TM 5-3805-293-10 MOTOR GRADER 120M

TM 5-3805-293-10 TECHNICAL MANUAL OPERATOR'S MANUAL FOR

MOTORIZED ROAD GRADER MODEL 120M (NSN 3805-01-560-2384)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY DECEMBER 2010 &'()*+,"(-'./

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WARNING SUMMARY

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This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual.

FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11. EXPLANATION OF SAFETY WARNING ICONS

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

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

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

FLYING PARTICLES - arrows bouncing off face with face shield show that particles flying through the air will harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury potential from improper lifting techniques.

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

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

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

PINCH POINT - Object crushing human figure shows that areas between vehicles or parts present a danger to life or limb.

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

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GENERAL SAFETY WARNING DESCRIPTION

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WARNING 120M MOTOR GRADER OPERATION

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Use of seat belt while operating machine is mandatory. Failure to follow this warning may result in injury or death to personnel in the event of an accident or machine overturn.

WARNING

COMPRESSED AIR

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Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) when using compressed air. Failure to follow this warning may result in injury or death to personnel.

WARNING

HEARING PROTECTION

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Hearing protection is required when standing within 50 ft (15.2 m) of the 120M Motor Grader while it is operating. Failure to wear hearing protection may result in hearing loss.

WARNING

HEAVY COMPONENTS

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Use extreme caution when handling heavy parts. Lifting device is required when parts weigh 50 lb (23 kg) for a single person lift, over 100 lb (45 kg) for a two person lift, and over 150 lb (68 kg) for a three or more person lift. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel or damage to equipment.

WARNING

HOT COMPONENTS Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts. Failure to follow this warning may result in injury to personnel. b

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GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

SLAVE STARTING ENGINE

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When slave starting the engine of the 120M Motor Grader: –

Use NATO slave cable that does NOT have loose or missing insulation.

–

DO NOT proceed if suitable cable is not available.

–

DO NOT use civilian-type jumper cables.

–

DO NOT allow disabled 120M Grader and booster vehicle to come in contact with each other at any time during slave starting.

Failure to follow these warnings may result in injury or death to personnel or damage to equipment. EXPLANATION OF HAZARDOUS MATERIALS ICONS BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

FIRE - flame shows that a material may ignite and cause burns.

HIGH PRESSURE FUEL - high pressure fuel spraying human hand shows that fuel escaping under great pressure can cause injury or death.

RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or organs.

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

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GENERAL SAFETY WARNING DESCRIPTION

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WARNING

BATTERIES • To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or injury to personnel. –

EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

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SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.

–

INTERNAL. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.

–

CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

–

CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals, and related accessories contain lead and lead components. These chemicals are known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!! • 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 can result from severe exposure. • Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when the engine of the 120M Motor Grader is operated. –

DO NOT operate engine in enclosed areas.

–

DO NOT idle engine without adequate ventilation.

–

BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control

–

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.

–

BE AWARE. The field protective mask for Chemical, Biological, Radiological, and Nuclear (CBRN) protection will not protect you from carbon monoxide poisoning.

–

CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION! e

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WARNING

CARC PAINT

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• The following must be done before grinding, cutting, or welding any equipment that has been CARCcoated: –

Wear protective equipment (e.g., goggles, gloves, apron) when grinding or sanding CARC-coated equipment. Do not leave any skin exposed.

–

Use high-efficiency air purifying respirators when grinding or sanding CARCcoated equipment.

–

Never weld or cut CARC-coated equipment; grind or sand off CARC paint completely before welding.

–

CARC paint contains isocyanate (HDI) which is highly irritating to skin and respiratory system. High concentrations of HDI can produce symptoms of itching and reddening of skin, a burning sensation in throat, and nose and watering of the eyes. In extreme concentrations, HDI can cause coughing, shortness of breath, pain during respiration, increased sputum production, and chest tightness.

• Failure to follow these warnings may result in injury or death to personnel.

WARNING

HAZARDOUS WASTE DISPOSAL

0000

• When servicing this equipment, performing maintenance, or disposing of materials such as engine/ hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. • Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. • Failure to follow these warnings may result in injury or death to personnel.

WARNING

HYDRAULIC SYSTEM PRESSURE • DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. • Use a piece of cardboard, newspaper, or wood to check for pressurized leaks, to prevent fluid penetrating the skin. • Failure to follow these warnings may result in injury or death to personnel.

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WARNING

CBRN EXPOSURE If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel.

To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

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WARNING

SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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! 9 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 will enable us to respond quicker 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, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The E-mail address is [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726. " - Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS

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WP Sequence No.

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Page No.

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How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Chapter 1 - General Information, Equipment Description, and Theory of Operation General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003 Chapter 2 - Operator Instructions Description and Use of Operator Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005 Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006 Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007 Stowage and Decal/Data Plate Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008 Chapter 3 - Troubleshooting Procedures Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009 Operator Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011 Chapter 4 - PMCS Instructions Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012 Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013 Chapter 5 - Maintenance Instructions Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014 Blade Lift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015 Brake Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016 Centershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017 Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018 Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019 Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020 Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021 Fuel/water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023 Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024 Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025 Scarifier Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026 Scarifier Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027 Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028 Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029

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Chapter 6 - Supporting Information References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032 Index

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HOW TO USE THIS MANUAL

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NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your supervisor. INTRODUCTION 1.

This manual contains operating instructions, and operator-level maintenance procedures, for the Motorized Road Grader Model 120M.

2.

This manual is written in work package format:

3.

a.

Chapters divide the manual into major categories of information: General Information, Equipment Description, and Theory of Operation; Operator Instructions; Troubleshooting Procedures; Preventive Maintenance Checks and Services (PMCS) Instructions; Maintenance Instructions; and Supporting Information.

b.

Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002) located on the upper right-hand corner of each page. The work package page number (e.g., 0001-1, 0001-2) is located centered at the bottom of each page.

Read through this manual to become familiar with its organization and contents before attempting to operate or maintain the equipment.

CONTENTS OF THIS MANUAL 1.

A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating or maintaining the grader.

2.

The Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual.

3.

Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general information about the grader, identifies the major components and systems, and describes how the components and systems work.

4.

Chapter 2, Operator Instructions, identifies operating controls and indicators and explains how to use them. This chapter covers grader operating procedures under usual and unusual conditions. It also contains the Stowage and Decal/Data Plate Guide.

5.

Chapter 3, Troubleshooting Procedures, describes procedures for locating and correcting malfunctions of the grader. Included in this chapter is the Troubleshooting Index. If the loader malfunctions, this index should always be consulted to locate the appropriate troubleshooting procedure.

6.

Chapter 4, Preventive Maintenance Checks and Services (PMCS) Instructions, contains operator-level preventive maintenance and lubrication procedures for the grader.

7.

Chapter 5, Maintenance Instructions, contains work packages with information on operator-level maintenance of the grader.

8.

Chapter 6, Supporting Information, contains the following: References; Components of End Item (COEI) and Basic Issue Items (BII) Lists; Additional Authorization List, and Expendable and Durable Items List.

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FEATURES OF THIS MANUAL 1.

This manual contains information on operating and maintaining the 120M Motorized Road Grader.

2.

WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are titled in BOLD print as a visual aid.

WARNING A WARNING indicates a hazard which may result in injury or death to personnel.

CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.

NOTE A NOTE is a statement containing information that will make the procedures easier to perform. 3.

Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.

4.

Within a procedural step, reference may be made to another chapter or work package in this manual or to another manual. These references indicate where you should look for more complete information. If you are instructed to: “Replace air filter (WP 0014)”, go to WP 0014 in this manual for instructions on air cleaner replacement.

5.

Illustrations are placed after, and as close as possible to, the procedural steps to which they apply. Callouts placed on the art are text or numbers.

6.

Numbers located at the lower right corner of art (e.g., 469-0033; 469-0850) are art control numbers and are used for tracking purposes only. Disregard these numbers.

7.

Technical instructions include standard units as well as metric units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual.

8.

Location Terms. The terms left, right, front, or rear are used to describe areas of the equipment. These terms indicate location as seen when seated in the driver’s seat and facing forward.

9.

Unless another MOS is specified in the initial setup of a work package, all tasks are to be performed by a Construction Equipment Operator, Military Occupational Speciality (MOS) 21E.

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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

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0001

OPERATOR MAINTENANCE 0 0 0 1

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GENERAL INFORMATION

SCOPE

0001

1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the 120M Motor Grader. 2. Model Numbers and Equipment Names. Grader, Road, Motorized, Diesel Engine Driven (DED), Heavy, Commercial Construction Equipment (CCE) Model 120M. 3. Purpose of Equipment. The 120M Motor Grader is used for rough and finished grading, low and high bank sloping, flat and V-ditching, scarifying bituminous road mixes, and snow removal. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, site preparation for pipeline, and river crossing. MAINTENANCE FORMS, RECORDS, AND REPORTS

0001

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 or AR 700-138, Army Logistics Readiness and Sustainability. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

0001

If your 120M Motor Grader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. (EMail: [email protected]) We will send you a reply. The preferred method for submitting Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. If the above method is not available to you, put it on an SF 368 (Product Quality Deficiency Report), 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 48397-5000. CORROSION PREVENTION AND CONTROL (CPC)

0001

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. 2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. 3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. 4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, TAMMS Users Manual. OZONE DEPLETING SUBSTANCES

0000 00

There are no ozone depleting substances contained on the machine or used during machine maintenance. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.

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0001

PREPARATION FOR STORAGE OR SHIPMENT

0001

General

0001

1. This work package contains requirements and procedures for administrative storage of equipment that is issued to and in use by Army activities worldwide. 2. The requirements specified herein are necessary to maintain equipment in administrative storage in such a way as to achieve the maximum readiness condition. 3. Equipment that is placed in administrative storage should be capable of being readied to perform its mission within a 24-hour period, or as otherwise may be prescribed by the approving authority. Before equipment is placed in administrative storage, a current PMCS should be completed and deficiencies corrected. 4. Report equipment in administrative storage as prescribed for all reportable equipment. 5. Perform inspections, maintenance services, and lubrication as specified herein. 6. Records and reports to be maintained for equipment in administrative storage are those prescribed by DA PAM 750-8 for equipment in use. 7. A 10 percent variance is acceptable on time used to determine the required maintenance actions. 8. Accomplishment of applicable PMCS, as mentioned throughout this work package, will be on a semiannual basis. Definition of Administrative Storage

0001

The placement of equipment in administrative storage can be for short periods of time when a shortage of maintenance effort exists. Items should be ready for use within the time factors as determined by the directing authority. During the storage period, appropriate maintenance records must be kept. Preparation of Equipment for Administrative Storage Storage Site

0001

0001

1. Select the best available site for administrative storage. Separate stored equipment from equipment in use. Conspicuously mark the area “ADMINISTRATIVE STORAGE.” 2. Covered space is preferred. 3. Open sites should be improved hardstand, if possible. Unimproved sites should be firm, well drained, and free of excessive vegetation. Storage Plan

0001

1. Store equipment to provide maximum protection from the elements and to provide access for inspection, maintenance, and exercising. Anticipate removal or deployment problems and take suitable precautions. 2. Take into consideration environmental conditions, such as extreme heat or cold, high humidity, blowing sand, or loose debris, soft ground, mud, heavy snows, or any combination thereof, and take adequate precautions. 3. Establish a fire plan and provide for adequate fire fighting equipment and personnel. Maintenance Services and Inspection

0001

1. Maintenance Services. Prior to storage, perform the next scheduled PMCS. 2. Inspection. Inspect and approve the equipment prior to storage. Do not place non-mission-capable equipment in storage.

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0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED Correction of Shortcomings and Deficiencies

0001

Correct all shortcomings and deficiencies prior to storage, or obtain a deferment from the approving authority. Lubrication. Lubricate equipment in accordance with LO 5-3805-293-13. General Cleaning, Painting, and Preservation

0001

0001

CAUTION Do not direct water or steam, under pressure, against electrical wires or any exterior opening. Failure to follow this caution may result in damage to equipment. 1. Cleaning. Clean all equipment for dirt, grease, and other contaminants in accordance with applicable provisions of this manual. Do not use vapor degreasing. Remove foreign objects that are wedged in tire treads.

WARNING

Chemical Agent Resistant Coating (CARC) paint debris may be considered environmentally hazardous during removal. Consult local procedures prior to removal of CARC paint to ensure compliance with local laws. Failure to follow these warnings may result in injury or death to personnel. 2. Painting. Remove rust and damaged paint by scraping, wire brushing, sanding, or buffing. Sand to a smooth finish and spot paint as necessary (TB 43-0209). 3. Preservation. After cleaning and drying, immediately coat unpainted wear surfaces with oil or grease, as appropriate.

NOTE •

Place a piece of barrier material between desiccant bags and metal surfaces.

•

Air circulation under draped covers reduces deterioration from moisture and heat.

4. Weatherproofing. Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install all covers authorized for the equipment. Close and secure all openings except those required for venting and draining. Seal openings to prevent the entry of rain, snow, or dust. Insert desiccant when complete seal is required. Place equipment, and provide blocking or framing, to allow for ventilation and water drainage. Support cover away from item surfaces, which may rust, rot, or mildew. BII Items

0001

1. Process BII items simultaneously with the major item to which they are assigned. 2. If possible, store BII items with the major item. 3. If stored apart from the major item, mark BII items with tags indicating the major item, its registration or serial number, and location, and store in protective-type closures. In addition, place a tag or list indicating the location of the removed items in a conspicuous place on the major item. Maintenance Services

0001

After equipment has been placed in administrative storage, inspect, service, and exercise as specified in this manual.

0001-3

TM 5-3805-293-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED Inspection

0001

Inspection will usually be visual and must consist of at least a walk-around examination of all equipment to detect any deficiencies. Inspect equipment in open storage WEEKLY and equipment in covered storage MONTHLY. Inspect all equipment immediately after any severe storm or environmental change. The following are examples of things to look for during a visual inspection: 1. Low or flat tires. 2. Oil leaks. 3. Condition of preservatives, seals, and wraps. 4. Corrosion or other deterioration. 5. Missing or damaged parts. 6. Water in components. 7. Any other readily recognizable shortcomings or deficiencies. Repair During Administrative Storage

0001

Keep equipment in an optimum state of readiness. Accomplish the required services and repairs as expeditiously as possible. Whenever possible, perform all maintenance on-site. Exercising

0001

Exercise equipment in accordance with Table 1 and the following instructions: 1. Vehicle Major Exercise. Depreserve equipment by removing only that material restricting exercise. Close all drains, remove blocks, and perform all BEFORE operational checks. Make several right and left 90-degree turns. Make several hard-braking stops without skidding. While exercising, and when it is convenient and safe, operate all functional components such as moldboard, drawbar, scarifier, front wheel tilt, articulation, and all wheel drive. Perform all DURING and AFTER operational checks. 2. Scheduled Services. Scheduled services will include inspection per Inspection in this work package, and will be conducted in accordance with PMCS (WP 0013). Lubricate in accordance with instructions in LO 5-3805293-13. 3. Corrective Action. Immediately take action to correct shortcomings and deficiencies noted. Record inspection and exercise results on DA Form 2404 or DA Form 5988E. Record and report all maintenance actions on DA Form 2407. After exercising, restore the preservation to the original condition. Replenish lubricants used during exercising and note the amount on DA Form 2408. Table 1. Exercise Schedule. Weeks

01

2

01

4

01

6

01

8

01

10

01

12

01

14

01

16

01

18

01

20

01

22

01

24

Scheduled Services

X

Major Exercise

X

01

01

01

Rotation

0001

Rotate items in accordance with any rotational plan that will keep the equipment in an operational condition and reduce the maintenance effort.

0001-4

TM 5-3805-293-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED Procedures for Common Components and Miscellaneous Items Tires

0001

0001

If tires are found to be low by 5 psi (34 kPa) or more, damaged, or excessively worn, notify Field Level Maintenance. Seals

0001

Seals may develop leaks during storage or shortly thereafter. If leaking persists, notify Field Level Maintenance. Removal of Equipment from Administrative Storage Activation

0001

0001

Notify Field Level Maintenance to restore the equipment to normal operating condition. Servicing

0001

Resume the maintenance service schedule in effect at the commencement of storage or service the equipment before the scheduled dates in order to produce a staggered maintenance workload. Preparation of Equipment for Shipment

0001

1. Remove ether starting aid cylinder, if equipped (WP 0021). 2. After grader is positioned on transporter, park machine (WP 0005). 3. Secure grader frame by installing articulation lock pin (WP 0004). 4. Turn battery disconnect to OFF position (WP 0004). 5. Make sure cab doors, access doors, and access covers are secured.

0001-5

TM 5-3805-293-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

CAUTION Turbocharger may spin when engine is off due to air flow past grader exhaust pipe. Rotation of turbocharger without engine operation may result in damage to turbocharger. 6. Cover exhaust opening. 7. Chock grader tires. 8. Secure grader with tiedowns.

Figure 1. Tiedown Locations.

0001

9. Refer to FM 4-01.41 Army Rail Operations for additional instructions on processing, storage, and shipment of materiel. 10. Graders that have been removed from storage for shipment do not have to be reprocessed if they will reach their destination within the administrative storage period. Reprocess only if inspection reveals any corrosion or if anticipated in-transit weather conditions make it necessary. 11. When a grader is received that has already been processed for domestic shipment, as indicated on DD Form 1397, the grader does not have to be reprocessed for storage unless corrosion and deterioration are found during the inspection upon receipt. List on SF Form 364 all discrepancies found because of poor preservation, packaging, packing, marking, handling, loading, storage, or excessive preservation. Repairs that cannot be handled by the receiving unit must be annotated on DA Form 5988E or DA Form 2404 and reported to Field Level Maintenance.

0001-6

TM 5-3805-293-10

0001

WARRANTY INFORMATION

0001

The 120M Motor Grader has separate warranties for various components. See Table 2. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record. Report all defects to your supervisor, who will take appropriate action.

Table 2. Warranty Information. Warranted Component

Duration of Commercial Warranty

Base Machine (1)

1 Year/Unlimited Hours (1)

Ground Engaging Tools (GET)

Not limited by time

Caterpillar Battery (2)

3 Years (2)

Engine Emission Components (3)

5 Year/3,000 Hours (3)

Manufacturer Responsible

Caterpillar Inc.

Contact Information

Defense and Federal Products Phone 309-578-3295

Warranty - See Separate Manufacturer’s Warranty Statements Tires (4)

5 Years (4)

Bridgestone/Firestone

Phone 800-572-8905

Tires (4)

5 Years (4)

Michelin

Phone 877-574-8473

(1) Excluding batteries, GET, and tires that have separate warranties, as shown in the table. (2) Battery warranty is prorated after 12 months. (3) Army 120M Engine is EPA Certified. The Emissions Warranty applies to certain engine components. (4) Tire warranty is prorated based on tire age and tread wear.

0001-7

TM 5-3805-293-10

LIST OF ABBREVIATIONS/ACRONYMS

0001

0001

NOTE Refer to ASME Y14.38-2007, Abbreviations and Acronyms, for standard abbreviations. ABBREVIATION/ACRONYM

DEFINITION

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ampere AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Braking System A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Item B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Celsius CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code CBRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological, Radiological, Nuclear CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise CID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centimeter COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component of End Item CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cardiopulmonary Resuscitation CSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Structural Frame cu ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Foot cu m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Meter CW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module ECPC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Clutch Pressure Control ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control Unit EIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendation EMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Monitoring System F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Falling Object Protective Structure ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot gal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon GIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabarit International de Chargement HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating, Ventilation, and Air Conditioning I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer

0001-8

TM 5-3805-293-10

LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED ABBREVIATION/ACRONYM

0001

0001

DEFINITION

kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter LASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Ship lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Foot lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Inch LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Emitting Diode m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minute mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Millimeter MOPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mission Oriented Protective Posture MOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Military Occupational Specialty mph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miles per Hour NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization NBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton-meter NSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Stock Number OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United States PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services PQDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Report psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pint ROC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated Operating Capacity ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure RO/RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-off rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions per Minute SAHR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Applied Hydraulically Released SDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command SEABEE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naval Construction Engineer, Sea Barge SPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Purpose Kit TAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System TOE/MTOE . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment U/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit of Measure UV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ultra Violet V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt WCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim Action WP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Package

0001-9

TM 5-3805-293-10

0001

ELECTROMAGNETIC PULSE (EMP) EXPOSURE

0001

Components designated as EMP susceptible may be damaged by EMP exposure. If the machine is exposed to an EMP incident, verify proper operation and repair as necessary. THREAT OF CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) CONTAMINATION

0001

1. The 120M Motor Grader incorporates a CARC painted exterior. Materials used in the machine are metal, rubber, plastic, fabric, and glass. 2. In the event of CBRN contamination, see FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. COMMON TOOLS AND EQUIPMENT

0001

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), CTA 50909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Durable Items, as applicable to your unit. END OF WORK PACKAGE

0001-10

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OPERATOR MAINTENANCE 0 0 0

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EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

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1. The 120M Motor Grader provides the Army with the capability of rough and finished grading, low and high bank sloping, flat and V-ditching, scarifying, mixing bituminous road mixes, and snow removal. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, and site preparation for pipeline and river crossing. 2. The 120M Motor Grader has excellent maneuverability; fast, precise blade control without drift; superior visibility, convenience, and safety; and an advanced cab design featuring joysticks for control.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

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Figure 1. 120M Motor Grader (Left Side).

KEY

COMPONENT

DESCRIPTION

1

Operator Cab

Location of operator controls.

2

Primary Exit

Door on left side of machine provides primary entry/exit point for operator.

3

Exhaust Pipe

Directs exhaust fumes away from machine.

4

Air Cleaner

Removes debris from air entering engine.

5

Left Front Access Door

Provides access to coolant tank, circuit breakers, engine air filters, engine oil level gauge, transmission oil level gauge and transmission oil filler tube.

6

Left Rear Access Door

Provides access to NATO slave receptacle, battery disconnect switch, and hydraulic tank sight gauge.

7

Blade Side Shift Cylinder

Extends and retracts blade horizontally.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. 120M Motor Grader (Left Side).

KEY

COMPONENT

DESCRIPTION

1

Turn Signal

Flashes to indicate direction machine intends to turn.

2

Headlights

Provide light forward of machine.

3

Work Lights

Provide illumination of blade/work area.

4

Side View Mirror

Provides view toward rear and side of machine.

5

Grab Handle

Provides a hand-hold for cab entry and exit.

6

Steps

Provide safe means of climbing up to and down from cab.

7

Fuel Tank

Fuel storage.

8

Filler Neck and Cap

Provide means to fill fuel tank and seal tank.

9

Blackout Driving Light

Used when operating in blackout mode.

10

Scarifier Shank Stowage Rack

Provide stowage capability for up to five scarifier shanks.

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Figure 3. 120M Motor Grader (Right Side).

KEY

COMPONENT

DESCRIPTION

1

Rear Blackout Lights

Provide illumination during blackout mode.

2

Rear Work Lights

Provide illumination behind machine.

3

Right Rear Access Door

Provides access to batteries and refrigerant condenser.

4

Right Front Access Door

Provides access to refrigerant compressor

5

Right Front Access Panel

Provides access to engine drive belt.

6

Emergency Exit

Provides an emergency exit for operator.

7

Work Lights

Provide illumination of blade/work area.

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Figure 4. 120M Motor Grader (Right Side).

KEY

COMPONENT

DESCRIPTION

1

Radiator

Provides cooling for engine coolant.

2

Centershift Cylinder

Allows center point of blade to be shifted outward to either side to provide more blade reach.

3

Blade Lift Cylinders

Raise and lower each side of blade independently.

4

Scarifier Hydraulic Cylinder

Raises and lowers scarifier.

5

Scarifier Link Rods

Link rods with adjustable height setting.

6

Scarifier

Used for breaking up material.

7

Moldboard/Blade

Hydraulically controlled with replaceable end bits and cutting edges.

8

End Bit

Replaceable outer edges of blade.

9

Tandem Housing

Houses drive gears for tandem wheels.

10

Rear Hitch Pin

Attachment point for towing.

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EQUIPMENT DATA

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0002

Length Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ft 10 in. (8.49 m) Width Overall (blade perpendicular with centerline of machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ft. (3.767 m) Outside front tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 4 in. (2.54 m) Outside rear tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 5 in. (2.56 m) Wheelbase (centerline of front tire to centerline of rear tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ft. 10 in. (6.7 m) Height Top of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ft. 0 in. (3.4 m) Top of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft. 9 in. (3.3 m) Top of exhaust stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 7 in. (2.9 m) Top of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 9 in. (3.0 m) Weight (approximate operating) Without Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,080 lb (17,726 kg) With Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000 lb (20,412 kg) Engine Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6.6 Variable Horsepower (VHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 to 153 HP Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 RPM Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 cu. in. (6.6 L) Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct Injection Cooling system (thermostat opening temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 180°F (70 to 82qC) Cooling system (thermostat completely open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203qF (95qC) Transmission Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 speeds forward, 6 reverse CZM1-UP Range selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction trigger and gear selection buttons on left joystick Front Axles Wheel lean angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18q Rear Axle Tandem axle spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ft 11.5 in. (1.5 m)

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EQUIPMENT DATA – CONTINUED Service Brakes Type. . . . . . . . . . . . . . . . . . . . . Multiple disc, oil bathed, hydraulically activated, located at each tandem wheel Parking Brakes Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple disc, spring applied, hydraulically released Tires Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.00R 24 12PR (G-2) Inflation Without Armor Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 psi (241 kPa) Rear – All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa) With Armor Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 psi (379 kPa) Steering Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Turning Radius (frame fully articulated, front wheels NOT leaning) . . . . . . . . . . . . . . . . . . . . 26 ft. 9 in. (8.2 m) Steering Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.5q Articulation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20q Service Refill Capacities Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 gal. (341 L) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 gal. (33 L) Engine crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 gal. (15.5 L) Hydraulic system (tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 gal. (64.6 L) Transmission and differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 gal. (53 L) Tandem housing (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.0 gal. (56.8 L) All-wheel drive gearbox (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 gal. (7 L) Front wheel spindle bearing housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 gal. (0.5 L) Circle drive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 gal. (7.0 L) Electrical System Batteries Quantity Without Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Quantity With Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt DC System voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt DC Blade Range Circle centershift Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm) Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm) Blade Sideshift Hydraulic Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 in. (660 mm) Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 in. (510 mm)

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EQUIPMENT DATA – CONTINUED Blade Lift (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8 in. (427 mm) Blade Shoulder Reach (maximum) Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in. (190.5 cm) Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.6 in. (174.2 cm) Maximum Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3 in. (72 cm) Hydraulic Blade Tip Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40° Rearward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5° END OF WORK PACKAGE

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INTRODUCTORY INFORMATION 0

0 0 3

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THEORY OF OPERATION

INTRODUCTION

0003

1. The 120M Motor Grader consists of the following functional systems: engine, powertrain, brakes, electrical, steering, and hydraulics. 2. This work package explains how the systems and components of the machine work together. A functional description is provided for each major component and system. 3. The 120M Motor Grader is an all-purpose, medium sized, wheeled vehicle used for spreading and evening various types of granular material (dirt, stone, sand, etc.). Power is provided by a Caterpillar in-line, sixcylinder, direct injected, diesel engine. Hydraulically operated implements allow blade positioning for forward or backward grading, ditch or embankment grading, and snow removal. A scarifier allows loosening of compacted material prior to grading. Front leaning wheel and frame articulation provide maximum maneuverability. The grader has a sound-suppressing Rollover Protective Structure (ROPS) cab with insulation, heater, and windows, which allows for all-weather operation.

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ENGINE

0003

1. General. The grader is equipped with a Caterpillar C6.6 Acert VHP turbocharged diesel engine with six in-line cylinders, generating 153 horsepower @ 2,000 RPM. 2. Fuel System. Diesel fuel is drawn from the tank by a fuel transfer pump, filtered by a primary fuel filter, routed to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzles into the engine cylinders. Air is drawn in through dry-type, replaceable filter elements. A check valve removes incoming dust from the air and routes it out through the exhaust system. The air is routed from the filter assembly to the turbocharger which pressurizes the air and sends it to the air-to-air aftercooler. The aftercooler, located near the radiator, reduces the air temperature making it denser. The denser air charge allows for more air and fuel to be combusted per engine cycle, increasing engine output power. 3. Cooling System. Provides coolant to the engine. Coolant is circulated through the engine by a gear-driven water pump. The hydraulic oil cooler is located in front of the radiator. The engine oil cooler is integral to the engine. The transmission oil cooler is located behind an access cover below the left front access door. 4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan. The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head. 5. Exhaust System. The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow into exhaust pipes and a muffler to the atmosphere behind the cab.

Figure 1. Engine Components.

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ENGINE – CONTINUED

Figure 2. Engine Components.

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POWERTRAIN

0003

1. Transmission. Eight speeds are provided in forward and six in reverse. A transmission modulator control (inching pedal) disengages the transmission from the drive wheels. Inching allows the operator to vary the machine ground speed while keeping engine speed high for quick implement response. 2. Rear Axle Differential and Lock Differential. A four-wheeled tandem rear axle arrangement houses axle shafts driven by a lock-unlock equipped differential. The axle shafts turn the final drive sprocket chains through planetary reduction gears. The sprocket chains then drive the final drive sprockets. 3. Final Drive Assembly. The sprocket chains drive the final drive sprockets and axle shafts which turn the rear wheel spindles inside the tandem axle housing.

Figure 3. Powertrain Components.

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BRAKES

0003

1. General. The oil-bathed, multiple-disc service brakes are hydraulically activated. Each tandem wheel end contains a service brake unit. A brake wear indicator is easily accessible for checking brake wear. A compensator maintains consistent brake performance. 2. Service Brakes. A foot pedal is used for engaging multiple disc brake assemblies for each wheel within the tandem and spindle housings. 3. Parking Brakes. Multiple oil-bathed disc-type located in the transmission case. Electrically actuated by an ON/OFF switch on the right side of the instrument panel, the parking brake is spring applied and hydraulically released. The parking brake is integrated into the Operator Presence System to prevent unintended machine movement while the operator is not in the cab seat. 4. Brake Accumulators. Two brake accumulators, located behind the cab, assist in applying the service brakes. The accumulator remains charged even after the engine is shut down and provides limited braking ability.

Figure 4. Brake Components.

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ELECTRICAL

0003

1. The electrical system, interruptible by a lockable battery disconnect switch, consists of two 12V batteries connected in series with negative grounding, providing 24V to operate the electrical systems and components. 2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate the machine, including a NATO slave receptacle. 3. The major systems comprising the electrical system are: a. Starting system. b. Charging systems. c.

Messenger display system.

d. Service, work, and blackout lights. HYDRAULICS

0003

1. General. The hydraulic system is comprised of a single fluid tank, an implement and steering pump, a brake and hydraulic fan pump, a secondary steering pump, and a set of bank valves to distribute hydraulic fluid pressure to the various hydraulically activated systems (braking, steering, articulation, wheel lean, and earth moving components). The system also contains various control valves, check valves, sensors, and accumulators to maintain correct pressures. The fluid tank with a sight glass to check fluid level is located behind the left rear access door. A hydraulic fluid cooler is located in front of the radiator. 2. Steering System. The steering system utilizes hydraulic pressure produced by the implement and steering pump to actuate steering cylinders. An electric secondary hydraulic steering pump, located below the cab, provides hydraulic steering pressure in the event of implement and steering pump failure. 3. Steering Cylinders. There are two steering cylinders mounted at the front axle that turn the front wheels. The cylinders are powered by the hydraulic system and controlled by the steering pump and joystick controls. 4. Wheel Lean Cylinder. The wheel lean cylinder is mounted on the right side of the front axle. It is powered by the hydraulic system and controlled by a switch on the left joystick. The function of the wheel lean cylinder is to set the front wheels at an angle. This counteracts blade pressure exerted sideways against the front wheels when grading or moving heavy material. The wheel lean cylinder also sets front wheel angle to prevent the front of the machine from slipping sideways and downward when the machine is moving across a slope. 5. Ground Engagement Tools. The scarifier height, blade height, rotation, tilt, sideshift, centershift, and angle are all hydraulically powered and controlled using joysticks and joystick controls. 6. Brake System. The service brakes are hydraulically activated by pressing down on the foot pedal in the cab. Hydraulic pressure is provided by the engine driven fan and brake pump located behind the left front access door. The parking brake is spring actuated and hydraulically released via a switch located on the right side of the instrument panel activated by the operator. 7. All-Wheel Drive (AWD). All-wheel drive provides machine propulsion to the front tires when commanded by the operator. The AWD control is located on the right-side control panel. All-wheel drive can be operated in either CREEP or MANUAL mode by providing hydraulic fluid pressure to hydraulic motors at the front wheels. When in CREEP mode, the machine is propelled only by the front wheels. Speed in CREEP mode is variable from 0 to 5 mph (0 to 8 km/h). In MANUAL mode, the front wheels can be commanded to run at 99 percent, 100 percent, or 120 percent of rear wheel speed. END OF WORK PACKAGE

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CHAPTER 2 OPERATOR INSTRUCTIONS

26 TM 5-3805-293-10

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DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

GENERAL

0004

Do not attempt to operate the 120M Motor Grader until becoming familiar with the location and use of all controls and indicators. This work package describes all operator controls and indicators. MAIN ENTRY AND EXIT

0004

Figure 1. Steps and Handhold – Main Entry and Exit.

