................. 0020-13

Figure 23.

Move Quick Latch Switch to Unlatch Position.................................................................... 0020-14

Figure 24.

Quick Latch Wedges Retracted.......................................................................................... 0020-14

Figure 25.

Impact Breaker Removal.................................................................................................... 0020-15

Figure 26.

Quick Latch Switch to Latch Position................................................................................. 0020-15

Figure 27.

Open Hydraulic Thumb Circuit........................................................................................... 0020-16

INSTALLING AND OPERATING THE COMPACTOR................................................................................. WP 0021


Figure 1.

Close Hydraulic Thumb Circuit............................................................................................. 0021-2

Figure 2.

Move Quick Latch Switch..................................................................................................... 0021-3

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 3.

Raise Boom.......................................................................................................................... 0021-3

Figure 4.

Quick Latch Wedges Retracted............................................................................................ 0021-4

Figure 5.

Install Quick Latch................................................................................................................ 0021-4

Figure 6.

Position Quick Latch............................................................................................................. 0021-5

Figure 7.

Quick Latch Switch to Latch Position................................................................................... 0021-5

Figure 8.

Raise Boom for Clearance................................................................................................... 0021-6

Figure 9.

Engage Quick Latch Wedges............................................................................................... 0021-6

Figure 10.

Lock Safety Lock.................................................................................................................. 0021-7

Figure 11.

Connect Auxiliary Supply Line.............................................................................................. 0021-7

Figure 12.

Connect Auxiliary Return Line.............................................................................................. 0021-8

Figure 13.

Attachment Pedal Lock Release.......................................................................................... 0021-8

Figure 14.

Disconnect Auxiliary Return Line......................................................................................... 0021-9

Figure 15.

Connect Auxiliary Supply Line............................................................................................ 0021-10

Figure 16.

Unlock Safety Lock............................................................................................................. 0021-10

Figure 17.

Quick Latch Switch to Unlatch Position.............................................................................. 0021-11

Figure 18.

Raise Boom........................................................................................................................ 0021-11

Figure 19.

Disengage Quick Latch Wedges........................................................................................ 0021-12

Figure 20.

Retract Bucket Cylinder...................................................................................................... 0021-12

Figure 21.

Remove Quick Latch.......................................................................................................... 0021-13

Figure 22.

Quick Latch Switch to Latch Position................................................................................. 0021-13

Figure 23.

Close Hydraulic Thumb Circuit........................................................................................... 0021-14

OPERATING THE BARRIER GRAPPLE..................................................................................................... WP 0022


Figure 1.

Lifting Barrier Grapple.......................................................................................................... 0022-2

OPERATING THE DEEP DIG ARM............................................................................................................ WP 0023


Figure 1.

Deep Dig Control Pattern Switch.......................................................................................... 0023-1

Figure 2.

Turn Auto Idle Switch On..................................................................................................... 0023-2

Figure 3.

Pilot Shutoff Lever................................................................................................................ 0023-3

xi

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 4.

Turn RPM Dial...................................................................................................................... 0023-4

Figure 5.

Cycle Deep Dig Arm Cylinders............................................................................................. 0023-5

MOVING MACHINE ON/OFF AN EMBANKMENT...................................................................................... WP 0024


Figure 1.

Position Bucket..................................................................................................................... 0024-1

Figure 2.

Upperstructure Rotated........................................................................................................ 0024-2

Figure 3.

Position Bucket on Lower Level........................................................................................... 0024-3

Figure 4.

Rotate Upperstructure to Upper Level.................................................................................. 0024-3

USING THE VANDAL PROTECTION KIT................................................................................................... WP 0025


Figure 1.

Right Side Rear Cover Installation....................................................................................... 0025-1

Figure 2.

Right Side Center Cover Installation.................................................................................... 0025-1

Figure 3.

Right Side Front Cover Installation....................................................................................... 0025-2

Figure 4.

Lock Bar Installation............................................................................................................. 0025-2

Figure 5.

Front Door Cover Installation............................................................................................... 0025-3

Figure 6.

Center Door Cover Installation............................................................................................. 0025-3

Figure 7.

Lower Door Cover Installation.............................................................................................. 0025-4

Figure 8.

Side Upper Glass Cover Installation.................................................................................... 0025-4

Figure 9.

Side Lower Glass Cover Installation.................................................................................... 0025-5

Figure 10.

Right Rear Cab Cover Installation........................................................................................ 0025-5

Figure 11.

Left Rear Cab Cover Installation.......................................................................................... 0025-6

Figure 12.

Left Rear Cab Cover Removal............................................................................................. 0025-6

Figure 13.

Right Rear Cab Cover Removal........................................................................................... 0025-7

Figure 14.

Side Lower Glass Cover Removal....................................................................................... 0025-7

Figure 15.

Side Upper Glass Cover Removal....................................................................................... 0025-8

Figure 16.

Lower Door Cover Removal................................................................................................. 0025-8

Figure 17.

Center Door Cover Removal................................................................................................ 0025-9

Figure 18.

Front Door Cover Removal.................................................................................................. 0025-9

Figure 19.

Lock Bar Removal.............................................................................................................. 0025-10

xii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 20.

Right Side Front Cover Removal........................................................................................ 0025-10

Figure 21.

Right Side Center Cover Removal..................................................................................... 0025-10

Figure 22.

Right Side Rear Cover Removal........................................................................................ 0025-11

OPERATING THE HYDRAULIC HOSE REEL............................................................................................ WP 0026


Figure 1.

Hydraulic Tool Attachment................................................................................................... 0026-1

Figure 2.

Turn On Hydraulic Tool........................................................................................................ 0026-2

Figure 3.

Turn Off Hydraulic Tool........................................................................................................ 0026-2

Figure 4.

Hydraulic Tool Removal....................................................................................................... 0026-3

DECAL LOCATION GUIDE......................................................................................................................... WP 0027


Figure 1.

Left Side, Rear Cab Window, and Top Decals..................................................................... 0027-1

Figure 2.

Left Inside Door.................................................................................................................... 0027-2

Figure 3.

Top Under Engine Cover...................................................................................................... 0027-2

Figure 4.

Right Side on Hydraulic Reservoir....................................................................................... 0027-3

Figure 5.

Right Side............................................................................................................................. 0027-3

Figure 6.

Boom, Right Side, and Rear Cab Window........................................................................... 0027-4

Figure 7.

Counterweight...................................................................................................................... 0027-4

Figure 8.

Front and Rear Frame.......................................................................................................... 0027-5

Figure 9.

Cab on Seat......................................................................................................................... 0027-5

Figure 10.

Key Switch............................................................................................................................ 0027-5

Figure 11.

Windshield............................................................................................................................ 0027-6

Figure 12.

Side Window........................................................................................................................ 0027-6

Figure 13.

Upper and Lower Right Side Window.................................................................................. 0027-7

Figure 14.

Lower Right Side Window.................................................................................................... 0027-8

Figure 15.

Vandal Protection Kit............................................................................................................ 0027-9

Figure 16.

Upper Section Periodic Maintenance................................................................................. 0027-10

Figure 17.

Lower Section Periodic Maintenance................................................................................. 0027-11

Figure 18.

Ditch Cleaning Bucket........................................................................................................ 0027-12

xiii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 19.

Heavy Duty Bucket............................................................................................................. 0027-12

Figure 20.

Right Side Crush-All........................................................................................................... 0027-13

Figure 21.

Left Side Crush-All............................................................................................................. 0027-13

Figure 22.

Output Side Crush-All......................................................................................................... 0027-14

TOWING THE HYEX................................................................................................................................... WP 0028


LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................... WP 0029
OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)..................................................................... WP 0030
Figure 1.

Press and Hold Back Button................................................................................................ 0030-1

Figure 2.

Key Switch to ON Position................................................................................................... 0030-2

Figure 3.

Release Back Button............................................................................................................ 0030-2

Figure 4.

Highlight Service Menu........................................................................................................ 0030-3

Figure 5.

Select Monitoring.................................................................................................................. 0030-3

Figure 6.

Temperatures Displayed...................................................................................................... 0030-4

Figure 7.

Start Engine.......................................................................................................................... 0030-4

Figure 8.

Engine Speed Dial................................................................................................................ 0030-5

Figure 9.

Check Engine and Hydraulic Oil Temperatures................................................................... 0030-5

Table 1.

Machine Switch Selections................................................................................................... 0030-6

Figure 10.

Raise Machine...................................................................................................................... 0030-6

OPERATING IN COLD WEATHER 5F (-15C) OR COLDER ................................................................... WP 0031


Figure 1.

Press and Hold Back Button................................................................................................ 0031-1

Figure 2.

Key Switch to ON Position................................................................................................... 0031-2

Figure 3.

Release Back Button............................................................................................................ 0031-2

Figure 4.

Highlight Service Menu........................................................................................................ 0031-3

Figure 5.

Select Monitoring.................................................................................................................. 0031-3

Figure 6.

Temperatures Displayed...................................................................................................... 0031-4

Figure 7.

Start Engine.......................................................................................................................... 0031-4

Figure 8.

Engine Idle Speed................................................................................................................ 0031-5

xiv

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 9.

Monitor Temperatures Displayed......................................................................................... 0031-5

Table 1.

Machine Switch Selection.................................................................................................... 0031-6

Figure 10.

Raise Machine...................................................................................................................... 0031-7

SLAVE STARTING...................................................................................................................................... WP 0032


Figure 1.

Slave Receptacle................................................................................................................. 0032-2

SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................... WP 0033
Figure 1.

Open and Close Roof Exit.................................................................................................... 0033-1

Figure 2.

Emergency Exit Tool............................................................................................................ 0033-2

OPERATING THE COOLANT HEATER...................................................................................................... WP 0034


Figure 1.

Coolant Heater Control Panel.............................................................................................. 0034-2

Figure 2.

Adjusting Time and Day....................................................................................................... 0034-2

Figure 3.

Setting Program................................................................................................................... 0034-3

Figure 4.

Adjusting Run Time.............................................................................................................. 0034-4

Figure 5.

Manually Start Coolant Heater............................................................................................. 0034-4

Figure 6.

Manually Start Coolant Heater Continued............................................................................ 0034-5

MOVING UP/DOWN STEEP OR SLIPPERY SLOPES............................................................................... WP 0035


Figure 1.

Buckle Seat Belt................................................................................................................... 0035-1

Figure 2.

Pulling Machine Up.............................................................................................................. 0035-2

Figure 3.

Buckle Seat Belt................................................................................................................... 0035-3

Figure 4.

Pushing Machine.................................................................................................................. 0035-3

Figure 5.

Traveling Down.................................................................................................................... 0035-4

FORDING THE HYEX................................................................................................................................. WP 0036


Figure 1.

Fording Line......................................................................................................................... 0036-1

Figure 2.

Pilot Shutoff Lever................................................................................................................ 0036-2

Figure 3.

Check Monitor...................................................................................................................... 0036-2

Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES


TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE............................................... WP 0037

xv

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


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

xvi

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
SLOW TRAVEL SPEED ONLY................................................................................................................... WP 0065
TRAVEL IS JERKY...................................................................................................................................... WP 0066
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED..................................................... WP 0067
QUICK LATCH DOES NOT OPERATE....................................................................................................... WP 0068
COMPACTOR DOES NOT OPERATE........................................................................................................ WP 0069
BREAKER DOES NOT OPERATE.............................................................................................................. WP 0070
BREAKER OPERATES SLOWLY............................................................................................................... WP 0071
CRUSH-ALL DOES NOT OPERATE........................................................................................................... WP 0072
BARRIER GRAPPLE DOES NOT HOLD LOAD......................................................................................... WP 0073
DEEP DIG DOES NOT OPERATE.............................................................................................................. WP 0074
HYDRAULIC HOSE REEL DOES NOT OPERATE..................................................................................... WP 0075
Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................... WP 0076
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0077
Table 1.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES.......................... 0077-1

Figure 1.

Exterior of Machine.............................................................................................................. 0077-3

Figure 2.

Exterior of Machine Continued............................................................................................. 0077-4

Figure 3.

Coolant Level....................................................................................................................... 0077-5

Figure 4.

Engine Oil............................................................................................................................. 0077-6

Figure 5.

Exhaust Components........................................................................................................... 0077-7

Figure 6.

Hydraulic Reservoir Cap...................................................................................................... 0077-7

Figure 7.

Fuel Tank and Fuel Level..................................................................................................... 0077-8

Figure 8.

Fuel Filters............................................................................................................................ 0077-9

Figure 9.

Engine Oil Filter.................................................................................................................... 0077-9

Figure 10.

Boom, Arm, Quick Latch, and Hydraulic Thumb................................................................ 0077-10

Figure 11.

Bucket and Teeth............................................................................................................... 0077-11

Figure 12.

Air Cleaner Housing and Hose Reel.................................................................................. 0077-12

xvii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 13.

Batteries............................................................................................................................. 0077-13

Figure 14.

Batteries Continued............................................................................................................ 0077-14

Figure 15.

Cab Glass........................................................................................................................... 0077-15

Figure 16.

Mirrors and Wiper Arm....................................................................................................... 0077-15

Figure 17.

Cab Door, Hinges, and Latches......................................................................................... 0077-16

Figure 18.

Fire Extinguisher................................................................................................................ 0077-17

Figure 19.

Pedals and Levers.............................................................................................................. 0077-18

Figure 20.

Pilot Control Levers............................................................................................................ 0077-19

Figure 21.

Seat Belt............................................................................................................................. 0077-20

Figure 22.

Ignition Switch.................................................................................................................... 0077-20

Figure 23.

Monitor............................................................................................................................... 0077-21

Figure 24.

Position Boom and Arm...................................................................................................... 0077-22

Figure 25.

Hydraulic Oil Level Check.................................................................................................. 0077-22

Figure 26.

Breaker............................................................................................................................... 0077-23

Figure 27.

Compactor.......................................................................................................................... 0077-24

Figure 28.

Crush-All............................................................................................................................. 0077-25

Figure 29.

Barrier Grapple................................................................................................................... 0077-26

Figure 30.

Deep Dig Arm and Bucket.................................................................................................. 0077-27

Figure 31.

Deep Dig Bucket................................................................................................................ 0077-28

Figure 32.

Ditch Cleaning Bucket........................................................................................................ 0077-29

Figure 33.

Position Boom and Arm...................................................................................................... 0077-31

Figure 34.

Hydraulic Oil Level Check.................................................................................................. 0077-31

Figure 35.

Fuel Tank and Fuel Level Check........................................................................................ 0077-32

Figure 36.

Engine Oil Check................................................................................................................ 0077-33

Figure 37.

Engine Compartment......................................................................................................... 0077-33

Figure 38.

Exterior of Machine Check................................................................................................. 0077-34

Figure 39.

Swing Gearbox Oil Level Check......................................................................................... 0077-35

xviii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 40.

Hydraulic Pump Oil Level Check........................................................................................ 0077-36

Figure 41.

Serpentine Belt Check........................................................................................................ 0077-37

Figure 42.

Air Conditioner Belt Check................................................................................................. 0077-38

Figure 43.

Fan Check.......................................................................................................................... 0077-39

Chapter 5 - OPERATOR MAINTENANCE INSTRUCTIONS


GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0078
TAKING ENGINE OIL SAMPLE.................................................................................................................. WP 0079
Figure 1.

Engine Oil Sampling Valve................................................................................................... 0079-1

TRACK SAG CHECK .................................................................................................................................. WP 0080


Figure 1.

Raise Machine...................................................................................................................... 0080-1

Figure 2.

Rotate Track......................................................................................................................... 0080-2

Figure 3.

Shut Machine Off.................................................................................................................. 0080-3

Figure 4.

Measure Track Sag.............................................................................................................. 0080-4

Figure 5.

Start Machine....................................................................................................................... 0080-5

Figure 6.

Lower Machine..................................................................................................................... 0080-5

TIGHTENING TRACK TENSION................................................................................................................. WP 0081


Figure 1.

Tighten Track....................................................................................................................... 0081-1

LOOSENING TRACK TENSION................................................................................................................. WP 0082


Figure 1.

Loosen Track........................................................................................................................ 0082-1

TAKING HYDRAULIC OIL SAMPLE........................................................................................................... WP 0083


Figure 1.

Hydraulic Oil Sampling Valve............................................................................................... 0083-1

CAB FUSE REPLACEMENT....................................................................................................................... WP 0084


Figure 1.

Fuse Box Access Cover Removal........................................................................................ 0084-2

Figure 2.

Main Fuse Box Cover Removal............................................................................................ 0084-3

Figure 3.

Fuse Removal...................................................................................................................... 0084-4

Figure 4.

Fuse Installation................................................................................................................... 0084-5

Figure 5.

Main Fuse Box Cover Installation......................................................................................... 0084-6

xix

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 6.

Fuse Box Access Cover Installation..................................................................................... 0084-7

BUCKET TEETH REPLACEMENT.............................................................................................................. WP 0085


Figure 1.

Tooth Removal..................................................................................................................... 0085-1

Figure 2.

Tooth Installation.................................................................................................................. 0085-2

Figure 3.

Bucket Tooth Removal......................................................................................................... 0085-2

Figure 4.

Bucket Tooth Installation...................................................................................................... 0085-3

PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................................. WP 0086


Figure 1.

Drain Fuel Filter/Water Separators....................................................................................... 0086-1

Figure 2.

Drain Fuel Filter/Water Separators Continued..................................................................... 0086-2

PRIMARY AND SECONDARY AIR CLEANER SERVICE.......................................................................... WP 0087


Figure 1.

Cover Removal..................................................................................................................... 0087-1

Figure 2.

Primary Air Cleaner Removal............................................................................................... 0087-2

Figure 3.

Secondary Air Cleaner Removal.......................................................................................... 0087-2

Figure 4.

Primary Air Cleaner Service................................................................................................. 0087-3

Figure 5.

Air Cleaner Housing Service................................................................................................ 0087-4

Figure 6.

Cover and Dust Boot Service............................................................................................... 0087-4

Figure 7.

Secondary Air Cleaner Installation....................................................................................... 0087-5

Figure 8.

Primary Air Cleaner Installation............................................................................................ 0087-5

Figure 9.

Cover Installation.................................................................................................................. 0087-6

HYDRAULIC RESERVOIR SERVICE......................................................................................................... WP 0088


Figure 1.

Hydraulic Reservoir Cover Removal.................................................................................... 0088-1

Figure 2.

Hydraulic Reservoir Sight Glass........................................................................................... 0088-2

Figure 3.

Hydraulic Reservoir Cover Installation................................................................................. 0088-3

FRESH AIR FILTER SERVICE.................................................................................................................... WP 0089


Figure 1.

Filter Removal...................................................................................................................... 0089-1

Figure 2.

Inspect Seal.......................................................................................................................... 0089-2

Figure 3.

Clean Filter........................................................................................................................... 0089-3

xx

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 4.

Clean Housing...................................................................................................................... 0089-3

Figure 5.

Filter Installation................................................................................................................... 0089-4

AIR CONDITIONER/HEATER FILTER SERVICE....................................................................................... WP 0090


Figure 1.

Filter Removal...................................................................................................................... 0090-1

Figure 2.

Clean Filter........................................................................................................................... 0090-2

Figure 3.

Clean Housing...................................................................................................................... 0090-3

Figure 4.

Filter Installation................................................................................................................... 0090-3

DRAINING WATER AND SEDIMENT FROM FUEL TANK......................................................................... WP 0091


Figure 1.

Remove Fuel Cap................................................................................................................ 0091-1

Figure 2.

Drain Hose........................................................................................................................... 0091-2

Figure 3.

Drain Valve........................................................................................................................... 0091-3

Figure 4.

Install Fuel Cap.................................................................................................................... 0091-4

CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT..................................................................... WP 0092


Figure 1.

Curtain Adjustment............................................................................................................... 0092-2

Figure 2.

Clearance Check.................................................................................................................. 0092-3

Figure 3.

Clamp Installation................................................................................................................. 0092-4

Figure 4.

Spring Compression............................................................................................................. 0092-5

MAINTENANCE AFTER FORDING............................................................................................................ WP 0093


Figure 1.

Draining Mud or Water......................................................................................................... 0093-1

Chapter 6 - OPERATOR SUPPORTING INFORMATION


REFERENCES............................................................................................................................................ WP 0094
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................ WP 0095
Table 1.

COMPONENTS OF END ITEM........................................................................................... 0095-2

Table 2.

BASIC ISSUE ITEMS........................................................................................................... 0095-4

ADDITIONAL AUTHORIZATION LIST (AAL).............................................................................................. WP 0096


Table 1.

Additional Authorization List................................................................................................. 0096-1

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

xxi

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
SPECIAL PURPOSE KITS (SPK) LIST....................................................................................................... WP 0098
Table 1.

Special Purpose Kits............................................................................................................ 0098-2

TROUBLESHOOTING NOTES................................................................................................................... WP 0099


HYEX TRANSPORTABILITY INSTRUCTIONS........................................................................................... WP 0100
Figure 1.

Military Load Classification................................................................................................... 0100-1

Figure 2.

HYEX Dimensions................................................................................................................ 0100-2

Figure 3.

HYEX Transportation Data Plate.......................................................................................... 0100-3

Figure 4.

HYEX Lifting and Tie Down Points....................................................................................... 0100-4

Table 1.

HYEX Lift and Tie Down Information.................................................................................... 0100-4

Figure 5.

M870 Loading....................................................................................................................... 0100-5

Figure 6.

M870A1 Loading.................................................................................................................. 0100-6

Figure 7.

M870A3 Loading.................................................................................................................. 0100-7

Figure 8.

GIC Rail Clearance.............................................................................................................. 0100-8

Figure 9.

Standard Cab Clearance...................................................................................................... 0100-9

Figure 10.

Armored Cab Clearance..................................................................................................... 0100-10

Figure 11.

HTTX Railcar Loading Overhead View.............................................................................. 0100-10

Figure 12.

HTTX Railcar Loading Side View....................................................................................... 0100-11

Figure 13.

C-5 Aircraft Loading........................................................................................................... 0100-11

Figure 14.

C-17 Aircraft Loading......................................................................................................... 0100-12

Figure 15.

Marine Loading................................................................................................................... 0100-12

Figure 16.

Standard Rock Bucket........................................................................................................ 0100-13

Figure 17.

Standard Ditch Cleaning Bucket........................................................................................ 0100-14

Figure 18.

Standard Buckets Loaded On M870A1.............................................................................. 0100-15

Figure 19.

Standard Buckets Loaded On M870A3.............................................................................. 0100-15

Figure 20.

Deep Dig Arm..................................................................................................................... 0100-16

Figure 21.

Deep Dig Bucket................................................................................................................ 0100-16

Figure 22.

Deep Dig Ditch Cleaning Bucket........................................................................................ 0100-17

xxii

TM 5-3805-294-10

TABLE OF CONTENTS - Continued


Page No.
WP Sequence No.
Figure 23.

Crush-All............................................................................................................................. 0100-18

Figure 24.

Compactor.......................................................................................................................... 0100-18

Figure 25.

Impact Breaker................................................................................................................... 0100-19

Figure 26.

Barrier Grapple................................................................................................................... 0100-19

Figure 27.

Crush-All On M870A1........................................................................................................ 0100-20

Figure 28.

Crush-All On M870A3........................................................................................................ 0100-20

Figure 29.

Standard Buckets Loaded On HTTX Railcar...................................................................... 0100-21

Figure 30.

Crush-All Loaded On HTTX Railcar................................................................................... 0100-21

Figure 31.

Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.................... 0100-22

Figure 32.

Deep Dig Arm and Buckets Loaded On HTTX Railcar....................................................... 0100-22

Index

xxiii/xxiv blank

TM 5-3805-294-10

HOW TO USE THIS MANUAL

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

xxv

TM 5-3805-294-10

HOW TO USE THIS MANUAL - Continued


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

xxvi

TM 5-3805-294-10

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

TM 5-3805-294-10

0001

OPERATOR MAINTENANCE
GENERAL INFORMATION

SCOPE
This manual contains instructions for operation, operator troubleshooting, and operator-performed maintenance on
the Hydraulic Excavator Type 1 (HYEX). The HYEX is used for construction operations.
MAINTENANCE FORMS AND RECORDS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094); or
AR 700-138, Army Logistics Readiness and Sustainability (WP 0094).
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your HYEX needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you 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

Additional Authorization List

A/C

Air Conditioning

ACC

Accessory

AEPS

Army Electronic Product Support

A/I or A.I.

Auto-Idle

AOAP

Army Oil Analysis Program

BII

Basic Issue Items

CAGEC

Commercial and Government Entity Code

cm

Centimeter

COEI

Components of End Item

CPC

Corrosion Prevention and Control

CTA

Common Table of Allowance

Economy

ECU

Engine Control Unit

EDRS

Electronic Deficiency Reports

EIR

Equipment Improvement Record

FC

Full-Cool

FH

Full-Heat

ft

Feet

gal

Gallon

Hour

HET

Heavy Equipment Transport

hp

Horsepower

H/P

High Power

0001-2

0001

TM 5-3805-294-10
LIST OF ABBREVIATIONS/ACRONYMS - Continued
Table 1.

List of Abbreviations/Acronyms - Continued.

HYEX

Hydraulic Excavator

in.

Inch

INT

Intermittent

kg

Kilogram

kohm

Kilo ohm

Liter

L/h

Liter/hour

Meter

mm

Millimeter

Power

PMCS

Preventive Maintenance Checks and Services

P/N

Part Number

psi

Pounds per Square Inch

QDR

Quality Deficiency Report

TAMMS

The Army Maintenance Management System

END OF WORK PACKAGE

0001-3/4 blank

0001

TM 5-3805-294-10

0002

OPERATOR MAINTENANCE
EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES


Overview
The Hydraulic Excavator Type 1 (HYEX), NSN 3805-01-573-0677, is a 21-24 Metric Ton, diesel powered, crawler
mounted, hoe type hydraulic excavator. The HYEX digs, elevates, swings, and dumps material by action of the boom,
the arm, and the bucket.
The HYEX is powered by a John Deere six-cylinder, PowerTech, 414 cu in. (6.8 L) engine driving two identical
variable displacement, bent-axis, piston type hydraulic pumps and a fixed displacement, external gear pilot pump.
The hydraulic pumps and pilot pump combination provide the hydraulic and control pressure for the machine to
operate.
Propulsion is provided by two-speed hydraulic travel motors, (one on each side), that drive two track chains with 51
triple semi-grouser 32 in. (800 mm) wide track shoes. Each hydraulic travel motor is of a bidirectional planetary drive/
axial piston motor design with spring applied and hydraulically released travel brakes.
The HYEX upper structure is capable of continuous 360degree rotation driven by a swing gearbox and bidirectional
swing motor mounted on top of the swing gearbox. The swing motor has a spring applied and hydraulically released
park brake. The park brake prevents the upperstructure from uncontrolled swinging. The swing park brake is released
when swing, boom, arm, or bucket function is actuated.
The boom, arm, hydraulic thumb, and bucket hydraulic cylinders provide linear actuation for their associated
components. These cylinders vary in size, but are similar in design and function.
The HYEX is configured with a retractable hydraulic hose reel, with pressure and return hoses of 50 ft (15.24 m)
length and 0.5 in. (1.27 cm) diameter, located on the cab side of the excavator to operate hand-held tools. The
hydraulic circuit is a controlled pressure source with adjustable flow rates between 8-12 GPM (30.28-45.42 LPM)
with adjustable nominal pressure limit of 2,000 psi (137.89 bar).
Operating Capabilities
The HYEX can excavate undisturbed hard, medium, and soft soils to a minimum depth range of 22-24 ft
(6.7-7.3 m). It has a minimum horizontal bucket reach at ground level of 30 ft (9.14 m). Maximum possible bucket
and stick forces are capable of penetrating and excavating very difficult soils (such as caliche) and conditions (such
as frozen soils).
The HYEX is capable of dumping into the Family of Medium Tactical Vehicles (FMTV), 5 ton with a bed height of 6
ft 9 in., to a M917 20 ton with a bed height of 10 ft 2 in. HYEX is capable of dumping into an Engineer Mission Module
(EMM) when on equal level ground.
The HYEX operates under environmental climatic conditions from -25F to 120F (-31.6C to 48.8C) without
restriction, and when required, down to -40F (-40C) using the coolant heater cold weather starting kit.
The HYEX will start and operate during and after fording operations in fresh water in any depth up to 40 in. (1 m)
including wave action.
Attachments for HYEX are connected to the excavator arm (stick) using the Quick Latch (a hydraulic quick connect/
disconnect coupler system) and hydraulic quick-disconnect hydraulic hose connections on the arm. The only
exception is the Deep Digging Attachment Arm that must be pinned directly to the end of the excavator arm.

0002-1

TM 5-3805-294-10

0002

Attachments
The HYEX digging and loading attachments are as follows:
Heavy Duty Bucket (for general purpose excavating and in material, such as dense clay and light rock) with

heaped capacity of 1.5 sq yd (1.25 sq m), a 42 in. (107 cm) outside lip width, and five pick-shaped pointed
teeth.
Heavy Duty Bucket (for use with the deep digging attachment) with heaped capacity of 0.5 sq yd (0.41 sq

m), 30 in. (76 cm) outside lip width, and four pick-shaped pointed teeth.
Ditch Cleaning Bucket (Utility) with heaped capacity of 1.33 sq yd (1.11 sq m), 60 in. (152 cm) outside lip

width, and no teeth.


Ditch Cleaning Bucket (Utility), (for use with the deep digging attachment) with heaped capacity of 0.75 sq

yd (0.62 sq m), 60 in. (152 cm) outside lip width, and no teeth.
Hydraulic thumb clamp is configured to work with heavy duty bucket listed above, and is compatible with

the ditch cleaning bucket listed above. The hydraulic thumb will fully retract or fold back when not in use,
enabling unhampered use of bucket(s), and can be pinned in the fully retracted position directly to the end
of the excavator arm (stick).
Deep Digging Attachment Arm (20 ft (6.09 m) long) is pinned directly to the end of the excavator arm (stick).

The Deep Digging Attachment Arm allows attachment of either the 30 in. (76 cm), 0.5 sq yd (0.41 sq m),
digging bucket (with teeth), or the 60 in. (152 cm), 0.75 sq yd (0.62 sq m), ditch cleaning bucket (no teeth).
This attachment uses additional counterweight and control selections to enable operation for digging to a
depth of 40 ft (12.19 m).
The HYEX construction attachments are as follows:
Hydraulic Impact Breaker (impact energy class of 5,000 lb-ft (6779 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

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS


5

6
8

9
HYEX00104

Figure 1.
Table 1.

Right View of HYEX.

Right View of HYEX.

FUEL TANK. Contains JP-8, diesel, or other NATO-approved fuels for engine operation.

HYDRAULIC RESERVOIR. Contains hydraulic oil for the hydraulic system.

HYDRAULIC PUMPS. Draws hydraulic fluid from the hydraulic reservoir and provides hydraulic
pressure and control pressure to the rest of the hydraulic system.

COUNTERWEIGHT. Adds stability to the machine during digging and lifting operations.

ARM CYLINDER. Extends and retracts the arm.

BOOM CYLINDERS. Raises and lowers the boom.

ATTACHMENT CYLINDER. Curls the bucket while digging and allows for dumping.

HYDRAULIC THUMB CYLINDER. Extends and retracts the hydraulic thumb.

TOOL BOX. Used for storage of Basic Issue Items (BII).

0002-3

TM 5-3805-294-10

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued

20
17

10

16
11
19

12

16
18
15
13
Figure 2.
Table 2.

14

HYEX00105

Left View of HYEX.

Left View of HYEX.

10

ENGINE. Drives the hydraulic pumps and the pilot pump.

11

RADIATOR. Contains coolant which provides engine cooling.

12

BATTERIES. Two 12-volt batteries provide current for the electrical system.

13

CAB. All digging and travel functions are controlled by the operator.

14

TRAVEL MOTORS. Drives the machine forward or backward and provides turning capability.

15

BUCKET. Used for digging operations.

16

ARM. Used to connect quick latch or different attachments depending on mission.

17

HYDRAULIC THUMB. Used with the bucket attachment to clamp and lift.

18

UNDERCARRIAGE. Consists of the lower structure and the track assemblies.

19

UPPERSTRUCTURE. Consists of the upperstructure, engine/hydraulic pump compartment, cab,


boom and arm, and accessories.

20

HYDRAULIC HOSE REEL. Quick attach hose reel used to power hydraulic tools and accessories.

0002-4

TM 5-3805-294-10

0002

IDENTIFICATION PLATES
Maintain, in a secure location, an up-to-date inventory of all product and component serial numbers.
Regularly verify that identification plates have not been removed. Report any evidence of tampering to appropriate
agencies and order duplicate plates.
Mark your machine with your own numbering system and take color photographs from several angles of each plate.

22
21

HYEX01506

Figure 3.
Table 3.

Data Plates.

Data Plates.

21

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

22

SERIAL NUMBER PLATE. Has the machine serial on it.

0002-5

TM 5-3805-294-10

EQUIPMENT DATA
Table 4.

Equipment Data.

ENGINE:
Model

PowerTech

Manufacturer

John Deere

Horsepower (2,000 rpm)

177 hp (132 kW)

Number of Cylinders

Displacement

414 cu in. (6.8 L)

CAPACITIES:
Fuel Tank

132 gal (500 L)

Cooling System

7.9 gal (29.9 L)

Engine Oil (including oil filter)

6.5 gal (24.6 L)

Hydraulic Reservoir

64.2 gal (243 L)

Hydraulic System

74 gal (280 L)

Swing Gearbox

2.4 gal (9.1 L)

Travel Gearbox (each)

2.1 gal (7.9 L)

Pump Drive Gearbox

1.2 qt (1.1 L)

0002-6

0002

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued

12
3
7

1
8
2
10
11

HYEX00106

Figure 4.
Table 5.

HYEX Specifications.

HYEX Specification.

ITEM

DESCRIPTION

MEASUREMENT

SPECIFICATION

Sprocket Center to Idler Center

Distance

12 ft 7 in. (3840 mm)

Undercarriage

Length

15 ft 3 in. (4640 mm)

Counterweight Clearance

Distance

3 ft 7 in. (1090 mm)

Rear End Swing Radius

Distance

9 ft 8 in. (2940 mm)

Upper Structure Width (excluding back


mirrors)

Distance

9 ft 6 in. (2890 mm)

Cab

Height

9 ft 11 in. (3020 mm)

Minimum Ground Clearance

Distance

1 ft 6 in. (460 mm)

Center of Sprocket to Center of Sprocket

Distance

8 ft 6 in. (2590 mm)

Track Shoes

Width

32 in. (800 mm)

10

Undercarriage

Width

133 in. (2780 mm)

11

Machine

Overall Length

399 in. (10134 mm)

12

Machine

Transport Height

122 in. (3099 mm)

13

Machine

Shipping Weight

66,000 lb (29937 kg)

0002-7

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued

2
6

HYEX00107

Figure 5. HYEX Working Ranges.

0002-8

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued


Table 6.

HYEX Working Ranges.

ITEM

DESCRIPTION

MEASUREMENT

SPECIFICATION

Maximum Digging reach

Distance

35 ft 6 in. (10810 mm)

Maximum Digging reach at Ground Level

Distance

34 ft 11 in. (10640 mm)

Minimum Swing Radius

Radius

11 ft 4 in. (3460 mm)

Maximum Cutting Height

Height

34 ft 6 in. (10520 mm)

Maximum Dumping Height

Height

24 ft 9 in. (7540 mm)

Maximum Digging Depth

Depth

24 ft 7 in. (7490 mm)

Maximum Digging Depth (flat bottom)

Depth

24 ft 1 in. (7330 mm)

Maximum Vertical Wall

Depth

21 ft 9 in. (6630 mm)

Tail Swing Radius

Radius

9 ft 8 in. (2940 mm)

0002-9

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued

NOTE
Ratings are at quick latch lift hook, using standard counterweight, situated on firm, level,
uniform supporting surface, and with the machine configured with the standard arm and
bucket. Ratings do not apply to any attachments.
HYEX is equipped with an overload alarm. When lifting over the side and the weight limit is exceeded the alarm will
sound until weight limit is within range.
Table 7.

Front Lift Capacities.

LIFTING OVER FRONT IN 1,000 lb (454 kg)


ft (m)

5 (1.52)

10 (3.05)

15 (4.57)

20 (6.10)

20 (6.10)

25 (7.62)

30 (9.14)

7.55 lb
(3.42 kg)*

15 (4.57)

8.52 lb
(3.86 kg)*

8.61 lb
(3.90 kg)*

6.26 lb
(2.84 kg)*

10 (3.05)

14.69 lb
(6.66 kg)*

11.56 lb
(5.24 kg)*

10.05 lb
(4.56 kg)*

8.09 lb
(3.66 kg)*

5 (1.25)

20.76 lb
(9.41 kg)*

14.49 lb
(6.57 kg)*

11.62 lb
(5.27 kg)*

9.68 lb
(4.39 kg)

Ground Line

24.56 lb
(11.14 kg)*

16.88 lb
(7.65 kg)*

12.79 lb
(5.80 kg)

9.46 lb
(4.29 kg)

13.06 lb
(5.92 kg)*

25.71 lb
(11.66 kg)*

17.90 lb
(8.11 kg)

12.48 lb
(5.66 kg)

9.31 lb
(4.22 kg)

22.51 lb
(10.21 kg)*

25.00 lb
(11.33 kg)*

17.77 lb
(8.06 kg)

12.39 lb
(5.62 kg)

29.63 lb
(13.43 kg)*

22.54 lb
(10.22 kg)*

16.71 lb
(7.57 kg)*

12.31 lb
(5.58 kg)

17.28 lb
(7.83 kg)*

12.10 lb
(5.48 kg)*

-5 (-1.52)
-10 (-3.05)
-15 (-4.57)
-20 (6.10)

15.60 lb
(7.07 kg)*

* Hydraulically Limited Capacity

0002-10

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued

Table 8.

Side Lift Capacities.

