Excavator John Deree

TM 5-3805-294-10
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
HYDRAULIC EXCAVATOR (HYEX)

(JOHN DEERE 240D LCR)
TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH
NSN 3805-01-573-0677 (EIC : ALL)
DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY

0$5&+
TM 5-3805-294-10
WARNING SUMMARY
This warning summary contains general safety and hazardous materials warnings that must be understood and
applied during operation and maintenance of the machine. Failure to observe these precautions or operating this
machine without training or instruction may result in serious injury or death to personnel.
FIRST AID
First aid is defined as "urgent and immediate lifesaving and other measures, which may be performed for casualties
by nonmedical personnel when medical personnel are not immediately available."
FOR FIRST AID INFORMATION, REFER TO FM 4-25.11.
EXPLANATION OF SAFETY WARNING ICONS
AIR PRESSURE - Human hand blocking air gun shows the need to reduce air
pressure before use, or debris may injure user and/or damage equipment.
BIOLOGICAL - Abstract bug symbol shows that a material may contain bacteria
or viruses that present a danger to life or health.
EAR PROTECTION - Headphones over ears show that noise level will harm ears.
ELECTRICAL - Electrical wire to hand with electricity symbol running through

human hand shows that shock hazard is present.
EXPLOSION - Human figure in front of explosion symbol shows that the material
may explode if subjected to high temperatures, sources of ignition, or high pressure.
EXTREMELY COLD SURFACE - Hand touching object with ice formed on both
shows that surface is extremely cold and can damage human tissue.
EYE PROTECTION - Person with goggles shows that material will injure the eyes.
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WARNING SUMMARY - Continued
EXPLANATION OF SAFETY WARNING ICONS - Continued
FIRE - Flame shows that material may ignite and cause burns.
FIRE EXTINGUISHER - Fire extinguisher shows that material may ignite and a fire
extinguisher should be within easy reach.
HEAVY OBJECT - Human figure stooping over heavy object shows physical injury
potential for improper lifting technique, and/or aid of assistant(s) and/or lifting device
(as required).
HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush
and harm.
HEAVY PARTS - Foot with heavy object on top shows that heavy parts can crush
and harm.
HEAVY PARTS - Moving heavy object pinning human figure against stationary
object shows that heavy, moving parts/objects present a danger to life or limb.
HEAVY PARTS - Heavy object on human figure shows that heavy parts present a
danger to life or limb.
HOT AREA - Hand over object radiating heats shows that part is hot and can burn.
MOVING PARTS - Hand with fingers caught between gears shows that the moving
parts of the equipment present a danger to life or limb.
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EXPLANATION OF SAFETY WARNING ICONS - Continued
POISON - Skull and crossbones symbol shows that dangerous gases, sprays,
vapors, liquids, or materials contain compounds that present a danger to life or
health.
PROJECTILE HAZARD - Human body with object passing through it shows that a
projectile hazard exists.
RADIATION - Three circular wedges show that the material emits radioactive
energy and can injure human tissue.
SEAT BELT USE - Human figure wearing seat belt indicates a seat belt must be
used to prevent injury or death in the event of a vehicle crash or rollover.
SKIN IRRITATION - Hand radiating shows that material can cause skin irritation.
SLICK FLOOR - Wavy line on floor with legs prone shows that slick floor presents
a danger of falling.
STEAM HAZARD - Human engulfed in steam cloud shows steam hazard exists
that could injure/burn human tissue.
VAPOR - Human figure in a cloud shows that material vapors present a danger to
life or health.
WARNING - Triangle with exclamation point within shows that a WARNING is

present that indicates a potential hazard, which may cause injury or death to
personnel.
WARNING DESCRIPTIONS
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WARNING
Perform a complete walk around the machine prior to starting the engine. Ensure sufficient
clearance from personnel and equipment for safe operation of machine. Prior to starting
engine, sound horn to alert personnel. Failure to comply may result in injury or death to
personnel.
WARNING
SAFE CLEARANCE:
• Before moving the machine or operating the boom, ensure that the boom has at least 10
ft. (3 m) of clearance from overhead wires, power lines, or structures. If lines are near to
your operating area, notify your supervisor prior to operating the boom. Failure to comply
may result in injury or death to personnel.
• Keep personnel clear of the machine when traveling. Failure to comply may result in injury
or death to personnel.
WARNING
PREVENTING CAVE IN
• Work perpendicular to or at an angle to excavation, with travel motors to the rear of the
machine. Failure to comply may result in injury or death to personnel.
• Do not drive near the edge of an excavation or trench. Failure to comply may result in
injury or death to personnel.
• Do not dig under the machine. Failure to comply may result in injury or death to personnel.
• To prevent the spoil pile from caving in the excavation, spoil piles should be placed at
least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.
WARNING
DIESEL FUEL
• Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow
open flame or sparks in the vicinity while working on any part of fuel system. Keep fire
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extinguisher within easy reach when working with fuel. Failure to comply may result in
• Spilled fuel is slippery and creates a hazardous condition. Clean up and properly dispose
of spilled fuel as soon as possible. Failure to comply may result in injury or death to
personnel.
• Do not work on fuel system when engine is hot. Failure to comply may result in injury or
death to personnel.
• Safety glasses must be worn when working on pressurized systems. Failure to comply
WARNING
LUBRICATING OIL
• Prolonged contact with lubricating oil may cause skin rash. Remove saturated clothing
immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure
to comply may result in injury or death to personnel.
• Spilled oil is slippery and creates a hazardous condition. Clean up and properly dispose
of hydraulic oil. Failure to comply may result in injury or death to personnel.
WARNING
Ensure electrical power is off prior to working on all electrical connections. Remove all jewelry
such as rings, ID tags, bracelets, etc., prior to working on or around vehicle. Jewelry and tools
can catch on equipment, contact positive electrical circuits, and cause a direct short, severe
burns, or electrical shock. Failure to comply may result in injury or death to personnel.
WARNING
LEAD-ACID BATTERIES
• Avoid battery electrolyte contact with skin, eyes, and clothing. If battery electrolyte spills,
take the following immediate action to stop burning effects:
• External - If battery electrolyte contacts skin, immediately flush affected area with cold
running water. Failure to comply may result in injury or death to personnel.
• Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15
minutes and seek immediate medical attention. IMPORTANT - If only one eye is affected,
ensure the affected eye is always kept lower than the unaffected eye, during both flushing
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and transport. This will help keep the affected eye from draining into and contaminating
the unaffected eye. Failure to comply may result in injury or death to personnel.
• Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Follow
with milk of magnesia, a beaten egg, or vegetable oil and seek immediate medical
attention. Failure to comply may result in injury or death to personnel.
• Clothing or vehicle - Immediately flush area with cold water and neutralize battery
electrolyte with baking soda or household ammonia solution. Failure to comply may result
in injury or death to personnel.
• Batteries produce explosive gases. Do not smoke or use open flame near batteries. Do
not allow hot, sparking, or glowing objects near batteries. If batteries are giving off gases,
the presence of heat, flame, or spark may cause fire and/or explosion. Failure to comply
• Wear proper eye protection, gloves, and an apron when working near batteries. Failure
WARNING
Chemical Agent Resistant Coating (CARC) paint contains isocyanate which is highly irritating
to skin and respiratory system. High concentrations of isocyanate can produce symptoms of
itching and reddening of skin, a burning sensation in the throat and nose, and watering of the
eyes. In extreme concentrations, isocyanate can cause cough, shortness of breath, pain
during respiration, increased sputum production, and chest tightness. First aid for ingestion:
do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove
contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek
medical attention. First aid for eye contact: flush with water for 15 minutes or until irritation
subsides. If symptoms persist, seek medical attention. First aid for inhalation: move to fresh
air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.
Failure to comply may result in injury or death to personnel.
WARNING
If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be
handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBC
NCO for appropriate handling or disposal instructions. Failure to comply may result in injury
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WARNING
Personnel hearing can be permanently damaged if exposed to constant high noise levels of
85 dB or greater. Failure to comply may result in injury to personnel.
WARNING
Unless otherwise specified, perform all maintenance procedures with all attachments lowered
to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may
result in injury or death to personnel.
WARNING
Do not operate bucket or any attachment if the quick attach wedge is not fully seated and the
safety lock pin is not in the locked position . The bucket or attachment may fall. One exception
to this rule is when specifically instructed to do so during the removing and installing of bucket
or attachment to and from machine. Failure to comply may result in injury or death to
personnel.
WARNING
CARBON MONOXIDE
• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives
the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide
produces symptoms of headache, dizziness, loss of muscular control, apparent
drowsiness, and coma. Permanent brain damage or death to personnel can result from
severe exposure.
• Carbon monoxide occurs in exhaust fumes from internal combustion engines. It also
occurs in exhaust fumes from engine coolant heater (arctic machine only). Carbon
monoxide can become dangerously concentrated under conditions of inadequate
ventilation. The following precautions must be observed to ensure safety of personnel
when engine of HYEX is operated:
1. DO NOT operate engine in enclosed areas without adequate ventilation.
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WARNING SUMMARY
2. DO NOT idle engine without adequate ventilation.

3. DO NOT drive machine with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area
• Expose to fresh air
• Keep person warm
• DO NOT permit physical exercise
• Administer cardiopulmonary resuscitation (CPR) if necessary
• Notify a Medic
6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection
will NOT protect you from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD
VENTILATION. Failure to comply may result in injury or death to personnel.
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LIST OF EFFECTIVE PAGES/WORK PACKAGES
NOTE: Zero in the "Change No." column indicates an original page or work package.
Date of issue for the original manual is:
Original 07 March 2011
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 54 AND TOTAL NUMBER OF
WORK PACKAGES IS 100 CONSISTING OF THE FOLLOWING:
CHANGE CHANGE
PAGE/WP NO. NO. PAGE/WP NO. NO.
Front Cover 0 WP0033 (2 pgs) 0

Warning summary (10 pgs) 0 WP0034 (6 pgs) 0
i-ii 0 WP0035 (6 pgs) 0
iii-xxiv 0 WP0036 (4 pgs) 0
How to use this manual (2 pgs) 0 Chapter 3 title page 0
Chapter 1 title page 0 Blank 0
Blank 0 WP0037 (2 pgs) 0
WP0001 (4 pgs) 0 WP0038 (2 pgs) 0
WP0002 (12 pgs) 0 WP0039 (2 pgs) 0
WP0003 (10 pgs) 0 WP0040 (2 pgs) 0
Chapter 2 title page 0 WP0041 (2 pgs) 0
WP0004 (16 pgs) 0 WP0043 (2 pgs) 0
WP0005 (8 pgs) 0 WP0044 (2 pgs) 0
WP0006 (2 pgs) 0 WP0045 (2 pgs) 0
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WP0030 (8 pgs) 0 WP0069 (2 pgs) 0
WP0031 (8 pgs) 0 WP0070 (2 pgs) 0
WP0032 (2 pgs) 0 WP0071 (2 pgs) 0
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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