KEY

COMPONENT

DESCRIPTION

1

Handhold

Provides hand grips for mounting and dismounting machine.

2

Steps

Provide stepped platform for mounting and dismounting machine.

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ALTERNATE EXIT

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Figure 2. Alternate Exit.

KEY 1

COMPONENT Right Door

0004

DESCRIPTION Provides alternate exit from cab.

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ARTICULATION LOCK PIN

0004

Figure 3. Articulation Lock Pin.

KEY

COMPONENT

DESCRIPTION

1

Articulation Lock Pin

Prevents machine from articulating. Pin shown installed in rear frame pocket.

2

Spring Rods

Pull back on spring rod to release lock pin.

3

Lock Pin Storage Bracket

Articulation lock pin stowage location during machine operation.

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WHEEL LEAN LOCK BOLT

0004

Figure 4. Wheel Lean Lock Bolt.

0004

0004

KEY

COMPONENT

DESCRIPTION

1

Wheel Lean Lock Bolt/Nut

Locks lean bar to left front axle to prevent front wheels from tilting. Stowed in BII tool box. Used only during maintenance repairs. Not for shipping/storage.

2

Lean Bar (left side)

Connects both front wheels to lean cylinder. 0004

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DOOR HANDLES AND LATCHES

0004

Figure 5. Door Handles.

KEY

COMPONENT

0004

DESCRIPTION

1

Outer Door Handle

Unlatches door from outside cab.

2

Inner Door Handle

Unlatches door from inside cab.

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0004

DOOR HANDLES AND LATCHES – CONTINUED

Figure 6. Door Latch and Release.

KEY

COMPONENT

DESCRIPTION

1

Latch Assembly

Secures open door to cab.

2

Remote Latch Release

Unlatches door from inside cab.

0004-6

0004

TM 5-3805-293-10

0004

SEAT

0004

Figure 7. Seat.

KEY 1

COMPONENT Lumbar Support Knob

2

Fore/Aft Lever

3

Seat Height Lever

4

Weight Adjustment Knob

5

Backrest Adjustment Lever

6

Seat Cushion Tilt

DESCRIPTION Rotate knob counterclockwise to increase stiffness of lumbar support. Rotate knob clockwise to decrease stiffness. Pull up on lever to adjust seat forward or rearward. Release lever to lock. Pull up on lever to adjust seat upward or downward. Release lever to lock. Rotate knob clockwise to increase height of seat. Rotate knob counterclockwise to decrease seat height. Pull up on lever to adjust seat back lean angle. Release lever to lock seat back. Front of seat cushion is pinned in a groove. Grasp seat pan and rotate “forward-up-and-back” to position seat into a steep angle. Grasp seat pan and rotate forward-down-and-back to position seat at normal angle.

0004-7

0004

TM 5-3805-293-10

0004

SEAT BELT

0004

Figure 8. Retractable Seat Belt.

KEY 1

COMPONENT Seat Belt (Retractable)

DESCRIPTION Secures operator in seat.

0004-8

0004

TM 5-3805-293-10

0004

WRIST RESTS, ARM PADS, AND CONTROL PODS

0004

Figure 9. Wrist Rests, Arm Pads, and Control Pods.

KEY

COMPONENT

0004

DESCRIPTION

1

Wrist Rest Height Adjustment Knob

Pull wrist rest height adjustment knob to allow adjustment of wrist rest. Release knob to lock. Right side shown, left side similar.

2

Control Pod Fore/Aft Adjustment Lever

Pull up on lever to allow fore/aft adjustment of control pods. Release lever to lock. Left side shown, right side similar.

3

Arm Pad Adjustment Knob

Turn knob counterclockwise to allow adjustment of arm pads. Turn knob clockwise to lock. Left side shown, right side similar.

4

Control Pod Vertical Adjustment Knob

Turn knob counterclockwise to allow height adjustment of control pods. Turn knob clockwise to lock. Left side shown, right side similar.

0004-9

TM 5-3805-293-10

0004

JOYSTICK CONTROLS

0004

Figure 10. Left Joystick Controls.

KEY

COMPONENT

DESCRIPTION

1

Downshift Switch

Depress switch to downshift to desired gear in forward or reverse.

2

Wheel Lean Control - LEFT

Press button to lean wheels left. Wheels will remain leaning after button is released.

3

Upshift Switch

Depress switch to upshift to desired gear in forward or reverse.

4

Wheel Lean Control - RIGHT

Press button to lean wheels right. Wheels will remain leaning after button is released.

5

Automatic Articulation Centering Control

Press and release button to return machine articulation to CENTER position. Machine will move gradually. Automatic articulation (centering) can be cancelled by pressing button again or rotating left joystick.

0004-10

0004

TM 5-3805-293-10

0004

JOYSTICK CONTROLS – CONTINUED KEY

COMPONENT

DESCRIPTION

6

Steer - LEFT

Move left joystick LEFT to turn front wheels to the left. When joystick is released, front wheels will remain aligned with joystick.

7

Steer - RIGHT

Move left joystick RIGHT to turn wheels to the right. When joystick is released, front wheels will remain aligned with joystick.

8

Blade Lower and Blade Float for Left Side

Blade Lower - Push left joystick forward to lower left end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position. Blade Float - Push left joystick to the most forward DETENT position. When joystick is released, blade will remain in float position until joystick is moved forward or backward. Joystick returns to HOLD position. Extra effort may be necessary to push joystick forward into the FLOAT position.

9

Blade Lift for Left Side

Pull left joystick rearward to raise left end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position.

10

Articulation Control

Articulation Right - Twist left joystick clockwise to move rear of machine to the right. When joystick is released, articulation will remain in selected position. Joystick returns to HOLD position. Articulation Left - Twist left joystick counterclockwise to move rear of machine to the left. When joystick is released, articulation will remain in selected position. Joystick returns to HOLD position.

0004-11

TM 5-3805-293-10

JOYSTICK CONTROLS – CONTINUED

0004

0004

Figure 11. Right Joystick Controls.

0004-12

0004

TM 5-3805-293-10

0004

JOYSTICK CONTROLS – CONTINUED KEY

COMPONENT

DESCRIPTION

1

Blade Sideshift Control - LEFT

Move right joystick left to sideshift blade to the left. When joystick is released, blade sideshift will remain in selected position. Joystick will return to HOLD position.

2

Blade Sideshift Control - RIGHT

Move right joystick right to sideshift blade to the right. When joystick is released, blade sideshift will remain in selected position. Joystick will return to HOLD position.

3

Blade Lower and Blade Float for Right Side

Blade Lower - Push right joystick forward to lower right end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position. Blade Float - Push right joystick to the most forward DETENT position. When joystick is released, blade will remain in float position until joystick is moved forward or backward. Joystick returns to HOLD position. Extra effort may be necessary to push joystick forward into the FLOAT position.

4

Blade Lift for Right Side

Pull right joystick rearward to raise right end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position.

5

Centershift Control - LEFT

Push left side of thumb button to move drawbar left. When button is released, drawbar remains in selected position. Button returns to HOLD position.

6

Centershift Control - RIGHT

Push right side of thumb button to move drawbar right. When button is released, drawbar remains in selected position. Button returns to HOLD position.

7

Blade Pitch Control - FORWARD

Push top of thumb button to pitch blade forward. When button is released, blade remains in selected position. Button returns to HOLD position.

8

Blade Pitch Control - BACKWARD

Push bottom of thumb button to pitch blade backward. When button is released, blade remains in selected position. Button returns to HOLD position.

9

Blade Circle Drive Control

Circle Drive Clockwise - Twist right joystick in clockwise direction to rotate blade clockwise. When joystick is released, blade remains in selected position. Joystick returns to HOLD position. Circle Drive Counterclockwise - Twist right joystick in counterclockwise direction to rotate blade counterclockwise. When joystick is released, blade remains in selected position. Joystick returns to HOLD position.

10

Horn Button

Press to activate horn.

11

Turn Signal Switch

Push right side of button to activate right turn signal indicator. Push left side of button to activate left turn signal indicator. Turn signal will remain ON until switch is manually returned to center position.

0004-13

TM 5-3805-293-10

0004

JOYSTICK CONTROLS – CONTINUED

Figure 12. Joystick Controls.

KEY 1

COMPONENT Throttle Resume/Decel Switch

0004

DESCRIPTION Pull trigger switch to resume engine speed previously selected. Hold trigger switch to decrease engine speed by approximately 100 RPM/per second held. Bump trigger switch to decrease engine speed in 100 RPM increments.

2

Differential Lock Control

Push to engage or disengage differential lock. Locks differential to increase traction in soft or wet ground.

3

Transmission Control Switch

Pull top of switch to engage transmission in REVERSE. Move switch to middle position to place transmission in NEUTRAL. Pull bottom of switch to engage transmission in FORWARD.

0004-14

TM 5-3805-293-10

0004

MID-MOUNT SCARIFIER CONTROL ROLLER AND ARCTIC HEATER SWITCH

Figure 13. Mid-Mount Scarifier Control.

KEY 1

COMPONENT Mid-Mount Scarifier Control Roller

DESCRIPTION Extend - Roll thumb wheel down to extend (lower) scarifier. When thumb wheel is released, scarifier remains in selected position. Thumb wheel returns to HOLD position. Retract - Roll thumb wheel up to retract (raise) scarifier. When thumb wheel is released, scarifier remains in selected position. Thumb wheel returns to HOLD position.

2

Arctic Heater Switch

Press button to activate and deactivate arctic heater.

0004-15

0004

0004

TM 5-3805-293-10

0004

FORWARD CONTROLS AND INDICATORS

0004

469-0018

Figure 14. Forward Controls and Indicators.

KEY

COMPONENT

DESCRIPTION

1

Centershift Lock Indicator

Illuminates when centershift lock is DISENGAGED.

2

Secondary Steering Test Switch

Allows operator to test secondary steering system.

3

Parking Brake Switch

Engages and disengages parking brakes.

4

Engine Start Switch

Turn switch clockwise to ON position to activate electrical circuits in cab. Turn switch clockwise to START position to start engine. Turn switch counterclockwise to shut off engine and electrical power. If engine fails to start, switch must be returned to the OFF position before attempting to start engine.

5

Accelerator Control

Depress pedal to increase engine speed. Release pedal to decrease engine speed.

6

Service Brake Control

Depress pedal to apply service brakes to slow or stop machine.

7

Transmission Modulator Control (Inching Pedal)

Disengages power to the wheels as pedal is depressed. Pedal fully depressed completely disengages power to wheels.

0004-16

0004

TM 5-3805-293-10

0004

RIGHT-SIDE CONTROL PANEL

0004

Figure 15. Right-Side Control Panel. KEY

COMPONENT

DESCRIPTION

1

Centershift Lock Switch

Push bottom of switch to engage centershift lock. Press red tab and push top of switch to disengage centershift lock.

2

Defroster Fan Switch

Push top of switch to operate defroster fan at HIGH speed. Move switch to center position for MEDIUM speed. Push bottom of switch for LOW speed.

3

Blade Cushion Switch

Machine not equipped with blade cushion option.

4

Power Port (12V)

Remove cap to access port to power 12V electrical equipment or accessories.

5

Throttle Set/Accel Switch

Allows operator to set speed of throttle.

6

Electrical Coolant Switch

Push button to turn arctic heater ON. Push button again to turn OFF.

7

Throttle Hold Mode Switch

Allows Operator to set mode for throttle hold function. Mode options include OFF, AUTOMATIC, and MANUAL.

8

Hazard Flasher Switch

Push top of switch to activate hazard flashers. Push bottom of switch to deactivate.

9

Front and Rear Worklight Switch

Push top of switch to activate front worklights only. Push bottom of switch to activate front and rear worklights. Move switch to middle position to deactivate all worklights.

10

Headlight Dimmer Switch

Push top of switch to activate high beams. Push bottom of switch to deactivate high beams; low beams remain ON.

0004-17

0004

TM 5-3805-293-10

0004

ALL-WHEEL DRIVE (AWD) CONTROLS

0004

Figure 16. All-Wheel Drive Controls. . KEY

COMPONENT

DESCRIPTION

1

All-Wheel Drive Control

Controls speed (aggression) of front wheels when AWD is activated.

2

All-Wheel Drive Mode Switch

Three-position switch used to engage all-wheel drive. Turn switch to left of center for CREEP mode. Turn switch to right of center for MANUAL mode. Turn switch to center position to turn off AWD.

3

Manual Mode Indicator Light

Indicator illuminates when MANUAL mode is activated.

0004-18

0004

TM 5-3805-293-10

0004

HEATING AND AIR CONDITIONING CONTROLS

0004

Figure 17. Heater and Air Conditioning Controls.

KEY 1

COMPONENT Fan Speed Switch

DESCRIPTION Turn switch counterclockwise to OFF position. Turn switch clockwise to operate fan at low, medium, high, and maximum speeds. To pressurize cab to prevent dust entry when neither heating nor cooling is desired, adjust fan speed and temperature to comfortable levels. Do not activate air conditioning.

2

Temperature Variable Control

Adjust temperature from minimum (full left) to maximum (full right).

3

Air Conditioning Switch

Push top of switch to activate air conditioning. Push bottom of switch to deactivate air conditioning. To defog windshield, activate air conditioning and adjust fan speed and temperature to decrease moisture level in cab.

0004-19

0004

TM 5-3805-293-10

0004

WIPER/WASHER CONTROLS

0004

Figure 18. Wiper/Washer Controls.

KEY 1

COMPONENT Left Door Wiper/Washer Control

0004

DESCRIPTION Turn knob clockwise one notch to activate intermittent wipers at long delay. Continue turning knob to decrease delay. Turn knob to next notch for continuous low wiper speed. Turn knob to next notch for continuous high wiper speed. Turn knob all the way left to shut off wipers. Push knob to activate window washer.

2

Front Windshield Wiper/Washer Control

Operates the same as left door wiper/washer control.

3

Right Door Wiper/Washer Control

Operates the same as left door wiper/washer control.

0004-20

TM 5-3805-293-10

0004

MONITORING SYSTEM

0004

Figure 19. Monitoring System. KEY

COMPONENT

DESCRIPTION

1

Left Turn Signal Indicator

Flashes when left turn signal is activated.

2

Left Blade Float Indicator

Illuminates when left blade float is activated.

3

Battery Charge Alert Indicator

Illuminates when a problem with machine voltage or alternator is present.

4

Electric Coolant Heater Alert Indicator

Illuminates when coolant heater is activated.

5

Engine System Alert Indicator

Illuminates when an engine problem is present.

6

Implement System Alert Indicator

Illuminates when an implement system problem is present.

7

Throttle Lock Indicator

Illuminates when throttle lock is activated.

8

Primary Steering Alert Indicator

Illuminates when a steering system problem is present.

9

Action Light Alert Indicator

Illuminates when a problem occurs with machine.

10

Analog Tachometer

Displays engine speed in revolutions per minute.

11

Parking Brake Indicator

Illuminates when parking brakes are engaged.

12

Transmission System Alert Indicator

Illuminates when a transmission system problem is present.

13

Differential Lock Indicator

Illuminates when differential lock is activated.

14

Secondary Steering System Alert Indicator

Illuminates RED when a system problem is present. Illuminates GREEN when system is activated or being tested.

15

High Beam Indicator

Illuminates when high beams are activated.

16

Brake System Indicator

Illuminates when a general fault occurs in brake system.

17

Operator Not Present Alert Indicator

Illuminates when under specific conditions operator is not in cab.

18

Right Blade Float Indicator

Illuminates when right blade float is activated.

19

Right Turn Signal Indicator

Flashes when right turn signal is activated.

20

Articulation Angle Gauge

Indicates amount of right or left articulation.

21

Fuel Level Gauge

Indicates amount of fuel in tank.

22

LCD Display

Provides information on ground speed, actual gear and direction, operator requested gear, service hour meter.

23

Hydraulic Oil Temperature Gauge

Indicates hydraulic oil temperature. Red area indicates oil temperature above 199°F (93ºC).

24

Coolant Temperature Gauge

Indicates coolant temperature. Red area indicates coolant temperature above 225ºF (107ºC).

0004-21

0004

TM 5-3805-293-10

0004

MESSENGER DISPLAY AND IMPLEMENT LOCKOUT SWITCH

0004

Figure 20. Messenger Display and Implement Lockout Switch. KEY

COMPONENT

DESCRIPTION

1

Messenger Display

Provides machine information through various menus (Performance Menu, Totals Menu, Settings Menu, Service Menu), includes a self-diagnostic function test and four distinct warning categories to alert the operator of a situation requiring attention.

2

Implement Lockout Switch

Push top of switch to lock out implement controls. Push bottom of switch to unlock implement controls. Implements must be locked out during transport or while loading to prevent inadvertent movement. Note: Steering is not affected by position of switch.

0004-22

0004

TM 5-3805-293-10

0004

MILITARY LIGHT SWITCH

0004

Figure 21. Military Light Switch. KEY

COMPONENT

0004

DESCRIPTION

1

Military Light Switch

Controls operation of service, blackout, parking, and instrument panel lights. When operating in blackout mode, worklights, service, and directional lights are disabled. Backup alarm and horn are also disabled in blackout mode.

2

Mode Switch

Used to select desired mode of lighting. Release unlock lever to change modes.

3

Unlock Lever

Lift up to unlock mode switch. Returns to locked position when released.

4

Panel Brightness Switch

Not applicable to 120M.

0004-23

TM 5-3805-293-10

0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE

0004

Figure 22. Battery Disconnect Switch and Slave Receptacle. KEY 1

COMPONENT Battery Disconnect Switch

DESCRIPTION Disconnects batteries from rest of machine. Includes a mechanical lockout cover to prevent unwanted access to switch. Insert disconnect switch key and turn switch clockwise to the ON position to activate machine electrical system and enable engine start. Insert key and turn switch counterclockwise to the OFF position to deactivate machine electrical systems or to shut down engine if it must be stopped quickly.

2

24V Slave Receptacle

Connection for 24V slave start cable.

0004-24

0004

TM 5-3805-293-10

0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE – CONTINUED

Figure 23. Arctic Heater Fuel Shutoff Valve.

KEY 1

COMPONENT Arctic Heater Fuel Shutoff Valve

DESCRIPTION Lever in horizontal position indicates valve is closed, shutting off fuel supply from tank. Lever in vertical position indicates valve is open, allowing fuel flow from tank to arctic heater.

END OF WORK PACKAGE

0004-25/(26 blank)

0004

34 TM 5-3805-293-10

0005

OPERATOR MAINTENANCE

-

OPERATION UNDER USUAL CONDITIONS Scope; Initial Adjustment Before Use; Mounting and Dismounting; Seat, Seat Belt, and Control Adjustments; Engine Starting and Machine Warm-up; Parking; Articulation Lock Pin Installation; Messenger Display; Machine Warning Summaries; Joystick Steering; Differential Lock Control; Transmission Operation; Throttle Hold Mode Switch; Centershift Lock Switch; All-Wheel Drive (AWD); Slope Operation; Scarifier Operation 0 0 0

5

INITIAL SETUP Tools and Special Tools Strap, Tiedown (WP 0032, Item 18)

0

References

0

WP 0004 WP 0006 WP 0007 WP 0013 WP 0027 WP 0032

SCOPE

0

0

0

0

0

0

0

0005

1. This work package provides instructions on operating the 120M Motor Grader under usual conditions. 2. Refer to WP 0006 for advanced operation instructions and operator tips. 3. Refer to WP 0007 for operating instructions under unusual conditions. 4. Before, during, and after operation, perform applicable Preventive Maintenance Checks and Services (PMCS) (WP 0013). INITIAL ADJUSTMENT BEFORE USE

0005

1. Perform all Before PMCS checks and services (WP 0013). 2. Pull back on spring rod and remove articulation lock pin from frame pocket. Stow in lock pin storage bracket and engage spring rod to lock pin in place. 3. If installed, remove wheel lean lock bolt (WP 0004). Stow in machine-mounted tool box. 4. Turn battery disconnect switch to ON position (WP 0004). END OF TASK

0005-1

TM 5-3805-293-10

MOUNTING AND DISMOUNTING

0005

0005

WARNING •

Mount and dismount the machine only at locations that have steps and handholds.

•

Clean steps and handholds prior to mounting machine.

•

Face machine during mounting and dismounting.

•

Maintain three-point contact (two hands and one foot, or one hand and two feet) at all times.

•

Do not mount or dismount a moving machine.

•

Do not jump off a moving machine.

•

Do not carry tools or supplies when mounting or dismounting machine.

•

Do not use any controls as handholds during mounting or dismounting.

•

Failure to follow these warnings may result in injury or death to personnel.

1. Open left door. 2. Enter machine from left side and occupy operator’s seat. 3. Close left door. END OF TASK SEAT, SEAT BELT, AND CONTROL ADJUSTMENTS 1. Adjust operator’s seat (WP 0004). 2. Grasp seat belt and pull out of retractor in one continuous motion, then insert catch into buckle. Seat belt adjusts tension automatically. Make sure belt is positioned low across lap (WP 0004). 3. Adjust wrist rests, control pods, and arm pads (WP 0004). 4. With the aid of an assistant, adjust mirrors to obtain a clear view behind machine. END OF TASK

0005-2

0005

TM 5-3805-293-10

ENGINE STARTING AND MACHINE WARM-UP

0005

WARNING

•

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

•

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 can result from severe exposure.

•

Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when the engine of the 120M Grader is operated.

•

DO NOT operate engine in enclosed areas.

•

DO NOT idle engine without adequate ventilation.

•

BE ALERT for exhaust poisoning symptoms. They are:

•

•

Headache

•

Dizziness

•

Sleepiness

•

Loss of muscular control

0005

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. •

BE AWARE. The field protective mask for Chemical, Biological, Radiological, Nuclear (CBRN) protection will not protect you from carbon monoxide poisoning.

•

CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

0005-3

TM 5-3805-293-10

0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED

WARNING

Hearing protection is required when standing within 26 ft (8 m) of the 120M Motor Grader while it is operating. Failure to wear hearing protection may result in hearing loss. 1. Check to make sure all bystanders are clear of machine before starting engine. 2. Place transmission control switch in NEUTRAL (WP 0004). 3. Engage parking brake (WP 0004).

WARNING Monitoring system will perform an automatic self-diagnostic functional test whenever engine start switch is turned to ON position. If action alarm does not sound or monitoring displays are not functioning, do not start or operate machine until cause has been corrected. Failure to follow this warning may result in injury or death to personnel as any Warning Category 3 notifications will not be relayed to operator.

NOTE •

Automatic self-diagnostic functional test verifies outputs (gauges, alert indicators, and alarms) are operating correctly.

•

Gauges must sweep to the far right of their scale and then back.

•

Alert indicators must come on momentarily.

•

All segments of the LCD must come on momentarily.

•

Action alarm must sound.

4. Turn engine start switch to ON but do not start engine. Allow monitoring system to perform self-diagnostic functional test (WP 0004).

CAUTION •

When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30 seconds. Allow starting motor to cool for two minutes before cranking again or damage to starting motor or batteries may result.

•

When ambient temperature is between -1°F (-18°C) and -25°F (-32°C), it may be necessary to crank engine for up to 60 seconds.

•


•

Shut down engine immediately if engine system indicator or action light indicator comes on. Notify Field Level Maintenance. Failure to follow this caution may result in damage to engine or other machine systems.

NOTE If engine fails to start, you must turn ignition switch to the OFF position, then back to ON and START. 5. Turn and hold engine start switch to START. Release when engine starts.

0005-4

TM 5-3805-293-10

0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED 6. Allow engine to run at low idle speed while observing engine system indicator or action light indicator. If either indicator comes on during warm-up, shut down engine immediately and notify Field Level Maintenance. 7. Continue to idle machine while monitoring hydraulic oil temperature on Messenger dIsplay. Only operate machine after hydraulic oil temperature is equal to or greater than 41°F (5°C). If necessary to raise hydraulic oil temperature, cycle all implement and steering controls to allow warm hydraulic oil to circulate through all hydraulic lines. END OF TASK PARKING

0005

Stopping Machine

0005

1. Choose a level surface to stop machine whenever possible. 2. Decrease engine speed. 3. Apply service brakes to slow machine. Apply transmission modulator pedal and service brakes to stop machine (WP 0004). 4. Place transmission control switch in NEUTRAL position (WP 0004). 5. Engage parking brake (WP 0004). 6. Lower scarifier to the ground and apply a slight downward pressure (WP 0004). 7. Angle blade to either side, lower onto wood blocks and tilt forward. 8. Lock out hydraulic controls by placing the hydraulic lockout switch in the LOCK position (WP 0004). Stopping Engine

0005

CAUTION Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of engine components. 1. Operate engine at low idle for five minutes to allow engine and components to cool gradually. 2. Turn engine start switch to OFF (WP 0004). Leaving Machine

0005

WARNING Use caution and maintain three-point contact at all times when dismounting machine. Failure to follow this warning may result in injury or death to personnel. 1. 2. 3. 4. 5.

Exit cab through left door. Use steps and hand holds to dismount. Face machine when dismounting (WP 0004). Perform all After PMCS (WP 0013). Turn battery disconnect switch to OFF (WP 0004). Secure machine against vandalism. Lock all covers and compartments.

Operator Presence System

0005

The Operator Presence System automatically engages the parking brake when the operator leaves seat when the parking brake is disengaged, and machine is running but not moving. Once the operator returns to the seat, the parking brake must be disengaged by cycling the switch to the ON position then back to OFF position (WP 0004). If the steering joystick was disturbed during this process, steering joystick will need to be realigned with front wheels. Refer to Joystick Steering in this work package. END OF TASK

0005-5

TM 5-3805-293-10

ARTICULATION LOCK PIN INSTALLATION

0005

0005

1. Start engine. 2. Press automatic articulation centering control on left joystick to align front and rear frames (WP 0004). 3. Shut down engine. 4. Pull back spring rod (Figure 1, Item 1) and remove articulation lock pin (Figure 1, Item 2) from storage bracket (Figure 1, Item 3).

Figure 1. Articulation Lock Pin in Storage Bracket.

005

5. Insert articulation lock pin (Figure 2, Item 1) into rear frame pocket, pull back spring rod (Figure 2, Item 3) and ensure pin lower flange (Figure 2, Item 4) contacts rear frame, then release spring rod. 6. Rotate pin until spring rod falls into detent in pin (Figure 2, Item 2).

Figure 2. Articulation Lock Pin Installed. END OF TASK

0005-6

005

TM 5-3805-293-10

0005

MESSENGER DISPLAY

0005

The Messenger system provides real-time machine performance and diagnostic data with an easy-to-use interface. The Messenger monitors all system data and alerts the operator to any faults through a digital text display. The Messenger includes a Performance menu, a Totals menu, a Settings menu, and a Service menu. Each menu has numerous options which allow the operator to adjust certain settings or monitor specific system data.

Figure 3. Messenger Display

005

1. The digital display area (Figure 3, Item 1) displays system information. 2. The OK button (Figure 3, Item 2) confirms selections after you have made them by scrolling with the Down/ Right button (Figure 3, Item 3) and the Up/Left button (Figure 3, Item 4). 3. The Down/Right button (Figure 3, Item 3) is used to scroll down and/or right through information shown on the digital display area (Figure 3, Item 1). 4. The Up/Left button (Figure 3, Item 4) is used to scroll up and/or left through information shown on the digital display area (Figure 3, Item 1). 5. The Back button (Figure 3, Item 5) is used to return to information previously shown on the digital display area (Figure 3, Item 1). 6. The Implement Lockout switch (Figure 3, Item 6) locks and unlocks implement controls.

0005-7

TM 5-3805-293-10

0005

MESSENGER DISPLAY – CONTINUED Performance Menu

0005

The default information displayed by the Messenger is the Performance menu (Figure 4).

Figure 4. Performance Menu.

005

The following options are available through the Performance menu. a. ENGINE SPEED. When scrolling to this option, display shows engine speed in revolutions per minute (RPM). b. MPH GROUND SPEED. When scrolling to this option, display shows ground speed in miles per hour (mph) or kilometers per hour (km/h). c.

ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant temperature in degrees Fahrenheit (°F) or in degrees Celsius (°C).

d. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot point. e. FUEL LEVEL. When scrolling to this option, display shows amount of fuel remaining as a percentage of full. f.

HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature in degrees Fahrenheit (°F) or in degrees Celsius (°C).

g. REQ GEAR. When scrolling to this option, display shows gear that is selected by operator. h. ACTUAL GEAR. When scrolling to this option, display shows gear that is currently engaged in transmission. i.

TOS. When scrolling to this option, display shows transmission output speed.

j.

TRANSMISSION OIL TEMPERATURE. When scrolling to this option, display shows transmission oil temperature in degrees Fahrenheit (°F) or in degrees Celsius (°C).

k.

IMPLEMENT LOCKOUT SWITCH POSITION. When scrolling to this option, display shows position of implement lockout switch.

l.

IMPLEMENT PILOT SUPPLY SOLENOID. When scrolling to this option, display shows status of implement pilot supply solenoid.

0005-8

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0005

MESSENGER DISPLAY – CONTINUED m. BLADE LEFT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of blade left lift cylinder float. n. BLADE RIGHT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of blade right lift cylinder float. o. SECONDARY STEERING SYSTEM TEST. When scrolling to this option, display shows status of secondary steering system test. p. SECONDARY STEERING REQUEST SIGNAL. When scrolling to this option, display shows secondary steering request signal. q. CHARGE FILTER BYPASS STATUS. When scrolling to this option, display shows status of powertrain filter bypass. r.

TRANSMISSION MODULATOR CONTROL (INCHING PEDAL) POSITION. When scrolling to this option, display shows position of transmission modulator control (inching pedal).

Totals Menu

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The Totals menu has three sub-menus: Lifetime Totals, Trip Totals, and Trip Reset.

Figure 5. Totals Menu.

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MESSENGER DISPLAY – CONTINUED 1. The following options are available through the Lifetime Totals sub-menu: a. FORWARD DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of distance travelled in forward direction in miles or kilometers. b. REVERSE DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of distance travelled in reverse direction in miles or kilometers. c.

TOTAL FUEL. When scrolling to this option, display shows lifetime total of amount of fuel consumed by machine.

d. SERVICE HOURS. When scrolling to this option, display shows lifetime total of number of hours machine has run. 2. The following options are available through the Trip Totals sub-menu:

NOTE Total Fuel and Service Hours can be reset to zero from each of these screens. a. TOTAL FUEL. When scrolling to this option, display shows amount of fuel consumed by machine since trip total has been reset. b. SERVICE HOURS. When scrolling to this option, display shows total of number of hours machine has run since trip total has been reset. 3. The following option is available through the Trip Reset sub-menu: CLEAR TRIP TOTALS. When scrolling to this option, you can reset trip total values. Settings Menu

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The Settings menu has four sub-menus: Monitoring System, Machine, Transmission, and Implement.