LIFTING OVER SIDE IN 1,000 lb (454 kg)


ft (m)

5 (1.52)

10 (3.05)

15 (4.57)

20 (6.10)

20 (6.10)

25 (7.62)

30 (9.14)

7.55 lb
(3.42 kg)*

15 (4.57)

8.52 lb
(3.86 kg)*

8.61 lb
(3.90 kg)*

6.26 lb
(2.84 kg)*

10 (3.05)

14.69 lb
(6.66 kg)*

11.56 lb
(5.24 kg)*

8.88 lb
(4.02 kg)

6.29 lb
(2.85 kg)

5 (1.52)

18.90 lb
(8.57 kg)

12.10 lb
(5.48 kg)

8.39 lb
(3.80 kg)

6.04 lb
(2.73 kg)

Ground Line

17.62 lb
(7.99 kg)

11.35 lb
(5.14 kg)

7.96 lb
(3.61 kg)

5.81 lb
(2.63 kg)

13.06 lb
(5.92 kg)*

17.16 lb
(7.78 kg)

10.92 lb
(4.95 kg)

7.68 lb
(3.48 kg)

5.67 lb
(2.57 kg)

22.51 lb
(10.21 kg)*

17.15 lb
(7.77 kg)

10.80 lb
(4.89 kg)

7.59 lb
(3.44 kg)

29.63 lb
(13.44 kg)*

17.46 lb
(7.91 kg)

10.96 lb
(4.97 kg)

7.77 lb
(3.52 kg)

17.28 lb
(7.83 kg)*

11.53 lb
(5.22 kg)

-5 (-1.52)
-10 (-3.05)
-15 (-4.57)
-20 (6.10)

15.60 lb
(7.07 kg)*

* Hydraulically Limited Capacity

0002-11

TM 5-3805-294-10

0002

EQUIPMENT DATA - Continued


HYEX weights with attachments.
Table 9.

HYEX Weights With Attachments.

Machine Weight

Attachment and Weight

Total weight

66,000 (29937 kg)

Barrier Grappler 750 lb (341 kg)

66,750 lb (30277 kg)

66,000 (29937 kg)

Compactor 840 lb (381 kg)

66,840 lb (30318 kg)

66,000 (29937 kg)

Heavy Duty Bucket 1,600 lb (726 kg). 67,600 lb (30663 kg)

66,000 (29937 kg)

Ditching Bucket 1,600 lb (726 kg)

67,600 lb (30663 kg)

66,000 (29937 kg)

Breaker 4,900 lb (2223 kg)

70,900 lb (32160 kg)

66,000 (29937 kg)

Crush-All 5,800 lb (2631 kg)

71,800 lb (32568 kg)

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

Attachment and Weight

Total Weight

67,550 lb (30640 kg)

Deep Dig Bucket 1,000 lb (454 kg)

68,550 lb (31094 kg)

67,550 lb (30640 kg)

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


(454 kg)

END OF WORK PACKAGE

0002-12

TM 5-3805-294-10

0003

OPERATOR MAINTENANCE
THEORY OF OPERATION

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

0003-1

TM 5-3805-294-10

0003

ECU - Continued
Electrical System

5
1
HYEX01511

Figure 1. Electrical System Components.


Table 1.

Electrical System Components.

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.

Hydraulic System Components.

Hydraulic System Components.

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 hydraulic reservoir is pressurized ensuring that hydraulic oil is always


supplied to the pumps.

Main Control Valve

The control valve consists of two monoblock valves referred to as the left control
valve and right control valve. There is a spool in each valve to control the boom,
arm, and travel functions. All other functions are supplied by a single spool in
one or the other of the valves. All spools are moved by pilot oil. Each valve
section controls the flow rate and direction for its hydraulic circuit.

0003-3

TM 5-3805-294-10

0003

Hydraulic System - Continued

10

11

14

13
15
9

16

12

17
HYEX01512

Figure 3. Hydraulic System Components Continued.


Table 3.

Hydraulic System Components Continued.

10

Pilot Signal Manifold

The pilot signal manifold is in the pilot system between the pilot control valves
and the control valve and regulators. The manifold receives a pilot signal from
the pilot control valves and sends the signal on multiple paths simultaneously
so there is little lag between operation of the pilot control valves, pump stroke,
and function movement.

11

Swing Motor

The swing motor uses hydraulic pressure supplied by the pumps to make the
upper structure rotate. It has a spring-applied hydraulically-released swing
brake. The swing brake engages as soon as the swing controls are released.

12

Rotary Manifold

The rotary manifold allows the upper structure of the machine to rotate relative
to the undercarriage while still supplying hydraulic oil to the travel motors.

13

Boom Cylinders

The boom cylinders are attached to the main frame and the boom. When
activated they raise and lower the boom.

14

Arm Cylinder

The arm cylinder is attached between the boom and the arm. When activated,
this cylinder moves the arm in and out.

0003-4

TM 5-3805-294-10

0003

Hydraulic System - Continued


Table 3.

Hydraulic System Components Continued - Continued.

15

Hydraulic Thumb
Cylinder

The hydraulic thumb cylinder is attached between the arm and the thumb.
When activated, this cylinder extends and retracts the hydraulic thumb. The
hydraulic thumb cylinder circuit can be closed to provide the hydraulic power
to operate the crush-all, breaker, compactor and deep dig arm accessories.

16

Bucket Cylinder

The bucket cylinder is attached between the arm and the quick latch. When
activated, this cylinder extends and curls the bucket or attachments.

17

Load Holding Valves

Reduced leakage valves are used in the boom head-end circuit and arm rodend circuit. The function of a reduced leakage valve is to reduce cylinder drift
by stopping leakage from the cylinder back through the control valve.

Powertrain

21
18
20

19
HYEX01513

Figure 4.
Table 4.

Powertrain Components.

Powertrain Components.

18

Track Chain Adjuster

The track chain adjuster is located between the frame and the track chain idler.
Grease is added or removed to adjust the track sag. The recoil spring is located
with the track chain adjuster and absorbs shocks to the tracks and track chain
idler.

19

Track

The track assembly consists of the chain and shoes. The travel motor drives
the track to move the machine.

20

Rollers

The machine has two carrier rollers and nine lower track rollers on each side
of the machine. The rollers guide the tracks and keep the tracks in contact with
the ground.

21

Travel Motor

The travel motors are located inside the tracks to prevent damage during
operation. The travel system has a spring-applied hydraulically-released
parking brake. The parking brake engages as soon as the travel controls are
released.

0003-5

TM 5-3805-294-10

0003

Fuel System

22

24
27

23

25

26
HYEX01514

28
Figure 5. Fuel System Components.
Table 5.

Fuel System Components.

22

Fuel Transfer Pump

The fuel transfer pump pulls fuel from the fuel tank through the water separator
and sends it through the fuel filters to the high-pressure fuel injection pump.

23

Primary Fuel/Water
Separator

The primary water separator keeps large particles and contaminants from
entering the high-pressure fuel pump.

24

Secondary Fuel/Water
Separator

The secondary water separator keeps small particles and contaminants from
entering the pressure fuel pump.

25

Lubricity Canister

The lubricity canister is a spin-on canister with a lubricant that is slowly released
into the fuel. To enable use of all types of diesel fuels.

26

Fuel Tank

The fuel tank has 132 gal (500 liter) capacity and is equipped with a low fuel
level alarm and vented fill cap.

27

Fuel Tank Strainer

The strainer is designed to keep debris from entering the fuel system.

28

Fuel Tank Drain Valve

The drain valve is used to remove water and debris from the fuel tank.

0003-6

TM 5-3805-294-10

0003

Fuel System - Continued

30

29

HYEX01515

Figure 6.
Table 6.

High-Pressure Pump and Injectors.

High-Pressure Pump and Injectors.

29

High-Pressure Fuel
Pump

The high-pressure fuel pump increases the fuel pressure to send exact
amounts of fuel to the injector nozzles.

30

Fuel Injectors

The fuel injectors turn the stream of fuel into a fine spray, which permits good
combustion in the cylinder. There is one nozzle for each cylinder. The injectors
are located under the rocker arm cover.

0003-7

TM 5-3805-294-10

0003

Fuel System - Continued


Cooling

31

33

32

34
HYEX01516

Figure 7.
Table 7.

Cooling Package.
Cooling Package.

31

Radiator

Coolant circulates through the radiator to be cooled after leaving the cylinder
block.

32

Hydraulic Oil Cooler

The hydraulic oil cooler uses air from the fan to cool the oil before returning it
to the reservoir.

33

Charge Air Cooler

The charge air cooler cools the air supplied to the engine to decrease fuel
consumption and emissions.

34

Fuel Cooler

Fuel is circulated across the cooler to lower fuel temperature.

0003-8

TM 5-3805-294-10

0003

Cooling - Continued

35

36

37

HYEX01517

Figure 8.
Table 8.

Cooling System Components.

Cooling System Components.

35

Coolant Surge Tank

The coolant surge tank is where the coolant level is checked and added.

36

Engine Oil Cooler

Coolant from the radiator passes through the engine oil cooler to maintain a
safe operating temperature.

37

Fan

The variable speed fan is located at the front of the engine and is driven by a
hydraulic motor. The speed of the fan is varied to provide the amount of airflow
that the engine coolant, charge air cooler, or hydraulic cooler need, ensuring
maximum fuel efficiency, reduced noise levels, and faster engine warm up. A
reversing function reverses the cooling fan to help clean the cooling package
of dirt and debris.

END OF WORK PACKAGE

0003-9/10 blank

TM 5-3805-294-10

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

TM 5-3805-294-10

0004

OPERATOR MAINTENANCE
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

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

Front Switch Panel.

4
5

1
Figure 1.

HYEX00867

Front Switch Panel.

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

Table 1. Front Switch Panel - Continued.


Key

Control/Indicator

Function

Engine Speed Dial

The dial is used to increase or decrease engine speed.

4
5

1
Figure 2.

HYEX00867

Front Switch Panel Continued.

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.

Power Mode Switch

This is a three-position switch. The H/P mode is used when more hydraulic
power is desired for raising the boom and rolling the bucket during excavation
work. The Power (P) mode is used when performing general digging
operations. The Economy (E) mode is used to increase fuel efficiency and
reduces noise level.

Travel Mode Switch

This is a two-position switch. It is used to select fast or slow speed of travel.

Key Switch

This is a four-position switch. When in the OFF position, the key can be
removed. Moving the switch to the ACC position allows the radio to be turned
on or off. In the ON position, all electrical functions will operate. Move and
release the switch to the START position starts the machine.

0004-2

TM 5-3805-294-10

Table 2.

0004

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


16

15 14 13

10

12

11

HYEX00868

17

Figure 3. Heater/Air Conditioner (A/C) Controller and Radio.


Key

Control/Indicator

Function

Blower Fan Speed


Buttons

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

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


Key

Control/Indicator

Function

12

OFF Button

When pressed the A/C and blower fans will turn off. Blower fans will turn on if
one of the blower fan speed buttons is pressed even if the OFF button is on or
off.
16

15 14 13

10

12

11

HYEX00868

17

Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued.


13

Temperature
Control Buttons

Press buttons to set temperature from full-cool (FC) to full-heat (FH). The
monitor display will show FC or FH.

14

Recirculating Mode
Button

Press the recirculating mode button to close the fresh air vent and circulate air
already in the cab.

15

Fresh Air Mode


Button

Press fresh air mode to route outside air into the cab.

16

Mode Button

Press to select air vent. Selected vent will display on the monitor display.

17

Radio Display

The radio display contains standard AM/FM radio tuning and volume controls.

0004-4

TM 5-3805-294-10

Table 3.

22

23

0004

Control Pedals and Levers.

21

20

18

19

HYEX00869

Figure 5.

Control Pedals and Levers.

Key

Control/Indicator

Function

18

Attachment Pedal

Primarily used to open and close the hydraulic thumb. When attachments are
connected, hydraulic valve selection will disable the hydraulic thumb and
enable this pedal to operate the attachment.

19

Attachment Pedal
Lock

Locks attachment pedal in the neutral position to disable the hydraulic thumb
or any attachments that are connected.

20

Right Travel Pedal

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

21

Right Travel Lever

Use this hand lever to perform the same functions as the right travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.

0004-5

TM 5-3805-294-10

Table 3.

0004

Control Pedals and Levers - Continued.

Key

Control/Indicator

Function

22

Left Travel Pedal

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

22

23

21

20

18

19

HYEX00869

Figure 6. Control Pedals and Levers Continued.


23

Left Travel Lever

Use this hand lever to perform the same functions as the left travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.

0004-6

TM 5-3805-294-10

Table 4.

0004

Left Console and Pilot Shutoff Lever.

24

25

26

27

28

HYEX00870

Figure 7. Left Console and Pilot Shutoff Lever.


Key

Control/Indicator

Function

24

Pilot Shutoff Lever

Controls hydraulic functions on the machine. With the lever in the locked
position, hydraulic functions are not operational. In the unlocked position, all
hydraulic functions operate. The engine will not start with the lever in the
unlocked position.

25

Travel Alarm Switch

After the initial 13-second alarm, depressing the right half of the switch will shut
the alarm off.

26

Rear Cab Work


Lights Switch

Turns the rear cab work lights on and off.

27

Auxiliary Control
Switch

Disables the right joystick left and right button auxiliary function.

28

Reversing Cooling
Fan Switch

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

0004-7

TM 5-3805-294-10

Table 5.

0004

Right and Left Pilot Control Levers.

31
32

30

29

HYEX00871

Figure 8.

Right Pilot Control Lever.

Key

Control/Indicator

Function

29

Right Pilot Control


Lever

When pushed forward, the boom lowers. When pulled back, the boom raises.
When pulled left, the bucket will curl. When pushed right, the bucket will dump.
When released the lever will return to the neutral position.

30

Power Dig Button

Pressing the power dig button gives the operator an 8-second increase in
hydraulic power.

31

Left Button Auxiliary


Function

Used to close crush-all lid if connected.

32

Right Button
Auxiliary Function

Used to open crush-all lid if connected.

0004-8

TM 5-3805-294-10

0004

Table 5. Right and Left Pilot Control Levers - Continued.


Key

Control/Indicator

Function

33

Left Pilot Control


Lever

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

34

33

HYEX00872

Figure 9.
34

Horn Button

Left Pilot Control Lever.

When pressed the horn will sound.

0004-9

TM 5-3805-294-10

Table 6.

0004

Seat Controls.

39
40

35
38
37

36

41

HYEX00873

Figure 10.

Seat Controls.

Key

Control/Indicator

Function

35

Seat Angle Lever

Allows seat to be adjusted to a desired angle.

36

Seat Adjustment
Handle

Pull up handle to adjust the seat forward or backward.

37

Seat Weight
Adjustment Knob

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

38

Lumbar Adjustment

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

0004-10

TM 5-3805-294-10

Table 6.

0004

Seat Controls - Continued.

Key

Control/Indicator

Function

39

Backrest
Adjustment Lever

Pull up lever to release backrest and adjust to desired position, then release
lever.

40

Armrest Angle
Adjustment

Turn dial to adjust armrest to desired angle.

41

Seat Assembly
Adjustment Lever

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

0004-11

TM 5-3805-294-10

Table 7.

0004

Cab Door Release Lever and Coolant Heater Display.

43

44

45

46

47

48

42

HYEX00874

Figure 11. Cab Door Release Lever and Coolant Heater Display.
Key

Control/Indicator

Function

42

Cab Door Release


Lever

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

43

Coolant Heater
Display

Displays date and time.

44

Clock Button

Pressing button displays date and time and allows to change date and time
settings.

45

Preset Button

Press the preset button to program the desired time to start cycle.

46

Heat Display

Display will flash when a program is activated or if the coolant heater is


manually operated.

47

Lower Button

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

0004-12

TM 5-3805-294-10

Table 7.

0004

Cab Door Release Lever and Coolant Heater Display - Continued.

Key

Control/Indicator

Function

48

Raise Button

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

Table 8.

Quick Latch Control.

49

50

HYEX00875

Figure 12.

Quick Latch Control.

Key

Control/Indicator

Function

49

Quick Latch Switch

Used to lock and unlock quick latch.

50

Quick Latch Light

Illuminates when switch is in unlatch position.

0004-13

TM 5-3805-294-10

Table 9.

0004

Cab Light Switch.

51

HYEX01316

Figure 13.

Cab Light Switch.

Key

Control/Indicator

Function

51

Cab Light Switch

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

0004-14

TM 5-3805-294-10

Table 10.

0004

Hydraulic Hose Reel.

52
54
53

55
HYEX00876

Figure 14.

Hydraulic Hose Reel.

Key

Control/Indicator

Function

52

Hydraulic Hose Reel

Used for hydraulic tools.

53

Hydraulic Tool
Circuit Switch

Moved to the on position when using hydraulic tools.

54

Hydraulic Tool Flow


Regulator

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

55

Deep Dig Control


Pattern Switch

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

END OF WORK PACKAGE

0004-15/16 blank

TM 5-3805-294-10

0005

OPERATOR MAINTENANCE
DESCRIPTION AND USE OF MONITOR AND ALARMS

INTRODUCTION
The following tables and illustrations provide the description and use of the monitor buttons, indicators, and warning
indicators.
Table 1.

Monitor Buttons and Indicators.


A.I.

7777.7 h
F1
F2

F3
F4

17.3 L/h

8:01
1

F1

F2

F3

F4

Figure 1.

HYEX00858

Monitor.

Key

Control/Indicator

Function

Button 1

Press button to key in the number 1 or use as instructed depending on current


screen.

Button 2

Press button to key in the number 2 or use as instructed depending on current


screen.

Button 3

Press button to key in the number 3 or use as instructed depending on current


screen.

Button 4

Press button to key in the number 4 or use as instructed depending on current


screen.

Button 5

Press button to key in the number 5 or use as instructed depending on current


screen.

0005-1

TM 5-3805-294-10

Table 1.

0005

Monitor Buttons and Indicators - Continued.

Key

Control/Indicator

Function

Button 6/Return to
Default Screen
Button

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

A.I.

7777.7 h
F1
F2

F3
F4

17.3 L/h

11

8:01
1

F1

F2

F3

F4

12
13

14

8
Figure 2.

10

HYEX00859

Monitor Buttons.

Button 7/F1 function


button

Press button to key in the number 7 or to select the desired preset optional
function from any screen.

Button 8/F2 function


button

Press button to key in the number 8 or to select the desired preset optional
function from any screen.

Button 9/F3 function


button

Press button to key in the number 9 or to select the desired preset optional
function from any screen.

10

Button 0/F4 function


button

Press button to key in the number 0 or to select the desired preset optional
function from any screen.

11

Select Button

Use button as instructed depending on current screen.

12

Back Button

Use button as instructed depending on current screen.

0005-2

TM 5-3805-294-10

Table 1.

0005

Monitor Buttons and Indicators - Continued.

Key

Control/Indicator

Function

13

Hour Meter Button

Without key inserted or with key switch OFF, press and hold button to display
default screen and hour meter.

14

Alarm Indicator
Light

Lights when an abnormality has occurred.

Main Menu
Time Set
Attachment Adjustment
Operating Conditions
Maintenance Settings

F1

F2

F3

F4

15

HYEX01319

Figure 3.
15

Menu Button

Main Menu.

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

0005-3

TM 5-3805-294-10

Table 1.

0005

Monitor Buttons and Indicators - Continued.

Key

Control/Indicator

Function

16

Coolant
Temperature Gauge

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

17

18

19 20 21 22

24

A.I.

7777.7 h

23
25

F1
F2

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

The icon for the current attachment being used is displayed.

18

Auto-Idle Indicator

When selecting auto-idle from the front switch panel, the auto-idle icon
displays.

19

Auxiliary Indicator

Optional auxiliary data icon displays.

20

Auxiliary Indicator

Optional auxiliary data icon displays.

21

Auxiliary Indicator

Optional auxiliary data icon displays.

22

Engine Preheat
Indicator

If preheat is required, the preheat icon is displayed.

23

Hour Meter

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

0005-4

TM 5-3805-294-10

Table 1.

Monitor Buttons and Indicators - Continued.

Key

Control/Indicator

Function

24

F1 Function Button
Indicator

Optional indicator icon is displayed.

25

F2 Function Button
Indicator

Optional indicator icon is displayed.

26

F3 Function Button
Indicator

Optional indicator icon is displayed.

27

F4 Function Button
Indicator

Optional indicator icon is displayed.

28

Fuel Gauge

Shows level of fuel in fuel tank.

29

Fuel Rate Display

Fuel consumption in Liter/hour (L/h) is displayed.

30

Clock

Indicates present time.

0005-5

0005

TM 5-3805-294-10

Table 2.

31

0005

Warning Indicators and Alarms.

33

32

36

35

34

39
37

38
HYEX00861

Figure 5.

Warning Indicators and Alarms.

Key

Control/Indicator

Function

31

Engine Overheat
Alarm

Displays when engine coolant temperature has abnormally increased.

32

Engine Warning
Alarm

Displays when engine has an abnormal operating condition.

33

Engine Oil Pressure


Alarm

Displays when oil pressure has decreased.

34

Alternator Alarm

Displays when an abnormality in the electrical system has occurred.

0005-6

TM 5-3805-294-10

0005

Table 2. Warning Indicators and Alarms - Continued.


Key

Control/Indicator

Function

35

Remaining Fuel
Alarm

Displays when fuel level is low.

36

Hydraulic Oil Filter


Alarm

Displays when hydraulic filter is clogged.

37

Air Cleaner Clogged


Alarm

Displays when air cleaner are clogged.

38

Work Mode Alarm

Displays when work mode is abnormal.

39

Pilot Shutoff Lever


Alarm

Displays when pilot shutoff system is abnormal.

40
HYEX00862

Figure 6.
40

Overload Alarm

Overload Alarm.

Illuminates when an overload condition exists when digging.

END OF WORK PACKAGE

0005-7/8 blank

TM 5-3805-294-10

0006

OPERATOR MAINTENANCE
ADJUSTING THE OPERATOR'S SEAT

INITIAL SETUP:
Not Applicable

ADJUSTMENT

NOTE
Proper seat adjustment is achieved when operator can reach the foot control pedals and the
travel levers easily with the seat belt buckled.
1.

Push down on handle (Figure 1, Item 1) to tilt seat (Figure 1, Item 2).

13

11
10

12

2
6

1
7
3

4
Figure 1.

HYEX00145

Operator's Seat Adjustments.

2.

Turn knob (Figure 1, Item 3) to set operator weight.

3.

Pull up on handle (Figure 1, Item 4) to slide seat (Figure 1, Item 2).

4.

Push on lever (Figure 1, Item 5) to slide seat (Figure 1, Item 2) and controls (Figure 1, Item 6).

0006-1

TM 5-3805-294-10
ADJUSTMENT - Continued
5.

Squeeze bulb (Figure 1, Item 7) to increase lumbar support.

6.

Push button (Figure 1, Item 8) to decrease lumbar support.

7.

Pull up on handle (Figure 1, Item 9) to unlock backrest (10).

8.

Raise or lower headrest (Figure 1, Item 11) to desired height.

9.

Tilt headrest (Figure 1, Item 11) to desired angle.

10.

Turn dial (Figure 1, Item 12) on underside of armrest (Figure 1, Item 13) to adjust angle.

END OF TASK
END OF WORK PACKAGE

0006-2

0006

TM 5-3805-294-10

0007

OPERATOR MAINTENANCE
STARTING THE ENGINE

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

STARTING THE ENGINE

WARNING

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

Buckle the seat belt (Figure 1, Item 1).

HYEX00090

Figure 1.

Seat Belt.

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

Place pilot shutoff lever (Figure 2, Item 2) in LOCKED (up) position.

0007-1

TM 5-3805-294-10

0007

STARTING THE ENGINE - Continued


2

HYEX00091

Figure 2.
3.

Pilot Shutoff Lever.

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

HYEX00092

Figure 3.
4.

Engine Speed Dial Slow Idle.

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

0007-2

TM 5-3805-294-10

0007

STARTING THE ENGINE - Continued

HYEX00093

Figure 4.

Key Switch ON.

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

Wait for "System Starting" screen (Figure 5, Item 5) to change to default screen (Figure 5, Item 6).
6

System Starting...
1

F1

F2

F3

F4

HYEX00094

Figure 5.

System Starting and Default Screen.

NOTE
At approximately 32F (0C) or below, the pre-heat indicator will be displayed for up to 15
seconds depending on engine fuel temperature.
6.

Wait until engine preheat indicator (Figure 6, Item 7) is no longer displayed.

0007-3

TM 5-3805-294-10

0007

STARTING THE ENGINE - Continued


7
A.I.

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

Figure 7. Key Switch to START.

0007-4

TM 5-3805-294-10

0007

STARTING THE ENGINE - Continued

CAUTION
If alarm indicators are still displayed after starting the engine, immediately shut down the
engine. Failure to comply may result in damage to equipment.
Do not run engine at fast idle or rapidly accelerate engine until it has reached normal
operating temperature. Failure to comply may result in damage to equipment.
8.

After the engine is started, ensure that no alarm indicators (Figure 8, Item 8) are displayed.

HYEX00096

Figure 8.
9.

Alarm indicator.

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

HYEX00100

Figure 9.
10.

Engine Speed Dial Turned to 1/3 Position.

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

0007-5

TM 5-3805-294-10

0007

STARTING THE ENGINE - Continued

HYEX00092

Figure 10. Return Engine Speed Dial to Slow Idle.


END OF TASK
END OF WORK PACKAGE

0007-6

TM 5-3805-294-10

0008

OPERATOR MAINTENANCE
MOVING THE HYEX

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

MOVING THE HYEX

WARNING

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

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

Move pilot shutoff lever (Figure 1, Item 1) to the unlocked (down) position.

120

LOCK

HYEX00146

Figure 1.

Pilot Shutoff Lever Unlocked.

0008-1

TM 5-3805-294-10

0008

MOVING THE HYEX - Continued


2.

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

HYEX00147

Figure 2.

Boom and Arm Raised.

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

NOTE
If carrying a heavy load, keep travel mode switch in the low position for more control of the
machine.
3.

Move travel mode switch (Figure 3, Item 4) to high position.

HYEX00148

Figure 3. Travel Mode Switch.

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

0008-2

TM 5-3805-294-10

0008

MOVING THE HYEX - Continued


4.

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

HYEX01297

Figure 4.

Moving Forward and Backwards.

5.

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

6.

Allowing both foot pedals (Figure 4, Items 5 and 6), or both travel levers (Figure 4, Items 7 and 8) to return to
center, will stop the HYEX.

END OF TASK
STEERING THE HYEX

WARNING

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

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

0008-3

TM 5-3805-294-10

0008

STEERING THE HYEX - Continued


1.

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

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

STEERING THE HYEX - Continued

HYEX01291

Figure 7.
4.

Counter-Rotate.

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

END OF TASK
END OF WORK PACKAGE

0008-5/6 blank

TM 5-3805-294-10

0009

OPERATOR MAINTENANCE
SHUTTING DOWN THE HYEX

INITIAL SETUP:
References
WP 0004

References (cont.)
WP 0011
WP 0010

SAFELY PARK HYEX


1.

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

4
1

HYEX02418

Figure 1.

Machine In Parked Position.

NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2.

Keeping angle between arm (Figure 1, Item 2) and boom (Figure 1, Item 3), position flat side of bucket (Figure
1, Item 4) on the ground. (WP 0004)

END OF TASK
SHUT DOWN ENGINE
1.

If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.

0009-1

TM 5-3805-294-10

0009

SHUT DOWN ENGINE - Continued

HYEX00153

Figure 2.

Auto-Idle Switch and Engine Speed Dial.

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

NOTE
Engine speed dial shown approximately at 1/3 position.
2.

Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.

3.

Turn engine speed dial (Figure 3, Item 6) to slow idle position.

0009-2

TM 5-3805-294-10

0009

SHUT DOWN ENGINE - Continued

HYEX00154

Figure 3.
4.

Engine Speed Dial.

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

HYEX00155

Figure 4.
5.

Pilot Shutoff Lever.

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

0009-3

TM 5-3805-294-10

0009

SHUT DOWN ENGINE - Continued

HYEX00157

Figure 5. Key Switch Turned OFF.

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

Close windows. (WP 0011)

END OF TASK
END OF WORK PACKAGE

0009-4

TM 5-3805-294-10

0010

OPERATOR MAINTENANCE
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED

INITIAL SETUP:
References
WP 0004
WP 0011

Equipment Condition
Engine running. (WP 0007)

SAFELY PARK MACHINE


1.

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

3
1

4
HYEX01637

Figure 1.

Machine In Parked Position.

NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2.

Keeping angle between deep dig arm (Figure 1, Item 2) and arm (Figure 1, Item 3) at approximately 90 degrees,
position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004)

END OF TASK
SHUT DOWN ENGINE
1.

If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.

0010-1

TM 5-3805-294-10

0010

SHUT DOWN ENGINE - Continued

HYEX01507

Figure 2.

Auto-Idle Switch and Engine Speed Dial.

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

NOTE
Engine speed dial shown approximately at 1/3 position.
2.

Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.

3.

Turn engine speed dial (Figure 3, Item 6) to slow idle position.

0010-2

TM 5-3805-294-10

0010

SHUT DOWN ENGINE - Continued

HYEX01508

Figure 3.
4.

Engine Speed Dial.

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

HYEX01509

Figure 4.
5.

Pilot Shutoff Lever.

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

0010-3

TM 5-3805-294-10

0010

SHUT DOWN ENGINE - Continued

HYEX01510

Figure 5. Key Switch Turned OFF.

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

Close windows. (WP 0011)

END OF TASK
END OF WORK PACKAGE

0010-4

TM 5-3805-294-10

0011

OPERATOR MAINTENANCE
OPENING AND CLOSING WINDOWS

INITIAL SETUP:
Not Applicable

WINDSHIELD

NOTE
The wiper will not operate with windshield open.
The washer can operate with windshield open.
1.

Pull lock pin (Figure 1, Item 1) inward and rotate into notch.

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.

Lock Windshield Open.

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

0011-2

TM 5-3805-294-10

0011

WINDSHIELD - Continued

5
2

HYEX00163

Figure 4.

Release Windshield Latch.

WARNING

Window closes rapidly when released. Use lower handle to prevent window from free falling.
Failure to comply may result in injury or death to personnel.
6.

Pull on latch release bar (Figure 4, Item 2).

7.

Hold handle (Figure 5, Item 4) and lower windshield (Figure 5, Item 3) until it is latched in the closed position.

4
3

HYEX00161

Figure 5.
8.

Close Windshield.

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

0011-3

TM 5-3805-294-10

0011

WINDSHIELD - Continued

HYEX00160

Figure 6.
9.

Latch Windshield.

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

END OF TASK
CAB DOOR WINDOW
1.

To open, release latch (Figure 7, Item 6) and slide cab door window (Figure 7, Item 7) forward.

6
7

HYEX01411

Figure 7.
2.

Open and Close Cab Door Window.

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

END OF TASK

0011-4

TM 5-3805-294-10

0011

SKYLIGHT WINDOW (SECONDARY EXIT)


1.

Slide access cover (Figure 8, Item 8) open.

HYEX03377

Figure 8.
2.

Open Access Cover.

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

10

HYEX00167

Figure 9.

Open and Close Skylight Window.

3.

To close, pull down on handle (Figure 9, Item 10) and engage two latches (Figure 9, Item 9).

4.

Slide access cover (Figure 10, Item 8) closed.

0011-5

TM 5-3805-294-10

0011

SKYLIGHT WINDOW (SECONDARY EXIT) - Continued

HYEX03377

Figure 10.

Close Access Cover.

END OF TASK
END OF WORK PACKAGE

0011-6

TM 5-3805-294-10

0012

OPERATOR MAINTENANCE
USING THE RIFLE MOUNT

INITIAL SETUP:
Not Applicable

STOW

NOTE
Rifle mount is designed to store an M4 with optics, M240B, M249, or M16 series weapon with
and without M203 grenade launcher.
1.

Place butt of weapon in rear mounting bracket (Figure 1, Item 1).

HYEX00999

Figure 1.
2.

Stow Weapon In Rear Bracket

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

0012-1

TM 5-3805-294-10

0012

STOW - Continued

HYEX00998

Figure 2. Stow Weapon In Front Bracket


3.

If necessary, loosen two handles (Figure 2, Item 3) and slide front mounting bracket (Figure 2, Item 2) on two
rails (Figure 2, Item 4).

4.

Tighten two handles (Figure 2, Item 3).

END OF TASK
REMOVE
1.

Lift barrel of weapon from front mounting bracket (Figure 3, Item 2).

HYEX00998

Figure 3. Remove Weapon From Front Bracket


2.

Remove butt of weapon from rear mounting bracket (Figure 4, Item 1).

0012-2

TM 5-3805-294-10

0012

REMOVE - Continued

HYEX00999

Figure 4. Remove Weapon From Rear Bracket


END OF TASK
END OF WORK PACKAGE

0012-3/4 blank

TM 5-3805-294-10

0013

OPERATOR MAINTENANCE
GENERAL MONITOR OPERATION

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

TIME ADJUSTMENT

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

Press menu button.

Main Menu

TIME SET

Time Set
Attachment Adjustment
Operating Conditions

SELECT
BUTTON

Maintenance Settings

BUTTON 1

BUTTON 2

F1

F2

F3

F4

MENU
BUTTON
HYEX00057

Figure 1.

Select Time Set Menu.

2.

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

3.

Press select button to open Time Set menu.

0013-1

TM 5-3805-294-10

0013

TIME ADJUSTMENT - Continued


4.

Press button 1 or button 2 to select date or time.


Time Set
2005 /

12 /

12 :

BUTTON
1

23

23

SELECT
BUTTON
1

F1

F2

F3

F4

BACK
BUTTON

BUTTON BUTTON BUTTON


2
3
4
Figure 2.

HYEX00058

Adjust Time.

5.

Press button 3 or button 4 to adjust date or time up or down.

6.

After desired date and time is achieved, press button 1 or button 2 until the apply setting icon is highlighted.

7.

Press select button and "Data is being applied" will display on the screen.

8.

Press back button until default screen is displayed.

END OF TASK
DISPLAYING OPERATING CONDITIONS
1.

Press menu button 1.


Main Menu
Time Set

OPERATING
CONDITIONS

Attachment Adjustment
Operating Conditions
Maintenance Settings

SELECT
BUTTON
1

BUTTON
1

F1

F2

F3

F4

BUTTON
2
Figure 3.

BACK
BUTTON

MENU
BUTTON

Select Operating Conditions Menu.

2.

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

3.

Press select button.

0013-2

HYEX00059

TM 5-3805-294-10

0013

DISPLAYING OPERATING CONDITIONS - Continued


4.

Operating Conditions menu will be displayed.


Operating Conditions
Reset Data. OK?

SELECT
BUTTON
1

F1

F2

F3

F4

BACK
BUTTON
HYEX00060

Figure 4.

Reset Operating Conditions.

5.

To reset data, press select button.

6.

The Reset Data. OK? is displayed.

7.

If reset is not desired, press back button.

8.

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

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

0013-3/4 blank

TM 5-3805-294-10

0014

OPERATOR MAINTENANCE
REMOVING AND INSTALLING BUCKET

INITIAL SETUP:
References
WP 0007

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

REMOVING BUCKET

WARNING

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

NOTE
The ditch cleaning bucket and 42 inch rock bucket are removed the same way. 42 inch rock
bucket shown.
1.

Lift and rotate safety lock pin lever (Figure 1, Item 1).
1

HYEX03379

Figure 1.

Unlock Safety Lock Pin.

2.

Start engine. (WP 0007)

3.

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

0014-1

TM 5-3805-294-10

0014

REMOVING BUCKET - Continued


2

3
HYEX03380

Figure 2.
4.

Raise Boom.

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

HYEX00939

Figure 3.
5.

Move Quick Latch Switch to Unlatch Position.

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

0014-2

TM 5-3805-294-10

0014

REMOVING BUCKET - Continued


5

6
HYEX03387

Figure 4.

Extend Bucket Cylinder.

WARNING

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

Slowly retract bucket cylinder (Figure 5, Item 5) and position quick latch (Figure 5, Item 7) in vertical position.

HYEX03384

Figure 5.

Retract Bucket Cylinder.

NOTE
Ensure that arm is just past the vertical position prior to setting bucket on the ground.
7.

Slowly lower boom (Figure 6, Item 2) and place bucket (Figure 6, Item 3) on ground.

0014-3

TM 5-3805-294-10

0014

REMOVING BUCKET - Continued


2

3
HYEX03382

Figure 6.
8.

Lower Boom.

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

HYEX00939

Figure 7.
9.

Position Quick Latch Switch to Latch position.

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

0014-4

TM 5-3805-294-10

0014

REMOVING BUCKET - Continued

3
HYEX03389

Figure 8.

Remove Quick Latch.

END OF TASK
INSTALLING BUCKET

WARNING

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

NOTE
The ditch cleaning bucket and 42 inch rock bucket are installed the same way. 42 inch rock
bucket shown.
1.

Move quick latch switch (Figure 9, Item 4) in the unlatch position.

0014-5

TM 5-3805-294-10

0014

INSTALLING BUCKET - Continued

HYEX00939

Figure 9.
2.

Position Quick Latch Switch to Unlatch position.

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

HYEX03385

Figure 10.

Raise Boom for Clearance.

WARNING

With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch.
Ensure that personnel are clear of equipment when removing or installing bucket. Slowly
retract or extend bucket cylinder when removing or installing bucket. Failure to comply may
result in injury or death to personnel.
3.

Slowly extend bucket cylinder (Figure 11, Item 5) until quick latch wedges (Figure 11, Item 6) are fully retracted.

0014-6

TM 5-3805-294-10

0014

INSTALLING BUCKET - Continued


5

6
HYEX03383

Figure 11.
4.

Retract Wedges.

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


5
7

3
HYEX03381

Figure 12.

Install Quick Latch.

5.

Install quick latch (Figure 12, Item 7) to bucket (Figure 12, Item 3).

6.

Extend bucket cylinder (Figure 12, Item 5) until quick latch (Figure 12, Item 7) is resting on bucket (Figure 12,
Item 3).

7.

Move quick latch switch (Figure 13, Item 4) in latch position.

0014-7

TM 5-3805-294-10

0014

INSTALLING BUCKET - Continued

HYEX00939

Figure 13. Position Quick Latch Switch toLatch position.


8.

Raise boom (Figure 14, Item 2) to allow for ground clearance.


2
5

6
HYEX03386

Figure 14.

Raise Boom.

9.

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

10.

Position bucket (Figure 15, Item 3) on ground.

0014-8

TM 5-3805-294-10

0014

INSTALLING BUCKET - Continued

HYEX03378

Figure 15.
11.

Safety Pin Locked.

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

END OF TASK
END OF WORK PACKAGE

0014-9/10 blank

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

INITIAL SETUP:
Tools and Special Tools
Suitable Lifting Device

Equipment Condition
Engine running. (WP 0007)

Personnel Required
Horizontal Construction Engineer 12N (2)

LIFTING

WARNING

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

NOTE
Use a suitable lifting device and tether lines to guide load.
Coordinate hand signals with assistant prior to lifting.
1.

Secure lifting device (Figure 1, Item 1) to load (Figure 1, Item 2).

0015-1

0015

TM 5-3805-294-10

0015

LIFTING - Continued

5
3
1

2
HYEX00919

Figure 1.

Lifting with Quick Latch Loop.

2.

Curl bucket (Figure 1, Item 3) and retract arm (Figure 1, Item 4).