CHANGE CHANGE
PAGE/WP NO. NO. PAGE/WP NO. NO.
WP0072 (2 pgs) 0 WP0087 (6 pgs) 0

WP0073 (2 pgs) 0 WP0088 (4 pgs) 0
WP0074 (2 pgs) 0 WP0089 (4 pgs) 0
WP0075 (2 pgs) 0 WP0090 (4 pgs) 0
Chapter 4 title page 0 WP0091 (4 pgs) 0
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WP0077 (40 pgs) 0 Chapter 6 title page 0
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WP0084 (8 pgs) 0 INDEX-1 - INDEX-4 0
WP0085 (4 pgs) 0 Inside back cover 0
WP0086 (2 pgs) 0 Back cover 0
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TM 5-3805-294-10
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 07 MARCH 2011
TECHNICAL MANUAL
OPERATOR’S MANUAL
FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)
NSN 3805-01-573-0677 (EIC ALL)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any errors, or if you would like to recommend any
improvements to the procedures in this publication, please let us know. The preferred method is to
submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the
Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is
https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the
AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS website
will enable us to respond more quickly to your comments and better manage the DA Form 2028
program.
You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM
Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle
Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI
48397-5000. The e-mail address is: tacomlcmc.daform2028@us.army.mil. The fax number is DSN
793-0726 or Commercial (309) 782-0726. A reply will be furnished to you.
DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.+($'48$57(56
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TABLE OF CONTENTS
Page No.
WP Sequence No.
How to Use this Manual
Chapter 1 - OPERATOR GENERAL INFORMATION
GENERAL INFORMATION.......................................................................................................................... WP 0001
Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2
EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002
Figure 1. Right View of HYEX............................................................................................................. 0002-3
Table 1. Right View of HYEX............................................................................................................. 0002-3
Figure 2. Left View of HYEX................................................................................................................ 0002-4
Table 2. Left View of HYEX................................................................................................................ 0002-4
Figure 3. Data Plates........................................................................................................................... 0002-5
Table 3. Data Plates........................................................................................................................... 0002-5
Table 4. Equipment Data.................................................................................................................... 0002-6
Figure 4. HYEX Specifications............................................................................................................ 0002-7
Table 5. HYEX Specification.............................................................................................................. 0002-7
Figure 5. HYEX Working Ranges........................................................................................................ 0002-8
Table 6. HYEX Working Ranges........................................................................................................ 0002-9
Table 7. Front Lift Capacities........................................................................................................... 0002-10
Table 8. Side Lift Capacities............................................................................................................. 0002-11
Table 9. HYEX Weights With Attachments...................................................................................... 0002-12
Table 10. Deep Dig Arm Weights....................................................................................................... 0002-12
THEORY OF OPERATION.......................................................................................................................... WP 0003
Figure 1. Electrical System Components............................................................................................ 0003-2
Table 1. Electrical System Components............................................................................................ 0003-2
Figure 2. Hydraulic System Components............................................................................................ 0003-3
Table 2. Hydraulic System Components............................................................................................ 0003-3
Figure 3. Hydraulic System Components Continued........................................................................... 0003-4
Table 3. Hydraulic System Components Continued........................................................................... 0003-4
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TABLE OF CONTENTS - Continued
Page No.
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Figure 4. Powertrain Components....................................................................................................... 0003-5
Table 4. Powertrain Components....................................................................................................... 0003-5
Figure 5. Fuel System Components.................................................................................................... 0003-6
Table 5. Fuel System Components.................................................................................................... 0003-6
Figure 6. High-Pressure Pump and Injectors...................................................................................... 0003-7
Table 6. High-Pressure Pump and Injectors...................................................................................... 0003-7
Figure 7. Cooling Package.................................................................................................................. 0003-8
Table 7. Cooling Package.................................................................................................................. 0003-8
Figure 8. Cooling System Components............................................................................................... 0003-9
Table 8. Cooling System Components............................................................................................... 0003-9
Chapter 2 - OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS........................................... WP 0004
Table 1. Front Switch Panel............................................................................................................... 0004-1
Figure 1. Front Switch Panel............................................................................................................... 0004-1
Figure 2. Front Switch Panel Continued.............................................................................................. 0004-2
Table 2. Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3
Figure 3. Heater/Air Conditioner (A/C) Controller and Radio.............................................................. 0004-3
Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued............................................. 0004-4
Table 3. Control Pedals and Levers................................................................................................... 0004-5
Figure 5. Control Pedals and Levers................................................................................................... 0004-5
Figure 6. Control Pedals and Levers Continued.................................................................................. 0004-6
Table 4. Left Console and Pilot Shutoff Lever.................................................................................... 0004-7
Figure 7. Left Console and Pilot Shutoff Lever.................................................................................... 0004-7
Table 5. Right and Left Pilot Control Levers....................................................................................... 0004-8
Figure 8. Right Pilot Control Lever...................................................................................................... 0004-8
Figure 9. Left Pilot Control Lever......................................................................................................... 0004-9
Table 6. Seat Controls...................................................................................................................... 0004-10
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Figure 10. Seat Controls...................................................................................................................... 0004-10
Table 7. Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12
Figure 11. Cab Door Release Lever and Coolant Heater Display....................................................... 0004-12
Table 8. Quick Latch Control............................................................................................................ 0004-13
Figure 12. Quick Latch Control............................................................................................................ 0004-13
Table 9. Cab Light Switch................................................................................................................ 0004-14
Figure 13. Cab Light Switch................................................................................................................ 0004-14
Table 10. Hydraulic Hose Reel........................................................................................................... 0004-15
Figure 14. Hydraulic Hose Reel........................................................................................................... 0004-15
DESCRIPTION AND USE OF MONITOR AND ALARMS........................................................................... WP 0005
Table 1. Monitor Buttons and Indicators............................................................................................. 0005-1
Figure 1. Monitor................................................................................................................................. 0005-1
Figure 2. Monitor Buttons.................................................................................................................... 0005-2
Figure 3. Main Menu............................................................................................................................ 0005-3
Figure 4. Monitor Indicators................................................................................................................. 0005-4
Table 2. Warning Indicators and Alarms............................................................................................ 0005-6
Figure 5. Warning Indicators and Alarms............................................................................................ 0005-6
Figure 6. Overload Alarm.................................................................................................................... 0005-7
ADJUSTING THE OPERATOR'S SEAT...................................................................................................... WP 0006
Figure 1. Operator's Seat Adjustments................................................................................................ 0006-1
STARTING THE ENGINE............................................................................................................................ WP 0007
Figure 1. Seat Belt............................................................................................................................... 0007-1
Figure 2. Pilot Shutoff Lever................................................................................................................ 0007-2
Figure 3. Engine Speed Dial Slow Idle................................................................................................ 0007-2
Figure 4. Key Switch ON..................................................................................................................... 0007-3
Figure 5. System Starting and Default Screen.................................................................................... 0007-3
Figure 6. Preheat Indicator.................................................................................................................. 0007-4
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Figure 7. Key Switch to START........................................................................................................... 0007-4
Figure 8. Alarm indicator..................................................................................................................... 0007-5
Figure 9. Engine Speed Dial Turned to 1/3 Position........................................................................... 0007-5
Figure 10. Return Engine Speed Dial to Slow Idle................................................................................ 0007-6
MOVING THE HYEX................................................................................................................................... WP 0008
Figure 1. Pilot Shutoff Lever Unlocked................................................................................................ 0008-1
Figure 2. Boom and Arm Raised......................................................................................................... 0008-2
Figure 3. Travel Mode Switch.............................................................................................................. 0008-2
Figure 4. Moving Forward and Backwards.......................................................................................... 0008-3
Figure 5. Right Turn............................................................................................................................. 0008-4
Figure 6. Left Turn............................................................................................................................... 0008-4
Figure 7. Counter-Rotate..................................................................................................................... 0008-5
SHUTTING DOWN THE HYEX................................................................................................................... WP 0009
Figure 1. Machine In Parked Position.................................................................................................. 0009-1
Figure 2. Auto-Idle Switch and Engine Speed Dial.............................................................................. 0009-2
Figure 3. Engine Speed Dial................................................................................................................ 0009-3
Figure 5. Key Switch Turned OFF....................................................................................................... 0009-4
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED................................................. WP 0010
Figure 1. Machine In Parked Position.................................................................................................. 0010-1
Figure 2. Auto-Idle Switch and Engine Speed Dial.............................................................................. 0010-2
Figure 5. Key Switch Turned OFF....................................................................................................... 0010-4
OPENING AND CLOSING WINDOWS....................................................................................................... WP 0011
Figure 1. Open Windshield.................................................................................................................. 0011-1
Figure 2. Raise Windshield.................................................................................................................. 0011-2
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Figure 3. Lock Windshield Open......................................................................................................... 0011-2
Figure 4. Release Windshield Latch.................................................................................................... 0011-3
Figure 5. Close Windshield.................................................................................................................. 0011-3
Figure 6. Latch Windshield.................................................................................................................. 0011-4
Figure 7. Open and Close Cab Door Window..................................................................................... 0011-4
Figure 8. Open Access Cover............................................................................................................. 0011-5
Figure 9. Open and Close Skylight Window........................................................................................ 0011-5
Figure 10. Close Access Cover............................................................................................................. 0011-6
USING THE RIFLE MOUNT........................................................................................................................ WP 0012
Figure 1. Stow Weapon In Rear Bracket............................................................................................. 0012-1
Figure 2. Stow Weapon In Front Bracket............................................................................................ 0012-2
Figure 3. Remove Weapon From Front Bracket.................................................................................. 0012-2
Figure 4. Remove Weapon From Rear Bracket.................................................................................. 0012-3
GENERAL MONITOR OPERATION............................................................................................................ WP 0013
Figure 1. Select Time Set Menu.......................................................................................................... 0013-1
Figure 2. Adjust Time.......................................................................................................................... 0013-2
Figure 3. Select Operating Conditions Menu....................................................................................... 0013-2
Figure 4. Reset Operating Conditions................................................................................................. 0013-3
REMOVING AND INSTALLING BUCKET................................................................................................... WP 0014
Figure 1. Unlock Safety Lock Pin........................................................................................................ 0014-1
Figure 2. Raise Boom.......................................................................................................................... 0014-2
Figure 3. Move Quick Latch Switch to Unlatch Position...................................................................... 0014-2
Figure 4. Extend Bucket Cylinder........................................................................................................ 0014-3
Figure 5. Retract Bucket Cylinder........................................................................................................ 0014-3
Figure 6. Lower Boom......................................................................................................................... 0014-4
Figure 7. Position Quick Latch Switch to Latch position...................................................................... 0014-4
Figure 8. Remove Quick Latch............................................................................................................ 0014-5
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Figure 9. Position Quick Latch Switch to Unlatch position.................................................................. 0014-6
Figure 10. Raise Boom for Clearance................................................................................................... 0014-6
Figure 11. Retract Wedges.................................................................................................................... 0014-7
Figure 12. Install Quick Latch................................................................................................................ 0014-7
Figure 13. Position Quick Latch Switch toLatch position....................................................................... 0014-8
Figure 15. Safety Pin Locked................................................................................................................ 0014-9
LIFTING WITH HYEX.................................................................................................................................. WP 0015
Figure 1. Lifting with Quick Latch Loop............................................................................................... 0015-2
OPERATING TECHNIQUES....................................................................................................................... WP 0016
Figure 1. Leveling Machine................................................................................................................. 0016-1
Figure 2. Add or Remove Material....................................................................................................... 0016-1
Figure 3. Arm Digging.......................................................................................................................... 0016-3
Figure 4. Bucket Digging..................................................................................................................... 0016-4
Figure 5. Planning Spoil Piles.............................................................................................................. 0016-5
Figure 6. Trenching............................................................................................................................. 0016-6
Figure 7. Cleaning Cave In.................................................................................................................. 0016-6
Figure 8. Trenching on a Slope........................................................................................................... 0016-7
Figure 9. Straight Line Trenching........................................................................................................ 0016-8
Figure 10. Back Filling........................................................................................................................... 0016-9
Figure 11. Truck Loading..................................................................................................................... 0016-10
OPERATING THE HYDRAULIC THUMB.................................................................................................... WP 0017
Figure 1. Clamping With Bucket.......................................................................................................... 0017-1
Figure 2. Clamping With Hydraulic Thumb.......................................................................................... 0017-2
Figure 3. Releasing Objects................................................................................................................ 0017-3
SELECTING AN ATTACHMENT ON THE MONITOR................................................................................ WP 0018
Figure 1. Select Attachment................................................................................................................ 0018-1
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Table 1. Attachment Selection........................................................................................................... 0018-1
Figure 2. Attachment Specification Screen......................................................................................... 0018-2
INSTALLING AND OPERATING THE CRUSH-ALL.................................................................................... WP 0019
Figure 1. Close Hydraulic Thumb Circuit............................................................................................. 0019-1
Figure 2. Move Quick Latch Switch to Unlatch Position...................................................................... 0019-2
Figure 5. Quick Latch Switch to Latch Position................................................................................... 0019-4
Figure 6. Position Crush-All................................................................................................................. 0019-4
Figure 7. Connect Auxiliary Supply Line.............................................................................................. 0019-5
Figure 8. Connect Auxiliary Return Line.............................................................................................. 0019-5
Figure 9. Crush-All Operation.............................................................................................................. 0019-7
Figure 10. Open Lid............................................................................................................................... 0019-9
Figure 11. Clearing Jam from Crush-All................................................................................................ 0019-9
Figure 12. Push Crush-All Rotor Backwards....................................................................................... 0019-10
Figure 13. Position Crush-All............................................................................................................... 0019-10
Figure 14. Disconnect Auxiliary Return Line....................................................................................... 0019-11
Figure 15. Disconnect Auxiliary Supply Line....................................................................................... 0019-12
Figure 16. Move Quick Latch Switch................................................................................................... 0019-12
Figure 17. Raise Boom........................................................................................................................ 0019-13
Figure 18. Remove Quick Latch.......................................................................................................... 0019-14
Figure 19. Move Quick Latch Switch................................................................................................... 0019-14
Figure 20. Open Hydraulic Thumb Circuit........................................................................................... 0019-15
INSTALLING AND OPERATING THE IMPACT BREAKER........................................................................ WP 0020
Figure 2. Move Quick Latch Switch..................................................................................................... 0020-2
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Figure 4. Quick Latch Wedges Retracted............................................................................................ 0020-3
Figure 7. Move Quick Latch Switch to Latch Position......................................................................... 0020-5
Figure 8. Quick Latch Wedges Engaged............................................................................................. 0020-5
Figure 9. Safety Pin to Lock Position................................................................................................... 0020-6
Figure 12. Breaker Tool Lock Bolt......................................................................................................... 0020-8
Figure 13. Insert Breaker Tool............................................................................................................... 0020-9
Figure 14. Lock Breaker Tool................................................................................................................ 0020-9
Figure 15. Breaker Operation.............................................................................................................. 0020-10
Figure 16. Tool Removal..................................................................................................................... 0020-10
Figure 17. Remove Breaker Tool........................................................................................................ 0020-11
Figure 18. Lock Breaker Tool.............................................................................................................. 0020-11
Figure 19. Disconnect Auxiliary Return Line....................................................................................... 0020-12
Figure 20. Disconnect Auxiliary Supply Line....................................................................................... 0020-12
Figure 21. Safety Pin to Unlock Position............................................................................................. 0020-13
Figure 22. Raise Boom for Clearance................................................................................................. 0020-13
Figure 23. Move Quick Latch Switch to Unlatch Position.................................................................... 0020-14
Figure 24. Quick Latch Wedges Retracted.......................................................................................... 0020-14
Figure 25. Impact Breaker Removal.................................................................................................... 0020-15
Figure 26. Quick Latch Switch to Latch Position................................................................................. 0020-15
Figure 27. Open Hydraulic Thumb Circuit........................................................................................... 0020-16
INSTALLING AND OPERATING THE COMPACTOR................................................................................. WP 0021
Figure 2. Move Quick Latch Switch..................................................................................................... 0021-3
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WP Sequence No.
Figure 4. Quick Latch Wedges Retracted............................................................................................ 0021-4
Figure 6. Position Quick Latch............................................................................................................. 0021-5
Figure 7. Quick Latch Switch to Latch Position................................................................................... 0021-5
Figure 8. Raise Boom for Clearance................................................................................................... 0021-6
Figure 9. Engage Quick Latch Wedges............................................................................................... 0021-6
Figure 10. Lock Safety Lock.................................................................................................................. 0021-7
Figure 13. Attachment Pedal Lock Release.......................................................................................... 0021-8
Figure 14. Disconnect Auxiliary Return Line......................................................................................... 0021-9
Figure 15. Connect Auxiliary Supply Line............................................................................................ 0021-10
Figure 16. Unlock Safety Lock............................................................................................................. 0021-10
Figure 17. Quick Latch Switch to Unlatch Position.............................................................................. 0021-11
Figure 18. Raise Boom........................................................................................................................ 0021-11
Figure 19. Disengage Quick Latch Wedges........................................................................................ 0021-12
Figure 20. Retract Bucket Cylinder...................................................................................................... 0021-12
Figure 21. Remove Quick Latch.......................................................................................................... 0021-13
Figure 22. Quick Latch Switch to Latch Position................................................................................. 0021-13
Figure 23. Close Hydraulic Thumb Circuit........................................................................................... 0021-14
OPERATING THE BARRIER GRAPPLE..................................................................................................... WP 0022
Figure 1. Lifting Barrier Grapple.......................................................................................................... 0022-2
OPERATING THE DEEP DIG ARM............................................................................................................ WP 0023
Figure 1. Deep Dig Control Pattern Switch.......................................................................................... 0023-1
Figure 2. Turn Auto Idle Switch On..................................................................................................... 0023-2
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WP Sequence No.
Figure 4. Turn RPM Dial...................................................................................................................... 0023-4
Figure 5. Cycle Deep Dig Arm Cylinders............................................................................................. 0023-5
MOVING MACHINE ON/OFF AN EMBANKMENT...................................................................................... WP 0024
Figure 1. Position Bucket..................................................................................................................... 0024-1
Figure 2. Upperstructure Rotated........................................................................................................ 0024-2
Figure 3. Position Bucket on Lower Level........................................................................................... 0024-3
Figure 4. Rotate Upperstructure to Upper Level.................................................................................. 0024-3
USING THE VANDAL PROTECTION KIT................................................................................................... WP 0025
Figure 1. Right Side Rear Cover Installation....................................................................................... 0025-1
Figure 2. Right Side Center Cover Installation.................................................................................... 0025-1
Figure 3. Right Side Front Cover Installation....................................................................................... 0025-2
Figure 4. Lock Bar Installation............................................................................................................. 0025-2
Figure 5. Front Door Cover Installation............................................................................................... 0025-3
Figure 6. Center Door Cover Installation............................................................................................. 0025-3
Figure 7. Lower Door Cover Installation.............................................................................................. 0025-4
Figure 8. Side Upper Glass Cover Installation.................................................................................... 0025-4
Figure 9. Side Lower Glass Cover Installation.................................................................................... 0025-5
Figure 10. Right Rear Cab Cover Installation........................................................................................ 0025-5
Figure 11. Left Rear Cab Cover Installation.......................................................................................... 0025-6
Figure 12. Left Rear Cab Cover Removal............................................................................................. 0025-6
Figure 13. Right Rear Cab Cover Removal........................................................................................... 0025-7
Figure 14. Side Lower Glass Cover Removal....................................................................................... 0025-7
Figure 15. Side Upper Glass Cover Removal....................................................................................... 0025-8
Figure 16. Lower Door Cover Removal................................................................................................. 0025-8
Figure 17. Center Door Cover Removal................................................................................................ 0025-9
Figure 18. Front Door Cover Removal.................................................................................................. 0025-9
Figure 19. Lock Bar Removal.............................................................................................................. 0025-10
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Figure 20. Right Side Front Cover Removal........................................................................................ 0025-10
Figure 21. Right Side Center Cover Removal..................................................................................... 0025-10
Figure 22. Right Side Rear Cover Removal........................................................................................ 0025-11
OPERATING THE HYDRAULIC HOSE REEL............................................................................................ WP 0026
Figure 1. Hydraulic Tool Attachment................................................................................................... 0026-1
Figure 2. Turn On Hydraulic Tool........................................................................................................ 0026-2
Figure 3. Turn Off Hydraulic Tool........................................................................................................ 0026-2
Figure 4. Hydraulic Tool Removal....................................................................................................... 0026-3
DECAL LOCATION GUIDE......................................................................................................................... WP 0027
Figure 1. Left Side, Rear Cab Window, and Top Decals..................................................................... 0027-1
Figure 2. Left Inside Door.................................................................................................................... 0027-2
Figure 3. Top Under Engine Cover...................................................................................................... 0027-2
Figure 4. Right Side on Hydraulic Reservoir....................................................................................... 0027-3
Figure 5. Right Side............................................................................................................................. 0027-3
Figure 6. Boom, Right Side, and Rear Cab Window........................................................................... 0027-4
Figure 7. Counterweight...................................................................................................................... 0027-4
Figure 8. Front and Rear Frame.......................................................................................................... 0027-5
Figure 9. Cab on Seat......................................................................................................................... 0027-5
Figure 10. Key Switch............................................................................................................................ 0027-5
Figure 11. Windshield............................................................................................................................ 0027-6
Figure 12. Side Window........................................................................................................................ 0027-6
Figure 13. Upper and Lower Right Side Window.................................................................................. 0027-7
Figure 14. Lower Right Side Window.................................................................................................... 0027-8
Figure 15. Vandal Protection Kit............................................................................................................ 0027-9
Figure 16. Upper Section Periodic Maintenance................................................................................. 0027-10
Figure 17. Lower Section Periodic Maintenance................................................................................. 0027-11
Figure 18. Ditch Cleaning Bucket........................................................................................................ 0027-12
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WP Sequence No.
Figure 19. Heavy Duty Bucket............................................................................................................. 0027-12
Figure 20. Right Side Crush-All........................................................................................................... 0027-13
Figure 21. Left Side Crush-All............................................................................................................. 0027-13
Figure 22. Output Side Crush-All......................................................................................................... 0027-14
TOWING THE HYEX................................................................................................................................... WP 0028
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................... WP 0029
OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)..................................................................... WP 0030
Figure 1. Press and Hold Back Button................................................................................................ 0030-1
Figure 2. Key Switch to ON Position................................................................................................... 0030-2
Figure 3. Release Back Button............................................................................................................ 0030-2
Figure 4. Highlight Service Menu........................................................................................................ 0030-3
Figure 5. Select Monitoring.................................................................................................................. 0030-3
Figure 6. Temperatures Displayed...................................................................................................... 0030-4
Figure 7. Start Engine.......................................................................................................................... 0030-4
Figure 9. Check Engine and Hydraulic Oil Temperatures................................................................... 0030-5
Table 1. Machine Switch Selections................................................................................................... 0030-6
Figure 10. Raise Machine...................................................................................................................... 0030-6
OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER ................................................................... WP 0031
Figure 1. Press and Hold Back Button................................................................................................ 0031-1
Figure 2. Key Switch to ON Position................................................................................................... 0031-2
Figure 3. Release Back Button............................................................................................................ 0031-2
Figure 4. Highlight Service Menu........................................................................................................ 0031-3
Figure 5. Select Monitoring.................................................................................................................. 0031-3
Figure 6. Temperatures Displayed...................................................................................................... 0031-4
Figure 7. Start Engine.......................................................................................................................... 0031-4
Figure 8. Engine Idle Speed................................................................................................................ 0031-5
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WP Sequence No.
Figure 9. Monitor Temperatures Displayed......................................................................................... 0031-5
Table 1. Machine Switch Selection.................................................................................................... 0031-6
SLAVE STARTING...................................................................................................................................... WP 0032
Figure 1. Slave Receptacle................................................................................................................. 0032-2
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)....................... WP 0033
Figure 1. Open and Close Roof Exit.................................................................................................... 0033-1
Figure 2. Emergency Exit Tool............................................................................................................ 0033-2
OPERATING THE COOLANT HEATER...................................................................................................... WP 0034
Figure 1. Coolant Heater Control Panel.............................................................................................. 0034-2
Figure 2. Adjusting Time and Day....................................................................................................... 0034-2
Figure 3. Setting Program................................................................................................................... 0034-3
Figure 4. Adjusting Run Time.............................................................................................................. 0034-4
Figure 5. Manually Start Coolant Heater............................................................................................. 0034-4
Figure 6. Manually Start Coolant Heater Continued............................................................................ 0034-5
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES............................................................................... WP 0035
Figure 1. Buckle Seat Belt................................................................................................................... 0035-1
Figure 2. Pulling Machine Up.............................................................................................................. 0035-2
Figure 3. Buckle Seat Belt................................................................................................................... 0035-3
Figure 4. Pushing Machine.................................................................................................................. 0035-3
Figure 5. Traveling Down.................................................................................................................... 0035-4
FORDING THE HYEX................................................................................................................................. WP 0036
Figure 1. Fording Line......................................................................................................................... 0036-1
Figure 3. Check Monitor...................................................................................................................... 0036-2
Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE............................................... WP 0037
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WP Sequence No.
TRAVEL ALARM DOES NOT OPERATE.................................................................................................... WP 0038
WINDSHIELD WIPER AND WASHER DO NOT OPERATE....................................................................... WP 0039
CAB DOME LIGHT DOES NOT OPERATE................................................................................................ WP 0040
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE............................................................................ WP 0041
CAB FRONT WORK LIGHTS DO NOT OPERATE..................................................................................... WP 0042
CAB REAR WORK LIGHTS DO NOT OPERATE....................................................................................... WP 0043
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE..................................................................... WP 0044
AIR CONDITIONER DOES NOT OPERATE............................................................................................... WP 0045
ENGINE CRANKS BUT DOES NOT START OR HARD TO START.......................................................... WP 0046
ENGINE WILL NOT CRANK........................................................................................................................ WP 0047
ENGINE RUNS POORLY............................................................................................................................ WP 0048
EXCESSIVE FUEL CONSUMPTION.......................................................................................................... WP 0049
EXCESSIVE OIL CONSUMPTION.............................................................................................................. WP 0050
ENGINE IDLES POORLY............................................................................................................................ WP 0051
AUTO-IDLE DOES NOT WORK.................................................................................................................. WP 0052
ENGINE NOT DEVELOPING FULL POWER.............................................................................................. WP 0053
ENGINE OIL PRESSURE LOW.................................................................................................................. WP 0054
ENGINE COOLANT TEMPERATURE ABOVE NORMAL........................................................................... WP 0055
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE....................................................... WP 0056
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE......................................................................... WP 0057
NO HYDRAULIC FUNCTIONS.................................................................................................................... WP 0058
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER............................................. WP 0059
POWER DIG DOES NOT WORK................................................................................................................ WP 0060
HYDRAULIC OIL OVERHEATS.................................................................................................................. WP 0061
HYDRAULIC OIL FOAMS............................................................................................................................ WP 0062
NO SWING FUNCTION............................................................................................................................... WP 0063
SWING FUNCTION IS JERKY.................................................................................................................... WP 0064
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WP Sequence No.
SLOW TRAVEL SPEED ONLY................................................................................................................... WP 0065
TRAVEL IS JERKY...................................................................................................................................... WP 0066
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED..................................................... WP 0067
QUICK LATCH DOES NOT OPERATE....................................................................................................... WP 0068
COMPACTOR DOES NOT OPERATE........................................................................................................ WP 0069
BREAKER DOES NOT OPERATE.............................................................................................................. WP 0070
BREAKER OPERATES SLOWLY............................................................................................................... WP 0071
CRUSH-ALL DOES NOT OPERATE........................................................................................................... WP 0072
BARRIER GRAPPLE DOES NOT HOLD LOAD......................................................................................... WP 0073
DEEP DIG DOES NOT OPERATE.............................................................................................................. WP 0074
HYDRAULIC HOSE REEL DOES NOT OPERATE..................................................................................... WP 0075
Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................... WP 0076
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0077
Table 1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES.......................... 0077-1
Figure 1. Exterior of Machine.............................................................................................................. 0077-3
Figure 2. Exterior of Machine Continued............................................................................................. 0077-4
Figure 3. Coolant Level....................................................................................................................... 0077-5
Figure 4. Engine Oil............................................................................................................................. 0077-6
Figure 5. Exhaust Components........................................................................................................... 0077-7
Figure 6. Hydraulic Reservoir Cap...................................................................................................... 0077-7
Figure 7. Fuel Tank and Fuel Level..................................................................................................... 0077-8
Figure 8. Fuel Filters............................................................................................................................ 0077-9
Figure 9. Engine Oil Filter.................................................................................................................... 0077-9
Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb................................................................ 0077-10
Figure 11. Bucket and Teeth............................................................................................................... 0077-11
Figure 12. Air Cleaner Housing and Hose Reel.................................................................................. 0077-12
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Figure 13. Batteries............................................................................................................................. 0077-13
Figure 14. Batteries Continued............................................................................................................ 0077-14
Figure 15. Cab Glass........................................................................................................................... 0077-15
Figure 16. Mirrors and Wiper Arm....................................................................................................... 0077-15
Figure 17. Cab Door, Hinges, and Latches......................................................................................... 0077-16
Figure 18. Fire Extinguisher................................................................................................................ 0077-17
Figure 19. Pedals and Levers.............................................................................................................. 0077-18
Figure 20. Pilot Control Levers............................................................................................................ 0077-19
Figure 21. Seat Belt............................................................................................................................. 0077-20
Figure 22. Ignition Switch.................................................................................................................... 0077-20
Figure 23. Monitor............................................................................................................................... 0077-21
Figure 24. Position Boom and Arm...................................................................................................... 0077-22
Figure 25. Hydraulic Oil Level Check.................................................................................................. 0077-22
Figure 26. Breaker............................................................................................................................... 0077-23
Figure 27. Compactor.......................................................................................................................... 0077-24
Figure 28. Crush-All............................................................................................................................. 0077-25
Figure 29. Barrier Grapple................................................................................................................... 0077-26
Figure 30. Deep Dig Arm and Bucket.................................................................................................. 0077-27
Figure 31. Deep Dig Bucket................................................................................................................ 0077-28
Figure 32. Ditch Cleaning Bucket........................................................................................................ 0077-29
Figure 33. Position Boom and Arm...................................................................................................... 0077-31
Figure 34. Hydraulic Oil Level Check.................................................................................................. 0077-31
Figure 35. Fuel Tank and Fuel Level Check........................................................................................ 0077-32
Figure 36. Engine Oil Check................................................................................................................ 0077-33
Figure 37. Engine Compartment......................................................................................................... 0077-33
Figure 38. Exterior of Machine Check................................................................................................. 0077-34
Figure 39. Swing Gearbox Oil Level Check......................................................................................... 0077-35
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WP Sequence No.
Figure 40. Hydraulic Pump Oil Level Check........................................................................................ 0077-36
Figure 41. Serpentine Belt Check........................................................................................................ 0077-37
Figure 42. Air Conditioner Belt Check................................................................................................. 0077-38
Figure 43. Fan Check.......................................................................................................................... 0077-39
Chapter 5 - OPERATOR MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0078
TAKING ENGINE OIL SAMPLE.................................................................................................................. WP 0079
Figure 1. Engine Oil Sampling Valve................................................................................................... 0079-1
TRACK SAG CHECK .................................................................................................................................. WP 0080
Figure 2. Rotate Track......................................................................................................................... 0080-2
Figure 3. Shut Machine Off.................................................................................................................. 0080-3
Figure 4. Measure Track Sag.............................................................................................................. 0080-4
Figure 5. Start Machine....................................................................................................................... 0080-5
Figure 6. Lower Machine..................................................................................................................... 0080-5
TIGHTENING TRACK TENSION................................................................................................................. WP 0081
Figure 1. Tighten Track....................................................................................................................... 0081-1
LOOSENING TRACK TENSION................................................................................................................. WP 0082
Figure 1. Loosen Track........................................................................................................................ 0082-1
TAKING HYDRAULIC OIL SAMPLE........................................................................................................... WP 0083
Figure 1. Hydraulic Oil Sampling Valve............................................................................................... 0083-1
CAB FUSE REPLACEMENT....................................................................................................................... WP 0084
Figure 1. Fuse Box Access Cover Removal........................................................................................ 0084-2
Figure 2. Main Fuse Box Cover Removal............................................................................................ 0084-3
Figure 3. Fuse Removal...................................................................................................................... 0084-4
Figure 4. Fuse Installation................................................................................................................... 0084-5
Figure 5. Main Fuse Box Cover Installation......................................................................................... 0084-6
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WP Sequence No.
Figure 6. Fuse Box Access Cover Installation..................................................................................... 0084-7
BUCKET TEETH REPLACEMENT.............................................................................................................. WP 0085
Figure 1. Tooth Removal..................................................................................................................... 0085-1
Figure 2. Tooth Installation.................................................................................................................. 0085-2
Figure 3. Bucket Tooth Removal......................................................................................................... 0085-2
Figure 4. Bucket Tooth Installation...................................................................................................... 0085-3
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE................................................. WP 0086
Figure 1. Drain Fuel Filter/Water Separators....................................................................................... 0086-1
Figure 2. Drain Fuel Filter/Water Separators Continued..................................................................... 0086-2
PRIMARY AND SECONDARY AIR CLEANER SERVICE.......................................................................... WP 0087
Figure 1. Cover Removal..................................................................................................................... 0087-1
Figure 2. Primary Air Cleaner Removal............................................................................................... 0087-2
Figure 3. Secondary Air Cleaner Removal.......................................................................................... 0087-2
Figure 4. Primary Air Cleaner Service................................................................................................. 0087-3
Figure 5. Air Cleaner Housing Service................................................................................................ 0087-4
Figure 6. Cover and Dust Boot Service............................................................................................... 0087-4
Figure 7. Secondary Air Cleaner Installation....................................................................................... 0087-5
Figure 8. Primary Air Cleaner Installation............................................................................................ 0087-5
Figure 9. Cover Installation.................................................................................................................. 0087-6
HYDRAULIC RESERVOIR SERVICE......................................................................................................... WP 0088
Figure 1. Hydraulic Reservoir Cover Removal.................................................................................... 0088-1
Figure 2. Hydraulic Reservoir Sight Glass........................................................................................... 0088-2
Figure 3. Hydraulic Reservoir Cover Installation................................................................................. 0088-3
FRESH AIR FILTER SERVICE.................................................................................................................... WP 0089
Figure 1. Filter Removal...................................................................................................................... 0089-1
Figure 2. Inspect Seal.......................................................................................................................... 0089-2
Figure 3. Clean Filter........................................................................................................................... 0089-3
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WP Sequence No.
Figure 4. Clean Housing...................................................................................................................... 0089-3
Figure 5. Filter Installation................................................................................................................... 0089-4
AIR CONDITIONER/HEATER FILTER SERVICE....................................................................................... WP 0090
Figure 1. Filter Removal...................................................................................................................... 0090-1
Figure 2. Clean Filter........................................................................................................................... 0090-2
Figure 3. Clean Housing...................................................................................................................... 0090-3
Figure 4. Filter Installation................................................................................................................... 0090-3
DRAINING WATER AND SEDIMENT FROM FUEL TANK......................................................................... WP 0091
Figure 1. Remove Fuel Cap................................................................................................................ 0091-1
Figure 2. Drain Hose........................................................................................................................... 0091-2
Figure 3. Drain Valve........................................................................................................................... 0091-3
Figure 4. Install Fuel Cap.................................................................................................................... 0091-4
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT..................................................................... WP 0092
Figure 1. Curtain Adjustment............................................................................................................... 0092-2
Figure 2. Clearance Check.................................................................................................................. 0092-3
Figure 3. Clamp Installation................................................................................................................. 0092-4
Figure 4. Spring Compression............................................................................................................. 0092-5
MAINTENANCE AFTER FORDING............................................................................................................ WP 0093
Figure 1. Draining Mud or Water......................................................................................................... 0093-1
Chapter 6 - OPERATOR SUPPORTING INFORMATION
REFERENCES............................................................................................................................................ WP 0094
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS........................................ WP 0095
Table 1. COMPONENTS OF END ITEM........................................................................................... 0095-2
Table 2. BASIC ISSUE ITEMS........................................................................................................... 0095-4
ADDITIONAL AUTHORIZATION LIST (AAL).............................................................................................. WP 0096
Table 1. Additional Authorization List................................................................................................. 0096-1
EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0097
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WP Sequence No.
SPECIAL PURPOSE KITS (SPK) LIST....................................................................................................... WP 0098
Table 1. Special Purpose Kits............................................................................................................ 0098-2
TROUBLESHOOTING NOTES................................................................................................................... WP 0099
HYEX TRANSPORTABILITY INSTRUCTIONS........................................................................................... WP 0100
Figure 1. Military Load Classification................................................................................................... 0100-1
Figure 2. HYEX Dimensions................................................................................................................ 0100-2
Figure 3. HYEX Transportation Data Plate.......................................................................................... 0100-3
Figure 4. HYEX Lifting and Tie Down Points....................................................................................... 0100-4
Table 1. HYEX Lift and Tie Down Information.................................................................................... 0100-4
Figure 5. M870 Loading....................................................................................................................... 0100-5
Figure 6. M870A1 Loading.................................................................................................................. 0100-6
Figure 7. M870A3 Loading.................................................................................................................. 0100-7
Figure 8. GIC Rail Clearance.............................................................................................................. 0100-8
Figure 9. Standard Cab Clearance...................................................................................................... 0100-9
Figure 10. Armored Cab Clearance..................................................................................................... 0100-10
Figure 11. HTTX Railcar Loading Overhead View.............................................................................. 0100-10
Figure 12. HTTX Railcar Loading Side View....................................................................................... 0100-11
Figure 13. C-5 Aircraft Loading........................................................................................................... 0100-11
Figure 14. C-17 Aircraft Loading......................................................................................................... 0100-12
Figure 15. Marine Loading................................................................................................................... 0100-12
Figure 16. Standard Rock Bucket........................................................................................................ 0100-13
Figure 17. Standard Ditch Cleaning Bucket........................................................................................ 0100-14
Figure 18. Standard Buckets Loaded On M870A1.............................................................................. 0100-15
Figure 19. Standard Buckets Loaded On M870A3.............................................................................. 0100-15
Figure 20. Deep Dig Arm..................................................................................................................... 0100-16
Figure 21. Deep Dig Bucket................................................................................................................ 0100-16
Figure 22. Deep Dig Ditch Cleaning Bucket........................................................................................ 0100-17
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Figure 23. Crush-All............................................................................................................................. 0100-18
Figure 24. Compactor.......................................................................................................................... 0100-18
Figure 25. Impact Breaker................................................................................................................... 0100-19
Figure 26. Barrier Grapple................................................................................................................... 0100-19
Figure 27. Crush-All On M870A1........................................................................................................ 0100-20
Figure 28. Crush-All On M870A3........................................................................................................ 0100-20
Figure 29. Standard Buckets Loaded On HTTX Railcar...................................................................... 0100-21
Figure 30. Crush-All Loaded On HTTX Railcar................................................................................... 0100-21
Figure 31. Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.................... 0100-22
Figure 32. Deep Dig Arm and Buckets Loaded On HTTX Railcar....................................................... 0100-22
Index
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TM 5-3805-294-10
HOW TO USE THIS MANUAL
This Technical Manual (TM) is designed to help you safely and efficiently operate and maintain the Hydraulic
Excavator Type 1 (HYEX), NSN 3805-01-573-0677.
Instructions are included to cover most circumstances. However, it is impossible to address every scenario you may
encounter. If you are unsure of what to do after looking in this TM, always contact your direct supervisor.
These instructions provide the user with a general knowledge of the equipment, characteristics, and operating
procedures of the HYEX. Troubleshooting and maintenance procedures are provided at crew maintenance levels.
Operating instructions for most circumstances will be provided, but the user's best guide will be knowledge of the
machine and its operation. In an emergency, a quick instinctive response based on that knowledge is essential.
This manual contains a "References" Work Package (WP). Occasionally a different Technical Manual (TM) will be
referenced in the text of this manual. A link will appear in parenthesis along with the manual that is referenced. The
link lists the references WP in the manual. This will allow the user to see the TM number and the title.
TABLE OF CONTENTS
The table of contents provides a quick reference of each WP by Title and WP number, and lists each Figure and
Table within that WP to assist in finding the required information except blank pages.
WORK PACKAGE NUMBERS
The WP number is found in the upper right corner of each page. It is also found at the bottom center of every page.
INITIAL SETUP BLOCK
The initial setup block contains information vital for the completion of the WP. In some instances, it may contain the
words "Not Applicable".
The following is a list of what is found in the initial setup block.
1. TOOLS AND SPECIAL TOOLS: These are all of the tools required to complete the tasks in the WP.
2. MATERIALS/PARTS: Any part to include oil, grease, or rags to complete the tasks in the WP.
3. PERSONNEL REQUIRED: Lists the number and Military Occupation Skill (MOS) required to complete the
WP.
4. REFERENCES: When the reference is in the same manual, it will only list the WP number. If the reference
is in a different manual, it will list the title and the WP number and will link you to the References WP for
additional information.
5. EQUIPMENT CONDITION: This is how the machine needs to be configured before starting the work.
6. TIME TO COMPLETE: Not all WP will have the time to complete listed. Normally, maintenance and servicing
procedures will list the time it should take to complete that WP.
WARNINGS, CAUTIONS, AND NOTES
Read all WARNINGS, CAUTIONS, and NOTES before performing any procedure.
Abbreviated formatted warnings are recognized when a warning in a WP has a single word that will be printed in all
caps and BOLD. The full warning is in the warning summary and should be read prior to continuing the WP.
Warning, caution, and note headings and certain essential information are printed in BOLD type for clarity. This is
critical data to ensure personal safety, prevent damage to the machine, and clarify unique data or procedures used
on the HYEX.
xxv
TM 5-3805-294-10
HOW TO USE THIS MANUAL - Continued
CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
Chapter 1 presents general information, as well as the characteristics, capabilities, and features of the HYEX. Also
included in Chapter 1 is HYEX theory of operation.
CHAPTER 2 OPERATOR INSTRUCTIONS
Chapter 2 provides operator instructions for starting and shutting off the machine, operation of standard functions,
and driving procedures. Chapter 2 also provides operator instructions for individual equipment items in the HYEX.
Included are description and location of driver's controls, fire suppression system, and the coolant heater system.
CHAPTER 3 TROUBLESHOOTING PROCEDURES
Chapter 3 provides operator level troubleshooting procedures for various malfunctions that may occur during
machine operation. The troubleshooting index is a quick reference by WP of the common malfunctions/symptoms
which you may find during the operation or maintenance of the HYEX or its attachments.
CHAPTER 4 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Chapter 4 lists operator level preventive maintenance checks and services (PMCS) that are performed before
machine operation, while it is being operated, and after the mission is completed. The PMCS table lists the item to
be checked or serviced, the check or service procedure, and the criteria for determining whether the equipment
being checked is ready for its mission.
CHAPTER 5 MAINTENANCE INSTRUCTIONS
Chapter 5 lists maintenance instructions the crew can perform on the machine.
CHAPTER 6 SUPPORTING INFORMATION
Chapter 6 lists the regulations, forms, pamphlets, field manuals, technical bulletins, and technical manuals that apply
to this manual. Chapter 6 also includes Components of End Item (COEI), Basic Issue Items (BII), Additional
Authorization List (AAL), and Expendable/Durable supplies and materials lists.
xxvi
TM 5-3805-294-10
CHAPTER 1
OPERATOR GENERAL INFORMATION

NSN 3805-01-573-0677
TM 5-3805-294-10 0001
OPERATOR MAINTENANCE
GENERAL INFORMATION
SCOPE
This manual contains instructions for operation, operator troubleshooting, and operator-performed maintenance on
the Hydraulic Excavator Type 1 (HYEX). The HYEX is used for construction operations.
MAINTENANCE FORMS AND RECORDS
Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual (WP 0094); or
AR 700-138, Army Logistics Readiness and Sustainability (WP 0094).
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)
If your HYEX needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you don’t like about your equipment. Let us know why you don’t like the design or performance. If you have Internet
access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/
aespublic.cfm (scroll down and choose "Submit Quality Deficiency Report" bar). The internet form lets you choose
to submit an EIR, a Product Quality Deficiency Report (PDQR) or a Warranty Claim Action (WCA). You may also
submit your information using an SF Form 368 (Product Quality Deficiency Report). You can send your SF Form
368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The
Army Maintenance Management System (TAMMS) Users Manual (WP 0094), and mail it to us at: Department of
the Army, U.S. Army Tank-Automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile
Road, Warren, MI 38397-5000. We will send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
Corrosion Prevention and Control (CPC) of Army materials is a continuing concern. It is important that any corrosion
problems with the HYEX be reported so that the problem can be corrected and improvements can be made to prevent
the problem in the future. While corrosion is typically associated with rusting of metals, corrosion can also include
deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of
these materials may be a corrosion problem. If a corrosion problem is identified, it can be reported using Standard
Form 368, Product Quality Deficiency report (WP 0094). Use of key words, such as corrosion, rust, deterioration,
and cracking, will ensure that the information is identified as a CPC problem.
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE
For procedures to destroy the HYEX to prevent its use by the enemy, refer to TM 750-244-6, Procedures for
Destruction of Tank-Automotive Equipment to Prevent Enemy Use (WP 0094).
PREPARATION FOR STORAGE OR SHIPMENT
Contact Field Maintenance for instructions on preparation for storage or shipment.
WARRANTY INFORMATION
The HYEX is warranted by John Deere. The warranty starts on the date found in block 23 of DA Form 2408-9,
Equipment Control Record (WP 0094). Refer to TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D
LC (WP 0094).
0001-1
TM 5-3805-294-10 0001
LIST OF ABBREVIATIONS/ACRONYMS
Table 1. List of Abbreviations/Acronyms.
Abbreviation/Acronym Description
AAL Additional Authorization List
A/C Air Conditioning
ACC Accessory
AEPS Army Electronic Product Support
A/I or A.I. Auto-Idle
AOAP Army Oil Analysis Program
BII Basic Issue Items
CAGEC Commercial and Government Entity Code
cm Centimeter
COEI Components of End Item
CPC Corrosion Prevention and Control
CTA Common Table of Allowance
E Economy
ECU Engine Control Unit
EDRS Electronic Deficiency Reports
EIR Equipment Improvement Record
FC Full-Cool
FH Full-Heat
ft Feet
gal Gallon
h Hour
HET Heavy Equipment Transport
hp Horsepower
H/P High Power
0001-2
TM 5-3805-294-10 0001
LIST OF ABBREVIATIONS/ACRONYMS - Continued
Table 1. List of Abbreviations/Acronyms - Continued.
HYEX Hydraulic Excavator
in. Inch
INT Intermittent
kg Kilogram
kohm Kilo ohm
L Liter
L/h Liter/hour
m Meter
mm Millimeter
P Power
PMCS Preventive Maintenance Checks and Services
P/N Part Number
psi Pounds per Square Inch
QDR Quality Deficiency Report
TAMMS The Army Maintenance Management System
END OF WORK PACKAGE
0001-3/4 blank
TM 5-3805-294-10 0002
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
Overview
The Hydraulic Excavator Type 1 (HYEX), NSN 3805-01-573-0677, is a 21-24 Metric Ton, diesel powered, crawler
mounted, hoe type hydraulic excavator. The HYEX digs, elevates, swings, and dumps material by action of the boom,
the arm, and the bucket.
The HYEX is powered by a John Deere six-cylinder, PowerTech, 414 cu in. (6.8 L) engine driving two identical
variable displacement, bent-axis, piston type hydraulic pumps and a fixed displacement, external gear pilot pump.
The hydraulic pumps and pilot pump combination provide the hydraulic and control pressure for the machine to
operate.
Propulsion is provided by two-speed hydraulic travel motors, (one on each side), that drive two track chains with 51
triple semi-grouser 32 in. (800 mm) wide track shoes. Each hydraulic travel motor is of a bidirectional planetary drive/
axial piston motor design with spring applied and hydraulically released travel brakes.
The HYEX upper structure is capable of continuous 360–degree rotation driven by a swing gearbox and bidirectional
swing motor mounted on top of the swing gearbox. The swing motor has a spring applied and hydraulically released
park brake. The park brake prevents the upperstructure from uncontrolled swinging. The swing park brake is released
when swing, boom, arm, or bucket function is actuated.
The boom, arm, hydraulic thumb, and bucket hydraulic cylinders provide linear actuation for their associated
components. These cylinders vary in size, but are similar in design and function.
The HYEX is configured with a retractable hydraulic hose reel, with pressure and return hoses of 50 ft (15.24 m)
length and 0.5 in. (1.27 cm) diameter, located on the cab side of the excavator to operate hand-held tools. The
hydraulic circuit is a controlled pressure source with adjustable flow rates between 8-12 GPM (30.28-45.42 LPM)
with adjustable nominal pressure limit of 2,000 psi (137.89 bar).
Operating Capabilities
The HYEX can excavate undisturbed hard, medium, and soft soils to a minimum depth range of 22-24 ft
(6.7-7.3 m). It has a minimum horizontal bucket reach at ground level of 30 ft (9.14 m). Maximum possible bucket
and stick forces are capable of penetrating and excavating very difficult soils (such as caliche) and conditions (such
as frozen soils).
The HYEX is capable of dumping into the Family of Medium Tactical Vehicles (FMTV), 5 ton with a bed height of 6
ft 9 in., to a M917 20 ton with a bed height of 10 ft 2 in. HYEX is capable of dumping into an Engineer Mission Module
(EMM) when on equal level ground.
The HYEX operates under environmental climatic conditions from -25°F to 120°F (-31.6°C to 48.8°C) without
restriction, and when required, down to -40°F (-40°C) using the coolant heater cold weather starting kit.
The HYEX will start and operate during and after fording operations in fresh water in any depth up to 40 in. (1 m)
including wave action.
Attachments for HYEX are connected to the excavator arm (stick) using the Quick Latch (a hydraulic quick connect/
disconnect coupler system) and hydraulic quick-disconnect hydraulic hose connections on the arm. The only
exception is the Deep Digging Attachment Arm that must be pinned directly to the end of the excavator arm.
0002-1
TM 5-3805-294-10 0002
Attachments
The HYEX digging and loading attachments are as follows:

• Heavy Duty Bucket (for general purpose excavating and in material, such as dense clay and light rock) with
heaped capacity of 1.5 sq yd (1.25 sq m), a 42 in. (107 cm) outside lip width, and five pick-shaped pointed
teeth.
• Heavy Duty Bucket (for use with the deep digging attachment) with heaped capacity of 0.5 sq yd (0.41 sq
m), 30 in. (76 cm) outside lip width, and four pick-shaped pointed teeth.
• Ditch Cleaning Bucket (Utility) with heaped capacity of 1.33 sq yd (1.11 sq m), 60 in. (152 cm) outside lip
width, and no teeth.
• Ditch Cleaning Bucket (Utility), (for use with the deep digging attachment) with heaped capacity of 0.75 sq
yd (0.62 sq m), 60 in. (152 cm) outside lip width, and no teeth.
• Hydraulic thumb clamp is configured to work with heavy duty bucket listed above, and is compatible with
the ditch cleaning bucket listed above. The hydraulic thumb will fully retract or fold back when not in use,
enabling unhampered use of bucket(s), and can be pinned in the fully retracted position directly to the end
of the excavator arm (stick).
• Deep Digging Attachment Arm (20 ft (6.09 m) long) is pinned directly to the end of the excavator arm (stick).
The Deep Digging Attachment Arm allows attachment of either the 30 in. (76 cm), 0.5 sq yd (0.41 sq m),
digging bucket (with teeth), or the 60 in. (152 cm), 0.75 sq yd (0.62 sq m), ditch cleaning bucket (no teeth).
This attachment uses additional counterweight and control selections to enable operation for digging to a
depth of 40 ft (12.19 m).
The HYEX construction attachments are as follows:
• Hydraulic Impact Breaker (impact energy class of 5,000 lb-ft (6779 N•m)), with operating weight between
4,500-5,500 lb (2041.2-2494.7 kg), capable of 450 full-stroke blows/min and using a tool with a diameter of
5.5 in. (13.97 cm). Each Hydraulic Impact Breaker is supplied with a moil point (1 each), a chisel point (1
each), and a blunt point (1 each).
• Hydraulic Driven Plate Compactor with a base plate size of 23.5 X 40 X 1.5 in. (59.69 X 101.6 X 3.81 cm)
operating at 2100 blows/min and 15,250 lbs (6917.28 kg) of impulse force.
• Hydraulic Crushing Attachment (Crush-All) is capable of operating as a loader, hopper, feeder, crusher, and
conveyor. The Crush-All is capable of crushing concrete with and without rebar, stone, asphalt, brick, block,
and debris with a minimum size of 24 in. wide x 24 in. long x 10 in. thick (60.96 cm wide x 60.96 cm long x
25.4 cm thick) and has minimum hopper capacity of 0.6 cu. yd (0.45 cu m). The Crush-All has reversible
strike plates to increase the operational serviceability interval.
• Barrier Grapple is capable of lifting, moving, and emplacing barriers weighing 400-16,000 lb (181.4-7257.4
kg) with a barrier width of 6-12 in. (15.24-30.48 cm). The barrier grapple has a fully automatic actuator which
allows the barriers to be lifted, latched, placed, and unlatched automatically without the aid of an assistant.
0002-2
TM 5-3805-294-10 0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
4 3 2 1 9
HYEX00104
Figure 1. Right View of HYEX.
Table 1. Right View of HYEX.
1 FUEL TANK. Contains JP-8, diesel, or other NATO-approved fuels for engine operation.
2 HYDRAULIC RESERVOIR. Contains hydraulic oil for the hydraulic system.
3 HYDRAULIC PUMPS. Draws hydraulic fluid from the hydraulic reservoir and provides hydraulic
pressure and control pressure to the rest of the hydraulic system.
4 COUNTERWEIGHT. Adds stability to the machine during digging and lifting operations.
5 ARM CYLINDER. Extends and retracts the arm.
6 BOOM CYLINDERS. Raises and lowers the boom.
7 ATTACHMENT CYLINDER. Curls the bucket while digging and allows for dumping.
8 HYDRAULIC THUMB CYLINDER. Extends and retracts the hydraulic thumb.
9 TOOL BOX. Used for storage of Basic Issue Items (BII).
0002-3
TM 5-3805-294-10 0002
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
20 10
17 16
11
12 19
16
18
15
13 14 HYEX00105
Figure 2. Left View of HYEX.
Table 2. Left View of HYEX.
10 ENGINE. Drives the hydraulic pumps and the pilot pump.
11 RADIATOR. Contains coolant which provides engine cooling.
12 BATTERIES. Two 12-volt batteries provide current for the electrical system.
13 CAB. All digging and travel functions are controlled by the operator.
14 TRAVEL MOTORS. Drives the machine forward or backward and provides turning capability.
15 BUCKET. Used for digging operations.
16 ARM. Used to connect quick latch or different attachments depending on mission.
17 HYDRAULIC THUMB. Used with the bucket attachment to clamp and lift.
18 UNDERCARRIAGE. Consists of the lower structure and the track assemblies.
19 UPPERSTRUCTURE. Consists of the upperstructure, engine/hydraulic pump compartment, cab,

boom and arm, and accessories.
20 HYDRAULIC HOSE REEL. Quick attach hose reel used to power hydraulic tools and accessories.
0002-4
TM 5-3805-294-10 0002
IDENTIFICATION PLATES
Maintain, in a secure location, an up-to-date inventory of all product and component serial numbers.
Regularly verify that identification plates have not been removed. Report any evidence of tampering to appropriate
agencies and order duplicate plates.
Mark your machine with your own numbering system and take color photographs from several angles of each plate.
22
21
HYEX01506
Figure 3. Data Plates.
Table 3. Data Plates.
21 IDENTIFICATION PLATE. The identification plate has the model, serial number, registration number,
manufacture's name and the warranty information on it.
22 SERIAL NUMBER PLATE. Has the machine serial on it.
0002-5
TM 5-3805-294-10 0002
EQUIPMENT DATA
Table 4. Equipment Data.
ENGINE:
Model PowerTech
Manufacturer John Deere
Horsepower (2,000 rpm) 177 hp (132 kW)
Number of Cylinders 6
Displacement 414 cu in. (6.8 L)
CAPACITIES:
Fuel Tank 132 gal (500 L)
Cooling System 7.9 gal (29.9 L)
Engine Oil (including oil filter) 6.5 gal (24.6 L)
Hydraulic Reservoir 64.2 gal (243 L)
Hydraulic System 74 gal (280 L)
Swing Gearbox 2.4 gal (9.1 L)
Travel Gearbox (each) 2.1 gal (7.9 L)
Pump Drive Gearbox 1.2 qt (1.1 L)
0002-6
TM 5-3805-294-10 0002
EQUIPMENT DATA - Continued
5 4
6 12
9 7
1
8
2
10
11
HYEX00106
Figure 4. HYEX Specifications.
Table 5. HYEX Specification.
ITEM DESCRIPTION MEASUREMENT SPECIFICATION
1 Sprocket Center to Idler Center Distance 12 ft 7 in. (3840 mm)
2 Undercarriage Length 15 ft 3 in. (4640 mm)
3 Counterweight Clearance Distance 3 ft 7 in. (1090 mm)
4 Rear End Swing Radius Distance 9 ft 8 in. (2940 mm)
5 Upper Structure Width (excluding back Distance 9 ft 6 in. (2890 mm)

mirrors)
6 Cab Height 9 ft 11 in. (3020 mm)
7 Minimum Ground Clearance Distance 1 ft 6 in. (460 mm)
8 Center of Sprocket to Center of Sprocket Distance 8 ft 6 in. (2590 mm)
9 Track Shoes Width 32 in. (800 mm)
10 Undercarriage Width 133 in. (2780 mm)
11 Machine Overall Length 399 in. (10134 mm)
12 Machine Transport Height 122 in. (3099 mm)
13 Machine Shipping Weight 66,000 lb (29937 kg)
0002-7
TM 5-3805-294-10 0002
4 5
1 9
2
6 7 8
HYEX00107
Figure 5. HYEX Working Ranges.
0002-8
TM 5-3805-294-10 0002
Table 6. HYEX Working Ranges.
ITEM DESCRIPTION MEASUREMENT SPECIFICATION
1 Maximum Digging reach Distance 35 ft 6 in. (10810 mm)
2 Maximum Digging reach at Ground Level Distance 34 ft 11 in. (10640 mm)
3 Minimum Swing Radius Radius 11 ft 4 in. (3460 mm)
4 Maximum Cutting Height Height 34 ft 6 in. (10520 mm)
5 Maximum Dumping Height Height 24 ft 9 in. (7540 mm)
6 Maximum Digging Depth Depth 24 ft 7 in. (7490 mm)
7 Maximum Digging Depth (flat bottom) Depth 24 ft 1 in. (7330 mm)
8 Maximum Vertical Wall Depth 21 ft 9 in. (6630 mm)
9 Tail Swing Radius Radius 9 ft 8 in. (2940 mm)
0002-9
TM 5-3805-294-10 0002
NOTE
Ratings are at quick latch lift hook, using standard counterweight, situated on firm, level,
uniform supporting surface, and with the machine configured with the standard arm and
bucket. Ratings do not apply to any attachments.
HYEX is equipped with an overload alarm. When lifting over the side and the weight limit is exceeded the alarm will
sound until weight limit is within range.
Table 7. Front Lift Capacities.
LIFTING OVER FRONT IN 1,000 lb (454 kg)
ft (m) 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 25 (7.62) 30 (9.14)
20 (6.10) 7.55 lb
(3.42 kg)*
15 (4.57) 8.52 lb 8.61 lb 6.26 lb

(3.86 kg)* (3.90 kg)* (2.84 kg)*
10 (3.05) 14.69 lb 11.56 lb 10.05 lb 8.09 lb

(6.66 kg)* (5.24 kg)* (4.56 kg)* (3.66 kg)*
5 (1.25) 20.76 lb 14.49 lb 11.62 lb 9.68 lb

(9.41 kg)* (6.57 kg)* (5.27 kg)* (4.39 kg)
Ground Line 24.56 lb 16.88 lb 12.79 lb 9.46 lb

(11.14 kg)* (7.65 kg)* (5.80 kg) (4.29 kg)
-5 (-1.52) 13.06 lb 25.71 lb 17.90 lb 12.48 lb 9.31 lb

(5.92 kg)* (11.66 kg)* (8.11 kg) (5.66 kg) (4.22 kg)
-10 (-3.05) 15.60 lb 22.51 lb 25.00 lb 17.77 lb 12.39 lb

(7.07 kg)* (10.21 kg)* (11.33 kg)* (8.06 kg) (5.62 kg)
-15 (-4.57) 29.63 lb 22.54 lb 16.71 lb 12.31 lb

(13.43 kg)* (10.22 kg)* (7.57 kg)* (5.58 kg)
-20 (6.10) 17.28 lb 12.10 lb

(7.83 kg)* (5.48 kg)*
* Hydraulically Limited Capacity
0002-10
TM 5-3805-294-10 0002
Table 8. Side Lift Capacities.
LIFTING OVER SIDE IN 1,000 lb (454 kg)
ft (m) 5 (1.52) 10 (3.05) 15 (4.57) 20 (6.10) 25 (7.62) 30 (9.14)
20 (6.10) 7.55 lb
(3.42 kg)*
15 (4.57) 8.52 lb 8.61 lb 6.26 lb

(3.86 kg)* (3.90 kg)* (2.84 kg)*
10 (3.05) 14.69 lb 11.56 lb 8.88 lb 6.29 lb

(6.66 kg)* (5.24 kg)* (4.02 kg) (2.85 kg)
5 (1.52) 18.90 lb 12.10 lb 8.39 lb 6.04 lb

(8.57 kg) (5.48 kg) (3.80 kg) (2.73 kg)
Ground Line 17.62 lb 11.35 lb 7.96 lb 5.81 lb

(7.99 kg) (5.14 kg) (3.61 kg) (2.63 kg)
-5 (-1.52) 13.06 lb 17.16 lb 10.92 lb 7.68 lb 5.67 lb

(5.92 kg)* (7.78 kg) (4.95 kg) (3.48 kg) (2.57 kg)
-10 (-3.05) 15.60 lb 22.51 lb 17.15 lb 10.80 lb 7.59 lb

(7.07 kg)* (10.21 kg)* (7.77 kg) (4.89 kg) (3.44 kg)
-15 (-4.57) 29.63 lb 17.46 lb 10.96 lb 7.77 lb

(13.44 kg)* (7.91 kg) (4.97 kg) (3.52 kg)
-20 (6.10) 17.28 lb 11.53 lb

(7.83 kg)* (5.22 kg)
* Hydraulically Limited Capacity
0002-11
TM 5-3805-294-10 0002
HYEX weights with attachments.
Table 9. HYEX Weights With Attachments.
Machine Weight Attachment and Weight Total weight
66,000 (29937 kg) Barrier Grappler 750 lb (341 kg) 66,750 lb (30277 kg)
66,000 (29937 kg) Compactor 840 lb (381 kg) 66,840 lb (30318 kg)
66,000 (29937 kg) Heavy Duty Bucket 1,600 lb (726 kg). 67,600 lb (30663 kg)
66,000 (29937 kg) Ditching Bucket 1,600 lb (726 kg) 67,600 lb (30663 kg)
66,000 (29937 kg) Breaker 4,900 lb (2223 kg) 70,900 lb (32160 kg)
66,000 (29937 kg) Crush-All 5,800 lb (2631 kg) 71,800 lb (32568 kg)
Deep dig arm weighs 3,000 lb (1361 kg) and additional counterweight with four mounts and two spacer plates for
deep dig arm operation weigh 1,550 lb (703 kg).
Table 10. Deep Dig Arm Weights.
Machine/Deep Dig Arm/ Attachment and Weight Total Weight

Counterweight
67,550 lb (30640 kg) Deep Dig Bucket 1,000 lb (454 kg) 68,550 lb (31094 kg)
67,550 lb (30640 kg) Deep Ditch Cleaning Bucket 1,000 lb 68,550 lb (31094 kg)
(454 kg)
END OF WORK PACKAGE
0002-12
TM 5-3805-294-10 0003
THEORY OF OPERATION
SCOPE
This section explains how components of the HYEX work together. A functional description is given for the engine,
Electronic Control Unit (ECU), fuel system, cooling system, electrical system, and hydraulic system.
Engine
The engine is a John Deere 6068H PowerTech Plus, 6.8L, 6-cylinder diesel engine. The 6068H includes a
turbocharger, electronic control unit, 4-valve per cylinder head, electronic fuel injectors, and a high-pressure common
rail fuel system. The 6068H is air-to-air after cooled to help reduce exhaust emissions while maintaining low-speed
torque. The engine application includes a hydraulically-driven cool-on-demand fan system.
ECU
The electronic control system serves as an engine governor, controlling the engine speed by delivering fuel, in
precise amounts, and at precise time according to a given set of engine conditions in relation to piston position. In
order to achieve this, the control system performs the following functions:
• Constantly monitors engine operating conditions
• Performs system diagnosis
• Notify operator of machine faults through the monitor
• Can derate or shut down engine to prevent damage
0003-1
TM 5-3805-294-10 0003
ECU - Continued
Electrical System
3 2
1
HYEX01511
Figure 1. Electrical System Components.
Table 1. Electrical System Components.
1 Batteries The batteries provide power for the electrical circuits. Two 12-volt batteries are
connected in series to provide 24-volt starting power.
2 Alternator The alternator provides 28-volt, 80-amp. current to charge the batteries and
operate the electrical system.
3 Starter Motor Part of the starting circuit, the starter motor is used to turn the engine flywheel
fast enough to start the engine.
4 Slave Receptacle The slave receptacle can be used to charge the batteries and slave start the
engine from an external power source. The slave receptacle can also be used
to charge and slave start other equipment.
5 Fuse Panel The fuse panel provides centrally located fuses that will open the battery circuit
if there is a shorted, grounded wire or excessive current draw by a defective
component in the corresponding circuit. When the circuit is open, no current
will flow through the electrical system. Fuses are easily replaced. If a fuse
continually trips, the affected component or vehicle electrical system requires
repair.
0003-2
TM 5-3805-294-10 0003
Hydraulic System
10 11
14
13
15
16
9 12
7 8
17
HYEX01512
6
Figure 2. Hydraulic System Components.
Table 2. Hydraulic System Components.
6 Main Pumps The HYEX has two main hydraulic pumps that supply hydraulic oil for all
functions including boom, arm, bucket, swing, and travel.
7 Pilot Pump The pilot pump is a small gear pump that keeps oil moving through the pilot
system. It also provides the pressure to move the spools in the main hydraulic
valve and to release the spring-applied hydraulically-released swing and park
brakes.
8 Hydraulic Reservoir The hydraulic reservoir is pressurized ensuring that hydraulic oil is always
supplied to the pumps.
9 Main Control Valve The control valve consists of two monoblock valves referred to as the left control
valve and right control valve. There is a spool in each valve to control the boom,
arm, and travel functions. All other functions are supplied by a single spool in
one or the other of the valves. All spools are moved by pilot oil. Each valve
section controls the flow rate and direction for its hydraulic circuit.
0003-3
TM 5-3805-294-10 0003
Hydraulic System - Continued
10 11
14
13
15
16
9 12
7 8
17
HYEX01512
6
Figure 3. Hydraulic System Components Continued.
Table 3. Hydraulic System Components Continued.
10 Pilot Signal Manifold The pilot signal manifold is in the pilot system between the pilot control valves
and the control valve and regulators. The manifold receives a pilot signal from
the pilot control valves and sends the signal on multiple paths simultaneously
so there is little lag between operation of the pilot control valves, pump stroke,
and function movement.
11 Swing Motor The swing motor uses hydraulic pressure supplied by the pumps to make the
upper structure rotate. It has a spring-applied hydraulically-released swing
brake. The swing brake engages as soon as the swing controls are released.
12 Rotary Manifold The rotary manifold allows the upper structure of the machine to rotate relative
to the undercarriage while still supplying hydraulic oil to the travel motors.
13 Boom Cylinders The boom cylinders are attached to the main frame and the boom. When
activated they raise and lower the boom.
14 Arm Cylinder The arm cylinder is attached between the boom and the arm. When activated,
this cylinder moves the arm in and out.
0003-4
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Hydraulic System - Continued
Table 3. Hydraulic System Components Continued - Continued.
15 Hydraulic Thumb The hydraulic thumb cylinder is attached between the arm and the thumb.
Cylinder When activated, this cylinder extends and retracts the hydraulic thumb. The
hydraulic thumb cylinder circuit can be closed to provide the hydraulic power
to operate the crush-all, breaker, compactor and deep dig arm accessories.
16 Bucket Cylinder The bucket cylinder is attached between the arm and the quick latch. When
activated, this cylinder extends and curls the bucket or attachments.
17 Load Holding Valves Reduced leakage valves are used in the boom head-end circuit and arm rod-
end circuit. The function of a reduced leakage valve is to reduce cylinder drift
by stopping leakage from the cylinder back through the control valve.
Powertrain
21
18
20
19
HYEX01513
Figure 4. Powertrain Components.
Table 4. Powertrain Components.
18 Track Chain Adjuster The track chain adjuster is located between the frame and the track chain idler.
Grease is added or removed to adjust the track sag. The recoil spring is located
with the track chain adjuster and absorbs shocks to the tracks and track chain
idler.
19 Track The track assembly consists of the chain and shoes. The travel motor drives
the track to move the machine.
20 Rollers The machine has two carrier rollers and nine lower track rollers on each side
of the machine. The rollers guide the tracks and keep the tracks in contact with
the ground.
21 Travel Motor The travel motors are located inside the tracks to prevent damage during
operation. The travel system has a spring-applied hydraulically-released
parking brake. The parking brake engages as soon as the travel controls are
released.
0003-5
TM 5-3805-294-10 0003
Fuel System
22 24
27
23
25 26
HYEX01514
28
Figure 5. Fuel System Components.
Table 5. Fuel System Components.
22 Fuel Transfer Pump The fuel transfer pump pulls fuel from the fuel tank through the water separator
and sends it through the fuel filters to the high-pressure fuel injection pump.
23 Primary Fuel/Water The primary water separator keeps large particles and contaminants from
Separator entering the high-pressure fuel pump.
24 Secondary Fuel/Water The secondary water separator keeps small particles and contaminants from
Separator entering the pressure fuel pump.
25 Lubricity Canister The lubricity canister is a spin-on canister with a lubricant that is slowly released
into the fuel. To enable use of all types of diesel fuels.
26 Fuel Tank The fuel tank has 132 gal (500 liter) capacity and is equipped with a low fuel
level alarm and vented fill cap.
27 Fuel Tank Strainer The strainer is designed to keep debris from entering the fuel system.
28 Fuel Tank Drain Valve The drain valve is used to remove water and debris from the fuel tank.
0003-6
TM 5-3805-294-10 0003
Fuel System - Continued
30
29 HYEX01515
Figure 6. High-Pressure Pump and Injectors.
Table 6. High-Pressure Pump and Injectors.
29 High-Pressure Fuel The high-pressure fuel pump increases the fuel pressure to send exact
Pump amounts of fuel to the injector nozzles.
30 Fuel Injectors The fuel injectors turn the stream of fuel into a fine spray, which permits good
combustion in the cylinder. There is one nozzle for each cylinder. The injectors
are located under the rocker arm cover.
0003-7
TM 5-3805-294-10 0003
Fuel System - Continued
Cooling
31
33
32
34
HYEX01516
Figure 7. Cooling Package.
Table 7. Cooling Package.
31 Radiator Coolant circulates through the radiator to be cooled after leaving the cylinder
block.
32 Hydraulic Oil Cooler The hydraulic oil cooler uses air from the fan to cool the oil before returning it
to the reservoir.
33 Charge Air Cooler The charge air cooler cools the air supplied to the engine to decrease fuel
consumption and emissions.
34 Fuel Cooler Fuel is circulated across the cooler to lower fuel temperature.
0003-8
TM 5-3805-294-10 0003
Cooling - Continued
35
36 37
HYEX01517
Figure 8. Cooling System Components.
Table 8. Cooling System Components.
35 Coolant Surge Tank The coolant surge tank is where the coolant level is checked and added.
36 Engine Oil Cooler Coolant from the radiator passes through the engine oil cooler to maintain a
safe operating temperature.
37 Fan The variable speed fan is located at the front of the engine and is driven by a
hydraulic motor. The speed of the fan is varied to provide the amount of airflow
that the engine coolant, charge air cooler, or hydraulic cooler need, ensuring
maximum fuel efficiency, reduced noise levels, and faster engine warm up. A
reversing function reverses the cooling fan to help clean the cooling package
of dirt and debris.
END OF WORK PACKAGE
0003-9/10 blank
TM 5-3805-294-10
CHAPTER 2
OPERATOR INSTRUCTIONS
NSN 3805-01-573-0677
TM 5-3805-294-10 0004
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
INTRODUCTION
The following tables and illustrations provide the description and use of the controls and indicators pertaining to the
front switch panel, heater and air conditioner control panel, control pedals and levers, left console, left and right
control levers, seat controls and arm rest, coolant heater and cab door, and warning indicators and alarms.
Table 1. Front Switch Panel.
1 2 7 HYEX00867
Figure 1. Front Switch Panel.
Key Control/Indicator Function
1 Washer/Wiper Wiper switch has several positions. The OFF position stops the wipers from
Switch operating and parks them. The INT position operates the wipers intermittently
at the interval selected by the switch position. The ON position operates the
wipers continuously. To operate the washer, push and hold switch down for no
more than 20 seconds. Note that the wiper will not operate unless the
windshield is completely closed.
2 Operating Lights This is a three-position switch. The first position turns on the drive light. Front
Switch Switch panel will also illuminate. The second position turns on the boom work
lights, the front cab work lights, and the drive light. If the default screen on the
monitor is displayed, the background goes from white to black.
0004-1
TM 5-3805-294-10 0004
Table 1. Front Switch Panel - Continued.
3 Engine Speed Dial The dial is used to increase or decrease engine speed.
1 2 7 HYEX00867
Figure 2. Front Switch Panel Continued.
4 Auto-Idle (A/I) This is a two-position switch. In the ON position, it will reduce the engine speed
Switch after 4 seconds when control levers are in the neutral position. In the OFF
position the operator can set the engine speed to improve machine control.
5 Power Mode Switch This is a three-position switch. The H/P mode is used when more hydraulic
power is desired for raising the boom and rolling the bucket during excavation
work. The Power (P) mode is used when performing general digging
operations. The Economy (E) mode is used to increase fuel efficiency and
reduces noise level.
6 Travel Mode Switch This is a two-position switch. It is used to select fast or slow speed of travel.
7 Key Switch This is a four-position switch. When in the OFF position, the key can be
removed. Moving the switch to the ACC position allows the radio to be turned
on or off. In the ON position, all electrical functions will operate. Move and
release the switch to the START position starts the machine.
0004-2
TM 5-3805-294-10 0004
Table 2. Heater/Air Conditioner (A/C) Controller and Radio.
16 9 15 14 13 10 12 11
HYEX00868
17
Figure 3. Heater/Air Conditioner (A/C) Controller and Radio.
8 Blower Fan Speed Increases or decreases the speed of the blower fans. Turns on blower fans
Buttons when A/C is off.
9 Monitor Display Displays blower fan speed, selected air vent, and temperature setting.
10 A/C Button When pressed, it turns on the air conditioning (A/C) and illuminates the A/C
indicator.
11 AUTO Button When pressed, it turns on the AUTO and A/C indicators. Air flow-in temperature
at the vent, blower fan speed, vent locations, and fresh air port are then
automatically controlled.
0004-3
TM 5-3805-294-10 0004
Table 2. Heater/Air Conditioner (A/C) Controller and Radio - Continued.
12 OFF Button When pressed the A/C and blower fans will turn off. Blower fans will turn on if
one of the blower fan speed buttons is pressed even if the OFF button is on or
off.
16 9 15 14 13 10 12 11
HYEX00868
17
Figure 4. Heater/Air Conditioner (A/C) Controller and Radio Continued.
13 Temperature Press buttons to set temperature from full-cool (FC) to full-heat (FH). The
Control Buttons monitor display will show FC or FH.
14 Recirculating Mode Press the recirculating mode button to close the fresh air vent and circulate air
Button already in the cab.
15 Fresh Air Mode Press fresh air mode to route outside air into the cab.
Button
16 Mode Button Press to select air vent. Selected vent will display on the monitor display.
17 Radio Display The radio display contains standard AM/FM radio tuning and volume controls.
0004-4
TM 5-3805-294-10 0004
Table 3. Control Pedals and Levers.
22 23 21 20 18 19
HYEX00869
Figure 5. Control Pedals and Levers.
18 Attachment Pedal Primarily used to open and close the hydraulic thumb. When attachments are
connected, hydraulic valve selection will disable the hydraulic thumb and
enable this pedal to operate the attachment.
19 Attachment Pedal Locks attachment pedal in the neutral position to disable the hydraulic thumb
Lock or any attachments that are connected.
20 Right Travel Pedal Controls the direction of travel and steers the machine. Pushing down on the
top of the pedal moves the machine forward. Pushing down on the bottom of
the pedal moves the machine backwards.
21 Right Travel Lever Use this hand lever to perform the same functions as the right travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.
0004-5
TM 5-3805-294-10 0004
Table 3. Control Pedals and Levers - Continued.
22 Left Travel Pedal Controls the direction of travel and steers the machine. Pushing down on the
top of the pedal moves the machine forward. Pushing down on the bottom of
the pedal moves the machine backwards.
22 23 21 20 18 19
HYEX00869
Figure 6. Control Pedals and Levers Continued.
23 Left Travel Lever Use this hand lever to perform the same functions as the left travel pedal with
increased control. Pushing forward on the lever moves the machine forward.
Pulling the lever moves the machine backwards.
0004-6
TM 5-3805-294-10 0004
Table 4. Left Console and Pilot Shutoff Lever.
24 25 26 27 28 HYEX00870
Figure 7. Left Console and Pilot Shutoff Lever.
24 Pilot Shutoff Lever Controls hydraulic functions on the machine. With the lever in the locked
position, hydraulic functions are not operational. In the unlocked position, all
hydraulic functions operate. The engine will not start with the lever in the
unlocked position.
25 Travel Alarm Switch After the initial 13-second alarm, depressing the right half of the switch will shut
the alarm off.
26 Rear Cab Work Turns the rear cab work lights on and off.
Lights Switch
27 Auxiliary Control Disables the right joystick left and right button auxiliary function.
Switch
28 Reversing Cooling This is a three position switch that controls the direction that the cooling fan is
Fan Switch moving. AUTO: Every 60 minutes the cooling fan will automatically reverse
direction for 15 seconds without intervention from the operator. OFF Fan
resumes normal operation. MANUAL: Fan will reverse direction for 15 seconds
when right portion of switch is pressed.
0004-7
TM 5-3805-294-10 0004
Table 5. Right and Left Pilot Control Levers.
31
32
30
29
HYEX00871
Figure 8. Right Pilot Control Lever.
29 Right Pilot Control When pushed forward, the boom lowers. When pulled back, the boom raises.
Lever When pulled left, the bucket will curl. When pushed right, the bucket will dump.
When released the lever will return to the neutral position.
30 Power Dig Button Pressing the power dig button gives the operator an 8-second increase in
hydraulic power.
31 Left Button Auxiliary Used to close crush-all lid if connected.