Figure 6. Settings Menu.

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MESSENGER DISPLAY – CONTINUED 1. The following options are available through the Monitoring System sub-menu: a. LANGUAGE. Select this option to change display language. b. UNITS. Select this option to set the desired measurement system (English or Metric). c.

CONTRAST ADJUST. Select this option to adjust display contrast to improve visibility. A bar graph is displayed to show level of contrast.

d. BACKLIGHT ADJUST. Select this option to adjust brightness of Messenger display area, switch lights, and instrument panel lights for better visibility. Headlights and/or taillights must be turned ON to make these adjustments. A bar graph is displayed to show level of brightness. 2. The following options are available through the Machine sub-menu: a. PRODUCT ID. Select this option to view product identification number. b. EQUIPMENT ID. Select this option to view equipment identification number. 3. The following options are available through the Transmission sub-menu: a. GEAR SELECTION. When scrolling to this option, display shows gear of transmission. b. TRANSMISSION INITIAL FORWARD GEAR. When scrolling to this option, display shows initial forward gear. c.

TRANSMISSION INITIAL REVERSE GEAR. When scrolling to this option, display shows initial reverse gear.

d. MIN FORWARD AUTOSHIFT GEAR. Not applicable. e. MIN REVERSE AUTOSHIFT GEAR. Not applicable. f.

MAX FORWARD AUTOSHIFT GEAR. Not applicable.

g. MAX REVERSE AUTOSHIFT GEAR. Not applicable.

NOTE The following list shows Caterpillar approved lubricants. Refer to Expendable and Durable Items List (WP 0032) for lubricant options. h. TRANSMISSION OIL TYPE.When scrolling to this option, display shows viscosity of oil in transmission. i.

TDTO SAE 0W-20. When scrolling to this option, display shows Cat TDTO SAE 0W-20 oil type.

j.

TDTO SAE 0W-30. When scrolling to this option, display shows Cat TDTO SAE 0W-30 oil type (OEA-30).

k.

TDTO SAE 5W-30. When scrolling to this option, display shows Cat TDTO SAE 5W-30 oil type.

l.

TDTO SAE 10W. When scrolling to this option, display shows Cat TDTO SAE 10W oil type (OE/HDO-10).

m. ARCTIC TDTO. When scrolling to this option, display shows Cat Arctic TDTO oil type (OEA-30). n. TDTO TMS. When scrolling to this option, display shows Cat TDTO TMS oil type. o. TDTO SAE 30. When scrolling to this option, display shows Cat TDTO SAE 30 oil type (OE/HDO-30). p. TDTO SAE 50. When scrolling to this option, display shows Cat TDTO SAE 50 oil type. 4. The following option is available through the Implement sub-menu: AUXILIARY POD STATUS. When scrolling to this option, display shows status of machine implements (enabled or not enabled).

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MESSENGER DISPLAY – CONTINUED Service Menu

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The Service menu (Figure 7) has two main sub-menus, Diagnostics/Events and Service Parameters, and numerous sub-sub-menus under Service Parameters for service parameters, system tests, system information, service tests, calibration, and tattletale.

Figure 7. Service Menu.

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The following option is available through the Diagnostics/Events sub-menu: VIEW DIAGNOSTICS. Select this option to view diagnostics/events logged by the monitoring system. A password is required to change any settings in this menu. System Parameters Sub-Menu

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a. The following options are available through the Monitoring system sub-sub-menu: (1) BATTERY VOLTAGE. When scrolling to this option, display shows available battery voltage. (2) FUEL LEVEL. When scrolling to this option, display shows fuel tank fill level. (3) ALTERNATOR STATUS. When scrolling to this option, display shows status of alternator. b. The following options are available through the Engine sub-sub-menu: (1) ENGINE RPM. When scrolling to this option, display shows engine speed in revolutions per minute. (2) DESIRED ENGINE RPM. When scrolling to this option, display shows desired engine speed in revolutions per minute. (3) ENGINE OIL PRESSURE. When scrolling to this option, display shows engine oil pressure. (4) ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant temperature. (5) FUEL PRS. When scrolling to this option, display shows fuel pressure. (6) AIR PRS. When scrolling to this option, display shows intake manifold air pressure. (7) AIR TEMP. When scrolling to this option, display shows intake manifold air temperature. (8) ATMOSPHERIC PRS. When scrolling to this option, display shows atmospheric pressure.

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MESSENGER DISPLAY – CONTINUED (9) RT TURBO INLET PRS. When scrolling to this option, display shows turbocharger inlet pressure. (10)THROTTLE POSITION. When scrolling to this option, display shows throttle position. (11) FUEL VOLUME When scrolling to this option, display shows amount of fuel delivered by fuel injectors. c.

The following options are available through the Transmission sub-sub-menu: (1) REQ GEAR. When scrolling to this option, display shows gear selected by operator. (2) ACTUAL GEAR. When scrolling to this option, display shows actual gear engaged in transmission. (3) TOS. When scrolling to this option, display shows transmission output speed. (4) TRANS OIL TEMP. When scrolling to this option, display shows transmission oil temperature. (5) CHARGE FILTER. When scrolling to this option, display shows status of charge filter bypass for transmission. (6) TRANSMISSION MODULATOR CONTROL (INCHING PEDAL) POS. When scrolling to this option, display shows position of inching pedal.

d. The following options are available through the Steering sub-sub-menu: (1) STEERING CONTROL POS. When scrolling to this option, display shows position of steering control. (2) STEERING DUTY CYCLE. When scrolling to this option, display shows status of steering signal for duty cycle. (3) LEFT CYL EXT. When scrolling to this option, display shows position of left steering cylinder. (4) RIGHT CYL EXT. When scrolling to this option, display shows position of right steering cylinder. (5) SECONDARY STEERING POS. When scrolling to this option, display shows position of secondary steering test switch. (6) SECONDARY STEERING TEST. When scrolling to this option, display shows status of secondary steering test. (7) SECONDARY STEERING SIGNAL. When scrolling to this option, display shows status of command signal for the secondary steering. (8) SECONDARY STEERING RELAY. When scrolling to this option, display shows status of secondary steering relay. e. The following options are available through the Implement sub-sub-menu: (1) HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature. (2) HYD OIL PRS. When scrolling to this option, display shows main hydraulic oil pressure. (3) LOCKOUT POS. When scrolling to this option, display shows position of implement lockout switch. (4) PILOT SUPPLY. When scrolling to this option, display shows status of implement pilot supply solenoid. (5) BLADE LEFT LIFT POS. When scrolling to this option, display shows lift position for left side of blade. (6) BLADE LEFT LIFT CYL. When scrolling to this option, display shows status of blade float function for left lift cylinder. (7) BLADE RIGHT LIFT POS. When scrolling to this option, display shows lift position for right side of blade. (8) BLADE RIGHT LIFT CYL. When scrolling to this option, display shows status of blade float function for right lift cylinder. (9) WHEEL LEFT LEAN POS. When scrolling to this option, display shows wheel lean (left) position. (10)WHEEL RIGHT LEAN POS. When scrolling to this option, display shows wheel lean (right) position. (11) PITCH FORWARD POS. When scrolling to this option, display shows blade pitch forward position.

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MESSENGER DISPLAY – CONTINUED (12)PITCH BACKWARD POS. When scrolling to this option, display shows blade pitch backward position. (13)SIDESHIFT POS. When scrolling to this option, display shows position of blade sideshift. (14)CIRCLE LEFT SIDESHIFT POS. When scrolling to this option, display shows left position of circle drawbar. (15)CIRCLE RIGHT SIDESHIFT POS. When scrolling to this option, display shows right position of circle drawbar. (16)CIRCLE DRIVE POS. When scrolling to this option, display shows position of circle drive. (17)ARTICULATION POS. When scrolling to this option, display shows position of articulation joint. (18)AUTO ARTICULATION POS. When scrolling to this option, display shows status of automatic articulation centering control. f.

The following options are available through the Brake sub-sub-menu: (1) PARK BRAKE SWITCH. When scrolling to this option, display shows status of parking brake switch. (2) BRAKE SOLENOID. When scrolling to this option, display shows status of parking brake solenoid. (3) PARK BRAKE PRS. When scrolling to this option, display shows status of parking brake pressure. (4) PARK BRAKE. When scrolling to this option, display shows park brake status (engaged or disengaged). (5) SERVICE BRAKE. When scrolling to this option, display shows status of service brake pedal.

g. The following options are available through the All-Wheel Drive sub-sub-menu; (1) RIGHT MOTOR SPD. When scrolling to this option, display shows right AWD motor speed. (2) LEFT MOTOR SPD. When scrolling to this option, display shows left AWD motor speed. (3) AWD MODE. When scrolling to this option, display shows status of AWD mode. (4) AWD SWITCH. When scrolling to this option, display shows status of AWD switch. (5) LEFT DESIRED RATIO. When scrolling to this option, display shows left desired ratio. (6) LEFT GEAR RATIO. When scrolling to this option, display shows left gear ratio. (7) RIGHT DESIRED RATIO. When scrolling to this option, display shows right desired ratio. (8) RIGHT GEAR RATIO. When scrolling to this option, display shows right gear ratio. (9) LEFT CLUTCH PRESSURE. When scrolling to this option, display shows left clutch pressure. (10)RIGHT CLUTCH PRESSURE. When scrolling to this option, display shows right clutch pressure. (11) AWD STATUS. When scrolling to this option, display shows status of AWD system. (12)HYDRAULIC OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature in degrees Fahrenheit (ºF) or in degrees Celsius (ºC). System Test Sub-Menu

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SYSTEM SELF TEST. When scrolling to this option, display shows status of system self test.

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MESSENGER DISPLAY – CONTINUED System Information Sub-Menu

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1. The following information is available through the Engine sub-sub menu: a. ENGINE SERIAL #. When scrolling to this option, display shows engine serial number. b. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. c.

ECM PART #. When scrolling to this option, display shows ECM part number.

d. SW PART #. When scrolling to this option, display shows software part number. e. SW RELEASE DATE. When scrolling to this option, display shows software release date. f.

SW DESCRIPTION. When scrolling to this option, display shows software description.

2. The following information is available through the Trans/Chassis sub-sub menu: a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. b. ECM PART #. When scrolling to this option, display shows ECM part number. c.

SW PART #. When scrolling to this option, display shows software part number.

d. SW RELEASE DATE. When scrolling to this option, display shows software release date. e. SW DESCRIPTION. When scrolling to this option, display shows software description. 3. The following information is available through the Monitoring System sub-sub menu: a. EQUIPMENT ID. When scrolling to this option, display shows equipment identification number. b. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. c.

ECM PART #. When scrolling to this option, display shows ECM part number.

d. SW PART #. When scrolling to this option, display shows software part number. e. SW RELEASE DATE. When scrolling to this option, display shows software release date. f.

SW DESCRIPTION. When scrolling to this option, display shows software description.

4. The following information is available through the Implement System sub-sub menu: a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. b. ECM PART #. When scrolling to this option, display shows ECM part number. c.


d. SW RELEASE DATE. When scrolling to this option, display shows software release date. e. SW DESCRIPTION. When scrolling to this option, display shows software description. 5. The following information is available through the Implement Control 2 System sub-sub menu: a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. b. ECM PART #. When scrolling to this option, display shows ECM part number. c.


d. SW RELEASE DATE. When scrolling to this option, display shows software release date. e. SW DESCRIPTION. When scrolling to this option, display shows software description.

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MESSENGER DISPLAY – CONTINUED 6. The following information is available through the All-Wheel Drive System sub-sub menu: a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number. b. ECM PART #. When scrolling to this option, display shows ECM part number. c.


d. SW RELEASE DATE. When scrolling to this option, display shows software release date. e. SW DESCRIPTION. When scrolling to this option, display shows software description. Service Test Sub-Menu

0005

1. MANUAL LUBE MODE TEST. When scrolling to this option, display shows option to begin manual lube mode test. 2. STEERING DEAD ENGINE.

NOTE Press OK when messenger displays NEXT. a. NEXT. When scrolling to this option, display shows option to begin Steering Dead Engine test. b. Before test can be performed, the machine must meet the following conditions: (1) No warnings for primary steering system. (2) No warnings for secondary steering system. (3) No warnings for implement systems. (4) Start switch in ON position. (5) Engine must be off. (6) Transmission must be in NEUTRAL. (7) Parking brake must be engaged. (8) Operator must be present. (9) Implements must be locked. c.

The following information is available through the Steering Dead Engine sub-sub menu: (1) ABORT. When scrolling to this option, display shows option to end Steering Dead Engine test. (2) NEXT. When scrolling to this option, display shows option to continue Steering Dead Engine test. (3) CALIBRATION INITIALIZING. When scrolling to this option, display shows Steering Dead Engine test has started.

d. When test begins, use left joystick to move front wheels. Secondary steering pump will be activated for a maximum of ten seconds. To cancel test, press ABORT button on Messenger or turn start switch to the OFF position. Calibration

0005

NOTE The transmission fill calibration is to be performed by Field Level Maintenance only. Calibration could take up to 45 minutes to complete. If calibration is interrupted or aborted, old calibration numbers will remain. TRANSMISSION FILL CALIBRATION. When scrolling to this option, display shows option to begin transmission fill calibration.

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MESSENGER DISPLAY – CONTINUED Tattletale

0005

The following information is available through the Tattletale sub-sub-menu: a. TATTLETALE MODE ACTIVE. When scrolling to this option, display shows tattletale mode is active. b. OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature. c.

ENGINE COOLANT TEMP. When scrolling to this option, display shows engine coolant temperature.

d. ENGINE SPEED. When scrolling to this option, display shows engine speed. e. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot point. f.

FUEL LEVEL. When scrolling to this option, display shows fuel tank fill level.

END OF TASK MACHINE WARNING SUMMARIES

0005

The Monitoring System provides three warning categories. The first warning category requires only operator awareness. The second warning category requires a change to machine operation or performance of maintenance to system. The third warning category requires immediate shutdown of machine. Warning Category 1

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In this category, only the alert indicator comes on. This category alerts the operator that the machine system needs attention. Warning Category 2

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In this category, the alert indicator and action light come on. This category requires a change in machine operation. The Messenger system will display a message. If action is required, instruction will be listed. Warning Category 2S

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In this category, the alert indicator and action light come on and action alarm sounds at a steady rate. This category requires an immediate change in machine operation. The Messenger system will display a message. If action is required, instruction will be listed. Warning Category 3

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In this category, the alert indicator and action light come on and action alarm sounds at a pulse rate. This category requires immediate shutdown of machine to prevent injury or death. This category requires immediate shutdown of machine to prevent severe damage to the machine. The Messenger system will display a message. If action is required, instruction will be listed. END OF TASK

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JOYSTICK STEERING

0005

NOTE Failure to properly align left (steering) joystick causes inability to steer machine, inability to disengage parking brake, and inability to shift transmission out of NEUTRAL position. Before operating machine, align left joystick in relation to steering angle of front wheels. 1. Start engine. 2. Move left joystick slowly and smoothly left or right to closely match steering angle of front wheels to synchronize joystick to front wheels. 3. During alignment, note the following conditions: a. Joystick alignment event disappears from Messenger display. b. Steering system alert indicators not illuminated on monitoring system. c.

Front wheels move with movement of left joystick.

END OF TASK

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DIFFERENTIAL LOCK CONTROL

0005

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CAUTION •

Do not engage the differential lock control at high speeds.

•

Do not turn machine with differential lock engaged.

•

Do not engage the differential lock control while one wheel is spinning. Decrease engine RPM until the wheel stops spinning. Anticipate using the differential lock before wheel slippage occurs.

•

Failure to follow these cautions will result in damage to machine.

NOTE •

In areas of high resistance, it may be necessary to turn the machine slightly in order to aid in unlocking the differential lock. Decreasing the engine RPM may also be helpful.

•

Differential lock can be engaged while machine is in motion.

•

Anticipate need for use of differential lock before wheel slippage occurs.

1. Engage differential lock by pushing switch on right joystick to increase traction on soft or wet ground (Figure 8). Differential lock indicator will illuminate on monitoring system when differential locks. 2. Continue grading. 3. Disengage differential lock by pushing switch on right joystick again.

Figure 8. Differential Lock Control and Indicator. END OF TASK

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TRANSMISSION OPERATION

0005

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The transmission has eight forward gears, six reverse gears, and inching capability through the use of a transmission modulator pedal. Shifting can be performed by either launching the machine from NEUTRAL or sequential speed shifting. Shuttle shifting (changing direction quickly) is also possible. Before operator takes control of machine, the following events must occur: 1. Parking brake must be engaged. 2. Operator must be present in seat. 3. Transmission control switch must be in NEUTRAL position. 4. Left joystick must be aligned with front wheels. 5. Operator disengages parking brake.

WARNING DO NOT leave operator seat while machine is in motion. Operator Presence System will not respond. Failure to follow this warning may result in injury of death to personnel.

NOTE Parking brake will automatically engage if the operator leaves the seat while the machine is stopped and parking brake is not already engaged. 6. To re-establish operational control after parking brake has been automatically set, operator must return to seat and reset parking brake by pushing top of parking brake switch, then pushing bottom of switch (Figure 9). Parking brake will disengage and allow operator to regain operational control. 7. If steering joystick was disturbed during step 6, repeat steps 1 though 5.

Figure 9. Parking Brake Switch.

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TRANSMISSION OPERATION – CONTINUED Moving Machine from NEUTRAL Using Automodulation

0005

CAUTION •

Avoid automodulation while machine is under load.

•

Selecting forward gears six through eight or reverse gears five or six is NOT recommended.

•

Failure to follow these cautions may result in damage to equipment.

NOTE •

Forward gears one through five and reverse gears one through four are recommended for automodulation.

•

Do not change engine speed while automodulating. Harsh shifting will result.

Automodulation entails shifting into forward or reverse gear by moving transmission control switch from NEUTRAL position to either FORWARD or REVERSE position (Figure 10). Transmission initial gear will engage smoothly via direction clutch. If initial gear is not desired, use upshift or downshift switch to select desired gear.

Figure 10. Transmission Control Switch.

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TRANSMISSION OPERATION – CONTINUED Moving Machine from NEUTRAL Using Transmission Modulation Control (Inching Pedal)

0005

1. Fully depress inching pedal (Figure 11). 2. Select direction and desired gear. 3. Release inching pedal slowly to launch machine.

469-0287

Figure 11. Transmission Modulation Control (Inching Pedal).

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TRANSMISSION OPERATION – CONTINUED Sequential Speed Shifting

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Sequential speed shifting allows the operator to change transmission gears while the machine is in motion. Activating Upshift and Downshift switches as desired will result in obtaining optimum ground speed for the operation being performed (Figure 12). Speed shifting can be performed at any loading as shifts are automatically compensated based on engine load. Upshifts can occur at any engine speed but should be matched to load. Several shifts can be commanded at one time, although there is a delay between shifts. Downshifting requires engine speed to be less than full throttle to prevent engine overspeeding. Downshift control requests are computer controlled. If engine speed is too high, engine speed is reduced to allow downshift to occur. Upon shift completion, throttle control is returned to the operator.

Figure 12. Transmission Upshift and Downshift Buttons.

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TRANSMISSION OPERATION – CONTINUED Shuttle Shifting

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CAUTION Do not perform shuttle shifting while using scarifier or while towing heavy load. Damage to equipment may result. Shuttle shifting, also known as directional shifting, allows operator to change machine direction quickly. Shuttle shifting is performed by moving the transmission control switch from FORWARD to REVERSE position or from REVERSE to FORWARD position WITHOUT stopping in the NEUTRAL position (Figure 13). If switch remains in NEUTRAL position for more than 0.2 seconds, transmission will shift into NEUTRAL. The shifts shown in Table 1 are allowed.

Table 1. Shuttle Shifting. ENGINE SPEED CONDITIONS FOR SHIFT

SHUTTLE SHIFT

OPERATOR INPUT

1 Forward to 1 Reverse 1 Reverse to 1 Forward

Entire engine speed range









Less than 1,500 RPM


Figure 13. Transmission Control Switch.

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TRANSMISSION OPERATION – CONTINUED Programmable Transmission Initial Gear Setting

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The initial gear is the gear that engages when the transmission control switch is engaged in FORWARD or REVERSE position without selecting a specific gear. Each direction can have only one initial gear, and each direction can use different initial gears. Initial gears can be the same as but not higher than what is set as maximum gear. Initial gear setting can be changed using the Messenger system when transmission is in NEUTRAL and the machine is stopped. Changes made are new defaults at time of change or after a power cycle. Programmable Transmission Maximum Gear Setting

0005

The maximum gear is the highest gear the transmission will shift into. Each direction can have only one maximum gear, and each direction can use different maximum gears. For FORWARD position, gears 3 through 8 are available. In REVERSE Position, gears 3 through 6 are available. Initial gear setting can be changed using Electronic Technician when transmission is in NEUTRAL and the machine is stopped. Changes made are new defaults at time of change or after a power cycle Transmission Modulator Control (inching pedal)

0005

The transmission modulator control (inching pedal) disengages power to the wheels. Press pedal in order to decrease power to the wheels. A sensor monitors pedal position and varies hydraulic pressure to direction clutches. When the pedal is fully depressed, power to the wheels will be disengaged. The inching pedal can be used in all load conditions and provides the operator with speed control between two distinct gears. This is useful when the operator demands high engine speed for quick implement control while varying ground speed.

CAUTION •

Avoid prolonged use of the inching pedal when moving heavy loads. Shift into lower gear to match load condition. Failure to follow this caution may result in equipment damage. • Do not use inching pedal as a clutch for directional changes. Machine is designed to “shuttle shift”. Failure to follow this caution may result in equipment damage. If the inching function is used in high load conditions, the operator should shift into a gear matched for that load condition. If constant stalling occurs, downshifting is advisable.

Figure 14. Transmission Modulation Control (Inching Pedal). END OF TASK

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THROTTLE HOLD MODE SWITCH

0005

The Throttle Hold Mode switch allows the operator to set a throttle hold mode function. Modes which can be selected include AUTOMATIC, OFF, and MANUAL.

NOTE The indicator light for the throttle lock will be illuminated when the throttle is locked during AUTOMATIC or MANUAL mode. To Select AUTOMATIC Mode

0005

1. Push top of Throttle Hold Mode switch (Figure 15). 2. Use accelerator control to increase engine speed to desired RPM. Push in top of Throttle Set/Accel switch to set the throttle at the current engine speed. 3. Use Throttle Set/Accel Switch and/or Throttle Resume/Decel switch to change throttle setting. 4. The throttle setting of AUTOMATIC mode will be suspended and engine speed will adjust to setting of accelerator control if either of the following conditions occur: a. Accelerator control is moved more than 20 percent. b. Service brakes are applied. 5. Push top of Throttle Set/Accel Switch to resume preset engine speed. 6. Resume feature will be disabled if any of the following conditions occur: a. Switch is moved to OFF mode. b. Switch is moved to MANUAL mode. c.

Engine start switch is moved to OFF position.

d. Engine is stalled.

Figure 15. Throttle Hold Mode Switch and Throttle Resume/Decel Switch.

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THROTTLE HOLD MODE SWITCH – CONTINUED To Select MANUAL Mode

0005

WARNING Applying service brakes or pressing accelerator control will not disengage throttle lock. Failure to follow this warning may result in injury or death to personnel. 1. Push bottom of Throttle Hold Mode switch. 2. Use accelerator control to increase engine speed to desired RPM. Push in top of throttle Set/Accel switch to set throttle at current engine speed. 3. Use Throttle Set/Accel switch and/or Throttle Resume/Decel switch to change throttle setting. 4. Engine speed will increase if accelerator control is pressed past throttle setting. When accelerator control is released, engine will return to preset engine speed.

NOTE The resume feature will not be available after the throttle lock is disengaged. 5. To disengage throttle lock: a. Move throttle Hold/Mode switch to OFF position. b. Move engine start switch to OFF position.

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THROTTLE HOLD MODE SWITCH – CONTINUED To Select OFF Mode

0005

Move switch to middle position. Throttle will only be operated by accelerator control. END OF TASK CENTERSHIFT LOCK SWITCH

0005

WARNING

Personal injury could result from the sudden movement of the blade when centershift lock pin is released. Before releasing centershift lockpin, be sure all personnel are clear of blade area, circle and blade are centered under machine, and blade is lowered to ground. 1. Use right joystick centershift control to shift drawbar left or right as required. Move drawbar to desired direction and position. Place both left and right sides of blade in FLOAT position to ground moldboard. 2. Press red tab to unlock then move centershift lock switch to DISENGAGED position (push top of switch) (Figure 16). When switch is in DISENGAGED position, an indicator light will illuminate on monitoring system.

Figure 16. Centershift Controls and Indicator.

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CENTERSHIFT LOCK SWITCH – CONTINUED 3. To move link bar to first hole or second hole on either side of center, proceed to Step a. To move link bar to third hole or farthest hole on either side of center, proceed to Step c. a. Make sure that left side of blade and right side of blade are in FLOAT position. Move right joystick centershift control in the opposite direction from what was used to position the drawbar in Step 1. As centershift cylinder moves, linkage will roll freely. Also, link bar will move sideways. b. Proceed to step 4. c.

Move left side and right side of blade out of FLOAT position.

d. Simultaneously move right joystick centershift control left, and lower right side of blade by moving right joystick forward. Simultaneously, raise left side of blade by moving left joystick backward. 4. Line up centershift lock pin with desired hole in link bar. Use centershift indicator on right lift arm to check alignment.

NOTE If centershift lock indicator light does not turn off, move link bar slightly to align hole with centershift lock pin. 5. Move centershift lock switch to ENGAGED position (push bottom of switch). Monitoring system centershift lock indicator light should go off when centershift lock pin is engaged. 6. Sideshift link bar toward desired direction. Use blade lift cylinders to adjust blade angle.

Figure 17. Centershift Indicator. END OF TASK

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ALL-WHEEL DRIVE (AWD)

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All-wheel drive (AWD) allows the operator to choose which wheels propel the machine and how fast the front wheels turn in relation to the rear wheels. All-Wheel Drive is controlled by an AWD Mode Switch (CREEP {turtle}, OFF {circle}, and MANUAL {hand} positions) and an AWD Control Dial (minus, circle, and plus signs) (Figure 18). •

With AWD off, only tandem wheels propel the machine. Machine speed is controlled by the accelerator pedal.

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When AWD is activated and CREEP mode engaged, only the front tires propel the machine. Front wheel speed (zero to 5 mph {8km/h}) is controlled by the AWD Control Dial. Creep mode provides very precise speed control when fine blading around obstacles, and prevents rear wheels from damaging finished surfaces due to driving force of rear wheels.

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When AWD is activated and MANUAL mode engaged, all six wheels propel the machine. Front wheel speed (98 to 120 percent of rear wheel speed) is controlled by the AWD Control Dial. The center detent is 100% or 1:1 front wheel speed to rear wheel speed. Higher aggression (101% to 120%) allows more power to be transmitted through the front wheels, providing better steering control in low traction conditions and when bank sloping when trying to keep front wheels on slope while rear wheels are on level ground.

Figure 18. All-Wheel Drive Controls. Operating Machine in Creep Mode

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1. Before turning AWD Mode switch to CREEP position, the machine must meet the following conditions: a. Machine stopped (zero ground speed). b. Engine running. c.

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Parking brake switch set to ENGAGED position.

d. Transmission control switch set to NEUTRAL position. 2. Turn AWD Mode switch to CREEP position. a. Rear transmission will be neutralized. b. AWD indicator will illuminate. 3. Disengage parking brake (WP 0004). 4. Move Transmission Control switch to desired direction (FORWARD or REVERSE). When in CREEP mode, power is supplied only to the front wheels.

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ALL-WHEEL DRIVE (AWD) – CONTINUED 5. Turn AWD Control Dial to desired speed. a. Turn control dial counterclockwise to decrease front wheel speed. Placing the dial in the full counterclockwise position will bring the machine to a stop. b. Turn the control dial to the center (detent) position to set front wheel speed at 2.5 mph (4 km/h). c.

Turn the control dial clockwise to increase front wheel speed. Placing the dial to the full clockwise position will set front wheel speed to a maximum of 5 mph (8 km/h).

6. Depressing transmission modulator control (inching pedal) proportionally reduces front wheel speed. a. With pedal fully depressed, machine comes to a stop. b. With pedal partially released, machine is propelled at speed in proportion to amount pedal is released, up to speed set on AWD Control Dial. c.

With pedal fully released, machine is propelled at speed set on AWD Control Dial.

Operating Machine in MANUAL Mode

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1. Before turning AWD Mode switch to MANUAL position, the machine must meet the following conditions: a. Actual gear is anything but NEUTRAL, eighth gear FORWARD, or sixth gear REVERSE. b. Engine running. c.

Parking brake switch set to DISENGAGED position.

d. Inching pedal not fully depressed. 2. Turn AWD Mode switch to MANUAL position. AWD indicator will illuminate.

NOTE •

While in MANUAL mode, amount of speed commanded to front wheels is affected by available traction.

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Transmission gear is also used to limit aggression. Aggression will be limited to 100 percent in gears above fifth FORWARD and above fourth REVERSE.

3. Turn AWD Control Dial to desired speed. a. Turning the dial to the full counterclockwise position (negative aggression) front wheels will turn at 99 percent of rear wheel speed. b. Turn the control dial to the center (detent) position to set front wheel speed at 100 percent of rear wheel speed. c.

Turning the dial to the full clockwise position (positive aggression) will set front wheel speed at 120 percent of rear wheel speed.

4. Depressing transmission modulator control (inching pedal) proportionally reduces front wheel speed. a. With pedal fully depressed, machine comes to a stop. b. With pedal partially released, machine is propelled at speed in proportion to amount pedal is released, up to speed set on AWD Control Dial. c.

With pedal fully released, machine is propelled at speed set on AWD Control Dial.

END OF TASK

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SLOPE OPERATION

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Safe operation depends on a number of factors including machine maintenance, operating speed, terrain conditions, fluid levels, tire inflation pressures, and most importantly–operator skill and judgment. When working on hills or slopes, consider the following points: •

Speed of travel – At higher speeds, forces of inertia tend to make machine less stable.

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Roughness of terrain or surface – The machine may be less stable on uneven terrain.

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Direction of travel – Avoid operating machine across the slope. When possible, operate the machine up and down rather than across slopes. Place heaviest end of machine uphill when you are working on an incline.

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Mounted equipment – Balance of machine may be impeded by the following components: equipment that is mounted on machine, machine configuration, weights, and counterweights.

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Nature of surface – Ground that has been newly filled with earth may collapse from weight of machine.

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Surface material – Rocks and moisture of surface material may drastically affect machine’s traction and stability. Rocky surfaces may promote side slipping of machine.

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Slippage due to excessive loads – This may cause downhill tracks or downhill tires to dig into the ground, which will increase angle of machine.

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Width of tires – Narrower tires further increase digging into ground which causes machine to be less stable.

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Implements attached to drawbar – This may decrease weight on uphill tires. The decreased weight will cause machine to be less stable.

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Height of working load of machine – When working loads are in higher positions, stability of machine is reduced.

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Operating equipment – Be aware of performance features of equipment in operation and effects on machine stability.

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Operating techniques – Keep all attachments or pulled loads low to ground for optimum stability.

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Machine systems have limitations on slopes – Slopes can affect the proper function and operation of the various machine systems. These machine systems are needed for machine control on slopes.

END OF TASK

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SCARIFIER OPERATION

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The scarifier, made of up to 11 shanks with teeth, is used to break up hard ground or material to a regulated depth to make it ready to grade. The number of shanks/teeth used depends on the consistency of the material being broken up. The center five shanks (with teeth) may be removed to allow scarifier assembly to be raised to gain additional ground clearance when necessary. The remaining shanks can be stowed upside down in the scarifier frame, if additional clearance is required. Up to five removed scarifier shanks may be stored in the scarifier shank stowage rack located at the front of the machine. A strap is provided to bind shanks together to avoid loss. Stow shanks in rack facing every other one backwards to allow stowage of up to five shanks. Refer to Scarifier Tooth and Shank Maintenance (WP 0027). Scarifier digging angle can be adjusted to accommodate different needs. Notify Field Level Maintenance if scarifier digging angle adjustment is required.