3.

Attach lifting device (Figure 1, Item 1) to quick latch loop (Figure 1, Item 5).

4.

With the aid of an assistant, raise load (Figure 1, Item 2) and verify stability of load and machine (Figure 1,
Item 6) before moving the machine.

END OF TASK
END OF WORK PACKAGE

0015-2

TM 5-3805-294-10

0016

OPERATOR MAINTENANCE
OPERATING TECHNIQUES

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

LEVELING MACHINE

NOTE
Operating on a firm, level surface optimizes machine stability.
1.

Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material.

HYEX01483

Figure 1.
2.

Leveling Machine.

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

HYEX01484

Figure 2.
3.

Add or Remove Material.

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

END OF TASK

0016-1

TM 5-3805-294-10
ARM DIGGING

WARNING

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

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

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

Position arm in a vertical position.

0016-2

0016

TM 5-3805-294-10

0016

ARM DIGGING - Continued

HYEX01486

Figure 3.

Arm Digging.

2.

Move arm away from machine approximately 2 ft (61 cm).

3.

While retracting arm curl bucket as bucket fills.

END OF TASK
BUCKET DIGGING

WARNING

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

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

0016-3

TM 5-3805-294-10

0016

BUCKET DIGGING - Continued


If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of
force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket
lightly does not work. Failure to comply may result in damage to equipment.

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

Lower bucket to the digging area.

HYEX01485

Figure 4.

Bucket Digging.

2.

Use boom to force bucket into ground.

3.

Retract arm and curl bucket at the same time until bucket is full.

4.

If bucket stalls, raise boom slightly then continue to curl bucket .

5.

If arm stalls, roll back bucket to break out.

END OF TASK

0016-4

TM 5-3805-294-10

0016

PLANNING SPOIL PILES

WARNING

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

Place spoil piles at least 3 ft (1 m) away from excavation. The deeper the excavation, the further away the spoil
pile should be placed.

HYEX01487

Figure 5.

Planning Spoil Piles.

2.

If required, place spoil piles for convenient truck loading or backfilling.

3.

On slopes, place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.

END OF TASK
TRENCHING

WARNING

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

0016-5

TM 5-3805-294-10

0016

TRENCHING - Continued
Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
Do not dig under the machine. Failure to comply may result in injury or death to personnel.
To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
1.

Before starting work, walk the site to uncover hazards and to plan the job.

HYEX01504

Figure 6.

Trenching.

2.

Check for buried utility lines, pipes, and gas or oil pipelines.

3.

Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench.

4.

The deeper the trench, the further away the spoil pile should be placed.

END OF TASK
CLEANING A CAVE IN
1.

If you cannot clean a cave in from the machine's current position, DO NOT back over the trench.

HYEX01503

Figure 7.

Cleaning Cave In.

2.

Drive the machine to the cave in.

3.

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

0016-6

TM 5-3805-294-10

0016

CLEANING A CAVE IN - Continued


4.

Clean cave in from the side of the trench.

END OF TASK
TRENCHING ON A SLOPE

WARNING

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

NOTE
The deeper the trench the further away the spoil pile should be.
1.

When trenching across a slope, level the machine so that the bottom of the trench will be level.

HYEX01488

Figure 8.

Trenching on a Slope.

2.

Level machine by counter-rotating tracks or by digging a shelf.

3.

Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.

END OF TASK

0016-7

TM 5-3805-294-10

0016

STRAIGHT LINE TRENCHING

WARNING

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

NOTE
The deeper the trench, the further away the spoil pile should be.
1.

Drive two stakes in the ground at the beginning of the trench.

HYEX01489

Figure 9.

Straight Line Trenching.

2.

Drive the first stake immediately behind the start point of the trench. Drive the second stake approximately
30 ft (9 m) behind the first stake.

3.

Use stakes as a sight gauge. They are especially helpful when the machine is moved often.

END OF TASK
BACKFILLING

WARNING

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

0016-8

TM 5-3805-294-10

0016

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

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

NOTE
The bucket side can be used for finish grading.
1.

Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine.

HYEX01490

Figure 10.
2.

Back Filling.

Use material from spoil pile to backfill.

END OF TASK

0016-9

TM 5-3805-294-10

0016

TRUCK LOADING

WARNING

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

Position bucket and slowly dump load in vehicle at the front center of the bed.

HYEX01491

Figure 11.
2.

Truck Loading.

Continue to fill bed from front to rear.

END OF TASK
END OF WORK PACKAGE

0016-10

TM 5-3805-294-10

0017

OPERATOR MAINTENANCE
OPERATING THE HYDRAULIC THUMB

INITIAL SETUP:
Not Applicable

GENERAL HYDRAULIC THUMB INFORMATION


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

Position hydraulic thumb (Figure 1, Item 1) near the object to be picked up.

HYEX01175

Figure 1.
2.

Clamping With Bucket.

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

0017-1

TM 5-3805-294-10

0017

CLAMPING WITH THE BUCKET - Continued


3.

Gently move the bucket control to pick the object up without crushing it.

END OF TASK
CLAMPING WITH THE HYDRAULIC THUMB

NOTE
This method is less precise and should only be used when there is no concern about crushing
the object being lifted.
1.

Position hydraulic thumb (Figure 2, Item 1) in the store position.

1
2

HYEX01174

Figure 2. Clamping With Hydraulic Thumb.


2.

Curl bucket (Figure 2, Item 2) and position it near or in contact with the object being picked up.

3.

Move hydraulic thumb (Figure 2, Item 1) to grasp and clamp the object.

END OF TASK

0017-2

TM 5-3805-294-10

0017

MOVING AND RELEASING CLAMPED OBJECTS

WARNING

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

Move object to desired location.

1
2

HYEX01174

Figure 3.
2.

Releasing Objects.

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

END OF TASK
END OF WORK PACKAGE

0017-3/4 blank

TM 5-3805-294-10

0018

OPERATOR MAINTENANCE
SELECTING AN ATTACHMENT ON THE MONITOR

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

SELECTING ATTACHMENT
1.

Press F1 button and Work Mode screen will be displayed.


Work Mode
Dig

Breaker 1

Crusher 1

Pulverizer 1

BUTTON
1
1

F1
BUTTON

Breaker 2

F1

F2

F3

F4

BUTTON
5

BUTTON BUTTON BUTTON


2
3
4
Figure 1.

2.

HYEX00172

Select Attachment.

Use the following table to select attachment.


Table 1.

Attachment Selection.

Attachment to be used

Monitor key pad button

Attachment mode to be selected

Bucket/Thumb

Dig

Breaker

Breaker 1

Compactor

Breaker 2

Crush-All

Pulverizer 1

Deep dig arm

Crusher 1

0018-1

TM 5-3805-294-10

0018

SELECTING ATTACHMENT - Continued


3.

The attachment specification screen will be displayed.


Breaker 1
Maximum Pump Flow Rate

288.0 L/min

Maximum Engine Speed

1800 min-1

Valve Selector O/T

Accumulator

2-Speed Selector OFF

2ndary Hydraulic Relief Selector ON

OFF

SELECT
BUTTON
1

F1

F2

F3

F4

HYEX00173

Figure 2. Attachment Specification Screen.


4.

Verify the attachment specifications are the same as displayed on the monitor.

5.

Press the select button. The default screen will be displayed.

END OF TASK
END OF WORK PACKAGE

0018-2

TM 5-3805-294-10

0019

OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE CRUSH-ALL

INITIAL SETUP:
Tools and Special Tools
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)

References (cont.)
WP 0009
WP 0018
WP 0092
Equipment Condition
Safely park and shutdown machine. (WP 0009)
Bucket removed. (WP 0014)

Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
References
WP 0007

INSTALLING CRUSH-ALL
1.

Start machine. (WP 0007)

2.

Retract hydraulic thumb cylinder (Figure 1, Item 1).

3
4
2
6

5
3

HYEX03392

Figure 1.

Close Hydraulic Thumb Circuit.

3.

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

4.

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

0019-1

TM 5-3805-294-10

0019

INSTALLING CRUSH-ALL - Continued

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.

Using prybar to push pin (Figure 1, Item 3), install pin in thumb lock position (Figure 1, Item 5).

6.

Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.

Close two auxiliary circuit shut off valves (Figure 1, Item 6).

8.

Move quick latch switch (Figure 2, Item 7) to unlatch position.

HYEX03393

Figure 2.
9.

Move Quick Latch Switch to Unlatch Position.

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

0019-2

TM 5-3805-294-10

0019

INSTALLING CRUSH-ALL - Continued


8

9
HYEX03394

Figure 3.
10.

Extend Bucket Cylinder.

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

10

11

HYEX03397

Figure 4.

Install Quick Latch.

11.

Install quick latch (Figure 4, Item 10) to crush-all (Figure 4, Item 11).

12.

Extend bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is resting on crush-all (Figure 4,
Item 11).

13.

Move quick latch switch (Figure 5, Item 7) to latch position.

0019-3

TM 5-3805-294-10

0019

INSTALLING CRUSH-ALL - Continued

HYEX03393

Figure 5. Quick Latch Switch to Latch Position.


14.

Raise boom (Figure 6, Item 12) to allow adequate ground clearance of crush-all (Figure 6, Item 11).
12

14

13

11
HYEX03395

Figure 6.

Position Crush-All.

15.

Curl crush-all (Figure 6, Item 11) as in Figure 6 until quick latch wedges (Figure 6, Item 9) are fully engaged
to crush-all (Figure 6, Item 11).

16.

Rotate safety lock pin lever (Figure 6, Item 13) to lock position.

17.

Extend arm cylinder (Figure 6, Item 14) and lower boom (Figure 6, Item 12) to position crush-all (Figure 6, Item
11) on ground.

18.

Shutdown machine. (WP 0009)

19.

Clean cap (Figure 7, Item 15) and machine quick disconnect (Figure 7, Item 16) with rag.

0019-4

TM 5-3805-294-10

0019

INSTALLING CRUSH-ALL - Continued

18
16
17

15
HYEX01501

Figure 7.

Connect Auxiliary Supply Line.

20.

Clean plug (Figure 7, Item 17) and attachment quick disconnect (Figure 7, Item 18) with rag.

21.

Remove cap (Figure 7, Item 15) from machine quick disconnect (Figure 7, Item 16).

22.

Remove plug (Figure 7, Item 17) from attachment quick disconnect (Figure 7, Item 18).

23.

Connect attachment quick disconnect (Figure 7, Item 18) to machine quick disconnect (Figure 7, Item 16).

24.

Clean plug (Figure 8, Item 19) and machine quick disconnect (Figure 8, Item 20) with rag.

27

28
29

26
24
22
20
23, 25
19, 21
HYEX01502

Figure 8.

Connect Auxiliary Return Line.

25.

Clean cap (Figure 8, Item 21) and attachment quick disconnect (Figure 8, Item 22) with rag.

26.

Remove plug (Figure 8, Item 19) from machine quick disconnect (Figure 8, Item 20).

27.

Remove cap (Figure 8, Item 20) from attachment quick disconnect (Figure 8, Item 21).

28.

Connect attachment quick disconnect (Figure 8, Item 22) to machine quick disconnect (Figure 8, Item 20).

29.

Clean plug (Figure 8, Item 23) and machine quick disconnect (Figure 8, Item 24).

30.

Clean cap (Figure 8, Item 25) and attachment quick disconnect (Figure 8, Item 26) with rag.

31.

Remove plug (Figure 8, Item 23) from machine quick disconnect Figure 8, Item (24).

32.

Remove cap (Figure 8, Item 25) from attachment quick disconnect (Figure 8, Item 26).

33.

Connect attachment quick disconnect (Figure 8, Item 26) to machine quick disconnect (Figure 8, Item 25).

0019-5

TM 5-3805-294-10
INSTALLING CRUSH-ALL - Continued
34.

Remove cap (Figure 8, Item 27) from connector (Figure 8, Item 28).

35.

Attach connector (Figure 8, Item 29) to connector (Figure 8, Item 28).

END OF TASK
OPERATION
1.

Start machine. (WP 0007)

2.

Select the Pulverizer 1 on the monitor. (WP 0018)

3.

Turn on the Auxiliary Control Switch. (WP 0004)

4.

Adjust discharge size as needed. (WP 0092)

WARNING

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

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

NOTE
When crushing concrete, asphalt, brick, block, or softer stone, the maximum feed size is
18 in. x 18 in. (45.72 cm x 45.72 cm).
When crushing slag, limestone, or other materials with dirt, the maximum feed size is 15
in. x 5 in. (38.1 cm x 12.7 cm).
To reduce dust output, wet down material prior to crushing.
5.

Place engine at full speed while crushing. (WP 0004)

6.

Lift Crush-All (Figure 9, Item 11) approximately 6 ft (182.8 cm) off ground.

0019-6

0019

TM 5-3805-294-10

0019

OPERATION - Continued
34
31

30
32

33

11

HYEX01499

Figure 9.

Crush-All Operation.

7.

Curl crush-all (Figure 9, Item 11) to vertical position.

8.

Release attachment pedal lock (Figure 9, Item 30).

9.

Press attachment pedal (Figure 9, Item 31) to turn on Crush-All (Figure 9, Item 11).

10.

Allow Crush-All (Figure 9, Item 11) to run for 5 minutes with no load.

11.

Press attachment pedal (Figure 9, Item 31) and press button (Figure 9, Item 32) to open lid (Figure 9, Item
33).

NOTE
Scooping material is best performed by arming into the material, then boom up and curl as
the Crush-All is elevated above material.
12.

Scoop material and raise Crush-All (Figure 9, Item 11) away from material.

13.

Curl Crush-All (Figure 9, Item 11) to vertical position.

NOTE
Reduce dust by keeping bottom of Crush-All close to stock pile.
14.

Swing Crush-All (Figure 9, Item 11) over stock pile.

15.

Press button (Figure 9, Item 34) to close lid (Figure 9, Item 32).

16.

Allow all material to pass through crush-all (Figure 9, Item 11).

NOTE
To avoid jamming, hold attachment pedal until all material has been discharged.
17.

Release attachment pedal (Figure 9, Item 31) to turn off crush-all (Figure 9, Item 11).

0019-7

TM 5-3805-294-10

0019

OPERATION - Continued
18.

Engage attachment pedal lock (Figure 9, Item 30).

END OF TASK
JAMMING

WARNING

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

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

NOTE
These steps may be used to clear uncrushable material from machine.
It may be necessary to shake Crush-All.
1.

Press attachment pedal (Figure 10, Item 31) and press button (Figure 10, Item 32) to open lid (Figure 10, Item
33).

0019-8

TM 5-3805-294-10

0019

JAMMING - Continued

31
32

33

HYEX03431

Figure 10.
2.

Open Lid.

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

11

HYEX03148

Figure 11.

Clearing Jam from Crush-All.

3.

Safely park and shutdown machine. (WP 0009)

4.

Use a sturdy piece of lumber to push rotor (Figure 12, Item 34) in reverse.

0019-9

TM 5-3805-294-10

0019

JAMMING - Continued
35

34

HYEX03149

Figure 12. Push Crush-All Rotor Backwards.


5.

If material is jammed between the curtain (Figure 12, Item 35) and rotor (Figure 12, Item 34), raise curtain.
(WP 0092)

6.

If material will not dislodge, contact Field Level Maintenance.

END OF TASK
REMOVING CRUSH-ALL
1.

Raise boom (Figure 13, Item 12) to allow adequate ground clearance of crush-all (Figure 13, Item 11).
12

14

11
HYEX03432

Figure 13.

Position Crush-All.

2.

Curl crush-all (Figure 13, Item 11) under as shown in Figure 13.

3.

Extend arm cylinder (Figure 13, Item 14), lower boom (Figure 13, Item 12), and position crush-all (Figure 13,
Item 11) on ground.

4.

Shutdown machine. (WP 0009)

0019-10

TM 5-3805-294-10

0019

REMOVING CRUSH-ALL - Continued


5.

Remove connector (Figure 14, Item 29) from connector (Figure 14, Item 28).

27

28
29

26
24
22
20
23, 25
19, 21
HYEX01502

Figure 14.

Disconnect Auxiliary Return Line.

6.

Install cap (Figure 14, Item 27) to connector (Figure 14, Item 28).

7.

Clean attachment quick disconnect (Figure 14, Item 26) and machine quick disconnect (Figure 14, Item 24)
with rag.

8.

Clean cap (Figure 14, Item 25) and plug (Figure 14, Item 23) with rag.

9.

Remove attachment quick disconnect (Figure 14, Item 26) from machine quick disconnect (Figure 14, Item
24).

10.

Install cap (Figure 14, Item 25) to attachment quick disconnect (Figure 14, Item 26).

11.

Install plug (Figure 14, Item 23) to machine quick disconnect (Figure 14, Item 24).

12.

Clean attachment quick disconnect (Figure 14, Item 22) and machine quick disconnect (Figure 14, Item 20)
with rag.

13.

Clean cap (Figure 14, Item 21) and plug (Figure 14, Item 19) with rag.

14.

Remove attachment quick disconnect (Figure 14, Item 22) from machine quick disconnect (Figure 14, Item
20).

15.

Install cap (Figure 14, Item 21) to attachment quick disconnect (Figure 14, Item 22).

16.

Install plug (Figure 14, Item 19) to machine quick disconnect (Figure 14, Item 20).

17.

Clean attachment quick disconnect (Figure 15, Item 18) and machine quick disconnect (Figure 15, Item 16)
with rag.

0019-11

TM 5-3805-294-10

0019

REMOVING CRUSH-ALL - Continued

18
16
17

15
HYEX01501

Figure 15. Disconnect Auxiliary Supply Line.


18.

Clean cap (Figure 15, Item 15) and plug (Figure 15, Item 17) with rag.

19.

Remove attachment quick disconnect (Figure 15, Item 18) from machine quick disconnect (Figure 15, Item
16).

20.

Install plug (Figure 15, Item 17) to attachment quick disconnect (Figure 15, Item 18).

21.

Install cap (Figure 15, Item 15) to machine quick disconnect (Figure 15, Item 16).

22.

Start machine. (WP 0007)

23.

Move quick latch switch (Figure 16, Item 7) to unlatch position.

HYEX03393

Figure 16. Move Quick Latch Switch.


24.

Raise boom (Figure 17, Item 12) to allow adequate ground clearance of crush-all (Figure 17, Item 11).

0019-12

TM 5-3805-294-10

0019

REMOVING CRUSH-ALL - Continued


12

14

13

11
HYEX03433

Figure 17.
25.

Raise Boom.

Lift and rotate safety lock pin lever (Figure 17, Item 13) to unlock position.

WARNING

With quick latch wedges disengaged from crush-all, the crush-all could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing crush-all.
Slowly retract or extend bucket cylinder when removing or installing crush-all. Failure to
comply may result in injury or death to personnel.
26.

Fully extend bucket cylinder (Figure 17, Item 8) until quick latch wedges (Figure 17, Item 9) are fully retracted.

27.

Retract bucket cylinder (Figure 17, Item 8), arm cylinder (Figure 17, Item 14), and lower boom to position crushall (Figure 17, Item 11) on the ground.

28.

Retract bucket cylinder (Figure 18, Item 8) and position quick latch (Figure 18, Item10) in vertical position.

0019-13

TM 5-3805-294-10

0019

REMOVING CRUSH-ALL - Continued


8

10

11

HYEX03397

Figure 18. Remove Quick Latch.


29.

Remove quick latch (Figure 18, Item 10) from crush-all (Figure 18, Item 11).

30.

Move quick latch switch (Figure 19, Item 7) to latch position.

HYEX03393

Figure 19. Move Quick Latch Switch.


31.

Lower arm (Figure 20, Item 35) to ground.

0019-14

TM 5-3805-294-10

0019

REMOVING CRUSH-ALL - Continued

3
4
2
4
1

5
3

5
35

HYEX01500

Figure 20.

Open Hydraulic Thumb Circuit.

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
32.

Open two auxiliary circuit shut off valves (Figure 20, Item 6).

33.

Remove retaining clip (Figure 20, Item 2) from pin (Figure 20, Item 3).

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
34.

Retract or extend thumb cylinder (Figure 20, Item 1) to remove pin (Figure 20, Item 3) from thumb lock position
(Figure 20, Item 5).

35.

Install pin (Figure 20, Item 3) in storage position (Figure 20, Item 4).

36.

Install retaining pin (Figure 20, Item 2) on pin (Figure 20, Item 3).

37.

Shutdown machine. (WP 0009)

END OF TASK
END OF WORK PACKAGE

0019-15/16 blank

TM 5-3805-294-10

0020

OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE IMPACT BREAKER

INITIAL SETUP:
Tools and Special Tools
Screwdriver, Pry Bar, 12 in. (304 mm) Long
(WP 0095, Table 2, Item 11)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)

Materials/Parts (cont.)
(WP 0097, Table 1, Item 10)
Rags, Wiping (WP 0097, Table 1, Item 15)

Materials/Parts
Grease, Automotive and Artillery, GAA

Equipment Condition
Machine safely parked and shutdown. (WP 0009)
Bucket removed. (WP 0014)

References
WP 0007
WP 0009
WP 0018

INSTALLING IMPACT BREAKER


1.

Start the machine. (WP 0007)

2.

Retract hydraulic thumb cylinder (Figure 1, Item 1).

3
4
2
6

5
3

HYEX01321

Figure 1.

Close Hydraulic Thumb Circuit.

3.

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

4.

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

0020-1

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.

With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).

6.

Install retaining clip (Figure 1, Item 2) to pin (Figure 1, Item 3).

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.

Close two auxiliary circuit shutoff valves (Figure 1, Item 6).

8.

Move quick latch switch (Figure 2, Item 7) to UNLATCH position.

HYEX03398

Figure 2. Move Quick Latch Switch.


9.

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

0020-2

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued

HYEX03399

Figure 3.
10.

Raise Boom.

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

10
HYEX03400

Figure 4.
11.

Quick Latch Wedges Retracted.

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

0020-3

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued


9

8
11

12
HYEX03402

Figure 5.
12.

Install Quick Latch.

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

WARNING

With quick latch wedges disengaged from impact breaker, the impact breaker could fall off
of the quick latch. Ensure that personnel are clear of equipment when removing or installing
impact breaker. Slowly retract or extend bucket cylinder when removing or installing impact
breaker. Failure to comply may result in injury or death to personnel.
13.

With the aid of an assistant slowly raise boom (Figure 5, Item 8) to allow for adequate ground clearance of
quick latch (Figure 5, Item 11).

14.

Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on impact breaker
(Figure 6, Item 12)

12

11
HYEX03403

Figure 6.

Extend Bucket Cylinder.

0020-4

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued


15.

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

HYEX03398

Figure 7.
16.

Move Quick Latch Switch to Latch Position.

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

10

12
HYEX03401

Figure 8.

Quick Latch Wedges Engaged.

17.

Retract bucket cylinder (Figure 8, Item 9) and place impact breaker (Figure 8, Item 12) on ground.

18.

Shutdown machine. (WP 0009)

19.

Rotate safety lock pin lever (Figure 9, Item 13) to lock position.

0020-5

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued

HYEX03406

13

Figure 9.
20.

Safety Pin to Lock Position.

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

17
15
16

14
HYEX01322

Figure 10. Connect Auxiliary Supply Line.


21.

Clean plug (Figure 10, Item 16) and attachment quick disconnect (Figure 10, Item 17) with rag.

22.

Remove cap (Figure 10, Item 14) from machine quick disconnect (Figure 10, Item 15).

23.

Remove plug (Figure 10, Item 16) from attachment quick disconnect (Figure 10, Item 17).

24.

Connect attachment quick disconnect (Figure 10, Item 17) to machine quick disconnect (Figure 10, Item 15).

25.

Clean plug (Figure 11, Item 18) and machine quick disconnect (Figure 11, Item 19) with rag.

0020-6

TM 5-3805-294-10

0020

INSTALLING IMPACT BREAKER - Continued

21
19
18
20
HYEX01323

Figure 11.

Connect Auxiliary Return Line.

26.

Clean cap (Figure 11, Item 20) and attachment quick disconnect (Figure 11, Item 21) with rag.

27.

Remove plug (Figure 11, Item 18) from machine quick disconnect (Figure 11, Item 19).

28.

Remove cap (Figure 11, Item 20) from attachment quick disconnect (Figure 11, Item 21).

29.

Connect attachment quick disconnect (Figure 11, Item 21) to machine quick disconnect (Figure 11, Item 19).

END OF TASK
TOOL INSTALLATION

NOTE
Select the proper tool before operation.
Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to
medium hardness.
Moil is for demolition of medium hardness rock or materials except layered rock.
Blunt is for breaking large, medium hardness rocks into smaller pieces.
1.

Press and turn lock bolt (Figure 12, Item 22) to unlocked position with slot (Figure 12, Item 23) pointed to the
tool end of breaker (Figure 12, Item 12).

0020-7

TM 5-3805-294-10

0020

TOOL INSTALLATION - Continued

22

23
24

12

26
25

HYEX01326

Figure 12.

Breaker Tool Lock Bolt.

2.

Push the retaining axle (Figure 12, Item 24) out of the breaker (Figure 12, Item 12) through hole (Figure 12,
Item 25).

3.

Repeat Steps 1 and 2 for other retaining axle.

4.

Lubricate bushing (Figure 12, Item 26) with grease.

WARNING

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

NOTE
Ensure cavity is free of debris and tool is properly lubricated.
5.

With the aid of an assistant and suitable lifting device, slide tool (Figure 13, Item 27) into breaker (Figure 13,
Item 12) with side notches (Figure 13, Item 28) in alignment with axle slots (Figure 13, Item 29).

0020-8

TM 5-3805-294-10

0020

TOOL INSTALLATION - Continued

29

12

27
28
HYEX01327

Figure 13.
6.

Insert Breaker Tool.

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

12
24

23

22

HYEX01328

Figure 14.

Lock Breaker Tool.

7.

Press and turn lock bolt (Figure 14, Item 22) to locked position with slot (Figure 14, Item 23) pointed to top of
breaker (Figure 14, Item 12).

8.

Repeat Steps (Figure 14, Item 6) and (Figure 14, Item 7) for other retaining axle.

END OF TASK
OPERATING IMPACT BREAKER
1.

Start the machine. (WP 0007)

2.

Select work mode BREAKER 1 on the monitor. (WP 0018)

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

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

0020-9

TM 5-3805-294-10

0020

OPERATING IMPACT BREAKER - Continued


Increase down pressure when strokes have a metallic sound.
Decrease down pressure when strokes cause strong vibrations in the machine.
3.

Release attachment pedal lock (Figure 15, Item 30).

30

31

12

HYEX01520

Figure 15.

Breaker Operation.

4.

Apply boom (Figure 15, Item 8) down pressure to impact breaker (Figure 15, Item 12) on work area.

5.

Press attachment pedal (Figure 15, Item 31) to start impact breaker (Figure 15, Item 12).

6.

Release attachment pedal (Figure 15, Item 31) to stop impact breaker (Figure 15, Item 12) before retracting
from work area.

7.

Engage attachment pedal lock (Figure 15, Item 30).

END OF TASK
TOOL REMOVAL
1.

Raise breaker (Figure 16, Item 12) off ground and extend bucket cylinder (Figure 16, Item 9) until breaker is
horizontal.
9

24

12

23

25
22
HYEX03440

Figure 16.

Tool Removal.

0020-10

TM 5-3805-294-10

0020

TOOL REMOVAL - Continued


2.

Press and turn lock bolt (Figure 16, Item 22) to unlocked position with slot (Figure 16, Item 23) pointed to the
tool end of breaker (Figure 16, Item 12).

3.

Push the retaining axle (Figure 16, Item 24) out of the breaker (Figure 16, Item 12) through hole (Figure 16,
Item 25).

4.

Repeat Steps 2 and 3 for other retaining axle.

WARNING

Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without
the aid of an assistant and suitable lifting device. Failure to comply may result in injury or
death to personnel.
5.

With the aid of an assistant and suitable lifting device, slide tool (Figure 17, Item 27) out of breaker (Figure 17,
Item 12).

12

27

HYEX03439

Figure 17.
6.

Remove Breaker Tool.

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

12
24

23

22

HYEX01328

Figure 18.
7.

Lock Breaker Tool.

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

0020-11

TM 5-3805-294-10

0020

TOOL REMOVAL - Continued


8.

Repeat Steps 6 and 7 for other retaining axle.

END OF TASK
REMOVING IMPACT BREAKER
1.

Safely park and shut down machine. (WP 0009)

2.

Clean machine quick disconnect (Figure 19, Item 19) and attachment quick disconnect (Figure 19, Item 21)
with rag.

21
19
18
20
HYEX01323

Figure 19. Disconnect Auxiliary Return Line.


3.

Clean cap (Figure 19, Item 20) and plug (Figure 19, Item 18) with rag.

4.

Remove attachment quick disconnect (Figure 19, Item 21) from machine quick disconnect (Figure 19, Item
19).

5.

Install cap (Figure 19, Item 20) to attachment quick disconnect (Figure 19, Item 21).

6.

Install plug (Figure 19, Item 18) to machine quick disconnect (Figure 19, Item 19).

7.

Clean machine quick disconnect (Figure 20, Item 15) and attachment quick disconnect (Figure 20, Item 17)
with rag.

17
15
16

14
HYEX01322

Figure 20. Disconnect Auxiliary Supply Line.


8.

Clean cap (Figure 20, Item 14) and plug (Figure 20, Item 16) with rag.

9.

Remove attachment quick disconnect (Figure 20, Item 17) from machine quick disconnect (Figure 20, Item
15).

0020-12

TM 5-3805-294-10

0020

REMOVING IMPACT BREAKER - Continued


10.

Install plug (Figure 20, Item 16) to attachment quick disconnect (Figure 20, Item 17).

11.

Install cap (Figure 20, Item 14) to machine quick disconnect (Figure 20, Item 15).

12.

Lift and rotate safety lock pin lever (Figure 21, Item 13) to unlock position.

HYEX03406

13

Figure 21.

Safety Pin to Unlock Position.

13.

Start the machine. (WP 0007)

14.

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

HYEX03399

Figure 22.
15.

Raise Boom for Clearance.

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

0020-13

TM 5-3805-294-10

0020

REMOVING IMPACT BREAKER - Continued

HYEX03398

Figure 23. Move Quick Latch Switch to Unlatch Position.


16.

Extend bucket cylinder (Figure 24, Item 9) until quick latch wedges (Figure 24, Item 10) are fully retracted.
9

10

12
HYEX03401

Figure 24.
17.

Quick Latch Wedges Retracted.

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

0020-14

TM 5-3805-294-10

0020

REMOVING IMPACT BREAKER - Continued


9

8
11

12
HYEX03402

Figure 25.

Impact Breaker Removal.

18.

Lower boom (Figure 25, Item 8) until impact breaker (Figure 25, Item 12) is resting on ground.

19.

Remove quick latch (Figure 25, Item 11) from impact breaker (Figure 25, Item 12).

20.

Move quick latch switch (Figure 26, Item 7) to LATCH position.

HYEX03398

Figure 26.

Quick Latch Switch to Latch Position.

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
21.

Open two auxiliary circuit shutoff valves (Figure 27, Item 6).

0020-15

TM 5-3805-294-10

0020

REMOVING IMPACT BREAKER - Continued

3
4
2
6

5
3

HYEX01321

Figure 27. Open Hydraulic Thumb Circuit.


22.

Remove retaining pin (Figure 27, Item 2) from pin (Figure 27, Item 3).

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
23.

With the aid of an assistant, extend or retract thumb cylinder (Figure 27, Item 1), as needed, while using prybar
to remove pin (Figure 27, Item 3) from thumb lock position (Figure 27, Item 5).

24.

Install pin (Figure 27, Item 3) in storage position (Figure 27, Item 4).

25.

Install retaining pin (Figure 27, Item 2) to pin (Figure 27, Item 3).

26.

Safely park and shut down machine. (WP 0009)

END OF TASK
END OF WORK PACKAGE

0020-16

TM 5-3805-294-10

0021

OPERATOR MAINTENANCE
INSTALLING AND OPERATING THE COMPACTOR

INITIAL SETUP:
Tools and Special Tools
Screwdriver, Pry Bar, 12 in. (304 mm) Long
(WP 0095, Table 2, Item 11)
Wrench, Open End, Adjustable 0.95 in. (24 mm)
(WP 0095, Table 2, Item 19)
Wrench, Open End, 2 1/2 in. (63.5 mm)
(WP 0095, Table 2, Item 15)
Wrench, Open End, 3 in. (76 mm)
(WP 0095, Table 2, Item 14)

References (cont.)
WP 0009
WP 0018
Equipment Condition
Safely park and shutdown machine. (WP 0009)
Bucket removed. (WP 0014)

Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)
References
WP 0007

INSTALLING COMPACTOR
1.

Start machine. (WP 0007)

WARNING

Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
2.

Retract hydraulic thumb cylinder (Figure 1, Item 1).

0021-1

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued

3
4
2
6

5
3

HYEX03411

Figure 1. Close Hydraulic Thumb Circuit.


3.

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

4.

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

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5.

With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).

6.

Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).

NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7.

Close two auxiliary circuit shut off valves (Figure 1, Item 6).

8.

Move quick latch switch (Figure 2, Item 7) to UNLATCH position.

0021-2

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued

HYEX03412

Figure 2.
9.

Move Quick Latch Switch.

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

HYEX03413

Figure 3.
10.

Raise Boom.

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

0021-3

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued


9

10
HYEX03414

Figure 4. Quick Latch Wedges Retracted.


11.

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

12

HYEX03415

Figure 5.

Install Quick Latch.

12.

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

13.

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

0021-4

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued


9

11

12
HYEX03416

Figure 6.
14.

Position Quick Latch.

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

HYEX03412

Figure 7. Quick Latch Switch to Latch Position.

WARNING

With quick latch wedges disengaged from compactor, the compactor could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing compactor.
Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to
comply may result in injury or death to personnel.
15.

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

0021-5

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued

HYEX03413

Figure 8. Raise Boom for Clearance.


16.

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

12
10
HYEX03417

Figure 9. Engage Quick Latch Wedges.


17.

Retract bucket cylinder (Figure 9, Item 9) and position compactor (Figure 9, Item 12) on ground.

18.

Shutdown machine. (WP 0009)

19.

Rotate safety lock pin lever (Figure 10, Item 13) to lock position.

0021-6

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued


13

HYEX03418

Figure 10.
20.

Lock Safety Lock.

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

17
15
16

14
HYEX03419

Figure 11.

Connect Auxiliary Supply Line.

21.

Clean plug (Figure 11, Item 16) and attachment quick disconnect (Figure 11, Item 17) with rag.

22.

Remove cap (Figure 11, Item 14) from machine quick disconnect (Figure 11, Item 15).

23.

Remove plug (Figure 11, Item 16) from attachment quick disconnect (Figure 11, Item 17).

24.

Connect attachment quick disconnect (Figure 11, Item 17) to machine quick disconnect (Figure 11, Item 15).

25.

Clean plug (Figure 12, Item 18) and machine quick disconnect (Figure 12, Item 19) with rag.

0021-7

TM 5-3805-294-10

0021

INSTALLING COMPACTOR - Continued

21
19
18
20
HYEX03420

Figure 12.

Connect Auxiliary Return Line.

26.

Clean cap (Figure 12, Item 20) and attachment quick disconnect (Figure 12, Item 21) with rag.

27.

Remove plug (Figure 12, Item 18) from machine quick disconnect (Figure 12, Item 19).

28.

Remove cap (Figure 12, Item 20) from attachment quick disconnect (Figure 12, Item 21).

29.

Connect attachment quick disconnect (Figure 12, Item 21) to machine quick disconnect (Figure 12, Item 19).

END OF TASK
OPERATING THE COMPACTOR
1.

Start the machine. (WP 0007)

2.

Select Breaker 2 on the monitor. (WP 0018)

3.

Release attachment pedal lock (Figure 13, Item 22).


22

23
12

24
HYEX01325

Figure 13. Attachment Pedal Lock Release.


4.

Press attachment pedal (Figure 13, Item 23) to turn on compactor (Figure 13, Item 12).

5.

Position compactor (Figure 13, Item 12) on work surface.

6.

Apply boom down pressure to deflect rubber isolators (Figure 13, Item 24) approximately half way.

0021-8

TM 5-3805-294-10

0021

OPERATING THE COMPACTOR - Continued


7.

Move compactor (Figure 13, Item 12) over work surface while continuing to apply down pressure.

8.

Release attachment pedal (Figure 13, Item 23) to stop compactor (Figure 13, Item 12).

9.

Engage attachment pedal lock (Figure 13, Item 22).

10.

Safely park and shutdown machine. (WP 0009)

END OF TASK
REMOVING THE COMPACTOR
1.

Clean attachment quick disconnect (Figure 14, Item 21) and machine quick disconnect (Figure 14, Item 19)
with rag.

21
19
18
20
HYEX03420

Figure 14.

Disconnect Auxiliary Return Line.

2.

Clean cap (Figure 14, Item 20) with rag.

3.

Clean plug (Figure 14, Item 18) with rag.

4.

Remove attachment quick disconnect (Figure 14, Item 21) from machine quick disconnect (Figure 14, Item
19).

5.

Install cap (Figure 14, Item 20) to attachment quick disconnect (Figure 14, Item 21).

6.

Install plug (Figure 14, Item 18) to machine quick disconnect (Figure 14, Item 19).

7.

Clean attachment quick disconnect (Figure 15, Item 17) and machine quick disconnect (Figure 15, Item 15)
with rag.

0021-9

TM 5-3805-294-10

0021

REMOVING THE COMPACTOR - Continued

17
15
16

14
HYEX03419

Figure 15. Connect Auxiliary Supply Line.


8.

Clean plug (Figure 15, Item 16) with rag.

9.

Clean cap (Figure 15, Item 14) with rag.

10.

Remove attachment quick disconnect (Figure 15, Item 17) from machine quick disconnect (Figure 15, Item
15).

11.

Install plug (Figure 15, Item 16) to attachment quick disconnect (Figure 15, Item 17).

12.

Install cap (Figure 15, Item 14) to machine quick disconnect (Figure 15, Item 15).

13.

Rotate safety lock pin lever (Figure 16, Item 13) to unlock position.
13

HYEX03421

Figure 16.

Unlock Safety Lock.

14.

Start the machine. (WP 0007)

15.

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

0021-10

TM 5-3805-294-10

0021

REMOVING THE COMPACTOR - Continued

HYEX03412

Figure 17. Quick Latch Switch to Unlatch Position.


16.

Raise boom (Figure 18, Item 8) to allow for adequate ground clearance.

HYEX03413

Figure 18.

Raise Boom.

WARNING

With quick latch wedges disengaged from compactor, the compactor could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing compactor.
Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to
comply may result in injury or death to personnel.
17.