Function
32 Right Button Used to open crush-all lid if connected.

Auxiliary Function
0004-8
TM 5-3805-294-10 0004
Table 5. Right and Left Pilot Control Levers - Continued.
33 Left Pilot Control When pushed forward, the arm will go out. When pulled back, the arm will come
Lever in. When pushed left, machine swings left. When pulled right, machine swings
right. When released, lever returns to the neutral position.
34
33
HYEX00872
Figure 9. Left Pilot Control Lever.
34 Horn Button When pressed the horn will sound.
0004-9
TM 5-3805-294-10 0004
Table 6. Seat Controls.
39
40
35
38
37
41 36 HYEX00873
Figure 10. Seat Controls.
35 Seat Angle Lever Allows seat to be adjusted to a desired angle.
36 Seat Adjustment Pull up handle to adjust the seat forward or backward.

Handle
37 Seat Weight Turn knob to adjust seat suspension to the proper weight of the operator.
Adjustment Knob
38 Lumbar Adjustment Squeeze ball to add air for desired lumbar firmness. Press button next to ball
to release air.
0004-10
TM 5-3805-294-10 0004
Table 6. Seat Controls - Continued.
39 Backrest Pull up lever to release backrest and adjust to desired position, then release
Adjustment Lever lever.
40 Armrest Angle Turn dial to adjust armrest to desired angle.

Adjustment
41 Seat Assembly Pull handle to slide entire seat to desired distance from travel pedals.
Adjustment Lever
0004-11
TM 5-3805-294-10 0004
Table 7. Cab Door Release Lever and Coolant Heater Display.
43
44 45 46 47 48 42 HYEX00874
Figure 11. Cab Door Release Lever and Coolant Heater Display.
42 Cab Door Release Push down to release cab door from the locked open position.
Lever
43 Coolant Heater Displays date and time.

Display
44 Clock Button Pressing button displays date and time and allows to change date and time
settings.
45 Preset Button Press the preset button to program the desired time to start cycle.
46 Heat Display Display will flash when a program is activated or if the coolant heater is
manually operated.
47 Lower Button Used to lower time, date, or operating time depending on current screen.
0004-12
TM 5-3805-294-10 0004
Table 7. Cab Door Release Lever and Coolant Heater Display - Continued.
48 Raise Button Used to raise time, date, or operating time depending on current screen.
Table 8. Quick Latch Control.
49
50
HYEX00875
Figure 12. Quick Latch Control.
49 Quick Latch Switch Used to lock and unlock quick latch.
50 Quick Latch Light Illuminates when switch is in unlatch position.
0004-13
TM 5-3805-294-10 0004
Table 9. Cab Light Switch.
51
HYEX01316
Figure 13. Cab Light Switch.
51 Cab Light Switch Cab light has a two-position switch that turns the light on and off. It will only
illuminate with the key switch turned on. (Not present when armored cab is
installed).
0004-14
TM 5-3805-294-10 0004
Table 10. Hydraulic Hose Reel.
52
54
53
55
HYEX00876
Figure 14. Hydraulic Hose Reel.
52 Hydraulic Hose Reel Used for hydraulic tools.
53 Hydraulic Tool Moved to the on position when using hydraulic tools.

Circuit Switch
54 Hydraulic Tool Flow Used to regulate the flow of hydraulic fluid when using the hydraulic hose reel.
Regulator
55 Deep Dig Control Moved to the on position when using deep dig arm to enable the deep dig
Pattern Switch control pattern.
END OF WORK PACKAGE
0004-15/16 blank
TM 5-3805-294-10 0005
DESCRIPTION AND USE OF MONITOR AND ALARMS
INTRODUCTION
The following tables and illustrations provide the description and use of the monitor buttons, indicators, and warning
indicators.
Table 1. Monitor Buttons and Indicators.
A.I.
7777.7 h
F1
F2
F
H F3
F4
E
C 17.3 L/h
8:01
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
1 2 3 4 5 HYEX00858
Figure 1. Monitor.
1 Button 1 Press button to key in the number 1 or use as instructed depending on current
screen.
screen.
screen.
screen.
screen.
0005-1
TM 5-3805-294-10 0005
Table 1. Monitor Buttons and Indicators - Continued.
6 Button 6/Return to Press button to key in the number 6, or to return to the default screen.
Default Screen
Button
A.I.
7777.7 h
F1
F2
F
H F3
F4
E
C 17.3 L/h 11
8:01
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
12
13
14 6 7 8 9 10 HYEX00859
Figure 2. Monitor Buttons.
7 Button 7/F1 function Press button to key in the number 7 or to select the desired preset optional
button function from any screen.
11 Select Button Use button as instructed depending on current screen.
12 Back Button Use button as instructed depending on current screen.
0005-2
TM 5-3805-294-10 0005
13 Hour Meter Button Without key inserted or with key switch OFF, press and hold button to display
default screen and hour meter.
14 Alarm Indicator Lights when an abnormality has occurred.

Light
Main Menu
Time Set
Attachment Adjustment
Operating Conditions
Maintenance Settings
1 2 3 4 5
15
6 7 8 9 0
F1 F2 F3 F4
HYEX01319
Figure 3. Main Menu.
15 Menu Button Press button to display main menu from any screen. Main menu includes time
set, attachment adjustment, operating conditions, and maintenance settings.
0005-3
TM 5-3805-294-10 0005
16 Coolant Indicates the engine coolant temperature. Needle should be around the center
Temperature Gauge of the scale during operation.
17 18 19 20 21 22 24
A.I. 23
7777.7 h 25
F1
F2
F
H F3
F4
E 28
C 17.3 L/h
8:01
16
1 2 3 4 5
29
6 7 8 9 0
27
F1 F2 F3 F4
26
HYEX00860
30
Figure 4. Monitor Indicators.
17 Work Mode The icon for the current attachment being used is displayed.
Indicator
18 Auto-Idle Indicator When selecting auto-idle from the front switch panel, the auto-idle icon
displays.
19 Auxiliary Indicator Optional auxiliary data icon displays.
22 Engine Preheat If preheat is required, the preheat icon is displayed.

Indicator
23 Hour Meter Total machine operation hours counted since the machine started working are
displayed in the unit of hour (h). One digit after the decimal point indicates
tenths of an hour (6 minutes).
0005-4
TM 5-3805-294-10 0005
24 F1 Function Button Optional indicator icon is displayed.

Indicator

Indicator

Indicator

Indicator
28 Fuel Gauge Shows level of fuel in fuel tank.
29 Fuel Rate Display Fuel consumption in Liter/hour (L/h) is displayed.
30 Clock Indicates present time.
0005-5
TM 5-3805-294-10 0005
Table 2. Warning Indicators and Alarms.
32 33
31
34 35 36
39
37 38
HYEX00861
Figure 5. Warning Indicators and Alarms.
31 Engine Overheat Displays when engine coolant temperature has abnormally increased.
Alarm
32 Engine Warning Displays when engine has an abnormal operating condition.

Alarm
33 Engine Oil Pressure Displays when oil pressure has decreased.

Alarm
34 Alternator Alarm Displays when an abnormality in the electrical system has occurred.
0005-6
TM 5-3805-294-10 0005
Table 2. Warning Indicators and Alarms - Continued.
35 Remaining Fuel Displays when fuel level is low.

Alarm
36 Hydraulic Oil Filter Displays when hydraulic filter is clogged.

Alarm
37 Air Cleaner Clogged Displays when air cleaner are clogged.

Alarm
38 Work Mode Alarm Displays when work mode is abnormal.
39 Pilot Shutoff Lever Displays when pilot shutoff system is abnormal.

Alarm
40
HYEX00862
Figure 6. Overload Alarm.
40 Overload Alarm Illuminates when an overload condition exists when digging.
END OF WORK PACKAGE
0005-7/8 blank
TM 5-3805-294-10 0006
ADJUSTING THE OPERATOR'S SEAT
INITIAL SETUP:
Not Applicable
ADJUSTMENT
NOTE
Proper seat adjustment is achieved when operator can reach the foot control pedals and the
travel levers easily with the seat belt buckled.
1. Push down on handle (Figure 1, Item 1) to tilt seat (Figure 1, Item 2).
13
8 9
11
12
10
2
1
7
3
5 4 HYEX00145
Figure 1. Operator's Seat Adjustments.

2. Turn knob (Figure 1, Item 3) to set operator weight.
3. Pull up on handle (Figure 1, Item 4) to slide seat (Figure 1, Item 2).
4. Push on lever (Figure 1, Item 5) to slide seat (Figure 1, Item 2) and controls (Figure 1, Item 6).
0006-1
TM 5-3805-294-10 0006
ADJUSTMENT - Continued
5. Squeeze bulb (Figure 1, Item 7) to increase lumbar support.

6. Push button (Figure 1, Item 8) to decrease lumbar support.
7. Pull up on handle (Figure 1, Item 9) to unlock backrest (10).
8. Raise or lower headrest (Figure 1, Item 11) to desired height.
9. Tilt headrest (Figure 1, Item 11) to desired angle.
10. Turn dial (Figure 1, Item 12) on underside of armrest (Figure 1, Item 13) to adjust angle.
END OF TASK
END OF WORK PACKAGE
0006-2
TM 5-3805-294-10 0007
STARTING THE ENGINE
INITIAL SETUP:
Equipment Condition
Before operations Preventive Maintenance Checks
and Services performed. (WP 0077)
Operators seat adjusted. (WP 0006)
STARTING THE ENGINE
WARNING
Perform a complete walk around the machine prior to starting the engine. Ensure sufficient
clearance from personnel and equipment for safe operation of machine. Prior to starting
engine sound horn to alert personnel. Failure to comply may result in injury or death to
personnel.
1. Buckle the seat belt (Figure 1, Item 1).
HYEX00090
Figure 1. Seat Belt.
NOTE
Engine will not start unless pilot shutoff lever is in the LOCKED (up) position.
2. Place pilot shutoff lever (Figure 2, Item 2) in LOCKED (up) position.
0007-1
TM 5-3805-294-10 0007
STARTING THE ENGINE - Continued
HYEX00091
Figure 2. Pilot Shutoff Lever.
3. Turn engine speed dial (Figure 3, Item 3) to slow idle position.
HYEX00092
Figure 3. Engine Speed Dial Slow Idle.

4. Turn key switch (Figure 4, Item 4) to ON position.
0007-2
TM 5-3805-294-10 0007
HYEX00093
Figure 4. Key Switch ON.
NOTE
When the ignition key is turned to the ON position, the "System Starting" screen will display
for about 2 seconds. The default screen will then be displayed.
5. Wait for "System Starting" screen (Figure 5, Item 5) to change to default screen (Figure 5, Item 6).
System Starting...
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX00094
Figure 5. System Starting and Default Screen.
NOTE
At approximately 32°F (0°C) or below, the pre-heat indicator will be displayed for up to 15
seconds depending on engine fuel temperature.
6. Wait until engine preheat indicator (Figure 6, Item 7) is no longer displayed.
0007-3
TM 5-3805-294-10 0007
A.I.
7777.7 h
F1
F2
F
H F3
F4
E
C 17.3 L/h
8:01
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX00095
Figure 6. Preheat Indicator.
CAUTION
• Never operate starter longer than 20 seconds at a time. If engine fails to start, return key
switch to OFF position and wait 2 minutes before attempting to start again. Failure to
comply may result in damage to equipment.
• After a false start, wait until engine stops spinning before turning the key again. Failure
to comply may result in damage to equipment.
NOTE
Key switch will return to ON position when key is released.
7. Turn key switch (Figure 7, Item 4) to START position and release when engine starts.
HYEX00099
Figure 7. Key Switch to START.
0007-4
TM 5-3805-294-10 0007
CAUTION
• If alarm indicators are still displayed after starting the engine, immediately shut down the
engine. Failure to comply may result in damage to equipment.
• Do not run engine at fast idle or rapidly accelerate engine until it has reached normal
operating temperature. Failure to comply may result in damage to equipment.
8. After the engine is started, ensure that no alarm indicators (Figure 8, Item 8) are displayed.
HYEX00096
Figure 8. Alarm indicator.

9. Move engine speed dial (Figure 9, Item 3) right 1/3 and allow engine to idle for 30 seconds.
HYEX00100
Figure 9. Engine Speed Dial Turned to 1/3 Position.

10. Turn engine speed dial (Figure 10, Item 3) to slow idle position until machine reaches normal operating
temperature.
0007-5
TM 5-3805-294-10 0007
HYEX00092
Figure 10. Return Engine Speed Dial to Slow Idle.
END OF TASK
END OF WORK PACKAGE
0007-6
TM 5-3805-294-10 0008
MOVING THE HYEX
INITIAL SETUP:
Equipment Condition
Engine running. (WP 0007)
MOVING THE HYEX
WARNING
• Before moving the machine or operating the boom, ensure that the boom has at least 10
ft (3 m) of clearance from overhead wires, power lines, or structures. If lines are near to
your operating area, notify your supervisor prior to operating the boom. Failure to comply
NOTE
• If traveling long distances, ensure that travel motors are at the back of the machine.
• If travel motors are at the front of the machine, the machine moves in opposite direction
as described in these procedures.
• When traveling up slopes, keep the bucket on the uphill side and just above the ground.
• When traveling down a slope, operate control pedals or levers slowly.
1. Move pilot shutoff lever (Figure 1, Item 1) to the unlocked (down) position.
120
LOCK
HYEX00146
Figure 1. Pilot Shutoff Lever Unlocked.
0008-1
TM 5-3805-294-10 0008
MOVING THE HYEX - Continued
2. Raise boom (Figure 2, Item 2) and arm (Figure 2, Item 3) off of ground to allow for sufficient visibility and to
keep machine stable.
HYEX00147
Figure 2. Boom and Arm Raised.
CAUTION
When traveling over rough terrain, reduce travel speed to avoid undercarriage damage.
Failure to comply may result in damage to equipment.
NOTE
If carrying a heavy load, keep travel mode switch in the low position for more control of the
machine.
3. Move travel mode switch (Figure 3, Item 4) to high position.
HYEX00148
Figure 3. Travel Mode Switch.
NOTE
Travel speed of machine is controlled by the foot pedals or travel levers.
0008-2
TM 5-3805-294-10 0008
MOVING THE HYEX - Continued
4. Push down on the front of both foot pedals (Figure 4, Items 5 and 6), or push both travel levers (Figure 4, Items
7 and 8) forward to move HYEX forward.
7 8
5 6
HYEX01297
Figure 4. Moving Forward and Backwards.

5. Push down on the rear of both foot pedals (Figure 4, Items 5 and 6) or pull both travel levers (Figure 4, Items
7 and 8) to move the HYEX backwards.
6. Allowing both foot pedals (Figure 4, Items 5 and 6), or both travel levers (Figure 4, Items 7 and 8) to return to
center, will stop the HYEX.
END OF TASK
STEERING THE HYEX
WARNING
• Use care when backing the machine. Watch clearances. Have an assistant direct you if
you cannot see where you are going. Failure to comply may result in injury or death to
personnel.
NOTE
If travel motors are at the front of the machine, the machine moves in opposite direction as
described in these procedures.
0008-3
TM 5-3805-294-10 0008
STEERING THE HYEX - Continued
1. Pushing front of left foot pedal (Figure 5, Item 5) or push left travel lever (Figure 5, Item 7) forward with right
foot pedal (Figure 5, Item 6) and right travel lever (Figure 5, Item 8) at center turns the HYEX right.
7 8
5 6
HYEX01296
Figure 5. Right Turn.

2. Pushing front of right foot pedal (Figure 6, Item 6) or push right travel lever (Figure 6, Item 8) forward with left
foot pedal (Figure 6, Item 5) and left travel lever (Figure 6, Item 7) at center turns the HYEX left.
7 8
5 6
HYEX01295
Figure 6. Left Turn.
3. Pushing front of left foot pedal (Figure 7, Item 6), or push left travel lever (Figure 7, Item 8) forward and push
down on rear of right foot pedal (Figure 7, Item 7) or pull right travel lever (Figure 7, Item 8) back to counter-
rotate.
0008-4
TM 5-3805-294-10 0008
STEERING THE HYEX - Continued
7 8
5 6
HYEX01291
Figure 7. Counter-Rotate.
4. Allowing both foot pedals (Figure 7, Items 5 and 6) or both travel levers (Figure 7, Items 7 and 8) to return to
center will stop the HYEX.
END OF TASK
END OF WORK PACKAGE
0008-5/6 blank
TM 5-3805-294-10 0009
SHUTTING DOWN THE HYEX
INITIAL SETUP:
References References (cont.)

WP 0004 WP 0011
WP 0010
SAFELY PARK HYEX
1. Park machine (Figure 1, Item 1) on solid, level surface.
HYEX02418
Figure 1. Machine In Parked Position.
NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2. Keeping angle between arm (Figure 1, Item 2) and boom (Figure 1, Item 3), position flat side of bucket (Figure
1, Item 4) on the ground. (WP 0004)
END OF TASK
SHUT DOWN ENGINE
1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.
0009-1
TM 5-3805-294-10 0009
SHUT DOWN ENGINE - Continued
HYEX00153
Figure 2. Auto-Idle Switch and Engine Speed Dial.
CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may
result in damage to equipment.
NOTE
Engine speed dial shown approximately at 1/3 position.
2. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.
0009-2
TM 5-3805-294-10 0009
HYEX00154
Figure 3. Engine Speed Dial.
4. Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position.
HYEX00155

5. Turn key switch (Figure 5, Item 8) to OFF position and remove key.
0009-3
TM 5-3805-294-10 0009
HYEX00157
Figure 5. Key Switch Turned OFF.
CAUTION
Ensure all windows and doors are closed when machine is parked to prevent electrical system
damage during inclement weather. Failure to comply may result in damage to equipment.
6. Close windows. (WP 0011)
END OF TASK
END OF WORK PACKAGE
0009-4
TM 5-3805-294-10 0010
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED
INITIAL SETUP:
References Equipment Condition

WP 0004 Engine running. (WP 0007)
WP 0011
SAFELY PARK MACHINE
1. Park machine (Figure 1, Item 1) on solid, level surface.
4
HYEX01637
Figure 1. Machine In Parked Position.
NOTE
Do not force bucket on or in the ground. Bucket should be resting on the ground.
2. Keeping angle between deep dig arm (Figure 1, Item 2) and arm (Figure 1, Item 3) at approximately 90 degrees,
position flat side of bucket (Figure 1, Item 4) on the ground. (WP 0004)
END OF TASK
SHUT DOWN ENGINE
1. If Auto-Idle (A/I) switch (Figure 2, Item 5) is on, turn Auto-Idle (A/I) switch to the OFF position.
0010-1
TM 5-3805-294-10 0010
HYEX01507
Figure 2. Auto-Idle Switch and Engine Speed Dial.
CAUTION
Turbocharger may be damaged if engine is not shut down properly. Failure to comply may
result in damage to equipment.
NOTE
Engine speed dial shown approximately at 1/3 position.
2. Turn engine speed dial (Figure 2, Item 6) to 1/3 position for 2 minutes without a load.
0010-2
TM 5-3805-294-10 0010
HYEX01508
4. Move pilot shutoff lever (Figure 4, Item 7) to LOCKED (up) position.
HYEX01509

5. Turn key switch (Figure 5, Item 8) to OFF position and remove key.
0010-3
TM 5-3805-294-10 0010
HYEX01510
Figure 5. Key Switch Turned OFF.
CAUTION
Ensure all windows and doors are closed when machine is parked to prevent electrical system
damage during inclement weather. Failure to comply may result in damage to equipment.
6. Close windows. (WP 0011)
END OF TASK
END OF WORK PACKAGE
0010-4
TM 5-3805-294-10 0011
OPENING AND CLOSING WINDOWS
INITIAL SETUP:
Not Applicable
WINDSHIELD
NOTE
• The wiper will not operate with windshield open.
• The washer can operate with windshield open.
1. Pull lock pin (Figure 1, Item 1) inward and rotate into notch.
2
1
3
HYEX00160
Figure 1. Open Windshield.
2. Pull on latch release bar (Figure 1, Item 2) to open windshield (Figure 1, Item 3).
3. Lift on handle (Figure 2, Item 4) to raise windshield (Figure 2, Item 3) until it latches open.
0011-1
TM 5-3805-294-10 0011
WINDSHIELD - Continued
HYEX00161
Figure 2. Raise Windshield.
WARNING
Lock pin must be used to secure upper front window in raised position. Failure to comply may
4. Release lock pin (Figure 3, Item 1) from notch and slide into cab frame lock hole (Figure 3, Item 5).
HYEX00162
Figure 3. Lock Windshield Open.

5. To close the windshield, pull lock pin (Figure 4, Item 1) inward from cab frame lock hole (Figure 4, Item 5) and
rotate into notch.
0011-2
TM 5-3805-294-10 0011
HYEX00163
Figure 4. Release Windshield Latch.
WARNING
Window closes rapidly when released. Use lower handle to prevent window from free falling.
6. Pull on latch release bar (Figure 4, Item 2).
7. Hold handle (Figure 5, Item 4) and lower windshield (Figure 5, Item 3) until it is latched in the closed position.
HYEX00161
Figure 5. Close Windshield.

8. Press glass (Figure 6, Item 3) until bar (Figure 6, Item 2) snaps into place.
0011-3
TM 5-3805-294-10 0011
2
1
3
HYEX00160
Figure 6. Latch Windshield.

9. Release lock pin (Figure 6, Item 1) from notch.
END OF TASK
CAB DOOR WINDOW
1. To open, release latch (Figure 7, Item 6) and slide cab door window (Figure 7, Item 7) forward.
HYEX01411
Figure 7. Open and Close Cab Door Window.
2. To close, slide cab door window (Figure 7, Item 7) to rear until latch (Figure 7, Item 6) engages.
END OF TASK
0011-4
TM 5-3805-294-10 0011
SKYLIGHT WINDOW (SECONDARY EXIT)
1. Slide access cover (Figure 8, Item 8) open.
HYEX03377
Figure 8. Open Access Cover.
2. To open, release two latches (Figure 9, Item 9) and push up on handle (Figure 9, Item 10).
10
9 9
HYEX00167
Figure 9. Open and Close Skylight Window.
3. To close, pull down on handle (Figure 9, Item 10) and engage two latches (Figure 9, Item 9).
4. Slide access cover (Figure 10, Item 8) closed.
0011-5
TM 5-3805-294-10 0011
SKYLIGHT WINDOW (SECONDARY EXIT) - Continued
HYEX03377
Figure 10. Close Access Cover.
END OF TASK
END OF WORK PACKAGE
0011-6
TM 5-3805-294-10 0012
USING THE RIFLE MOUNT
INITIAL SETUP:
Not Applicable
STOW
NOTE
Rifle mount is designed to store an M4 with optics, M240B, M249, or M16 series weapon with
and without M203 grenade launcher.
1. Place butt of weapon in rear mounting bracket (Figure 1, Item 1).
HYEX00999
Figure 1. Stow Weapon In Rear Bracket

2. Place barrel of weapon in front mounting bracket (Figure 2, Item 2).
0012-1
TM 5-3805-294-10 0012
STOW - Continued
3 2
4 HYEX00998
Figure 2. Stow Weapon In Front Bracket

3. If necessary, loosen two handles (Figure 2, Item 3) and slide front mounting bracket (Figure 2, Item 2) on two
rails (Figure 2, Item 4).
4. Tighten two handles (Figure 2, Item 3).
END OF TASK
REMOVE
1. Lift barrel of weapon from front mounting bracket (Figure 3, Item 2).
3 2
4 HYEX00998
Figure 3. Remove Weapon From Front Bracket

2. Remove butt of weapon from rear mounting bracket (Figure 4, Item 1).
0012-2
TM 5-3805-294-10 0012
REMOVE - Continued
HYEX00999
Figure 4. Remove Weapon From Rear Bracket
END OF TASK
END OF WORK PACKAGE
0012-3/4 blank
TM 5-3805-294-10 0013
GENERAL MONITOR OPERATION
INITIAL SETUP:
Equipment Condition
TIME ADJUSTMENT
NOTE
After approximately 1 minute the monitor will return to the default screen.
1. Press menu button.
Main Menu
TIME SET Time Set
Attachment Adjustment
Maintenance Settings SELECT
BUTTON
1 2 3 4 5
BUTTON 1
6 7 8 9 0
F1 F2 F3 F4
BUTTON 2 MENU
BUTTON
HYEX00057
Figure 1. Select Time Set Menu.
2. Press button 1 or button 2 until the Time Set menu is highlighted.

3. Press select button to open Time Set menu.
0013-1
TM 5-3805-294-10 0013
TIME ADJUSTMENT - Continued
4. Press button 1 or button 2 to select date or time.
Time Set
2005 / 12 / 23
12 : 23
SELECT
BUTTON
BUTTON
1 1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4 BACK
BUTTON
BUTTON BUTTON BUTTON

2 3 4 HYEX00058
Figure 2. Adjust Time.

5. Press button 3 or button 4 to adjust date or time up or down.
6. After desired date and time is achieved, press button 1 or button 2 until the apply setting icon is highlighted.
7. Press select button and "Data is being applied" will display on the screen.
8. Press back button until default screen is displayed.
END OF TASK
DISPLAYING OPERATING CONDITIONS
1. Press menu button 1.
Main Menu
Time Set
OPERATING Attachment Adjustment
CONDITIONS Operating Conditions

Maintenance Settings
SELECT
BUTTON
1 2 3 4 5
6 7 8 9 0
BACK
F1 F2 F3 F4 BUTTON
BUTTON
1
BUTTON MENU
2 BUTTON HYEX00059
Figure 3. Select Operating Conditions Menu.
2. Press button 1 or button 2 until the Operating Conditions menu is highlighted.

3. Press select button.
0013-2
TM 5-3805-294-10 0013
DISPLAYING OPERATING CONDITIONS - Continued
4. Operating Conditions menu will be displayed.
Reset Data. OK?
SELECT
BUTTON
1 2 3 4 5
6 7 8 9 0 BACK
F1 F2 F3 F4
BUTTON
HYEX00060
Figure 4. Reset Operating Conditions.
5. To reset data, press select button.