Figure 19. Scarifier Shank Stowage Rack. END OF TASK END OF WORK PACKAGE

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OPERATOR MAINTENANCE 0 0

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ADVANCED OPERATION AND OPERATOR TIPS Scope, Traveling and Earth Moving Operations

INITIAL SETUP References WP 0005 WP 0007 WP 0013

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1. This work package provides advanced operation instructions and operator tips for operating the 120M Motor Grader. 2. Refer to WP 0005 for operating instructions under usual conditions. 3. Refer to WP 0007 for operating instructions under unusual conditions. 4. Before, during, and after operation, perform applicable PMCS (WP 0013).

NOTE Machine shown in illustrations in this work package represents a generic motor grader. Functions described are applicable to the 120M Motor Grader.

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TRAVELING AND EARTH MOVING OPERATIONS

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Turning Around Using Articulation

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CAUTION •

Make sure differential lock is unlocked before turning or maneuvering through tight corners.

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Do not allow the blade to contact the tires when articulating the machine.

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Failure to follow these cautions may result in damage to the machine.

NOTE AWD set to 120% will reduce turning radius in soft surfaces. 1. Turn left and articulate frame left.

Figure 1. Left Turn - Frame Articulated Left.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 2. Turn right and articulate frame right.

Figure 2. Right Turn - Frame Articulated Right. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Turning Around in Tight Areas

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CAUTION •

Make sure differential lock is unlocked before turning or maneuvering through tight corners (WP 0004).

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Do not allow the blade to contact the tires when articulating the machine.

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Failure to follow this caution may result in damage to the machine.

1. Lean wheels slightly in direction of turn (right for right turn, left for left turn), then turn wheels.

Figure 3. Turning in a Tight Area.

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2. Travel as far forward as possible.


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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 3. Turn front wheels in the opposite direction. Back machine as far as possible to line it up with new direction of travel.


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4. Turn wheels to new travel direction. Travel forward and straighten wheels after turn is completed.

Figure 6. Turning in a Tight Area. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Backing Out of a Drop-off or Ditch

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NOTE This procedure is for backing out of a drop-off or ditch on the left side. Reverse articulation and turning direction if drop-off or ditch is on right side. 1. Stop machine. Raise blade and implements.

Figure 7. Backing Out of Drop-Off or Ditch.

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2. Articulate right while moving back slowly.

Figure 8. Articulating Right While Backing Slowly.

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3. Turn left while moving back slowly.

Figure 9. Steering Left While Backing Slowly.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 4. Continue to back out until machine is completely out of drop-off or ditch.

Figure 10. Backing Out of Drop-Off or Ditch.

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END OF TASK Grading Around an Object

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1. Press transmission modulator pedal to move machine slowly (inch) around an object.

Figure 11. Approaching Object.

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NOTE Grade as close to the object as possible to minimize hand cleanup. 2. Grade close to object.

Figure 12. Grading Close to Object.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 3. While traveling in a straight line, adjust blade sideshift and/or drawbar centershift to grade around object.

Figure 13. Sideshifting Blade to Avoid Object.

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4. When passing object, begin to move blade back to center position. 5. Once past object, blade should be back in original position.

Figure 14. Grading Past Object. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Grading on an “S” Curve

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CAUTION Do not allow the blade to contact the tires when articulating the machine. Failure to follow this caution may result in damage to the machine. 1. Articulate left, turn left, and sideshift right.

Figure 15. Entering “S” Curve.

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2. Turn straight and move sideshift as necessary.

Figure 16. Center of “S” Curve.

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3. Articulate right, turn right and sideshift left.

Figure 17. Reversing Direction on “S” Curve.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 4. Continue to grade.

Figure 18. Exiting “S” Curve.

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END OF TASK Scarifying Operations

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CAUTION •

When using the scarifier, the frame must be straight.

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When carrying the scarifier in the fully raised position, do not allow the scarifier beam or shanks to contact the drawbar.

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Raise the scarifier when turning. Failure to follow these cautions may cause damage to machine.

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Do not reverse the scarifier teeth. They may impact frame.

NOTE •

If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce number of shanks being used.

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Use all shanks in light material, fewer shanks in heavier material.

•

Break up paving by digging under surface and lifting scarifier.

1. Position the grader outside the working area of the project to configure the grader for scarifying. 2. Raise the scarifier log all the way up. 3. Raise the moldboard 4-6 in. (100-150 mm) off the surface and pitch the blade halfway. 4. Circle the blade to a 25-30 degree angle. 5. Centershift until the heel cylinder is straight up and down. 6. Fully raise the moldboard 4-6 in. (100-150 mm) above the surface. 7. Lower the scarifier log to the surface. 8. Place the grader in forward motion. 9. Lower the scarifier log as it crosses the project starting point and penetrate the surface 10. Scarify the entire length of the area to a minimum depth of 6 in. (150 mm). 11. Raise the scarifier log at the finish point. 12. Exit the project area, pull off at a 45 degree angle, and stop the grader. 13. Return to the starting point, ensuring you are not backing over the scarified area, and reposition the grader for a second scarifying pass. 14. Overlap teeth on subsequent passes. 15. Repeat until completed. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Right-Hand Grading

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NOTE During right-hand grading, left lift (heel) cylinder will be vertical, and right lift (toe) cylinder will be slightly angled. 1. Position the grader outside the working area of the project approximately 12-18 in. (30-45 cm) from the right boundary of the project area. 2. Raise the scarifier log all the way up. 3. Lower the moldboard to within 4-6 in. (100-150 mm) from the surface. This will provide unrestricted movement and prevent metal-to-metal contact. 4. Pitch the blade half way.

Figure 19. Pitch Blade Half Way.

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5. Circle the blade counterclockwise to a 25-30 degree angle with the toe facing the right front tire. 6. Centershift the circle assembly to the left until the heel cylinder is straight up and down.

Figure 20. Adjusting Centershift.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 7. Lean the front wheels toward the heel.

Figure 21. Leaning Wheels Toward Heel.

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8. Lower the moldboard to the ground.

Figure 22. Lower Moldboard to Ground.

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9. Place the grader in motion.

Figure 23. Place Grader in Motion.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 10. As the moldboard crosses the project start line, apply enough down pressure on both heel and toe to penetrate the surface 0.5 in. (12 mm).

Figure 24. Adjust Moldboard to Penetrate Surface.

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11. Maintain a straight course, adjusting the moldboard slightly to carry the material the length of the project.

NOTE Feathering is a process accomplished by raising the moldboard in 1/2 to 1 inch increments, while in a forward motion. Two or three seconds are recommended between each upward adjustment until all the material in front of the moldboard passes under it. 12. Be sure to feather the material out at the end of the pass.

Figure 25. Feathering Material. 13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side. 14. Stop the grader and straighten the front wheels. 15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles. 16. Position the grader to straddle the windrow just made and back up straight to the start point. Ensure the windrow is between the wheels, and do not drive on top of it. 17. Stop the grader just outside the boundary line. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Left-Hand Grading

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NOTE During left-hand grading, right lift (heel) cylinder will be vertical and left lift (toe) cylinder will be slightly angled. 1. Position the grader outside the working area of the project centered on the previous windrow of the project area. 2. Raise the scarifier log all the way up. 3. Lower the moldboard to within 4-6 in. (100-150 mm) of the surface. 4. Pitch the blade half way.

Figure 26. Pitch Blade Halfway.

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5. Circle the blade clockwise to a 25-30 degree angle with the toe facing the left front tire. 6. Centershift the circle assembly to the right until the heel cylinder is straight up and down.

Figure 27. Adjusting Centershift.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 7. Lean the front wheels toward the heel.

Figure 28. Leaning Wheels Toward Heel.

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8. Lower the moldboard to the ground.

Figure 29. Lower Moldboard to Ground.

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9. Place the grader in motion.


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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 10. As the moldboard crosses the project start line, apply enough down pressure on both heel and toe to penetrate the surface 0.5 in. (12 mm).

Figure 31. Adjust Moldboard to Penetrate Surface.

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11. Maintain a straight course, adjusting the moldboard slightly to carry the material the length of the project.

NOTE Feathering is a process accomplished by raising the moldboard in 1/2 to 1 inch increments, while in a forward motion. Two or three seconds are recommended between each upward adjustment until all the material in front of the moldboard passes under it. 12. Be sure to feather the material out at the end of the pass.

Figure 32. Feathering Material.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side. 14. Stop the grader and straighten the front wheels.

WARNING Never back the grader with the front tires leaned. Steering accuracy is compromised. After completing each general position, always return the front wheels to straight up and down position prior to executing the next position. Failure to follow this warning may result in personal injury or death. 15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles. 16. Execute a three-point turn toward the toe and position the grader to straddle the windrow just made. Ensure the windrow is between the wheels, and do not drive on top of it. 17. Stop the grader just outside the boundary line. END OF TASK Center Windrow

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1. Position the grader to straddle the last windrow made. 2. Raise the scarifier log all the way up. 3. Raise the moldboard 4-6 in. (100-150 mm) off the surface and pitch the blade halfway. 4. Circle the blade to 0 degree angle. 5. Centershift the circle assembly until both lift cylinders are equally spaced to the main frame. 6. Lower the moldboard to half the height of the windrow to be spread.

NOTE Do not lean the front wheels. The wheels will remain straight during this grading method. 7. Place the grader in forward motion, making only minor adjustments to the moldboard. 8. Continue to the end of the project or until material in front of the moldboard passes under it. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Road Building - “V” Ditch Method

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NOTE The steps in this procedure are for one side of the road. Repeat these steps for the opposite side. 1. Position the grader outside the working area of the project to configure the grader for “V” ditching. 2. Place the grader into ditching position as follows; a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement. b. Pitch the blade halfway. c.

Center the blade on the circle by side shifting if needed.

d. Center shift until the heel cylinder is straight up and down. e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire. f.

Raise the heel cylinder all the way up.

g. Lean the front wheels toward the heel. 3. Perform a marking cut followed by a ditching (heavy) cut.

Figure 33. Marking and Ditching Cuts.

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4. Continue until a desired depth is reached or a slope of 3:1 is achieved.

Figure 34. Ditch Cuts.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 5. Spread to center.

Figure 35. Center Windrow Position.

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6. Clean shoulder and spread to center.

Figure 36. Leveling the Area.

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7. Slope and cut back side of ditch and then clean bottom.

Figure 37. Cutting Back Side of Ditch.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 8. Make a ditching pass to clean and shape inside slope.

Figure 38. Cleaning and Shaping Inside Slope.

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9. Finish shoulder pass.

Figure 39. Finishing Shoulder Pass.

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10. Level and finish.

Figure 40. Leveling and Finishing. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Right-Hand “V” Ditching

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CAUTION •

Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow this caution may result in damage to machine.

•

Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls may be forced against the back slope, causing tire sidewall damage and also forcing dirt between the tire and rim, causing air loss and flat tires.

NOTE •

Steps 1 through 7 pertain to making a “Marking Cut.”

•

Ditching is normally done on the right side of the grader as it has greater reach to this side.

1. Position the grader outside the working area of the project.

Figure 41. Positioning Grader.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 2. Place the grader into ditching position as follows; a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement. b. Pitch the blade halfway. c.


d. Center shift until the heel cylinder is straight up and down. e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire. f.


g. Lean the front wheels toward the heel.

Figure 42. Leaning Wheels Toward the Heel.

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NOTE The grader is now in the ditching position. Align the right front tire on top of the proposed ditch line. Make a visual check to finish point of the ditch. Maintain control of the grader and do not permit it to deviate from the proposed ditch line. 3. Place the grader in motion and as the right front tire passes over the starting point of the ditch, lower the toe.

Figure 43. Adjusting Blade to Deliver Material.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTE At this point, the primary concern is to follow the proposed ditch line. Example: If stakes are utilized, ensure the right front tire is directly in line with the next stake. 5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward movement until the rear tires pass over and off the marking cut. 6. Straighten the front wheels and steer the grader to the right approximately 45 degrees to the ditch. 7. Back the grader along the outside edge of the windrow to the start point.

NOTE •

After the initial marking cut, ensure quality control on all remaining cuts. The marking cut provides and excellent track for the grader to follow. The grader is set up already for the ditching cut to follow.

•

Steps 8 through 13 pertain to making “Ditching Cuts.”

8. Pull forward and stop the grader just as the right front tire enters the marking cut.

Figure 44. Positioning Right Front Tire and Right End of Blade.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 9. Lean the front tires toward the heel.

Figure 45. Leaning Wheels.

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10. Place the grader in forward motion and apply as much down pressure to the toe of the blade as the grader will handle - cut depth should not exceed 4-6 in. (100-150 mm).

CAUTION Attempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pulling to one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TO STEER OUT OF THE PULL. 11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching cuts until the desired depth is achieved.

Figure 46. Reposition Grader.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 12. Repeat ditch cut as necessary.

Figure 47. Repeat Ditch Cut as Necessary.

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13. Back the grader along the outside edge of the windrow to the start point.

NOTE •

Steps 14 through 26 pertain to cleaning the shoulder of the ditch.

•

This task is accomplished by placing the grader in the wide side reach position.

14. Position the grader so the right front tire is approximately 12-15 in. (30-38 cm) to the left of the ditch center line and stop the grader. 15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the moldboard to 0 degrees. 16. Center shift all the way to the right. 17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface. 18. Blade side shift all the way right.

CAUTION Do not adjust the moldboard height, especially the heel (left lift) cylinder. The view is obscured because the heel is under the main frame of the grader. 19. Circle the moldboard counterclockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside edge of the right front tire (approximately a 45 degree angle).

Figure 48. Setting Blade to Deliver Material.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 20. Place the grader in forward motion and maintain a position and course so the tow of the moldboard passes directly over the center of the ditch. 21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 49. Lower the Blade to the Ground.

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22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the moldboard passes under it or is windrowed off the heel. 23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTION Do not back the grader in the wide reach position. A safety factor is apparent; the moldboard would be extended out past the tires. By placing the moldboard in the right hand general grading position, the safety factor is minimized and the moldboard is positioned to execute the next maneuver. 24. Stop the grader and place the moldboard in the right hand general grading position. 25. Ensure the front wheels are straight up and down prior to backing the grader. 26. Back the grader to the starting point by straddling the windrow.

NOTE Steps 27 through 33 pertain to skimming the surface to spread material towards center establishing a crown in the road. 27. Stop the grader outside the starting point of the project and lean the wheels toward the heel. 28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the surface.


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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 29. Place the grader in forward motion and maintain a straight course by keeping the grader centered on the windrow.

NOTE With the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditch should pass under and off the heel of the moldboard, thereby establishing the crown of the road. 30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road. 31. At the end of the pass, ensure the material is feathered prior to stopping the grader. 32. Straighten the front wheels and raise both lift cylinders all the way up. 33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch on the other side of the project area going the opposite direction.

NOTE Steps 34 through 39 pertain to “Center Windrow Positioning.” 34. Position the grader in the center windrow. 35. Lower the blade to approximately 4-6 in. (100-150 mm) above the ground. 36. Circle the blade until it is at a 0 degree angle. 37. Lateral shift the circle assembly until the cylinders are in a V shape. 38. Position the front wheels straight up and down. 39. Lower the blade to half the height of the windrow.

NOTE •

Steps 40 through 42 pertain to “Leveling the Area.”

•

Determine which of the following procedures is applicable to the current task. Proceed to the step indicated. Right to Left - go to Step 40 Left to Right - go to Step 41 Center to Right/Center to Left - go to Step 42

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 40. Right to Left a. Beginning at the right side of the area boundary, blade the material from the right side to the left side. b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material along the left boundary. 41. Left to Right a. Beginning at the left side of the area boundary, blade the material from the left side to the right side. b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material along the right boundary. 42. Center to Right / Center to Left a. Beginning at approximately the center line of the area, blade (level) the material from the center starting point to the left boundary line. b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the right boundary line. END OF TASK Left-Hand “V” Ditching

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CAUTION •

Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow this caution may result in damage to machine.

•

Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls may be forced against the back slope, causing tire sidewall damage and also forcing dirt between the tire and rim, causing air loss and flat tires.

NOTE Steps 1 through 7 pertain to making a “Marking Cut.” 1. Position the grader outside the working area of the project.

Figure 51. Positioning Grader.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

NOTE Ditching is normally done on the right side of the grader as it has greater reach to this side. 2. Place the grader into ditching position as follows; a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement. b. Pitch the blade halfway. c.


d. Centershift until the heel cylinder is straight up and down. e. Rotate the moldboard so the toe is just behind the outside edge of the left front tire. f.


g. Lean the front wheels toward the heel.

Figure 52. Leaning Wheels Toward the Heel.

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NOTE The grader is now in the ditching position. Align the right front tire on top of the proposed ditch line. Make a visual check to finish point of the ditch. Maintain control of the grader and do not permit it to deviate from the proposed ditch line. 3. Place the grader in motion and as the left front tire passes over the starting point of the ditch, lower the toe.


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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTE At this point, the primary concern is to follow the proposed ditch line. Example: If stakes are utilized, ensure the left front tire is directly in line with the next stake. 5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward movement until the rear tires pass over and off the marking cut. 6. Straighten the front wheels and steer the grader to the left approximately 45 degrees to the ditch. 7. Back the grader along the outside edge of the windrow to the start point.

NOTE •

After the initial marking cut, ensure quality control on all remaining cuts. The marking cut provides and excellent track for the grader to follow. The grader is set up already to the ditching cut to follow.

•

Steps 8 through 13 pertain to making “Ditching Cuts.”

8. Pull forward and stop the grader just as the left front tire enters the marking cut.

Figure 54. Tire Position.

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9. Lean the front tires toward the heel.

Figure 55. Wheels Placed for Continued Ditching.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 10. Place the grader in forward motion and apply as much down pressure to the toe of the blade as the grader will handle - not to exceed 4-6 in. (100-150 mm).

CAUTION Attempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pulling to one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TO STEER OUT OF THE PULL. 11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching cuts until the desired depth is achieved.

Figure 56. Reposition Grader.

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12. Repeat ditch cut as necessary.

Figure 57. Repeat Ditch Cut as Necessary.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 13. Back the grader along the outside edge of the windrow to the start point.

NOTE •

Steps 14 through 26 pertain to cleaning the shoulder of the ditch.

•

This task is accomplished by placing the grader in the wide side reach position.

14. Position the grader so the left front tire is approximately 12-15 in. (30-38 cm) to the right of the ditch center line and stop the grader. 15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the moldboard to 0 degrees. 16. Centershift all the way to the left. 17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface. 18. Blade side shift all the way left.

CAUTION Do not adjust the moldboard height, especially the heel (right) lift cylinder. The view is obscured because the heel is under the main frame of the grader. 19. Circle the moldboard clockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside edge of the left front tire (approximately a 45 degree angle).


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20. Place the grader in forward motion and maintain a position and course so the toe of the moldboard passes directly over the center of the ditch. 21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 59. Lowering Blade to the Ground.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the moldboard passes under it or is windrowed off the heel. 23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTION Do not back the grader in the wide reach position. A safety factor is apparent; the moldboard would be extended out past the tires. By placing the moldboard in the left hand general grading position, the safety factor is minimized and the moldboard is positioned to execute the next maneuver. 24. Stop the grader and place only the moldboard in the left hand general grading position. 25. Ensure the front wheels are straight up and down prior to backing the grader. 26. Back the grader to the starting point by straddling the windrow.

NOTE Steps 27 through 33 pertain to skimming the surface to spread material towards center establishing a crown in the road. 27. Stop the grader outside the starting point of the project and lean the wheels toward the heel. 28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the surface.


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29. Place the grader in forward motion and maintain a straight course by keeping the grader centered on the windrow.

NOTE With the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditch should pass under and off the heel of the moldboard, thereby establishing the crown of the road. 30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road. 31. At the end of the pass, ensure the material is feathered prior to stopping the grader. 32. Straighten the front wheels and raise both lift cylinders all the way up. 33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch on the other side of the project area going the opposite direction.

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NOTE Steps 34 through 39 pertain to “Center Windrow Positioning.” 34. Position the grader in the center windrow. 35. Lower the blade to approximately 4-6 in. (100-150 mm) above the ground. 36. Circle the blade until it is at a 0 degree angle. 37. Lateral shift the circle assembly until the cylinders are in a V shape. 38. Position the front wheels straight up and down. 39. Lower the blade to half the height of the windrow.

NOTE •

Steps 40 through 42 pertain to “Leveling the Area.”

•

Determine which of the following procedures is applicable to the current task then proceed to the step indicated. Right to Left - go to Step 40 Left to Right - go to Step 41 Center to Right/Center to Left - go to Step 42

40. Right to Left a. Beginning at the right side of the area boundary, blade the material from the right side to the left side. b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material along the left boundary. 41. Left to Right a. Beginning at the left side of the area boundary, blade the material from the left side to the right side. b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material along the right boundary. 42. Center to Right / Center to Left a. Beginning at approximately the center line of the area, blade (level) the material from the center starting point to the left boundary line. b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the right boundary line. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Ditch Back Sloping

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CAUTION Make sure blade is lowered to ground before retracting the centershift lock pin. Failure to follow this caution may result in damage to machine. 1. Position grader outside of the ditch. 2. Circle moldboard to 0 degrees to the grader frame and lower moldboard to approximately 2 in. (50 mm) above the ground. 3. Side shift the moldboard all the way to the right. 4. Centershift circle assembly all the way to the right.

CAUTION Lower moldboard as needed to prevent metal-to-metal contact between lift arm and frame. 5. Lower moldboard to the ground.

NOTE Activating blade float will relieve all pressure from the moldboard. 6. Retract centershift lock pin. 7. Using right and left blade control levers, position the centershift saddle to the far left centershift position. 8. Place the centershift lockpin into the far left centershift position.

NOTE You may have to move the blade controls to completely seat the centershift lockpin. 9. Move the centershift lock lever to the LOCKED position, and then back to the INDEX and RUN position. 10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the grader.

Figure 61. Adjusting Blade.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 11. Circle the moldboard assembly to the right to the desired position. 12. Position the heel of the moldboard in front of the right rear tire.

Figure 62. Heel Position.

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13. Lower the toe to the desired degree of slope.

Figure 63. Positioning Blade.

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14. Lean wheels into the slope for a heavier cut, and away from the slope for a lighter cut.

Figure 64. Leaning Wheels IN for Heavier Cut.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 15. Reverse procedures to return the moldboard to general grading position.

Figure 65. Leaning Wheels AWAY for Lighter Cut.

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END OF TASK Grading in a Wet Ditch

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1. Articulate machine so front wheels and blade are in ditch. Steer with front wheels.

NOTE This method may be used to avoid obstructions whenever cleaning old ditches, which may have tree overhangs, rock ledges, etc. 2. Keep rear wheels on shoulder to prevent wheel slippage in wet or soft material in ditch.

Figure 66. Positioning Wheels to Prevent Slippage. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Flat Bottom Ditching

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1. If no “V” ditch exists, build a “V” ditch to desired depth of flat bottom ditch.

NOTE The shoulder slope should be flatter than normal, ending at the finished shoulder line. 2. Tip blade forward.

Figure 67. Pitching Blade.

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CAUTION Make sure the blade is lowered to the ground before retracting the centershift lock pin. Failure to follow this caution may result in damage to machine. 3. Move centershift lock pin to right-center position. 4. Have right front tire in bottom of “V” ditch.

Figure 68. Positioning Tire in Bottom of Ditch.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 5. Set blade so toe is inside right front tire at desired width of flat bottom ditch.

Figure 69. Setting Blade.

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6. Lower right lift cylinder to set depth of cut.

Figure 70. Lowering Right Lift Cylinder.

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7. Raise left lift cylinder to set desired shoulder slope. 8. Lean front wheels to the left. Cut second “V” ditch to same depth or slightly above first one.

Figure 71. Raising Left Lift Cylinder and Leaning Wheels.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 9. Cut a flat bottom. Set right lift cylinder to required depth.

Figure 72. Setting Right Lift Cylinder and Cutting Bottom.

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10. Set left lift cylinder as required.

Figure 73. Setting Left Lift Cylinder.

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CAUTION Make sure the blade is lowered to the ground before retracting the centershift lock pin. Failure to follow this caution may result in damage to machine. 11. Move centershift lock pin to far-right position. 12. Start right front tire in bottom of first “V” ditch. 13. Set right end of blade at bottom of backslope.

Figure 74. Positioning Right Front Tire and Right End of Blade.

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14. Lower right lift cylinder so point of blade is on established grade of ditch.


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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 15. Lower left lift cylinder to desired depth of cut. Lean front wheels to left. 16. Set blade at a sharp angle and move material up the slope of ditch. 17. Spread windrow and finish final grade.

Figure 76. Finishing Final Grade.

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END OF TASK Grading on a 3-to-1 Slope

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WARNING •

Only an experienced operator should operate the machine on a steep side slope.

•

Never fully articulate the machine uphill on steep slopes.

•

Failure to follow these warnings may cause injury to personnel or damage to equipment.

NOTE •

When working on steep slopes, operate the machine in first gear, at a reduced engine speed.

•

When working on slopes, use the accelerator to control the speed of the machine.

•

When operating on extreme slopes, use crab steering to keep the back of the grader on the downhill side of cut.

1. Articulate frame to place frame in an offset position for maximum stability.

Figure 77. Articulating Frame for Stability.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 2. Use crab steering when front of machine tends to slip due to heavy side load on blade.

Figure 78. Crab Steering to Overcome Heavy Load.

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END OF TASK High Bank Cuts - Right Side

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1. Clean roadbed to ensure roadbed at base of cut is uniform.

Figure 79. Cleaning Roadbed.

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2. If material is hard, slope roadbed slightly in to bank to keep machine from sliding away from bank. 3. Pitch blade 3/4 to full position forward.

Figure 80. Pitching Blade Forward.

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CAUTION Make sure the blade is lowered to the ground before retracting the centershift lock pin. Failure to follow this caution may result in damage to machine. 4. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm) above the ground. 5. Side shift the moldboard all the way to the right. 6. Centershift the circle assembly all the way to the right.

CAUTION Lower the moldboard as needed to prevent metal-to-metal contact between the lift arm and frame. 7. Lower the moldboard to the ground.

NOTE Activating blade float will relieve all pressure from the moldboard. 8. Retract centershift lock pin. 9. Using right and left joysticks, position the centershift saddle to the far left centershift position. 10. Place the centershift lockpin into the far left centershift position.

NOTE You may need to move the blade controls to completely seat the centershift lockpin. 11. Press the centershift lock switch to engage and lock centershift lockpin. 12. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the grader. 13. Circle the moldboard assembly to the right to the desired position.

Figure 81. Setting Blade Position.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 14. Lower left lift cylinder to set heel of blade at bottom of slope and in line with outer edge of rear tire.


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15. Ensure right rear tires are in “V” at base of slope.

Figure 83. Positioning Right Rear Tire.

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16. Lower right lift cylinder to set desired degree of bank slope. 17. Move into cut gradually.

Figure 84. Beginning Cut.

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NOTE The wheels should be near the vertical position. 18. Lean wheels toward slope for a heavier cut.

Figure 85. Leaning Wheels In for Heavier Cut.

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NOTE The procedure shown is for right side. Position blade opposite to that shown for left side. 19. Lean wheels away from slope for a lighter cut. Keep material from slope moved to outside of rear wheels.

Figure 86. Leaning Wheels Away for Lighter Cut. END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Extreme Side Reach

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CAUTION Make sure the blade is lowered to the ground before retracting the centershift lock pin. Failure to follow this caution may result in damage to machine.

NOTE The following steps are for extreme side reach to the right. For extreme left side reach, position the centershift lock pin and blade to the far left. 1. Position the grader outside the working area of the project. 2. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm) above the ground. 3. Side shift the moldboard all the way to the right. 4. Centershift the circle assembly all the way to the right.

CAUTION Lower the moldboard as needed to prevent metal-to-metal contact between the lift arm and frame. 5. Lower the moldboard to the ground.

NOTE Activating blade float will relieve all pressure from the moldboard. 6. Retract centershift lock pin. 7. Using right and left joysticks, position the centershift saddle to the far left centershift position. 8. Place the centershift lockpin into the far left centershift position.

NOTE You may need to move the blade controls to completely seat the centershift lockpin. 9. Press the centershift lock switch to engage lockpin. 10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the grader. Circle the moldboard assembly to the right to the desired position. 11. Move centershift lock pin to far right position. 12. Sideshift blade to far right position. 13. Centershift circle assembly to far right position. 14. Circle the blade to the desired angle. 15. Lower blade to desired depth to deliver material to side.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED Mid-Mounted Scarifier Operation

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CAUTION •

When using the scarifier, the frame must be straight.

•

When carrying the scarifier in the fully raised position, do not allow the scarifier beam or shanks to contact the drawbar.

•

Raise the scarifier when turning.

•

Do not reverse the scarifier teeth. They may impact frame.

•

Failure to follow these cautions may cause damage to machine.

NOTE •

If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce number of shanks being used.

•

Use all shanks in light material, fewer shanks in heavier material.

•

Break up paving by digging under surface and lifting scarifier.

1. Enter material gradually, while traveling in a straight line. 2. Keep scarifier as deep as conditions permit. Match travel speed to load. 3. All teeth can remain in scarifier when level grading with blade. 4. Clean scarifier when material begins to accumulate. END OF TASK END OF WORK PACKAGE

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14 TM 5-3805-293-10

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OPERATION UNDER UNUSUAL CONDITIONS Slave Starting, Extreme Cold, Extreme Heat, Mud or Soft Surfaces, Sandy or Dusty Areas, Saltwater Areas, High Altitudes, Snow and Ice, Fording, Recovery and Towing Techniques, Operating Portable Fire Extinguisher, Secondary Steering, Stopping Engine if an Electrical Malfunction Occurs, Moving Machine Out of Danger. 0 0 0 7

INITIAL SETUP References FM 9-207 FM 21-305 FM 31-70 FM 31-71 FM 90-3 LO 5-3805-293-13

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WP 0004 WP 0005 WP 0013 WP 0021 WP 0025 WP 0025 WP 0027

GENERAL

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WARNING This machine has been designed to operate safely and efficiently within the limits specified in this TM. Operation beyond these limits is prohibited in accordance with FM 21-305 without written approval from: Commander, U.S. Army Tank-Automotive and Armaments Command, ATTN: AMSTA-DSA-CS, Warren, MI 48397-5000. This section contains instructions for safely operating the 120M Motor Grader under unusual conditions. In addition to normal preventive maintenance, special care must be taken to keep the machine operational in extreme temperatures and other environmental conditions.

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SLAVE STARTING

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WARNING

•

When slave starting, use NATO slave cable that does NOT have loose or missing insulation.

•

DO NOT proceed if suitable cable is not available.

•

DO NOT use civilian-type jumper cables.

•

DO NOT allow disabled and booster machines to come in contact with each other at any time during slave starting. Failure to follow these warnings may cause injury or death to personnel.

NOTE Ensure that both disabled machine and booster machine are equipped with serviceable NATO slave receptacles. 1. Remove cover from slave receptacle (Figure 1, Item 1) on disabled machine and booster machine. 2. Connect slave cable to booster machine slave receptacle. 3. Connect other end of slave cable to slave receptacle of disabled machine, located on left side of engine compartment. 4. Turn battery disconnect switch of disabled machine to ON position. 5. Start booster machine and run at a speed just above idle. 6. Wait approximately five minutes, then crank disabled machine. If engine fails to crank, notify Field Level Maintenance. 7. After starting disabled machine, return booster machine to idle. 8. Remove slave cable from disabled machine, then from booster machine. 9. Replace cover on slave receptacle (Figure 1, Item 1).

Figure 1. Slave Receptacle.