Extend bucket cylinder (Figure 19, Item 9) until quick latch wedges (Figure 19, Item 10) are disengaged from
compactor (Figure 19, Item 12).

0021-11

TM 5-3805-294-10

0021

REMOVING THE COMPACTOR - Continued

12
10
HYEX03417

Figure 19. Disengage Quick Latch Wedges.


18.

Retract bucket cylinder (Figure 20, Item 9) until quick latch (Figure 20, Item 11) is in vertical position.
9
11

HYEX03422

Figure 20.

Retract Bucket Cylinder.

NOTE
Removal of the arm/quick latch from the compactor is seldom done the same way twice. A
combination of slow and smooth boom down and arm in movements is required.
19.

Fully retract arm cylinder (Figure 21, Item 24).

0021-12

TM 5-3805-294-10

0021

REMOVING THE COMPACTOR - Continued


24
8

9
11

12
25

Figure 21.
20.

HYEX03424

Remove Quick Latch.

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

NOTE
The compactor will likely become wedged between the ground the quick latch/arm until it
"pops" out of the hooks. When this wedged situation occurs, ensure that the tracks do not
begin to raise. If tracks begin to raise: stop movements, raise boom, and try again.
21.

Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure
21, Item 12), then begin to boom down while continuing to arm in until quick latch (Figure 21, Item 11) is
removed from compactor.

22.

Move quick latch switch (Figure 22, Item 7) to LATCH position.

HYEX03412

Figure 22.

Quick Latch Switch to Latch Position.

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

0021-13

TM 5-3805-294-10

0021

REMOVING THE COMPACTOR - Continued


23.

Open two auxiliary circuit shutoff valves (Figure 23, Item 6).

3
4
2
6

5
3

HYEX03411

Figure 23. Close Hydraulic Thumb Circuit.


24.

Remove retaining pin (Figure 23, Item 2) from pin (Figure 23, Item 3).

WARNING

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

NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
25.

With the aid of an assistant, extend or retract thumb cylinder (Figure 23, Item 1), as needed, while using prybar
to remove pin (Figure 23, Item 3) from thumb lock position (Figure 23, Item 5).

26.

Install pin (Figure 23, Item 3) in storage position (Figure 23, Item 4).

27.

Install retaining pin (Figure 23, Item 2) to pin (Figure 23, Item 3).

28.

Safely park and shutdown machine. (WP 0009)

END OF TASK
END OF WORK PACKAGE

0021-14

TM 5-3805-294-10

0022

OPERATOR MAINTENANCE
OPERATING THE BARRIER GRAPPLE

INITIAL SETUP:
Tools and Special Tools
Lifting Device, Minimum Capacity 16,000 lbs
(72574.8 kg)

Equipment Condition
Engine running. (WP 0007)

BARRIER GRAPPLE OPERATION

WARNING

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

NOTE
Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16,000 lb (7257.48 kg).
1.

Attach barrier grapple (Figure 1, Item 1) to quick latch loop (Figure 1, Item 2) with suitable lifting device (Figure
1, Item 3).

0022-1

TM 5-3805-294-10

0022

BARRIER GRAPPLE OPERATION - Continued

HYEX02585

Figure 1. Lifting Barrier Grapple.


2.

Position barrier grapple (Figure 1, Item 1) near center of barrier (Figure 1, Item 4).

3.

Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically close on the barrier.

CAUTION
Avoid jerky lifting, striking, and poor alignment with barriers. Failure to comply may result in
damage to equipment.
4.

Slowly raise barrier grapple (Figure 1, Item 1) and barrier (Figure 1, Item 4).

5.

Position barrier (Figure 1, Item 4) in desired location.

6.

Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically latch open and release the barrier.

0022-2

TM 5-3805-294-10
BARRIER GRAPPLE OPERATION - Continued
7.

Raise barrier grapple (Figure 1, Item 1).

END OF TASK
END OF WORK PACKAGE

0022-3/4 blank

0022

TM 5-3805-294-10

0023

OPERATOR MAINTENANCE
OPERATING THE DEEP DIG ARM

INITIAL SETUP:
References
WP 0010
WP 0077

Equipment Condition
Engine running. WP 0007

DEEP DIG ARM OPERATION

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

NOTE
After the Deep Dig Attachment has been installed on the machine, the following steps must
be performed to enable Deep Dig Arm Operation.
1.

Remove clip (Figure 1, Item 1) from switch bracket (Figure 1, Item 2).

HYEX01519

Figure 1.

Deep Dig Control Pattern Switch.

2.

Move switch (Figure 1, Item 3) to ON position and install pin (Figure 1, Item 1).

3.

Switch A/I (Figure 2, Item 4) to on position

0023-1

TM 5-3805-294-10

0023

DEEP DIG ARM OPERATION - Continued

HYEX03404

Figure 2. Turn Auto Idle Switch On.


4.

Move pilot shutoff lever (Figure 3, Item 5) to unlocked position (down).

0023-2

TM 5-3805-294-10

0023

DEEP DIG ARM OPERATION - Continued

5
HYEX01518

Figure 3.
5.

Pilot Shutoff Lever.

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

0023-3

TM 5-3805-294-10

0023

DEEP DIG ARM OPERATION - Continued

HYEX03405

Figure 4.

Turn RPM Dial.

NOTE
When the deep dig control pattern switch is in the ON position, the arm cylinder is
controlled by the attachment pedal and can only be retracted.
The arm cylinder can only be retracted. It is necessary to occasionally retract the arm
cylinder due to the weight of the deep dig arm.
With the deep dig control pattern switch in the ON position, the pilot control levers operate
in the same way.
6.

Slowly cycle bucket cylinder (Figure 5, Item 5) and deep dig bucket cylinder (Figure 5, Item 6) until full smooth
movement of each cylinder is obtained.

0023-4

TM 5-3805-294-10

0023

DEEP DIG ARM OPERATION - Continued

HYEX01636

Figure 5.

Cycle Deep Dig Arm Cylinders.

7.

Park and shut down machine. (WP 0010)

8.

Check hydraulic oil level. (WP 0077)

END OF TASK
END OF WORK PACKAGE

0023-5/6 blank

TM 5-3805-294-10

0024

OPERATOR MAINTENANCE
MOVING MACHINE ON/OFF AN EMBANKMENT

INITIAL SETUP:
Not Applicable

MOVING MACHINE ON AN EMBANKMENT

CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to
comply may result in damage to equipment.
1.

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

3
5
2
4

HYEX01102

Figure 1.

Position Bucket.

2.

Lower boom (Figure 1, Item 3) to raise undercarriage until front of tracks (Figure 1, Item 4) clear edge of
embankment.

3.

Drive machine (Figure 1, Item 5) towards upper level as arm (Figure 1, Item 2) is retracted.

4.

Slowly raise boom (Figure 1, Item 3) until tracks (Figure 1, Item 4) are resting on upper level of embankment.

5.

Rotate upper structure (Figure 2, Item 6) 180 degrees towards lower level of embankment.

0024-1

TM 5-3805-294-10

0024

MOVING MACHINE ON AN EMBANKMENT - Continued

6
5
3
2

4
1

HYEX01104

Figure 2.

Upperstructure Rotated.

6.

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

7.

Drive machine (Figure 2, Item 5) towards upper level while extending arm (Figure 2, Item 2) until machine is
completely on upper level of embankment.

END OF TASK
MOVING MACHINE OFF AN EMBANKMENT

CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to
comply may result in damage to equipment.
1.

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

0024-2

TM 5-3805-294-10

0024

MOVING MACHINE OFF AN EMBANKMENT - Continued

5
3
2

4
1

HYEX00689

Figure 3.

Position Bucket on Lower Level.

2.

Drive machine (Figure 3, Item 5) towards lower level while raising boom (Figure 3, Item 3) and retracting arm
(Figure 3, Item 2) until front of tracks (Figure 3, Item 4) reach lower level of embankment.

3.

Raise bucket (Figure 4, Item 1) off of the ground and rotate upper structure (Figure 4, Item 6) 180 degrees
towards upper level of embankment.

3
2
5

1
4

HYEX01103

Figure 4.
4.

Rotate Upperstructure to Upper Level.

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

TM 5-3805-294-10

0024

MOVING MACHINE OFF AN EMBANKMENT - Continued


5.

Lower boom (Figure 4, Item 3) slightly and drive machine (Figure 4, Item 5) towards lower level as the arm
(Figure 4, Item 2) is extended.

6.

When tracks (Figure 4, Item 4) clear upper level of embankment, slowly raise boom (Figure 4, Item 3) until
machine (Figure 4, Item 5) is on lower level.

END OF TASK
END OF WORK PACKAGE

0024-4

TM 5-3805-294-10

0025

OPERATOR MAINTENANCE
USING THE VANDAL PROTECTION KIT

INITIAL SETUP:
Not Applicable

RIGHT SIDE CAB INSTALLATION


1.

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

HYEX01548

Figure 1.
2.

Right Side Rear Cover Installation.

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

HYEX01549

Figure 2.

Right Side Center Cover Installation.

0025-1

TM 5-3805-294-10

0025

RIGHT SIDE CAB INSTALLATION - Continued


3.

Position cover (Figure 3, Item 7) on cab hook (Figure 3, Item 8) and behind brackets (Figure 3, Item 9).
8

HYEX01550

Figure 3.
4.

Right Side Front Cover Installation.

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

11

10
11

12

HYEX01551

Figure 4. Lock Bar Installation.


END OF TASK
LEFT SIDE CAB INSTALLATION
1.

Position cover (Figure 5, Item 13) over door hook (Figure 5, Item 14) and behind brackets (Figure 5, Item 15).

0025-2

TM 5-3805-294-10

0025

LEFT SIDE CAB INSTALLATION - Continued

14

13

15

HYEX01552

Figure 5.
2.

Front Door Cover Installation.

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

16

18

HYEX01553

Figure 6.
3.

Center Door Cover Installation.

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

0025-3

TM 5-3805-294-10

0025

LEFT SIDE CAB INSTALLATION - Continued

20

20

21

24
23

22
Figure 7.

19

HYEX01554

Lower Door Cover Installation.

4.

Position hinge (Figure 7, Item 22) over tab (Figure 7, Item 23) and turn lock (Figure 7, Item 24) to lock in place.

5.

Position cover (Figure 8, Item 25) over cab hooks (Figure 8, Item 26) and behind bracket (Figure 8, Item 27).

26

26

25

27

HYEX01555

Figure 8. Side Upper Glass Cover Installation.


6.

Position cover (Figure 9, Item 28) over hooks (Figure 9, Item 29) and behind brackets (Figure 9, Item 30).

0025-4

TM 5-3805-294-10

0025

LEFT SIDE CAB INSTALLATION - Continued


29

30
28

33
32
31

HYEX01556

Figure 9.
7.

Side Lower Glass Cover Installation.

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

END OF TASK
REAR CAB INSTALLATION
1.

Position cover (Figure 10, Item 34) over cab hook (Figure 10, Item 35) and behind brackets (Figure 10, Item
36).
34 35

36

Figure 10.
2.

HYEX01557

Right Rear Cab Cover Installation.

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

0025-5

TM 5-3805-294-10

0025

REAR CAB INSTALLATION - Continued

38

40

39

37
Figure 11.
3.

HYEX01558

Left Rear Cab Cover Installation.

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

END OF TASK
REAR CAB REMOVAL
1.

Turn lock (Figure 12, Item 40) to unlock.

38

40

39

37

HYEX01558

Figure 12. Left Rear Cab Cover Removal.


2.

Remove cover (Figure 12, Item 37) from behind brackets (Figure 12, Item 39) and from tab (Figure 12, Item
38).

0025-6

TM 5-3805-294-10

0025

REAR CAB REMOVAL - Continued


3.

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

36

Figure 13.

HYEX01557

Right Rear Cab Cover Removal.

END OF TASK
LEFT SIDE CAB REMOVAL
1.

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

30
28

33
32
31

HYEX01556

Figure 14.

Side Lower Glass Cover Removal.

2.

Remove cover (Figure 14, Item 28) from behind brackets (Figure 14, Item 30) and hooks (Figure 14, Item 29).

3.

Remove cover (Figure 15, Item 25) from behind bracket (Figure 15, Item 27) and cab hooks (Figure 15, Item
26).

0025-7

TM 5-3805-294-10

0025

LEFT SIDE CAB REMOVAL - Continued

26

26

25

27

HYEX01555

Figure 15. Side Upper Glass Cover Removal.


4.

Turn lock (Figure 16, Item 24) to unlock and remove hinge (Figure 16, Item 22) from tab (Figure 16, Item 23).

20

20

21

24
23

22

19

HYEX01554

Figure 16. Lower Door Cover Removal.


5.

Remove cover (Figure 16, Item 19) from behind brackets (Figure 16, Item 21) and hooks (Figure 16, Item 20).

6.

Remove cover (Figure 17, Item 16) from behind brackets (Figure 17, Item 18) and cab hooks (Figure 17, Item
17).

0025-8

TM 5-3805-294-10

0025

LEFT SIDE CAB REMOVAL - Continued


17

16

18

HYEX01553

Figure 17.
7.

Center Door Cover Removal.

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

14

13

15

HYEX01552

Figure 18.

Front Door Cover Removal.

END OF TASK
RIGHT SIDE CAB REMOVAL
1.

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

0025-9

TM 5-3805-294-10

0025

RIGHT SIDE CAB REMOVAL - Continued

11

10
11

12

HYEX01551

Figure 19.
2.

Lock Bar Removal.

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

HYEX01550

Figure 20. Right Side Front Cover Removal.


3.

Remove cover (Figure 21, Item 4) from behind brackets (Figure 21, Item 6) and cab hook (Figure 21, Item 5).

HYEX01549

Figure 21. Right Side Center Cover Removal.

0025-10

TM 5-3805-294-10

0025

RIGHT SIDE CAB REMOVAL - Continued


4.

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

HYEX01548

Figure 22.

Right Side Rear Cover Removal.

END OF TASK
END OF WORK PACKAGE

0025-11/12 blank

TM 5-3805-294-10

0026

OPERATOR MAINTENANCE
OPERATING THE HYDRAULIC HOSE REEL

INITIAL SETUP:
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

References
WP 0007
WP 0009

CONNECTING HYDRAULIC TOOL


1.

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

5
6

2
4
1
3
HYEX01097

Figure 1.

Hydraulic Tool Attachment.

2.

Remove cover (Figure 1, Item 3) from quick coupler (Figure 1, Item 4).

3.

Using a clean rag, wipe quick coupler (Figure 1, Item 2) and (Figure 1, Item 4) and couplers on tool to be
connected.

4.

Connect quick coupler (Figure 1, Item 2) on return hose (Figure 1, Item 5) to hydraulic tool.

5.

Connect quick coupler (Figure 1, Item 4) on supply hose (Figure 1, Item 6) to hydraulic tool.

6.

Start engine. (WP 0007)

0026-1

TM 5-3805-294-10

0026

CONNECTING HYDRAULIC TOOL - Continued


7.

Move hand held hydraulic tool circuit switch (Figure 2, Item 7) to ON position.

8
7
HYEX01096

Figure 2.
8.

Turn On Hydraulic Tool.

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

END OF TASK
DISCONNECTING HYDRAULIC TOOL
1.

Move flow regulator (Figure 3, Item 8) to lowest setting.

8
7
HYEX01096

Figure 3.

Turn Off Hydraulic Tool.

2.

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

3.

Shut engine off. (WP 0009)

0026-2

TM 5-3805-294-10

0026

DISCONNECTING HYDRAULIC TOOL - Continued


4.

Operate hydraulic tool to relieve pressure from hoses.

5.

Disconnect quick coupler (Figure 4, Item 4) on supply hose (Figure 4, Item 6) from hydraulic tool.

5
6

2
4
1
3
HYEX01097

Figure 4.

Hydraulic Tool Removal.

6.

Disconnect quick coupler (Figure 4, Item 2) on return hose (Figure 4, Item 5) from hydraulic tool.

7.

Install cover (Figure 4, Item 3) to quick coupler (Figure 4, Item 4).

8.

Install cover (Figure 4, Item 1) to quick coupler (Figure 4, Item 2).

END OF TASK
END OF WORK PACKAGE

0026-3/4 blank

TM 5-3805-294-10

0027

OPERATOR MAINTENANCE
DECAL LOCATION GUIDE

INITIAL SETUP:
Not Applicable

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

240D

24 VOLTS
DC SLAVE
RECEPTACLE

LCR

DIESEL
ONLY

HYEX01457

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

0027-1

TM 5-3805-294-10

0027

DECALS - Continued

DRY AIR CLEANER


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

DO NOT USE OIL


HYEX01449

Figure 2.

Left Inside Door.

HYEX01448

Figure 3. Top Under Engine Cover

0027-2

TM 5-3805-294-10

0027

DECALS - Continued

IMPORTANT
OIL
LEVEL
Fully
Retracted
Fully
Retracted

3 Without Bucket

Check oil level cold with


excavator in position
shown above.

HYEX01447

Figure 4.

Right Side on Hydraulic Reservoir.

FUEL TANK SUMP


WATER DRAIN

TRANSPORTATION DATA

Drain water and sediment from fuel


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

GROSS WEIGHT
EQUIPMENT TIEDOWN DESIGN LIMIT LOAD LIFTING DESIGN LIMIT LOAD
-

60,000 LB.

NO. OF SLINGS REQUIRED


LENGTH OF SLINGS

4
12 FT.

EQUIPMENT TIEDOW PROVISIONS


LIFTING PROVISIONS
SWING CENTERLINE

T247868

CENTER OF
GRAVITY

44 MM [1.7 IN.]

1212 MM [47.5 IN.]

HYEX01445

Figure 5.

Right Side.

0027-3

TM 5-3805-294-10

0027

DECALS - Continued

LIFT
ENGINE OIL
SAMPLE VALVE
HYD
OIL
SAMPLE
VALVE

HYEX01444

Figure 6.

Boom, Right Side, and Rear Cab Window.

HYEX01446

Figure 7.

Counterweight.

0027-4

TM 5-3805-294-10

0027

DECALS - Continued

TIEDOWN
HYEX01442

Figure 8.

Front and Rear Frame.

LOCK

HYEX01450

Figure 9.
O FF

Cab on Seat.

AC
C

ON

S TA
RT
HYEX01530

Figure 10.

Key Switch.

0027-5

TM 5-3805-294-10

0027

DECALS - Continued

CAUTION

FRONT WINDOW
HANDLE

Avoid injury from slip or fall. DO NOT use as a handhold.


T223082
Window handle will move with the front window.

HYEX01531

Figure 11.

Windshield.

240DLC LIFT IN 1000 LBS.


WITH 1920 LB. BUCKET, 11 FT. 10 IN. ARM AND 32 INCH SHOES

10'

15'

20'

25'

IMPORTANT

30'

7.55*
7.55*
8.52*
8.52*

8.61*
8.61*

6.26*
6.26*

14.69* 11.56* 10.05*


14.69* 11.56* 8.88

8.09*
6.29

20.76* 14.49* 11.62*


18.90 12.10
8.39

9.68
6.04

24.56* 16.88* 12.79


17.62 11.35
7.96

9.46
5.81

13.06* 25.71* 17.90


13.06* 17.16 10.92

12.48
7.68

15.60* 22.51* 25.00* 17.77


15.60* 22.51* 17.15 10.80

12.39
7.59

SECONDARY EXIT
Use tool to break window.

9.31
5.67

Always keep tool in machine.


T190393

29.63* 22.54* 16.71* 12.31


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

HYEX01532

T218383

Figure 12.

Side Window.

0027-6

TM 5-3805-294-10

0027

DECALS - Continued

CAUTION

ATTACHMENT MODE SELECTION PROCEDURE


1. Press Key F1 to display the work
mode screen.
2. While referring to the table below,
press the key corresponding to the
attachment mode you are going to use.
Attachment
to be used
Bucket or
Thumb

Attachment mode
Key No.
to be selected
1

Excavation

Hammer/
Breaker
Alternative
Hammer/Breaker

Breaker 1

Breaker 2

Pulverizer

Pulverizer 1

Crusher

Crusher 1

Work Mode
Breaker 2

Dig

Breaker 1

Pulverizer 1

To prevent injury from the


front window falling, lock
window in place with the
lock pin.
T187353

Crusher 1

F1

F2

F3

F4

DANGER

2
F1

Serious injury or death


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

WORK MODE SCREEN

3. The specifications of the selected


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

Crusher 1
Maximum Pump Flow Rate

420 L/min

Maximum Engine Speed

1900 min-1

Valve Selector C/V

Accumulator

2-Speed Selector ON

2ndary Hydraulic Relief Selector OFF

OFF

T146667

F1

F2

F3

F4

CONFIRM
ATTACHMENT SPECIFICATION SCREEN

Affix this label to interior glass of operator's cab

T223619

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

HYEX01533

Figure 13.

Upper and Lower Right Side Window.

0027-7

TM 5-3805-294-10

0027

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

min1

ENGINE RPM CONTROL


Turn CW to increase
Turn CCW to decrease

A/I

H/P
P
E

AVOID DEATH OR SERIOUS INJURY - READ AND UNDERSTAND THE


OPERATOR'S MANUAL AND SAFETY MANUAL PRIOR TO OPERATING
THIS MACHINE.
Controls may be changed for attachment or operator preference. Try
control pattern before operating.
Always lower working tools to the ground and engage hydraulic control
lockout lever before leaving operator's seat.
Keep riders off machine.

AUTOMATIC SPEED CHANGE


OFF

CAUTION

Avoid contact between boom/attachments and overhead obstacles


whenever operating, traveling or transporting machine.

A/I - Auto Idle


Engine speed is temporarily reduced, if
control levers are in Neutral for 4 seconds.

Keep bystanders clear of machine; especially before moving boom,


swinging upperstructure or traveling.

POWER MODE
H/P - Select for heavy digging, maximum productivity.

Upperstructure position affects travel direction. Try pedals or levers to


determine travel direction before moving machine.

P - Select for standard digging


E - Select for light digging, maximum fuel economy.

Avoid tipping - Do not lift or move objects that exceed machine stability.
T219580

Avoid parking machine on an incline.

T159887

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

Figure 14. Lower Right Side Window.

0027-8

TM 5-3805-294-10

0027

DECALS - Continued

1.
2.

3.

COVERS ARE SHOWN BELOW TO AID IN


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

2
1

1
2

CAB, REAR

CAB, RIGHT SIDE

CAB, FRONT

CAB, LEFT SIDE


T218467

HYEX01538

Figure 15.

Vandal Protection Kit.

0027-9

TM 5-3805-294-10

0027

DECALS - Continued

240DLCR PERIODIC MAINTENANCE

T260750

REFER TO OPERATOR'S MANUAL FOR DETAILED INFORMATION


INTERVAL
HOURS

ITEM
NO.

AS
REQUIRED

4
23
24
26

FUEL TANK INLET SCREEN


WINDSHIELD WASHER FLUID
AIR CLEANER
TRACK SAG

1
1
1
2

REMOVE AND CLEAN (A)


ADD AS REQUIRED
CHECK - CLEAN DUST VALVE AND/OR ELEMENT (A)
CHECK - ADJUST (A)

HYDRAULIC SYSTEM OIL LEVEL

16
20

ENGINE OIL LEVEL


ENGINE COOLANT LEVEL

1
1

CHECK WITH EXTENDED BUCKET CYLINDER,


RETRACTED ARM CYLINDER AND BUCKET ON GROUND (A)
CHECK (A)
COOLANT LEVEL TO BE ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD

5
12

FUEL TANK SUMP


WATER SEPARATOR

1
1

DRAIN WATER AND SEDIMENT (A)


DRAIN WATER

29

WORKING TOOL PIVOTS

GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS


FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS. GREASE
DAILY WHEN WORKING IN WATER

3
6
10
12
14
16
19
20
21
22
24

SWING GEARBOX OIL LEVEL


HYDRAULIC TANK SUMP
ENGINE OIL FILTER
DOSER ELEMENT
PUMP DRIVE GEARBOX
ENGINE OIL
A/C BELT
RADIATOR COOLANT LEVEL
BATTERY WATER LEVEL
TRAVEL GEARBOX OIL LEVEL
AIR CLEANER

1
1
1
1
1
1
1
1
2
2
1

CHECK DIPSTICK
DRAIN WATER SEDIMENT (A)
REPLACE (A) (C)
REPLACE (A)
CHECK DIPSTICK
DRAIN AND REFILL
CHECK AND ADJUST
CHECK - LEVEL IN BOTTLE BETWEEN "MAX COLD" AND "MIN COLD" MARKS (A)
CHECK - TO BOTTOM OF FILLER NECK - CLEAN AND TIGHTEN TERMINALS
CHECK - REMOVE PLUG
CLEAN ELEMENT

FRONT END PIN JOINTS

16

2
10
12
13
16
18
25
27
28

SWING BEARING GEAR


ENGINE OIL FILTER
WATER SEPARATOR FILTER
FUEL FILTER
ENGINE OIL
AIR INTAKE HOSES
FRESH AIR FILTER
CAB RECIRCULATING AIR FILTER
SWING BEARING

1
1
1
1
1
2
1
1
2

GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR
FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS.
GREASE DAILY WHEN WORKING IN WATER
GREASE - ADD 1 LB. [0.5 Kg] (A) (D)
REPLACE (A) (C)
REPLACE (A)
REPLACE - 500 HOURS OR AS REQUIRED (A)
DRAIN AND REFILL (B) (C)
CHECK FOR CRACKS AND LOOSE CONNECTIONS (A)
CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS
CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS
GREASE - 8 SHOTS EACH - EVERY 45 FOR ONE REVOLUTION (A)

3
9
11
14
15
19
24

SWING GEAR BOX OIL


HYDRAULIC OIL FILTER
PILOT CONTROL OIL FILTER
PUMP DRIVE GEARBOX
ENGINE CRANKCASE VENT TUBE
SERPENTINE BELT
AIR CLEANER

1
1
1
1
1
1
1

DRAIN AND REFILL (A)


REPLACE (A)
REPLACE (A)
DRAIN AND REFILL
REMOVE AND CLEAN (A)
INSPECT AND REPLACE AS NECESSARY
REPLACE ELEMENTS AND DUST VALVE

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

8
17
20

HYDRAULIC SYSTEM OIL


ENGINE VALVE LASH
RADIATOR

1
1
1

HYDO-SEE LUBRICANTS

22

TRAVEL GEARBOX OIL

DRAIN AND REFILL EVERY 2000 HOURS. CLEAN SUCTION SCREEN (A)
REFER TO SERVICE MANUAL
DRAIN, FLUSH AND REFILL WITH PROPER COOLANT. FILL RADIATOR, FILL BOTTLE
TO ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD (A)
DRAIN AND REFILL EACH (A)

10
OR
DAILY
50
OR WEEKLY

MAINTENANCE
POINTS

ITEM

100

250

500

1000

2000

DESCRIPTION

APPROVED MATERIAL

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

MPGM-SEE LUBRICANTS

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

MPGM-SEE LUBRICANTS

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

JD FILTER AND VALVE

PROPER COOLANT (A)


MPL-SEE LUBRICANTS

HYEX01534

Figure 16. Upper Section Periodic Maintenance.

0027-10

TM 5-3805-294-10

0027

DECALS - Continued

(A) SEE OPERATOR'S MANUAL.


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

DRAIN AND REFILL CAPACITIES


ITEM

U.S. MEASURE

FUEL TANK
COOLING SYSTEM
ENGINE CRANKCASE
(INCLUDING FILTER)
HYDRAULIC RESERVOIR
HYDRAULIC SYSTEM
SWING BEARING GEAR
SWING GEAR REDUCTION
TRAVEL GEARBOX (EACH)
PUMP DRIVE GEARBOX

132 GAL
31.6 QT
26 QT
(6.5 GAL)
39 GAL
63.4 GAL
22 LB
7.5 QT
6.5 QT
1.2 QT

METRIC
500 L
29.9 L
24.6 L
147.6 L
240 L
10 Kg
7L
6.2 L
1.1 L

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

[EO] ENGINE OIL

SAE 15W40

USE JOHN DEERE PLUS 50


ENGINE OILS MEETING: MILITARY SPECIFICATIONS MIL-PRF-2104
VISCOSITY GRADE SAE 15W40 IS PREFERRED
(1) - MAY USE MIL-PRF-46167 ARCTIC OIL
BUT DRAIN INTERVAL IS REDUCED TO ONE-HALF OF NORMAL

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

[HYDO] HYDRAULIC OIL

SAE 10W30

2000 HOUR CHANGE INTERVAL


FACTORY FILLED WITH JD PLUS 50 10W30
MEETING MILITARY SPECIFICATIONS MIL-PRF-2104
MEETING MILITARY SPECIFICATIONS ARTIC MIL-PRF-46167
MEETING MILITARY SPECIFICATIONS BIOBASED MIL-PRF-32073

SAE 5W30
SAE 15W40
MIL-46167
MIL-32073-GR1
MIL-32073-GR5
SAE 90: 85W140

[MPL] MULTIPURPOSE LUBRICANT


USE

SAE 80W90

JOHN DEERE API GL-5 GEAR OIL

SAE 75W

OILS MEETING API GL-5 OR MILITARY SPECIFICATIONS


MIL-L-2105B OR MIL-L-2105C

ARCTIC OIL

[MPGM] MULTIPURPOSE GREASE WITH MOLYBDENUM DISULFIDE


NLGI NO. 2
J.D. HIGH TEMP/EP

USE JOHN DEERE MOLY HIGH-TEMPERATURE EXTREME


PRESSURE (EP) GREASE
SAE MULTIPURPOSE EP GREASE CONTAINING 3 TO 5%
MOLYBDENUM DISULFIDE

NLGI NO. 0 OR 1
ARCTIC GREASE

HYEX01535

Figure 17.

Lower Section Periodic Maintenance.


0027-11

TM 5-3805-294-10

0027

DECALS - Continued

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

HYEX01441

Figure 18. Ditch Cleaning Bucket.

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

HYEX01440

Figure 19.

Heavy Duty Bucket.

0027-12

TM 5-3805-294-10

0027

DECALS - Continued

HYEX01437

Figure 20.

Right Side Crush-All.

HYEX01438

Figure 21.

Left Side Crush-All.

0027-13

TM 5-3805-294-10

0027

DECALS - Continued

DANGER

DANGER

SHUT OFF
EXCAVATOR PRIOR
TO MAINTENANCE

ALL PERSONNEL
STAND CLEAR
FLYING DEBRIS

DANGER

DANGER

HIGH PRESSURE
HYDRAULIC
SYSTEM

DO NOT OPERATE
WITHOUT GUARDS

HYEX01439

Figure 22. Output Side Crush-All.


END OF TASK
END OF WORK PACKAGE

0027-14

TM 5-3805-294-10

0028

OPERATOR MAINTENANCE
TOWING THE HYEX

INITIAL SETUP:
Not Applicable

TOWING

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

0028-1/2 blank

TM 5-3805-294-10

0029

OPERATOR MAINTENANCE
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE

INITIAL SETUP:
Not Applicable

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

0029-1/2 blank

TM 5-3805-294-10

0030

OPERATOR MAINTENANCE
OPERATING IN COLD WEATHER 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.

Press and hold back button.

BACK BUTTON

HYEX01413

Figure 1.
2.

Press and Hold Back Button.

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

0030-1

TM 5-3805-294-10

0030

STARTING - Continued

HYEX01414

Figure 2.

Key Switch to ON Position.

3.

Release back button when monitor goes to default screen.

4.

Press menu button.

BACK
BUTTON

MENU
BUTTON

Figure 3.
5.

Release Back Button.

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

0030-2

HYEX01415

TM 5-3805-294-10

0030

STARTING - Continued
Main Menu
Fuel Rate Display/No Display
Back Monitor Settings

SERVICE
MENU

Language/
Service Menu

SELECT
BUTTON
1

BUTTON 1

F1

F2

F3

F4

BUTTON 2
HYEX01416

Figure 4.

Highlight Service Menu.

6.

Press the select button.

7.

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

MONITORING

SELECT
BUTTON

BUTTON 2
1

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

Coolant Temperature (E)

0 oC

Actual Engine Speed

Fuel Temperature

0 oC

ON
1

F1

F2

F3

F4

HYEX01418

Figure 6. Temperatures Displayed.

NOTE
If hydraulic oil temperature is 32F (0C) or below, engine will run at 1400 rpm for 15 minutes
or until hydraulic oil temperature reaches 36F (2C).
9.

Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.

HYEX01419

Figure 7.
10.

Start Engine.

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

0030-4

TM 5-3805-294-10

0030

STARTING - Continued

HYEX01420

Figure 8.
11.

Engine Speed Dial.

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

Monitoring
Hydraulic Oil Temperature

0 oC

Coolant Temperature (E)

0 oC

Actual Engine Speed

Fuel Temperature

0 oC

ON
1

F1

F2

F3

F4

HYEX01418

Figure 9.

Check Engine and Hydraulic Oil Temperatures.

NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders
are fully raised, the overload alarm may sound even if the machine is not in an overload
condition. Lower the boom cylinders until the alarm is no longer displayed.
12.

Set machine switch selections for temperatures between 5 and 32F (-15 and 0C) per Table 1.

0030-5

TM 5-3805-294-10

0030

STARTING - Continued
Table 1.

Machine Switch Selections.

Engine Speed

Speed Dial to Half Speed

Power Mode Switch Position

High Power (HP) Mode

Auto-Idle (A/I) Switch Position

OFF

Travel Speed Switch

Slow (Turtle)

13.

Select dig mode on monitor. (WP 0018)

WARNING

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

CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
14.

Operate swing, boom, arm, hydraulic thumb, and bucket functions slowly and short distances initially in each
direction. (WP 0004)

15.

Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is
obtained.

16.

Swing upperstructure (Figure 10, Item 3) 90 degrees.

5
6

3
7

Figure 10.

HYEX01421

Raise Machine.

17.

Place round side of bucket (Figure 10, Item 4) on ground.

18.

Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees,
slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.

0030-6

TM 5-3805-294-10

0030

STARTING - Continued
19.

Operate travel lever for raised track for approximately 5 minutes. (WP 0004)

20.

Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.

21.

Repeat Steps 14 to 18 for opposite track.

END OF TASK
END OF WORK PACKAGE

0030-7/8 blank

TM 5-3805-294-10

0031

OPERATOR MAINTENANCE
OPERATING IN COLD WEATHER 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.

Press and hold back button.

BACK
BUTTON

HYEX01423

Figure 1.

Press and Hold Back Button.

0031-1

TM 5-3805-294-10

0031

STARTING - Continued
3.

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

HYEX01424

Figure 2.
4.

Key Switch to ON Position.

Release back button when monitor goes to default screen.

BACK
BUTTON

MENU
BUTTON

Figure 3.

Release Back Button.

5.

Press menu button.

6.

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

0031-2

HYEX01415

TM 5-3805-294-10

0031

STARTING - Continued
Main Menu
Fuel Rate Display/No Display
Back Monitor Settings

SERVICE
MENU

Language/
Service Menu

SELECT
BUTTON
1

BUTTON 1

F1

F2

F3

F4

BUTTON 2
HYEX01430

Figure 4.

Highlight Service Menu.

7.

Press the select button.

8.

Press button one or button two until monitoring is highlighted, then press the select button.

MONITORING

Service Menu
Troubleshooting
Monitoring
Ver. Controller Version

SELECT
BUTTON
1

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

Coolant Temperature (E)

0 oC

Actual Engine Speed

Fuel Temperature

0 oC

ON
1

F1

F2

F3

F4

HYEX01432

Figure 6. Temperatures Displayed.

NOTE
If hydraulic oil temperature is 32F (0C) or below, engine will run at 1400 rpm for 15 minutes
or until hydraulic oil temperature reaches 36F (2C).
10.

Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.

HYEX01433

Figure 7.
11.

Start Engine.

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

0031-4

TM 5-3805-294-10

0031

STARTING - Continued

HYEX01434

Figure 8.
12.

Engine Idle Speed.

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

Monitoring
Hydraulic Oil Temperature

0 oC

Coolant Temperature (E)

0 oC

Actual Engine Speed

Fuel Temperature

0 oC

ON
1

F1

F2

F3

F4

HYEX01432

Figure 9.

Monitor Temperatures Displayed.

0031-5

TM 5-3805-294-10

0031

STARTING - Continued

NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders
are fully raised, the overload alarm may sound even if the machine is not in an overload
condition. Lower the boom cylinders until the alarm is no longer displayed.
13.

Set machine switch selections for temperatures between 5F (-15C) and below per Table 1.
Table 1.

Machine Switch Selection.

Machine Specification

Temperatures 5 to 0F (-15 to
-18C)

Temperature Below 0F (-18C)

Engine Speed

Speed Dial to Half Speed

Speed Dial to Half Speed

Power Mode Switch Position

High Power (HP) Mode

Economy (E) Mode

Auto-Idle (A/I) Switch Position

OFF

OFF

Travel Speed Switch

Slow (Turtle)

Slow (Turtle)

14.

Select dig mode on monitor. (WP 0018)

WARNING

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

CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
15.

Operate swing, boom, arm, and bucket functions slowly and short distances initially in each direction.
(WP 0004)

16.

Continue cycling cylinders by increasing travel each cycle until full smooth movement of function is obtained.

17.

Swing upperstructure (Figure 10, Item 3) 90 degrees.

0031-6

TM 5-3805-294-10

0031

STARTING - Continued

5
6

3
7

Figure 10.

HYEX01435

Raise Machine.

18.

Place round side of bucket (Figure 10, Item 4) on ground.

19.

Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees,
slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.

20.

Operate travel lever for raised track for approximately 5 minutes. (WP 0004)

21.

Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.

22.

Repeat Steps 15 to 19 for opposite track.

END OF TASK
END OF WORK PACKAGE

0031-7/8 blank

TM 5-3805-294-10
OPERATOR MAINTENANCE
SLAVE STARTING

INITIAL SETUP:
References
WP 0007

SLAVE STARTING

WARNING

An explosive gas is produced while batteries are in use or being charged. Keep flames and
sparks away from battery area. Ensure batteries are charged in a well-ventilated area. Failure
to comply may result in injury or death to personnel.

NOTE
Ensure that booster vehicle is equipped with a slave receptacle.
1.

Contact Field Maintenance to get a slave cable.

2.

Connect the slave cable to booster vehicle slave receptacle.

3.

Remove cap (Figure 1, Item 1) from slave receptacle (Figure 1, Item 2).

0032-1

0032

TM 5-3805-294-10

0032

SLAVE STARTING - Continued

HYEX00866

Figure 1.

Slave Receptacle.

4.

Connect slave cable to slave receptacle (Figure 1, Item 2).

5.

Run booster vehicle at a speed just above idle. Refer to booster vehicle Operator's Manual.