6. The Reset Data. OK? is displayed.
7. If reset is not desired, press back button.
8. When finished with menu, press back button until default screen is displayed.
END OF TASK
MAINTENANCE SETTINGS
Maintenance settings are to be accessed only by the Field Level maintainer.
END OF TASK
END OF WORK PACKAGE
0013-3/4 blank
TM 5-3805-294-10 0014
REMOVING AND INSTALLING BUCKET
INITIAL SETUP:

WP 0007 Machine safely parked and shut down.
(WP 0009)
REMOVING BUCKET
WARNING
With quick latch wedges disengaged from bucket, the bucket can fall off of the quick latch.
Ensure that personnel are clear of equipment when removing or installing bucket. Slowly
retract or extend bucket cylinder when removing or installing bucket. Failure to comply may
NOTE
The ditch cleaning bucket and 42 inch rock bucket are removed the same way. 42 inch rock
bucket shown.
1. Lift and rotate safety lock pin lever (Figure 1, Item 1).
HYEX03379
Figure 1. Unlock Safety Lock Pin.
2. Start engine. (WP 0007)

3. Raise boom (Figure 2, Item 2) to allow adequate ground clearance for bucket (Figure 2, Item 3).
0014-1
TM 5-3805-294-10 0014
REMOVING BUCKET - Continued
3
HYEX03380
Figure 2. Raise Boom.
4. Move quick latch switch (Figure 3, Item 4) to unlatch position.
HYEX00939
Figure 3. Move Quick Latch Switch to Unlatch Position.

5. Fully extend bucket cylinder (Figure 4, Item 5) until quick latch wedges (Figure 4, Item 6) are fully retracted.
0014-2
TM 5-3805-294-10 0014
6
HYEX03387
Figure 4. Extend Bucket Cylinder.
WARNING
6. Slowly retract bucket cylinder (Figure 5, Item 5) and position quick latch (Figure 5, Item 7) in vertical position.
HYEX03384
Figure 5. Retract Bucket Cylinder.
NOTE
Ensure that arm is just past the vertical position prior to setting bucket on the ground.
7. Slowly lower boom (Figure 6, Item 2) and place bucket (Figure 6, Item 3) on ground.
0014-3
TM 5-3805-294-10 0014
3
HYEX03382
Figure 6. Lower Boom.
8. Move quick latch switch (Figure 7, Item 4) in latch position.
HYEX00939
Figure 7. Position Quick Latch Switch to Latch position.

9. Remove quick latch (Figure 8, Item 7) from bucket (Figure 8, Item 3).
0014-4
TM 5-3805-294-10 0014
3
HYEX03389
Figure 8. Remove Quick Latch.
END OF TASK
INSTALLING BUCKET
WARNING
NOTE
The ditch cleaning bucket and 42 inch rock bucket are installed the same way. 42 inch rock
bucket shown.
1. Move quick latch switch (Figure 9, Item 4) in the unlatch position.
0014-5
TM 5-3805-294-10 0014
INSTALLING BUCKET - Continued
HYEX00939
Figure 9. Position Quick Latch Switch to Unlatch position.

2. Raise boom (Figure 10, Item 2) to allow for adequate ground clearance.
HYEX03385
Figure 10. Raise Boom for Clearance.
WARNING
3. Slowly extend bucket cylinder (Figure 11, Item 5) until quick latch wedges (Figure 11, Item 6) are fully retracted.
0014-6
TM 5-3805-294-10 0014
6
HYEX03383
Figure 11. Retract Wedges.

4. Position quick latch (Figure 12, Item 7) in vertical position.
3
HYEX03381
Figure 12. Install Quick Latch.
5. Install quick latch (Figure 12, Item 7) to bucket (Figure 12, Item 3).
6. Extend bucket cylinder (Figure 12, Item 5) until quick latch (Figure 12, Item 7) is resting on bucket (Figure 12,
Item 3).
7. Move quick latch switch (Figure 13, Item 4) in latch position.
0014-7
TM 5-3805-294-10 0014
HYEX00939
Figure 13. Position Quick Latch Switch toLatch position.

8. Raise boom (Figure 14, Item 2) to allow for ground clearance.
2
5
6
HYEX03386
9. Fully extend bucket cylinder (Figure 14, Item 5) to ensure quick latch wedges (Figure 14, Item 6) are fully
engaged.
10. Position bucket (Figure 15, Item 3) on ground.
0014-8
TM 5-3805-294-10 0014
HYEX03378
Figure 15. Safety Pin Locked.
11. Rotate safety lock pin lever (Figure 15, Item 1) to lock position.
END OF TASK
END OF WORK PACKAGE
0014-9/10 blank
TM 5-3805-294-10 0015
LIFTING WITH HYEX
INITIAL SETUP:
Tools and Special Tools Equipment Condition

Suitable Lifting Device Engine running. (WP 0007)
Personnel Required
Horizontal Construction Engineer 12N (2)
LIFTING
WARNING
LIFTING GUIDELINES:
• Do not use machine to lift personnel. Failure to comply may result in injury or death to
personnel.
• Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death
to personnel.
• Ensure load does not exceed the capacity of machine or lifting device. Failure to comply
• Lift load only as high as necessary. Failure to comply may result in injury or death to
personnel.
• Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may
• Personnel must remain clear of lifted items. Failure to comply may result in injury or death
to personnel.
NOTE
• Use a suitable lifting device and tether lines to guide load.
• Coordinate hand signals with assistant prior to lifting.
1. Secure lifting device (Figure 1, Item 1) to load (Figure 1, Item 2).
0015-1
TM 5-3805-294-10 0015
LIFTING - Continued
5
3
1
HYEX00919
Figure 1. Lifting with Quick Latch Loop.
2. Curl bucket (Figure 1, Item 3) and retract arm (Figure 1, Item 4).
3. Attach lifting device (Figure 1, Item 1) to quick latch loop (Figure 1, Item 5).
4. With the aid of an assistant, raise load (Figure 1, Item 2) and verify stability of load and machine (Figure 1,
Item 6) before moving the machine.
END OF TASK
END OF WORK PACKAGE
0015-2
TM 5-3805-294-10 0016
OPERATING TECHNIQUES
INITIAL SETUP:
Equipment Condition
LEVELING MACHINE
NOTE
Operating on a firm, level surface optimizes machine stability.
1. Create a level worksite by counter-rotating the tracks 30 degrees to each side to compact the surface material.
HYEX01483
Figure 1. Leveling Machine.

2. If necessary, use bucket to add or remove material to level the worksite.
HYEX01484
Figure 2. Add or Remove Material.

3. If material is added, drive over new material to compact it until the worksite feels stable.
END OF TASK
0016-1
TM 5-3805-294-10 0016
ARM DIGGING
WARNING
PREVENTING CAVE IN
CAUTION
• When bucket cylinder is fully extended, do not strike the ground or use the bucket for
tamping. Failure to comply may result in damage to equipment.
• Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down
walls using swing motion. Failure to comply may result in damage to equipment.
• Do not side load bucket, swing bucket to level material, or strike objects from the side
with the bucket. Failure to comply may result in damage to equipment.
• If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of
force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket
lightly does not work. Failure to comply may result in damage to equipment.
NOTE
• Initial cut should be approximately 4 ft (122 cm) long and 3-4 in. (76-102 mm) deep.
• Remaining cuts should be approximately 4 ft (122 cm) long and 4-6 in. (102-152 mm)
deep.
1. Position arm in a vertical position.
0016-2
TM 5-3805-294-10 0016
ARM DIGGING - Continued
HYEX01486
Figure 3. Arm Digging.
2. Move arm away from machine approximately 2 ft (61 cm).

3. While retracting arm curl bucket as bucket fills.
END OF TASK
BUCKET DIGGING
WARNING
PREVENTING CAVE IN
CAUTION
• When bucket cylinder is fully extended, do not strike the ground or use the bucket for
tamping. Failure to comply may result in damage to equipment.
• Do not use the bucket as a hammer, pile driver, or attempt to shift rocks and break down
walls using swing motion. Failure to comply may result in damage to equipment.
• Do not side load bucket, swing bucket to level material, or strike objects from the side
with the bucket. Failure to comply may result in damage to equipment.
0016-3
TM 5-3805-294-10 0016
BUCKET DIGGING - Continued
• If you clean the bucket by rapping it against the cylinder stops, use MINIMUM amount of
force to prevent damage to the cylinders. Clean the bucket by hand if rapping the bucket
lightly does not work. Failure to comply may result in damage to equipment.
NOTE
• Ensure that correct bucket is used for the type of material being excavated.
• Excavate in thin layers to fragment material and to ease in dumping material from the
bucket. This especially applies to sticky materials.
• For power digging and for working in confined areas, use the bucket cylinder for digging.
1. Lower bucket to the digging area.
HYEX01485
Figure 4. Bucket Digging.
2. Use boom to force bucket into ground.

3. Retract arm and curl bucket at the same time until bucket is full.
4. If bucket stalls, raise boom slightly then continue to curl bucket .
5. If arm stalls, roll back bucket to break out.
END OF TASK
0016-4
TM 5-3805-294-10 0016
PLANNING SPOIL PILES
WARNING
PREVENTING CAVE IN
1. Place spoil piles at least 3 ft (1 m) away from excavation. The deeper the excavation, the further away the spoil
pile should be placed.
HYEX01487
Figure 5. Planning Spoil Piles.
2. If required, place spoil piles for convenient truck loading or backfilling.

3. On slopes, place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.
END OF TASK
TRENCHING
WARNING
PREVENTING CAVE IN
0016-5
TM 5-3805-294-10 0016
TRENCHING - Continued
1. Before starting work, walk the site to uncover hazards and to plan the job.
HYEX01504
Figure 6. Trenching.
2. Check for buried utility lines, pipes, and gas or oil pipelines.
3. Prevent a cave in by digging a "V" shaped trench placing the spoil pile at least 3 ft (1 m) away from the trench.
4. The deeper the trench, the further away the spoil pile should be placed.
END OF TASK
CLEANING A CAVE IN
1. If you cannot clean a cave in from the machine's current position, DO NOT back over the trench.
HYEX01503
Figure 7. Cleaning Cave In.
2. Drive the machine to the cave in.

3. Park the machine at a 90 degree angle to the trench with the travel motors to the rear of the machine.
0016-6
TM 5-3805-294-10 0016
CLEANING A CAVE IN - Continued
4. Clean cave in from the side of the trench.
END OF TASK
TRENCHING ON A SLOPE
WARNING
PREVENTING CAVE IN
NOTE
The deeper the trench the further away the spoil pile should be.
1. When trenching across a slope, level the machine so that the bottom of the trench will be level.
HYEX01488
Figure 8. Trenching on a Slope.
2. Level machine by counter-rotating tracks or by digging a shelf.

3. Place spoil piles on the upper side of the slope to improve machine stability and ease backfilling.
END OF TASK
0016-7
TM 5-3805-294-10 0016
STRAIGHT LINE TRENCHING
WARNING
PREVENTING CAVE IN
NOTE
The deeper the trench, the further away the spoil pile should be.
1. Drive two stakes in the ground at the beginning of the trench.
HYEX01489
Figure 9. Straight Line Trenching.
2. Drive the first stake immediately behind the start point of the trench. Drive the second stake approximately
30 ft (9 m) behind the first stake.
3. Use stakes as a sight gauge. They are especially helpful when the machine is moved often.
END OF TASK
BACKFILLING
WARNING
PREVENTING CAVE IN
0016-8
TM 5-3805-294-10 0016
BACKFILLING - Continued
CAUTION
Do not use side of bucket to backfill. Failure to comply may result in damage to equipment.
NOTE
The bucket side can be used for finish grading.
1. Position machine at a 90 degree angle to the excavation with the travel motors to the rear of the machine.
HYEX01490
Figure 10. Back Filling.
2. Use material from spoil pile to backfill.
END OF TASK
0016-9
TM 5-3805-294-10 0016
TRUCK LOADING
WARNING
PREVENTING CAVE IN
1. Position bucket and slowly dump load in vehicle at the front center of the bed.
HYEX01491
Figure 11. Truck Loading.

2. Continue to fill bed from front to rear.
END OF TASK
END OF WORK PACKAGE
0016-10
TM 5-3805-294-10 0017
OPERATING THE HYDRAULIC THUMB
INITIAL SETUP:
Not Applicable
GENERAL HYDRAULIC THUMB INFORMATION
The hydraulic thumb was designed to be used for the following:

1. Clamping and lifting.
2. Medium duty scrap handling.
3. Demolition of wood and brick structures.
4. Medium duty land clearing/grubbing.
5. Bulky loose materials.
6. Logging.
The hydraulic thumb was not designed and should not be used for the following:
1. Ripping up concrete or asphalt.
2. Quarry applications.
3. Heavy scrap handling.
4. Heavy land clearing.
5. Heavy grubbing.
6. Breaking ledge rock.
CLAMPING WITH THE BUCKET
1. Position hydraulic thumb (Figure 1, Item 1) near the object to be picked up.
HYEX01175
Figure 1. Clamping With Bucket.
2. Curl the bucket (Figure 1, Item 2) until it begins to force the object to the hydraulic thumb (Figure 1, Item 1).
0017-1
TM 5-3805-294-10 0017
CLAMPING WITH THE BUCKET - Continued
3. Gently move the bucket control to pick the object up without crushing it.
END OF TASK
CLAMPING WITH THE HYDRAULIC THUMB
NOTE
This method is less precise and should only be used when there is no concern about crushing
the object being lifted.
1. Position hydraulic thumb (Figure 2, Item 1) in the store position.
HYEX01174
Figure 2. Clamping With Hydraulic Thumb.
2. Curl bucket (Figure 2, Item 2) and position it near or in contact with the object being picked up.
3. Move hydraulic thumb (Figure 2, Item 1) to grasp and clamp the object.
END OF TASK
0017-2
TM 5-3805-294-10 0017
MOVING AND RELEASING CLAMPED OBJECTS
WARNING
• Never lift clamped objects over personnel. The possibility of the clamped object to fall
always exists. Failure to comply may result in injury or death to personnel.
• Always keep object close to machine when lifting with the hydraulic thumb and bucket.
When the object is moved away from the machine using the boom or arm, the machine
becomes unstable and could roll over. Failure to comply may result in injury or death to
personnel.
• Always look before releasing a load. Never release load while moving or turning. Failure
1. Move object to desired location.
HYEX01174
Figure 3. Releasing Objects.
2. Retract either the hydraulic thumb (Figure 3, Item 1) or bucket (Figure 3, Item 2) to release object.
END OF TASK
END OF WORK PACKAGE
0017-3/4 blank
TM 5-3805-294-10 0018
SELECTING AN ATTACHMENT ON THE MONITOR
INITIAL SETUP:
Equipment Condition
SELECTING ATTACHMENT
1. Press F1 button and Work Mode screen will be displayed.
Work Mode
Dig Breaker 2 Crusher 1
2 1
Breaker 1 Pulverizer 1
1 1
BUTTON
1 1 2 1 1
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
BUTTON
5
F1 BUTTON BUTTON BUTTON
BUTTON 2 3 4 HYEX00172
Figure 1. Select Attachment.
2. Use the following table to select attachment.
Table 1. Attachment Selection.
Attachment to be used Monitor key pad button Attachment mode to be selected
Bucket/Thumb 1 Dig
Breaker 2 Breaker 1
Compactor 3 Breaker 2
Crush-All 4 Pulverizer 1
Deep dig arm 5 Crusher 1
0018-1
TM 5-3805-294-10 0018
SELECTING ATTACHMENT - Continued
3. The attachment specification screen will be displayed.
Breaker 1
Maximum Pump Flow Rate 288.0 L/min
Maximum Engine Speed 1800 min-1
Valve Selector O/T Accumulator OFF
2-Speed Selector OFF 2ndary Hydraulic Relief Selector ON

SELECT
BUTTON
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX00173
Figure 2. Attachment Specification Screen.
4. Verify the attachment specifications are the same as displayed on the monitor.
5. Press the select button. The default screen will be displayed.
END OF TASK
END OF WORK PACKAGE
0018-2
TM 5-3805-294-10 0019
INSTALLING AND OPERATING THE CRUSH-ALL
INITIAL SETUP:
Tools and Special Tools References (cont.)

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

2. Retract hydraulic thumb cylinder (Figure 1, Item 1).
3
4
2
6 1
5
3
HYEX03392
Figure 1. Close Hydraulic Thumb Circuit.

3. Remove retaining clip (Figure 1, Item 2) from pin (Figure 1, Item 3).
4. Remove pin (Figure 1, Item 3) from storage position (Figure 1, Item 4).
0019-1
TM 5-3805-294-10 0019
INSTALLING CRUSH-ALL - Continued
WARNING
Keep hands away from pin and alignment holes while thumb is being moved. Only use prybar
to push pin. Failure to comply may result in injury or death to personnel.
NOTE
Thumb may need to be repositioned multiple times with slight movements of the cylinder until
proper alignment of thumb to arm is achieved in order for pin to slide completely through.
5. Using prybar to push pin (Figure 1, Item 3), install pin in thumb lock position (Figure 1, Item 5).
6. Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).
NOTE
There are two auxiliary circuit shutoff valves. There is one located on both sides of the arm.
Left side shown.
7. Close two auxiliary circuit shut off valves (Figure 1, Item 6).
HYEX03393
9. Fully extend bucket cylinder (Figure 3, Item 8) to ensure quick latch wedges (Figure 3, Item 9) are fully retracted.
0019-2
TM 5-3805-294-10 0019
9
HYEX03394

10. Retract bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is in the vertical position.
8
10
11
HYEX03397
11. Install quick latch (Figure 4, Item 10) to crush-all (Figure 4, Item 11).
12. Extend bucket cylinder (Figure 4, Item 8) until quick latch (Figure 4, Item 10) is resting on crush-all (Figure 4,
Item 11).
13. Move quick latch switch (Figure 5, Item 7) to latch position.
0019-3
TM 5-3805-294-10 0019
HYEX03393
Figure 5. Quick Latch Switch to Latch Position.
14. Raise boom (Figure 6, Item 12) to allow adequate ground clearance of crush-all (Figure 6, Item 11).
14 12
13
8 9 11 HYEX03395
Figure 6. Position Crush-All.
15. Curl crush-all (Figure 6, Item 11) as in Figure 6 until quick latch wedges (Figure 6, Item 9) are fully engaged
to crush-all (Figure 6, Item 11).
17. Extend arm cylinder (Figure 6, Item 14) and lower boom (Figure 6, Item 12) to position crush-all (Figure 6, Item
11) on ground.
18. Shutdown machine. (WP 0009)
19. Clean cap (Figure 7, Item 15) and machine quick disconnect (Figure 7, Item 16) with rag.
0019-4
TM 5-3805-294-10 0019
18
16
17
15
HYEX01501
Figure 7. Connect Auxiliary Supply Line.

20. Clean plug (Figure 7, Item 17) and attachment quick disconnect (Figure 7, Item 18) with rag.
21. Remove cap (Figure 7, Item 15) from machine quick disconnect (Figure 7, Item 16).
22. Remove plug (Figure 7, Item 17) from attachment quick disconnect (Figure 7, Item 18).
23. Connect attachment quick disconnect (Figure 7, Item 18) to machine quick disconnect (Figure 7, Item 16).
24. Clean plug (Figure 8, Item 19) and machine quick disconnect (Figure 8, Item 20) with rag.
27 28
29
26
24
22
20
23, 25
19, 21
HYEX01502
Figure 8. Connect Auxiliary Return Line.

25. Clean cap (Figure 8, Item 21) and attachment quick disconnect (Figure 8, Item 22) with rag.
26. Remove plug (Figure 8, Item 19) from machine quick disconnect (Figure 8, Item 20).
27. Remove cap (Figure 8, Item 20) from attachment quick disconnect (Figure 8, Item 21).
29. Clean plug (Figure 8, Item 23) and machine quick disconnect (Figure 8, Item 24).
31. Remove plug (Figure 8, Item 23) from machine quick disconnect Figure 8, Item (24).
0019-5
TM 5-3805-294-10 0019
34. Remove cap (Figure 8, Item 27) from connector (Figure 8, Item 28).
35. Attach connector (Figure 8, Item 29) to connector (Figure 8, Item 28).
END OF TASK
OPERATION

2. Select the Pulverizer 1 on the monitor. (WP 0018)
3. Turn on the Auxiliary Control Switch. (WP 0004)
4. Adjust discharge size as needed. (WP 0092)
WARNING
• Ensure operator protection guard is installed prior to operation. Failure to comply may
• Crush-All can throw objects at any time during operation. Ensure personnel maintain
distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel.
• Do not reach into machine to remove debris. Failure to comply may result in injury or
death to personnel.
• Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may
CAUTION
Do not overload Crush-All, strike objects or ground, or use sides of Crush-All to move material.
Failure to comply may result in damage to equipment.
NOTE
• When crushing concrete, asphalt, brick, block, or softer stone, the maximum feed size is
18 in. x 18 in. (45.72 cm x 45.72 cm).
• When crushing slag, limestone, or other materials with dirt, the maximum feed size is 15
in. x 5 in. (38.1 cm x 12.7 cm).
• To reduce dust output, wet down material prior to crushing.
5. Place engine at full speed while crushing. (WP 0004)
6. Lift Crush-All (Figure 9, Item 11) approximately 6 ft (182.8 cm) off ground.
0019-6
TM 5-3805-294-10 0019
OPERATION - Continued
34
31 30
32
33
11
HYEX01499
Figure 9. Crush-All Operation.

7. Curl crush-all (Figure 9, Item 11) to vertical position.
8. Release attachment pedal lock (Figure 9, Item 30).
9. Press attachment pedal (Figure 9, Item 31) to turn on Crush-All (Figure 9, Item 11).
10. Allow Crush-All (Figure 9, Item 11) to run for 5 minutes with no load.
11. Press attachment pedal (Figure 9, Item 31) and press button (Figure 9, Item 32) to open lid (Figure 9, Item
33).
NOTE
Scooping material is best performed by arming into the material, then boom up and curl as
the Crush-All is elevated above material.
12. Scoop material and raise Crush-All (Figure 9, Item 11) away from material.
13. Curl Crush-All (Figure 9, Item 11) to vertical position.
NOTE
Reduce dust by keeping bottom of Crush-All close to stock pile.
14. Swing Crush-All (Figure 9, Item 11) over stock pile.
15. Press button (Figure 9, Item 34) to close lid (Figure 9, Item 32).
16. Allow all material to pass through crush-all (Figure 9, Item 11).
NOTE
To avoid jamming, hold attachment pedal until all material has been discharged.
17. Release attachment pedal (Figure 9, Item 31) to turn off crush-all (Figure 9, Item 11).
0019-7
TM 5-3805-294-10 0019
OPERATION - Continued
18. Engage attachment pedal lock (Figure 9, Item 30).
END OF TASK
JAMMING
WARNING
• Ensure operator protection guard is installed prior to operation. Failure to comply may
• Crush-All can throw objects at any time during operation. Ensure personnel maintain
distance of 150 ft (45.72 m). Failure to comply may result in injury or death to personnel.
• Do not reach into machine to remove debris. Failure to comply may result in injury or
death to personnel.
• Do not operate Crush-All with guards, panels, or covers removed. Failure to comply may
CAUTION
Do not attempt to clear jam by striking Crush-All on ground. Failure to comply may result in
damage to equipment.
NOTE
• These steps may be used to clear uncrushable material from machine.
• It may be necessary to shake Crush-All.
1. Press attachment pedal (Figure 10, Item 31) and press button (Figure 10, Item 32) to open lid (Figure 10, Item
33).
0019-8
TM 5-3805-294-10 0019
JAMMING - Continued
31
32
33
HYEX03431
Figure 10. Open Lid.
2. Retract bucket cylinder (Figure 11, Item 8) to dump crush-all (Figure 10, Item 11) upside down and allow
material to fall out.
11
HYEX03148
Figure 11. Clearing Jam from Crush-All.

3. Safely park and shutdown machine. (WP 0009)
4. Use a sturdy piece of lumber to push rotor (Figure 12, Item 34) in reverse.
0019-9
TM 5-3805-294-10 0019
JAMMING - Continued
35
34
HYEX03149
Figure 12. Push Crush-All Rotor Backwards.

5. If material is jammed between the curtain (Figure 12, Item 35) and rotor (Figure 12, Item 34), raise curtain.
(WP 0092)
6. If material will not dislodge, contact Field Level Maintenance.
END OF TASK
REMOVING CRUSH-ALL
14 12
11 HYEX03432
Figure 13. Position Crush-All.
2. Curl crush-all (Figure 13, Item 11) under as shown in Figure 13.
3. Extend arm cylinder (Figure 13, Item 14), lower boom (Figure 13, Item 12), and position crush-all (Figure 13,
Item 11) on ground.
0019-10
TM 5-3805-294-10 0019
REMOVING CRUSH-ALL - Continued
5. Remove connector (Figure 14, Item 29) from connector (Figure 14, Item 28).
27 28
29
26
24
22
20
23, 25
19, 21
HYEX01502
Figure 14. Disconnect Auxiliary Return Line.

6. Install cap (Figure 14, Item 27) to connector (Figure 14, Item 28).
7. Clean attachment quick disconnect (Figure 14, Item 26) and machine quick disconnect (Figure 14, Item 24)
with rag.
8. Clean cap (Figure 14, Item 25) and plug (Figure 14, Item 23) with rag.
9. Remove attachment quick disconnect (Figure 14, Item 26) from machine quick disconnect (Figure 14, Item
24).
10. Install cap (Figure 14, Item 25) to attachment quick disconnect (Figure 14, Item 26).
11. Install plug (Figure 14, Item 23) to machine quick disconnect (Figure 14, Item 24).
with rag.
20).
with rag.
0019-11
TM 5-3805-294-10 0019
18
16
17
15
HYEX01501
Figure 15. Disconnect Auxiliary Supply Line.

16).
20. Install plug (Figure 15, Item 17) to attachment quick disconnect (Figure 15, Item 18).
21. Install cap (Figure 15, Item 15) to machine quick disconnect (Figure 15, Item 16).
HYEX03393
Figure 16. Move Quick Latch Switch.

0019-12
TM 5-3805-294-10 0019
14 12
13
8 9 11 HYEX03433
25. Lift and rotate safety lock pin lever (Figure 17, Item 13) to unlock position.
WARNING
With quick latch wedges disengaged from crush-all, the crush-all could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing crush-all.
Slowly retract or extend bucket cylinder when removing or installing crush-all. Failure to
comply may result in injury or death to personnel.
26. Fully extend bucket cylinder (Figure 17, Item 8) until quick latch wedges (Figure 17, Item 9) are fully retracted.
27. Retract bucket cylinder (Figure 17, Item 8), arm cylinder (Figure 17, Item 14), and lower boom to position crush-
all (Figure 17, Item 11) on the ground.
28. Retract bucket cylinder (Figure 18, Item 8) and position quick latch (Figure 18, Item10) in vertical position.
0019-13
TM 5-3805-294-10 0019
8
10
11
HYEX03397
29. Remove quick latch (Figure 18, Item 10) from crush-all (Figure 18, Item 11).
30. Move quick latch switch (Figure 19, Item 7) to latch position.
HYEX03393

31. Lower arm (Figure 20, Item 35) to ground.
0019-14
TM 5-3805-294-10 0019
3
4
2
4
6 1
5
5 3
35
HYEX01500
Figure 20. Open Hydraulic Thumb Circuit.
NOTE
Left side shown.
32. Open two auxiliary circuit shut off valves (Figure 20, Item 6).
WARNING
NOTE
34. Retract or extend thumb cylinder (Figure 20, Item 1) to remove pin (Figure 20, Item 3) from thumb lock position
(Figure 20, Item 5).
35. Install pin (Figure 20, Item 3) in storage position (Figure 20, Item 4).
36. Install retaining pin (Figure 20, Item 2) on pin (Figure 20, Item 3).
END OF TASK
END OF WORK PACKAGE
0019-15/16 blank
TM 5-3805-294-10 0020
INSTALLING AND OPERATING THE IMPACT BREAKER
INITIAL SETUP:
Tools and Special Tools Materials/Parts (cont.)