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END OF TASK EXTREME COLD

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General

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Extreme cold causes many problems that an operator must be aware of, such as: 1. Lubricants can thicken and congeal. 2. Batteries may freeze or lose their electrical efficiency. 3. Electrical insulation may crack and cause short circuits. 4. Fuel may not readily atomize for combustion. 5. Various materials will become hard, brittle, and easily damaged. 6. Cooling system requires adequate protection from extreme cold. 7. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use. 8. Refer to FM 9-207, FM 31-70, and FM 31-71 for additional cold weather operational information. Checks

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1. Perform all Before PMCS checks and services (WP 0013). 2. Lubricate in accordance with LO 5-3805-293-13. 3. Check to ensure tires and ground engaging tools are not frozen to ground. 4. Drain a small amount of fuel from the fuel/water separator to ensure fuel is not gelled (WP 0013).

CAUTION If oil is too cold to drip off oil level gauge, do not attempt to start engine. Notify Field Level Maintenance. 5. Check engine and transmission/differential oils to ensure they are thin enough to flow. Oil must be thin enough to drip from oil level gauge (dipstick). 6. Ensure ether starting aid cylinder is in place and not empty (WP 0021). Starting Procedures – Machine NOT Equipped with Arctic Kit

CAUTION •


•


•


•

Shut down engine immediately if engine system indicator or action light indicator comes on. Notify Field Maintenance. Failure to follow this caution may result in damage to engine or other machine systems.

1. Start engine (WP 0005). 2. Check that oil pressure light on instrument panel goes out within 10 seconds of engine starting. 3. Allow engine to idle for at least five minutes before moving machine.

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EXTREME COLD – CONTINUED Starting Procedures – Machine Equipped with Arctic Kit

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CAUTION •

At temperatures nearing -40°F (-40°C), it is necessary to shut off the arctic heater at least 30 seconds before attempting to start the machine’s engine. Failure to follow this caution may result in internal damage to the heater or localized boiling of the coolant in the heater body which may cause a heater hose to come off.

•


•


•


•

Shut down engine immediately if engine system indicator or action light indicator comes on. Notify Field Maintenance. Failure to follow this caution may result in damage to engine or other machine systems.

NOTE •

If engine coolant heater has not been started for several months, or if heater is being started for the first time, it may take several attempts to start.

•

If engine coolant heater fails to start at first attempt, it will automatically attempt to start a second time. If heater still does not start, it will shut down.

•

During operation, engine coolant heater continually senses supply voltage. If voltage is too low or too high, heater will automatically shut down. If this occurs, notify Field Level Maintenance.

1. Activate engine coolant heater as follows: a. Turn battery disconnect switch to ON position (WP 0004). b. Activate engine coolant heater switch (WP 0004). 2. Allow heater to run up to 40 minutes. 3. Push engine coolant heater button to turn heater off, then wait at least 30 seconds.

CAUTION At temperatures of less than -25°F (-32°C), be sure to keep starter engaged until engine speed approaches 500 rpm. Multiple short (15-second) start attempts at cold temperatures can result in engine bearing damage due to inadequate lubrication. 4. Start engine (WP 0005). 5. Check that engine oil pressure light on monitor system registers pressure within 10 seconds of engine starting. 6. Allow engine to idle for at least five minutes before moving machine.

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EXTREME COLD – CONTINUED Machine Operation

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1. Move machine approximately 100 yards (91 m) in both forward and reverse directions to exercise transmission and powertrain. 2. Test brakes and vehicle controls carefully. 3. Slowly exercise ground engaging tools to warm hydraulic oil. Cycle each control several times. Monitor Messenger until transmission oil temperature reaches 41°F (5°C) (WP 0005). 4. Operate machine under light loads until machine is sufficiently warmed up (warm air blows from heater vents). 5. Frequently monitor Messenger system, alert indicators, and gauges. Take appropriate action if a problem is noted, and if necessary, notify Field Level Maintenance. Parking Machine

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1. Clean snow, ice, and mud from machine as soon as possible after shutdown. 2. When possible, park in sheltered area, or if shelter is not available, park machine so radiator is not facing the wind. 3. If shelter is not available, park machine on dry, high ground, and place planks or dunnage under tires and ground engaging tools to make a raised and relatively dry platform. 4. Perform all After PMCS checks and services (WP 0013). END OF TASK SNOW PLOWING

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Snow plowing should be performed as soon after snow falls as possible. Plowing techniques vary greatly depending on amount of snow and type of plowing required. The information provided here is a limited overview of snow plowing techniques and procedures. Operating Speed

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Generally, increased road speed is required to ensure snow is pushed off and away from road while retaining control of machine. Too much speed may cause machine to bounce and cause a choppy road surface. Use of Tire Chains

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1. Install chains either on rear tires only, or on both front and rear tires, when plowing in slippery conditions. 2. Reduce travel speeds with tire chains installed. 3. Use bungee cords to keep chains tight around tire. Check chains often during operation. 4. Avoid excessive tire spin with chains installed to prevent damage to road surface. 5. Avoid driving on hard surface roads with chains installed to prevent chain and tire wear.

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SNOW PLOWING – CONTINUED Use of Moldboard

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CAUTION Tip moldboard forward to prevent cutting into road surface and causing damage to equipment. 1. Tip moldboard forward to prevent damage to road surface and machine. This allows the cutting edge to ride over road surface, instead of cutting into it, which could cause damage to machine and the road surface. 2. When plowing over asphalt or frozen ground, use blade float to allow moldboard to move freely over uneven surfaces, and prevent road damage. Use of All Wheel Drive (AWD)

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All wheel drive provides additional steering and traction control, and reduces the need for tire chains. END OF TASK EXTREME HEAT

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General

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Extreme heat causes problems that an operator must be aware of, such as:

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1. Fuel expands. Do not fill tanks more than 80% full to allow for expansion. 2. Be alert for the possibility of overheating. 3. It is important to maintain engine speed to circulate engine coolant to help engine cooling. 4. Air filter elements will require checking more frequently. They will require cleaning or replacement if ENGINE SYSTEM indicator illuminates on the monitor system. Checks

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1. Perform all Before PMCS checks and services (WP 0013). 2. Lubricate in accordance with LO 5-3805-293-13. Machine Operation

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1. During very hot weather operation, avoiding continuous high engine RPM will help prevent machine from overheating. Alter operating procedures accordingly. 2. Check coolant level in coolant tank at frequent intervals throughout any single work shift (WP 0013). 3. Keep radiator and grille free of bugs, dust, dirt, mud, and other foreign matter. Clean frequently if necessary (WP 0025). 4. Monitor engine coolant temperature gauge. Red range on gauge indicates coolant temperature is above 225°F (107°C). If coolant temperature indicator comes on, machine may be operated at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field Level Maintenance. 5. Monitor hydraulic oil temperature gauge. Red range on gauge indicates coolant temperature is above 199°F (93°C). If hydraulic oil temperature indicator comes on, machine may be operated at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field Level Maintenance. 6. Refer to FM 90-3 for additional extreme heat operation information.

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EXTREME HEAT – CONTINUED Parking

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1. When possible, park machine under cover. Refer to WP 0005. 2. Perform all After PMCS checks and services (WP 0013). END OF TASK MUD OR SOFT SURFACES

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1. Before entering mud or other soft surfaces, check conditions and engage all-wheel drive and differential lock (WP 0005). Select appropriate transmission gear range. Enter soft area at a medium speed for gear range selected. 2. Maintain steady pressure on accelerator pedal to keep machine rolling until solid ground is reached. Do not accelerate to point where wheels spin, if possible. 3. If machine gets stuck, try to pull out slowly in a low gear. Boards, dunnage, or similar materials may be placed under tires to provide traction. 4. Clean and inspect for proper lubrication. END OF TASK SANDY OR DUSTY AREAS

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Checks

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1. Perform all Before PMCS checks and services (WP 0013). 2. Lubricate in accordance with LO 5-3805-293-13. 3. Check radiator for build-up of sand/dirt/debris often. Clean when necessary (WP 0025). Machine Operation

0007

1. Maintain steady speeds with transmission in lower gears. 2. Engage differential lock and AWD when required (WP 0005). 3. Keep machine rolling through sand without straining engine or powertrain. If machine gets stuck, refer to Recovery and Towing in this work package. 4. Monitor engine coolant and hydraulic oil temperature gauges on monitor system more frequently during operation. 5. If ENGINE SYSTEM indicator illuminates on the monitor system, check and clean or replace engine air filter elements. 6. Check hydraulic cylinders, circle top, centershift linkage, and articulation cylinders frequently. Do not allow dust, dirt, or sand to collect on these components as their smooth working surfaces can be damaged by such abrasive materials.

0007-7

TM 5-3805-293-10

0007

SANDY OR DUSTY AREAS – CONTINUED Parking

0007

1. Park machine (WP 0005). 2. Perform all After PMCS checks and services (WP 0013). 3. Clean spouts on fuel containers and areas around filler cap and filler tube before adding fuel. 4. Cover windshield to guard against sand blasting. END OF TASK SALTWATER AREAS

0007

1. Keep the machine as clean as possible. Wash down with fresh water after use. 2. Inspect wiring connections closely for corrosion. 3. Keep lubrication points clean and well lubricated. 4. Check machine frequently for rust/corrosion. Clean and spot paint as necessary. END OF TASK HIGH ALTITUDES

0007

NOTE Engine operates at less than peak performance at high altitudes. 1. Coolant level and engine indicators must be watched closely. 2. Add coolant if necessary. END OF TASK SNOW AND ICE

0007

1. Fuel tank should be kept full. Keep snow and ice away from fuel filler. 2. Clean snow away from outside indicators. Driving

0007

1. Engage differential lock as required and accelerate slowly to avoid spinning tires. 2. Drive at slower speeds. 3. Give signals sooner. 4. Apply brakes sooner to give early warning of intention to stop. This will also help to avoid skidding. 5. Maintain double the normal distance from the machine ahead. 6. Keep windshields, mirrors, and lights clean and free of snow and ice. 7. If approaching a difficult stretch of road, stop and inspect road carefully before driving on it. 8. Select transmission gear range that best suits road condition. Stopping

0007

1. Ease up on accelerator, leaving machine in gear. 2. Apply service brakes lightly and evenly. DO NOT pump service brake pedal. 3. Always avoid sudden braking.

0007-8

TM 5-3805-293-10

0007

Parking

0007

If parking on icy, slushy, wet, or muddy surfaces, place boards, dunnage, or other materials that will provide traction underneath tires. This will guard against tires freezing to the ground or becoming pocketed in ice, and will provide some traction when machine is started and moving again. END OF TASK FORDING

0007

The 120M Motor Grader can ford water up to 30 in. (76 cm) including height of wake.

CAUTION Do not ford even the narrowest stream more than 30 in. (76 cm) deep. Failure to follow this caution may result in damage to machine. 1. Check depth of water at its deepest point. 2. Ensure the bottom is stable enough for fording. 3. Remove center five scarifier shanks and stow in scarifier shank stowage rack. Flip remaining shanks upside down in scarifier frame (WP 0027). 4. Start engine and allow it to fully warm up (WP 0005). 5. Ensure engine system indicator and action light indicator are not illuminated, and all gauges are indicating proper machine operation (WP 0005). 6. Raise scarifier and blade to their maximum height (WP 0005).

WARNING During fording operation, if blade is not set perpendicular to centerline of machine, force of the water could cause operator to lose control of machine. Failure to follow this warning may result in injury or death to personnel. 7. Set blade perpendicular to centerline of machine.

NOTE Fording speed should not exceed 3-4 mph (5-6 km/h). Once in the water, do not stop until the opposite bank is reached. 8. Engage transmission in low gear (WP 0005). 9. Release parking brake (WP 0005). 10. Enter water slowly to minimize waves and backsplash and continue across body of water WITHOUT STOPPING until the opposite bank is reached. 11. If machine stalls, refer to Recovery and Towing Techniques in this work package. 12. Once machine is out of water, lubricate machine completely IAW LO 5-3805-293-13. END OF TASK

0007-9

TM 5-3805-293-10

0007

RECOVERY AND TOWING TECHNIQUES

0007

WARNING •

Ensure recovery line is strong enough (rated capacity of 150% of gross weight of the towed machine) and is in good condition.

•

Attach recovery line only to towing connection points provided on frame.

•

DO NOT have tension on the recovery line when inspecting it.

•

DO NOT jerk on recovery line; it may break.

•

DO NOT allow riders on machine being recovered.

•


CAUTION •

Recovery of a disabled machine with engine stopped may cause transmission damage. Transmission will not have lubrication.

•

If further evacuation is necessary, notify Field Level Maintenance to tow or haul machine to convenient location for repairs.

NOTE Towing must be performed by Field Level Maintenance. Towing With a Running Engine

0007

If the engine is running, the machine can be towed for a short distance. The powertrain and the steering system must be operable for towing with engine running. 1. Fasten tow line or tow bar to front or rear towing connection points on frame (Figure 2 and Figure 3).

Figure 2. Front Towing Connection Points.

0007-10

0007

TM 5-3805-293-10

0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED

Figure 3. Rear Towing Connection Points.

0007

2. Disengage parking brake. 3. Place transmission control switch in NEUTRAL position. 4. Raise attachments off the ground. 5. Tow machine as required. Towing With a Dead Engine

0007

CAUTION Towing of a disabled machine with the engine stopped may cause transmission damage. The transmission will not have lubrication. Do not tow a disabled machine any farther than is necessary to reach a convenient location for repairs.

NOTE If the brakes are in good operating condition, the machine has limited wheel brake ability. The pedal effort is high due to the lack of hydraulic boost. 1. Turn on secondary steering pump on stopped machine. You can steer machine while secondary steering pump is on. Secondary steering pump will be activated for a maximum of ten seconds. While secondary steering pump is activated you can use left joystick to align front wheels of machine.

WARNING When the driveshaft is removed, the machine has NO parking brake. The machine can roll and cause personal injury or death. Block the wheels securely so that the machine cannot move. 2. If you suspect internal transmission failure or driveline failure, remove driveshaft located between the differential and transmission.

0007-11

TM 5-3805-293-10

0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED 3. Fasten tow line or tow bar to front or rear towing connection points on frame (Figure 2 or Figure 3). 4. Remove wheel blocks. Tow machine slowly. Do not tow machine faster than 1.2 mph (2 km/h). END OF TASK OPERATING PORTABLE FIRE EXTINGUISHER

0007

1. Remove fire extinguisher from storage. 2. Hold fire extinguisher upright. Stand back 8 ft (2.4 m) from base of fire, point nozzle toward fire, and pull safety pin. 3. Squeeze lever, discharging chemical at base of fire. Use a side-to-side motion to spread chemical. 4. After using fire extinguisher, order new fire extinguisher. END OF TASK SECONDARY STEERING

0007

WARNING •

Personal injury or death can occur if steering is lost completely during operation.

•

Do not continue to operate the machine using secondary steering. If the secondary steering activates during operation, immediately park machine in a safe location. Notify Field Level Maintenance.

•

The machine’s batteries must have a normal charge and the secondary steering electrical system must be in proper working condition. A low charge condition, or any defect in the battery, battery cells, or electrical circuit can cause loss of secondary steering and could result in personal injury and/or damage to the machine.

CAUTION Once secondary steering system has been activated, it should remain on no longer than one minute. This should be sufficient time to safely steer machine to a stop. When the machine is stopped, turn engine start switch to OFF position to turn off secondary steering. Prolonged use of secondary steering system (longer than one minute) will cause electric motor to overheat and cause damage to its components. If secondary steering system is activated for longer than one minute, replace the pump, motor, and relay. Also, wiring must be inspected for damage due to overheating. Notify Field Level Maintenance. 1. The secondary steering pump will activate automatically when the main steering power source fails, such as a primary steering pump failure or engine failure. The secondary steering control will activate automatically when the primary steering control system fails. Engine start switch must be in ON position for this system to operate. 2. The primary steering system pressure indicator will illuminate when there is a problem with the primary steering system. 3. The secondary steering system indicator will be amber in color when secondary steering system is active or secondary steering system is being tested. Alert indicator will be red in color when a problem with secondary steering system exists. 4. If a problem exists with the primary steering system or the secondary steering system, an alert indicator and an action light come on and an action alarm sounds at a pulse rate. Notify Field Level Maintenance. END OF TASK

0007-12

TM 5-3805-293-10

0007

STOPPING ENGINE IF AN ELECTRICAL MALFUNCTION OCCURS

0007

1. Ensure parking brake is engaged. 2. Turn engine start switch to OFF position. 3. Turn battery disconnect switch (Figure 4, Item 1) to OFF position. 4. Notify Field Level Maintenance.

Figure 4. Battery Disconnect Switch.

0007

END OF TASK MOVING MACHINE OUT OF DANGER

0007

The machine can be moved out of danger by allowing the operator to override steering alignment and parking brake engagement.

WARNING Driving through the parking brake will cause the front wheels to auto-align upon machine movement. Avoid traveling excessive distances while driving through the parking brake. Extreme heat and wear will severely shorten the life of the parking brake. The loss of the parking brake system could result in injury or death to personnel.

CAUTION Do not use wheel lean lock bolt and bracket to center the wheel lean of machine. Damage to equipment may result.

NOTE •

“1F” and “1R” are the only gears available to drive through the parking brake. Upshifting will not change selected gear.

•

A warning category 3 will activate during machine movement. The event will be logged in Messenger but the alarm should deactivate once the transmission control switch is returned to NEUTRAL position.

0007-13

TM 5-3805-293-10

0007

MOVING MACHINE OUT OF DANGER – CONTINUED To drive through the parking brake: a. Start engine. Transmission control switch must be in NEUTRAL position and parking brake must be engaged to allow engine to start. b. Fully depress inching pedal. With parking brake engaged, “1F/1R” will flash on LCD display on monitoring system. c.

Select direction of travel on transmission control switch.

d. Raise engine speed to full throttle, then release inching pedal. Machine movement will be jerky since powertrain is trying to propel machine against engaged parking brake. e. When desired location is reached, depress inching pedal and move transmission control switch to NEUTRAL position to stop machine. END OF TASK END OF WORK PACKAGE

0007-14

14 TM 5-3805-293-10

0008


-

STOWAGE AND DECAL/DATA PLATE GUIDE Stowage, Warning Message Labels, Caution and Notice Message Labels 0 0 0 8

SCOPE

0008

This work package identifies BII stowage, decals and data plate. STOWAGE

0008

Basic Issue Items (BII)

0008

Stow all basic issue items (BII) in tool box (Figure 1, Item 1) located on drawbar above mid-mount scarifier (Figure 1, Item 2). Refer to WP 0031 for complete list of BII.

Figure 1. Tool Box.

0008-1

0008

TM 5-3805-293-10

WARNING MESSAGE LABELS

0008

0008

WARNING Failure to follow the warning safety messages listed here may result in injury or death to personnel.

Figure 2. Warning Message Labels.

0008-2

0008

TM 5-3805-293-10

0008

WARNING MESSAGE LABELS – CONTINUED

KEY

LABEL IDENTIFICATION

WARNING DEFINITION

08

1

Lift Here

Identifies proper location to attach lift device to machine.

2

Do Not Operate

Do not operate or work on this machine unless you have read and understand the instructions and warnings in this manual.

3

Unplanned Blade Movement

Personal injury could result from sudden movement of the blade when the centershift lock pin is released. To prevent unexpected blade movement and possible injury, lower the blade to the ground before you unlock the centershift linkage. See WP 0005 for complete instructions before releasing the centershift lockpin.

4

Tie Down

Identifies proper location to attach tie-down to machine.

5

No Clearance

Stay back a safe distance. No clearance for a person in this area when the machine turns. Severe injury or death from crushing could occur.

6

Improper Connections for Jump

Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to WP 0007 for the correct slave starting procedure.

Start Cables

0008-3

08

TM 5-3805-293-10

0008



0008-4

0008

TM 5-3805-293-10

0008


KEY


WARNING DEFINITION

08

1

Seat Belt

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

2

Do Not Weld On the ROPS/FOPS Structure

Structural damage, an overturn, modification, alteration, or improper repair can impair this structure’s protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. This will void the certification. This machine has been certified to the standards listed on decal. Maximum mass of machine, which includes operator and attachments without a payload, should not exceed mass listed on decal.

3

Engine Coolant

Cooling system is pressurized. Hot coolant can cause serious burns, injury, or death. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

4

No Clearance

Stay back a safe distance. No clearance for a person in this area when the machine turns. Severe injury or death from crushing could occur.

5

No Clearance

Connect the steering frame lock between the front and the rear frames before lifting, transporting, or servicing the machine in the articulation area. Disconnect the steering frame lock and secure the steering frame lock before resuming operation. Severe injury or death could occur.

6

Accumulator

Cold ambient temperatures could result in loss of secondary braking capability due to inadequate hydraulic accumulator nitrogen pre-charge. Loss of secondary braking system as well as main hydraulic pressure will result in little or no braking capability. Perform a brake accumulator check anytime machine has been idle for longer than two hours below 13°F (25°C).

0008-5

08

TM 5-3805-293-10

0008



KEY 1

LABEL INDENTIFICATION Recoil Spring

WARNING DEFINITION

08

Housing contains a highly compressed spring that can cause injury or death. Only trained Field Level Maintenance personnel may disassemble parking brake housing.

0008-6

0008

08

TM 5-3805-293-10

0008


Figure 5. Warning Message Label.

KEY 1

LABEL INDENTIFICATION CBRN (Chemical, Biological, Radiological and Nuclear).

WARNING DEFINITION

08

0008

08

If CBRN exposure is suspected, all air filter media will be handled by personnel wearing full CBRN protective equipment.

0008-7

TM 5-3805-293-10

0008

CAUTION AND NOTICE MESSAGE LABELS

0008

CAUTION Failure to follow cautions listed may result in damage to equipment.

Figure 6. Additional Message Labels. KEY 1

LABEL IDENTIFICATION Air Conditioning System (Caution Label)

LABEL DEFINITION

08

Field Level Maintenance to refer to TM 5-3805-293-23 before any maintenance is performed on air conditioning system. (Not applicable to operator.)

0008-8

0008

08

TM 5-3805-293-10

0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED

Figure 7. Additional Message Labels. KEY


LABEL DEFINITION

08

1

Do Not Weld or Drill (Caution Label)

Do not weld or drill on frame. (Not applicable to operator.)

2

Fuel Type

Diesel or JP-8 Fuel only

3

Extended Life Coolant

Refer to PMCS (WP 0013) before any maintenance is performed on cooling system.

4

24V Slave

Grader equipped with a 24V slave receptacle.

5

Articulation Bearing

Identifies location of grease points for articulation bearings.

0008-9

0008

08

TM 5-3805-293-10

0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED

Figure 8. Additional Message Labels. KEY

COMPONENT

DESCRIPTION

1

Cooling System Drain

Identifies location of engine coolant drain valve. (Not applicable to operator.)

2

Hydraulic Tank Drain

Identifies location of hydraulic fluid tank drain valve. (Not applicable to operator.)

3

Engine Oil Drain

Identifies location of engine oil drain valve. (Not applicable to operator.)

0008-10

0008

TM 5-3805-293-10

0008

DATA PLATE

0008

Figure 9. Data Plate. KEY

COMPONENT

0008

DESCRIPTION

1

Shipping Data Plate

Provides tiedown, lift, and shipping weight information.

2

Lubrication Data Plate

Provides lubrication information for machine systems.

0008-11

TM 5-3805-293-10

UNIQUE IDENTIFICATION (UID) LABELS

0008

0008

Figure 10. UID Labels.

Figure 11. UID Labels – Continued.

0008-12

0008

0008

TM 5-3805-293-10

0008

UNIQUE IDENTIFICATION (UID) LABELS – CONTINUED

Figure 12. UID Labels – Continued.

Figure 13. UID Labels – Continued. END OF WORK PACKAGE 0008-13/(14 blank)

0008

0008

TM 5-3805-293-10

CHAPTER 3 TROUBLESHOOTING PROCEDURES

4 TM 5-3805-293-10

0009


-

TROUBLESHOOTING INTRODUCTION

GENERAL

0009

1. This chapter provides information for identifying and correcting malfunctions that you may find while operating the 120M Motor Grader. 2. WP 0010, Troubleshooting Symptom Index lists common malfunctions which may occur and refers you to the proper page in WP 0011 for a troubleshooting procedure. 3. If you are unaware of the location of an item mentioned in troubleshooting, refer to WP 0002, Equipment Description and Data or WP 0004, Description and Use of Operator Controls and Indicators. 4. Before performing troubleshooting, read and follow all safety instructions found in the warning summary at the front of this manual. 5. This chapter cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify Field Maintenance. 6. When troubleshooting a malfunction: a. Locate the symptom or symptoms in WP 0010, Troubleshooting Index that best describes the malfunction. If the appropriate symptom is not listed, notify Field Maintenance. b. Turn to the page in WP 0011, Troubleshooting Procedures where the troubleshooting procedures for the malfunction in question are described. Headings at the top of each page show how each troubleshooting procedure is organized: Malfunction, Test or Inspection (in step number order), and Corrective Action. c.

Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational. DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so.

EXPLANATION OF HEADINGS

0009

The headings in WP 0011 are defined as follows: a. MALFUNCTION. A visual or operational indication that something is wrong with the equipment. b. TEST OR INSPECTION. A procedure to isolate the problem in a system or component. c.

CORRECTIVE ACTION. A procedure to correct the problem.

0009-1

TM 5-3805-293-10

0009

MONITORING SYSTEM WARNINGS

0009

The Monitoring System provides three warning categories. The first warning category requires only operator awareness. The second warning category requires a change to machine operation or the performance of maintenance to the system. The third warning category requires immediate shutdown of the machine. 0009

Table 1. WARNING Category 1 Alert Machine system needs attention.

ALERT TO OPERATOR •

Alert indicator activated.

ACTION REQUIRED 1. Check Messenger system for alert message. 2. Follow instructions on Messenger system.

Category 2 Alert A change in machine operation is required.

•


1. Check Messenger system for alert message.

•

Action light activated.

Category 2S Alert Immediate change in machine operation is required.

•


•


1. Check Messenger system for alert message.

•

Action alarm sounds at a steady rate.

2. Follow instructions on Messenger system.

Category 3 Alert Immediate need to shut down machine.

•


•


•

Action alarm sounds at a pulse rate.

2. Follow instructions on Messenger system.

WARNING Failure to follow this warning may result in injury or death to personnel or damage to equipment. 1. Shut down machine immediately. 2. Check Messenger system for alert message. 3. Follow instructions on Messenger system.

0009-2

TM 5-3805-293-10

0009

MONITORING SYSTEM WARNINGS – CONTINUED

Figure 14. Alert Indicators.

KEY 1 2 3 4 5 6 7 8 9 10 11

COMPONENT Battery Charge Alert Indicator Electric Coolant Heater Alert Indicator Engine System Alert Indicator Implement System Alert Indicator Primary Steering Alert Indicator Action Light Alert Indicator Parking Brake Indicator Transmission System Alert Indicator Secondary Steering System Alert Indicator Brake System Indicator Operator Not Present Alert Indicator

DESCRIPTION Illuminates when a problem with machine voltage or alternator is present. Illuminates when coolant heater is activated. Illuminates when an engine problem is present. Illuminates when an implement system problem is present. Illuminates when a steering system problem is present. Illuminates when a problem occurs with machine. Illuminates when parking brakes are engaged. Illuminates when a transmission system problem is present. Illuminates RED when a system problem is present. Illuminates GREEN when system is activated or being tested. Illuminates when a general fault occurs in brake system. Illuminates when under specific conditions operator is not in cab.

0009-3/(4 Blank)

09

2 TM 5-3805-293-10

0010


1 0

-

OPERATOR TROUBLESHOOTING SYMPTOM INDEX

Malfunction/Symptom

Troubleshooting Procedure Page

ELECTRICAL SYSTEM

00010

Backup Alarm Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1 All Ground Engaging Tools Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1 Certain Ground Engaging Tools Inoperative – Others Operate Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2 Defroster Fan Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2 Differential Lock Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2 Directional Turn Signals Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2 Dome Lamp Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3 Headlight(s) Inoperative when SER Drive or Park Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3 Parking Light(s) Inoperative When SER Drive or Park Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . 0011-3 Heater and Air Conditioning Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3 High Beams Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3 Horn Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4 Monitor System Backlight Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4 Monitor System Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4 Primary Blade Worklights, Secondary Blade Worklights, or Rear Worklights Inoperative. . . . . . . . . . . . . . . . 0011-4 Stoplights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5 Taillights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5 Windshield Wiper, Left Door Wiper, or Right Door Wiper Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5 ENGINE Coolant Temperature Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6 Engine Cannot Reach Top Engine RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7 Engine Cranks But Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7 Engine Does Not Crank When Start Switch Is Engaged.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8 Engine Does Not Idle Properly, Misfires, or Runs Rough After Warmup Period. . . . . . . . . . . . . . . . . . . . . . . . 0011-8 Engine Starts But Dies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8 Excessive Exhaust Smoke at Normal Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8 Excessive Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9 Engine Quits While Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9 Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9 HYDRAULIC SYSTEM

00010

Travel Time for Blade Lift Cylinders is Slow, Hydraulic Oil Temperature Equal to or Greater Than 32°F (0°C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9 Travel Time for Scarifier is Slow, Hydraulic Oil Temperature Equal to or Greater Than 32°F (0°C). . . . . . . . 0011-10

0010-1

TM 5-3805-293-10

0010

STEERING Machine Slowly Drifts In Either Direction, Wanders, Or Pulls To One Side On Level Pavement. . . . . . . . . . 0011-11 Machine Steering is Slow or Responds Intermittently. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-11 Machine Turns Correctly During Normal Driving Conditions, but Turns Slowly with a Load.. . . . . . . . . . . . . 0011-11 Machine Turns Slowly in Both Directions After Reaching Operating Temperature. . . . . . . . . . . . . . . . . . . . . 0011-11 Machine Turns Slowly in One Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12 Steering is Erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12 TRANSMISSION Slow or Erratic Transmission Engagement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12 Transmission Does Not Operate in Any Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12 ALL-WHEEL DRIVE Wheel Speed or Engine Speed Surges at High Aggression Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-13 END OF WORK PACKAGE

0010-2

14 TM 5-3805-293-10

0011


-

TROUBLESHOOTING PROCEDURES

Electrical System, Engine, Hydraulic System, Steering, Transmission, All-Wheel Drive INITIAL SETUP Materials/Parts Goggles, Industrial (WP 0032, Item 10) Gloves, Chemical and Oil Protective (WP 0032, Item 9) 0

0

0

References LO-5-3805-293-13 WP 0004 WP 0005 WP 0013 WP 0014 WP 0018 WP 0019

0

0

0

0

0

References - Continued WP 0020 WP 0022 WP 0023 WP 0025 Equipment Conditions Machine parked on level ground (WP 0005) Blade and scarifier lowered to ground (WP 0005)

0

0

0

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ELECTRICAL SYSTEM 1. BACKUP ALARM INOPERATIVE. Step 1.

Step 2.

Ensure STOP LIGHT or SER DRIVE has been selected on military light switch (WP 0004). a.

Select STOP LIGHT or SER DRIVE.

b.

If problem persists, go to Step 2.

Check for blown fuse at fuse panel. a.

Replace fuse (WP 0023).

b.

If problem persists, notify Field Level Maintenance.

2. ALL GROUND ENGAGING TOOLS INOPERATIVE. Step 1.

Step 2.

Check that implement lockout switch is in UNLOCK position (WP 0004). a.

Push bottom of implement lockout switch.

b.




b.


0011-1

0

0

0

0

0

0

0

0

TM 5-3805-293-10

0011


ELECTRICAL SYSTEM – CONTINUED 3. CERTAIN GROUND ENGAGING TOOLS INOPERATIVE – OTHERS OPERATE PROPERLY. Step 1.

Step 2.

Check that implement lockout switch is in UNLOCK position (WP 0004). a.

Push bottom of implement lockout switch.

b.


Check for blown fuse(s) at fuse panel. a.


b.


4. DEFROSTER FAN INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


5. DIFFERENTIAL LOCK INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


6. DIRECTIONAL TURN SIGNALS INOPERATIVE. Step 1.

Step 2.