6.

Start engine. (WP 0007)

7.

After starting machine, return booster vehicle to idle. Refer to booster vehicle Operator's Manual.

8.

Remove the slave cable from slave receptacle (Figure 1, Item 2).

9.

Install cap (Figure 1, Item 1) to slave receptacle (Figure 1, Item 2).

10.

Remove slave cable from booster vehicle.

END OF TASK
END OF WORK PACKAGE

0032-2

TM 5-3805-294-10

0033

OPERATOR MAINTENANCE
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)

INITIAL SETUP:
Not Applicable

SKYLIGHT WINDOW (SECONDARY EXIT)


1.

Slide back liner.

2.

Release two latches (Figure 1, Item 1).

HYEX00943

Figure 1.
3.

Open and Close Roof Exit.

Push on handle (Figure 1, Item 2) and exit machine.

END OF TASK
REAR WINDOW (EMERGENCY EXIT)
1.

Remove emergency exit tool (Figure 2, Item 3) from holder (Figure 2, Item 4).

0033-1

TM 5-3805-294-10

0033

REAR WINDOW (EMERGENCY EXIT) - Continued

HYEX00944

Figure 2. Emergency Exit Tool.

WARNING

When using emergency exit tool to break glass, shield eyes and face from broken glass.
Failure to comply may result in injury or death to personnel.
2.

Using emergency exit tool (Figure 2, Item 3) smash rear window (Figure 2, Item 5). One or two strikes with
emergency exit tool (Figure 2, Item 3) should shatter glass.

3.

Push remaining glass from window edges and exit machine.

END OF TASK
END OF WORK PACKAGE

0033-2

TM 5-3805-294-10
OPERATOR MAINTENANCE
OPERATING THE COOLANT HEATER

INITIAL SETUP:
Not Applicable

COOLANT HEATER OPERATION

WARNING

The coolant heater must be switched off while the fuel tank on the machine is being filled.
Failure to comply may result in injury or death to personnel.
DO NOT operate engine or coolant heater in a closed place without proper ventilation.
Failure to comply may result in injury or death to personnel.

CAUTION
If a fault arises during coolant heater operation, the heat symbol will flash on the control panel
display and a three-digit fault code will be displayed. Shut down the coolant heater and notify
field maintenance. Failure to comply may result in damage to equipment.

NOTE
Coolant heater is only required to be used when temperature is -25 F (-32 C) or colder.
The timer can control operation of the coolant heater for up to 7 days in advance.
The default timer setting is for the coolant heater to operate for 120 minutes before
automatically turning off.

0034-1

0034

TM 5-3805-294-10

0034

COOLANT HEATER OPERATION - Continued


1.

The coolant heater control panel (Figure 1, Item 1) is located on left outer console of operator's seat.

2
1
M0

20:30

HYEX00023

Figure 1. Coolant Heater Control Panel.


2.

The coolant heater control panel display (Figure 1, Item 2) indicates a weekday and time and allows
programming of heater cycle times.

END OF TASK
ADJUSTING COOLANT HEATER TIME AND DAY

NOTE
All symbols will flash on coolant heater control panel (Figure 2, Item 1) display after extended
power loss. The clock requires resetting to ensure proper operation of the coolant heater.
1.

Push and hold clock button (Figure 2, Item 3) until time (Figure 2, Item 4) indicator begins to flash.

M0

3 20:30

HYEX00022

Figure 2. Adjusting Time and Day.


2.

Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust time up or down.

3.

When time is correct wait approximately 5 seconds and day (Figure 2, Item 7) will begin to flash.

4.

Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust day (Figure 2,
Item 7) up or down.

5.

When day (Figure 2, Item 7) is correct wait approximately 5 seconds and day will stop flashing.

0034-2

TM 5-3805-294-10

0034

ADJUSTING COOLANT HEATER TIME AND DAY - Continued


6.

Time (Figure 2, Item 4) and day (Figure 2, Item 7) is set.

END OF TASK
SETTING AND SELECTING COOLANT HEATER PROGRAM

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

Press the preset button (Figure 3, Item 8) until the desired program number (Figure 3, Item 9) begins to flash.

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.

Start time (Figure 3, Item 4) and day (Figure 3, Item 7) is set.

7.

Program number (Figure 3, Item 9) will be displayed.

8.

Repeat Steps 1 through 7 if additional days of programing is desired.

END OF TASK
ADJUSTING COOLANT HEATER RUN TIME

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

0034-3

TM 5-3805-294-10

0034

ADJUSTING COOLANT HEATER RUN TIME - Continued


Adjusting the run time must be performed every time a start program is selected.
1.

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

120

10

HYEX00021

Figure 4. Adjusting Run Time.


2.

Press the left arrow button (Figure 4, Item 5) or right arrow button (Figure 4, Item 6) to adjust run time (Figure
4, Item 11) up or down.

3.

After desired run time (Figure 4, Item 11) is selected, wait approximately 5 seconds and run time is set.

END OF TASK
USING COOLANT HEATER MANUALLY
1.

Press heater button (Figure 5, Item 10) and the coolant heater will start and run.

11

120

10
Figure 5.

HYEX00020

Manually Start Coolant Heater.

2.

If desired, press the left arrow button (Figure 5, Item 5) or right arrow button (Figure 5, Item 6) to adjust run
time (Figure 5, Item 11) up or down.

3.

To manually shut coolant heater off press the heater button (Figure 6, Item 10). The coolant heater will do a
normal cool-down cycle and then turn itself off.

0034-4

TM 5-3805-294-10

0034

USING COOLANT HEATER MANUALLY - Continued

11

120

10
Figure 6.

HYEX00020

Manually Start Coolant Heater Continued.

END OF TASK
END OF WORK PACKAGE

0034-5/6 blank

TM 5-3805-294-10

0035

OPERATOR MAINTENANCE
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES

INITIAL SETUP:
Not Applicable

PULLING MACHINE UP

WARNING

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

Buckle seat belt (Figure 1, Item 1).

HYEX00687

Figure 1.
2.

Buckle Seat Belt.

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

0035-1

TM 5-3805-294-10

0035

PULLING MACHINE UP - Continued

4
5

HYEX00674

Figure 2. Pulling Machine Up.


3.

Push bucket (Figure 2, Item 4) into the ground on the top of the slope.

4.

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

END OF TASK
PUSHING MACHINE UP

WARNING

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

Buckle seat belt (Figure 3, Item 1).

0035-2

TM 5-3805-294-10

0035

PUSHING MACHINE UP - Continued

HYEX00687

Figure 3.
2.

Buckle Seat Belt.

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

3
6

HYEX00677

Figure 4.
3.

Pushing Machine.

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

0035-3

TM 5-3805-294-10

0035

PUSHING MACHINE UP - Continued


4.

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

END OF TASK
TRAVELING DOWN

WARNING

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

Position undercarriage so travel motors (Figure 5, Item 2) will be on the uphill end of machine (Figure 5, Item
3).

3
6

HYEX00677

Figure 5.
2.

Traveling Down.

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

0035-4

TM 5-3805-294-10
TRAVELING DOWN - Continued
3.

Slowly travel down the slope.

END OF TASK
END OF WORK PACKAGE

0035-5/6 blank

0035

TM 5-3805-294-10

0036

OPERATOR MAINTENANCE
FORDING THE HYEX

INITIAL SETUP:
References
WP 0093

FORDING

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

NOTE
Use travel control levers during fording operations to maintain better control of machine
speed.
1.

Ensure bottom at fording site is firm enough that 40 in. (1 m) maximum fording depth will not be exceeded and
machine will not become mired.

HYEX01311

Figure 1.

Fording Line.

2.

Ensure that engine is operating normally and is at normal operating temperature.

3.

Move pilot shutoff lever (Figure 2, Item 1) to unlocked (down) position.

0036-1

TM 5-3805-294-10

0036

FORDING - Continued

Figure 2.
4.

HYEX00367

Pilot Shutoff Lever.

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

5
2

Figure 3.

HYEX00368

Check Monitor.

5.

Position travel speed selector (Figure 3, Item 3) in slow position.

6.

Raise engine speed dial (Figure 3, Item 4) to 1/3 throttle position.

7.

Move travel levers (Figure 3, Item 5) forward 1/4 travel.

8.

Enter the water slowly to minimize surges of backwash into the upperstructure.

9.

If machine accidently enters water deeper than 40 in. (1.0 m), move travel levers (Figure 3, Item 5) back 1/4
travel and slowly back machine out of deep water.

0036-2

TM 5-3805-294-10
FORDING - Continued
10.

After fording perform, maintenance after fording. (WP 0093)

END OF TASK
END OF WORK PACKAGE

0036-3/4 blank

0036

TM 5-3805-294-10

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

TM 5-3805-294-10

0037

OPERATOR MAINTENANCE
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE

TROUBLESHOOTING SYMPTOM INDEX


Malfunction/Symptom

Troubleshooting Procedure

ELECTRICAL SYSTEM
1.

Travel Alarm Does Not Operate ....................................................................................................... WP 0038

2.

Windshield Wiper and Washer Do Not Operate ............................................................................... WP 0039

3.

Cab Dome Light Does Not Operate ................................................................................................. WP 0040

4.

Boom, Cab, And Drive Lights Do Not Operate ................................................................................. WP 0041

5.

Cab Front Work Lights Do Not Operate ........................................................................................... WP 0042

6.

Cab Rear Work Lights Do Not Operate ............................................................................................ WP 0043

7.

Low Note and High Note Horns Do Not Operate ............................................................................. WP 0044

8.

Air Conditioner Does Not Operate ................................................................................................... WP 0045

ENGINE
1.

Engine Cranks But Will Not Start Or Hard To Start .......................................................................... WP 0046

2.

Engine Will Not Crank ...................................................................................................................... WP 0047

3.

Engine Runs Poorly ......................................................................................................................... WP 0048

4.

Excessive Fuel Consumption ........................................................................................................... WP 0049

5.

Excessive Oil Consumption .............................................................................................................. WP 0050

6.

Engine Idles Poorly .......................................................................................................................... WP 0051

7.

Auto-Idle Does Not Work ................................................................................................................. WP 0052

8.

Engine Not Developing Full Power .................................................................................................. WP 0053

9.

Engine Oil Pressure Low .................................................................................................................. WP 0054

10.

Engine Coolant Temperature Above Normal ................................................................................... WP 0055

11.

Engine Emits Excessive Black Or Gray Exhaust Smoke ................................................................. WP 0056

12.

Engine Emits Excessive White Exhaust Smoke ............................................................................... WP 0057

HYDRAULICS SYSTEM
1.

No Hydraulic Functions .................................................................................................................... WP 0058

2.

Hydraulic Functions Are Slow Or Have Little Or No Power .............................................................. WP 0059

3.

Power Dig Does Not Work ............................................................................................................... WP 0060

4.

Hydraulic Oil Overheats ................................................................................................................... WP 0061

5.

Hydraulic Oil Foams ......................................................................................................................... WP 0062

0037-1

TM 5-3805-294-10

0037

TROUBLESHOOTING SYMPTOM INDEX - Continued


Malfunction/Symptom

Troubleshooting Procedure

6.

No Swing Function ........................................................................................................................... WP 0063

7.

Swing Function Is Jerky ................................................................................................................... WP 0064

8.

Slow Travel Speed Only ................................................................................................................... WP 0065

9.

Travel Is Jerky .................................................................................................................................. WP 0066

10.

Engine Stops When Travel Or Control Lever Actuated .................................................................... WP 0067

11.

Quick Latch Does Not Operate ........................................................................................................ WP 0068

12.

Compactor Does Not Operate .......................................................................................................... WP 0069

13.

Breaker Does Not Operate ............................................................................................................... WP 0070

14.

Breaker Operates Slowly ................................................................................................................. WP 0071

15.

Crush-All Does Not Operate ............................................................................................................ WP 0072

16.

Barrier Grapple Does Not Hold Load ............................................................................................... WP 0073

17.

Deep Dig Does Not Operate ............................................................................................................ WP 0074

18.

Hydraulic Hose Reel Does Not Operate ........................................................................................... WP 0075

END OF WORK PACKAGE

0037-2

TM 5-3805-294-10

0038

OPERATOR MAINTENANCE
TRAVEL ALARM DOES NOT OPERATE

INITIAL SETUP:
References
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Travel Alarm Does Not Operate.
Malfunction
Travel Alarm Fuse
Blown.

Test or Inspection
1.

Remove F5 OPT.1 (ALT) 5A


fuse. (WP 0084)

2.

Visually inspect F5 OPT.1


(ALT) 5A fuse for blown fuse.

END OF WORK PACKAGE

0038-1/2 blank

Corrective Action

1.

If fuse blown, replace F5 OPT.


1 (ALT) 5A fuse. (WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0039

OPERATOR MAINTENANCE
WINDSHIELD WIPER AND WASHER DO NOT OPERATE

INITIAL SETUP:
References
WP 0009
WP 0011
WP 0084

Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Windshield Wiper and Washer Do Not Operate.
Malfunction
1.

2.

Upper Front
Window Not Fully
Closed.

Windshield Wiper
and Washer Fuse
Blown.

Test or Inspection
1.

If machine is equipped with a


Supplemental Armor Set,
proceed to Malfunction 2.

2.

Check upper front window to


ensure window is fully closed.
(WP 0011)

1.

Shut engine off. (WP 0009)

2.

Remove F2 WIPER 10A fuse.


(WP 0084)

3.

Visually inspect F2 WIPER


10A fuse for blown fuse.

END OF WORK PACKAGE

0039-1/2 blank

Corrective Action

1.

If fully closed, proceed to


Malfunction 2.

2.

If not fully closed, readjust and


close upper front window.
(WP 0011)

1.

If fuse blown, replace F2


WIPER 10A fuse. (WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0040

OPERATOR MAINTENANCE
CAB DOME LIGHT DOES NOT OPERATE

INITIAL SETUP:
References
WP 0004
WP 0009
WP 0084

Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Cab Dome Light Does Not Operate.
Malfunction
1.

2.

Test or Inspection

Cab Dome Light


Switch is OFF (up).

Radio and Dome


Light Fuse Blown.

Check cab dome light switch


position. (WP 0004)

1.

Shut engine off. (WP 0009)

2.

Remove F11 RADIO 5A fuse.


(WP 0084)

3.

Visually inspect F11 RADIO


5A fuse for blown fuse.

END OF WORK PACKAGE

0040-1/2 blank

Corrective Action
1.

If switch is ON (down), proceed


to Malfunction 2.

2.

If switch is OFF (up), position


cab dome light switch ON
(down). (WP 0004)

1.

If fuse blown, replace F11


RADIO 5A fuse. (WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0041

OPERATOR MAINTENANCE
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE

INITIAL SETUP:
References
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Boom, Cab, And Drive Lights Do Not Operate.
Malfunction
Work and Drive
Lights Fuse Blown.

Test or Inspection
1.

Remove F1 LAMP 20A fuse.


(WP 0084)

2.

Visually inspect F1 LAMP 20A


fuse for blown fuse.

END OF WORK PACKAGE

0041-1/2 blank

Corrective Action

1.

If fuse blown, replace F1 LAMP


20A fuse. (WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0042

OPERATOR MAINTENANCE
CAB FRONT WORK LIGHTS DO NOT OPERATE

INITIAL SETUP:
References
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Cab Front Work Lights Do Not Operate.
Malfunction
Cab Front Work
Lights Fuse Blown.

Test or Inspection
1.

Remove F22 CAB LAMP


FRONT 10A fuse. (WP 0084)

2.

Visually inspect F22 CAB


LAMP FRONT 10A fuse for
blown fuse.

END OF WORK PACKAGE

0042-1/2 blank

Corrective Action

1.

If fuse blown, replace F22 CAB


LAMP FRONT 10A fuse.
(WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0043

OPERATOR MAINTENANCE
CAB REAR WORK LIGHTS DO NOT OPERATE

INITIAL SETUP:
References
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Cab Rear Work Lights Do Not Operate.
Malfunction
Cab Rear Work
Lights Fuse Blown.

Test or Inspection
1.

Remove F23 CAB LAMP


REAR 10A fuse. (WP 0084)

2.

Visually inspect F23 CAB


LAMP REAR 10A fuse for
blown fuse.

END OF WORK PACKAGE

0043-1/2 blank

Corrective Action

1.

If fuse blown, replace F23 CAB


LAMP REAR 10A fuse.
(WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0044

OPERATOR MAINTENANCE
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE

INITIAL SETUP:
References
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Low Note And High Note Horns Do Not Operate.
Malfunction
Horn Fuse Blown.

Test or Inspection
1.

Remove F17 HORN 10A


fuse. (WP 0084)

2.

Visually inspect F17 HORN


10A fuse for blown fuse.

END OF WORK PACKAGE

0044-1/2 blank

Corrective Action

1.

If fuse blown, replace F17


HORN 10A fuse. (WP 0084)

2.

If fuse not blown, notify Field


Maintenance.

TM 5-3805-294-10

0045

OPERATOR MAINTENANCE
AIR CONDITIONER DOES NOT OPERATE

INITIAL SETUP:
References
WP 0077
WP 0084
WP 0089
WP 0090

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Air Conditioner Does Not Operate.
Malfunction
1.

2.

3.

Air Conditioner and


Heater 5A Fuse
Blown.

Air Conditioner and


Heater 20A Fuse
Blown.

Fresh Air Filter


Clogged or
Damaged.

Test or Inspection
1.

Remove F15 AIRCON 5A


fuse. (WP 0084)

2.

Visually inspect F15 AIRCON


5A fuse for blown fuse.

1.

Remove F3 HEATER 20A


fuse. (WP 0084)

2.

Visually inspect F3 HEATER


20A fuse for blown fuse.

1.

Remove fresh air filter.


(WP 0089)

2.

Visually inspect fresh air filter


and housing for clog and
damage.

0045-1

Corrective Action

1.

If fuse blown, replace F15


AIRCON 5A fuse. (WP 0084)

2.

If fuse not blown, proceed to


Malfunction 2.

1.

If fuse blown, replace F3


HEATER 20A fuse.
(WP 0084)

2.

If fuse not blown, proceed to


Malfunction 3.

1.

If clogged, service fresh air


filter and housing. (WP 0089)

2.

If damaged, notify Field


Maintenance.

3.

If not clogged and not


damaged, proceed to
Malfunction 4.

TM 5-3805-294-10

0045

Table 1. Air Conditioner Does Not Operate - Continued.


Malfunction
4.

5.

6.

Air Conditioner/
Heater Filter
Clogged or
Damaged.

Air Conditioner
Condenser Dirty or
Damaged.

Air Conditioner Belt


Worn or Damaged.

Test or Inspection
1.

Remove air conditioner/heater


filter. (WP 0090)

2.

Visually inspect air


conditioner/heater filter and
housing for clog and damage.

Visually inspect air


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

Visually inspect air conditioner


belt for wear and damage.
(WP 0077)

END OF WORK PACKAGE

0045-2

Corrective Action

1.

If clogged, service air


conditioner/heater filter and
housing. (WP 0090)

2.

If damaged, notify Field


Maintenance.

3.

If not clogged and not


damaged, proceed to
Malfunction 5.

1.

If dirty, clean air conditioner


condenser. (WP 0077)

2.

If damaged, notify Field


Maintenance.

3.

If not dirty and not damaged,


proceed to Malfunction 6.

1.

If worn or damaged, notify


Field Maintenance.

2.

If not worn and not damaged,


notify Field Maintenance.

TM 5-3805-294-10

0046

OPERATOR MAINTENANCE
ENGINE CRANKS BUT DOES NOT START OR HARD TO START

INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077

References (cont.)
WP 0086
WP 0087
Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Cranks But Does Not Start or Hard to Start.
Malfunction
1.

2.

3.

Test or Inspection

Engine Cranks
Slowly.

Fuel Level Low.

Air Cleaners Dirty


or Clogged.

Crank engine. (WP 0007)

1.

Turn key switch to ON position,


but DO NOT START ENGINE.
(WP 0007)

2.

Visually inspect monitor to


verify at least 1/4 tank of fuel is
available. (WP 0005)

3.

Turn key switch to OFF


position. (WP 0009)

1.

Start engine. (WP 0007)

2.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

0046-1

Corrective Action
1.

If engine cranks slowly, notify


Field Maintenance.

2.

If engine does not crank


slowly, proceed to Malfunction
2.

1.

If fuel level is low, service


machine. (WP 0077)

2.

If fuel level is OK, proceed to


Malfunction 3.

TM 5-3805-294-10

0046

Table 1. Engine Cranks But Does Not Start or Hard to Start - Continued.
Malfunction

Test or Inspection
3.

4.

5.

Leaking Fuel Lines


and Fittings.

Fuel Filter/Water
Separators Contain
Water or Sediment.

Shut down engine. (WP 0009)

Visually inspect fuel lines and


fittings for leakage.
(WP 0077)

1.

Drain primary and final fuel


filter/water separators of water
or sediment. (WP 0086)

2.

Start engine. (WP 0007)

END OF WORK PACKAGE

0046-2

Corrective Action
1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaner. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, proceed to
Malfunction 4.

1.

If fuel lines and fittings are


leaking, notify Field
Maintenance.

2.

If fuel lines and fittings are not


leaking, proceed to
Malfunction 5.

1.

If engine starts, malfunction


corrected.

2.

If engine does not start, notify


Field Maintenance.

TM 5-3805-294-10

0047

OPERATOR MAINTENANCE
ENGINE WILL NOT CRANK

INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009

References (cont.)
WP 0077
WP 0084
Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Will Not Crank.
Malfunction
1.

2.

Pilot Shutoff Lever


in UNLOCKED
(down) Position.

Discharged
Batteries.

Test or Inspection
1.

Place pilot shutoff lever in


LOCK (up) position.
(WP 0007)

2.

Start engine. (WP 0007)

1.

Turn key switch to ON position,


but DO NOT START ENGINE.
(WP 0007)

2.

Observe monitor for battery


warning alarm. (WP 0005)

3.

Turn key switch to OFF


position. (WP 0009)

0047-1

Corrective Action

1.

If engine starts, malfunction


corrected.

2.

If engine does not crank,


proceed to Malfunction 2.

1.

If monitor displays battery


warning alarm, notify Field
Maintenance.

2.

If monitor does not display


battery warning alarm,
proceed to Malfunction 3.

TM 5-3805-294-10

0047

Table 1. Engine Will Not Crank - Continued.


Malfunction
3.

Blown Fuses.

Test or Inspection
1.

Corrective Action

Remove the following fuses:


F8 ECM 20A fuse.
(WP 0084)
F10 CONTROLLER 5A
fuse. (WP 0084)
F16 POWER ON 5A fuse.
(WP 0084)

2.

4.

Corroded or Loose
Battery
Connections.

Visually inspect fuses for


blown fuse.

Visually inspect batteries for


corroded or loose
connections. (WP 0077)

END OF WORK PACKAGE

0047-2

1.

If fuse blown, replace fuse.


(WP 0084)

2.

If no fuse blown, proceed to


Malfunction 4.

1.

If battery connections are


corroded or loose, notify Field
Maintenance.

2.

If battery connections are not


corroded or loose, notify Field
Maintenance that engine does
not crank.

TM 5-3805-294-10

0048

OPERATOR MAINTENANCE
ENGINE RUNS POORLY

INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077
WP 0086

References (cont.)
WP 0087
WP 0091
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Runs Poorly.
Malfunction
1.

2.

Air Cleaners Dirty


or Clogged.

Fuel Filter/Water
Separators Contain
Water or Sediment.

Test or Inspection
1.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

2.

Shut down engine. (WP 0009)

1.

Drain primary and final fuel


filter/water separators of water
or sediment. (WP 0086)

2.

Start engine. (WP 0007)

0048-1

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, proceed to
Malfunction 2.

1.

If engine runs properly,


malfunction corrected.

2.

If engine runs poorly,


Malfunction 3.

TM 5-3805-294-10

0048

Table 1. Engine Runs Poorly - Continued.


Malfunction
3.

Fuel Tank is
Contaminated.

Test or Inspection
1.

Shut down engine. (WP 0009)

2.

Drain water and sediment from


fuel tank. (WP 0091)

3.

Clean fuel strainer.


(WP 0077)

4.

Start engine. (WP 0007)

END OF WORK PACKAGE

0048-2

Corrective Action

1.

If clean fuel does not become


present, Notify Field
Maintenance.

2.

If clean fuel becomes present,


proceed to Step 3.

1.

If engine runs properly,


malfunction corrected.

2.

If engine runs poorly, shut


down engine. (WP 0009)
Notify Field Maintenance.

TM 5-3805-294-10

0049

OPERATOR MAINTENANCE
EXCESSIVE FUEL CONSUMPTION

INITIAL SETUP:
References
WP 0005
WP 0009

References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Excessive Fuel Consumption.
Malfunction
1.

2.

Air Cleaners Dirty


or Clogged.

Leaking Fuel Lines


and Fittings.

Test or Inspection
1.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

2.

Shut down engine. (WP 0009)

Visually inspect fuel lines and


fittings for leakage.
(WP 0077)

END OF WORK PACKAGE

0049-1/2 blank

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, proceed to
Malfunction 2.

1.

If fuel lines or fittings are


leaking, notify Field
Maintenance.

2.

If fuel lines or fittings are not


leaking, notify Field
Maintenance.

TM 5-3805-294-10

0050

OPERATOR MAINTENANCE
EXCESSIVE OIL CONSUMPTION

INITIAL SETUP:
References
WP 0005
WP 0009

References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Excessive Oil Consumption.
Malfunction
1.

2.

Air Cleaners Dirty


or Clogged.

Oil Shows Signs Of


Contamination.

Test or Inspection
1.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

2.

Shut down engine. (WP 0009)

Visually inspect engine oil


dipstick for coolant or fuel
contaminants. (WP 0077) Oil
containing coolant will have a
creamy brown appearance or
oil containing fuel will be
diluted and smell like fuel.

END OF WORK PACKAGE

0050-1/2 blank

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, proceed to
Malfunction 2.

1.

If oil dipstick shows signs of


contaminants, notify Field
Maintenance.

2.

If oil dipstick shows no signs of


contaminants, notify Field
Maintenance.

TM 5-3805-294-10

0051

OPERATOR MAINTENANCE
ENGINE IDLES POORLY

INITIAL SETUP:
References
WP 0005
WP 0007
WP 0009
WP 0077

References (cont.)
WP 0086
WP 0087
Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Idles Poorly.
Malfunction
1.

2.

Warning Lights and


Alarms are Present.

Fuel Filter/Water
Separators Contain
Water or Sediment.

Test or Inspection
1.

Start engine. (WP 0007) If


engine does not immediately
idle poorly, allow engine to run
until engine starts to exhibit
poor idle symptoms.

2.

Observe monitor (WP 0005)


for warning lights and alarms.

3.

Shut down engine. (WP 0009)

1.

Drain primary and final fuel


filter/water separators of water
or sediment. (WP 0086)

2.

Start engine. (WP 0007)

0051-1

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If any other warning lights and


alarms are present, notify Field
Maintenance.

3.

If no warning lights and alarms


are present, proceed to
Malfunction 2.

1.

If engine idles properly,


malfunction corrected.

2.

If engine idles poorly, proceed


to Malfunction 3.

TM 5-3805-294-10

0051

Table 1. Engine Idles Poorly - Continued.


Malfunction
3.

Leaking Fuel Lines


and Fittings.

Test or Inspection
1.

Shut down engine. (WP 0009)

2.

Visually inspect fuel lines and


fittings for leakage.
(WP 0077)

END OF WORK PACKAGE

0051-2

Corrective Action

1.

If fuel lines and fittings are


leaking, notify Field
Maintenance.

2.

If fuel lines and fittings are not


leaking, notify Field
Maintenance.

TM 5-3805-294-10

0052

OPERATOR MAINTENANCE
AUTO-IDLE DOES NOT WORK

INITIAL SETUP:
References
WP 0004
WP 0005
WP 0009

Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Auto-Idle Does Not Work.
Malfunction
1.

2.

3.

Engine Speed Does


Not Lower With
Auto-Idle (A. I.)
Turned ON.

Auto-Idle (A. I.)


Indicator Not
Displayed On
Monitor.

Hydraulic
Operations Being
Performed.

Test or Inspection
1.

Turn engine speed dial to high


idle position (H). (WP 0004)

2.

Turn A.I. switch to ON


position. (WP 0004)

Verify A.I. indicator is


displayed on monitor.
(WP 0005)

Verify if hydraulic operations


are being performed.
(WP 0004)

0052-1

Corrective Action

1.

If engine speed lowers in 4 - 6


seconds, proceed to
Malfunction 4.

2.

If engine speed does not lower


in 4 - 6 seconds, proceed to
Malfunction 2.

1.

If A. I. indicator is not displayed


on monitor with A. I. switch in
ON position, shut down
engine. (WP 0009) Notify
Field Maintenance.

2.

If A. I. indicator is displayed on
monitor, proceed to
Malfunction 3.

1.

If hydraulic operations are


being performed, cease any
hydraulic operations being
performed, verify engine
speed adjusts to A. I. speed
within 4 - 6 seconds.
(WP 0004) If engine speed
does not adjust to A.I. speed
within 4 - 6 seconds, shut down
engine. (WP 0009) Notify
Field Maintenance.

TM 5-3805-294-10

0052

Table 1. Auto-Idle Does Not Work - Continued.


Malfunction

4.

Engine Speed Does


Not Raise With
Auto-Idle (A. I.)
Turned ON and
Hydraulic
Functions Being
Performed.

Test or Inspection

Operate hydraulic functions.


(WP 0004)

END OF WORK PACKAGE

0052-2

Corrective Action
2.

If hydraulic operations are not


being performed, shut down
engine. (WP 0009) Notify
Field Maintenance.

1.

If engine speed raises, no fault


at this time. Shut down
engine. (WP 0009)

2.

If engine speed does not raise,


shut down engine. (WP 0009)
Notify Field Maintenance.

TM 5-3805-294-10

0053

OPERATOR MAINTENANCE
ENGINE NOT DEVELOPING FULL POWER

INITIAL SETUP:
References
WP 0005
WP 0009

References (cont.)
WP 0077
WP 0087
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Not Developing Full Power.
Malfunction
1.

2.

3.

Air Cleaners Dirty


or Clogged.

Exhaust Pipes
Dented or
Restricted.

Leaking Fuel Lines


or Fittings.

Test or Inspection
1.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

2.

Shut down engine. (WP 0009)

Visually inspect exhaust pipes


and muffler for dents and
restrictions. (WP 0077)

Visually inspect fuel lines and


fittings for leakage.
(WP 0077)

END OF WORK PACKAGE

0053-1/2 blank

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, proceed to
Malfunction 2.

1.

If exhaust pipes are dented or


restricted, notify Field
Maintenance.

2.

If exhaust pipes are not dented


or restricted, proceed to
Malfunction 3.

1.

If fuel lines and fittings are


leaking, notify Field
Maintenance.

2.

If fuel lines and fittings are not


leaking, notify Field
Maintenance.

TM 5-3805-294-10

0054

OPERATOR MAINTENANCE
ENGINE OIL PRESSURE LOW

INITIAL SETUP:
References
WP 0077

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Oil Pressure Low.
Malfunction
Low Engine Oil
Level.

Test or Inspection
Check engine oil level.
(WP 0077)

END OF WORK PACKAGE

0054-1/2 blank

Corrective Action
1.

If engine oil level is low, service


machine. (WP 0077)

2.

If engine oil level is full, notify


Field Maintenance.

TM 5-3805-294-10

0055

OPERATOR MAINTENANCE
ENGINE COOLANT TEMPERATURE ABOVE NORMAL

INITIAL SETUP:
References
WP 0077

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Coolant Temperature Above Normal.
Malfunction
1.

2.

3.

4.

Engine Coolant
Level Low.

Engine Oil Level


Low.

Radiator Damaged
or Has Foreign
Objects/Debris.

Surge Tank Cap is


Loose.

Test or Inspection
Visually inspect engine coolant
level. (WP 0077)

Visually inspect engine oil


level. (WP 0077)

Visually inspect radiator for


damage, foreign objects and
debris. (WP 0077)

Visually inspect surge tank cap


for looseness or damage.
(WP 0077)

END OF WORK PACKAGE

0055-1/2 blank

Corrective Action
1.

If level is low, service radiator.


(WP 0077)

2.

If level is not low, proceed to


Malfunction 2.

1.

If level is low, service engine.


(WP 0077)

2.

If level is not low, proceed to


Malfunction 3.

1.

If radiator has foreign objects/


debris, remove foreign objects/
debris.

2.

If radiator is damaged, notify


Field Maintenance.

3.

If radiator does not have


foreign objects/debris or does
not have damage, proceed to
Malfunction 4.

1.

If cap is loose, secure cap.

2.

If cap is damaged, notify Field


Maintenance.

3.

If cap is not damaged or loose,


notify Field Maintenance.

TM 5-3805-294-10

0056

OPERATOR MAINTENANCE
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE

INITIAL SETUP:
References
WP 0005
WP 0009
WP 0087

Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Emits Excessive Black Or Gray Exhaust Smoke.
Malfunction
Air Cleaners Dirty
or Clogged.

Test or Inspection
1.

Observe monitor for air cleaner


clogged alarm. (WP 0005)

2.

Shut down engine. (WP 0009)

END OF WORK PACKAGE

0056-1/2 blank

Corrective Action

1.

If air cleaner clogged alarm is


displayed, remove foreign
objects/debris or replace air
cleaners. (WP 0087)

2.

If air cleaner clogged alarm is


not displayed, notify Field
Maintenance.

TM 5-3805-294-10

0057

OPERATOR MAINTENANCE
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE

INITIAL SETUP:
References
WP 0007
WP 0009
WP 0077

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Emits Excessive White Exhaust Smoke.
Malfunction
1.

2.

Test or Inspection

Oil Shows Signs Of


Contamination.

White Exhaust
Smoke Excessive at
Normal Operating
Temperature.

Visually inspect engine oil


dipstick for coolant or fuel
contaminants. (WP 0077) Oil
containing coolant will have a
creamy brown appearance or
oil containing fuel will be
diluted and smell like fuel.
1.

Operate engine to normal


operating temperature.
(WP 0007)

2.

Observe engine exhaust.

3.

Shut down engine. (WP 0009)

END OF WORK PACKAGE

0057-1/2 blank

Corrective Action
1.

If oil dipstick shows signs of


contaminants, notify Field
Maintenance.

2.

If oil dipstick shows no signs of


contaminants, Malfunction 2.

1.

If engine emits white exhaust,


notify Field Maintenance.

2.

If engine does not emit white


exhaust, no fault at this time.

TM 5-3805-294-10

0058

OPERATOR MAINTENANCE
NO HYDRAULIC FUNCTIONS

INITIAL SETUP:
References
WP 0004
WP 0009

References (cont.)
WP 0077
WP 0088
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. No Hydraulic Functions.
Malfunction
1.

2.

Pilot Shutoff Lever


in LOCK (up)
Position.

Hydraulic Oil Level


Low.

Test or Inspection
1.

Place pilot shutoff lever in


UNLOCKED (down) position.
(WP 0004)

2.

Operate control pedals and


levers. (WP 0004)

3.

Shut engine off. (WP 0009)

Check hydraulic oil level.


(WP 0077)

END OF WORK PACKAGE

0058-1/2 blank

Corrective Action

1.

If hydraulic functions operate,


malfunction corrected.

2.

If hydraulic functions do not


operate, proceed to
Malfunction 2.

1.

If hydraulic oil level is correct,


notify Field Maintenance.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

TM 5-3805-294-10

0059

OPERATOR MAINTENANCE
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER

INITIAL SETUP:
References
WP 0030
WP 0031
WP 0077
WP 0088

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Functions Are Slow or Have Little or No Power.
Malfunction
1.

2.

3.

Hydraulic Oil Level


Low.

Hydraulic Oil Cold.

Hydraulic Reservoir
Fill Cap is Damaged
or Missing
Hardware.

Test or Inspection
Check hydraulic oil level.
(WP 0077)

Corrective Action
1.

If hydraulic oil level is correct,


proceed to Malfunction 2.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

Perform operating in cold


weather below 5F (-15C)
(WP 0031) or operating in cold
weather 32 to 5F (0 to
-15C). (WP 0030)

1.

If hydraulic functions operate


properly, malfunction
corrected.

2.

If hydraulic functions do not


operate properly, proceed to
Malfunction 3.

Visually inspect hydraulic


reservoir fill cap for damage or
missing hardware. (WP 0077)

1.

If damaged or missing
hardware, notify Field
Maintenance.

2.

if not damaged or missing


hardware, notify Field
Maintenance.

END OF WORK PACKAGE

0059-1/2 blank

TM 5-3805-294-10

0060

OPERATOR MAINTENANCE
POWER DIG DOES NOT WORK

INITIAL SETUP:
References
WP 0077
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Power Dig Does Not Work.
Malfunction
1.

2.

Solenoid Fuse
Blown.

Hydraulic Oil Hoses


Damaged or Has
Leaks.

Test or Inspection
1.

Remove F4 SOLENOID 10A


fuse. (WP 0084)

2.

Visually inspect F4
SOLENOID 10A fuse for blown
fuse.

Visually inspect hydraulic oil


hoses for damage and leaks.
(WP 0077)

END OF WORK PACKAGE

0060-1/2 blank

Corrective Action

1.

If fuse blown, replace F4


SOLENOID 10A fuse.
(WP 0084)

2.

If fuse not blown, proceed to


Malfunction 2.

1.

If damaged or leaking, notify


Field Maintenance.

2.

If not damaged or leaking,


notify Field Maintenance.

TM 5-3805-294-10

0061

OPERATOR MAINTENANCE
HYDRAULIC OIL OVERHEATS

INITIAL SETUP:
References
WP 0077
WP 0088

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Oil Overheats.
Malfunction
1.

2.

Cooling Package
Has Damage,
Foreign Objects/
Debris.

Hydraulic Oil Level


Low.

Test or Inspection
Visually inspect cooling
package for damage, foreign
objects/debris. (WP 0077)

Check hydraulic oil level.


(WP 0077)

END OF WORK PACKAGE

0061-1/2 blank

Corrective Action
1.

If damaged, notify Field


Maintenance.

2.

If not damaged but has foreign


objects/debris, remove foreign
objects/debris.

3.

If not damaged and does not


have foreign objects/debris,
proceed to Malfunction 2.

1.

If hydraulic oil level is correct,


notify Field Maintenance.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

TM 5-3805-294-10

0062

OPERATOR MAINTENANCE
HYDRAULIC OIL FOAMS

INITIAL SETUP:
References
WP 0077
WP 0088

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Oil Foams.
Malfunction
1.

2.

Hydraulic Oil Level


Low.

Hydraulic Oil Hoses


are Damaged.