Screwdriver, Pry Bar, 12 in. (304 mm) Long (WP 0097, Table 1, Item 10)
(WP 0095, Table 2, Item 11) Rags, Wiping (WP 0097, Table 1, Item 15)
Wrench, Open End, 2 1/2 in. (63.5 mm) References
WP 0007
Wrench, Open End, 3 in. (76 mm) WP 0009
(WP 0095, Table 2, Item 14) WP 0018
Materials/Parts Equipment Condition

Grease, Automotive and Artillery, GAA Machine safely parked and shutdown. (WP 0009)
Bucket removed. (WP 0014)
INSTALLING IMPACT BREAKER
1. Start the machine. (WP 0007)

3
4
2
6 1
5
3
HYEX01321

0020-1
TM 5-3805-294-10 0020
INSTALLING IMPACT BREAKER - Continued
WARNING
NOTE
5. With the aid of an assistant, extend or retract thumb cylinder (Figure 1, Item 1), as needed, while using prybar
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).
6. Install retaining clip (Figure 1, Item 2) to pin (Figure 1, Item 3).
NOTE
Left side shown.
7. Close two auxiliary circuit shutoff valves (Figure 1, Item 6).
8. Move quick latch switch (Figure 2, Item 7) to UNLATCH position.
HYEX03398
0020-2
TM 5-3805-294-10 0020
HYEX03399

retracted.
10
HYEX03400
Figure 4. Quick Latch Wedges Retracted.
0020-3
TM 5-3805-294-10 0020
11
12
HYEX03402
12. Install quick latch (Figure 5, Item 11) to impact breaker (Figure 5, Item 12).
WARNING
With quick latch wedges disengaged from impact breaker, the impact breaker could fall off
of the quick latch. Ensure that personnel are clear of equipment when removing or installing
impact breaker. Slowly retract or extend bucket cylinder when removing or installing impact
breaker. Failure to comply may result in injury or death to personnel.
13. With the aid of an assistant slowly raise boom (Figure 5, Item 8) to allow for adequate ground clearance of
quick latch (Figure 5, Item 11).
14. Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on impact breaker
(Figure 6, Item 12)
12
11
HYEX03403
0020-4
TM 5-3805-294-10 0020
15. Move quick latch switch (Figure 7, Item 7) to LATCH position.
HYEX03398
Figure 7. Move Quick Latch Switch to Latch Position.

16. Extend bucket cylinder (Figure 8, Item 9) until quick latch wedges (Figure 8, Item 10) are fully engaged to
impact breaker (Figure 8, Item 12).
10
12 HYEX03401
Figure 8. Quick Latch Wedges Engaged.
17. Retract bucket cylinder (Figure 8, Item 9) and place impact breaker (Figure 8, Item 12) on ground.
0020-5
TM 5-3805-294-10 0020
HYEX03406
13
Figure 9. Safety Pin to Lock Position.
17
15
16
14
HYEX01322

0020-6
TM 5-3805-294-10 0020
21
19
18
20
HYEX01323

END OF TASK
TOOL INSTALLATION
NOTE
• Select the proper tool before operation.
• Chisel is for most earth moving duties in narrow trenches and layered rock or soil up to
medium hardness.
• Moil is for demolition of medium hardness rock or materials except layered rock.
• Blunt is for breaking large, medium hardness rocks into smaller pieces.
1. Press and turn lock bolt (Figure 12, Item 22) to unlocked position with slot (Figure 12, Item 23) pointed to the
tool end of breaker (Figure 12, Item 12).
0020-7
TM 5-3805-294-10 0020
TOOL INSTALLATION - Continued
22 23
24
12
26
25
HYEX01326
Figure 12. Breaker Tool Lock Bolt.

2. Push the retaining axle (Figure 12, Item 24) out of the breaker (Figure 12, Item 12) through hole (Figure 12,
Item 25).
3. Repeat Steps 1 and 2 for other retaining axle.
4. Lubricate bushing (Figure 12, Item 26) with grease.
WARNING
Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without
the aid of an assistant and suitable lifting device. Failure to comply may result in injury or
death to personnel.
NOTE
Ensure cavity is free of debris and tool is properly lubricated.
5. With the aid of an assistant and suitable lifting device, slide tool (Figure 13, Item 27) into breaker (Figure 13,
Item 12) with side notches (Figure 13, Item 28) in alignment with axle slots (Figure 13, Item 29).
0020-8
TM 5-3805-294-10 0020
TOOL INSTALLATION - Continued
12 29
27
28
HYEX01327
Figure 13. Insert Breaker Tool.

6. Install retaining axle (Figure 14, Item 24) to breaker (Figure 14, Item 12).
12
24
23 22
HYEX01328
Figure 14. Lock Breaker Tool.

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

2. Select work mode BREAKER 1 on the monitor. (WP 0018)
CAUTION
Breaker must be lubricated every 2 hours of use and every hour during dusty conditions.
Failure to comply may result in damage to the attachment.
NOTE
• Keep tool perpendicular to work surface.
• Keep machine close to work area.
• Maintain constant, even pressure as tool penetrates work surface.
0020-9
TM 5-3805-294-10 0020
OPERATING IMPACT BREAKER - Continued
• Increase down pressure when strokes have a metallic sound.

• Decrease down pressure when strokes cause strong vibrations in the machine.
8 30
12 31
HYEX01520
Figure 15. Breaker Operation.

4. Apply boom (Figure 15, Item 8) down pressure to impact breaker (Figure 15, Item 12) on work area.
5. Press attachment pedal (Figure 15, Item 31) to start impact breaker (Figure 15, Item 12).
6. Release attachment pedal (Figure 15, Item 31) to stop impact breaker (Figure 15, Item 12) before retracting
from work area.
END OF TASK
TOOL REMOVAL
1. Raise breaker (Figure 16, Item 12) off ground and extend bucket cylinder (Figure 16, Item 9) until breaker is
horizontal.
9 24
12
23
25
22
HYEX03440
Figure 16. Tool Removal.
0020-10
TM 5-3805-294-10 0020
TOOL REMOVAL - Continued
2. Press and turn lock bolt (Figure 16, Item 22) to unlocked position with slot (Figure 16, Item 23) pointed to the
tool end of breaker (Figure 16, Item 12).
3. Push the retaining axle (Figure 16, Item 24) out of the breaker (Figure 16, Item 12) through hole (Figure 16,
Item 25).
WARNING
Breaker tools weigh approximately 275 lb (102 kg). Do not attempt to lift or move tools without
the aid of an assistant and suitable lifting device. Failure to comply may result in injury or
death to personnel.
5. With the aid of an assistant and suitable lifting device, slide tool (Figure 17, Item 27) out of breaker (Figure 17,
Item 12).
12
27
HYEX03439
Figure 17. Remove Breaker Tool.

6. Install retaining axle (Figure 18, Item 24) to breaker (Figure 18, Item 12).
12
24
23 22
HYEX01328
Figure 18. Lock Breaker Tool.

7. Press and turn lock bolt (Figure 18, Item 22) to locked position with slot (Figure 18, Item 23) pointed to top of
breaker (Figure 18 , Item 12).
0020-11
TM 5-3805-294-10 0020
TOOL REMOVAL - Continued
END OF TASK
REMOVING IMPACT BREAKER
1. Safely park and shut down machine. (WP 0009)

2. Clean machine quick disconnect (Figure 19, Item 19) and attachment quick disconnect (Figure 19, Item 21)
with rag.
21
19
18
20
HYEX01323

19).
7. Clean machine quick disconnect (Figure 20, Item 15) and attachment quick disconnect (Figure 20, Item 17)
with rag.
17
15
16
14
HYEX01322
Figure 20. Disconnect Auxiliary Supply Line.

15).
0020-12
TM 5-3805-294-10 0020
REMOVING IMPACT BREAKER - Continued
12. Lift and rotate safety lock pin lever (Figure 21, Item 13) to unlock position.
HYEX03406
13
Figure 21. Safety Pin to Unlock Position.

HYEX03399

0020-13
TM 5-3805-294-10 0020
HYEX03398
16. Extend bucket cylinder (Figure 24, Item 9) until quick latch wedges (Figure 24, Item 10) are fully retracted.
10
12 HYEX03401
17. Retract bucket cylinder (Figure 25, Item 9) until tool end of impact breaker (Figure 25, Item 12) is resting on
ground and quick latch (Figure 25, Item 11) is in vertical position.
0020-14
TM 5-3805-294-10 0020
11
12
HYEX03402
Figure 25. Impact Breaker Removal.

18. Lower boom (Figure 25, Item 8) until impact breaker (Figure 25, Item 12) is resting on ground.
19. Remove quick latch (Figure 25, Item 11) from impact breaker (Figure 25, Item 12).
HYEX03398
NOTE
Left side shown.
21. Open two auxiliary circuit shutoff valves (Figure 27, Item 6).
0020-15
TM 5-3805-294-10 0020
3
4
2
6 1
5
3
HYEX01321
Figure 27. Open Hydraulic Thumb Circuit.

22. Remove retaining pin (Figure 27, Item 2) from pin (Figure 27, Item 3).
WARNING
NOTE
to remove pin (Figure 27, Item 3) from thumb lock position (Figure 27, Item 5).
25. Install retaining pin (Figure 27, Item 2) to pin (Figure 27, Item 3).
26. Safely park and shut down machine. (WP 0009)
END OF TASK
END OF WORK PACKAGE
0020-16
TM 5-3805-294-10 0021
INSTALLING AND OPERATING THE COMPACTOR
INITIAL SETUP:

Screwdriver, Pry Bar, 12 in. (304 mm) Long WP 0009
(WP 0095, Table 2, Item 11) WP 0018
Wrench, Open End, 2 1/2 in. (63.5 mm) Equipment Condition
Safely park and shutdown machine. (WP 0009)
Wrench, Open End, 3 in. (76 mm) Bucket removed. (WP 0014)
Materials/Parts
References
WP 0007
INSTALLING COMPACTOR
WARNING
0021-1
TM 5-3805-294-10 0021
INSTALLING COMPACTOR - Continued
3
4
2
6 1
5
3
HYEX03411

WARNING
NOTE
to install pin (Figure 1, Item 3) to thumb lock position (Figure 1, Item 5).
6. Install retaining clip (Figure 1, Item 2) on pin (Figure 1, Item 3).
NOTE
Left side shown.
7. Close two auxiliary circuit shut off valves (Figure 1, Item 6).
0021-2
TM 5-3805-294-10 0021
HYEX03412
HYEX03413

retracted.
0021-3
TM 5-3805-294-10 0021
10
HYEX03414
11
12
HYEX03415
12. Install quick latch (Figure 5, Item 11) to compactor (Figure 5, Item 12).
13. Extend bucket cylinder (Figure 6, Item 9) until quick latch (Figure 6, Item 11) is resting on compactor (Figure
6, Item 12).
0021-4
TM 5-3805-294-10 0021
11
12
HYEX03416
Figure 6. Position Quick Latch.
HYEX03412
WARNING
With quick latch wedges disengaged from compactor, the compactor could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing compactor.
Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to
0021-5
TM 5-3805-294-10 0021
HYEX03413
16. Extend bucket cylinder (Figure 9, Item 9) until quick latch wedges (Figure 9, Item 10) are fully engaged to
compactor (Figure 9, Item 12).
12
10
HYEX03417
Figure 9. Engage Quick Latch Wedges.
17. Retract bucket cylinder (Figure 9, Item 9) and position compactor (Figure 9, Item 12) on ground.
0021-6
TM 5-3805-294-10 0021
13
HYEX03418
Figure 10. Lock Safety Lock.
17
15
16
14
HYEX03419

0021-7
TM 5-3805-294-10 0021
21
19
18
20
HYEX03420

END OF TASK
OPERATING THE COMPACTOR

2. Select Breaker 2 on the monitor. (WP 0018)
22
23
12
24
HYEX01325
Figure 13. Attachment Pedal Lock Release.

4. Press attachment pedal (Figure 13, Item 23) to turn on compactor (Figure 13, Item 12).
5. Position compactor (Figure 13, Item 12) on work surface.
6. Apply boom down pressure to deflect rubber isolators (Figure 13, Item 24) approximately half way.
0021-8
TM 5-3805-294-10 0021
OPERATING THE COMPACTOR - Continued
7. Move compactor (Figure 13, Item 12) over work surface while continuing to apply down pressure.
8. Release attachment pedal (Figure 13, Item 23) to stop compactor (Figure 13, Item 12).
END OF TASK
REMOVING THE COMPACTOR
with rag.
21
19
18
20
HYEX03420
2. Clean cap (Figure 14, Item 20) with rag.

3. Clean plug (Figure 14, Item 18) with rag.
19).
with rag.
0021-9
TM 5-3805-294-10 0021
REMOVING THE COMPACTOR - Continued
17
15
16
14
HYEX03419
8. Clean plug (Figure 15, Item 16) with rag.

9. Clean cap (Figure 15, Item 14) with rag.
15).
13. Rotate safety lock pin lever (Figure 16, Item 13) to unlock position.
13
HYEX03421
Figure 16. Unlock Safety Lock.

0021-10
TM 5-3805-294-10 0021
HYEX03412
Figure 17. Quick Latch Switch to Unlatch Position.

HYEX03413
WARNING
With quick latch wedges disengaged from compactor, the compactor could fall off of the quick
latch. Ensure that personnel are clear of equipment when removing or installing compactor.
Slowly retract or extend bucket cylinder when removing or installing compactor. Failure to
17. Extend bucket cylinder (Figure 19, Item 9) until quick latch wedges (Figure 19, Item 10) are disengaged from
compactor (Figure 19, Item 12).
0021-11
TM 5-3805-294-10 0021
12
10
HYEX03417
Figure 19. Disengage Quick Latch Wedges.
18. Retract bucket cylinder (Figure 20, Item 9) until quick latch (Figure 20, Item 11) is in vertical position.
11
HYEX03422
Figure 20. Retract Bucket Cylinder.
NOTE
Removal of the arm/quick latch from the compactor is seldom done the same way twice. A
combination of slow and smooth boom down and arm in movements is required.
19. Fully retract arm cylinder (Figure 21, Item 24).
0021-12
TM 5-3805-294-10 0021
24
8
11
12
25 HYEX03424
20. Lower boom (Figure 21, Item 8) until compactor plate (Figure 21, Item 25) is just touching the ground.
NOTE
The compactor will likely become wedged between the ground the quick latch/arm until it
"pops" out of the hooks. When this wedged situation occurs, ensure that the tracks do not
begin to raise. If tracks begin to raise: stop movements, raise boom, and try again.
21. Start with arm in movement until a small amount of pressure is placed on the ground with the compactor (Figure
21, Item 12), then begin to boom down while continuing to arm in until quick latch (Figure 21, Item 11) is
removed from compactor.
HYEX03412
NOTE
Left side shown.
0021-13
TM 5-3805-294-10 0021
23. Open two auxiliary circuit shutoff valves (Figure 23, Item 6).
3
4
2
6 1
5
3
HYEX03411

24. Remove retaining pin (Figure 23, Item 2) from pin (Figure 23, Item 3).
WARNING
NOTE
to remove pin (Figure 23, Item 3) from thumb lock position (Figure 23, Item 5).
27. Install retaining pin (Figure 23, Item 2) to pin (Figure 23, Item 3).
END OF TASK
END OF WORK PACKAGE
0021-14
TM 5-3805-294-10 0022
OPERATING THE BARRIER GRAPPLE
INITIAL SETUP:

Lifting Device, Minimum Capacity 16,000 lbs Engine running. (WP 0007)
(72574.8 kg)
BARRIER GRAPPLE OPERATION
WARNING
LIFTING GUIDELINES:
• Do not use machine to lift personnel. Failure to comply may result in injury or death to
personnel.
• Do not hook lifting device to bucket teeth. Failure to comply may result in injury or death
to personnel.
• Ensure load does not exceed the capacity of machine or lifting device. Failure to comply
• Lift load only as high as necessary. Failure to comply may result in injury or death to
personnel.
• Move load slowly. Do not allow lifted items to strike obstacles. Failure to comply may
• Personnel must remain clear of lifted items. Failure to comply may result in injury or death
to personnel.
NOTE
Barrier grapple weighs 870 lb (395 kg) with a lift capacity of 16,000 lb (7257.48 kg).
1. Attach barrier grapple (Figure 1, Item 1) to quick latch loop (Figure 1, Item 2) with suitable lifting device (Figure
1, Item 3).
0022-1
TM 5-3805-294-10 0022
BARRIER GRAPPLE OPERATION - Continued
HYEX02585
Figure 1. Lifting Barrier Grapple.
2. Position barrier grapple (Figure 1, Item 1) near center of barrier (Figure 1, Item 4).
3. Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically close on the barrier.
CAUTION
Avoid jerky lifting, striking, and poor alignment with barriers. Failure to comply may result in
4. Slowly raise barrier grapple (Figure 1, Item 1) and barrier (Figure 1, Item 4).
5. Position barrier (Figure 1, Item 4) in desired location.
6. Slowly lower barrier grapple (Figure 1, Item 1) on to barrier (Figure 1, Item 4) until tension is released from
lifting device (Figure 1, Item 3). The barrier grapple will automatically latch open and release the barrier.
0022-2
TM 5-3805-294-10 0022
BARRIER GRAPPLE OPERATION - Continued
7. Raise barrier grapple (Figure 1, Item 1).
END OF TASK
END OF WORK PACKAGE
0022-3/4 blank
TM 5-3805-294-10 0023
OPERATING THE DEEP DIG ARM
INITIAL SETUP:

WP 0010 Engine running. WP 0007
WP 0077
DEEP DIG ARM OPERATION
CAUTION
Do not attempt to extend the arm cylinder with the deep dig arm attached. The deep dig arm
can strike the machine. Failure to comply may result in damage to equipment.
NOTE
After the Deep Dig Attachment has been installed on the machine, the following steps must
be performed to enable Deep Dig Arm Operation.
1. Remove clip (Figure 1, Item 1) from switch bracket (Figure 1, Item 2).
HYEX01519
3 2 1
Figure 1. Deep Dig Control Pattern Switch.
2. Move switch (Figure 1, Item 3) to ON position and install pin (Figure 1, Item 1).
3. Switch A/I (Figure 2, Item 4) to on position
0023-1
TM 5-3805-294-10 0023
DEEP DIG ARM OPERATION - Continued
HYEX03404
Figure 2. Turn Auto Idle Switch On.

4. Move pilot shutoff lever (Figure 3, Item 5) to unlocked position (down).
0023-2
TM 5-3805-294-10 0023
5
HYEX01518

5. Turn RPM dial (Figure 4, Item 6) to max RPM setting.
0023-3
TM 5-3805-294-10 0023
HYEX03405
Figure 4. Turn RPM Dial.
NOTE
• When the deep dig control pattern switch is in the ON position, the arm cylinder is
controlled by the attachment pedal and can only be retracted.
• The arm cylinder can only be retracted. It is necessary to occasionally retract the arm
cylinder due to the weight of the deep dig arm.
• With the deep dig control pattern switch in the ON position, the pilot control levers operate
in the same way.
6. Slowly cycle bucket cylinder (Figure 5, Item 5) and deep dig bucket cylinder (Figure 5, Item 6) until full smooth
movement of each cylinder is obtained.
0023-4
TM 5-3805-294-10 0023
HYEX01636
Figure 5. Cycle Deep Dig Arm Cylinders.
7. Park and shut down machine. (WP 0010)

8. Check hydraulic oil level. (WP 0077)
END OF TASK
END OF WORK PACKAGE
0023-5/6 blank
TM 5-3805-294-10 0024
MOVING MACHINE ON/OFF AN EMBANKMENT
INITIAL SETUP:
Not Applicable
MOVING MACHINE ON AN EMBANKMENT
CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to
1. Position flat surface of bucket (Figure 1, Item 1) on upper level of embankment with arm (Figure 1, Item 2) to
boom (Figure 1, Item 3) angle at 90 degrees.
5
2
HYEX01102
Figure 1. Position Bucket.
2. Lower boom (Figure 1, Item 3) to raise undercarriage until front of tracks (Figure 1, Item 4) clear edge of
embankment.
3. Drive machine (Figure 1, Item 5) towards upper level as arm (Figure 1, Item 2) is retracted.
4. Slowly raise boom (Figure 1, Item 3) until tracks (Figure 1, Item 4) are resting on upper level of embankment.
5. Rotate upper structure (Figure 2, Item 6) 180 degrees towards lower level of embankment.
0024-1
TM 5-3805-294-10 0024
MOVING MACHINE ON AN EMBANKMENT - Continued
3
2
4
1
HYEX01104
Figure 2. Upperstructure Rotated.
6. Position flat surface of bucket (Figure 2, Item 1) on lower level of embankment with arm (Figure 2, Item 2) to
7. Drive machine (Figure 2, Item 5) towards upper level while extending arm (Figure 2, Item 2) until machine is
completely on upper level of embankment.
END OF TASK
MOVING MACHINE OFF AN EMBANKMENT
CAUTION
Do not allow machine to impact the ground with the bucket absorbing the force. Failure to
1. Position flat surface of bucket (Figure 3, Item 1) on lower level of embankment with arm (Figure 3, Item 2) to
0024-2
TM 5-3805-294-10 0024
MOVING MACHINE OFF AN EMBANKMENT - Continued
5
3
4
1
HYEX00689
Figure 3. Position Bucket on Lower Level.
2. Drive machine (Figure 3, Item 5) towards lower level while raising boom (Figure 3, Item 3) and retracting arm
(Figure 3, Item 2) until front of tracks (Figure 3, Item 4) reach lower level of embankment.
3. Raise bucket (Figure 4, Item 1) off of the ground and rotate upper structure (Figure 4, Item 6) 180 degrees
towards upper level of embankment.
3
2
5
HYEX01103
Figure 4. Rotate Upperstructure to Upper Level.
4. Position flat surface of bucket (Figure 4, Item 1) on upper level of embankment with arm (Figure 4, Item 2) to
0024-3
TM 5-3805-294-10 0024
MOVING MACHINE OFF AN EMBANKMENT - Continued
5. Lower boom (Figure 4, Item 3) slightly and drive machine (Figure 4, Item 5) towards lower level as the arm
(Figure 4, Item 2) is extended.
6. When tracks (Figure 4, Item 4) clear upper level of embankment, slowly raise boom (Figure 4, Item 3) until
machine (Figure 4, Item 5) is on lower level.
END OF TASK
END OF WORK PACKAGE
0024-4
TM 5-3805-294-10 0025
USING THE VANDAL PROTECTION KIT
INITIAL SETUP:
Not Applicable
RIGHT SIDE CAB INSTALLATION
1. Position cover (Figure 1, Item 1) on cab hook (Figure 1, Item 2) and behind brackets (Figure 1, Item 3).
2 1
HYEX01548
Figure 1. Right Side Rear Cover Installation.
5 4
HYEX01549
Figure 2. Right Side Center Cover Installation.
0025-1
TM 5-3805-294-10 0025
RIGHT SIDE CAB INSTALLATION - Continued
8 7
HYEX01550
Figure 3. Right Side Front Cover Installation.
4. Position plate (Figure 4, Item 10) over tabs (Figure 4, Item 11) and turn lock (Figure 4, Item 12) to lock in place.
11 10
11
12
HYEX01551
Figure 4. Lock Bar Installation.
END OF TASK
LEFT SIDE CAB INSTALLATION
1. Position cover (Figure 5, Item 13) over door hook (Figure 5, Item 14) and behind brackets (Figure 5, Item 15).
0025-2
TM 5-3805-294-10 0025
LEFT SIDE CAB INSTALLATION - Continued
14 13
15
HYEX01552
Figure 5. Front Door Cover Installation.
2. Position cover (Figure 6, Item 16) over cab hook (Figure 6, Item 17) and behind brackets (Figure 6, Item 18).
17 16
18
HYEX01553
Figure 6. Center Door Cover Installation.

3. Position cover (Figure 7, Item 19) over hooks (Figure 7, Item 20) and behind brackets (Figure 7, Item 21).
0025-3
TM 5-3805-294-10 0025
20 20
21
24
23
22 19 HYEX01554
Figure 7. Lower Door Cover Installation.
4. Position hinge (Figure 7, Item 22) over tab (Figure 7, Item 23) and turn lock (Figure 7, Item 24) to lock in place.
5. Position cover (Figure 8, Item 25) over cab hooks (Figure 8, Item 26) and behind bracket (Figure 8, Item 27).
26 26
25
27
HYEX01555
Figure 8. Side Upper Glass Cover Installation.
6. Position cover (Figure 9, Item 28) over hooks (Figure 9, Item 29) and behind brackets (Figure 9, Item 30).
0025-4
TM 5-3805-294-10 0025
29
30
28
33
32
31 HYEX01556
Figure 9. Side Lower Glass Cover Installation.
7. Place hinge (Figure 9, Item 31) over tab (Figure 9, Item 32) and turn lock (Figure 9, Item 33) to lock in place.
END OF TASK
REAR CAB INSTALLATION
1. Position cover (Figure 10, Item 34) over cab hook (Figure 10, Item 35) and behind brackets (Figure 10, Item
36).
34 35
36 HYEX01557
Figure 10. Right Rear Cab Cover Installation.

2. Position cover (Figure 11, Item 37) over tab (Figure 11, Item 38) and behind brackets (Figure 11, Item 39).
0025-5
TM 5-3805-294-10 0025
REAR CAB INSTALLATION - Continued
38
40
39
37 HYEX01558
Figure 11. Left Rear Cab Cover Installation.
3. Turn lock (Figure 11, Item 40) to lock in place.
END OF TASK
REAR CAB REMOVAL
1. Turn lock (Figure 12, Item 40) to unlock.
38
40
39
37 HYEX01558
Figure 12. Left Rear Cab Cover Removal.
2. Remove cover (Figure 12, Item 37) from behind brackets (Figure 12, Item 39) and from tab (Figure 12, Item
38).
0025-6
TM 5-3805-294-10 0025
REAR CAB REMOVAL - Continued
3. Remove cover (Figure 13, Item 34) from behind brackets (Figure 13, Item 36) and cab hook (Figure 13, Item
35).
34 35
36 HYEX01557
Figure 13. Right Rear Cab Cover Removal.
END OF TASK
LEFT SIDE CAB REMOVAL
1. Turn lock (Figure 14, Item 33) to unlock and remove hinge (Figure 14, Item 31) from tab (Figure 14, Item 32).
29
30
28
33
32
31 HYEX01556
Figure 14. Side Lower Glass Cover Removal.
2. Remove cover (Figure 14, Item 28) from behind brackets (Figure 14, Item 30) and hooks (Figure 14, Item 29).
3. Remove cover (Figure 15, Item 25) from behind bracket (Figure 15, Item 27) and cab hooks (Figure 15, Item
26).
0025-7
TM 5-3805-294-10 0025
LEFT SIDE CAB REMOVAL - Continued
26 26
25
27
HYEX01555
Figure 15. Side Upper Glass Cover Removal.
4. Turn lock (Figure 16, Item 24) to unlock and remove hinge (Figure 16, Item 22) from tab (Figure 16, Item 23).
20 20
21
24
23
22 19 HYEX01554
Figure 16. Lower Door Cover Removal.
5. Remove cover (Figure 16, Item 19) from behind brackets (Figure 16, Item 21) and hooks (Figure 16, Item 20).
6. Remove cover (Figure 17, Item 16) from behind brackets (Figure 17, Item 18) and cab hooks (Figure 17, Item
17).
0025-8
TM 5-3805-294-10 0025
LEFT SIDE CAB REMOVAL - Continued
17 16
18
HYEX01553
Figure 17. Center Door Cover Removal.
7. Remove cover (Figure 18, Item 13) from behind brackets (Figure 18, Item 15) and door hooks (Figure 18, Item
14).
14 13
15
HYEX01552
Figure 18. Front Door Cover Removal.
END OF TASK
RIGHT SIDE CAB REMOVAL
1. Turn lock (Figure 19, Item 12) to unlock and remove plate (Figure 19, Item 10) from tabs (Figure 19, Item 11).
0025-9
TM 5-3805-294-10 0025
RIGHT SIDE CAB REMOVAL - Continued
11 10
11
12
HYEX01551
Figure 19. Lock Bar Removal.
2. Remove cover (Figure 20, Item 7) from behind brackets (Figure 20, Item 9) and cab hook (Figure 20, Item 8).
8 7
HYEX01550
Figure 20. Right Side Front Cover Removal.
5 4
HYEX01549
Figure 21. Right Side Center Cover Removal.
0025-10
TM 5-3805-294-10 0025
RIGHT SIDE CAB REMOVAL - Continued
2 1
HYEX01548
Figure 22. Right Side Rear Cover Removal.
END OF TASK
END OF WORK PACKAGE
0025-11/12 blank
TM 5-3805-294-10 0026
OPERATING THE HYDRAULIC HOSE REEL
INITIAL SETUP:

Rags, Wiping (WP 0097, Table 1, Item 15) Machine safely parked and shut down.
(WP 0009)
References
WP 0007
WP 0009
CONNECTING HYDRAULIC TOOL
1. Remove cover (Figure 1, Item 1) from quick coupler (Figure 1, Item 2).
5
6
2
4
1
3
HYEX01097
Figure 1. Hydraulic Tool Attachment.

2. Remove cover (Figure 1, Item 3) from quick coupler (Figure 1, Item 4).
3. Using a clean rag, wipe quick coupler (Figure 1, Item 2) and (Figure 1, Item 4) and couplers on tool to be
connected.
4. Connect quick coupler (Figure 1, Item 2) on return hose (Figure 1, Item 5) to hydraulic tool.
5. Connect quick coupler (Figure 1, Item 4) on supply hose (Figure 1, Item 6) to hydraulic tool.
0026-1
TM 5-3805-294-10 0026
CONNECTING HYDRAULIC TOOL - Continued
7. Move hand held hydraulic tool circuit switch (Figure 2, Item 7) to ON position.
8
7
HYEX01096
Figure 2. Turn On Hydraulic Tool.