Step 3.

Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP 0004). a.


b.


Check electrical connector at lamp assembly. a.

Reconnect connectors, if required.

b.

If connectors are okay, go to Step 3.




0011-2

TM 5-3805-293-10

0011


ELECTRICAL SYSTEM – CONTINUED 7. DOME LAMP INOPERATIVE. Step 1.

Step 2.

Step 3.



b.


Check for burned out or defective bulb. a.

Replace bulb (WP 0020).

b.




b.


8. HEADLIGHT(S) INOPERATIVE WHEN SER DRIVE OR PARK FUNCTIONS ARE SELECTED. Step 1.

Step 2.

Ensure SER DRIVE or STOP LIGHT function has been selected on military light switch (WP 0004). a.

Select SER DRIVE or STOP LIGHT.

b.


Check lights for disconnected or damaged connectors. a.


b.

If connectors are secure or if damage is found, notify Field Level Maintenance.

9. PARKING LIGHT(S) INOPERATIVE WHEN SER DRIVE OR PARK FUNCTIONS ARE SELECTED. Step 1.

Step 2.

Ensure STOP LIGHT function has been selected on military light switch (WP 0004). a.

Select STOP LIGHT.

b.


Check lights for disconnected or damaged connectors. a.


b.


10. HEATER AND AIR CONDITIONING INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


11. HIGH BEAMS INOPERATIVE. a.

Ensure SER DRIVE function has been selected on military light switch (WP 0004).

b.


0011-3

TM 5-3805-293-10

0011


ELECTRICAL SYSTEM – CONTINUED 12. HORN INOPERATIVE. Step 1.

Step 2.

Step 3.



b.




b.


Check wiring harness connector is properly connected to horn. a.

Reconnect connector, if required.

b.

If connector is okay or if harness damage is found, notify Field Level Maintenance.

13. MONITOR SYSTEM BACKLIGHT INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


14. MONITOR SYSTEM INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


15. PRIMARY BLADE WORKLIGHTS, SECONDARY BLADE WORKLIGHTS, OR REAR WORKLIGHTS INOPERATIVE. Step 1.

Step 2.

Step 3.



b.




b.


Check wiring harness connector is properly connected to worklight. If fault is found, notify Field Level Maintenance.

0011-4

TM 5-3805-293-10


ELECTRICAL SYSTEM – CONTINUED 16. STOPLIGHTS INOPERATIVE. Step 1.

Step 2.


Select SER DRIVE or PARK.

b.


Check lights for disconnected connections or damage. a.


b.


17. TAILLIGHTS INOPERATIVE. Ensure SER DRIVE function has been selected on military light switch (WP 0004). a.

Select SER DRIVE.

b.


18. WINDSHIELD WIPER, LEFT DOOR WIPER, OR RIGHT DOOR WIPER INOPERATIVE. Check for blown fuse at fuse panel. a.


b.


0011-5

0011

TM 5-3805-293-10


ENGINE

WARNING

•

Do not perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

•

Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow this warning may result in injury or death to personnel.

CAUTION Do not crank engine for longer than 30 seconds. Allow starter motor to cool for two minutes before cranking again or damage to equipment may result. 1. COOLANT TEMPERATURE TOO HIGH.

WARNING

•

Do NOT service the cooling system unless engine has been allowed to cool down. This is a pressurized system and escaping steam or hot coolant will cause serious burns.

•

Do NOT remove cooling system pressure cap when engine is hot. Allow engine to cool down. Remove pressure cap slowly to relieve system pressure.

•

Wear protective eye, hand, and skin protection when handling coolant.

•


Step 1.

Step 2.

Check coolant level in coolant tank (WP 0013). a.

Fill coolant tank to specifications (WP 0013).

b.


Check radiator for dirt, debris, or damaged fins. a.

Clean dirt and debris from radiator (WP 0025).

b.

If problem persists or if fins are damaged, notify Field Level Maintenance.

0011-6

0011

TM 5-3805-293-10


ENGINE – CONTINUED 2. ENGINE CANNOT REACH TOP ENGINE RPM. Step 1.

Step 2.

Step 3.

Check for diagnostic codes (WP 0005). a.

If diagnostic codes are present, notify Field Level Maintenance.

b.

If no diagnostic codes are present, go to Step 2.

Check air filters (WP 0014). a.

Clean or replace air filters (WP 0014).

b.


Check fuel supply. a.

Verify fuel is not solidified (temperatures below 32°F (0°C)).

b.

Add fuel (WP 0013).

c.


3. ENGINE CRANKS BUT WILL NOT START. Step 1.

Step 2.

Step 3.

Step 4.



b.

If there are no diagnostic codes, go to Step 2.



b.


Verify fuel level. a.

Add fuel as necessary (WP 0013).

b.


Check circuit breakers. a.

Reset circuit breakers (WP 0018).

b.


0011-7

0011

TM 5-3805-293-10


ENGINE – CONTINUED 4. ENGINE DOES NOT CRANK WHEN START SWITCH IS ENGAGED. Step 1.

Step 2.

Step 3.

Verify parking brake is engaged and transmission control switch is in NEUTRAL position. a.

Engage parking brake and move transmission control switch to NEUTRAL.

b.


Verify battery disconnect switch is turned to ON position. a.

Turn battery disconnect switch to ON position.

b.


Check circuit breakers (WP 0019). a.


b.


5. ENGINE DOES NOT IDLE PROPERLY, MISFIRES, OR RUNS ROUGH AFTER WARMUP PERIOD. Step 1.

Step 2.

Step 3.



b.




b.


Check for water in fuel (WP 0013). a.

Drain fuel/water separator (WP 0022).

b.


6. ENGINE STARTS BUT DIES. Step 1.

Step 2.



b.


Check for water in fuel (WP 0013). a.

Drain fuel/water separator (WP 0022).

b.


7. EXCESSIVE EXHAUST SMOKE AT NORMAL OPERATING TEMPERATURE. Check air filters (WP 0014). a.


b.


0011-8

0011

TM 5-3805-293-10


ENGINE – CONTINUED 8. EXCESSIVE OIL CONSUMPTION. Step 1.

Step 2.

Step 3.

Check for misreading of oil level. a.

Accurately measure oil level.

b.




b.


Check for loose or leaking oil lines and oil leaks. If loose or leaking oil lines or leaks are found, notify Field Level Maintenance.

9.

ENGINE QUITS WHILE RUNNING. Step 1.

Step 2.

Step 3.

Step 4.

Check fuel level on gauge and in Messenger (WP 0005). a.

Add fuel if low.

b.




b.


Check fuel/water separator bowl for presence of fuel and that fuel is not gelled. a.

If fuel is not present or is gelled, notify Field Level Maintenance.

b.

If fuel is present and not gelled, go to Step 4.



b.


10. LOW ENGINE OIL PRESSURE. Check engine oil level. a.

Fill oil to specification (LO 5-3805-293-13).

b.


0011-9

0011

TM 5-3805-293-10

0011


HYDRAULIC SYSTEM

WARNING

Wear safety goggles when performing any hydraulic maintenance procedures. Failure to follow this warning may result in injury or death to personnel.

NOTE It is normal for hydraulic functions to operate slowly when hydraulic oil is very cold (less than 32°F (0°C). Allow machine additional time to warm up if required. 1. TRAVEL TIME FOR BLADE LIFT CYLINDERS IS SLOW, HYDRAULIC OIL TEMPERATURE EQUAL TO OR GREATER THAN 32°F (0°C). Step 1.

Step 2.

Check blade hydraulic cylinder for buildup of debris. a.

Remove debris.

b.


Check hydraulic fluid level (LO 5-3805-293-13). a.

Add hydraulic fluid as necessary (LO 5-3805-293-13).

b.


2. TRAVEL TIME FOR SCARIFIER IS SLOW, HYDRAULIC OIL TEMPERATURE EQUAL TO OR GREATER THAN 32°F (0°C). Step 1.

Step 2.

Check scarifier area for buildup of debris. a.

Remove debris.

b.




b.


0011-10

TM 5-3805-293-10

0011


STEERING

WARNING •

Hitch and steering movement can reduce clearances suddenly. Stop engine before servicing. Failure to follow this warning may result in injury or death to personnel.

•

Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment.

•

If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment.

1. MACHINE SLOWLY DRIFTS IN EITHER DIRECTION, WANDERS, OR PULLS TO ONE SIDE ON LEVEL PAVEMENT. Step 1.

Step 2.

Check tire pressures (WP 0013). a.

If tire inflation pressure is from 1 to 4 psi low, inflate to specifications (WP 0013).

b.

If tire inflation pressure is more than 4 psi low, notify Field Level Maintenance.

c.


Check steering linkage and hydraulic cylinders for damage. If damage is found, notify Field Level Maintenance.

2. MACHINE STEERING IS SLOW OR RESPONDS INTERMITTENTLY. Check hydraulic fluid level (LO 5-3805-293-13). a.


b.


3. MACHINE TURNS CORRECTLY DURING NORMAL DRIVING CONDITIONS, BUT TURNS SLOWLY WITH A LOAD. Step 1.

Step 2.

Check for oil leaks at steering cylinders. a.

If leaks are found, notify Field Level Maintenance.

b.

If no leaks are found and problem persists, go to Step 2.

Check hydraulic oil level (LO 5-3805-293-13). a.


b.


4. MACHINE TURNS SLOWLY IN BOTH DIRECTIONS AFTER REACHING OPERATING TEMPERATURE. Check hydraulic oil level (LO 5-3805-293-13). a.


b.


0011-11

TM 5-3805-293-10


STEERING – CONTINUED 5. MACHINE TURNS SLOWLY IN ONE DIRECTION. Step 1.

Step 2.

Check for oil leaks at steering cylinders. a.

If leaks are found, notify Field Level Maintenance.

b.

If no leaks are found and problem persists, go to Step 2.

Check hydraulic oil level (LO 5-3805-293-13). a.


b.


6. STEERING IS ERRATIC. Step 1.

Step 2.



b.


Check for air bubbles in hydraulic reservoir. If bubbles are found, notify Field Level Maintenance. TRANSMISSION

NOTE Before checking oil level, ensure machine is parked on level ground, parking brake is engaged, transmission control switch is in the NEUTRAL position, and the engine is warmed up and at low idle. 1. SLOW OR ERRATIC TRANSMISSION ENGAGEMENT. Step 1.

Check transmission fluid level (LO 5-3805-293-13). a.

Add fluid as necessary (LO 5-3805-293-13).

b.


2. TRANSMISSION DOES NOT OPERATE IN ANY GEAR. Step 1.

Step 2.

Check transmission fluid level (LO 5-3805-293-13). a.

Add fluid as necessary (LO 5-3805-293-13).

b.


Check circuit breakers (WP 0018). a.


b.


0011-12

0011

TM 5-3805-293-10


ALL-WHEEL DRIVE WHEEL SPEED OR ENGINE SPEED SURGES AT HIGH AGGRESSION SETTINGS. Machine being operated in sand or similar loose, dry conditions. Reduce aggression to a maximum of 100 percent.

END OF WORK PACKAGE

0011-13/(14 blank)

0011

TM 5-3805-293-10

CHAPTER 4 PMCS INSTRUCTIONS

4 TM 5-3805-293-10

0012


-

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL

00012

1. To ensure that the 120M Motor Grader is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in injury, damage, or equipment failure. 2. The PMCS Table in WP 0013 contains systematic instructions on inspections, lubrications, services, tests, and corrections to be performed by the operator to keep the equipment in good operating condition and ready for its primary mission. EXPLANATION OF TABLE ENTRIES

00012

1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E, Equipment Inspection and Maintenance Worksheet, include the item number for the check/service indicating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the Procedure column: a. Before procedures must be done immediately before you operate the grader. b. During procedures must be done while you are operating the grader. c.

After procedures must be done immediately after you have operated the grader.

d. Biweekly or Every 100 Service Hours procedures must be done once every two weeks or after every 100 hours of machine operation. e. Initial 500 Service Hours (or at first oil change) procedures must be done after the first 500 hours of machine operation or at the first engine oil change. f.

Every 500 Service Hours or 3 Months procedures must be done every 500 hours of machine operation or every three months.

g. Every 1,000 Service Hours or 6 Months procedures must be done every 1,000 hours of machine operation or every six months. h. Every 2,000 Service Hours or 2 Years procedures must be done every 2,000 hours of machine operation or every two years. i.

Yearly procedures must be done once each year.

3. Item to Check/Service Column. This column lists the item to be checked or serviced.

NOTE The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs and CAUTIONs appear before applicable procedures. You must observe these WARNINGs to prevent injury or death to yourself and others, and CAUTIONs to prevent your equipment from being damaged. 4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column, to know if the equipment is ready and available for its intended mission. You must perform the procedure at the time stated in the Interval column. 5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equipment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure.

0012-1

TM 5-3805-293-10

0012

GENERAL PMCS PROCEDURES

00012

1. Intervals (on-condition or hardtime) and the related manhour times are based on normal operation. The manhour time specified is the time you need to do all the services prescribed for a particular interval. Change the hardtime interval if your lubricants are contaminated or if you are operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The hardtime interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken. 2. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will spot anything wrong in a hurry. If the equipment does not perform as required, refer to the appropriate troubleshooting procedure in Chapter 3. 3. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find something seriously wrong, IMMEDIATELY report it to your supervisor. 4. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all that is needed to make all the checks. You will always need a rag (Item 17, WP 0032) or two.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may result in injury or death to personnel.

CAUTION Be especially careful when cleaning electrical system components including lighting. Damage or impaired operation could result if this caution is not observed. a. Keep Equipment Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use solvent cleaning compound (Item 2, WP 0032) on all metal surfaces. Use detergent (Item 4, WP 0032) and water when you clean rubber, plastic, and painted surfaces. Spot paint as required to prevent corrosion. b. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing, or damaged bolts, nuts, and screws to your supervisor. c.

Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. Report bad welds to your supervisor.

d. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Report loose connections and faulty wiring to your supervisor. e. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any worn, damaged, or loose hoses, lines, and fittings to your supervisor.

0012-2

TM 5-3805-293-10

0012

FLUID LEAKAGE

00012

NOTE Notify Field Level Maintenance of any leaks the operator cannot fix. It is necessary for you to know how fluid leakage affects the status of the 120M Motor Grader. Following are types/ classes of leakage you need to know to be able to determine the status of the 120M Motor Grader. Learn these leakage definitions and remember - when in doubt, notify your supervisor. Equipment operation is allowed with minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being checked/ inspected. When in doubt, notify your supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. Class III leaks should be reported immediately to your supervisor. Leakage Definitions for PMCS Class I

Seepage of fluid as indicated by wetness or discoloration, not great enough to form drops.

Class II

Leakage of fluid great enough to form drops, but not enough to cause drops to drip from the item being checked/inspected.

Class III

Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

GENERAL LUBRICATION PROCEDURES

00012

NOTE Refer to Lubrication Order (LO 5-3805-293-13). 1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under extreme conditions, lubricants should always be changed more frequently. When in doubt, notify your supervisor. 2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep container covers clean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep all lubrication equipment clean and ready for use. 3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to DA PAM 750-8 for maintenance forms and procedures to record and report any findings. 4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fittings with a clean Rag, Wiping (WP 0032, Item 17). After lubrication, wipe off excess oil or grease to prevent accumulation of foreign matter. 5. Refer to FM 9-207 for lubrication instructions in cold weather. 6. Refer to AR 70-12 for use of standardized lubricants. END OF WORK PACKAGE

0012-3/(4 blank)

56 TM 5-3805-293-10

0013


-

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP Tools and Special Tools Basic Issue Items (WP 0031)

0

0

Materials/Parts Antifreeze (WP 0032, Item 1) Cleaning Compound, Solvent, Type III (WP 0032, Item 2) Cleaning Compound, Windshield (WP 0032, Item 3) Detergent, General Purpose, Liquid (WP 0032, Item 4) Diesel Fuel, DF-1 Grade, Arctic (WP 0032, Item 5) Diesel Fuel, DF-2 Grade (WP 0032, Item 6) Fuel, Turbine, Aviation (WP 0032, Item 8) Grease, Automotive and Artillery (GAA) (WP 0032, Item 11) Lubricant, Dry Film (WP 0032, Item 12) Oil, Lubricating, OE/HDO-30 (WP 0032, Item 13) Oil, Lubricating, OE/HDO-15W/40 (WP 0032, Item 15) Oil, Lubricating, OEA Arctic (WP 0032, Item 16) Rag, Wiping (WP 0032, Item 17) 0

0

0

0

0

0

0

0

References WP 0004 WP 0005 WP 0010 WP 0014 WP 0015 WP 0017 WP 0019 WP 0021 WP 0022 WP 0024 WP 0026 WP 0027 WP 0032 LO 5-3805-293-13

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0013-1

Equipment Conditions Machine parked on level ground (WP 0005) Blade and scarifier lowered to ground (WP 0005) Parking brake engaged (WP 0004)

0

0

0

0

TM 5-3805-293-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) with Lubrication Information. LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

NOTE • Review all WARNINGs, CAUTIONs, and NOTEs before performing PMCS and operating the machine. • Perform all PMCS checks if: –

You are the assigned operator but have not operated the machine since the last weekly checks.

–

You are operating the machine for the first time.

• Unless otherwise indicated, perform PMCS with machine parked on level ground, parking brake applied, transmission in N (Neutral), blade lowered to the ground, wheels blocked, and engine shut down. • If leakage is detected during performance of PMCS, further investigation is required to determine location and cause of leak. • Walk around machine and look for any obvious leaks or damage. • During walk around, also visually check tires for low inflation, damage, and debris. LEFT SIDE 1

Before

Overall View

Check left side of machine for evidence of leakage or damage.

2

Before

All-Wheel Drive Hoses

Check all-wheel drive (AWD) hoses Class III leaks or damage and fittings for damage or leaks. that would impair operation are evident.

0013-2

Class III leaks or damage that would impair operation are evident.

TM 5-3805-293-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) with Lubrication Information - Continued. LOCATION ITEM NO. 3

MANINTERVAL HOURS Before



PROCEDURE

WARNING

Left Front Tire

• Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. Visually check tire for underinflation.

Tire pressure appears low.

4

Before

Lights

Check left front work light, headlight, front turn signal light, and blackout light for missing or damaged components.

Missing or damaged components if required for mission.

5

Before

Fuel Tank Filler Cap

Ensure fuel tank filler cap is present and secure.

Missing fuel tank filler cap.

Figure 1. Fuel Tank Filler Cap. 6

Before

Below Operator Compartment

Check hoses, cables, and connections below left side of operator compartment for damage or leaks.

0013-3

0013

Class III oil or hydraulic fluid leaks are present. Any fuel leakage is evident. Damage that would impair operation is evident.

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE Arctic Heater (if equipped)

PROCEDURE Check arctic heater fuel line (Figure 2, Item 1), coolant hoses (Figure 2, Item 2), grommets (Figure 2, Item 3), electrical harness and connector (Figure 2, Item 4), and exhaust tube (Figure 2, Item 5) for leaks, damaged or missing components.

NOT FULLY MISSION CAPABLE IF: Class III leaks or damaged or missing components if required for mission.

Figure 2. Arctic Heater. 8

Before

0.2

Engine Oil Level Check

a. Open left front access door. b. Clean area around engine oil level gauge (dipstick) (Figure 3, Item 2) and fill cap (Figure 3, Item 1). c. Remove oil level gauge, wipe Oil level is below or above clean and reinstall. Remove oil crosshatch area on gauge, level gauge and check level of oil. or fill cap missing. Maintain oil level between the marks on oil level gauge (Figure 3, Item 3).

0013-4

0013

TM 5-3805-293-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) with Lubrication Information - Continued. LOCATION ITEM NO.

MANINTERVAL HOURS

8 Before (Cont.)

0.2

ITEM TO CHECK/ SERVICE Engine Oil Level Check

PROCEDURE


d. Add oil as required through filler opening. Refer to LO 5-3805-29313 for proper grade of oil based on ambient temperature. Clean oil filler cap, then reinstall.

Figure 3. Oil Level Gauge (Dipstick) and Fill Cap.

0013-5

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

Coolant Level Checks

WARNING

• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

CAUTION • Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection and engine and/or cooling system damage may occur. • Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE • Some antifreeze is pre-mixed with water and does not require mixing with water. • Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. • It is allowable to mix traditional and pre-mix antifreeze types in the same cooling system.

0013-6

TM 5-3805-293-10

0013


MANINTERVAL HOURS

9 Before (Cont.)

ITEM TO CHECK/ SERVICE Coolant Level Checks

PROCEDURE


Check coolant level in coolant tank Coolant level is below ADD (Figure 4, Item 1). Maintain level mark. between FULL mark and ADD mark on coolant tank.

Figure 4. Coolant Tank Level.

0013-7

0013

TM 5-3805-293-10

0013





PROCEDURE

Transmission/ a. Clean area around transmission Differential Oil oil level gauge/fill cap (dipstick). Level Check b. Start engine and run engine at low idle (WP 0005). c. Remove oil level gauge/fill cap, wipe, clean, and reinstall. d. Remove oil level gauge/fill cap, Oil level does not register and check level of oil. on gauge, or fill cap missing.

NOTE Proceed to next step only if oil does not register on gauge. e. Add oil (WP 0032, Items 18 or 21) as required through oil filler tube. Refer to LO 5-3805-293-13 for proper grade of oil based on ambient temperature. f. Stop engine (WP 0005). g. Close left front access door.

Figure 5. Transmission/Differential Oil Level Check.

0013-8

0013

TM 5-3805-293-10

0013





PROCEDURE

Hydraulic Tank a. Open left rear access door. Sight Gauge b. Clean area around hydraulic tank sight gauge. c. Check oil level is visible in sight gauge.

NOTE Proceed to the following steps only if oil level is not visible in sight gauge. d. Operate machine until oil is warm (WP 0005).

Oil is not visible on sight gauge, oil level is above MAX mark on sight gauge, or fill cap missing.

e. Clean area around hydraulic oil filler cap. f. Maintain oil level above the MIN mark on sight gauge. g. Add oil (WP 0032, Items 18 or 21) as required through hydraulic oil filler cap. Refer to LO 5-3805293-13 for proper grade of oil based on ambient temperature.

Figure 6. Hydraulic Oil Level Check.

0013-9

0013

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE NATO Receptacle


PROCEDURE a. Ensure NATO slave receptacle cover is installed. b. Close left rear access door.

13

Before

WARNING

Left Rear Tires

• Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. Visually check tire for underinflation.


a. Check for damage to rear blackout light, taillights, turn signal lights, backup lights and rear worklight.


b. Check radiator grille, backup alarm, and towing pin for debris and damage.


REAR 14

Before

Rear of Machine

c. Check under engine Class III oil or hydraulic fluid compartment for evidence of fluid leaks are present. Any fuel leakages such as oil, coolant, fuel, leakage is evident. and hydraulic fluid. d. Check rear of machine for obvious damage that would impair operation.

0013-10


TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

RIGHT SIDE

15

Before

Right Rear Tires

WARNING • Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel or damage to equipment. Visually check tires for underinflation.


16

Before

Overall View

Check right side of machine for evidence of leakage or damage.

Class III leaks or damage that would impair operation are present.

17

Before

Right Rear Access Door

a. Open right rear access door.


b. Visually check for loose, damage, cracked components, or evidence of leaks. c. Close right rear access door.

0013-11

TM 5-3805-293-10

0013




PROCEDURE


Ether Cylinder a. Open right front access door. b. Remove ether cylinder and shake to check if cylinder is empty (WP 0021). Install new cylinder if required (WP 0021).


c. If no ether cylinder is present, ensure cap is installed on ether valve.

Figure 7. Ether Cylinder.

0013-12

0013

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE Engine Compartment


PROCEDURE a. Visually check for loose, damage, cracked components, or evidence of leaks.


b. Close right front access door. 20

Before

Below Operator Compartment

21

Before

Right Front Tire

a. Check hoses and connections Class III oil or hydraulic fluid below right side of operator leaks are present. Any fuel compartment for damage or leaks. leakage is evident. Damage that would impair operation b. Check cables for fraying or is evident. damage.

WARNING • Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. Visually check tire for underinflation.

22

Before

Lights


Check right front work light, Missing or damaged headlight, blackout drive light, components if necessary blade work light, and front turn for mission. signal light for missing or damaged components.

CAB INTERIOR

23

Before

Battery Disconnect Switch

Turn battery disconnect switch to ON position.

24

Before

Fire Extinguisher

a. Visually check for missing or damaged fire extinguisher. Ensure it is securely stowed in mounting bracket.

Fire extinguisher is missing or damaged.

b. Check gauge for pressure reading in green area on gauge.

Pressure gauge needle is in red area.

0013-13

TM 5-3805-293-10

0013


MANINTERVAL HOURS

24 Before (Cont.)

25

Before

ITEM TO CHECK/ SERVICE Fire Extinguisher

PROCEDURE


c. Check for damaged or missing seal.

Seal is broken or missing.

d. Inspect fire extinguisher inspection tag.

Inspection date is not current and/or tag is missing.

Operator Seat Check seat and seat belt mounting Seat belt is damaged. hardware (Figure 8, Item 1), seat belt buckle (Figure 8, Item 2), and seat belt (Figure 8, Item 3) for damage or wear (WP 0004).

Figure 8. Seat Belt Inspection.

0013

26

Before

Rearview Mirror and Side View Mirrors

Check and adjust inside rearview mirror. With an assistant, check and adjust side view mirrors.

27

Before

Lights

With an assistant, check operation Any lights do not function, if of lights (service and blackout light, required for mission. brake lights, turn signals and work lights) (WP 0005).

28

Before

Wipers and Washers (if equipped)

Operate all wipers and washers to Wipers and washers not verify correct operation (WP 0004). operating if required for mission.

0013-14

TM 5-3805-293-10

0013





PROCEDURE

Backup Alarm a. Verify that backup alarm and Horn functions when transmission is placed in R (Reverse) (WP 0005). b. Check operation of horn (WP 0005).

Backup alarm does not function.

Horn does not function.

NOTE Monitor system self-diagnostic test takes approximately 10 seconds to complete. 30

Before

Monitor System Indicators and Gauges

a. Turn engine start switch from Fails to enter diagnostic OFF position to ON position (do not test. start engine) to initialize selfdiagnostic test. b. Monitor the following: 1. All gauges must sweep to far Any gauge does not move. right position, then return.

Figure 9. Monitor System Display - Gauges. 2. All alert indicators must come on momentarily.

0013

Any alert light does not come on.

3. All segments in LCD display LCD display segment(s) must come on momentarily. inoperative 4. The action alarm must sound.

0013-15

Action alarm does not sound.

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE Left and Right Blade Float Indicators


PROCEDURE

WARNING Blade must be lowered before activating blade float. Failure to follow this warning may result in injury to personnel.

NOTE If engine fails to start, turn ignition switch to the OFF position, and retry. a. Start engine and run engine at low idle (WP 0005). b. Move right and left joysticks to Blade float indicators do not most forward detent (WP 0005). come ON. Blade float indicators should be ON in display. 32

Before

Action Light Indicator

a. Run engine at low idle (WP 0005). b. Monitor action light indicator in display. c. If action light indicator is ON, machine needs service.

Action light indicator is ON.

Figure 10. Monitor System Display - Action Light and Blade Float Indicators. 0013

0013-16

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE Messenger Display

PROCEDURE With engine running, observe the Messenger display.

NOT FULLY MISSION CAPABLE IF: Messenger displays error message or Messenger is not operating.

Figure 11. Messenger Display.

0013

34

Before

Differential Lock

Push control button on right joystick. Indicator light should go ON (WP 0004).

Differential lock indicator inoperative.

35

Before

Hydraulic Controls

Perform a functional check of all hydraulic systems: blade lift, centershift, circle drive, blade tilt, steering, wheel lean, and scarifier (WP 0005).

Class III oil leak is evident. Any hydraulic system or function does not operate properly.

36

Before

Brake Accumulator

a. Start engine and run for no less than one minute to increase accumulator pressure. b. Stop engine. c. Turn ignition switch to ON position. DO NOT start engine. d. Fully depress service brake slowly a minimum of five applications.

0013-17

TM 5-3805-293-10

0013


MANINTERVAL HOURS

36 Before (Cont.)

37

Before


PROCEDURE


Brake Accumulator

e. If brake system indicator light illuminates with less than five applications, notify Field Level Maintenance.

Brake system indicator light illuminates with less than five applications.

Pedals

Check accelerator pedal, service Pedal binds or does not brake pedal, and transmission operate properly. modulator control pedal for binding and obstructions.

Figure 12. Accelerator, Brake, and Transmission Pedals.

0013

38

During

Brakes

Check service brakes for pulling, grabbing, or reduced braking capacity.

Brakes pull, grab, or do not operate properly.

39

During

Steering

Check for smooth, controlled steering without pulling or drifting.

Steering is erratic.

40

During

Drive Train

Monitor grader operation for unusual noise or vibrations from engine, transmission, drive shafts, axles, and wheels.

Unusual noises or vibrations are present.

0013-18

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

41

During

Blade and Scarifier

Monitor blade and scarifier operations for unusual noise or vibrations.

Unusual noises or vibrations present.

42

During

Overall Leakage

Watch for evidence of fluid leakage.

Class III oil or hydraulic fluid leaks are present. Any fuel leakage is evident.

43

During

Instrument Panel

a. With machine fully warmed up, Gauges and warnings monitor indicators and gauges and indicate an abnormal reading. Messenger Display.

44

During

Air Conditioner, Heater and Defroster Fan

45

After

Overall View

b. If action light indicator is flashing, troubleshoot system (WP 0010).

Any flashing of action light indicator.

Check air conditioner, heater and defroster fan for correct operation.

Damaged or does not operate if required for mission.

NOTE Ensure machine is clean in order performance of PMCS inspections.

to

facilitate

a. Check under machine for Class III oil or hydraulic fluid evidence of fluid leakages such as leaks are present. Any fuel oil, coolant, fuel, or hydraulic fluid. leakage is evident. b. Check machine for obvious damage that would impair operation.

0013-19

Damage that would impair operation is evident.

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

LEFT SIDE

46

After

Left Front Wheel and Tire

WARNING • Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment.

47

After

Steering

a. Check tires for cuts or bulges in tread or sidewall area. Check for uneven wear and foreign material embedded in tread or sidewall area.

Tire has cuts, bulges, or foreign material in tread or sidewall area or other damage that would impair operation.

b. Clean area around valve stem, then remove valve stem cap.

Valve stem damaged.

c. Check tire inflation pressure with tire pressure gauge. Refer to WP 0002 for proper tire inflation pressures.

Tire inflation pressure more than 4 psi low.

d. Check for loose or missing lug bolts.

Loose, or two or more missing lug bolts.

e. Check wheel for damage.

Wheel damaged.

a. Check steering linkage for cracks, distortion, or damage.

Cracks or distortion in steering linkage that would impair operation.

b. Check left front steering cylinder Class III leaks or damage and hoses for damage or leaks. that would impair operation. 48

After

Drawbar

a. Check drawbar and drawbar pivot point for damage. b. Check all hoses and fittings for leaks.

0013-20

Class III leaks or damage that would impair operation.

TM 5-3805-293-10

0013


MANINTERVAL HOURS


PROCEDURE


49

After

Scarifier

Check scarifier frame, link sockets, and teeth for excessive wear (WP 0026 and WP 0027), damage, or missing components.

Damage that would impair operation, or missing six scarifier teeth if required for mission.

50

After

Hydraulic Cylinders

a. Check scarifier hydraulic cylinder and hoses for damage or leaks.


b. Check left blade lift cylinder and Class III leaks or damage that would impair operation. hoses for damage or leaks. c. Check centershift cylinder and hoses for damage or leaks. 51

After

Circle Drive

52

After

Blade, Cutting a. Check entire blade for damage Edges, and or distortion. End Bits


Check all circle drive and circle Class III leaks or damage that would impair operation. drive components for leaks, damage or debris. Remove debris. Damage or distortion.

b. Check all cutting edges and end Damage or loose bolts. bits for damage or loose bolts. c. Check all cutting edges and end Cutting edge or end bits are bits for excessive wear (WP 0019). worn to within 3/4 in. (19 mm) of blade. d. Check sideshift cylinder for Class III leaks or damage debris, damage, or leaks. Remove that would impair operation. debris. 53

After

Blade Work Lights

Ensure blade work lights are present and securely mounted.