Test or Inspection
Check hydraulic oil level.
(WP 0077)

Visually inspect hydraulic oil


hoses for damage. (WP 0077)

END OF WORK PACKAGE

0062-1/2 blank

Corrective Action
1.

If hydraulic oil level is correct,


proceed to Malfunction 2.

2.

If hydraulic oil level is low, fill oil


to proper level. (WP 0088)

3.

If hydraulic oil level is high,


notify Field Maintenance.

1.

If hydraulic oil hoses are


damaged, notify Field
Maintenance.

2.

If hydraulic oil hoses are not


damaged, notify Field
Maintenance.

TM 5-3805-294-10

0063

OPERATOR MAINTENANCE
NO SWING FUNCTION

INITIAL SETUP:
References
WP 0077
WP 0088

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. No Swing Function.
Malfunction
Hydraulic Oil Level
Low.

Test or Inspection
Check hydraulic oil level.
(WP 0077)

END OF WORK PACKAGE

0063-1/2 blank

Corrective Action
1.

If hydraulic oil level is correct,


notify Field Maintenance.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

TM 5-3805-294-10

0064

OPERATOR MAINTENANCE
SWING FUNCTION IS JERKY

INITIAL SETUP:
References
LO 5-3805-294-13 (WP 0094)

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Swing Function Is Jerky.
Malfunction
Lack of Grease in
Swing Bearing.

Test or Inspection
Visually inspect swing bearing
grease fittings (LO
5-3805-294-13). (WP 0094)

END OF WORK PACKAGE

0064-1/2 blank

Corrective Action
1.

If swing bearing lacks grease,


lubricate swing bearing grease
fittings (LO 5-3805-294-13).
(WP 0094)

2.

If swing bearing does not lack


grease, notify Field
Maintenance.

TM 5-3805-294-10

0065

OPERATOR MAINTENANCE
SLOW TRAVEL SPEED ONLY

INITIAL SETUP:
References
WP 0077
WP 0084
WP 0088

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Slow Travel Speed Only.
Malfunction
1.

2.

Solenoid Fuse
Blown.

Hydraulic Oil Level


Low.

Test or Inspection
1.

Remove F4 SOLENOID 10A


fuse. (WP 0084)

2.

Visually inspect F4
SOLENOID 10A fuse for blown
fuse.

Check hydraulic oil level.


(WP 0077)

END OF WORK PACKAGE

0065-1/2 blank

Corrective Action

1.

If fuse blown, replace F4


SOLENOID 10A fuse.
(WP 0084)

2.

If fuse not blown, proceed to


Malfunction 2.

1.

If hydraulic oil level is correct,


notify Field Maintenance.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

TM 5-3805-294-10

0066

OPERATOR MAINTENANCE
TRAVEL IS JERKY

INITIAL SETUP:
References
WP 0077
WP 0080

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Travel is Jerky.
Malfunction
1.

2.

Incorrect Track
Chain Tension.

Debris in Track
Frame.

Test or Inspection
Check track chain sag.
(WP 0080)

Visually inspect track frame for


jammed debris. (WP 0077)

END OF WORK PACKAGE

0066-1/2 blank

Corrective Action
1.

If track chain sag is within


specification, proceed to
Malfunction 2.

2.

If track chain sag is not within


specification, adjust track
chain tension. (WP 0080)

1.

If jammed with debris, remove


debris.

2.

If not jammed with debris,


notify Field Maintenance.

TM 5-3805-294-10

0067

OPERATOR MAINTENANCE
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED

INITIAL SETUP:
References
WP 0007
WP 0008
WP 0086

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Engine Stops When Travel or Control Lever Actuated.
Malfunction
Fuel Filter/Water
Separators Contain
Water or Sediment.

Test or Inspection
1.

Drain primary and final fuel


filter/water separators of water
or sediment. (WP 0086)

2.

Start engine. (WP 0007)

3.

Move HYEX. (WP 0008)

END OF WORK PACKAGE

0067-1/2 blank

Corrective Action

1.

If engine stops when either


control lever is actuated, notify
Field Maintenance.

2.

If engine stops when travel is


actuated, notify Field
Maintenance.

3.

If engine does not stop while


moving, malfunction
corrected.

TM 5-3805-294-10

0068

OPERATOR MAINTENANCE
QUICK LATCH DOES NOT OPERATE

INITIAL SETUP:
References
WP 0009
WP 0014

References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Quick Latch Does Not Operate.
Malfunction
1.

2.

3.

Quick Latch Switch


Does not Operate.

Test or Inspection
1.

Set quick latch switch to


UNLATCH position.
(WP 0014)

2.

Observe quick latch warning


light and alarm.

3.

Observe quick latch for


movement.

Safety Lock Pin


Lever in Locked
Position.

Quick Hitch Fuse


Blown.

Check quick latch safety lock


pin lever position. (WP 0014)

1.

Shut down engine. (WP 0009)

2.

Remove F26 QUICK HITCH


5A fuse. (WP 0084)

3.

Visually inspect F26 QUICK


HITCH 5A fuse for blown fuse.

0068-1

Corrective Action

1.

If warning light and alarm are


off, notify Field Maintenance.

2.

If warning light and alarm is on,


proceed to Malfunction 2.

1.

If in locked position, place


quick latch safety lock pin lever
in unlocked position.
(WP 0014)

2.

If in unlocked position, proceed


to Malfunction 3.

1.

If fuse blown, replace F26


QUICK HITCH 5A fuse.
(WP 0084)

2.

If fuse not blown, proceed to


Malfunction 4.

TM 5-3805-294-10

0068

Table 1. Quick Latch Does Not Operate - Continued.


Malfunction
4.

Quick Latch Has


Jammed Debris.

Test or Inspection
Visually inspect quick latch for
jammed debris. (WP 0077)

END OF WORK PACKAGE

0068-2

Corrective Action
1.

If quick latch does have


jammed debris, remove
jammed debris. (WP 0077)

2.

If quick latch does not have


jammed debris, notify Field
Maintenance.

TM 5-3805-294-10

0069

OPERATOR MAINTENANCE
COMPACTOR DOES NOT OPERATE

INITIAL SETUP:
References
WP 0077
WP 0020

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Compactor Does Not Operate.
Malfunction
1.

2.

3.

Hydraulic Supply
Quick Disconnect
Not Fully Seated.

Hydraulic Return
Quick Disconnect
Not Fully Seated.

Compactor Has
Jammed Debris.

Test or Inspection
Visually inspect hydraulic
supply quick disconnect.
(WP 0077)

Visually inspect hydraulic


return quick disconnect.
(WP 0077)

Visually inspect compactor for


jammed debris. (WP 0077)

END OF WORK PACKAGE

0069-1/2 blank

Corrective Action
1.

If quick disconnect is fully


seated, proceed to Malfunction
2.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

1.

If quick disconnect is fully


seated, proceed to Malfunction
3.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

1.

If compactor does have


jammed debris, remove
jammed debris. (WP 0077)

2.

If compactor does not have


jammed debris, notify Field
Maintenance.

TM 5-3805-294-10

0070

OPERATOR MAINTENANCE
BREAKER DOES NOT OPERATE

INITIAL SETUP:
References
WP 0020
WP 0077

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Breaker Does Not Operate.
Malfunction
1.

2.

3.

Hydraulic Supply
Quick Disconnect
Not Fully Seated.

Hydraulic Return
Quick Disconnect
Not Fully Seated.

Breaker Has
Jammed Debris.

Test or Inspection
Visually inspect hydraulic
supply quick disconnect.
(WP 0077)

Visually inspect hydraulic


return quick disconnect.
(WP 0077)

Visually inspect breaker for


jammed debris. (WP 0077)

END OF WORK PACKAGE

0070-1/2 blank

Corrective Action
1.

If quick disconnect is fully


seated, proceed to Malfunction
2.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

1.

If quick disconnect is fully


seated, proceed to Malfunction
3.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

1.

If breaker does have jammed


debris, remove jammed
debris. (WP 0077)

2.

If breaker does not have


jammed debris, notify Field
Maintenance.

TM 5-3805-294-10

0071

OPERATOR MAINTENANCE
BREAKER OPERATES SLOWLY

INITIAL SETUP:
References
WP 0009
WP 0018

References (cont.)
WP 0077
WP 0088
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Breaker Operates Slowly.
Malfunction
1.

2.

3.

Test or Inspection

Breaker
Attachment Not
Selected.

Hydraulic Supply
Hose is Damaged or
Has Leaks.

Hydraulic Return
Hose is Damaged or
Has Leaks.

Check attachment selection on


monitor. (WP 0018)

1.

Shut down engine. (WP 0009)

2.

Visually inspect hydraulic


supply hose. (WP 0077)

Visually inspect hydraulic


return hose. (WP 0077)

0071-1

Corrective Action
1.

If breaker attachment is
selected, proceed to
Malfunction 2.

2.

If breaker attachment is not


selected, select breaker
attachment on monitor.
(WP 0018)

1.

If hydraulic supply hose is


damaged or leaking, notify
Field Maintenance.

2.

If hydraulic supply hose is not


damaged or leaking, proceed
to Malfunction 3.

1.

If hydraulic return hose is


damaged or leaking, notify
Field Maintenance.

2.

If hydraulic return hose is not


damaged or leaking, proceed
to Malfunction 4.

TM 5-3805-294-10

0071

Table 1. Breaker Operates Slowly - Continued.


Malfunction
4.

Hydraulic Oil Level


Low.

Test or Inspection
Check hydraulic oil level.
(WP 0077)

END OF WORK PACKAGE

0071-2

Corrective Action
1.

If hydraulic oil level is correct,


notify Field Maintenance.

2.

If hydraulic oil level is not


correct, fill oil to proper level.
(WP 0088)

TM 5-3805-294-10

0072

OPERATOR MAINTENANCE
CRUSH-ALL DOES NOT OPERATE

INITIAL SETUP:
References
WP 0020
WP 0077
WP 0084

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Crush-All Does Not Operate.
Malfunction
1.

2.

3.

12-Volt Power
Outlet Fuse Blown.

Hydraulic Supply
Quick Disconnect
Not Fully Seated.

Hydraulic Return
Quick Disconnect
Not Fully Seated.

Test or Inspection
1.

Remove F6 OPT.2 (ALT) 10A


fuse. (WP 0084)

2.

Visually inspect F6 OPT.2


(ALT) 10A fuse for blown fuse.

Visually inspect hydraulic


supply quick disconnect.
(WP 0077)

Visually inspect hydraulic


return quick disconnect.
(WP 0077)

0072-1

Corrective Action

1.

If fuse blown, replace F6 OPT.


2 (ALT) 10A fuse. (WP 0084)

2.

If fuse not blown, proceed to


Malfunction 2.

1.

If quick disconnect is fully


seated, proceed to Malfunction
3.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

1.

If quick disconnect is fully


seated, proceed to Malfunction
4.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0020)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

TM 5-3805-294-10

0072

Table 1. Crush-All Does Not Operate - Continued.


Malfunction
4.

Crush-All Has
Jammed Debris.

Test or Inspection
Visually inspect crush-all for
jammed debris. (WP 0077)

END OF WORK PACKAGE

0072-2

Corrective Action
1.

If crush-all does have jammed


debris, remove jammed
debris. (WP 0077)

2.

If crush-all does not have


jammed debris, notify Field
Maintenance.

TM 5-3805-294-10

0073

OPERATOR MAINTENANCE
BARRIER GRAPPLE DOES NOT HOLD LOAD

INITIAL SETUP:
References
WP 0077

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

TROUBLESHOOTING PROCEDURE
Table 1. Barrier Grapple Does Not Hold Load.
Malfunction
Grip pads worn.

Test or Inspection
Visually inspect grip pads.
(WP 0077)

END OF WORK PACKAGE

0073-1/2 blank

Corrective Action
1.

If grip pads worn, notify Field


Maintenance.

2.

If grip pads not worn, notify


Field Maintenance.

TM 5-3805-294-10

0074

OPERATOR MAINTENANCE
DEEP DIG DOES NOT OPERATE

INITIAL SETUP:
References
WP 0009
WP 0023

References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Deep Dig Does Not Operate.
Malfunction
1.

2.

3.

Test or Inspection

Deep Dig Control


Pattern Switch is
OFF.

Cab Auxiliary
Power Connector
One Fuse Blown.

Hydraulic Supply
Quick Disconnect
Not Fully Seated.

Check deep dig control pattern


switch position. (WP 0023)

1.

Shut down engine. (WP 0009)

2.

Remove F13 AUX 10A fuse.


(WP 0084)

3.

Visually inspect F13 AUX 10A


fuse for blown fuse.

1.

Visually inspect hydraulic


supply quick disconnect.
(WP 0077)

2.

Visually inspect hydraulic


return quick disconnect.
(WP 0077)

3.

Visually inspect hydraulic


supply hose for damage.
(WP 0077)

0074-1

Corrective Action
1.

If switch is OFF, set deep dig


control pattern switch to ON.
(WP 0023)

2.

If switch is ON, proceed to


Malfunction 2.

1.

If fuse blown, replace F13 AUX


10A fuse. (WP 0084)

2.

If fuse not blown, proceed to


Malfunction 3.

TM 5-3805-294-10

0074

Table 1. Deep Dig Does Not Operate - Continued.


Malfunction

Test or Inspection
4.

Visually inspect hydraulic


return hose for damage.
(WP 0077)

END OF WORK PACKAGE

0074-2

Corrective Action
1.

If quick disconnect(s) is not


fully seated, reconnect quick
disconnect properly.
(WP 0023)

2.

If quick disconnect(s) is
damaged, notify Field
Maintenance.

3.

If hose(s) is damaged, notify


Field Maintenance.

4.

If quick disconnects are fully


seated and hoses are not
damaged, notify Field
Maintenance.

TM 5-3805-294-10

0075

OPERATOR MAINTENANCE
HYDRAULIC HOSE REEL DOES NOT OPERATE

INITIAL SETUP:
References
WP 0009
WP 0026

References (cont.)
WP 0077
WP 0084
Equipment Condition
Engine running. (WP 0007)

TROUBLESHOOTING PROCEDURE
Table 1. Hydraulic Hose Reel Does Not Operate.
Malfunction
1.

2.

3.

Test or Inspection

Hand Held
Hydraulic Tool
Circuit Switch is
OFF.

Cab Auxiliary
Power Connector
One Fuse Blown.

Hydraulic Supply
Quick Disconnect
Not Fully Seated.

Check hand held hydraulic tool


circuit switch position.
(WP 0026)

1.

Shut down engine. (WP 0009)

2.

Remove F13 AUX 10A fuse.


(WP 0084)

3.

Visually inspect F13 AUX 10A


fuse for blown fuse.

Visually inspect hydraulic


supply quick disconnect.
(WP 0077)

0075-1

Corrective Action
1.

If switch is OFF, set hand held


hydraulic tool circuit switch to
ON. (WP 0026)

2.

If switch is ON, proceed to


Malfunction 2.

1.

If fuse blown, replace F13 AUX


10A fuse. (WP 0084)

2.

If fuse not blown, proceed to


Malfunction 3.

1.

If quick disconnect is fully


seated, proceed to Malfunction
4.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0026)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

TM 5-3805-294-10

0075

Table 1. Hydraulic Hose Reel Does Not Operate - Continued.


Malfunction
4.

5.

6.

Hydraulic Return
Quick Disconnect
Not Fully Seated.

Test or Inspection
Visually inspect hydraulic
return quick disconnect.
(WP 0077)

Corrective Action
1.

If quick disconnect is fully


seated, proceed to Malfunction
5.

2.

If quick disconnect is not fully


seated, reconnect quick
disconnect properly.
(WP 0026)

3.

If quick disconnect is
damaged, notify Field
Maintenance.

Hydraulic Tool
Supply Hose Has
Damage.

Visually inspect hydraulic tool


supply hose for damage.
(WP 0077)

1.

If hose is not damaged,


proceed to Malfunction 6.

2.

If hose is damaged, notify Field


Maintenance.

Hydraulic Tool
Return Hose Has
Damage.

Visually inspect hydraulic tool


return hose for damage.
(WP 0077)

1.

If hose is not damaged, notify


Field Maintenance.

2.

If hose is damaged, notify Field


Maintenance.

END OF WORK PACKAGE

0075-2

TM 5-3805-294-10

CHAPTER 4
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND
SERVICES (PMCS)
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677

TM 5-3805-294-10

0076

OPERATOR MAINTENANCE
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

PREVENTIVE MAINTENANCE CHECKS AND SERVICES

NOTE
If the machine has reached the initial 250 hours of operation, contact field level
maintenance to perform the initial 250 hour service.
Tools supplied on the machine are to be used for Preventive Maintenance Checks and
Services (PMCS). Rags are also required for removing dirt and grease.
PMCS intervals should be performed more frequently when operating under unusual
conditions.
Perform PMCS on attachments only if they are to be used for the current mission.
This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The PMCS tables
contain checks and services necessary to ensure that the machine is ready for operation. Maintenance is performed
at specified intervals using the PMCS tables.
Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable.
Components in good condition are: not bent or twisted, chafed or burned, broken, or cracked. There should be no
signs of wear, fraying, dents, collapsing, tears, cuts, or deterioration.
Damage is any condition that affects safety or prevents a part or assembly from functioning normally or would render
the machine unserviceable for mission requirements.
MAINTENANCE RECORDS AND FORMS
Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The completed forms
and records have several uses. They are a permanent record of services, repairs, and modifications made to the
machine. They are reports to maintenance personnel, and to the Commander. They serve as a checklist to track
previous machine malfunctions and repair actions. Record results of PMCS on DA Form 2404, Equipment Inspection
and Maintenance Worksheet, or DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet.
For the information needed on forms and records, refer to DA PAM 750-8 The Army Maintenance Management
System (TAMMS) Users Manual.
GENERAL MAINTENANCE PROCEDURES

Cleanliness: Dirt, grease, oil, and debris can conceal serious problems. Use solvent cleaning compound
on all metal surfaces and soapy water on rubber or plastic surfaces.

Bolts, Nuts, and Screws: Check for loose bolts, nuts, and screws, as well as for those that are missing,
bent, or broken. Tighten or replace as necessary. If parts cannot be checked with a tool, look for signs of
chipped paint, bare metal, or rust around bolt heads.

Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a damaged weld
is discovered, notify Field Level Maintenance.

Electric Wires and Connectors: Look for cracked or broken insulation, exposed wires, and loose or broken
connectors. Tighten loose connectors and ensure wires are in good shape.

Fluid Hoses, Tubes, and Fittings: Look for wear, damage, or leaks. Ensure clamps and fittings are tight.
Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If connectors or
fittings are loose or if hoses, tubes, or fittings are broken or worn out, notify Field Level Maintenance.

0076-1

TM 5-3805-294-10

0076

WARNINGS AND CAUTIONS


Always observe the warnings and cautions appearing in your PMCS table. Warnings and cautions appear before
the applicable procedure. You must observe these warnings and cautions to prevent serious injury to personnel or
to prevent damage to the equipment.
ARMY OIL ANALYSIS PROGRAM (AOAP)
The engine and hydraulic oil and filters replacement are governed by the AOAP program. Samples for the engine
are taken every 90 days and once yearly for the hydraulic system. If sampling is not feasible due to mission, then
hard time intervals apply for oil and filter changes.
LUBRICATION INSTRUCTIONS

During adverse weather or unusually dusty conditions, lubrication may be required on a daily basis.

After fording operations, lubricate all lubrication points below fording line.

For detailed lubrication instructions, refer to: LO 5-3805-294-13 Lubrication Instructions for the Hydraulic
Excavator (HYEX).

PMCS COLUMN DESCRIPTION


The PMCS table columns are described as follows:
Item Number
The order that the PMCS should be performed. Use the item number when recording results on the DA Form 2404,
Equipment Inspection and Maintenance Worksheet or the DA Form 5988-E, Equipment Inspection and Maintenance
(Electronic) Worksheet.
Interval
Lists the interval at which the check or service is to be performed.
Item to be Inspected
Lists the item being checked or serviced.
Procedures
Describes the procedure for the check or service.
Equipment Not Ready or Available If
Describes a condition that renders the machine not mission capable.

0076-2

TM 5-3805-294-10

0076

Types of Preventive Maintenance Checks and Services (PMCS)


For each service interval, perform all checks and services listed and all checks and services associated with any
lower service interval.
Before: Do the Before (B) PMCS before operating the machine. Pay attention to the WARNINGS and
CAUTIONS.

During: Do the During (D) PMCS while machine or its components are in operation. Pay attention to the
WARNINGS and CAUTIONS.

After: Do the After (A) PMCS after operating the machine. Pay attention to the WARNINGS and CAUTIONS.

Monthly: Do the Monthly (M) PMCS once a month on the machine. Pay attention to the WARNINGS and
CAUTIONS.

Always perform PMCS in the same order, every time. Once practiced, problems can be spotted quickly. If an item
or component being inspected is inoperable or damaged, either troubleshoot by following instructions in the
Troubleshooting Section of this manual or repair and/or replace as described in the related maintenance task. If
there appears to be a malfunction that cannot be repaired immediately, complete either DA Form 2404,or DA Form
5988-E.
FLUID LEAKAGE

Class I: Seepage of fluid (as indicated by wetness or discoloration) not sufficient enough to form drops.

Class II: Leakage of fluid sufficient enough to form drops, but not sufficient enough to cause the drops to
drip from the item being inspected.

Class III: Leakage of fluid sufficient enough to form drops that fall from the item being inspected.

END OF WORK PACKAGE

0076-3/4 blank

TM 5-3805-294-10

0077

OPERATOR MAINTENANCE
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP:
Materials/Parts
Antifreeze, Arctic Type
(WP 0097, Table 1, Item 1)
Antifreeze (WP 0097, Table 1, Item 2)
Engine Oil (WP 0097, Table 1, Item 13)
Gloves (WP 0097, Table 1, Item 10)
Goggles (WP 0097, Table 1, Item 10)
Grease (WP 0097, Table 1, Item 10)
Penetrating Oil (WP 0097, Table 1, Item 14)
Rags, Wiping (WP 0097, Table 1, Item 15)
References
LO 5-3805-294-13 (WP 0094)

Table 1.
ITEM
NO.

INTERVAL

References (cont.)
TM 5-3805-295-13&P (WP 0094)
WP 0007
WP 0009
WP 0034
WP 0080
WP 0085
WP 0087
WP 0088
WP 0089
WP 0090
WP 0091
WP 0094

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES


ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

WARNING

Personnel hearing can be


permanently damaged if exposed to constant high noise
levels of 85 dB or greater.
Failure to comply may result
in injury to personnel.

WARNING

Unless otherwise specified,


perform all maintenance
procedures with all attachments lowered to the
ground, pilot shutoff lever in

0077-1

EQUIPMENT NOT
READY/
AVAILABLE IF:

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE
the up position, and engine
shut off. Failure to comply
may result in injury or death
to personnel.

WARNING

Ensure electrical power is


off prior to working on all
electrical connections. Remove all jewelry such as
rings, ID tags, bracelets,
etc., prior to working on or
around vehicle. Jewelry and
tools can catch on equipment, contact positive electrical circuits, and cause a
direct short, severe burns, or
electrical shock. Failure to
comply may result in injury
or death to personnel.

CAUTION
New machine break-in
maintenance is required at
250 hours. Contact Field
Maintenance to avoid early
wear or damage to the machine. Failure to comply may
result in voidance of warranty and damage to the machine.

NOTE
Perform Operator's Before
PMCS checks if:
You are the assigned
operator but have not
operated the machine
since the last PMCS
was performed.

0077-2

EQUIPMENT NOT
READY/
AVAILABLE IF:

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued


ITEM TO BE CHECKED
OR SERVICED

INTERVAL

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE
You are operating the
machine for the first
time.
Only perform PMCS on
attachments if they are
to be operated for
current mission.
The lubrication order is
to be used in
conjunction with the
PMCS.
For Armored Cab
PMCS, refer to
TM 5-3805-295-13&P.

Before

Exterior of Machine

Perform walk-around inspection of


the machine exterior. Check on
ground under machine (Figure 1,
Item 1) for evidence of fluid leakage
such as oil, coolant, or fuel.

Class III oil or


coolant leaks.
Any fuel leakage is evident.

Check machine (Figure 1, Item 1)


for obvious damage that would
impair operation.

Damage that
would impair
operation is evident.

3
1

4
Figure 1.

Exterior of Machine.

0077-3

HYEX01001

TM 5-3805-294-10

Table 1.
ITEM
NO.
2

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued


ITEM TO BE CHECKED
OR SERVICED

INTERVAL
Before

Left and Right Track


Chain and Rollers

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE
Check for loose or missing track
shoe (Figure 2, Item 2) and track
bolts.

Loose or missing track shoe.


One or more
bolts missing
from track shoe.

3
1

HYEX01001

Figure 2. Exterior of Machine Continued.

Before

Coolant Surge Tank

Check for oil leakage from carrier


roller (Figure 2, Item 3) or support
rollers (Figure 2, Item 4).

Oil leaking from


carrier roller or
support roller.

Check that coolant is at the MIN


COLD line (Figure 3, Item 5) on the
surge tank (Figure 3, Item 6).

Coolant level
below MIN
COLD level.

0077-4

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

6
Figure 3.

HYEX01002

Coolant Level.
If coolant is low, remove surge tank
cap (Figure 3, Item 7) and fill as
required.

Before

Engine Oil Level

Check that the surge tank (Figure 3,


Item 6) is not damaged.

Surge tank has


a Class III leak.

Check that surge tank cap (Figure


3, Item 7) is present and is not
broken or cracked.

Cap is missing
or is unserviceable.

Check oil level on the dipstick


(Figure 4, Item 8) and ensure that it
is between the ADD and FULL
marks.

Engine oil level


below the ADD
mark or engine
oil is overfull.

0077-5

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

8
9

HYEX01003

Figure 4.

Engine Oil.
If engine oil is low, remove cap
(Figure 4, Item 9) and add oil as
required (LO 5-3805-294-13).
(WP 0094)

Before

Engine Compartment

Check engine compartment for


obvious damage or leaks in hoses
or lines.

Any damage
that would impair safe operation of the machine.

Before

Exhaust Components

Check exhaust components for


leaks, loose parts, dents, or
damage.

Loose, leaking,
or damaged
components.

0077-6

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

HYEX03409

Exhaust Components.

Figure 5.
7

Before

Hydraulic Reservoir Cap

11

Press button (Figure 6, Item 10) on


hydraulic reservoir cap (Figure 6,
Item 11) to ensure that it is
operational and that cap is not
broken.

Hydraulic reservoir cap is broken, missing, or


button cannot
be pressed.

10

HYEX01004

Figure 6.
8

Before

Fuel Tank

Hydraulic Reservoir Cap.


Check fuel tank (Figure 7, Item 12)
for evidence of leaks.

0077-7

Any signs of
leaks from fuel
tank.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

14

13

12

HYEX01005

Figure 7.

Fuel Tank and Fuel Level.


Ensure fuel tank is full.
To fill fuel tank:
Remove fuel cap (Figure
7, Item 13).
Fill fuel tank (Figure 7,
Item 12) until band (Figure
7, Item 14) is visible.
Install fuel cap (Figure 7,
Item 13).

Before

Fuel Filters

Check primary fuel filter (Figure 8,


Item 15), fuel/water separator
(Figure 8, Item 16), and fuel lubricity
filter (Figure 8, Item 17) for
evidence of leaks.

0077-8

Any fuel leak.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

16

15

18

17

HYEX01006

Figure 8.

Fuel Filters.

10

Before

Hydraulic Oil Filter

Check hydraulic oil filter (Figure 8,


Item 18) for evidence of leaks.

Any Class III


leak.

11

Before

Hydraulic Pump
Compartment

Check hydraulic pump


compartment for obvious damage
or leaks in lines or hoses.

Any damage
that would impair safe operation of machine.

12

Before

Engine Oil Filter

Check engine oil filter (Figure 9,


Item 19) for evidence of leaks.

Any Class III


leak.

19

HYEX01007

Figure 9.

Engine Oil Filter.

0077-9

TM 5-3805-294-10

Table 1.
ITEM
NO.
13

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL
Before

0077

ITEM TO BE CHECKED
OR SERVICED
Boom, Arm, Quick Latch,
Hydraulic Thumb

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE
Check boom (Figure 10, Item 20),
arm (Figure 10, Item 21), quick
latch (Figure 10, Item 22), and
hydraulic thumb (Figure 10, Item
23) for damage that would impair
operation.
24

Damage that
impairs proper
operation.

27

20
25
26
23

21
24
26
24
22

24

HYEX01008

Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb.


Check cylinders (Figure 10, Item
24) for leaks.

Any Class III


leak.

Check hydraulic lines (Figure 10,


Item 25) and hoses (Figure 10, Item
26) for leaks.

Any Class III


leak.

Check for presence of hydraulic


thumb pin (Figure 10, Item 27).
14

Before

NOTE

Bucket

Only check bucket or attachment to be used for current


mission.
Check bucket (Figure 11, Item 28)
for cracks and missing teeth.

0077-10

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

Replace teeth as required.


(WP 0085)

28

HYEX01009

Figure 11.

15

Before

Primary and Secondary


Air Cleaner Housing

Bucket and Teeth.


Check bucket for loose, broken, or
missing hardware or mounting
bracket damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

Inspect and clean primary and


secondary air cleaner housing
(Figure 12, Item 29) for damage or
missing parts. (WP 0087)

Primary and
secondary air
cleaner housing
cracked or cover missing.

0077-11

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

29

30

33
32

31
HYEX01395

Figure 12.

Air Cleaner Housing and Hose Reel.


Squeeze ejector (Figure 12, Item
30) to remove dust.

16

Before

Hose Reel, Hoses, Deep


Dig Control Switch, and
Hand Held Hydraulic
Switch

Check deep dig control pattern


switch (Figure 12, Item 31) to
ensure it is in the OFF position. If
deep dig arm is installed, ensure
that deep dig control pattern switch
(Figure 12, Item 31) is in the ON
position.

Any lines are


cracked, frayed,
or broken.

Check hydraulic hand held tool


circuit switch (Figure 12, Item 32) to
ensure it is in the OFF position.
Check hydraulic hose reel and
hoses (Figure 12, Item 33) for
damage and leaks.

0077-12

Any class III


leak.

TM 5-3805-294-10

Table 1.
ITEM
NO.
17

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

Before

Batteries

WARNING

EQUIPMENT NOT
READY/
AVAILABLE IF:

LEAD-ACID BATTERIES
Remove four wing nuts (Figure 13,
Item 34), washers (Figure 13, Item
35), and two covers (Figure 13,
Item 36) from batteries (Figure 13,
Item 37).
Check batteries (Figure 13, Item
37) for leaks or cracks.

Batteries show
signs of leaking
or have cracks.

40

41

36

34, 35

37

38

Figure 13.

39

HYEX01011

Batteries.

Check battery cables (Figure 13,


Item 38) for looseness.
Install two covers (Figure 13, Item
36) to batteries (Figure 13, Item 37)
with four wing nuts (Figure 13, Item

0077-13

Battery cables
are loose.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

34) and washers (Figure 13, Item


35).
18

Before

Cooling Package

Check cooling package (Figure 13,


Item 39) for leaks and damage.

Any Class III


coolant leak.

19

Before

Fuel Cooler

Check fuel cooler (Figure 14, Item


40) and fuel lines for leaks.

Any fuel leak.

40

41

36

34, 35

37

Figure 14.

38

39

HYEX01011

Batteries Continued.
Check windshield washer reservoir
(Figure 14, Item 41) for fluid and
damage. Fill as required.

20

Before

Cab Glass

Check cooling compartment for


obvious damage or leaks.

Any damage
that would impair safe operation of the machine.
Any fuel leak or
class III fluid
leaks.

Check cab glass (Figure 15, Item


42) for cracks or chips.

Any broken
glass that impairs the operators vision. Any
glass missing.

0077-14

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

42

42
42

42
HYEX01012

Figure 15.
21

Before

Mirrors, Wiper, and


Operator Protection
Guard

Cab Glass.

Check that mirrors (Figure 16, Item


43) are present and serviceable.

43

43
45
44

HYEX01396

Figure 16.

Mirrors and Wiper Arm.


Check that operator protection
guard (Figure 16, Item 44) is
present and serviceable.

0077-15

Operator protection guard


missing.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE
Check that wiper arm and blade
(Figure 16, Item 45) are
serviceable.

22

Before

Door, Door Hinges, and


Latches

Check that hinges (Figure 17, Item


46) allow door (Figure 17, Item 47)
to swing freely.

46

Door is difficult
to open or close.

47

48
48

46

HYEX03430

Figure 17.

23

Before

Fire Extinguisher

Cab Door, Hinges, and Latches.


Check that door (Figure 17, Item
47) and latches (Figure 17, Item 48)
lock and release in open and closed
positions.

Door fails to
latch or latches
fail to release.

Check that fire extinguisher (Figure


18, Item 49) is present and is fully
charged.

Fire extinguisher is missing,


has been discharged, or has
an expired date
of service.

0077-16

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

49

HYEX01013

Figure 18.
24

Before

Cab Pedals and Levers

Fire Extinguisher.
Check that left and right travel pedal
and lever (Figure 19, Item 50) move
freely through their full range of
travel.

0077-17

Left or right travel pedal or lever


are binding or
do not move
freely through
full range of
travel.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

50

ITEM TO BE CHECKED
OR SERVICED

50

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

50

50

51

52

HYEX01399

Figure 19.

25

Before

Pilot Control Levers

Pedals and Levers.


Check that attachment pedal
(Figure 19, Item 51) moves freely
through range of travel and
attachment pedal lock (Figure 19,
Item 52) is operational.

Attachment
pedal does not
move freely or
attachment
pedal lock does
not operate.

Check left (Figure 20, Item 53) and


right (Figure 20, Item 54) pilot
control levers to ensure that they
move freely through full range of
motion.

Left or right pilot


control lever
binds or will not
move through
full range of motion.

0077-18

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

54

53

HYEX01397

Figure 20.

Pilot Control Levers.

26

Before

Horn

Press horn button to ensure horn


sounds.

Horn does not


sound.

27

Before

Seat Belt

Check that seat belt (Figure 21,


Item 55) is not frayed and fastens
together.

Seat belt is
frayed or will not
fasten together.

0077-19

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

55

HYEX01398

Figure 21.
28

Before

Monitor

Seat Belt.

Turn ignition switch (Figure 22, Item


56) to ON position.

56

HYEX01014

Figure 22.

Ignition Switch.

0077-20

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

NOTE
If default screen is not displayed after start up screen,
wait 10 seconds to ensure
default screen will be displayed.
Check that monitor (Figure 23, Item
57) comes on, then goes to default
screen.

Monitor does
not come on.
Monitor does
not go to default
screen.

57

System Starting...
1

F1

F2

F3

F4

HYEX01015

Figure 23.

Monitor.

29

Before

Starter

Start engine. (WP 0007)

Engine does not


start or starter
makes unusual
noises.

30

Before

Lights

Check that all lights operate.

Lights do not
operate.

31

Before

Wipers and Washer Fluid

Check that wipers and washer


pump works and has fluid.

Wipers do not
operate.

32

Before

Hydraulic Oil Level

To check hydraulic oil level:


Fully extend arm (Figure
24, Item 58).

Sight glass has


class III leak.

0077-21

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

Curl bucket (Figure 24,


Item 59).
Lower boom (Figure 24,
Item 60) until bucket is
resting on the ground.

60
58
59

Figure 24.

HYEX01016

Position Boom and Arm.

61

HYEX01017

Figure 25. Hydraulic Oil Level Check.


To fill hydraulic reservoir:
Open right door and
ensure that hydraulic oil is
between marks on sight
glass (Figure 25, Item 61).
Fill as required.
Shut down engine.
(WP 0009)
Service hydraulic
reservoir. (WP 0088)

0077-22

Reservoir is
empty.
Sight glass is
broken or damaged.
Any Class III
leaks.

TM 5-3805-294-10

Table 1.
ITEM
NO.
33

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

Before

Breaker

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

NOTE
Only perform PMCS on attachments that are required
for current mission.
Check breaker (Figure 26, Item 62)
for loose, broken, or missing
hardware or mounting bracket
damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

63

HYEX01018

62

Figure 26.

34

Before

Compactor

Breaker.

Check breaker hydraulic hoses


(Figure 26, Item 63) for leaks and
breaker for problems that would
impair operation.

Any class III


leak.

Check compactor (Figure 27, Item


64) for loose, broken, or missing
hardware or mounting bracket
damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

0077-23

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

65

64
HYEX01019

Figure 27.

35

Before

Crush-All

Compactor.

Check compactor hydraulic hoses


(Figure 27, Item 65) for leaks and
compactor for problems that would
impair operation.

Any class III


leak.

Check crush-all (Figure 28, Item


66) for loose, broken, or missing
hardware or mounting bracket
damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

0077-24

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

66
Figure 28.

67

EQUIPMENT NOT
READY/
AVAILABLE IF:

HYEX01020

Crush-All.

Check hydraulic hoses (Figure 28,


Item 67) for leaks and crush-all for
problems that would impair
operation.
36

Before

Lubricate

Lubricate crush-all daily before


each use (LO 5-3805-294-13).
(WP 0094)

37

Before

Barrier Grapple

Check barrier grapple (Figure 29,


Item 68) for loose, broken, or
missing hardware or mounting
bracket damage.

0077-25

Any class III


leak.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

69

68
HYEX02987

Figure 29.

Barrier Grapple.
Check barrier grapple for missing or
damaged pads.

Barrier grapple
pad missing or
damaged.

Check that barrier grapple lifting


device (Figure 29, Item 69) does
not have broken strands.

Barrier grapple
cable is kinked
or three or more
strands are broken.

38

Before

Barrier Grapple Actuator

Lubricate actuator before use with


penetrating oil.

39

Before

Deep Dig Arm

Check deep dig arm (Figure 30,


Item 70) for loose, broken, or
missing hardware or damage.

0077-26

Any loose, broken, or missing


hardware or
damage.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

72

71

70

HYEX01306

Figure 30.

40

Before

Deep Dig Bucket

Deep Dig Arm and Bucket.


Check deep dig arm hydraulic
hoses (Figure 30, Item 71) for
leaks, damage, or fraying.

Any class III


leak.

Check deep dig ditch cleaning


bucket (Figure 30, Item 72) for
loose, broken, or missing hardware
or mounting bracket damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

Check bucket (Figure 31, Item 73)


for cracks and missing teeth.
Replace teeth as required.
(WP 0085)

0077-27

TM 5-3805-294-10

Table 1.
ITEM
NO.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

73

Before

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

HYEX01307

Figure 31.

41

0077

Ditch Cleaning Bucket

Deep Dig Bucket.