8. Adjust flow regulator (Figure 2, Item 8) to tool specification.
END OF TASK
DISCONNECTING HYDRAULIC TOOL
1. Move flow regulator (Figure 3, Item 8) to lowest setting.
8
7
HYEX01096
Figure 3. Turn Off Hydraulic Tool.

2. Move hand held hydraulic tool circuit switch (Figure 3, Item 7) to OFF position.
3. Shut engine off. (WP 0009)
0026-2
TM 5-3805-294-10 0026
DISCONNECTING HYDRAULIC TOOL - Continued
4. Operate hydraulic tool to relieve pressure from hoses.

5. Disconnect quick coupler (Figure 4, Item 4) on supply hose (Figure 4, Item 6) from hydraulic tool.
5
6
2
4
1
3
HYEX01097
Figure 4. Hydraulic Tool Removal.

6. Disconnect quick coupler (Figure 4, Item 2) on return hose (Figure 4, Item 5) from hydraulic tool.
7. Install cover (Figure 4, Item 3) to quick coupler (Figure 4, Item 4).
8. Install cover (Figure 4, Item 1) to quick coupler (Figure 4, Item 2).
END OF TASK
END OF WORK PACKAGE
0026-3/4 blank
TM 5-3805-294-10 0027
DECAL LOCATION GUIDE
INITIAL SETUP:
Not Applicable
DECALS
This work package shows the typical location of all decals on the machine and attachments. Some are located inside
access panels or under the engine cover.
24 VOLTS
DC SLAVE
240D RECEPTACLE
LCR
DIESEL
ONLY
HYEX01457
Figure 1. Left Side, Rear Cab Window, and Top Decals.
0027-1
TM 5-3805-294-10 0027
DECALS - Continued
DRY AIR CLEANER

1. If equipped with automatic dust unloader vale, periodically clear valve
by squeezing or if equipped with dust cup, service daily.
2. If tractor is equipped with an air cleaner restriction indicator, clear the
primary element at the next refueling or daily service period if:
a. Indicator light on the instrument panel glows with the engine
running, or
b.Manual indicator on the outlet of the air cleaner shows red.
3. If tractor is not equipped with restriction indicator, service the filter
element every 250 hours or whem engine loses power or smokes
excessively.
4. Stop engine before removing filter element.
5. Service according to instructions on primary element.
6. Replace primary element yearly or if damaged or when if no longer
responds to cleaning, whichever occurs first.
7. If equipped with safety air cleaner or safety element, replace yearly or
ans required. DO NOT ATTEMPT TO CLEAN SAFETY CLEANER
OR ELEMENT.
DO NOT USE OIL
HYEX01449
Figure 2. Left Inside Door.
HYEX01448
Figure 3. Top Under Engine Cover
0027-2
TM 5-3805-294-10 0027
DECALS - Continued
IMPORTANT
OIL
LEVEL
Fully
Retracted
Fully
Retracted
3’ Without Bucket
Check oil level cold with

excavator in position
shown above.
HYEX01447
Figure 4. Right Side on Hydraulic Reservoir.
FUEL TANK SUMP

WATER DRAIN TRANSPORTATION DATA
GROSS WEIGHT - 60,000 LB.
Drain water and sediment from fuel EQUIPMENT TIEDOWN DESIGN LIMIT LOAD -
tank every 50 hours or weekly. LIFTING DESIGN LIMIT LOAD -
Allow water to settle to tank bottom
NO. OF SLINGS REQUIRED - 4
before draining. LENGTH OF SLINGS - 12 FT.
It may be possible when valve is
EQUIPMENT TIEDOW PROVISIONS
opened that fuel may drain out at
first. Wait several seconds to allow LIFTING PROVISIONS
enough time for water to drain SWING CENTERLINE
through hose.
Drain water and sediment into
container and dispose of properly.
T247868
CENTER OF
GRAVITY
44 MM [1.7 IN.] 1212 MM [47.5 IN.]
HYEX01445
Figure 5. Right Side.
0027-3
TM 5-3805-294-10 0027
DECALS - Continued
LIFT
ENGINE OIL
SAMPLE VALVE
HYD
OIL
SAMPLE
VALVE HYEX01444
Figure 6. Boom, Right Side, and Rear Cab Window.
HYEX01446
Figure 7. Counterweight.
0027-4
TM 5-3805-294-10 0027
DECALS - Continued
TIEDOWN HYEX01442
Figure 8. Front and Rear Frame.
LOCK
HYEX01450
Figure 9. Cab on Seat.
O FF AC
C
ON
S TA
RT
HYEX01530
Figure 10. Key Switch.
0027-5
TM 5-3805-294-10 0027
DECALS - Continued
CAUTION
FRONT WINDOW
Avoid injury from slip or fall. DO NOT use as a handhold.
HANDLE Window handle will move with the front window. T223082
HYEX01531
Figure 11. Windshield.
240DLC LIFT IN 1000 LBS.

WITH 1920 LB. BUCKET, 11 FT. 10 IN. ARM AND 32 INCH SHOES
10' 15' 20' 25'

7.55*
30'
IMPORTANT
7.55*
8.52*
8.52*
8.61*
8.61*
6.26*
6.26*
SECONDARY EXIT
14.69* 11.56* 10.05* 8.09* Use tool to break window.
14.69* 11.56* 8.88 6.29
20.76* 14.49* 11.62* 9.68
18.90 12.10 8.39 6.04
24.56* 16.88* 12.79 9.46
17.62 11.35 7.96 5.81
13.06* 25.71* 17.90 12.48 9.31
13.06* 17.16 10.92 7.68 5.67
15.60* 22.51* 25.00* 17.77 12.39
15.60* 22.51* 17.15 10.80 7.59 Always keep tool in machine.T190393
29.63* 22.54* 16.71* 12.31
29.63* 17.46 10.96 7.77
17.28* 12.10*
17.28* 11.53
RED - OVER THE FRONT
BLACK - OVER THE SIDE
*HYDRAULICALLY LIMITED
NOTE: SEE OPERATOR'S MANUAL FOR MORE
ACCURATE INFORMATION T218383 HYEX01532
Figure 12. Side Window.
0027-6
TM 5-3805-294-10 0027
DECALS - Continued
ATTACHMENT MODE SELECTION PROCEDURE

1. Press Key F1 to display the work Work Mode
CAUTION
mode screen. Dig Breaker 2 Crusher 1 To prevent injury from the
2. While referring to the table below,
front window falling, lock
2 1
press the key corresponding to the Breaker 1 Pulverizer 1

attachment mode you are going to use. 1 1 window in place with the
1 2 1 1
lock pin. T187353
Attachment Attachment mode
to be used Key No. to be selected 1 1 2 3 4 5
Bucket or Excavation
DANGER
6 7 8 9 0
Thumb 1 F1 F2 F3 F4
Hammer/ 2
2 Breaker 1
Breaker
Alternative F1 3 4 5 Serious injury or death
3 Breaker 2 can result from contact
Hammer/Breaker WORK MODE SCREEN
with electric lines.
Pulverizer 4 Pulverizer 1 Crusher 1 Never move any part of
Maximum Pump Flow Rate 420 L/min unit or load closer to
Crusher Crusher 1
Maximum Engine Speed 1900 min-1
electric line than 3 M
5 Valve Selector C/V Accumulator OFF
[10 FT.] plus twice the
2-Speed Selector ON 2ndary Hydraulic Relief Selector OFF
line insulator length.
3. The specifications of the selected T146667
attachment mode are displayed on the

screen and the attachment hydraulic 1 2 3 4 5
circuit is shifted to match operation of

the selected attachment. 6 7
F1 F2
8 9
F3
0
F4
4. Press the CONFIRM. The screen is

returned to the STANDARD screen and
the attachment becomes operable. CONFIRM
ATTACHMENT SPECIFICATION SCREEN
Affix this label to interior glass of operator's cab T223619
CAUTION
Alternate control
patterns are
available for this
machine. Always
verify control
response before
operating. T201519
HYEX01533
Figure 13. Upper and Lower Right Side Window.
0027-7
TM 5-3805-294-10 0027
DECALS - Continued
ENGINE OPERATION
STARTING - Set RPM's (dial or throttle position) at low idle, turn key on and wait
until glow plug warm-up indicator turns off; turn key to start and crank for 20
CAUTION
seconds maximum or less if required. Allow 2 minutes between cranking
attempts. DO NOT USE ETHER AS A STARTING AID. AVOID DEATH OR SERIOUS INJURY - READ AND UNDERSTAND THE
STOPPING - Reduce RPM's to low idle for 2 minutes with no load. Stop engine. OPERATOR'S MANUAL AND SAFETY MANUAL PRIOR TO OPERATING
ENGINE STALL - Remove load, restart immediately. Run 30 seconds at half THIS MACHINE.
speed before adding load. Controls may be changed for attachment or operator preference. Try
control pattern before operating.
H
ENGINE RPM CONTROL
min1 Always lower working tools to the ground and engage hydraulic control
Turn CW to increase
L lockout lever before leaving operator's seat.
Turn CCW to decrease
Keep riders off machine.
AUTOMATIC SPEED CHANGE
OFF Avoid contact between boom/attachments and overhead obstacles
A/I - Auto Idle whenever operating, traveling or transporting machine.
A/I Engine speed is temporarily reduced, if
control levers are in Neutral for 4 seconds. Keep bystanders clear of machine; especially before moving boom,
H/P swinging upperstructure or traveling.
P
E
POWER MODE
Upperstructure position affects travel direction. Try pedals or levers to
H/P - Select for heavy digging, maximum productivity. determine travel direction before moving machine.
P - Select for standard digging
Avoid tipping - Do not lift or move objects that exceed machine stability.
E - Select for light digging, maximum fuel economy.
T219580
Avoid parking machine on an incline. T159887
WARNING
• AVOID SERIOUS CRUSHING INJURY FROM BOOM
• NEVER place any part of body beyond window bars or frame. It could be crushed by the boom if boom
control lever is accidentally bumped or otherwise engaged.
• DO NOT remove window bars. If window is missing or broken, replace immediately. D3067125 S
HYEX01536
Figure 14. Lower Right Side Window.
0027-8
TM 5-3805-294-10 0027
DECALS - Continued
1. COVERS ARE SHOWN BELOW TO AID IN

DETERMINING LOCATION ON CAB. 3
2. START THE COVER INSTALLATION AT THE REAR OF 1
THE CAB.
CONTINUE INSTALLATION IN THE ORDER SHOWN
BELOW. 2
(RIGHT SIDE, FRONT, LEFT SIDE)
3. LOCK COVERS AFTER INSTALLATION. 1 2 4
2 1
1
2 4
3
5
5 3
CAB, REAR CAB, RIGHT SIDE CAB, FRONT CAB, LEFT SIDE
T218467
HYEX01538
Figure 15. Vandal Protection Kit.
0027-9
TM 5-3805-294-10 0027
DECALS - Continued
240DLCR PERIODIC MAINTENANCE T260750

REFER TO OPERATOR'S MANUAL FOR DETAILED INFORMATION
INTERVAL ITEM MAINTENANCE DESCRIPTION
ITEM APPROVED MATERIAL
HOURS NO. POINTS
AS 4 FUEL TANK INLET SCREEN 1 REMOVE AND CLEAN (A)

REQUIRED 23 WINDSHIELD WASHER FLUID 1 ADD AS REQUIRED
24 AIR CLEANER 1 CHECK - CLEAN DUST VALVE AND/OR ELEMENT (A)
26 TRACK SAG 2 CHECK - ADJUST (A) MPGM-SEE LUBRICANTS
7 HYDRAULIC SYSTEM OIL LEVEL 1 CHECK WITH EXTENDED BUCKET CYLINDER, HYDO-SEE LUBRICANTS
10
RETRACTED ARM CYLINDER AND BUCKET ON GROUND (A)
OR
16 ENGINE OIL LEVEL 1 CHECK (A) EO-SEE LUBRICANTS
DAILY
20 ENGINE COOLANT LEVEL 1 COOLANT LEVEL TO BE ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD PROPER COOLANT (A)
50 5 FUEL TANK SUMP 1 DRAIN WATER AND SEDIMENT (A)

OR WEEKLY 12 WATER SEPARATOR 1 DRAIN WATER
29 WORKING TOOL PIVOTS 4 GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS MPGM-SEE LUBRICANTS
100 FOR FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS. GREASE
DAILY WHEN WORKING IN WATER
3 SWING GEARBOX OIL LEVEL 1 CHECK DIPSTICK

6 HYDRAULIC TANK SUMP 1 DRAIN WATER SEDIMENT (A)
10 ENGINE OIL FILTER 1 REPLACE (A) (C) JD FILTER
12 DOSER ELEMENT 1 REPLACE (A) JD ELEMENT
250
14 PUMP DRIVE GEARBOX 1 CHECK DIPSTICK EO-SEE LUBRICANTS
16 ENGINE OIL 1 DRAIN AND REFILL EO-SEE LUBRICANTS
19 A/C BELT 1 CHECK AND ADJUST
20 RADIATOR COOLANT LEVEL 1 CHECK - LEVEL IN BOTTLE BETWEEN "MAX COLD" AND "MIN COLD" MARKS (A) PROPER COOLANT (A)
21 BATTERY WATER LEVEL 2 CHECK - TO BOTTOM OF FILLER NECK - CLEAN AND TIGHTEN TERMINALS DISTILLED WATER
22 TRAVEL GEARBOX OIL LEVEL 2 CHECK - REMOVE PLUG MPL-SEE LUBRICANTS
24 AIR CLEANER 1 CLEAN ELEMENT
1 FRONT END PIN JOINTS 16 GREASE - UNTIL IT ESCAPES AT JOINTS - FOR BREAK-IN, GREASE EVERY 4 HOURS FOR MPGM-SEE LUBRICANTS
FIRST 20 HOURS, EVERY 10 HOURS DURING FIRST 30-100 HOURS AND AT 250 HOURS.
GREASE DAILY WHEN WORKING IN WATER
2 SWING BEARING GEAR 1 GREASE - ADD 1 LB. [0.5 Kg] (A) (D)
500 10 ENGINE OIL FILTER 1 REPLACE (A) (C) JD FILTER
12 WATER SEPARATOR FILTER 1 REPLACE (A) JD FILTER
13 FUEL FILTER 1 REPLACE - 500 HOURS OR AS REQUIRED (A) JD FILTER
16 ENGINE OIL 1 DRAIN AND REFILL (B) (C) EO-SEE LUBRICANTS
18 AIR INTAKE HOSES 2 CHECK FOR CRACKS AND LOOSE CONNECTIONS (A)
25 FRESH AIR FILTER 1 CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS JD FILTER
27 CAB RECIRCULATING AIR FILTER 1 CLEAN ELEMENT; CHANGE EVERY 6 CLEANINGS JD FILTER
28 SWING BEARING 2 GREASE - 8 SHOTS EACH - EVERY 45º FOR ONE REVOLUTION (A) MPGM-SEE LUBRICANTS
3 SWING GEAR BOX OIL 1 DRAIN AND REFILL (A) MPL-SEE LUBRICANTS
9 HYDRAULIC OIL FILTER 1 REPLACE (A) JD FILTER
1000 11 PILOT CONTROL OIL FILTER 1 REPLACE (A) JD FILTER
14 PUMP DRIVE GEARBOX 1 DRAIN AND REFILL EO-SEE LUBRICANTS
15 ENGINE CRANKCASE VENT TUBE 1 REMOVE AND CLEAN (A)
19 SERPENTINE BELT 1 INSPECT AND REPLACE AS NECESSARY
24 AIR CLEANER 1 REPLACE ELEMENTS AND DUST VALVE JD FILTER AND VALVE
8 HYDRAULIC SYSTEM OIL 1 DRAIN AND REFILL EVERY 2000 HOURS. CLEAN SUCTION SCREEN (A) HYDO-SEE LUBRICANTS
2000 17 ENGINE VALVE LASH 1 REFER TO SERVICE MANUAL
20 RADIATOR 1 DRAIN, FLUSH AND REFILL WITH PROPER COOLANT. FILL RADIATOR, FILL BOTTLE PROPER COOLANT (A)
TO ABOVE "MIN COLD" MARK WHEN ENGINE IS COLD (A)
22 TRAVEL GEARBOX OIL 2 DRAIN AND REFILL EACH (A) MPL-SEE LUBRICANTS
HYEX01534
Figure 16. Upper Section Periodic Maintenance.
0027-10
TM 5-3805-294-10 0027
DECALS - Continued
(A) SEE OPERATOR'S MANUAL.

DRAIN AND REFILL CAPACITIES (B) FOR BREAK IN OR REBUILD, SEE OPERATOR'S MANUAL.
ITEM U.S. MEASURE METRIC (C) USE OF JP8 JET FUEL OR DIESEL FUEL WITH SULFUR CONTENT GREATER THAN
FUEL TANK 132 GAL 500 L 2000 PPM [0.20%] WILL REDUCE THE ENGINE OIL AND FILTER CHANGE
COOLING SYSTEM 31.6 QT 29.9 L INTERVAL TO 250 HOURS WITH PREMIUM OILS.
ENGINE CRANKCASE 26 QT 24.6 L (D) DRAIN WATER FROM GREASE SUMP WHEN IN WATER ABOVE
(INCLUDING FILTER) (6.5 GAL) TRACK.
HYDRAULIC RESERVOIR 39 GAL 147.6 L
HYDRAULIC SYSTEM 63.4 GAL 240 L 1 2 3 4 5 6 7 8 9 10 11 12 13
SWING BEARING GEAR 22 LB 10 Kg
SWING GEAR REDUCTION 7.5 QT 7L
TRAVEL GEARBOX (EACH) 6.5 QT 6.2 L 14
PUMP DRIVE GEARBOX 1.2 QT 1.1 L
15
16
17
18
19
20
29 28 27 26 25 24 23 22 21
LUBRICANTS
AIR TEMPERATURE RANGE DURING FILL PERIOD
°F - 40 - 22 -4 14 32 50 68 86 104 122
RECOMMENDED LUBRICANTS °C - 40 - 30 - 20 - 10 0 10 20 30 40 50
[EO] ENGINE OIL SAE 15W40

USE • JOHN DEERE PLUS 50
SAE 10W30
• ENGINE OILS MEETING: MILITARY SPECIFICATIONS MIL-PRF-2104
• VISCOSITY GRADE SAE 15W40 IS PREFERRED SAE 5W30
(1) - MAY USE MIL-PRF-46167 ARCTIC OIL
BUT DRAIN INTERVAL IS REDUCED TO ONE-HALF OF NORMAL SAE 0W40
SAE 30
(1) ARCTIC OIL
[HYDO] HYDRAULIC OIL SAE 10W30

2000 HOUR CHANGE INTERVAL
•FACTORY FILLED WITH JD PLUS 50 10W30 SAE 5W30
•MEETING MILITARY SPECIFICATIONS MIL-PRF-2104 SAE 15W40
•MEETING MILITARY SPECIFICATIONS ARTIC MIL-PRF-46167
•MEETING MILITARY SPECIFICATIONS BIOBASED MIL-PRF-32073 MIL-46167
MIL-32073-GR1
MIL-32073-GR5
SAE 90: 85W140

[MPL] MULTIPURPOSE LUBRICANT
SAE 80W90
USE • JOHN DEERE API GL-5 GEAR OIL
• OILS MEETING API GL-5 OR MILITARY SPECIFICATIONS
SAE 75W
MIL-L-2105B OR MIL-L-2105C ARCTIC OIL
[MPGM] MULTIPURPOSE GREASE WITH MOLYBDENUM DISULFIDE

NLGI NO. 2
USE • JOHN DEERE MOLY HIGH-TEMPERATURE EXTREME
PRESSURE (EP) GREASE J.D. HIGH TEMP/EP
• SAE MULTIPURPOSE EP GREASE CONTAINING 3 TO 5% NLGI NO. 0 OR 1
MOLYBDENUM DISULFIDE ARCTIC GREASE
HYEX01535
Figure 17. Lower Section Periodic Maintenance.
0027-11
TM 5-3805-294-10 0027
DECALS - Continued
WARNING
TOP OF WEDGE MUST BE
ENGAGED TO THIS AREA
BEFORE OPERATING
ATTACHMENT.
HYEX01441
Figure 18. Ditch Cleaning Bucket.
WARNING
TOP OF WEDGE MUST BE
ENGAGED TO THIS AREA
BEFORE OPERATING
ATTACHMENT.
HYEX01440
Figure 19. Heavy Duty Bucket.
0027-12
TM 5-3805-294-10 0027
DECALS - Continued
HYEX01437
Figure 20. Right Side Crush-All.
HYEX01438
Figure 21. Left Side Crush-All.
0027-13
TM 5-3805-294-10 0027
DECALS - Continued
DANGER DANGER
SHUT OFF ALL PERSONNEL
EXCAVATOR PRIOR STAND CLEAR
TO MAINTENANCE FLYING DEBRIS
DANGER DANGER
HIGH PRESSURE
DO NOT OPERATE
HYDRAULIC
WITHOUT GUARDS
SYSTEM
HYEX01439
Figure 22. Output Side Crush-All.
END OF TASK
END OF WORK PACKAGE
0027-14
TM 5-3805-294-10 0028
TOWING THE HYEX
INITIAL SETUP:
Not Applicable
TOWING
CAUTION
The travel motors require hydraulic pressure to release the parking brakes. Do not attempt
to tow the HYEX without Field Maintenance support. Field Maintenance must prepare the
travel motors before the HYEX can be towed. Failure to comply may result in damage to
equipment.
In the event during operation of the HYEX the machine becomes disabled and needs to be towed, notify Field level
maintenance.
END OF TASK
END OF WORK PACKAGE
0028-1/2 blank
TM 5-3805-294-10 0029
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE
INITIAL SETUP:
Not Applicable
LOWERING BOOM
In the event during operation of the HYEX the machine becomes disabled and the boom needs to be lowered, notify
Field level maintenance.
END OF TASK
END OF WORK PACKAGE
0029-1/2 blank
TM 5-3805-294-10 0030
OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)
INITIAL SETUP:

WP 0004 WP 0005
WP 0018
STARTING
NOTE
• In extreme cold conditions, an extended warm-up period will be necessary.
• Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly
warm.
1. Press and hold back button.
BACK BUTTON
HYEX01413
Figure 1. Press and Hold Back Button.

0030-1
TM 5-3805-294-10 0030
STARTING - Continued
HYEX01414
Figure 2. Key Switch to ON Position.
3. Release back button when monitor goes to default screen.

BACK
BUTTON
MENU
BUTTON HYEX01415
Figure 3. Release Back Button.
5. Press button one or button two until service menu is highlighted.
0030-2
TM 5-3805-294-10 0030
Main Menu
Fuel Rate Display/No Display
SERVICE Back Monitor Settings
MENU Language/
Service Menu
SELECT
BUTTON
1 2 3 4 5
BUTTON 1 6 7 8 9 0
F1 F2 F3 F4
BUTTON 2
HYEX01416
Figure 4. Highlight Service Menu.
6. Press the select button.

7. Press button one or button two until monitoring is highlighted then press the select button.
Service Menu
Troubleshooting
MONITORING Monitoring
Ver. Controller Version
SELECT
BUTTON 2 1 2 3 4 5
BUTTON
BUTTON 1
6 7 8 9 0
F1 F2 F3 F4
HYEX01417
Figure 5. Select Monitoring.

8. Press button 1 or 2 until the hydraulic oil temperature, coolant temperature, and actual engine speed are
displayed. (WP 0005)
0030-3
TM 5-3805-294-10 0030
Monitoring
Hydraulic Oil Temperature 0 oC
Coolant Temperature (E) 0 oC
Actual Engine Speed 0
Fuel Temperature 0 oC
ON
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX01418
Figure 6. Temperatures Displayed.
NOTE
If hydraulic oil temperature is 32°F (0°C) or below, engine will run at 1400 rpm for 15 minutes
or until hydraulic oil temperature reaches 36°F (2°C).
9. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.
HYEX01419
Figure 7. Start Engine.
10. Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at
fast or slow idle.
0030-4
TM 5-3805-294-10 0030
HYEX01420
11. Ensure engine coolant and hydraulic oil temperatures are above 0°F (-18°C) before proceeding to Step 12.
Monitoring
ON
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX01418
Figure 9. Check Engine and Hydraulic Oil Temperatures.
NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders
are fully raised, the overload alarm may sound even if the machine is not in an overload
condition. Lower the boom cylinders until the alarm is no longer displayed.
12. Set machine switch selections for temperatures between 5° and 32°F (-15° and 0°C) per Table 1.
0030-5
TM 5-3805-294-10 0030
Table 1. Machine Switch Selections.
Engine Speed Speed Dial to Half Speed
Power Mode Switch Position High Power (HP) Mode
Auto-Idle (A/I) Switch Position OFF
Travel Speed Switch Slow (Turtle)
13. Select dig mode on monitor. (WP 0018)
WARNING
Clear the area of all personnel during machine warm up procedures. Machine can move
unexpectedly. Failure to comply may result in injury or death to personnel.
CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
14. Operate swing, boom, arm, hydraulic thumb, and bucket functions slowly and short distances initially in each
direction. (WP 0004)
15. Continue cycling cylinders by increasing travel each cycle until full smooth movement of each function is
obtained.
16. Swing upperstructure (Figure 10, Item 3) 90 degrees.
5
6
7 4 HYEX01421
Figure 10. Raise Machine.

17. Place round side of bucket (Figure 10, Item 4) on ground.
18. Keeping angle between boom (Figure 10, Item 5) and arm (Figure 10, Item 6) between 90 and 110 degrees,
slowly lower boom (Figure 10, Item 5) to raise track (Figure 10, Item 7) off ground.
0030-6
TM 5-3805-294-10 0030
19. Operate travel lever for raised track for approximately 5 minutes. (WP 0004)
20. Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.
21. Repeat Steps 14 to 18 for opposite track.
END OF TASK
END OF WORK PACKAGE
0030-7/8 blank
TM 5-3805-294-10 0031
OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER
INITIAL SETUP:

WP 0004 WP 0018
WP 0034
STARTING
NOTE
• Contact Field Maintenance to ensure that all fluids meet the requirements for the current
operating conditions.
• In extreme cold conditions, an extended warm-up period will be necessary.
• Avoid sudden operation of all functions until the engine and hydraulic oils are thoroughly
warm.
1. If temperature is 5°F (-15°C) or below, operate coolant heater for 30 minutes. (WP 0034)
2. Press and hold back button.
BACK
BUTTON
HYEX01423
Figure 1. Press and Hold Back Button.
0031-1
TM 5-3805-294-10 0031
HYEX01424
Figure 2. Key Switch to ON Position.
4. Release back button when monitor goes to default screen.
BACK
BUTTON
MENU
BUTTON HYEX01415
Figure 3. Release Back Button.

6. Press button one or button two until service menu is highlighted.
0031-2
TM 5-3805-294-10 0031
Main Menu
Fuel Rate Display/No Display
SERVICE Back Monitor Settings
MENU Language/
Service Menu
SELECT
BUTTON
1 2 3 4 5
BUTTON 1 6 7 8 9 0
F1 F2 F3 F4
BUTTON 2
HYEX01430
Figure 4. Highlight Service Menu.
7. Press the select button.

8. Press button one or button two until monitoring is highlighted, then press the select button.
Service Menu
MONITORING Troubleshooting
Monitoring
Ver. Controller Version
SELECT
BUTTON
1 2 3 4 5
BUTTON 1
6 7 8 9 0
F1 F2 F3 F4
BUTTON 2
HYEX01431
Figure 5. Select Monitoring.
0031-3
TM 5-3805-294-10 0031
9. Ensure the hydraulic oil temperature, coolant temperature, and actual engine speed are displayed.
Monitoring
ON
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX01432
Figure 6. Temperatures Displayed.
NOTE
If hydraulic oil temperature is 32°F (0°C) or below, engine will run at 1400 rpm for 15 minutes
or until hydraulic oil temperature reaches 36°F (2°C).
10. Turn key switch (Figure 7, Item 1) to start engine. Release key when engine starts.
HYEX01433
Figure 7. Start Engine.
11. Move engine idle speed switch (Figure 8, Item 2) to half throttle and run engine for 5 minutes. Do not run at
fast or slow idle.
0031-4
TM 5-3805-294-10 0031
HYEX01434
Figure 8. Engine Idle Speed.