Missing or damaged components if necessary for mission.

54

After

Left Door

Check left door for damage or missing components.


55

After

Left Mirror and Check left side mirror and step for Step damage or missing components.

56

After

Rollover Protective Structure (ROPS)

Check ROPS for damage and loose or missing mounting bolts.

0013-21

Missing or damaged components if necessary for mission. Loose or missing ROPS bolts or damage to structure.

TM 5-3805-293-10

0013


MANINTERVAL HOURS After



PROCEDURE

Refueling

WARNING

• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow this warning may cause injury to personnel or damage to equipment. • Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.

NOTE • Place portable fire extinguisher within reach prior to refueling. • DO NOT overfill fuel tank. If fuel starts foaming from fuel tank, stop IMMEDIATELY to avoid fuel spillage. • Observe sight glass while adding fuel to ensure fuel spillage due to overfilling does not occur. a. Check fuel tank, filler tube, and filler cap for damage or leaks.

Any fuel leaks or damage are noted.

Figure 13. Fuel Tank, Filler Tube, Sight Glass, and Cap.

0013-22

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS

57 After (Cont.)

ITEM TO CHECK/ SERVICE Refueling

PROCEDURE b. Remove filler cap. Inspect filler cap, gasket, and screen for damage.

NOT FULLY MISSION CAPABLE IF: Filler cap, gasket or screen is missing or damaged.

c. Reinstall screen. d. Add fuel (WP 0032, Items 11, 12, or 15) to tank. DO NOT overfill. Reinstall filler cap and secure.

Figure 14. Filler Cap, Gasket, and Screen. 58

After

Articulation Lock Pin

Check articulation lock pin is present in lock pin storage bracket.

0013-23

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precaution and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel. 59

After

Primary and a. Remove air filter cover. Secondary Air Filters b. Ensure primary air filter is present. c. Remove primary and secondary Missing or damaged air air filters. filter components. d. Inspect and clean or replace filters (WP 0014). e. Install secondary and primary air filters. f. Install air filter cover.

Figure 15. Air Filters and Cover.

0013-24

0013

TM 5-3805-293-10

0013





PROCEDURE

Fuel/ Water Separator

WARNING

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Failure to follow this warning may cause injury to personnel or equipment damage. Drain fuel/water separator (WP 0022).

Figure 16. Fuel/Water Separator.

0013-25

Excessive amounts of water in fuel.

0013

TM 5-3805-293-10

0013



0.2


PROCEDURE


Transmission/ a. Clean area around transmission Differential Oil oil level gauge/fill cap. Level Check b. Start engine and run engine at low idle (WP 0005). Remove oil level gauge/fill cap, clean, and reinstall. c. Remove oil level gauge/fill cap and check level of oil. Maintain oil level between marks on oil level gauge/fill cap. d. Add oil (WP 0032, Item 18 or 21) as required through oil filler tube. e. Stop engine (WP 0005).

Figure 17. Transmission/Differential Oil Level Check. 62

After

0.2

Engine Oil Level Check

0013

a. Open left front access door. b. Clean area around engine oil Class III oil leak or damage level gauge (dipstick) (Figure 18, is evident. Item 2) and fill cap (Figure 18, Item 1).

0013-26

TM 5-3805-293-10

0013


MANINTERVAL HOURS

62 After (Cont.)

0.2

ITEM TO CHECK/ SERVICE Engine Oil Level Check

PROCEDURE


c. Add oil (WP 0032, Items 18 or Fill cap missing. 21) as required through oil filler cap opening. Refer to LO 5-3805-29313 for proper grade of oil based on ambient temperature. Clean oil filler cap, then reinstall.

Figure 18. Engine Oil Level Check.

0013-27

0013

TM 5-3805-293-10

0013



ITEM TO CHECK/ SERVICE Arctic Heater (if equipped)


PROCEDURE

Check arctic heater fuel line Class III leaks or damaged (Figure 19, Item 1), coolant hoses or missing components if (Figure 19, Item 2), grommets required for mission. (Figure 19, Item 3), electrical harness and connector (Figure 19, Item 4), and exhaust tube (Figure 19, Item 5) for leaks, damaged or missing components.

Figure 19. Arctic Heater. 64

After

Left Rear Wheels and Tires

0013

WARNING • Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. • If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level Maintenance. Failure to follow this warning may result in serious injury or death to personnel, or damage to equipment. a. Check tires for cuts or bulges in tread or sidewall area. Check for uneven wear and foreign material embedded in tread or sidewall area.


b. Clean area around valve stems, Valve stem damaged. then remove valve stem caps.

0013-28

TM 5-3805-293-10

0013


MANINTERVAL HOURS

64 After (Cont.)

ITEM TO CHECK/ SERVICE Left Rear Wheels and Tires

65

After

Left Tandem Housing

66

After

Coolant Level Checks


PROCEDURE c. Check tire inflation pressure with tire pressure gauge. Refer to WP 0002 for proper tire inflation pressures.



Loose or two or more missing lug bolts.

e. Check wheels for damage.

Wheel damaged.

Check for damage and leaks from tandem housing.

Class III oil leak or damage is evident.

WARNING

• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

CAUTION • Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection and engine and/or cooling system damage may occur. • Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE • Some antifreeze is pre-mixed with water and does not require mixing with water. • Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. • It is allowable to mix traditional and pre-mix antifreeze types in the same cooling system.

0013-29

TM 5-3805-293-10

0013


MANINTERVAL HOURS

66 After (Cont.)

ITEM TO CHECK/ SERVICE Coolant Level Checks

PROCEDURE


a. Check coolant level in coolant tank (Figure 20, Item 1). Maintain level between FULL mark and ADD mark on the coolant tank (Figure 20, Item 1). b. Close left front access door.

Figure 20. Coolant Tank. 67

After

0.2

0013

Hydraulic Tank a. Open left rear access door. Sight Gauge b. Clean area around hydraulic tank sight gauge and hydraulic oil filler cap. c. Maintain oil level above MIN mark on sight gauge. d. Add oil (WP 0032, Items 18 or 21) as required through filler tube. Refer to LO 5-3805-293-13 for proper oil based on ambient temperature.

0013-30

Fill cap missing.

TM 5-3805-293-10

0013


MANINTERVAL HOURS

67 After (Cont.)

0.2


PROCEDURE


Hydraulic Tank Sight Gauge

Figure 21. Hydraulic Oil Tank. 68

After

NATO Receptacle

0013

a. Ensure NATO slave receptacle cover is installed. b. Close left rear access door.

REAR

69

After

Rear of Machine

WARNING

Wear suitable eye protection and keep face and eyes away from exhausting air tank drain valves. Failure to do so may cause injury to personnel. a. Check for damage to rear blackout light, taillights, turn signal lights, and rear work light.


b. Check radiator grille and backup alarm for debris and damage.


0013-31

TM 5-3805-293-10

0013


MANINTERVAL HOURS

69 After (Cont.)

ITEM TO CHECK/ SERVICE Rear of Machine

PROCEDURE


c. Check under engine compartment for evidence of fluid leakages such as oil, coolant, fuel, and hydraulic fluid.

Class III oil or hydraulic fluid leaks are present. Any fuel leakage is evident. Damage that would impair operation is evident.

d. Check machine for obvious damage that would impair operation.


e. Check rear support brackets mounted on rear bumper for damaged or missing components.

Missing or damaged component if required for mission.

f. Check for presence of hitch pin. Missing or damaged component if required for mission.

RIGHT SIDE AND FRONT

70

After

Refrigerant Condenser and Hydraulic Oil Cooler

a. Open right rear access door. b. Check condenser and cooler for Refrigerant condenser and/ debris and damage. or hydraulic oil cooler damage. c. Close right rear access door.

0013-32

TM 5-3805-293-10

0013


MANINTERVAL HOURS

70 After (Cont.)



PROCEDURE

Refrigerant Condenser and Hydraulic Oil Cooler

Figure 22. Refrigerant Condenser and Hydraulic Oil Cooler. 71

After

Right Rear Wheels and Tires



b. Clean area around valve stems, Valve stem damaged. then remove valve stem caps.

0013-33

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS

71 After (Cont.)

ITEM TO CHECK/ SERVICE Right Rear Wheels and Tires


PROCEDURE c. Check tire inflation pressure with tire pressure gauge. Refer to WP 0002 for proper tire inflation pressures.



Loose or two or more missing lug bolts.

e. Check wheels for damage.

Wheel damaged.

72

After

Right Tandem Housing

Check for damage and leaks from right side tandem housing.

Class III oil leak or damage is evident.

73

After

Right Front Access Door

Visually check exhaust system, air intake system components, and turbocharger air tubes for looseness, damage, or missing components.

Missing, damaged, or loose components.

74

After

Frame Articulation Point Area

WARNING Hitch and steering movement can reduce clearances suddenly and cause injury to personnel. Always stop engine BEFORE working in area of hitch link. Visually check for any obstructions Damage that would impair between moving components of operation is evident. frame articulation point. Remove obstructions and check for damage.

75

After


Check ROPS for damage and loose or missing mounting bolts.

One loose or missing ROPS bolt or damage to structure.

76

After

Right Door

Check right door for damage or missing components.


77

After

Right Mirror

Check right side mirror for damage Missing or damaged or missing components. component.

78

After

Blade Work Lights

Work lights damaged or Ensure blade work lights are present and securely mounted and missing if required for not damaged. mission.

79

After

Hydraulic Cylinders

a. Check right lift cylinder and hoses for damage or leaks.

0013-34


TM 5-3805-293-10

0013


MANINTERVAL HOURS

79 After (Cont.)

80

After

ITEM TO CHECK/ SERVICE Hydraulic Cylinders

Circle Drive


PROCEDURE b. Check centershift cylinder and hoses for damage or leaks.


c. Check sideshift cylinder and hoses for damage or leaks.


a. Check all circle drive Damage to circle drive that components for damage or debris. would impair operation. Remove debris. b. Check circle drive for damage or leaks.


81

After

Scarifier

Check scarifier frame, link rod, and teeth for excessive wear, damage, or missing components (WP 0026, WP 0027).

Damage that would impair operation or missing six scarifier teeth, if required for mission.

82

After

Drawbar

a. Check drawbar and drawbar pivot point for damage.

Damage that would impair operation.

b. Check all hoses and fittings for damage or leaks.


a. Check steering linkage for cracks, distortion, or damage.

Cracks or distortion to steering linkage that would impair operation.

b. Check right front steering cylinder and hoses for damage or leaks.


83

84

After

After

Steering

Right Front Wheel and Tire


0013-35


TM 5-3805-293-10

0013


MANINTERVAL HOURS

84 After (Cont.)

85

After

ITEM TO CHECK/ SERVICE Right Front Wheel and Tire

0.2

Circle Drive Pinion Teeth

PROCEDURE


b. Clean area around valve stems, Valve stem damaged. then remove valve stem caps. c. Check tire inflation pressure with tire pressure gauge. Refer to WP 0002 for proper tire inflation pressures.



Loose, or two or more missing lug bolts.

e. Check for damage.

Wheel damaged.

a. Clean dirt and old lubricant from circle drive pinion teeth and from blade circle. b. Check pinion teeth and blade Teeth missing or damaged circle for missing or damaged gear if required for mission. teeth. c. Using GAA (WP 0032, Item 16), lubricate IAW LO 5-3805-293-13.

Figure 23. Circle Drive Lubrication.

0013-36

0013

TM 5-3805-293-10

0013



0.2

ITEM TO CHECK/ SERVICE Circle Top


PROCEDURE Apply dry film lubricant (WP 0032, Item 17) IAW LO 5-3805-293-13.

Figure 24. Circle Top Lubrication.

0013

CAB INTERIOR

87

Biweekly or Every 100 Engine Hours

Inside Cab Air Filter

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel.

CAUTION Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean or dry filter element. Failure to follow this caution may result in damage to equipment.

0013-37

TM 5-3805-293-10

0013


MANINTERVAL HOURS

87 Biweekly or (Cont.) Every 100 Engine Hours


PROCEDURE

Inside Cab Air a. Loosen two thumb screws Filter (Figure 25, Item 1) on filter cover (Figure 25, Item 2).

NOT FULLY MISSION CAPABLE IF: Filter missing if required for mission.

b. Remove filter cover (Figure 25, Item 2). c. Remove filter element and clean with either pressurized air or nonsudsing detergent. d. Rinse the filter and allow to dry. e. Inspect filter for damaged pleats or a damaged seal. If filter is damaged, replace filter. f. Install the filter element. g. Install filter cover (Figure 25, Item 2). h. Tighten two thumb screws (Figure 25, Item 1).

Figure 25. Inside Cab Air Filter.

0013-38

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS Biweekly or Every 100 Engine Hours

ITEM TO CHECK/ SERVICE Secondary Steering


PROCEDURE

WARNING Ensure immediate area around machine, specifically in front of machine, is free of all personnel. Failure to follow this warning may result in injury or death to personnel.

NOTE To protect secondary steering pump, secondary steering test will automatically shut off if switch is held in TEST position for more than 10 seconds. a. Ensure parking is engaged, transmission is in NEUTRAL, and then start engine (WP 0005). b. Push top of secondary steering switch (Figure 26, Item 1) and hold (TEST position). c. With secondary steering switch in TEST position, use left joystick to steer left, steer right, and steer center. Verify front wheels turn with each steering position. d. Release secondary steering switch. e. If alert indicator (Figure 26, Item 2) is illuminated after secondary steering switch is released, test has failed. Notify Field Level Maintenance.

Figure 26. Secondary Steering Test.

0013-39

Secondary steering fails test.

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

LEFT SIDE

89


Outside Cab Air Filter

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel.

CAUTION • Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean or dry filter element. Failure to follow this caution may result in damage to filter element. • Filter element must be completely dry before installation. Failure to follow this caution may result in damage to equipment. Biweekly or Every 100 Engine Hours

Outside Cab Air Filter

a. Loosen thumb screw (Figure 27, Item 3) and open outside cab air filter access cover (Figure 27, Item 2). b. Remove filter element (Figure 27, Item 1) and clean with either pressurized air or nonsudsing detergent. c. Rinse filter and allow to dry. d. Inspect filter for damaged pleats or a damaged seal. If filter is damaged, replace filter. e. Install filter element. f. Close outside cab air filter access cover (Figure 27, Item 2).

0013-40

Filter missing if required for mission.

TM 5-3805-293-10

0013


MANINTERVAL HOURS


ITEM TO CHECK/ SERVICE Outside Cab Air Filter


PROCEDURE g. Tighten thumb screw (Figure 27, Item 3).

Figure 27. Outside Cab Air Filter.

WARNING

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Failure to follow this warning may cause injury to personnel or damage to equipment. 90


Fuel Tank Water and Sediment

a. Articulate machine RIGHT, then shut off engine (WP 0005).

0013-41

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS


ITEM TO CHECK/ SERVICE Fuel Tank Water and Sediment

PROCEDURE


b. Place a suitable container under fuel tank.

c. Open the drain valve and allow water and sediment to drain.

Drain valve damaged or tank contains excessive water or sediment. Notify Field Level Maintenance.

d. Close drain valve. e. Start engine. Center machine articulation, then shut off engine (WP 0005).

Figure 28. Fuel Tank Drain.

0013-42

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

RIGHT SIDE AND REAR

91

Monthly

Batteries

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause death or serious injury to personnel. • DO NOT use compressed air to clean batteries. Use a clean, dry rag. a. Open right rear access door. b. Check battery holddown for looseness or damage.

Holddown is loose or damaged.

c. Inspect battery for a cracked case and evidence of leaking.

Battery case is cracked or leaks are evident.

d. Check for missing, broken, split, Damage is noted. or frayed battery cables. e. Check for damaged battery posts. f. Check electrolyte level in each cell unless equipped with maintenance-free batteries. If level is low, fill with distilled or clean drinking water to bottom of filler opening.

0013-43

Damage is noted.

TM 5-3805-293-10

0013


MANINTERVAL HOURS

91 Monthly (Cont.) 92

Monthly

ITEM TO CHECK/ SERVICE Batteries


PROCEDURE g. Close right rear access door.

Arctic Batteries (if equipped)

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause death or serious injury to personnel. • DO NOT use compressed air to clean batteries. Use a clean, dry rag. a. Disengage two arctic battery cover latches, and with the aid of an assistant, remove cover. b. Check battery holddowns for looseness or damage.

Holddown is loose or missing.

c. Inspect batteries for cracked cases and evidence of leaking.

Battery case(s) cracked or leaks are evident.

d. Check for missing, broken, split, Damage is noted. or frayed battery cables or connectors. e. Check for damaged battery posts. f. Check electrolyte level in each cell unless equipped with maintenance-free batteries. If level is low, fill with distilled or clean drinking water to bottom of filler opening.

0013-44

Damage is noted.

TM 5-3805-293-10

0013


MANINTERVAL HOURS

92 Monthly (Cont.) 93

Monthly

ITEM TO CHECK/ SERVICE Arctic Batteries (if equipped)


PROCEDURE g. With the aid of an assistant, install cover, then engage two latches.

All Systems Machine Exercise

WARNING

If machine is parked indoors, DO NOT run engine unless exhaust fumes are vented to the outside. Failure to follow this warning may cause injury or death due to carbon monoxide poisoning.

NOTE •

DO NOT exercise machine if it has been operated within the past month.

•

Ensure Before operation PMCS has been performed.

a. Start engine and run at idle for five minutes (WP 0005).

NOTE If temperature is below 32°F (0°C), operate controls prior to moving machine. b. After machine has idled for five minutes, begin to operate all controls slowly (WP 0004): 1. transmission in all ranges including reverse; 2. differential lock and center shift lock engaged and disengaged; 3. parking and service brakes applied and released; 4. steering and wheel lean from full left to full right; and 5. all grader hydraulic controls (blade lift, blade side shifts, blade centershift, blade tilt, and scarifier). c. Operate controls for another five minutes.

0013-45

TM 5-3805-293-10

0013


MANINTERVAL HOURS

93 Monthly (Cont.)

ITEM TO CHECK/ SERVICE All Systems Machine Exercise

PROCEDURE


d. Move machine and operate all controls through full motion, to bring all systems to operating temperature. e. Move machine and continue to operate all controls through full motion for 30 minutes remove bolt after machine systems have reached operating temperature. f. Stop machine and allow to idle for five minutes. g. Shut down engine. h. Perform After operation PMCS. 6. Check blade lift cylinder sockets for wear (WP 0015).

Cylinder sockets in need of adjustment if required for mission.

7. Check centershift cylinder sockets for wear (WP 0017).

Cylinder sockets in need of adjustment if required for mission.

8. Check scarifier link sockets for wear (WP 0026).

Link sockets in need of adjustment if required for mission.

9. Check moldboard wear strips (WP 0024).

Moldboard wear strips worn if required for mission.

0013-46

TM 5-3805-293-10

0013


MANINTERVAL HOURS



PROCEDURE

RIGHT SIDE AND REAR

94

Initial 500 Engine Hours (or at first oil change)

Batteries and Battery Cables

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause death or serious injury to personnel. • DO NOT use compressed air to clean batteries. Use a clean, dry rag.

CAUTION To reduce battery damage, check battery compartment for corrosion (greenish/white powder) and DO NOT jerk or pull on battery cables during visual inspection. Failure to follow this caution may result in damage to equipment. a. Open right rear access door. b. Check battery holddown for looseness or damage.

Holddown is loose or damaged.

c. Inspect battery for a cracked case and evidence of leaking.

Battery case is cracked or leaks are evident.

NOTE Original equipment batteries are maintenance-free, and do not have removable caps. d. Check for missing, broken, split, Damage is noted. or frayed battery cables.

0013-47

TM 5-3805-293-10

0013


MANINTERVAL HOURS

94 Initial 500 (Cont.) Engine Hours (or at first oil change)



PROCEDURE

Batteries and e. Check for damaged battery Battery Cables posts.

Damage is noted.

f. If equipped with nonmaintenance-free batteries, check electrolyte level in each cell. If level is low, fill with distilled or clean drinking water to bottom of filler opening. Close right rear access door. 95

Initial 500 Engine Hours (or at first oil change)

Arctic Batteries (if equipped)

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause death or serious injury to personnel. • DO NOT use compressed air to clean batteries. Use a clean, dry rag.

CAUTION To reduce battery damage, check battery compartment for corrosion (greenish/white powder) and DO NOT jerk or pull on battery cables during visual inspection. Failure to follow this caution may result in damage to equipment. a. Disengage two arctic battery cover latches, and with the aid of an assistant, remove cover. b. Check battery holddowns for looseness or damage.

0013-48

Holddown is loose or missing.

TM 5-3805-293-10

0013


MANINTERVAL HOURS

95 Initial 500 (Cont.) Engine Hours (or at first oil change)

ITEM TO CHECK/ SERVICE Arctic Batteries (if equipped)

PROCEDURE c. Inspect batteries for cracked cases and evidence of leaking.

NOT FULLY MISSION CAPABLE IF: Battery case(s) cracked or leaks are evident.

d. Check for missing, broken, split, Damage is noted. or frayed battery cables or connectors. e. Check for damaged battery posts.

Damage is noted.

f. If equipped with nonmaintenance-free batteries, inspect electrolyte level in each cell. If level is low, fill with distilled or clean drinking water to bottom of filler opening. g. With the aid of an assistant, install cover, then engage two latches.

BOTH SIDES

96

Every 500 Engine Hours or 3 Months

0.2

Tandem Drive Oil Level

a. Clean surface area around the oil check plug. b. Remove oil check plug. c. When tandem drive oil is full, oil Tandem drive oil level is should trickle from check plug low. opening. Notify Field Level Maintenance if oil level is low. d. Replace oil check plug.

0013-49

TM 5-3805-293-10

0013


MANINTERVAL HOURS

96 Every 500 (Cont.) Engine Hours or 3 Months

0.2



PROCEDURE

Tandem Drive Oil Level

Figure 29. Tandem Drive Oil Level Check. 97


Service Brake Holding Ability

WARNING

Be ALERT for personnel in the area while operating machine. Always check to ensure area is clear of personnel and obstructions before starting engine, moving machine, or lowering or raising blade. Failure to follow this warning may cause injury or death to personnel or damage to equipment.

CAUTION Allow machine to fully warm up (warm air blows from heater vents) before performing this test. Failure to follow this caution may result in damage to equipment. a. Fasten seat belt before testing brakes (WP 0005). b. Start engine (WP 0004).

0013-50

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS

97 Every 500 (Cont.) Engine Hours or 3 Months



PROCEDURE

Service Brake c. Raise blade slightly (WP 0004). Holding Ability

d. Depress transmission modulator control (WP 0004). e. Fully apply service brake (WP 0004). f. Select FIFTH SPEED FORWARD (WP 0004). g. Set throttle Hold Mode switch to MANUAL (WP 0004). h. Push and hold top of throttle SET/ACCEL switch to set engine at high idle speed. i. Gradually release transmission Service brakes do not hold. modulator control. Machine should not move and engine should stall. 98


Parking Brake Holding Ability

WARNING

Be ALERT for personnel in the area while operating machine. Always check to ensure area is clear of personnel and obstructions before starting engine, moving machine, or lowering or raising blade. Failure to follow this warning may cause injury or death to personnel or damage to equipment. a. Test brakes on hard, packed dirt. b. Fasten seat belt before testing brakes. c. Position the machine on a slope of 20 percent. d. Engage parking brake control. Release the service brake control. e. If machine moves, notify Field Level Maintenance.

0013-51

Parking brake does not hold.

TM 5-3805-293-10

0013


MANINTERVAL HOURS Every 500 Engine Hours or 3 Months

ITEM TO CHECK/ SERVICE Fuel System Prime

PROCEDURE


a. Open left front access door. b. Turn engine start switch to ON position for 2 minutes. c. Verify water separator is full of fuel. d. If water separator is not full of fuel, turn engine start switch OFF, then turn engine start switch ON. e. If water separator is still not full of fuel after 2 minutes, notify Field Level Maintenance.

Fuel system does not prime.

f. Close left front access door. 100


Exhaust System

Engine and exhaust system components may be extremely hot after engine is shut down. Do not touch any part of the exhaust system until engine has cooled down sufficiently. Failure to follow this warning may result in injury to personnel. a. Open right front access door. b. Check exhaust system pipes, clamps, and muffler for looseness, leakage, or damage. c. Close right rear access door.

0013-52

Looseness, damage or leaks are noted.

TM 5-3805-293-10

0013


MANINTERVAL HOURS


PROCEDURE


CAB

101

Every 1,000 Engine Hours or 6 Months


a. Check ROPS for drilled holes, Loose, damaged, or corrosion, loose, damaged, or missing mounting hardware missing mounting hardware. Notify is noted. Field Level Maintenance to retorque/replace mounting hardware. b. Check ROPS for any signs of cracking in base metal or welded areas.

Figure 30. ROPS Hardware.

0013-53

Any signs of damage or cracked welds are noted.

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS


PROCEDURE


LEFT SIDE

102

Every 2,000 Engine Hours or 2 Years

Cooling System Pressure Cap

WARNING

• Personal injury can result from hot coolant, steam, and alkali. • At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. • Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. • Do not attempt to tighten hose connections when the coolant is hot as the hose can come off causing burns. • Cooling system conditioner contains alkali. Avoid contact with skin and eyes. a. Open cooling system pressure cap access door (Figure 31, Item 1).

0013-54

TM 5-3805-293-10

0013


MANINTERVAL HOURS

102 Every (Cont.) 2,000 Engine Hours or 2 Years


PROCEDURE


Cooling System Pressure Cap

Figure 31. Cooling System Pressure Cap Access Door.

0013-55

0013

TM 5-3805-293-10

0013


MANINTERVAL HOURS

102 Every (Cont.) 2,000 Engine Hours or 2 Years

ITEM TO CHECK/ SERVICE Cooling System Pressure Cap

PROCEDURE


b. Clean area around cooling system pressure cap. c. Remove cooling system pressure cap. d. Clean cooling system pressure Cooling system pressure cap and inspect cap and cap seals cap is damaged. for damage. Replace cooling system pressure cap if damaged. e. Install cooling system pressure cap. f. Close cooling system pressure cap access door.

Figure 32. Cooling System Pressure Cap Seals. END OF WORK PACKAGE

0013-56

0013

TM 5-3805-293-10

CHAPTER 5 MAINTENANCE INSTRUCTIONS

4 TM 5-3805-293-10

0014


-

AIR FILTER ELEMENTS MAINTENANCE Removal, Cleaning and Inspection, Installation 0 0 1 4

INITIAL SETUP Tools and Special Tools Work Light Materials/Parts Rag, Wiping (WP 0032, Item 17)

0

0

Equipment Condition Machine parked (WP 0005) Left front access door opened (WP 0004)

0

0

0

0

0

Estimated Time to Complete 0.2 Hr

0014-1

0

0

TM 5-3805-293-10

REMOVAL

0014

00014

NOTE •

Replace the secondary air filter element if: (A) primary air filter element has been replaced three times since the secondary element has been replaced, (B) exhaust smoke is black even after primary element has been replaced, or (C) the secondary element has been in service for one year.

•

If hose comes off dust ejector, be sure to connect it during installation.

1. Disengage three latches (Figure 1, Item 1) and remove engine air filter cover (Figure 1, Item 2).

CAUTION Do not remove secondary air filter element (Figure 1, Item 4) until after the air filter housing is cleaned, and then only if it is being replaced. This will reduce the possibility of dirt entering the engine. Failure to follow this caution may result in damage to equipment. 2. Remove primary air filter element (Figure 1, Item 3).

Figure 1. Air Filter Housing and Elements. END OF TASK

0014-2

0014

TM 5-3805-293-10

CLEANING AND INSPECTION

0014

00014

1. Clean inside of air filter housing.

CAUTION •

Do not tap or strike air filter element to remove dust. Damage to air filter element may result.

•

Do not wash the air filter element.

•

Do not use air filter elements with damaged pleats, gaskets, or seals. Dirt entering engine will cause damage to engine components.

•

Do not attempt to clean a secondary air filter element.

•

Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean primary element.

•

Failure to follow these cautions may result in damage to equipment.

NOTE Use either low pressure compressed air or a vacuum to clean primary air filter element. Direct airflow from inside element and up and down pleats rather than across pleats. 2. With assistance from Field Level Maintenance personnel, clean primary element. 3. Inspect primary element for tears, holes, damaged pleats, gaskets, or seals. Discard if damaged. 4. Inspect element using a work light. Light should be visible through the element when light is placed inside element. If necessary, compare to a new element to confirm results.

CAUTION Do not remove secondary air filter element until you have the new element ready to install. This will reduce the possibility of dirt entering the engine. Failure to follow this caution may result in damage to equipment. 5. Remove secondary air filter element (Figure 1, Item 4). Discard element. END OF TASK INSTALLATION

00014

1. Install secondary air filter element (Figure 1, Item 4). 2. Install primary air filter element (Figure 1, Item 3).

0014-3

TM 5-3805-293-10

0014

INSTALLATION – CONTINUED 3. Position engine air filter cover (Figure 2, Item 1) ensuring proper orientation, and engage three latches (Figure 2, Item 2). 4. Check, and if necessary, connect hose to dust ejector (Figure 2, Item 3). 5. Close left front access door (WP 0004).

Figure 2. Air Filter Housing Cover. END OF TASK END OF WORK PACKAGE

0014-4

0014

2 TM 5-3805-293-10

0015


-

BLADE LIFT CYLINDER SOCKET INSPECTION Inspection

INITIAL SETUP Personnel

Equipment Condition - Continued Parking brake engaged (WP 0004) Blade rotated 90 degrees to frame and lowered to ground (WP 0005)

0

Two

0

0

0

Equipment Condition

0

0

Engine running (WP 0005)

0

Estimated Time to Complete

0

0

0.1 Hr INSPECTION

0

00015

NOTE Perform this inspection on both left- and right-side blade lift cylinders. 1. Operate blade lift cylinders slowly while having an assistant observe socket connections (Figure 1, Item 1) at top of circle (drawbar/blade) (Figure 1, Item 2). 2. Observe sockets for movement without circle movement, indicating adjustment required. 3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Blade Lift Cylinder Socket. END OF TASK END OF WORK PACKAGE

0015-1/(2 blank)

00015

2 TM 5-3805-293-10

0016


-

BRAKE ACCUMULATOR TEST Testing

INITIAL SETUP Equipment Condition

0

Machine parked (WP 0005)


0

0.1 Hr

TESTING

0

0

00016

WARNING •

Cold ambient temperatures could result in loss of secondary braking capability due to inadequate hydraulic accumulator nitrogen pre-charge. Loss of the secondary braking system as well as main hydraulic pressure will result in little or no braking capability and a potential for injury or death.

•

Perform a brake accumulator check anytime machine has been idle for longer than two hours below -13°F (-25°C). Failure to follow these warnings may result in injury or death to personnel.

NOTE Alert indicator will illuminate when brake accumulator pressure is below operational standard. 1. Move engine start switch to ON position. Alert indicator (Figure 1, Item 1) will come on if accumulator pressure is below operational standard.

Figure 1. Brake Accumulator Indicator.