Check bucket (Figure 31, Item 73)
for loose, broken, or missing
hardware or mounting bracket
damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

Check bucket (Figure 32, Item 74)


for loose, broken, or missing
hardware or mounting bracket
damage.

Loose, broken,
or missing hardware or mounting bracket is
cracked.

0077-28

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

74
HYEX01308

Figure 32.

Ditch Cleaning Bucket.

42

During

Monitor

Check monitor during operation for


any alarm. If alarm sounds or is
displayed on monitor, perform
corrective procedures as needed or
shut down engine. (WP 0009)

Any alarm
sounds or is displayed on monitor.

43

During

Engine speed Dial

Turn engine speed dial and ensure


engine speed increases.

Engine speed
dial does not operate.

44

During

Right-Hand Console
Switches

Operate right-hand console


switches.

Switches do not
operate.

45

During

Hydraulic Cylinders

Check that all hydraulic cylinders


operate smoothly and through full
range of travel.

Hydraulic cylinders do not operate normally


or have class III
leak.

46

During

Travel Motor, Steering,


and Brakes

Travel machine forward a short


distance and ensure that:
Machine travels in a
straight line.
Steers left and right.
Track chain does not
make any unusual or
popping noises.

If machine
doesn't travel in
a straight line.
Machine does
not steer left or
right.
Track chain
makes unusual

0077-29

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE
When travel levers or
pedals are released
machine stops.
Travel levers and pedals
return to center when
released.

EQUIPMENT NOT
READY/
AVAILABLE IF:
or popping
noises.
Machine does
not stop when
travel levers or
pedals are released.
Travel levers or
pedals do not
return to center
when released.

47

During

Travel Alarm

Ensure travel alarm operates when


machine is moved.

Travel alarm
does not operate.

48

During

Swing Motor and Swing


Brake

Swing upperstructure left or right


approximately 90 degrees then
release pilot control levers and
ensure upperstructure stops.

Upperstructure
does not stop or
drifts.

49

During

Air Conditioner/Heater

Ensure air conditioner/heater


blower motor operates.

Blower motor
does not operate when turned
on.

50

During

Breaker

CAUTION
Breaker must be lubricated
every 2 hours of use and every hour during dusty conditions. Failure to comply may
result in damage to the attachment.
During extreme dusty conditions,
lubricate breaker after every hour of
use LO 5-3805-294-13.
(WP 0094)

51

After

Hydraulic Oil Level

To check hydraulic oil level:


Fully extend arm (Figure
33, Item 58).
Curl bucket (Figure 33,
Item 59).
Lower boom (Figure 33,
Item 60) until bucket is
resting on the ground.
Open right door and
ensure that hydraulic oil is

0077-30

Sight glass has


class III leak.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

between marks on sight


glass (Figure 34, Item 61).
Fill as required.

60
58
59

Figure 33.

HYEX01016

Position Boom and Arm.

61

HYEX01017

Figure 34.

Hydraulic Oil Level Check.


To fill hydraulic reservoir:
Shut down engine.
(WP 0009)
Service hydraulic
reservoir. (WP 0088)
Start engine. (WP 0007)
Safely park and shut down
engine. (WP 0009)

52

After

Fuel Tank and Strainer

Check fuel tank and strainer (Figure


35, Item 12) for evidence of leaks or
damage.

0077-31

Any signs of
leaks or damage to fuel tank
or strainer, or
strainer is missing.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

14

13

12

HYEX01005

Figure 35. Fuel Tank and Fuel Level Check.


Ensure fuel tank is full.
To fill fuel tank:
Remove fuel cap (Figure
35, Item 13).
Fill fuel tank (Figure 35,
Item 12) until band (Figure
35, Item 14) is visible.
Install fuel cap (Figure 35,
Item 13).
53

After

CAUTION

Engine Oil Level

New machine break-in


maintenance is required at
250 hours. Contact Field
Maintenance to avoid early
wear or damage to the machine. Failure to comply may
result in voidance of warranty and damage to the machine.
Check oil level on the dipstick
(Figure 36, Item 8) and ensure that
it is between the ADD and FULL
marks.

0077-32

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

8
9

HYEX01003

Figure 36.

Engine Oil Check.


If engine oil is low, remove cap
(Figure 36, Item 9) and add oil as
required.

54

After

Engine Compartment,
Belts, and Hoses

Check engine compartment for


obvious damage or leaks in hoses
or lines. Check belts for cuts or
frays.

HYEX03410

Figure 37.

Engine Compartment.

0077-33

Any damage
that would impair safe operation of the machine.

TM 5-3805-294-10

Table 1.
ITEM
NO.
55

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

After

Exterior of Machine

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE
Perform walk-around inspection of
the machine exterior. Check on
ground under machine (Figure 38,
Item 1) for evidence of fluid leakage
such as oil, coolant, or fuel.

Class III oil or


coolant leaks.
Any fuel leakage is evident.

Check machine (Figure 38, Item 1)


for obvious damage that would
impair operation.

Damage that
would impair
operation is evident.

2
Figure 38.

HYEX01400

Exterior of Machine Check.


Check left and right track chains
(Figure 38, Item 2) for missing
shoes and mounting hardware.

56

Monthly

CAUTION

Swing Gearbox Oil

New machine break-in


maintenance is required at
250 hours. Contact Field
Maintenance to avoid early
wear or damage to the machine. Failure to comply may
result in voidance of warranty and damage to the machine.

0077-34

Any missing
track shoes or
mounting hardware.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE
Check that swing gearbox oil is
between marks on dipstick (Figure
39, Item 75).
76

EQUIPMENT NOT
READY/
AVAILABLE IF:
Oil level is not
on dipstick.

75

HYEX01410

Figure 39.

Swing Gearbox Oil Level Check.


To add oil:
Remove cap (Figure 39,
Item 76).
Add oil until it is between
the marks on the dipstick
(Figure 39, Item 75).
Install cap (Figure 39,
Item 76).

57

Monthly

Hydraulic Pump Gearbox


Oil

Check hydraulic pump gearbox oil


level on dipstick (Figure 40, Item
77).

0077-35

Oil level is below the "L"


mark.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

78

77

HYEX01409

Figure 40.

Hydraulic Pump Oil Level Check.


To add oil:
Remove cap (Figure 40,
Item 78).
Add oil until it reaches the
"H" mark on the dipstick
(Figure 40, Item 77).
Install cap (Figure 40,
Item 78).

58

Monthly

Primary and Final Fuel


Filter/Water Separators

Service primary and final fuel filter/


water separators. (WP 0086)

59

Monthly

Fuel Tank

Drain sediment from fuel tank.


(WP 0091)

60

Monthly

Coolant Heater

Run coolant heater (WP 0034) for


5 minutes to keep water pump from
seizing.

0077-36

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

EQUIPMENT NOT
READY/
AVAILABLE IF:

PROCEDURE

61

Monthly

Primary and Secondary


Air Cleaner

Service primary and secondary air


cleaner. (WP 0087)

62

Monthly

Serpentine Belt

Check serpentine belt (Figure 41,


Item 79) for cracks, cuts and frays.

Serpentine belt
is cut, broken, or
frayed.

79

HYEX01401

Figure 41.
63

Monthly

Air Conditioner Belt

Serpentine Belt Check.


Check air conditioner belt (Figure
42, Item 80) for cracks and cuts.

0077-37

Air conditioner
belt is cut or broken.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

80

HYEX01402

Figure 42.
64

Monthly

Fan

Air Conditioner Belt Check.


Check fan (Figure 43, Item 81) for
damage, debris, and hydraulic
leaks.

0077-38

Any damage
that would impair safe operation of machine.
Any debris that
would block air
flow through radiator.
Any class III hydraulic leak.

TM 5-3805-294-10

Table 1.
ITEM
NO.

0077

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued

INTERVAL

ITEM TO BE CHECKED
OR SERVICED

PROCEDURE

EQUIPMENT NOT
READY/
AVAILABLE IF:

81
HYEX01403

Figure 43.

Fan Check.

65

Monthly

Track Sag

Check track sag. (WP 0080)

66

Monthly

Fresh Air Filter

Service fresh air filter. (WP 0089)

67

Monthly

Air Conditioner/Heater
Filter Service

Service air conditioner/heater


filter. (WP 0090)

68

Monthly

Lubrication

Perform 100 lubrication in


accordance with, LO
5-3805-294-13. (WP 0094)

END OF TASK
END OF WORK PACKAGE

0077-39/40 blank

TM 5-3805-294-10

CHAPTER 5
OPERATOR MAINTENANCE INSTRUCTIONS
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677

TM 5-3805-294-10

0078

OPERATOR MAINTENANCE
GENERAL MAINTENANCE INSTRUCTIONS

INITIAL SETUP:
Not Applicable

GENERAL MAINTENANCE

NOTE
Instructions in this section provide general procedures to be followed for maintenance
authorized at the operator level. Specific instructions are found in the operator maintenance
section of this manual.
This section covers general maintenance instructions for the machine. Read all CAUTIONS and WARNINGS that
apply to all maintenance instructions.
Follow these maintenance practices when working on the machine.
Prior to starting any inspection or maintenance procedure, ensure that machine is safely parked and shut down.
INSPECTION
Electrical Parts. Inspect wiring harnesses for cracked, broken, chafed, bare, and burned insulation, or bare wires.
Inspect all terminal connectors for loose connections and broken parts. Inspect connectors for corrosion or signs of
sparking. This is an indication of a malfunction within the terminal. Notify Field Level maintenance of any part found
to be defective.
Tubing and Hosing. Check all hose surfaces for wear, damage, broken, or frayed coverings, and leaks. Check for
breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. Wet spots show
leaks, but a stain around a fitting or connector may also indicate a leak. If a connector or fitting is loose, broken, or
worn out, notify Field Level maintenance.
Metal Parts. Check bolts, nuts, and screws for obvious looseness. Also check for missing, bent, or broken pieces.
They cannot all be checked with a tool, but look for chipped paint, bare metal, or rust around bolt heads. Look for
loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Visually
inspect all castings and weldments for cracks.

0078-1

TM 5-3805-294-10

0078

CLEANING

WARNING

Never use fuel to clean parts. Fuel is highly flammable. Failure to comply may result in injury
or death to personnel.
Rubber Parts. Do not clean rubber parts in solvent cleaning compound. Wipe parts clean with a dry, cleaning
cloth.
Machine Exterior. Steam clean all exterior parts thoroughly. If pressurized water is not available, wash
painted surfaces of machine with solution of 1/4 cup of soap chips, to 1 gallon (4 L) of water.
Electrical Parts. Electrical parts such as coils, junction blocks, switches, and electrical parts that contain
insulation materials should not be soaked or sprayed with cleaning solutions. Clean these parts with a
cleaning cloth moistened with cleaning compound. Clean rubber parts with hot, soapy water and soft cloths.
Do not clean with solvents.
END OF TASK
END OF WORK PACKAGE

0078-2

TM 5-3805-294-10

0079

OPERATOR MAINTENANCE
TAKING ENGINE OIL SAMPLE

INITIAL SETUP:
Materials/Parts
Bottle, Oil Sample (WP 0097, Table 1, Item 3)
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Engine running. (WP 0007)
Time to Complete
0.2 Hour(s)

Personnel Required
Horizontal Construction Engineer 12N (1)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)

SAMPLING ENGINE
1.

Clean dirt from around cap (Figure 1, Item 1).

1
3

HYEX00909

Figure 1.

Engine Oil Sampling Valve.

2.

Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).

3.

Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.

4.

Release valve (Figure 1, Item 3).

5.

Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).

END OF TASK
END OF WORK PACKAGE

0079-1/2 blank

TM 5-3805-294-10

0080

OPERATOR MAINTENANCE
TRACK SAG CHECK

INITIAL SETUP:
References (cont.)
WP 0007
WP 0009
WP 0081
WP 0082

Tools and Special Tools


Measuring Tape (WP 0095, Table 2, Item 10)
Materials/Parts
Grease (WP 0097, Table 1, Item 10)
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Engine running. (WP 0007)

Personnel Required
Horizontal Construction Engineer 12N (2)

Time to Complete
0.5 Hour(s)

References
DA FORM 5988-E or DA FORM 2404 (WP 0094)

RAISING MACHINE

NOTE
Sag for left and right side tracks is checked the same way.
1.

Swing upperstructure (Figure 1, Item 1) 90 degrees.

3
4

1
5

Figure 1.

HYEX00383

Raise Machine.

2.

Place round side of bucket (Figure 1, Item 2) on ground.

3.

Keeping angle between boom (Figure 1, Item 3) and arm (Figure 1, Item 4) between 90 and 110 degrees,
slowly lower boom (Figure 1, Item 3) to raise track (Figure 1, Item 5) off ground.

END OF TASK

0080-1

TM 5-3805-294-10

0080

TRACK SAG CHECK


1.

Mark track (Figure 2, Item 5) to measure two full rotations of track in each direction.

Figure 2.

Rotate Track.

2.

Rotate track (Figure 2, Item 5) forward two full rotations and in reverse two full rotations.

3.

Move pilot shutoff lever (Figure 3, Item 6) to locked (up) position.

0080-2

HYEX00491

TM 5-3805-294-10

0080

TRACK SAG CHECK - Continued

6
Figure 3.

HYEX01309

Shut Machine Off.

4.

Turn key switch (Figure 3, Item 7) to OFF position.

5.

Measure for a distance of 11.8-13.2 in. (300-335 mm) between surface of track (Figure 4, Item 5) and bottom
of track frame (Figure 4, Item 8) at middle track roller (Figure 4, Item 9).

0080-3

TM 5-3805-294-10

0080

TRACK SAG CHECK - Continued

HYEX00838

Figure 4.

Measure Track Sag.

6.

If track sag is more than 13.2 in. (335 mm), Tighten Track Tension. (WP 0081)

7.

If track sag is less than 11.8 in. (300 mm), Loosen Track Tension. (WP 0082)

8.

If track sag is within limits, go to Lowering Machine task in this work package.

END OF TASK
LOWERING MACHINE
1.

Turn key switch (Figure 5, Item 7) to ON position and start engine.

0080-4

TM 5-3805-294-10

0080

LOWERING MACHINE - Continued

HYEX01309

6
Figure 5.

Start Machine.

2.

Move pilot shutoff lever (Figure 5, Item 6) to unlocked (down) position.

3.

Slowly raise boom (Figure 6, Item 3) until track (Figure 6, Item 5) is resting on ground.

3
4

1
5

Figure 6.

Lower Machine.

0080-5

HYEX00383

TM 5-3805-294-10
LOWERING MACHINE - Continued
4.

Raise boom (Figure 6, Item 3), arm (Figure 6, Item 4), and bucket (Figure 6, Item 2) off ground.

5.

Swing upperstructure (Figure 6, Item 1) 90 degrees.

6.

Safely park and shutdown machine. (WP 0009)

END OF TASK
END OF WORK PACKAGE

0080-6

0080

TM 5-3805-294-10

0081

OPERATOR MAINTENANCE
TIGHTENING TRACK TENSION

INITIAL SETUP:
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
WP 0080

Tools and Special Tools


Grease Gun (WP 0095, Table 2, Item 4)
Materials/Parts
Grease (WP 0097, Table 1, Item 10)
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Track sag checked. (WP 0080)

Personnel Required
Horizontal Construction Engineer 12N

Time to Complete
0.1 Hour(s)

TIGHTENING TRACK
1.

Add a small amount of grease to grease fitting (Figure 1, Item 1).

1
Figure 1.
2.

Tighten Track.

Check track sag. (WP 0080)

END OF TASK
END OF WORK PACKAGE

0081-1/2 blank

HYEX00384

TM 5-3805-294-10

0082

OPERATOR MAINTENANCE
LOOSENING TRACK TENSION

INITIAL SETUP:
Tools and Special Tools
Wrench, Open End, 24 mm
(WP 0095, Table 2, Item 4)

References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
WP 0007

Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Track sag checked. (WP 0080)

Personnel Required
Horizontal Construction Engineer 12N

Time to Complete
0.1 Hour(s)

LOOSENING TRACK TENSION


1.

Loosen nut (Figure 1, Item 1) and allow a small amount of grease to escape.

HYEX00385

Figure 1.
2.

Tighten nut (Figure 1, Item 1).

3.

Check track sag. (WP 0080)

Loosen Track.

END OF TASK
END OF WORK PACKAGE

0082-1/2 blank

TM 5-3805-294-10

0083

OPERATOR MAINTENANCE
TAKING HYDRAULIC OIL SAMPLE

INITIAL SETUP:
Materials/Parts
Bottle, Oil Sample (WP 0097, Table 1, Item 3)
Rags, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Engine running. (WP 0007)
Time to Complete
0.2 Hour(s)

Personnel Required
Horizontal Construction Engineer 12N (1)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)

SAMPLING HYDRAULIC OIL


1.

Clean dirt from around cap (Figure 1, Item 1).


3

HYEX00908

Figure 1.

Hydraulic Oil Sampling Valve.

2.

Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).

3.

Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.

4.

Release valve (Figure 1, Item 3).

5.

Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).

END OF TASK
END OF WORK PACKAGE

0083-1/2 blank

TM 5-3805-294-10
OPERATOR MAINTENANCE
CAB FUSE REPLACEMENT

INITIAL SETUP:
Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.2 Hour(s)

References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
Equipment Condition
Machine safely parked and shut down.
(WP 0009)

REMOVAL

NOTE
All fuses from both main and auxiliary fuse boxes are removed the same way. Main fuse
box shown.
Spare fuses are located in the fuse box. After using a spare fuse, notify Field maintenance
to get a replacement fuse.
1.

Remove fuse box access cover (Figure 1, Item 1) from cab rear tray (Figure 1, Item 2).

0084-1

0084

TM 5-3805-294-10

0084

REMOVAL - Continued

2
1

HYEX00089

Figure 1.
2.

Fuse Box Access Cover Removal.

Remove main fuse box cover (Figure 2, Item 3) from main fuse box (Figure 2, Item 4).

0084-2

TM 5-3805-294-10

0084

REMOVAL - Continued

3
4
HYEX00097

Figure 2.

Main Fuse Box Cover Removal.

3.

Locate fuse in question using key found on fuse box cover (Figure 2, Item 3).

4.

Remove fuse (Figure 3, Item 5) from main fuse box (Figure 3, Item 4).

0084-3

TM 5-3805-294-10

0084

REMOVAL - Continued

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.

Main Fuse Box Cover Installation.

Install fuse box access cover (Figure 6, Item 1) to cab rear tray (Figure 6, Item 2).

0084-6

TM 5-3805-294-10

0084

INSTALLATION - Continued

2
1

HYEX00089

Figure 6.

Fuse Box Access Cover Installation.

END OF TASK
END OF WORK PACKAGE

0084-7/8 blank

TM 5-3805-294-10

0085

OPERATOR MAINTENANCE
BUCKET TEETH REPLACEMENT

INITIAL SETUP:
Tools and Special Tools
Hammer, Hand, 3 lb (WP 0095, Table 2, Item 5)
Punch, Pin (WP 0095, Table 2, Item 9)

Equipment Condition
Machine safely parked and shut down.
(WP 0009)

Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.2 Hour(s)

References
DA FORM 5988-E or DA FORM 2404 (WP 0094)

HEAVY DUTY BUCKET TOOTH REMOVAL


1.

Using hammer and pin punch, drive out pin (Figure 1, Item 1) from tooth (Figure 1, Item 2) and shank (Figure
1, Item 3).

1
Figure 1.

2.

2
Tooth Removal.

Remove tooth (Figure 1, Item 2) from shank (Figure 1, Item 3).

END OF TASK

0085-1

HYEX01282

TM 5-3805-294-10

0085

HEAVY DUTY BUCKET TOOTH INSTALLATION


1.

Position tooth (Figure 2, Item 2) on shank (Figure 2, Item 3).

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

Figure 3. Bucket Tooth Removal.

0085-2

TM 5-3805-294-10

0085

DEEP DIG BUCKET TOOTH REMOVAL - Continued


2.

Remove tooth (Figure 3, Item 5) from shank (Figure 3, Item 6).

END OF TASK
DEEP DIG BUCKET TOOTH INSTALLATION
1.

Position tooth (Figure 4, Item 5) on shank (Figure 4, Item 6).

4
5

6
HYEX01281

Figure 4.
2.

Bucket Tooth Installation.

Using hammer, drive pin (Figure 4, Item 4) to tooth (Figure 4, Item 5) and shank (Figure 4, Item 6) until seated.

END OF TASK
END OF WORK PACKAGE

0085-3/4 blank

TM 5-3805-294-10

0086

OPERATOR MAINTENANCE
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE

INITIAL SETUP:
Tools and Special Tools
Pan, Drain

Equipment Condition
Machine safely parked and shut down (WP 0009)

Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.1 Hour(s)

DRAIN FUEL FILTER/WATER SEPARATORS

WARNING

DIESEL FUEL
1.

Disconnect wiring harness connector D01 (Figure 1, Item 1) from water in fuel (WIF) sensor (Figure 1, Item
2).

5
HYEX00103

Figure 1.

Drain Fuel Filter/Water Separators.

0086-1

TM 5-3805-294-10

0086

DRAIN FUEL FILTER/WATER SEPARATORS - Continued

NOTE
Place drain pan under fuel/water separators prior to draining.
2.

Loosen, but do not remove WIF sensor (Figure 2, Item 2), and drain water/sediment from primary fuel filter/
water separator (Figure 2, Item 3) for approximately 30 seconds.

5
HYEX00103

Figure 2. Drain Fuel Filter/Water Separators Continued.


3.

Tighten WIF sensor (Figure 2, Item 2).

4.

Connect wiring harness connector D01 (Figure 2, Item 1) to WIF sensor (Figure 2, Item 2).

5.

Loosen, but do not remove valve (Figure 2, Item 4), and drain water/sediment from final fuel filter/water
separator (Figure 2, Item 5) for approximately 30 seconds.

6.

Tighten valve (Figure 2, Item 4).

END OF TASK
END OF WORK PACKAGE

0086-2

TM 5-3805-294-10

0087

OPERATOR MAINTENANCE
PRIMARY AND SECONDARY AIR CLEANER SERVICE

INITIAL SETUP:
Materials/Parts
Rag, Wiping (WP 0097, Table 1, Item 15)

Equipment Condition
Engine off. (WP 0009)

Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.4 Hour(s)

REMOVAL
1.

Lift lever (Figure 1, Item 1) and rotate cover (Figure 1, Item 2) counterclockwise.

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

Figure 2. Primary Air Cleaner Removal.


4.

Remove secondary air cleaner (Figure 3, Item 5) from air cleaner housing (Figure 3, Item 3).

HYEX00075

Figure 3.

Secondary Air Cleaner Removal.

END OF TASK

0087-2

TM 5-3805-294-10

0087

SERVICING AIR CLEANERS

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from
user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed
air is used to clean parts. Always wear safety glasses when using compressed air. Failure to
comply may result in injury or death to personnel.

NOTE
Contact field level maintenance for an air hose and air nozzle to service the air cleaner.
Secondary air cleaner does not require servicing, only replacement.
1.

Lightly tap primary air cleaner (Figure 4, Item 4) to remove major amount of dirt from primary air cleaner.

HYEX00076

Figure 4.

Primary Air Cleaner Service.

2.

Start from inside, top of primary air cleaner (Figure 4, Item 4), blow remainder of debris out of primary air
cleaner.

3.

Work around and inward of primary air cleaner (Figure 4, Item 4) until primary air cleaner has been completely
blown out.

4.

Wipe out air cleaner housing (Figure 5, Item 3) with a clean rag.

0087-3

TM 5-3805-294-10

0087

SERVICING AIR CLEANERS - Continued


3

HYEX00077

Figure 5. Air Cleaner Housing Service.


5.

Wipe inside of cover (Figure 6, Item 2) with a clean rag and squeeze dust boot (Figure 6, Item 6) to remove
dust.

2
HYEX00078

Figure 6.

Cover and Dust Boot Service.

END OF TASK
INSTALLATION

NOTE
Dust valve will be at the 6 O'clock position when air cleaner cover is installed.
1.

Install secondary air cleaner (Figure 7, Item 5) to air cleaner housing (Figure 7, Item 3).

0087-4

TM 5-3805-294-10

0087

INSTALLATION - Continued
3

HYEX00084

Figure 7.
2.

Secondary Air Cleaner Installation.

Install primary air cleaner (Figure 8, Item 4) to air cleaner housing (Figure 8, Item 3).

HYEX00074

Figure 8.
3.

Primary Air Cleaner Installation.

Position cover (Figure 9, Item 2) on air cleaner housing (Figure 9, Item 3).

0087-5

TM 5-3805-294-10

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)

FILLING HYDRAULIC RESERVOIR

WARNING

Hydraulic system operates at high pressures and temperatures. Always allow hydraulic oil to
cool and relieve pressure in hydraulic reservoir before working on hydraulic system. Wear
eye protection and gloves to prevent injury. Open lines and hoses slowly and wait for any
residual pressure to relieve before continuing to open lines and hoses. Failure to comply may
result in injury or death to personnel.
1.

Press button (Figure 1, Item 1) to relieve pressure from hydraulic reservoir (Figure 1, Item 2).
1

2
HYEX00085

Figure 1. Hydraulic Reservoir Cover Removal.


2.

Remove four screws (Figure 1, Item 3) and hydraulic reservoir cover (Figure 1, Item 4) from hydraulic reservoir
(Figure 1, Item 2).

0088-1

TM 5-3805-294-10

0088

FILLING HYDRAULIC RESERVOIR - Continued

WARNING

LUBRICATING OIL
3.

Fill hydraulic reservoir (Figure 2, Item 2) until oil is between marks (Figure 2, Item 5) on sight glass (Figure 2,
Item 6). LO 5-3805-294-13 (WP 0094)

5
2
6

HYEX00086

Figure 2. Hydraulic Reservoir Sight Glass.


4.

Ensure O-ring (Figure 3, Item 7) is present and is not damaged. If O-ring is missing or damaged, notify field
maintenance.

0088-2

TM 5-3805-294-10

0088

FILLING HYDRAULIC RESERVOIR - Continued


4
3

HYEX00087

Figure 3. Hydraulic Reservoir Cover Installation.


5.

Install hydraulic reservoir cover (Figure 3, Item 4) to hydraulic reservoir (Figure 3, Item 2) with four screws
(Figure 3, Item 3).

END OF TASK
END OF WORK PACKAGE

0088-3/4 blank

TM 5-3805-294-10

0089

OPERATOR MAINTENANCE
FRESH AIR FILTER SERVICE

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

Materials/Parts
Rag, Wiping (WP 0097, Table 1, Item 15)
Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.2 Hour(s)

References
TM 5-3805-295-13&P (WP 0094)
DA FORM 5988-E or DA FORM 2404 (WP 0094)

REMOVAL

NOTE
After the fresh air filter has been serviced three times, it must be replaced by Field
Maintenance.
1.

Move two tabs (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).

Figure 1.
2.

Filter Removal.

Inspect seal (Figure 2, Item 4) on filter (Figure 2, Item 2).

0089-1

HYEX00168

TM 5-3805-294-10

0089

REMOVAL - Continued

Figure 2.
3.

HYEX00169

Inspect Seal.

If seal (Figure 2, Item 4) is damaged, contact field maintenance.

END OF TASK
SERVICE

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from
user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed
air is used to clean parts. Always wear safety glasses when using compressed air. Failure to
comply may result in injury or death to personnel.

NOTE
Contact field level maintenance for an air hose and air nozzle to service the air filter.
If HYEX is equipped with a Supplemental Armor Set, refer to and use procedure found
in TM 5-3805-295-13&P.
1.

Lightly tap filter (Figure 3, Item 2) with hand.

0089-2

TM 5-3805-294-10

0089

SERVICE - Continued

HYEX00170

Figure 3.

Clean Filter.

CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
to comply may result in damage to equipment.
2.

Blow remainder of debris from filter (Figure 3, Item 2).

3.

Wipe inside of housing (Figure 4, Item 3) with clean rag.

HYEX00171

Figure 4.

Clean Housing.

END OF TASK

0089-3

TM 5-3805-294-10

0089

INSTALLATION
1.

Install filter (Figure 5, Item 2) to housing (Figure 5, Item 3).

Figure 5.
2.

Filter Installation.

Ensure tabs (Figure 5, Item 1) lock.

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.

Lightly tap filter (Figure 2, Item 2) with hand.

0090-1

TM 5-3805-294-10

0090

SERVICE - Continued

HYEX00188

2
Figure 2.

Clean Filter.

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from
user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed
air is used to clean parts. Always wear safety glasses when using compressed air. Failure to
comply may result in injury or death to personnel.

CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
to comply may result in damage to equipment.
2.

Blow remainder of debris from filter (Figure 2, Item 2).

3.

Wipe inside of housing (Figure 3, Item 3) with clean rag.

0090-2

TM 5-3805-294-10

0090

SERVICE - Continued

HYEX00190

Figure 3.

Clean Housing.

END OF TASK
INSTALLATION
1.

Install filter (Figure 4, Item 2) to housing (Figure 4, Item 3).

Figure 4.
2.

Filter Installation.

Ensure tab (Figure 4, Item 1) locks.

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)

DRAINING WATER AND SEDIMENT

NOTE
Contact Field Maintenance for drain pan.
1.

Remove fuel tank fill cap (Figure 1, Item 1).

1
HYEX01298

Figure 1.
2.

Remove Fuel Cap.

Position drain pan under drain hose (Figure 2, Item 2).

0091-1

TM 5-3805-294-10

0091

DRAINING WATER AND SEDIMENT - Continued

HYEX00914

Figure 2.
3.

Drain Hose.

Open drain valve (Figure 3, Item 3) and drain water and sediment until a clear stream of fuel comes out.

0091-2

TM 5-3805-294-10

0091

DRAINING WATER AND SEDIMENT - Continued

HYEX00915

Figure 3.
4.

Close drain valve (Figure 3, Item 3).

5.

Dispose of waste properly.

6.

Install fuel tank fill cap (Figure 4, Item 1).

Drain Valve.

0091-3

TM 5-3805-294-10

0091

DRAINING WATER AND SEDIMENT - Continued

1
HYEX01298

Figure 4.

Install Fuel Cap.

END OF TASK
END OF WORK PACKAGE

0091-4

TM 5-3805-294-10
OPERATOR MAINTENANCE
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT

INITIAL SETUP:
Tools and Special Tools
Wrench 2-1/4
Wrench 2-1/2 (WP 0095, Table 2, Item 15)

Equipment Condition
Machine safely parked and shut down
(WP 0009)

Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.3 Hour(s)

References
DA FORM 5988-E or DA FORM 2404 (WP 0094)

DISCHARGE ADJUSTMENT

WARNING

Unless otherwise specified, perform all maintenance procedures with all attachments lowered
to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may
result in injury or death to personnel.

NOTE
Ensure curtain is set to desired discharge size before Crush-All operation.
There are no disassembly requirements to perform discharge adjustments. Adjustment
points are on the outside of the machine.
There are two adjustment points for lower curtain. Adjustment procedure is identical for
both points and must be adjusted at same time.
Raise curtain to increase discharge size.
Lower curtain to decrease discharge size.
To reduce dust, increase discharge size.
Repeat steps for opposite side.
1.

Loosen nut (Figure 1, Item 1) on nut (Figure 1, Item 2) and rod (Figure 1, Item 3).

0092-1

0092

TM 5-3805-294-10

0092

DISCHARGE ADJUSTMENT - Continued

3
5
6
7, 8, 9
10
11

2
1

HYEX03092

Figure 1.

Curtain Adjustment.

2.

Loosen nut (Figure 1, Item 2) on rod (Figure 1, Item 3) to release tension from spring (Figure 1, Item 4).

3.

Using wrench provided with crush-all loosen nut (Figure 1, Item 5) on nut (Figure 1, Item 6) and rod (Figure 1,
Item 3).

4.

Remove bolt (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and washer (Figure 1, Item 9) from clamp (Figure
1, Item 10) and plate (Figure 1, Item 11).

5.

Remove clamp (Figure 1, Item 10) from nut (Figure 1, Item 6) and plate (Figure 1, Item 11).

6.

Turn nut (Figure 2, Item 6) to raise or lower curtain (Figure 2, Item 12).

0092-2

TM 5-3805-294-10

0092

DISCHARGE ADJUSTMENT - Continued

12

14
13

HYEX03093

Figure 2.

Clearance Check.

CAUTION
Ensure surface of blow bar does not touch curtain. Failure to comply may result in damage
to equipment.
7.

Turn rotor (Figure 2, Item 13) manually. Verify curtain (Figure 2, Item 12) does not touch rotor (Figure 2, Item
13) or blow bars (Figure 2, Item 14).

8.

Position clamp (Figure 3, Item 10) on nut (Figure 3, Item 6) and plate (Figure 3, Item 11).

0092-3

TM 5-3805-294-10

0092

DISCHARGE ADJUSTMENT - Continued

11

7, 8, 9

10

HYEX03094

Figure 3.

Clamp Installation.

9.

Install clamp (Figure 3, Item 10) on plate (Figure 3, Item 11) with bolt (Figure 3, Item 7), lockwasher (Figure 3,
Item 8), and washer (Figure 3, Item 9).

10.

Using wrench provided with crush-all tighten nut (Figure 3, Item 5) against nut (Figure 3, Item 6) on rod (Figure
3, Item 3).

11.

Tighten nut (Figure 4, Item 2) and compress spring (Figure 4, Item 4) to align marks (Figure 4, Item 15) and
(Figure 4, Item 16).

0092-4

TM 5-3805-294-10

0092

DISCHARGE ADJUSTMENT - Continued


3

16

15

2
1

HYEX03095

Figure 4.
12.

Spring Compression.

Tighten nut (Figure 4, Item 1) against nut (Figure 4, Item 2) on rod (Figure 4, Item 3).

END OF TASK
END OF WORK PACKAGE

0092-5/6 blank

TM 5-3805-294-10

0093

OPERATOR MAINTENANCE
MAINTENANCE AFTER FORDING

INITIAL SETUP:
Tools and Special Tools
Grease Gun (WP 0095, Table 2, Item 4)
Wrench 17 mm (WP 0095, Table 2, Item 17)

References
LO 5-3805-294-13 (WP 0094)
DA FORM 5988-E or DA FORM 2404 (WP 0094)

Materials/Parts
Grease, Automotive and Artillery
(WP 0097, Table 1, Item 10)

Equipment Condition
Machine safely parked and shut down.
(WP 0094)

Personnel Required
Horizontal Construction Engineer 12N (1)

Time to Complete
0.5 Hour(s)

DRAINING MUD OR WATER


1.

Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from cover (Figure 1, Item 3).
1, 2

3, 4
5

HYEX03286

Figure 1.

Draining Mud or Water.

2.

Remove cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from machine (Figure 1, Item 5) and allow mud
or water to completely drain.

3.

Remove any contaminated grease.

4.

Install cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) to machine (Figure 1, Item 5) with two bolts (Figure
1, Item 1) and washers (Figure 1, Item 2).

0093-1

TM 5-3805-294-10
DRAINING MUD OR WATER - Continued
5.

If grease was removed, notify field level maintenance to service swing gear and swing bearing.

END OF TASK
END OF WORK PACKAGE

0093-2

0093

TM 5-3805-294-10

CHAPTER 6
OPERATOR SUPPORTING INFORMATION
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677

TM 5-3805-294-10

0094

OPERATOR MAINTENANCE
REFERENCES

SCOPE
This work package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in
this manual.
ARMY REGULATIONS
AR 25-52

Authorized Abbreviations and Brevity Codes

AR 310-25

Dictionary of United States Army Terms

AR 385-40

Accident Reporting and Records

AR 385-55

Prevention of Motor Vehicle Accidents

AR 700-138

Army Logistics Readiness and Sustainability

DEPARTMENT OF ARMY PAMPHLETS (DA PAM)


DA PAM 25-30

Consolidated Index of Army Publications and Blank Forms

DA PAM 750-8

The Army Maintenance Management System (TAMMS)


Users Manual

FIELD MANUALS
FM 1-02

Military Symbols

FM 3-11.5

Chemical, Biological, Radiological, and Nuclear


Decontamination

FM 3-97.6

Mountain Operations

FM 4-25.11

First Aid

FM 7-1

Military Training Management

FM 9-207

Operation and Maintenance of Ordnance Material in Cold


Weather (0F to -65F)

FM 20-3

Camouflage

FM 21-305

Manual for Wheeled Vehicle Driver

FM 31-70

Basic Cold Weather

FM 31-71

Northern Operations

FM 38-700 & 701

Preservation and Packing of Military Supplies and Equipment

FM 55-15

Transportation Reference Data

FM 90-3

Desert Operations

0094-1

TM 5-3805-294-10

0094

FORMS
DA Form 2404

Equipment Inspection and Maintenance Worksheet

DA Form 2408-9

Equipment Control Record

DA Form 5988-E

Equipment Inspection and Maintenance (Electronic)


Worksheet

DD Form 1149

Requisition and Invoice/Shipping Document

DD Form 1266

Request for Special Hauling Permit

DD Form 250

Material Inspection and Receiving Report

SF 368

Product Quality Deficiency Report

MILITARY HANDBOOK (MIL-HDBK)


MIL-HDBK-1791

Designing for Internal Aerial Delivery in Fixed Winged Aircraft

MILITARY STANDARD (MIL-STD)


MIL-STD-810

Enviromental Test Methods and Engineering Guidelines

MIL-STD-1366

Interface Standard for Transportability Criteria

TECHNICAL BULLLITENS
TB 5-3805-294-13

Warranty Program for Hydraulic Excavator 240D LC

TB 9-2300-281-35

Standards for Overseas Shipment or Domestic Issue of


Special Purpose Vehicles

TB 43-0209

Color, Marking, and Camouflage Painting of Military Vehicles,


Construction Equipment, and Materials Handling Equipment

TB 43-0216

Safety and Hazard Warnings for Operation and Maintenance


of TACOM Equipment

TB 55-45

Certification of Military Equipment for Transport in AMC/


CRAF Aircraft

TB 740-97-2

Preservation of USAMECOM Mechanical Equipment for


Shipment and Storage

TECHNICAL MANUALS
LO 5-3805-294-13

Lubrication Instructions for the Hydraulic Excavator (HYEX)

TM 5-3805-295-13&P

Operator's and Field Level Maintenance Manual for


Supplemental Armor Set for Hydraulic Excavator (HYEX)
(John Deere 240D LCR)

0094-2

TM 5-3805-294-10

0094

TECHNICAL MANUALS - Continued


TM 9-2330-381-13

Operator and Field Maintenance Manual for the Semitrailer,


Transporter, Heavy Equipment

TM 21-40

Chemical, Biological, Radiological, and Nuclear Defense

TM 38-250/AFR 71-4

Preparation of Hazardous Materials for Military Air Shipment

TM 55-2200-001-12

Transportability Guidance for Application of Blocking, Bracing


and Tiedown Materiels for Rail Transport

TM 750-244-6

Procedures for Destruction of Tank-Automotive Equipment to


Prevent Enemy Use

END OF WORK PACKAGE

0094-3/4 blank

TM 5-3805-294-10

0095

OPERATOR MAINTENANCE
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

INTRODUCTION
Scope
This work package lists COEI and BII for the Hydraulic Excavator (HYEX) to help you inventory items for safe
operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components of End Item (COEI). This list is for information purposes only and is not authority to requisition
replacements. These items are part of the HYEX. As part of the end item, these items must be with the end item
whenever it is issued or transferred between property accounts. Items of COEI are removed and separately
packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify
the items.
Basic Issue Items (BII). These essential items are required to place the (HYEX) in operation, operate it, and to do
emergency repairs. Although shipped separately packaged, BII must be with the Hydraulic Excavator during
operation and when it is transferred between property accounts. Listing these items is your authority to request/
requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished
to help you find and identify the items.
Explanation of Columns in the COEI List and BII List
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.