0016-1

00016

TM 5-3805-293-10

0016

TESTING – CONTINUED

00016

2. Start engine and run for at least one minute to increase accumulator pressure. Alert indicator should go off when pressure increases. 3. Shut down engine after one minute or when indicator goes off, whichever is longer. 4. With ignition in ON position, apply and release service brake pedal a minimum of five times, to decrease accumulator pressure, until alert indicator illuminates. 5. Notify Field Level Maintenance if alert indicator illuminates before the minimum five applications of the service brake pedal. END OF TASK END OF WORK PACKAGE

0016-2

2 TM 5-3805-293-10

0017


-

CENTERSHIFT CYLINDER SOCKET INSPECTION Inspection

INITIAL SETUP Personnel

0

Two

Equipment Condition - Continued

Parking brake engaged (WP 0004) Moldboard rotated 90 degrees to frame and lowered to ground (WP 0005)

0

Equipment Condition

0

0

0

0

Engine running (WP 0005)

0


0

0

0.1 Hr INSPECTION

0

00017

1. Operate centershift cylinder (Figure 1, Item 1) slowly while having an assistant observe lower socket connection (Figure 1, Item 3) at top of circle (Figure 1, Item 4) and then upper socket connection (Figure 1, Item 2) at centershift bar (Figure 1, Item 5). 2. Observe socket for movement without circle movement. 3. If socket moves without circle moving, notify Field Level Maintenance adjustment is required.

Figure 1. Centershift Cylinder Socket. END OF TASK END OF WORK PACKAGE

0017-1/(2 blank)

00017

2 TM 5-3805-293-10

0018


8

-

CIRCUIT BREAKER RESET Reset


0

Ignition ON (WP 0004) Left front access door open (WP 0002)


0

0.1 Hr

0

0

0

RESET

00018

1. Identify correct circuit breaker for inoperative system/circuit.

Figure 1. Circuit Breakers. KEY

COMPONENT

00018

DESCRIPTION

1

20 Amp Circuit Breaker

Not used.

2


Transmission and chassis control systems.

3


Ignition circuit.

4


Engine control system.

5


Alternator circuit.

6


Main - Feeds power to fuses in cab that are turned on when ignition is in ON position.

7


Load Circuit - Feeds power to fuses in cab that are continuously on.

0018-1

TM 5-3805-293-10

0018

RESET – CONTINUED 2. Push button to reset circuit breaker. Button should remain pushed in. This indicates circuit breaker was reset successfully.

Figure 2. Fast Speed Blower Circuit Breaker.

00018

3. If button does not remain in, notify Field Level Maintenance. END OF TASK FOLLOW-ON TASKS

00018

1. Close left front access door (WP 0002). 2. Turn ignition OFF (WP 0005). END OF TASK END OF WORK PACKAGE

0018-2

2 TM 5-3805-293-10

0019

OPERATOR MAINTENANCE 0

0 1 9

-

CUTTING EDGES AND END BITS INSPECTION Inspection


0

Machine parked (WP 0005) Blade tilted forward (WP 0004) Blade lowered onto wooden blocks


0

0.1 Hr

0

0

0

0

INSPECTION

00019

1. Visually inspect cutting edges (Figure 1, Item 2), and end bits (Figure 1, Item 1) for damage or excessive wear. 2. Notify Field Level Maintenance if cutting edges or end bits are damaged or worn to within approximately 3/4 in. (19 mm) (approximately the width of your thumb) of the blade.

Figure 1. Cutting Edges and End Bits. END OF TASK END OF WORK PACKAGE

0019-1/(2 blank)

00019

2 TM 5-3805-293-10

0020


2 0

-

DOMELAMP BULB REPLACEMENT Removal, Installation

INITIAL SETUP Equipment Condition Machine parked (WP 0005)

0


0

0.2 Hr

REMOVAL

0

0

00020

1. Remove domelamp cover (Figure 1, Item 1) from domelamp. 2. Remove domelamp bulb (Figure 1, Item 2) by pushing in slightly and turning bulb left to disengage bulb locking lugs. Pull bulb out of socket. END OF TASK INSTALLATION

00020

1. Install bulb (Figure 1, Item 2) in socket, push in slightly, and turn bulb right to engage bulb locking lugs. 2. Install cover (Figure 1, Item 1).

Figure 1. Domelamp Bulb Replacement. END OF TASK END OF WORK PACKAGE

0020-1/(2 blank)

00020

4 TM 5-3805-293-10

0021


-

ETHER STARTING AID CYLINDER REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Materials/Parts

0

Rag, Wiping (WP 0032, Item 17) Cylinder, Engine Starting (Ether) (WP 0032, Item 7) Goggles, Industrial (WP 0032, Item 10) 0

0

0

0

0021-1

Equipment Condition Machine parked (WP 0005) Right front access door open

0

0

0

TM 5-3805-293-10

REMOVAL

0021

00021

1. Loosen clamp (Figure 1, Item 2).

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in a well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious injury or death to personnel. 2. Unscrew and remove ether starting aid cylinder (Figure 1, Item 1) from valve (Figure 1, Item 3). Discard empty cylinder IAW local regulations and Unit SOP. 3. Remove gasket from valve (Figure 1, Item 3). Discard gasket.

Figure 1. Ether Starting Aid Cylinder.

0021

END OF TASK CLEANING AND INSPECTION

00021

Clean valve (Figure 1, Item 3) of any dirt or debris. Inspect valve for any damage. If damage is present, notify Field Level Maintenance. END OF TASK

0021-2

TM 5-3805-293-10

INSTALLATION

0021

00021

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in a well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious injury or death to personnel. Ensure gasket is properly seated in valve prior to installing cylinder. If gasket is not properly seated, ether will escape from valve. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious injury or death to personnel.

CAUTION Make sure gasket is positioned correctly on ether starting aid cylinder before installing. Failure to follow this caution may result in damage to gasket and ether leakage. 1. Install new gasket on valve (Figure 1, Item 3). 2. Install ether starting aid cylinder (Figure 1, Item 1) on valve. 3. Tighten clamp (Figure 1, Item 2). END OF TASK FOLLOW-ON TASK

00021

Close right front access door. END OF TASK END OF WORK PACKAGE

0021-3/(4 blank)

2 TM 5-3805-293-10

0022


2

-

FUEL/WATER SEPARATOR DRAIN Drain Fuel/Water Separator

INITIAL SETUP

0

Equipment Condition


0

Machine parked (WP 0005) Left front access door open (WP 0002)

0.2 Hr

0

0

0

0

DRAIN FUEL/WATER SEPARATOR

00022

WARNING

Fuel leaking or spilled onto hot surfaces or electrical components can cause a fire. Failure to follow this warning may cause injury or death to personnel and damage to equipment. 1. Place a suitable container beneath fuel/water separator bowl (Figure 1, Item 1). 2. If hose is not already connected to bowl, connect suitable hose (Figure 1, Item 2) to nipple on bowl and place open end into container. 3. Open fuel/water separator drain valve (Figure 1, Item 3) and allow water and sediment to drain into container. 4. Close valve once all water and sediment have drained from bowl. 5. Remove container and hose. 6. Dispose of fuel IAW local regulations and Unit SOP.

Figure 1. Fuel/Water Separator. END OF TASK 0022-1

0022

TM 5-3805-293-10

FOLLOW-ON TASK

0022

00022

Close left front access door. END OF TASK END OF WORK PACKAGE

0022-2

4 TM 5-3805-293-10

0023


0 2 3

-

FUSE REPLACEMENT Replacement

INITIAL SETUP Equipment Condition Machine parked (WP 0005)

0

0

0023-1


0

0

TM 5-3805-293-10

REPLACEMENT

0023

00023

NOTE •

Replace fuses with same type and amperage rating.

•

Fuse panel is located on cab floor left of operator’s seat.

1. Identify fuse requiring replacement.

Figure 1. Fuse Identification.

0023-2

00023

TM 5-3805-293-10

0023

REPLACEMENT – CONTINUED Fuse Number

Amperage Rating

Circuit

F1

15

LH Door Wiper

F2

15

Rear Flood

F3

10

Differential Lock

F4

20

Blade Flood #2

F5

15

Powered Seat - not used

F6

10

Defroster Fan

F7

10

Accugrade

F8

--

F9

10

Pin Puller / Cushion

NOT USED

F10

15

HVAC

F11

--

F12

10

NOT USED WAVES - not used

F13

--

F14

20

Blade Floods

NOT USED

F15

15

RH Door Wiper

F16

10

Turn Relays

F17

10

Quicklube - not used

F18

--

NOT USED

F19

--

NOT USED

F20

15

Front Wiper

F21

15

Condenser Fan Relay #1

F22

--

NOT USED

F23

--

NOT USED

F24

--

NOT USED

F25

15

F26

--

Condenser Fan Relay #2 NOT USED

F27

--

F28

15

AWD Controller

NOT USED

F29

15

Implement Controller #1

F30

10

Dash Cluster

F31

10

Dome Lamp

F32

10

Backlighting

F33

--

NOT USED

F34

10

F35

--

F36

15

Horn NOT USED Implement Controller #2

F37

15

12V Converter

F38

15

Blackout

F39

--

NOT USED

F40

15

Heater Unit

0023-3

TM 5-3805-293-10

0023

REPLACEMENT – CONTINUED 2. Remove fuse panel cover (Figure 2, Item 1).

Figure 2. Fuse Panel Cover. 3. Remove blown fuse. 4. Install new fuse.

NOTE Notify Field Level Maintenance if new fuse blows when component is turned on or if same fuse blows frequently. 5. Install fuse panel cover. END OF TASK END OF WORK PACKAGE

0023-4

00023

2 TM 5-3805-293-10

0024


0 2 4

-

MOLDBOARD WEAR STRIPS INSPECTION Inspection

INITIAL SETUP Personnel Required Three Equipment Condition

0

Equipment Condition - Continued Parking brake engaged (WP 0004) Engine running (WP 0005)

0

0

0

0

0

Moldboard rotated 90 degrees to frame and lowered to ground (WP 0005)


0

0.1 Hr

INSPECTION

0

0

00024

1. Operate moldboard lift cylinders slowly while an assistant observes moldboard (Figure 1, Item 1) and circle assembly (Figure 1, Item 2). 2. Observe circle assembly for movement without moldboard movement. 3. If circle assembly moves without moldboard moving, notify Field Level Maintenance that further inspection is required.

Figure 1. Moldboard Wear Strip Inspection. END OF TASK END OF WORK PACKAGE

0024-1/(2 blank)

00024

4 TM 5-3805-293-10

0025


-

RADIATOR CLEANING Removal, Cleaning, Installation 0 0 2

5


0

Rag, Wiping (WP 0032, Item 17) Equipment Condition


0

0.4 Hr

0

0

0

Machine parked (WP 0005)

0

WARNING

Allow engine to cool before cleaning radiator. Failure to follow this warning may result in injury to personnel. REMOVAL

00025

1. Open left rear access door (Figure 1, Item 1). 2. Remove two bolts (Figure 1, Item 3) from left rear access panel (Figure 1, Item 2) and open panel.

Figure 1. Left Rear Access Door and Panel.

0025-1

0025

TM 5-3805-293-10

0025

REMOVAL – CONTINUED 3. Remove two bolts (Figure 2, Item 1) from right rear access panel (Figure 2, Item 2) and open panel. 4. Open right rear access door (Figure 2, Item 3).

Figure 2. Right Rear Access Door and Panel.

0025

END OF TASK CLEANING

00025

WARNING

Cooling fins on radiator and other cooler assemblies can be very sharp. Be sure to wear protective gloves while working near these components. Failure to follow this warning could result in injury to personnel.

CAUTION Cooling fins on radiator and other cooler assemblies are easily bent and damaged, which can result-in reduced air flow and cooling capacity. Use caution when working near these components to avoid bending cooling fins. Failure to follow this caution may result in damage to equipment. Remove dirt and debris from around radiator. END OF TASK

0025-2

TM 5-3805-293-10

INSTALLATION

0025

00025

1. Close right rear access door (Figure 2, Item 3). 2. Close right rear access panel (Figure 2, Item 2) and install two bolts (Figure 2, Item 1). 3. Close left rear access panel (Figure 3, Item 2) and install two bolts (Figure 3, Item 3). 4. Close left rear access door (Figure 3, Item 1).

Figure 3. Left Rear Access Door and Panel. END OF TASK END OF WORK PACKAGE

0025-3/(4 blank)

0025

2 TM 5-3805-293-10

0026


-

SCARIFIER LINK SOCKET INSPECTION Inspection

INITIAL SETUP Estimated Time to Complete 0.1 Hr Personnel Required

0

Equipment Condition

0

Engine running (WP 0005) Parking brake engaged (WP 0004)

0

0

0

0

0

Two

0

INSPECTION

00026

1. Slowly operate scarifier up and down, making very light contact with ground, while having an assistant observe both scarifier link sockets (Figure 1, Item 1) on each side of machine. 2. Observe sockets (Figure 1, Item 1) for movement without scarifier movement, indicating adjustment is required. 3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Scarifier Link Sockets. END OF TASK END OF WORK PACKAGE

0026-1/(2 blank)

00026

4 TM 5-3805-293-10

0027


-

SCARIFIER TOOTH AND SHANK MAINTENANCE Inspection, Replacement

INITIAL SETUP Tools and Special Tools

0

Hammer (WP 0031, Item 6) Tooth Removing Tool, Scarifier (WP 0031, Item 16) 0

0

Material/Parts

0

Goggles, Industrial (WP 0032, Item 10)

0

Equipment Condition

0

Scarifier lowered onto 4-6 in. (100-150 mm) wood blocks (WP 0005) Machine parked (WP 0005)

0

0


INSPECTION

0

0

00027

1. Visually inspect scarifier teeth (Figure 1, Item 2) for excessive wear. Replace tooth when worn to dashed line (Figure 1, Item 3) shown in illustration. 2. Visually inspect shanks (Figure 1, Item 1) for cracks or breakage. 3. Proceed to Replacement in this work package if teeth or shanks require replacement.

Figure 1. Scarifier Tooth and Shank Inspection. END OF TASK

0027-1

0027

TM 5-3805-293-10

REPLACEMENT

0027

00027

WARNING

Eye protection is required when replacing scarifier teeth to protect against flying particles. Failure to follow this warning may result in injury to personnel. 1. Using tooth removing tool (Figure 2, Item 2) and a hammer, drive tooth (Figure 2, Item 1) off shank.

Figure 2. Scarifier Tooth Removal.

0027-2

0027

TM 5-3805-293-10

REPLACEMENT – CONTINUED

0027

00027

2. Clean dirt and debris from shank.

WARNING DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may result in injury to personnel.

NOTE Be sure rubber grommet (Figure 3, Item 5) remains with lock pin. 3. Using tooth removing tool (Figure 3, Item 3) pry up lock pin (Figure 3, Item 2) and remove.

Figure 3. Scarifier Shank Lock Pin Removal. 4. Remove shank (Figure 3, Item 1) from scarifier (Figure 3, Item 4). 5. Install shank (Figure 3, Item 1) on scarifier (Figure 3, Item 4). 6. Install lock pin with grommet (Figure 3, Item 2) on scarifier (Figure 3, Item 4).

0027-3

0027

TM 5-3805-293-10

0027

REPLACEMENT – CONTINUED

WARNING

DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may result in injury to personnel. 7. Position and drive tooth (Figure 4, Item 2) onto shank (Figure 4, Item 1) to secure.

Figure 4. Scarifier Tooth and Shank Installation. END OF TASK END OF WORK PACKAGE

0027-4

0027

2 TM 5-3805-293-10

0028


-

WINDOW WASHER TANK CHECK AND FILL Check and Fill


0

Cleaning Compound, Windshield (WP 0032, Item 3) Rag, Wiping (WP 0032, Item 17)

Equipment Condition Machine parked (WP 0005)

0

0

0

0


CHECK AND FILL

0

0

00028

NOTE •

Windshield washer tank is located inside the cab and left of operator’s seat.

•

Fluid level can be viewed through transparent tank.

•

Fill opening is outside machine at rear of left door.

1. Check fluid level in tank (Figure 1, Item 1). 2. Clean tank fill cap (Figure 1, Item 2) and surrounding area. 3. Remove tank fill cap (Figure 1, Item 2). 4. Fill tank with windshield cleaning compound. 5. Install tank fill cap (Figure 1, Item 2).

Figure 1. Windshield Washer Tank. END OF TASK END OF WORK PACKAGE

0028-1/(2 blank)

0028

2 TM 5-3805-293-10

0029


0 2 9

-

WINDOW WIPER BLADE REPLACEMENT Replacement


0


Machine parked, battery disconnect switch in ON position (WP 0005) Front windshield wiper stopped in center of glass (WP 0004)

0.3 Hr

0

0

CAUTION The wiper arm is spring-loaded. Do not let go of arm after blade has been removed. Carefully lower arm to glass or glass may break.

NOTE Except for positioning front windshield wiper blade in center of glass for access, replacement is identical for all wiper blades.

0029-1

0

0

TM 5-3805-293-10

0029

REPLACEMENT

00029

NOTE If front wiper is not being replaced, skip step 1 and go directly to step 2. 1. Position windshield wiper in center of windshield as follows: a. Turn ignition switch to ON position (WP 0004). Do not start engine. b. Activate front wiper (WP 0004). c.

When wiper is positioned in center of windshield, turn ignition switch to OFF position.

2. Raise wiper arm (Figure 1, Item 1) and blade (Figure 1, Item 4) up away from glass. 3. Squeeze release tab (Figure 1, Item 2) and remove blade (Figure 1, Item 4) from arm (Figure 1, Item 1). 4. Position new blade (Figure 1, Item 4) on arm (Figure 1, Item 1) and secure pivot insert (Figure 1, Item 3) to blade.

469-0311

Figure 1. Windshield Wiper Replacement. END OF TASK END OF WORK PACKAGE

0029-2

00029

TM 5-3805-293-10

CHAPTER 6 SUPPORTING INFORMATION

2 TM 5-3805-293-10

0030


0 3 0

-

REFERENCES

SCOPE

00030

This work package lists all publication indexes, forms, field manuals, technical manuals, and other publications referenced in this manual and which apply to operation and operator maintenance of the 120M Motor Grader. PUBLICATION INDEXES

00030

The following indexes should be consulted frequently for the latest changes or revisions and for new publications relating to material covered in this technical manual. Consolidated Army Publications and Forms Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30 The Army Maintenance Management System (TAMMS) Users Manual . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8 FORMS

00030

NOTE Refer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, for instructions on the use of maintenance forms. Accident-Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518 Equipment Control Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9 Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404 Equipment Inspection Maintenance Worksheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 5988-E Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407 Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 91 Processing and Deprocessing Record for Shipment, Storage, and Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397 Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 368 Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028 Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 364 Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14 Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2258 FIELD MANUALS

00030

Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 55-30 Basic Cold Weather Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70 Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-3 Earthmoving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-434 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11 Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 21-305-20 Multiservice Helicopter Sling Load: Basic Operations and Equipment . . . . . . . . . . . . . . . . . . . . . . . . FM 4-20.197 Multiservice Helicopter Sling Load: Single-Point Load Rigging Procedures . . . . . . . . . . . . . . . . . . . . FM 4-20.198 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5

0030-1

TM 5-3805-293-10

0030

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71 Operations and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 9-207 Railway Operating and Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-21 Recovery and Battle Damage Assessment and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-30.31 Rigging Techniques, Procedures, and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-125 TECHNICAL BULLETINS

00030

Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209 TECHNICAL MANUALS

00030

Operator’s, Unit, Direct Support, and General Support Maintenance Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14 Operator’s, Unit Maintenance Manual for Laser Leveling Equipment . . . . . . . . . . . . . . . . . . TM 5-6675-348-13&P Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-3 OTHER PUBLICATIONS

00030

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-2007 Army Logistics Readiness and Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 700-138 Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100 Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items). . . . . . . . . . . CTA 50-970 Field and Garrison Furnishings and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 50-909 Lubrication Order for Motorized Road Grader Model 120M . . . . . . . . . . . . . . . . . . . . . . . . . . . .LO 5-3805-293-13 Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and Logistic Support . . .AR 70-12 END OF WORK PACKAGE

0030-2

4 TM 5-3805-293-10

0031


3 1

-

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

INTRODUCTION

0031

Scope

00031

This work package lists COEI and BII for the 120M Motor Grader to help you inventory items for safe and efficient operation of the equipment. General

00031

The COEI and BII information is divided into the following lists: a. 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 120M Motor Grader. 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. b. Basic Issue Items (BII). These essential items are required to place the 120M Motor Grader in operation, operate it, and perform emergency repairs. Although shipped separately packaged, BII must be with the 120M Motor Grader 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

00031

Column (1) Illus Number. Gives you the number of the item illustrated. Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. 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 (UOC). When applicable, gives you a code if the item you need is not the same for different models of equipment. Column (5) U/I Unit of Issue. 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.

0031-1

TM 5-3805-293-10

0031

COEI LIST

0031

NOTE There are no COEI for the 120M Motor Grader. BII LIST

0031

Table 1. Basic Issue Items (BII).

031

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER

NSN

DESCRIPTION, PART NUMBER/(CAGEC)

UOC

U/I

QTY RQR

1

5140-01-524-7563

EA

1

2

5306-01-438-9715

2

EA

1

3

4210-01-493-8162

3

EA

1

4

4910-01-545-3635

EA

1

5

–

EA

1

6

5120-00-061-8546

EA

1

Bag, Tool 211-0136/(11083) Bolt, Machine 8T0670/(11083) Extinguisher, Fire B500T/(54905) Gauge, Tire Pressure 1P-545/(11083) Glass Hammer 8Y-6379 (11083) Hammer 11677028-3/(19207)

0031-2

1

4

5

6

TM 5-3805-293-10

0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued.

031

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER 7

NSN

DESCRIPTION, PART NUMBER/(CAGEC) Lubricating Gun, Hand 1142/(1PL57) Lubrication Order LO 5-3805-293-13 (19207) Manual, Operator’s TM 5-3805-293-10 (19207) Nut, Self-Locking, Hexagon 7X0851/(11083)

UOC

U/I

QTY RQR

7

EA

1

8

EA

1

9

EA

1

10

EA

1

EA

3

EA

1

4930-00-253-2478

8 9 10

5310-01-565-6246

11

5340-01-181-2579

12

5315-01-579-3794

Padlock and Keys 5P8502/(11083) Pin, Grooved, Head (Articulation Lock Pin) 2520977/(11083)

0031-3

11

12

TM 5-3805-293-10

0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued.

031

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER 13

NSN

DESCRIPTION, PART NUMBER/(CAGEC)

UOC

U/I

QTY RQR

5120-01-335-1562

EA

1

14

5120-01-528-9361

EA

1

15

–

EA

1

16

3805-00-423-9746

EA

1

17

9905-00-148-9546

EA

1

18

5120-01-518-2402

EA

1

Pliers, Slip Joint, 9.25 in. 91ACP/(55719) Screwdriver, Flat Tip 6V-7935/(11083) Strap XXXXX (11083) Tooth Removing Tool, Scarifier 6B-3260/(11083) Warning Device Kit, Highway 11669000 (19207) Wrench, Adjustable, 12-inch long 214-7330/(11083)

END OF WORK PACKAGE

0031-4

13

14

15

16

17

18

4 TM 5-3805-293-10

0032


3 2

-

EXPENDABLE AND DURABLE ITEMS LIST

INTRODUCTION Scope

00032

This work package lists expendable and durable items you will need to operate and maintain the 120M Motor Grader. 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

00032

1.

Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use antifreeze (WP 0032, Item 1)).

2.

Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item. C - Crew F - Field

3.

Column (3) National Stock Number (NSN). This is the National Stock Number assigned to the item, which you can use to requisition it.

4.

Column (4) Item Name Description, Part Number (CAGEC). 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).

5.

Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.

0032-1

TM 5-3805-293-10

0032

Table 1. Expendable and Durable Items for the 120M Motor Grader. (1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL

NATIONAL STOCK NUMBER

ITEM NAME, DESCRIPTION, PART NUMBER/(CAGEC)

U/I

1

C

2

Antifreeze 6850-01-383-4068

1 Gallon Bottle 672 4354 (1QK63)

GL

6850-01-441-3257

5 Gallon Can A-A-52624 (58536)

CN

6850-01-383-3918

55 Gallon Drum A-A-52624 (58536)

DR

C

Cleaning Compound, Solvent, Type III MIL-PRF-680/(81349) 6850-01-474-2318 6850-01-474-2320 6850-01-474-2321

3

C

Cleaning Compound, Windshield 0854-000/(0FTT5)

C

Detergent, General Purpose, Liquid 7930-00-282-9699/(83421) 7930-00-282-9699

CN CN DR

BT

1

2

2

2

3

4

1 Gallon Can

4

1

3

16 Ounce Bottle

4

1

2

1 Gallon Can 5 Gallon Can 55 Gallon Drum

6850-00-926-2275 4

1

CN 4

5

C

Diesel Fuel, DF-1 Grade, Arctic ASTM D 975/(81346)

5

9140-00-286-5286 9140-00-286-5287 9140-00-286-5288 6

C

C

8

C

5

5

Diesel Fuel, DF-2 Grade ASTM D 975/(81346) 9140-00-286-5294 9140-00-286-5295 9140-00-286-5296

7

7

8

Bulk 5 Gallon Can 55 Gallon Drum

5

6

2910-00-646-9727 9130-01-031-5816

6

6

8

GL CN DR

Cylinder, Engine Starting (Ether) MS39254-1/(19207) Fuel, Turbine, Aviation MIL-T-83133 GR JP-8/(81349)

0032-2

5

5

5

6

Bulk 5 Gallon Can 55 Gallon Drum

6

7

5

GL CN DR 7

8

DZ GL

6

6

6

7

8

TM 5-3805-293-10

0032

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued). (1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL



U/I

9

C

9

8415-01-297-6876

9

Gloves, Chemical and Oil Protective

9

326Y/LARDC/(88009) 10

C

10

4240-00-190-6432

10

Goggles, Industrial

10

ANSIZ-1989/(80204) 11

C

Grease, Automotive and Artillery (GAA)

11

9150-01-197-7688

11

9150-01-197-7693

11

9150-01-197-7690

11

9150-01-197-7692 12

C

13

C

12

11

9150-01-089-1697

12

9150-00-186-6681 9150-00-188-9858 9150-00-189-6729 14

M-10924-B/(81349) 14 Ounce Cartridge

CA

M-10924-C/(81349) 1-3/4 Pound Can

CN

M-10924-E/(81349) 35 Pound Can

CN

13

14

Oil, Lubricating, OE/HDO-40

Oil, Lubricating, OE/HDO-15W/40 MIL-PRF-2104/(81349) 9150-01-152-4117 9150-01-152-4118 9150-01-152-4119

CN CN DR 14

15

15

11

11

11

12

13

13

13

14

DR

14

15

1 Quart Can 5 Gallon Can 55 Gallon Drum

15

GAL

11

13

55 Gallon Drum

14

15

12

1 Quart Can 5 Gallon Can 55 Gallon Drum

13

C

C

TU

Lubricant, Dry Film MIL-PRF-46147C GL-420 (72657)

13

9150-00-188-9862 15

M-10924-A/(81349) 2-1/4 Ounce Tube

Oil, Lubricating, OE/HDO-30 MIL-PRF-2104/(81349)

13

11

CN CN DR

15

15

15

16

C

Oil, Lubricating, OEA Arctic

16

9150-00-402-4478 16

9150-00-402-2372 9150-00-491-7197

16

MIL-L-46167/(81349) 1 Quart Can MIL-PRF-46167/(81349) 5 Gallon Can MIL-PRF-46167/(81349) 55 Gallon Drum

16

16

QT

16

16

GL

16

16

DR

16

16

16

16

16

0032-3

TM 5-3805-293-10

0032

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued). (1)

(2)

(3)

(4)

(5)

ITEM NUMBER

LEVEL



U/I

17

C

Rag, Wiping 7920-00-205-1711/(64067)

17

7920-00-205-1711 18

C

50 Pound Bale

17

Strap, Tiedown

18

5975-00-903-2284 5975-00-984-6582

19

C

18

Tag, Marker 9905-00-537-8954/(64067)

19

19

BL

9905-00-537-8954

END OF WORK PACKAGE

0032-4

Bundle of 20

17

18

4 Inch Length, Black, Package of 100 MS3367-4-0/(96906) 6 Inch Length, Black, Package of 100 MS3367-1-0/(96906) 13.35 Inch Minimum Length, Brown MS3367-2-1/(96906)

18

5975-00-935-5946

17

18

HD

18

18

HD

18

18

EA 19

BD

18

TM 5-3805-293-10

INDEX Subject

WP Sequence No.-Page No.

A Abbreviations/Acronyms, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advanced Operation and Operator Tips Traveling and Earth Moving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All-Wheel Drive, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0001-8 WP 0006-1 WP 0014-1 WP 0003-1

B Blade Lift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015-1 Brake Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016-1

C Centershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017-1 Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination, Threat of . . . . . . . . . . . . . . . WP 0001-10 Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018-1 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031-1 Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1 Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-1

D Description and Use of Operator Controls and Indicators Mounting and Dismounting - Main Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-1 Description and Use of Operator’s Controls and Indicators All-Wheel Drive (AWD) Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-18 Alternate Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-2 Battery Disconnect Switch and Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-24 Door Handles and Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-5 Forward Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-16 Frame Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-3 Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-19 Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-10 Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-22 Mid-Mount Scarifier Control Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-15 Military Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-23 Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-21 Right-Side Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-17 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-7 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-8 Wheel Lean Lock Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-4 Wiper/Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-20 Wrist Rests, Arm Pads, and Control Pods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-9 Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1 Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020-1

E Electrical, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6

INDEX-1

TM 5-3805-293-10

INDEX - CONTINUED Subject WP Sequence No.-Page No. Electromagnetic Pulse (EMP) Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-10 Engine Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3 Engine, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0003-2 Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-6 Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1 Improvement Recommendations (EIR), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1 Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0021-1 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1

F Fire Extinguisher, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12 Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-9 Fuel/Water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0022-1 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0023-1

G General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1

H How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

L List of Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-8 Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1

M Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1 Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0024-1

O Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-1 Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-3 High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8 Moving Machine Out of Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13 Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7 Portable Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12 Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8 Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7 Secondary Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12 Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-2 Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8 Stopping Engine if Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-1 All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-30 Centershift Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-28 Differential Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-19 Engine Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3

INDEX-2

TM 5-3805-293-10

INDEX - CONTINUED Subject


Initial Adjustment Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1 Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-18 Machine Warning Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-17 Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-7 Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-5 Articulation Lock Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-6 Scarifier Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-33 Seat, Seat Belt, and Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2 Slope Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-32 Throttle Hold Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-26 Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-20

P Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4 Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012-1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013-1

R Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025-1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030-1 Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

S Scarifier Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stowage and Decal/Data Plate Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0026-1 WP 0027-1 WP 0001-2 WP 0008-1

T Theory of Operation All-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1 All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2 Engine Starting and Machine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4 Threat of Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination . . . . . . . . . . . . . . . WP 0001-10 Traveling and Earth Moving Operations, Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . WP 0006-1 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009-1 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011-1 Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010-1

INDEX-3

TM 5-3805-293-10

INDEX - CONTINUED Subject


W Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028-1 Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022-1

INDEX-4

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 1 Rock Island Arsenal, Rock Island, IL 61299-7630

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DATE

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*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

S2^{|]

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 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION NUMBER

COLM NO.

DATE

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LINE NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER NO.

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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.)

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U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Z[ [ \ ]

PUBLICATION/FORM NUMBER

DATE

TM /-!)"/-21!-1"

!" # $"%"

ITEM NO.

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DA FORM 2028, FEB 74

FIGURE TABLE NO. NO.

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*Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE EXTENSION

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00



DATE


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TM /-!)"/-21!-1" PAGE NO.

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DATE

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) FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION/FORM NUMBER

DATE

TM /-!)"/-21!-1"

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PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE Z[ DATE

TM /-3)"5-21!-1" PAGE NO.

COLM NO.

LINE NO.



!" # $"%"

NATIONAL STOCK REFERENCE NO. NUMBER

FIGURE NO.

ITEM NO.


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SIGNATURE

USAPPC V3.00

By Order of the Secretary of the Army: GEORGE W. CASEY JR. *HQHUDO8QLWHG6WDWHV$UP\ &KLHIRI6WDII Official:

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: $/0).0, requirements for TM 5-3805-293-10.

THE METRIC SYSTEM AND EQUIVALENTS Linear Measure

Square 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

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 = 0.0386 Sq Miles

Weights

Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (°F - 32) = °C 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius 9/5 C° +32 = F°

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour

1.609

Kilometers per Hour

Miles per Hour

0.621

\

TM 5-3805-293-10 MOTOR GRADER 120M

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