0095-1

TM 5-3805-294-10

Table 1.

0095

COMPONENTS OF END ITEM

(1)

(2)

(3)

(4)

(5)

(6)

ITEM
NUMBER

NATIONAL STOCK NUMBER


(NSN) AND ILLUSTRATION

DESCRIPTION, PART
NUMBER/(CAGEC)

USABLE
ON CODE

U/I

QTY
RQR

Ditch Cleaning Bucket


C909323-623315 (8U941)

EA

Quick Latch
C909332(1J955)

EA

Rock Bucket, 42 in.


909325-623327(8U941)

EA

Hydraulic Thumb
70N0013(3PSD7)

EA

HYEX01340

2540-01-478-1207

HYEX01359

HYEX01341

HYEX01360

0095-2

TM 5-3805-294-10

Table 1.

0095

COMPONENTS OF END ITEM - Continued

(1)

(2)

(3)

(4)

(5)

(6)

ITEM
NUMBER

NATIONAL STOCK NUMBER


(NSN) AND ILLUSTRATION

DESCRIPTION, PART
NUMBER/(CAGEC)

USABLE
ON CODE

U/I

QTY
RQR

EA

2590-01-474-7812

Vandal Protection Kit


AP33356 (75755)

HYEX01342

0095-3

TM 5-3805-294-10

Table 2.

0095

BASIC ISSUE ITEMS

(1)

(2)

(3)

(4)

(5)

(6)

ITEM
NUMBER

NATIONAL STOCK NUMBER


(NSN) AND ILLUSTRATION

DESCRIPTION, PART
NUMBER/(CAGEC)

USABLE
ON CODE

U/I

QTY
RQR

Bag, Mason
204900 (3PSD7)

EA

Cap
811438500 (1BVQ2)

EA

Cap, Pin
U42984 (3PSD7)

EA

Gun, Grease, Lever Action, 12


in. (304.8 mm)
7Y26518 (3PSD7)

EA

Hammer, Hand, 3 lb (1.36 kg)


B3-3LB(72987)

EA

Operator's Manual TM
5-3805-294-10

EA

Plug, Hex 37 Degree Flare, -12


205324(1BVQ2)

EA

Plug, Hex 37 Degree Flare, -6


R39783 (3PSD7)

EA

HYEX03287

HYEX03288

HYEX03289

4
HYEX01349

5
HYEX03327

6
TM 5-3805-294-10
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR

HYDRAULIC EXCAVATOR (HYEX)


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

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

HEADQUARTERS, DEPARTMENT OF THE ARMY


XXXX XXXX

HYEX01339

HYEX03290

8
HYEX03291

0095-4

TM 5-3805-294-10

Table 2.

0095

BASIC ISSUE ITEMS - Continued

(1)

(2)

(3)

(4)

(5)

(6)

ITEM
NUMBER

NATIONAL STOCK NUMBER


(NSN) AND ILLUSTRATION

DESCRIPTION, PART
NUMBER/(CAGEC)

USABLE
ON CODE

U/I

QTY
RQR

Punch, Drift
70-195(08292)

EA

Tape, Measuring 25 FT
68-445 (08292)

EA

Screwdriver, Pry Bar, 12 in.


(305 mm) Long
B107.60 (05047)

EA

Tooth, Surface Ripping


TX400 (1J955)

EA

Vice Grips
67-460 (08292)

EA

Wrench, Open End, 3 in. (76


mm)
T183966 (75755)

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

BASIC ISSUE ITEMS - Continued

(1)

(2)

(3)

(4)

(5)

(6)

ITEM
NUMBER

NATIONAL STOCK NUMBER


(NSN) AND ILLUSTRATION

DESCRIPTION, PART
NUMBER/(CAGEC)

USABLE
ON CODE

U/I

QTY
RQR

Wrench, Open End, 2 1/2 in.


(63.5 mm)
AT189507 (75755)

EA

Wrench, Allen, 5 mm (0.196


in.)
B18.3.2M (05047)

EA

Wrench, Open End, 17 mm


52-217 (08292)

EA

Wrench, Open End, 24 mm


52-224 (08292)

EA

Wrench, Open End,


Adjustable, 0.95 in. (24 mm)
Jaw Opening, 15 in. (381 mm)
Long
11655778-3 (19207)

EA

15

HYEX01345

16

5120-01-045-4889

HYEX01344

17

HYEX01356

18

5120 - 01-581-3318

HYEX01356

19

5120-00-240-5328

HYEX01343

END OF WORK PACKAGE

0095-6

TM 5-3805-294-10

0096

OPERATOR MAINTENANCE
ADDITIONAL AUTHORIZATION LIST (AAL)

INTRODUCTION
SCOPE
This work package lists additional items you are authorized for the support of the Hydraulic Excavator (HYEX).
GENERAL
This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it. These
items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (2) - Description, Part Number/(CAGEC). Identifies the Federal item name (in Initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Column (4) - Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (1).
Column (5) - Quantity Recommended (Qty Recom). Indicates the quantity recommended.
Table 1.

Additional Authorization List.

(1)

(2)

(3)

(4)

(5)

NATIONAL STOCK
NUMBER (NSN)

DESCRIPTION, PART NUMBER/


(CAGEC)

USABLE ON
CODE

U/I

QTY RECOM

EA

Compactor
IHC 00130FT (1N0L6)
END OF WORK PACKAGE

0096-1/2 blank

TM 5-3805-294-10

0097

OPERATOR MAINTENANCE
EXPENDABLE AND DURABLE ITEMS LIST

Introduction
Scope
This work package lists expendable/durable supplies and materials you will need to operate and maintain the
Hydraulic Excavator (HYEX). This list is for information only and is not authority to requisition the listed items. These
items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and
Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical
Department Expendable/Durable Items.
Explanation of Columns in the Expandable/Durable Items List
Column (1) - Item Number
This number is assigned to the entry in the listing and is referenced in the initial setup narrative instructions to identify
the material.
Column (2) - Level
This column identifies the lowest level of maintenance that requires the listed item.
C -- Operator/Crew

F -- Field

H -- Below Depot

D -- Depot

Column (3) - National Stock Number (NSN)


This is the NSN assigned to the item which you can use to requisition it.
Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number
(P/N)
This column provides the other information you need to identify the item. The last line below the description is the
part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).
Column (5) - Unit of Issue (U/I)
Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.
Table 1.

Expendable and Durable Items List

(1)

(2)

(3)

(4)

(5)

ITEM
NO.

LEVEL

NATIONAL STOCK
NUMBER (NSN)

ITEM NAME, DESCRIPTION, PART NUMBER/


(CAGEC)

U/I

6850-01-441-3248

Antifreeze, Permanent, Type: Arctic Grade 55-Gallon


Drum
A-A-52624 (58536)

0097-1

DR

TM 5-3805-294-10

Table 1.

0097

Expendable and Durable Items List - Continued

(1)

(2)

(3)

(4)

(5)

ITEM
NO.

LEVEL

NATIONAL STOCK
NUMBER (NSN)

ITEM NAME, DESCRIPTION, PART NUMBER/


(CAGEC)

U/I

6850-01-441-3257

Antifreeze, Permanent, Ethylene Glycol, Inhibited 5Gallon Can


A-A-52624 (58536)

CO

8125-01-193-3440

Bottle, Oil Sample


M44054 TYPE III (81349)

BX

6850-00-926-2275

Cleaning Compound, Windshield 1-pt Can


0854-000 (0FTT5)

BX

9130-01-031-5816

Fuel, JP8 Bulk


MILT83133 GR JP8 (81349)

GL

9140-01-413-7511

Fuel, DF-2, Regular Bulk


W-F-800 (81348)

GL

9140-00-286-5294

Fuel, DF-2, Regular Bulk


ASTM D 975 (58536)

GL

9140-01-412-1311

Fuel, DF-1, Winter Bulk


W-F-800 (81348)

GL

9140-00-286-5286

Fuel, DF-1, Winter Bulk


AA52557-1 (58536)

GL

10

9150-01-197-7688

Grease, Automotive and Artillery, GAA 2-1/4-oz Tube


M-10924-A (81349)

TU

11

9150-00-111-6256

Lubricating Oil, OEA Ice, Subzero 1-qt Can


MIL-PRF-46170 (81349)

QT

12

9150-00-111-6255

Lubricating Oil, OEA Ice, Subzero 5-gal Can


MIL-PRF-46170 (81349)

GL

13

9150-01-438-6076

Lubricating Oil, Engine OE/HDO 15W-40 1-qt Can


MIL-PRF-2104 (81349)

QT

14

9150-00-973-9504

Penetrating Oil Can, 8 oz Can


L3 (77628)

CN

15

7920-00-148-9666

Rag, Wiping
7920-00-148-9666 (80244)

BE

END OF WORK PACKAGE

0097-2

TM 5-3805-294-10

0098

OPERATOR MAINTENANCE
SPECIAL PURPOSE KITS (SPK) LIST

SCOPE
This work package lists the Special Purpose Kits (SPKs) for support of the Hydraulic Excavator (HYEX) Type 1.
Where to find operation instructions and troubleshooting procedures for the SPKs are also provided.
OPERATION INSTRUCTIONS FOR SPKS
For instructions on how to select the SPKs on the operators monitor, go to Selecting an Attachment On the
Monitor (WP 0018).
To operate the SPKs go to Operating the Barrier Grapple (WP 0022), Installing and Operating the Compactor and
Breaker (WP 0020), or Installing and Operating the Crush-All (WP 0019).
The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX
Type 1 by Field Maintenance. To operate the Deep Dig Arm, go to Operating the Deep Dig Arm (WP 0023).
TROUBLESHOOTING PROCEDURES FOR SPKS
To find troubleshooting procedures for the SPK items, go to the Troubleshooting Index (WP 0037).
INTRODUCTION TO THE SPECIAL PURPOSE KITS LIST
Special Purpose Kits (SPK) listed in Table 1 are for information purposes only and are not the authority to requisition
replacements. These items are part of the HYEX Type 1, but they are removed and separately packaged for
transportation or shipment. As part of the end item, these items must be with the end item whenever it is issued or
transferred between property accounts. Illustrations are furnished to help you find and identify the items.
EXPLANATION OF COLUMNS IN TABLE 1
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name followed by a minimum description
when needed. The last line below the description is the part number and the Commercial and Government Entity
Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (2).
Column (6) QTY RQD. Indicates the quantity required.

0098-1

TM 5-3805-294-10

0098

SCOPE - Continued
SPECIAL PURPOSE KITS
Table 1.
(1)
ITEM
NO.

(2)
NATIONAL STOCK NUMBER

Special Purpose Kits.


(3)
DESCRIPTION,
PART NUMBER/(CAGEC)

(4)
USABLE
ON CODE

(5)
U/I

(6)
QTY
RQD

Arm, Long Reach


502113 (1BVQ2)

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

Special Purpose Kits - Continued.


Crush-All
502063 (1BVQ2)

EA

Excavator Bucket (Deep Dig)


70G0001 (3PSD7)

EA

Bucket, Scoop Loader (Deep Dig)


70G0002 (3PSD7)

EA

HYEX02521

HYEX02523

HYEX02524

END OF WORK PACKAGE

0098-3/4 blank

TM 5-3805-294-10

0099

OPERATOR MAINTENANCE
TROUBLESHOOTING NOTES

Troubleshooting Notes
This paragraph contains troubleshooting information for locating and correcting some operating troubles which may
develop in the HYEX. This manual cannot list all possible malfunctions that may occur, nor can it include all tests,
inspections, and corrective actions. Notify field maintenance personnel if a malfunction is not listed, unless a
malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed.
Procedures. The troubleshooting symptom index lists possible malfunctions that may be experienced during
operation of machine or components. Each malfunction for an individual component, unit, or system is followed by
a list of tests or inspections and corrective actions.
Lubrication. When instructions to lubricate, grease, oil, or add oil appear in the troubleshooting table, refer to Operator
Preventive Maintenance Checks and Services. (WP 0077)
END OF WORK PACKAGE

0099-1/2 blank

TM 5-3805-294-10

0100

OPERATOR MAINTENANCE
HYEX TRANSPORTABILITY INSTRUCTIONS

HYEX TRANSPORTABILITY INSTRUCTIONS.


The HYEX can be transported via highway, rail, marine, C-5, and C-17 air transport and meets all weight and
dimensional requirements while in its standard configuration with no reduction or sectionalization required.
TRANSPORTABILITY RELATED PUBLICATIONS.
Additional information on transport procedures can be found in:
1. TB 9-2300-281-35, Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles
WP 0094.
2. TM 38-250/AFR 71-4, Preparation of Hazardous Materials for Military Air Shipment WP 0094.
TRANSPORTABILITY RELATED DEFINITIONS.
Technical terms that may be helpful while preparing the HYEX for transportation are:
1. Center of Gravity (CG). The balance point of a suspended item. The HYEX counterweight is used to shift
CG to the rear.
2. Curb Weight (CW). Total weight of operational HYEX including fuel, all system fluids, and on-vehicle Basic
Issue Items (BII). CW does not include crew weight, which in this case, is less than one percent of the gross
vehicle weight.
3. Gross Vehicle Weight (GVW). CW plus payload. For transport purposes, there is no payload. Therefore, the
GVW equals the CW.
MILITARY LOAD CLASSIFICATION.
The Military Load Classifications (MLC) for the HYEX are as follows:
1. HYEX Standard Cab System - MLC 32
2. HYEX Armored Cab System - MLC 34

HYEX03197

Figure 1.

Military Load Classification.

0100-1

TM 5-3805-294-10

0100

HYEX SHIPPING WEIGHT.


1. HYEX with Standard Cab shipping weight, without bucket or attachment = 58,900 lbs
2. HYEX with Armored Cab shipping weight without bucket or attachment = 63,000 lbs
HYEX HIGHWAY TRANSPORTABILITY.

NOTE
The HYEX is self-propelled at speeds up to 3.4 mph.
The unit transportation officer must contact local authorities to ensure the HYEX is not
required to have special permits prior to highway transporting.
The HYEX transport height is 10 feet 1 inch so it is capable of normal highway transport on trailers that have a bed
height of 40 inches or less. HYEX is transportable on common military trailers, especially the M870A1 and M870A3.
The HYEX is outfitted with a hydraulic quick latch for rapid exchange of attachments. HYEX can normally be
transported over the road with any of the standard buckets attached. Attaching the Crush-All for shipment may cause
the HYEX to exceed the 13 feet 6 inches transport height requirement.

33 FT. 4 IN. [10.15 M]


11 FT. 1 IN. [3.39 M]

10 FT. 1 IN. [3.07 M]

HYEX01365

Figure 2.

HYEX Dimensions.

HYEX RAIL TRANSPORTABILITY.


Due to the 30 inch track shoe requirement, the HYEX will have to be subjected to restrictive routes for rail movements.
The HYEX may easily be rail transported via routes subjected to DOD clearance diagrams. HYEX can be transported
via rail with any of the standard buckets attached.
HYEX MARINE TRANSPORTABILITY.
The HYEX can be shipped as roll-on/roll-off, LASH, SEABEE, water-way barge, or boat. On deck storage is
permissible with some protection for cylinder rods. The HYEX height of 10 feet 1 inch allows the sea shipment within
the LASH lighter.

0100-2

TM 5-3805-294-10

0100

HYEX LIFTING AND TIE DOWN PROVISIONS.


HYEX Transportation Data Plate shows location of the lifting points, tie down points, and machine center of gravity
(CG).

TRANSPORTATION DATA
GROSS WEIGHT
EQUIPMENT TIEDOWN DESIGN LIMIT LOAD
LIFTING DESIGN LIMIT LOAD
-

60,000 LB.

NO. OF SLINGS REQUIRED


LENGTH OF SLINGS

4
12 FT.

EQUIPMENT TIEDOW PROVISIONS


LIFTING PROVISIONS
SWING CENTERLINE

44 MM [1.7 IN.]

CENTER OF
GRAVITY

1212 MM [47.5 IN.]


HYEX03192

Figure 3.

HYEX Transportation Data Plate.

The following values are the HYEX Design Load Capabilities:


1. TieDown Provisions 1 and 2;
a. Longitudinal = 92,250 lbs
b. Vertical = 124,200 lbs
2. Tie Down Provisions 3 and 4;
a. Longitudinal = 110.250 lbs
b. Vertical = 110,250 lbs
3. Lift Provisions;
a. Rated design limit = 60,000 lbs, each shackle
b. Ultimate design factor 5:1

0100-3

TM 5-3805-294-10

0100

HYEX LIFTING AND TIE DOWN PROVISIONS - Continued.

HYEX LIFT AND TIE DOWN PROVISIONS

TIE
DOWN
2

TIE
DOWN
4

TIE
DOWN
3

CAB

TIE
DOWN
1

LIFT POINTS
=TIE DOWN 1
=TIE DOWN 2
=TIE DOWN 3
=TIE DOWN 4
HYEX03063

Figure 4. HYEX Lifting and Tie Down Points.


Table 1. HYEX Lift and Tie Down Information.
Provision

QTY

Location (Relative to CG)

1 - Tie Down

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

120 in. aft

5 in. below

15 in.

0100-4

Lateral

TM 5-3805-294-10

0100

HIGHWAY:
Figure (5) shows the HYEX on an M870 semi trailer. The top view also shows a possible M870 tie down configuration.
The front view shows the HYEX is at or below the maximum height restriction for highway transport.

1 FOOT EXTENSION
BOTH SIDES

13 FT. 6 IN. HEIGHT CLEARANCE LINE

M870
TRAILER
SECTION A-A
HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I
JOHN DEERE MODEL 240D LCR
Figure 5.

M870 Loading.

0100-5

HYEX03073

TM 5-3805-294-10

0100

HIGHWAY: - Continued
Figure (6) shows the HYEX on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down
configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.

1 FOOT EXTENSION
BOTH SIDES

A
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.

HYEX RAIL DIAGRAM

51.4 INCH
HIGH
RAILCAR

GIC RAIL CLEARANCE


WITH STANDARD CAB

HYEX03078

Figure 8. GIC Rail Clearance.

0100-8

TM 5-3805-294-10

0100

RAIL: - Continued

HYEX RAIL DIAGRAMS

AAR RAIL CLEARANCE


WITH STANDARD CAB

DOD RAIL CLEARANCE


WITH STANDARD CAB
HYEX03080

Figure 9.

Standard Cab Clearance.

0100-9

TM 5-3805-294-10

0100

RAIL: - Continued

HYEX RAIL DIAGRAMS

AAR RAIL CLEARANCE


WITH ARMORED CAB

DOD RAIL CLEARANCE


WITH ARMORED CAB
HYEX03064

Figure 10. Armored Cab Clearance.


Figures (11) and (12) show the proposed HYEX tie down configurations on the HTTX railcar.

HYEX01370

Figure 11. HTTX Railcar Loading Overhead View.

0100-10

TM 5-3805-294-10

0100

RAIL: - Continued

HYEX01371

Figure 12.

HTTX Railcar Loading Side View.

AIR:
The HYEX meets the requirements of MIL-HDBK-1791, Designing for Internal Aerial Delivery in Fixed Winged
Aircraft (WP 0094) for transport on C-17 and C-5 aircraft.
Figure (13) shows model of the HYEX, both standard and armored cab, inside the C-5 aircraft design envelope. The
model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft.

HYEX DIAGRAMS INSIDE C-5 AIRCRAFT


STANDARD CAB

ARMORED CAB

LOAD RAMP CLEARANCE

GROUND
PLANE

BOOM RAISED 152.4mm (6 inches)


ABOVE GROUND PLANE
Figure 13.

BOOM RAISED 152.4mm (6 inches)


ABOVE GROUND PLANE
HYEX03066
C-5 Aircraft Loading.

0100-11

TM 5-3805-294-10

0100

AIR: - Continued
Figure (14) shows model of the HYEX, both standard and armored cab, inside the C-17 aircraft design envelope.
The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft.

HYEX DIAGRAMS INSIDE C-17 AIRCRAFT

STANDARD CAB

ARMORED CAB

LOAD RAMP CLEARANCE

LOAD RAMP CLEARANCE

GROUND
PLANE

BOOM RAISED 152.4mm (6 inches)


ABOVE GROUND PLANE

BOOM RAISED 152.4mm (6 inches)


ABOVE GROUND PLANE
HYEX03065

Figure 14. C-17 Aircraft Loading.


MARINE:
Marine tie-down restraint depends on the size of the ship (decreasing on larger vessels), the expected sea state to
be encountered, and the stow location of a given ship. Generally, the restraint required will increase for locations
high and forward (or aft) in the ship. The most severe conditions will occur on exposed "weather decks," where strong
wind and wet conditions add to the problem. A ships crew may require additional lashing on exposed decks. Belowdeck locations that are closer to the vessels center of gravity and rotation will experience less severe motion.

HYEX01372

Figure 15.

Marine Loading.

0100-12

TM 5-3805-294-10

0100

HYEX STANDARD BUCKET AND SPECIAL PURPOSE KITS (SPK) TRANSPORTABILITY.


All HYEX attachments have lifting and tie-down provisions included for ease in preparing for transport. The standard
HYEX quick latch system enables ease in changing attachments. The HYEX attachments can be directly chained
down to railcar/trailer for transport.
HYEX Attachments Weights are as follows:
1. Standard Rock Bucket, 42 in. = 3,000 lb (1361 kg)
2. Standard Ditch Cleaning Bucket = 2,337 lb (1060 kg)
3. Impact Breaker = 4,970 lb (2254 kg)
4. Crush-All = 7,450 lb (3379 kg)
5. Barrier Grapple = 870 lb (395 kg)
6. Plate Compactor = 2,200 lb (998 kg)
7. Deep Dig Arm = 3,440 lb (1560 kg)
STANDARD BUCKET TIE DOWN PROVISIONS.
Figure (16) shows the Standard Rock Bucket lifting and tie-down provisions.
TIE DOWN PROVISIONS

HYEX03083

Figure 16.

Standard Rock Bucket.

0100-13

TM 5-3805-294-10

0100

STANDARD BUCKET TIE DOWN PROVISIONS - Continued.


Figure (17) shows the Standard Ditch Cleaning Bucket lifting and tie-down provisions.

TIE DOWN PROVISIONS

Figure 17.

HYEX03087

Standard Ditch Cleaning Bucket.

HIGHWAY:
Figure (18) shows the Standard Buckets on an M870A1 semi trailer. The top view also shows a possible M870A1
tie down configuration.

0100-14

TM 5-3805-294-10

0100

HIGHWAY: - Continued

HYEX STANDARD BUCKETS


ON M870A1 TRAILER

HYEX03071

Figure 18. Standard Buckets Loaded On M870A1.


Figure (19) shows the Standard Buckets on an M870A3 semi trailer. The top view also shows a possible M870A3
tie down configuration.
HYEX STANDARD BUCKETS
ON M870A3 TRAILER

HYEX03068

Figure 19. Standard Buckets Loaded On M870A3.

0100-15

TM 5-3805-294-10

0100

SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS.


Figure (20) shows the Deep Dig Arm lifting and tie-down provisions.

TIE DOWN PROVISIONS


HYEX03089

Figure 20.

Deep Dig Arm.

Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions.

TIE DOWN PROVISIONS

Figure 21.

HYEX03086

Deep Dig Bucket.

Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions.

0100-16

TM 5-3805-294-10

0100

SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
TIE DOWN PROVISIONS

HYEX03085

Figure 22.

Deep Dig Ditch Cleaning Bucket.

0100-17

TM 5-3805-294-10

0100

SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
Figure (23) shows the Crush-All lifting and tie-down provisions.
TIE DOWN PROVISIONS

HYEX03084

Figure 23.

Crush-All.

Figure (24) shows the Compactor lifting and tie-down provisions.

TIE DOWN PROVISIONS


Figure 24.

Compactor.

0100-18

HYEX03082

TM 5-3805-294-10

0100

SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
Figure (25) shows the Impact Breaker lifting and tie-down provisions.

TIE DOWN PROVISIONS


Figure 25.

HYEX03081

Impact Breaker.

Figure (26) shows the Barrier Grapple lifting and tie-down provisions.

TIE DOWN PROVISIONS

HYEX03147

Figure 26.

Barrier Grapple.

0100-19

TM 5-3805-294-10

0100

CRUSH-ALL TIE DOWNS FOR HIGHWAY TRANSPORT.


Figure (27) shows the Crush-All loaded on M870A1 semi trailer. The top view also shows possible M870A1 tie down
configuration.
HYEX CRUSH-ALL ATTACHMENTS
ON M870A1 TRAILER

HYEX03070

Figure 27. Crush-All On M870A1.


Figure (28) shows the Crush-All loaded on M870A3 semi trailer. The top view also shows possible M870A3 tie down
configuration.

HYEX CRUSH-ALL
ON M870A3 TRAILER

HYEX03067

Figure 28. Crush-All On M870A3.

0100-20

TM 5-3805-294-10

0100

TRANSPORTING ON RAIL.
Figures (29) through (32) shows the Standard Buckets and Special Purpose Kits loading and tie downs on a HTTX
railcar. The top view also shows possible HTTX railcar tie down configurations.

BUCKETS
ON HTTX RAILCAR

HYEX03077

Figure 29.

Standard Buckets Loaded On HTTX Railcar.

HYEX CRUSH-ALL ATTACHMENT


ON HTTX RAILCAR

HYEX03076

Figure 30.

Crush-All Loaded On HTTX Railcar.

0100-21

TM 5-3805-294-10

0100

TRANSPORTING ON RAIL - Continued.

HYEX IMPACT BREAKER, COMPACTOR, AND BARRIER GRAPPLE


ON HTTX RAILCAR

HYEX03074

Figure 31.

Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.


HYEX DEEP DIG ATTACHMENTS
ON HTTX RAILCAR

HYEX03075

Figure 32.

Deep Dig Arm and Buckets Loaded On HTTX Railcar.

END OF WORK PACKAGE

0100-22

TM 5-3805-294-10

INDEX
Subject

WP Sequence No.-Page No.

A
ADDITIONAL AUTHORIZATION LIST (AAL)..........................................................................
ADJUSTING THE OPERATOR'S SEAT.................................................................................
AIR CONDITIONER DOES NOT OPERATE..........................................................................
AIR CONDITIONER/HEATER FILTER SERVICE...................................................................
AUTO-IDLE DOES NOT WORK.............................................................................................

WP 0096-1
WP 0006-1
WP 0045-1
WP 0090-1
WP 0052-1

B
BARRIER GRAPPLE DOES NOT HOLD LOAD.....................................................................
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE.......................................................
BREAKER DOES NOT OPERATE.........................................................................................
BREAKER OPERATES SLOWLY...........................................................................................
BUCKET TEETH REPLACEMENT.........................................................................................

WP 0073-1
WP 0041-1
WP 0070-1
WP 0071-1
WP 0085-1

C
CAB DOME LIGHT DOES NOT OPERATE............................................................................
CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................
CAB FUSE REPLACEMENT...................................................................................................
CAB REAR WORK LIGHTS DO NOT OPERATE...................................................................
COMPACTOR DOES NOT OPERATE...................................................................................
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS...................
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT.................................................
CRUSH-ALL DOES NOT OPERATE......................................................................................

WP 0040-1
WP 0042-1
WP 0084-1
WP 0043-1
WP 0069-1
WP 0095-1
WP 0092-1
WP 0072-1

D
DECAL LOCATION GUIDE.....................................................................................................
DEEP DIG DOES NOT OPERATE.........................................................................................
DESCRIPTION AND USE OF MONITOR AND ALARMS.......................................................
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS.......................
DRAINING WATER AND SEDIMENT FROM FUEL TANK....................................................

WP 0027-1
WP 0074-1
WP 0005-1
WP 0004-1
WP 0091-1

E
ENGINE COOLANT TEMPERATURE ABOVE NORMAL......................................................
ENGINE CRANKS BUT DOES NOT START OR HARD TO START......................................
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE...................................
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE.....................................................
ENGINE IDLES POORLY.......................................................................................................
ENGINE NOT DEVELOPING FULL POWER.........................................................................
ENGINE OIL PRESSURE LOW..............................................................................................
ENGINE RUNS POORLY........................................................................................................
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED................................
ENGINE WILL NOT CRANK...................................................................................................
EQUIPMENT DESCRIPTION AND DATA..............................................................................
EXCESSIVE FUEL CONSUMPTION......................................................................................
EXCESSIVE OIL CONSUMPTION.........................................................................................
EXPENDABLE AND DURABLE ITEMS LIST.........................................................................

Index-1

WP 0055-1
WP 0046-1
WP 0056-1
WP 0057-1
WP 0051-1
WP 0053-1
WP 0054-1
WP 0048-1
WP 0067-1
WP 0047-1
WP 0002-1
WP 0049-1
WP 0050-1
WP 0097-1

TM 5-3805-294-10

INDEX - Continued
Subject

WP Sequence No.-Page No.

F
FORDING THE HYEX.............................................................................................................
FRESH AIR FILTER SERVICE...............................................................................................

WP 0036-1
WP 0089-1

G
GENERAL INFORMATION.....................................................................................................
GENERAL MAINTENANCE INSTRUCTIONS........................................................................
GENERAL MONITOR OPERATION.......................................................................................

WP 0001-1
WP 0078-1
WP 0013-1

H
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER........................
HYDRAULIC HOSE REEL DOES NOT OPERATE................................................................
HYDRAULIC OIL FOAMS.......................................................................................................
HYDRAULIC OIL OVERHEATS..............................................................................................
HYDRAULIC RESERVOIR SERVICE.....................................................................................
HYEX TRANSPORTABILITY INSTRUCTIONS......................................................................

WP 0059-1
WP 0075-1
WP 0062-1
WP 0061-1
WP 0088-1
WP 0100-1

I
INSTALLING AND OPERATING THE COMPACTOR............................................................
INSTALLING AND OPERATING THE CRUSH-ALL...............................................................
INSTALLING AND OPERATING THE IMPACT BREAKER....................................................
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......

WP 0021-1
WP 0019-1
WP 0020-1
WP 0076-1

L
LIFTING WITH HYEX..............................................................................................................
LOOSENING TRACK TENSION.............................................................................................
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE.................................................
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE.....................................................

WP 0015-1
WP 0082-1
WP 0044-1
WP 0029-1

M
MAINTENANCE AFTER FORDING........................................................................................
MOVING MACHINE ON/OFF AN EMBANKMENT.................................................................
MOVING THE HYEX...............................................................................................................
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES..........................................................

WP 0093-1
WP 0024-1
WP 0008-1
WP 0035-1

N
NO HYDRAULIC FUNCTIONS...............................................................................................
NO SWING FUNCTION..........................................................................................................

WP 0058-1
WP 0063-1

O
OPENING AND CLOSING WINDOWS...................................................................................
OPERATING IN COLD WEATHER 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

WP Sequence No.-Page No.

O
OPERATING THE HYDRAULIC HOSE REEL........................................................................
OPERATING THE HYDRAULIC THUMB................................................................................

WP 0026-1
WP 0017-1

P
POWER DIG DOES NOT WORK............................................................................................
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).....................................
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE............................
PRIMARY AND SECONDARY AIR CLEANER SERVICE......................................................

WP 0060-1
WP 0077-1
WP 0086-1
WP 0087-1

Q
QUICK LATCH DOES NOT OPERATE..................................................................................

WP 0068-1

R
REFERENCES........................................................................................................................
REMOVING AND INSTALLING BUCKET...............................................................................

WP 0094-1
WP 0014-1

S
SELECTING AN ATTACHMENT ON THE MONITOR............................................................
SHUTTING DOWN THE HYEX...............................................................................................
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED.............................
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY
EXIT).......................................................................................................................................
SLAVE STARTING..................................................................................................................
SLOW TRAVEL SPEED ONLY...............................................................................................
SPECIAL PURPOSE KITS (SPK) LIST...................................................................................
STARTING THE ENGINE.......................................................................................................
SWING FUNCTION IS JERKY................................................................................................

WP 0018-1
WP 0009-1
WP 0010-1
WP 0033-1
WP 0032-1
WP 0065-1
WP 0098-1
WP 0007-1
WP 0064-1

T
TAKING ENGINE OIL SAMPLE..............................................................................................
TAKING HYDRAULIC OIL SAMPLE.......................................................................................
THEORY OF OPERATION.....................................................................................................
TIGHTENING TRACK TENSION............................................................................................
TOWING THE HYEX...............................................................................................................
TRACK SAG CHECK .............................................................................................................
TRAVEL ALARM DOES NOT OPERATE...............................................................................
TRAVEL IS JERKY..................................................................................................................
TROUBLESHOOTING NOTES...............................................................................................
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE...........................

WP 0079-1
WP 0083-1
WP 0003-1
WP 0081-1
WP 0028-1
WP 0080-1
WP 0038-1
WP 0066-1
WP 0099-1
WP 0037-1

U
USING THE RIFLE MOUNT....................................................................................................
USING THE VANDAL PROTECTION KIT..............................................................................

WP 0012-1
WP 0025-1

W
WINDSHIELD WIPER AND WASHER DO NOT OPERATE...................................................

Index-3/4 blank

WP 0039-1

RECOMMENDED CHANGES TO PUBLICATIONS


AND BLANK FORMS
For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and


Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).

TO: (Forward to proponent of publication or form) (Include ZIP Code)

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000

Your mailing address

DATE

Date you filled out


this form.

PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
Title
PUBLICATION/FORM NUMBER
DATE

2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU

TM 
ITEM
NO.

PAGE
NO.

PARAGRAPH

LINE
NO. *

TYPED NAME, GRADE OR TITLE

Your Name
DA FORM 2028, FEB 74

0DUFK +<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

FIGURE TABLE
NO.
NO.

RECOMMENDED CHANGES AND REASON


(Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph.


TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION
Signature

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

U. S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000

FROM: (Activity and location) (Include ZIP Code)

DATE
Date you filled out this
form

Your address

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU
DATE

0 MarFK 
+<(; 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

PUBLICATION NUMBER

TM

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK REFERENCE FIGURE ITEM


NO.
NO.
NO.
NUMBER

TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

SAMPLE

PART III REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Signature
USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS


AND BLANK FORMS

Use Part II (reverse) for Repair Parts and


Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER

DATE

TM 
ITEM
NO.

PAGE
NO.

PARAGRAPH

LINE
NO. *

0 MarFK
FIGURE TABLE
NO.
NO.

TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
RECOMMENDED CHANGES AND REASON
(Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph.


TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS


EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
DATE

TM 

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK REFERENCE FIGURE


NO.
NO.
NUMBER

PART III REMARKS

TYPED NAME, GRADE OR TITLE

7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

0 MarFK 0
ITEM
NO.

TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS


AND BLANK FORMS

Use Part II (reverse) for Repair Parts and


Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER

DATE

TM 
ITEM
NO.

PAGE
NO.

PARAGRAPH

LINE
NO. *

0 MarFK
FIGURE TABLE
NO.
NO.

TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
RECOMMENDED CHANGES AND REASON
(Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph.


TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS


EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
DATE

TM 

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK REFERENCE FIGURE


NO.
NO.
NUMBER

PART III REMARKS

TYPED NAME, GRADE OR TITLE

7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

0 MarFK 0
ITEM
NO.

TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS


AND BLANK FORMS

Use Part II (reverse) for Repair Parts and


Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER

DATE

TM 
ITEM
NO.

PAGE
NO.

PARAGRAPH

LINE
NO. *

0 MarFK
FIGURE TABLE
NO.
NO.

TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
RECOMMENDED CHANGES AND REASON
(Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph.


TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS


EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
DATE

TM 

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK REFERENCE FIGURE


NO.
NO.
NUMBER

PART III REMARKS

TYPED NAME, GRADE OR TITLE

7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

0 MarFK 0
ITEM
NO.

TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS


AND BLANK FORMS

Use Part II (reverse) for Repair Parts and


Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 East 11 Mile Road, Warren, MI 48397-5000
PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER

DATE

TM 
ITEM
NO.

PAGE
NO.

PARAGRAPH

LINE
NO. *

0 MarFK
FIGURE TABLE
NO.
NO.

TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
RECOMMENDED CHANGES AND REASON
(Provide exact wording of recommended changes, if possible).

*Reference to line numbers within the paragraph or subparagraph.


TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS


EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

DATE

FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command


ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 E. 11 Mile Road, Warren, MI 48397-5000
PUBLICATION NUMBER

PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU +<(;
DATE

TM 

PAGE
NO.

COLM
NO.

LINE
NO.

NATIONAL STOCK REFERENCE FIGURE


NO.
NO.
NUMBER

PART III REMARKS

TYPED NAME, GRADE OR TITLE

7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK

0 MarFK 0
ITEM
NO.

TOTAL NO.
OF MAJOR
ITEMS
SUPPORTED

RECOMMENDED ACTION

(Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

USAPPC V3.00

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.


General, United States Army
Chief of Staff

Official:

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1103409
Distribution:
To be distributed in accordance with the Initial Distribution Number (IDN) 257856
requirements for TM 5-3805-294-10.

THE METRIC SYSTEM AND EQUIVALENTS


LINEAR MEASURE
1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches
1 Kilometer = 1000 Meters = 0.621 Miles

SQUARE MEASURE
1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles

WEIGHTS
1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces
1 Kilogram = 1000 Grams = 2.2 Lb
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

CUBIC MEASURE
1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches
1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
TEMPERATURE
5/9 ( F - 32) = C
212 Fahrenheit is equivalent to 100 Celsius
90 Fahrenheit is equivalent to 32.2 Celsius
32 Fahrenheit is equivalent to 0 Celsius
9/5 C + 32 = F

LIQUID MEASURE
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

APPROXIMATE CONVERSION FACTORS


MULTIPLY BY

1 CM 2
3
4
5

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