12. Monitor engine coolant and hydraulic oil. Once the oil temperatures reach 0°F (-18°C) the High Power (HP)
mode can be selected.
Monitoring
ON
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX01432
Figure 9. Monitor Temperatures Displayed.
0031-5
TM 5-3805-294-10 0031
NOTE
During warm-up procedures, if the upper structure is over the side and the boom cylinders
are fully raised, the overload alarm may sound even if the machine is not in an overload
condition. Lower the boom cylinders until the alarm is no longer displayed.
13. Set machine switch selections for temperatures between 5°F (-15°C) and below per Table 1.
Table 1. Machine Switch Selection.
Machine Specification Temperatures 5° to 0°F (-15° to Temperature Below 0°F (-18°C)

-18°C)
Engine Speed Speed Dial to Half Speed Speed Dial to Half Speed
Power Mode Switch Position High Power (HP) Mode Economy (E) Mode
Auto-Idle (A/I) Switch Position OFF OFF
Travel Speed Switch Slow (Turtle) Slow (Turtle)
14. Select dig mode on monitor. (WP 0018)
WARNING
Clear the area of all personnel during machine warm up procedures. Machine can move
unexpectedly. Failure to comply may result in injury or death to personnel.
CAUTION
Do not hold any hydraulic function over relief for more than 10 seconds. This can cause hot
spots in the control valve. Failure to comply may result in damage to equipment.
15. Operate swing, boom, arm, and bucket functions slowly and short distances initially in each direction.
(WP 0004)
16. Continue cycling cylinders by increasing travel each cycle until full smooth movement of function is obtained.
0031-6
TM 5-3805-294-10 0031
5
6
7 4 HYEX01435

20. Operate travel lever for raised track for approximately 5 minutes. (WP 0004)
21. Slowly raise boom (Figure 10, Item 5) to lower track (Figure 10, Item 7) to ground and swing upperstructure
back 90 degrees.
22. Repeat Steps 15 to 19 for opposite track.
END OF TASK
END OF WORK PACKAGE
0031-7/8 blank
TM 5-3805-294-10 0032
SLAVE STARTING
INITIAL SETUP:
References
WP 0007
SLAVE STARTING
WARNING
An explosive gas is produced while batteries are in use or being charged. Keep flames and
sparks away from battery area. Ensure batteries are charged in a well-ventilated area. Failure
NOTE
Ensure that booster vehicle is equipped with a slave receptacle.
1. Contact Field Maintenance to get a slave cable.
2. Connect the slave cable to booster vehicle slave receptacle.
3. Remove cap (Figure 1, Item 1) from slave receptacle (Figure 1, Item 2).
0032-1
TM 5-3805-294-10 0032
SLAVE STARTING - Continued
HYEX00866
Figure 1. Slave Receptacle.
4. Connect slave cable to slave receptacle (Figure 1, Item 2).

5. Run booster vehicle at a speed just above idle. Refer to booster vehicle Operator's Manual.
7. After starting machine, return booster vehicle to idle. Refer to booster vehicle Operator's Manual.
8. Remove the slave cable from slave receptacle (Figure 1, Item 2).
9. Install cap (Figure 1, Item 1) to slave receptacle (Figure 1, Item 2).
10. Remove slave cable from booster vehicle.
END OF TASK
END OF WORK PACKAGE
0032-2
TM 5-3805-294-10 0033
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY EXIT)
INITIAL SETUP:
Not Applicable
SKYLIGHT WINDOW (SECONDARY EXIT)
1. Slide back liner.

2. Release two latches (Figure 1, Item 1).
1 1
HYEX00943
Figure 1. Open and Close Roof Exit.
3. Push on handle (Figure 1, Item 2) and exit machine.
END OF TASK
REAR WINDOW (EMERGENCY EXIT)
1. Remove emergency exit tool (Figure 2, Item 3) from holder (Figure 2, Item 4).
0033-1
TM 5-3805-294-10 0033
REAR WINDOW (EMERGENCY EXIT) - Continued
3 HYEX00944
Figure 2. Emergency Exit Tool.
WARNING
When using emergency exit tool to break glass, shield eyes and face from broken glass.
2. Using emergency exit tool (Figure 2, Item 3) smash rear window (Figure 2, Item 5). One or two strikes with
emergency exit tool (Figure 2, Item 3) should shatter glass.
3. Push remaining glass from window edges and exit machine.
END OF TASK
END OF WORK PACKAGE
0033-2
TM 5-3805-294-10 0034
OPERATING THE COOLANT HEATER
INITIAL SETUP:
Not Applicable
COOLANT HEATER OPERATION
WARNING
• The coolant heater must be switched off while the fuel tank on the machine is being filled.
• DO NOT operate engine or coolant heater in a closed place without proper ventilation.
CAUTION
If a fault arises during coolant heater operation, the heat symbol will flash on the control panel
display and a three-digit fault code will be displayed. Shut down the coolant heater and notify
field maintenance. Failure to comply may result in damage to equipment.
NOTE
• Coolant heater is only required to be used when temperature is -25° F (-32° C) or colder.
• The timer can control operation of the coolant heater for up to 7 days in advance.
• The default timer setting is for the coolant heater to operate for 120 minutes before
automatically turning off.
0034-1
TM 5-3805-294-10 0034
COOLANT HEATER OPERATION - Continued
1. The coolant heater control panel (Figure 1, Item 1) is located on left outer console of operator's seat.
1
M0
20:30
HYEX00023
Figure 1. Coolant Heater Control Panel.

2. The coolant heater control panel display (Figure 1, Item 2) indicates a weekday and time and allows
programming of heater cycle times.
END OF TASK
ADJUSTING COOLANT HEATER TIME AND DAY
NOTE
All symbols will flash on coolant heater control panel (Figure 2, Item 1) display after extended
power loss. The clock requires resetting to ensure proper operation of the coolant heater.
1. Push and hold clock button (Figure 2, Item 3) until time (Figure 2, Item 4) indicator begins to flash.
4 7
M0
3 20:30
1
3 5 6 HYEX00022
Figure 2. Adjusting Time and Day.
2. Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust time up or down.
3. When time is correct wait approximately 5 seconds and day (Figure 2, Item 7) will begin to flash.
4. Press the left arrow button (Figure 2, Item 5) or right arrow button (Figure 2, Item 6) to adjust day (Figure 2,
Item 7) up or down.
5. When day (Figure 2, Item 7) is correct wait approximately 5 seconds and day will stop flashing.
0034-2
TM 5-3805-294-10 0034
ADJUSTING COOLANT HEATER TIME AND DAY - Continued
6. Time (Figure 2, Item 4) and day (Figure 2, Item 7) is set.
END OF TASK
SETTING AND SELECTING COOLANT HEATER PROGRAM
NOTE
• The coolant heater control panel can program three start cycle times within a 24-hour
period or one start cycle per day for 7 days. Only one program can be activated at one
time.
• Pressing the preset button (Figure 3, Item 8) until memory display is blank will delete
programs in memory.
1. Press the preset button (Figure 3, Item 8) until the desired program number (Figure 3, Item 9) begins to flash.
4 7
M0
9
3 20:30
8 5 6 HYEX01315
Figure 3. Setting Program.
2. Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust start time (Figure
3, Item 4) up or down.
3. When start time (Figure 3, Item 4) is set, wait approximately 5 seconds and day (Figure 3, Item 7) will begin
to flash.
4. Press the left arrow button (Figure 3, Item 5) or right arrow button (Figure 3, Item 6) to adjust day (Figure 3,
Item 7) up or down.
5. When day (Figure 3, Item 7) is set, wait approximately 5 seconds and day will stop flashing.
6. Start time (Figure 3, Item 4) and day (Figure 3, Item 7) is set.
7. Program number (Figure 3, Item 9) will be displayed.
8. Repeat Steps 1 through 7 if additional days of programing is desired.
END OF TASK
ADJUSTING COOLANT HEATER RUN TIME
NOTE
• The maximum amount of time for the coolant heater will run is 120 minutes.
0034-3
TM 5-3805-294-10 0034
ADJUSTING COOLANT HEATER RUN TIME - Continued
• Adjusting the run time must be performed every time a start program is selected.
1. Press the heater button (Figure 4, Item 10) and the preselected run time (Figure 4, Item 11) will appear on the
display (Figure 4, Item 2).
2
11
120
10 5 6 HYEX00021
Figure 4. Adjusting Run Time.
2. Press the left arrow button (Figure 4, Item 5) or right arrow button (Figure 4, Item 6) to adjust run time (Figure
4, Item 11) up or down.
3. After desired run time (Figure 4, Item 11) is selected, wait approximately 5 seconds and run time is set.
END OF TASK
USING COOLANT HEATER MANUALLY
1. Press heater button (Figure 5, Item 10) and the coolant heater will start and run.
11
120
10 5 6 HYEX00020
Figure 5. Manually Start Coolant Heater.
2. If desired, press the left arrow button (Figure 5, Item 5) or right arrow button (Figure 5, Item 6) to adjust run
time (Figure 5, Item 11) up or down.
3. To manually shut coolant heater off press the heater button (Figure 6, Item 10). The coolant heater will do a
normal cool-down cycle and then turn itself off.
0034-4
TM 5-3805-294-10 0034
USING COOLANT HEATER MANUALLY - Continued
11
120
10 5 6 HYEX00020
Figure 6. Manually Start Coolant Heater Continued.
END OF TASK
END OF WORK PACKAGE
0034-5/6 blank
TM 5-3805-294-10 0035
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES
INITIAL SETUP:
Not Applicable
PULLING MACHINE UP
WARNING
This procedure should only be used on a short slope of no more than 35 degrees to prevent
machine rollover. The machine depends on support of the boom, arm, and bucket during
entire procedure until the machine reaches the top or bottom of the slope. Do not attempt to
reposition the bucket or swing upperstructure during the procedure because the machine will
become unstable. Failure to comply may result in injury or death to personnel.
1. Buckle seat belt (Figure 1, Item 1).
HYEX00687
Figure 1. Buckle Seat Belt.

2. Position undercarriage so travel motors (Figure 2, Item 2) will be on the uphill end of machine (Figure 2, Item
3).
0035-1
TM 5-3805-294-10 0035
PULLING MACHINE UP - Continued
4
5
HYEX00674
Figure 2. Pulling Machine Up.
3. Push bucket (Figure 2, Item 4) into the ground on the top of the slope.
4. While using travel pedals pull the machine using the boom (Figure 2, Item 5) and arm cylinder (Figure 2, Item
6) to assist the travel motors (Figure 2, Item 2).
END OF TASK
PUSHING MACHINE UP
WARNING
1. Buckle seat belt (Figure 3, Item 1).
0035-2
TM 5-3805-294-10 0035
PUSHING MACHINE UP - Continued
HYEX00687
Figure 3. Buckle Seat Belt.

3).
3
6
5
2
HYEX00677
Figure 4. Pushing Machine.
3. Push bucket (Figure 4, Item 4) into the ground at the base of the slope.
0035-3
TM 5-3805-294-10 0035
PUSHING MACHINE UP - Continued
4. While using travel pedals push the machine using the boom (Figure 4, Item 5) and arm cylinder (Figure 4, Item
6) to assist the travel motors (Figure 4, Item 2).
END OF TASK
TRAVELING DOWN
WARNING
3).
3
6
5
2
HYEX00677
Figure 5. Traveling Down.
2. Using the boom (Figure 5, Item 5) and arm cylinder (Figure 5, Item 6) position bucket (Figure 5, Item 4) so it
will drag the ground while traveling down the slope.
0035-4
TM 5-3805-294-10 0035
TRAVELING DOWN - Continued
3. Slowly travel down the slope.
END OF TASK
END OF WORK PACKAGE
0035-5/6 blank
TM 5-3805-294-10 0036
FORDING THE HYEX
INITIAL SETUP:
References
WP 0093
FORDING
CAUTION
Do not ford water unless depth is known. Water deeper than 40.0 in. (1.0 m) may enter
machine systems and damage operating components. Failure to comply may result in
NOTE
Use travel control levers during fording operations to maintain better control of machine
speed.
1. Ensure bottom at fording site is firm enough that 40 in. (1 m) maximum fording depth will not be exceeded and
machine will not become mired.
HYEX01311
Figure 1. Fording Line.
2. Ensure that engine is operating normally and is at normal operating temperature.

3. Move pilot shutoff lever (Figure 2, Item 1) to unlocked (down) position.
0036-1
TM 5-3805-294-10 0036
FORDING - Continued
1 HYEX00367
4. Ensure that there are no alarms indicated on monitor (Figure 3, Item 2).
3 HYEX00368
Figure 3. Check Monitor.
5. Position travel speed selector (Figure 3, Item 3) in slow position.

6. Raise engine speed dial (Figure 3, Item 4) to 1/3 throttle position.
7. Move travel levers (Figure 3, Item 5) forward 1/4 travel.
8. Enter the water slowly to minimize surges of backwash into the upperstructure.
9. If machine accidently enters water deeper than 40 in. (1.0 m), move travel levers (Figure 3, Item 5) back 1/4
travel and slowly back machine out of deep water.
0036-2
TM 5-3805-294-10 0036
FORDING - Continued
10. After fording perform, maintenance after fording. (WP 0093)
END OF TASK
END OF WORK PACKAGE
0036-3/4 blank
TM 5-3805-294-10
CHAPTER 3
OPERATOR TROUBLESHOOTING PROCEDURES

NSN 3805-01-573-0677
TM 5-3805-294-10 0037
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE
TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting Procedure
ELECTRICAL SYSTEM
1. Travel Alarm Does Not Operate ....................................................................................................... WP 0038
2. Windshield Wiper and Washer Do Not Operate ............................................................................... WP 0039
3. Cab Dome Light Does Not Operate ................................................................................................. WP 0040
4. Boom, Cab, And Drive Lights Do Not Operate ................................................................................. WP 0041
5. Cab Front Work Lights Do Not Operate ........................................................................................... WP 0042
6. Cab Rear Work Lights Do Not Operate ............................................................................................ WP 0043
7. Low Note and High Note Horns Do Not Operate ............................................................................. WP 0044
8. Air Conditioner Does Not Operate ................................................................................................... WP 0045
ENGINE
1. Engine Cranks But Will Not Start Or Hard To Start .......................................................................... WP 0046
2. Engine Will Not Crank ...................................................................................................................... WP 0047
3. Engine Runs Poorly ......................................................................................................................... WP 0048
4. Excessive Fuel Consumption ........................................................................................................... WP 0049
5. Excessive Oil Consumption .............................................................................................................. WP 0050
6. Engine Idles Poorly .......................................................................................................................... WP 0051
7. Auto-Idle Does Not Work ................................................................................................................. WP 0052
8. Engine Not Developing Full Power .................................................................................................. WP 0053
9. Engine Oil Pressure Low .................................................................................................................. WP 0054
10. Engine Coolant Temperature Above Normal ................................................................................... WP 0055
11. Engine Emits Excessive Black Or Gray Exhaust Smoke ................................................................. WP 0056
12. Engine Emits Excessive White Exhaust Smoke ............................................................................... WP 0057
HYDRAULICS SYSTEM
1. No Hydraulic Functions .................................................................................................................... WP 0058
2. Hydraulic Functions Are Slow Or Have Little Or No Power .............................................................. WP 0059
3. Power Dig Does Not Work ............................................................................................................... WP 0060
4. Hydraulic Oil Overheats ................................................................................................................... WP 0061
5. Hydraulic Oil Foams ......................................................................................................................... WP 0062
0037-1
TM 5-3805-294-10 0037
TROUBLESHOOTING SYMPTOM INDEX - Continued
Malfunction/Symptom Troubleshooting Procedure
6. No Swing Function ........................................................................................................................... WP 0063

7. Swing Function Is Jerky ................................................................................................................... WP 0064
8. Slow Travel Speed Only ................................................................................................................... WP 0065
9. Travel Is Jerky .................................................................................................................................. WP 0066
10. Engine Stops When Travel Or Control Lever Actuated .................................................................... WP 0067
11. Quick Latch Does Not Operate ........................................................................................................ WP 0068
12. Compactor Does Not Operate .......................................................................................................... WP 0069
13. Breaker Does Not Operate ............................................................................................................... WP 0070
14. Breaker Operates Slowly ................................................................................................................. WP 0071
15. Crush-All Does Not Operate ............................................................................................................ WP 0072
16. Barrier Grapple Does Not Hold Load ............................................................................................... WP 0073
17. Deep Dig Does Not Operate ............................................................................................................ WP 0074
18. Hydraulic Hose Reel Does Not Operate ........................................................................................... WP 0075
END OF WORK PACKAGE
0037-2
TM 5-3805-294-10 0038
TRAVEL ALARM DOES NOT OPERATE
INITIAL SETUP:

(WP 0009)
TROUBLESHOOTING PROCEDURE
Table 1. Travel Alarm Does Not Operate.
Malfunction Test or Inspection Corrective Action
Travel Alarm Fuse 1. Remove F5 OPT.1 (ALT) 5A

Blown. fuse. (WP 0084)
2. Visually inspect F5 OPT.1 1. If fuse blown, replace F5 OPT.

(ALT) 5A fuse for blown fuse. 1 (ALT) 5A fuse. (WP 0084)
2. If fuse not blown, notify Field
Maintenance.
END OF WORK PACKAGE
0038-1/2 blank
TM 5-3805-294-10 0039
WINDSHIELD WIPER AND WASHER DO NOT OPERATE
INITIAL SETUP:

WP 0011
WP 0084
Table 1. Windshield Wiper and Washer Do Not Operate.
1. Upper Front 1. If machine is equipped with a

Window Not Fully Supplemental Armor Set,
Closed. proceed to Malfunction 2.
2. Check upper front window to 1. If fully closed, proceed to

ensure window is fully closed. Malfunction 2.
(WP 0011)
2. If not fully closed, readjust and
close upper front window.
(WP 0011)
2. Windshield Wiper 1. Shut engine off. (WP 0009)

and Washer Fuse
Blown.
2. Remove F2 WIPER 10A fuse.

(WP 0084)
3. Visually inspect F2 WIPER 1. If fuse blown, replace F2

10A fuse for blown fuse. WIPER 10A fuse. (WP 0084)
Maintenance.
END OF WORK PACKAGE
0039-1/2 blank
TM 5-3805-294-10 0040
CAB DOME LIGHT DOES NOT OPERATE
INITIAL SETUP:

WP 0009
WP 0084
Table 1. Cab Dome Light Does Not Operate.
1. Cab Dome Light Check cab dome light switch 1. If switch is ON (down), proceed
Switch is OFF (up). position. (WP 0004) to Malfunction 2.
2. If switch is OFF (up), position
cab dome light switch ON
(down). (WP 0004)
2. Radio and Dome 1. Shut engine off. (WP 0009)

Light Fuse Blown.
2. Remove F11 RADIO 5A fuse.

(WP 0084)
3. Visually inspect F11 RADIO 1. If fuse blown, replace F11

5A fuse for blown fuse. RADIO 5A fuse. (WP 0084)
Maintenance.
END OF WORK PACKAGE
0040-1/2 blank
TM 5-3805-294-10 0041
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE
INITIAL SETUP:

(WP 0009)
Table 1. Boom, Cab, And Drive Lights Do Not Operate.
Work and Drive 1. Remove F1 LAMP 20A fuse.

Lights Fuse Blown. (WP 0084)
2. Visually inspect F1 LAMP 20A 1. If fuse blown, replace F1 LAMP

fuse for blown fuse. 20A fuse. (WP 0084)
Maintenance.
END OF WORK PACKAGE
0041-1/2 blank
TM 5-3805-294-10 0042
CAB FRONT WORK LIGHTS DO NOT OPERATE
INITIAL SETUP:

(WP 0009)
Table 1. Cab Front Work Lights Do Not Operate.
Cab Front Work 1. Remove F22 CAB LAMP

Lights Fuse Blown. FRONT 10A fuse. (WP 0084)
2. Visually inspect F22 CAB 1. If fuse blown, replace F22 CAB

LAMP FRONT 10A fuse for LAMP FRONT 10A fuse.
blown fuse. (WP 0084)
Maintenance.
END OF WORK PACKAGE
0042-1/2 blank
TM 5-3805-294-10 0043
CAB REAR WORK LIGHTS DO NOT OPERATE
INITIAL SETUP:

(WP 0009)
Table 1. Cab Rear Work Lights Do Not Operate.
Cab Rear Work 1. Remove F23 CAB LAMP

Lights Fuse Blown. REAR 10A fuse. (WP 0084)
2. Visually inspect F23 CAB 1. If fuse blown, replace F23 CAB

LAMP REAR 10A fuse for LAMP REAR 10A fuse.
Maintenance.
END OF WORK PACKAGE
0043-1/2 blank
TM 5-3805-294-10 0044
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE
INITIAL SETUP:

(WP 0009)
Table 1. Low Note And High Note Horns Do Not Operate.
Horn Fuse Blown. 1. Remove F17 HORN 10A

fuse. (WP 0084)
2. Visually inspect F17 HORN 1. If fuse blown, replace F17

10A fuse for blown fuse. HORN 10A fuse. (WP 0084)
Maintenance.
END OF WORK PACKAGE
0044-1/2 blank
TM 5-3805-294-10 0045
AIR CONDITIONER DOES NOT OPERATE
INITIAL SETUP:

WP 0084 (WP 0009)
WP 0089
WP 0090
Table 1. Air Conditioner Does Not Operate.
1. Air Conditioner and 1. Remove F15 AIRCON 5A

Heater 5A Fuse fuse. (WP 0084)
Blown.
2. Visually inspect F15 AIRCON 1. If fuse blown, replace F15

5A fuse for blown fuse. AIRCON 5A fuse. (WP 0084)
2. If fuse not blown, proceed to
Malfunction 2.
2. Air Conditioner and 1. Remove F3 HEATER 20A

Heater 20A Fuse fuse. (WP 0084)
Blown.
2. Visually inspect F3 HEATER 1. If fuse blown, replace F3

20A fuse for blown fuse. HEATER 20A fuse.
(WP 0084)
Malfunction 3.
3. Fresh Air Filter 1. Remove fresh air filter.

Clogged or (WP 0089)
Damaged.
2. Visually inspect fresh air filter 1. If clogged, service fresh air

and housing for clog and filter and housing. (WP 0089)
damage.
2. If damaged, notify Field
Maintenance.
3. If not clogged and not
damaged, proceed to
Malfunction 4.
0045-1
TM 5-3805-294-10 0045
Table 1. Air Conditioner Does Not Operate - Continued.
4. Air Conditioner/ 1. Remove air conditioner/heater

Heater Filter filter. (WP 0090)
Clogged or
Damaged.
2. Visually inspect air 1. If clogged, service air

conditioner/heater filter and conditioner/heater filter and
housing for clog and damage. housing. (WP 0090)
Maintenance.
3. If not clogged and not
damaged, proceed to
Malfunction 5.
5. Air Conditioner Visually inspect air 1. If dirty, clean air conditioner

Condenser Dirty or conditioner/heater condenser condenser. (WP 0077)
Damaged. for dirt and damage.
(WP 0077)
Maintenance.
3. If not dirty and not damaged,
proceed to Malfunction 6.
6. Air Conditioner Belt Visually inspect air conditioner 1. If worn or damaged, notify
Worn or Damaged. belt for wear and damage. Field Maintenance.
(WP 0077)
2. If not worn and not damaged,
notify Field Maintenance.
END OF WORK PACKAGE
0045-2
TM 5-3805-294-10 0046
ENGINE CRANKS BUT DOES NOT START OR HARD TO START
INITIAL SETUP:

WP 0005 WP 0086
WP 0007 WP 0087
WP 0009
WP 0077
Equipment Condition
Machine safely parked and shut down.
(WP 0009)
Table 1. Engine Cranks But Does Not Start or Hard to Start.
1. Engine Cranks Crank engine. (WP 0007) 1. If engine cranks slowly, notify
Slowly. Field Maintenance.
2. If engine does not crank
slowly, proceed to Malfunction
2.
2. Fuel Level Low. 1. Turn key switch to ON position,

but DO NOT START ENGINE.
(WP 0007)
2. Visually inspect monitor to

verify at least 1/4 tank of fuel is
available. (WP 0005)
3. Turn key switch to OFF 1. If fuel level is low, service

position. (WP 0009) machine. (WP 0077)
2. If fuel level is OK, proceed to
Malfunction 3.
3. Air Cleaners Dirty 1. Start engine. (WP 0007)

or Clogged.
2. Observe monitor for air cleaner

clogged alarm. (WP 0005)
0046-1
TM 5-3805-294-10 0046
Table 1. Engine Cranks But Does Not Start or Hard to Start - Continued.
3. Shut down engine. (WP 0009) 1. If air cleaner clogged alarm is

displayed, remove foreign
objects/debris or replace air
cleaner. (WP 0087)
2. If air cleaner clogged alarm is
not displayed, proceed to
Malfunction 4.
4. Leaking Fuel Lines Visually inspect fuel lines and 1. If fuel lines and fittings are
and Fittings. fittings for leakage. leaking, notify Field
(WP 0077) Maintenance.
2. If fuel lines and fittings are not
leaking, proceed to
Malfunction 5.
5. Fuel Filter/Water 1. Drain primary and final fuel

Separators Contain filter/water separators of water
Water or Sediment. or sediment. (WP 0086)
2. Start engine. (WP 0007) 1. If engine starts, malfunction

corrected.
2. If engine does not start, notify
Field Maintenance.
END OF WORK PACKAGE
0046-2
TM 5-3805-294-10 0047
ENGINE WILL NOT CRANK
INITIAL SETUP:

WP 0005 WP 0077
WP 0007 WP 0084
WP 0009
Equipment Condition
(WP 0009)
Table 1. Engine Will Not Crank.
1. Pilot Shutoff Lever 1. Place pilot shutoff lever in

in UNLOCKED LOCK (up) position.
(down) Position. (WP 0007)
2. Start engine. (WP 0007) 1. If engine starts, malfunction

corrected.
2. If engine does not crank,
2. Discharged 1. Turn key switch to ON position,

Batteries. but DO NOT START ENGINE.
(WP 0007)
2. Observe monitor for battery

warning alarm. (WP 0005)
3. Turn key switch to OFF 1. If monitor displays battery

position. (WP 0009) warning alarm, notify Field
Maintenance.
2. If monitor does not display
battery warning alarm,
0047-1
TM 5-3805-294-10 0047
Table 1. Engine Will Not Crank - Continued.
3. Blown Fuses. 1. Remove the following fuses:

• F8 ECM 20A fuse.
(WP 0084)
• F10 CONTROLLER 5A
fuse. (WP 0084)
• F16 POWER ON 5A fuse.
(WP 0084)
2. Visually inspect fuses for 1. If fuse blown, replace fuse.

2. If no fuse blown, proceed to
Malfunction 4.
4. Corroded or Loose Visually inspect batteries for 1. If battery connections are

Battery corroded or loose corroded or loose, notify Field
Connections. connections. (WP 0077) Maintenance.
2. If battery connections are not
corroded or loose, notify Field
Maintenance that engine does
not crank.
END OF WORK PACKAGE
0047-2
TM 5-3805-294-10 0048
ENGINE RUNS POORLY
INITIAL SETUP:

WP 0005 WP 0087
WP 0007 WP 0091
WP 0009
WP 0077
Equipment Condition
WP 0086
Table 1. Engine Runs Poorly.
1. Air Cleaners Dirty 1. Observe monitor for air cleaner

or Clogged. clogged alarm. (WP 0005)

cleaners. (WP 0087)
Malfunction 2.

2. Start engine. (WP 0007) 1. If engine runs properly,

malfunction corrected.
2. If engine runs poorly,
Malfunction 3.
0048-1
TM 5-3805-294-10 0048
Table 1. Engine Runs Poorly - Continued.
3. Fuel Tank is 1. Shut down engine. (WP 0009)

Contaminated.
2. Drain water and sediment from 1. If clean fuel does not become
fuel tank. (WP 0091) present, Notify Field
Maintenance.
2. If clean fuel becomes present,
proceed to Step 3.
3. Clean fuel strainer.

(WP 0077)
4. Start engine. (WP 0007) 1. If engine runs properly,

2. If engine runs poorly, shut
down engine. (WP 0009)
Notify Field Maintenance.
END OF WORK PACKAGE
0048-2
TM 5-3805-294-10 0049
EXCESSIVE FUEL CONSUMPTION
INITIAL SETUP:

WP 0005 WP 0077
WP 0009 WP 0087
Equipment Condition
Table 1. Excessive Fuel Consumption.


cleaners. (WP 0087)
Malfunction 2.
2. Leaking Fuel Lines Visually inspect fuel lines and 1. If fuel lines or fittings are
and Fittings. fittings for leakage. leaking, notify Field
2. If fuel lines or fittings are not
leaking, notify Field
Maintenance.
END OF WORK PACKAGE
0049-1/2 blank
TM 5-3805-294-10 0050
EXCESSIVE OIL CONSUMPTION
INITIAL SETUP:

WP 0005 WP 0077
WP 0009 WP 0087
Equipment Condition
Table 1. Excessive Oil Consumption.


cleaners. (WP 0087)
Malfunction 2.
2. Oil Shows Signs Of Visually inspect engine oil 1. If oil dipstick shows signs of
Contamination. dipstick for coolant or fuel contaminants, notify Field
contaminants. (WP 0077) Oil Maintenance.
containing coolant will have a
2. If oil dipstick shows no signs of
creamy brown appearance or
contaminants, notify Field
oil containing fuel will be
Maintenance.
diluted and smell like fuel.
END OF WORK PACKAGE
0050-1/2 blank
TM 5-3805-294-10 0051
ENGINE IDLES POORLY
INITIAL SETUP:

WP 0005 WP 0086
WP 0007 WP 0087
WP 0009
WP 0077
Equipment Condition
(WP 0009)
Table 1. Engine Idles Poorly.
1. Warning Lights and 1. Start engine. (WP 0007) If

Alarms are Present. engine does not immediately
idle poorly, allow engine to run
until engine starts to exhibit
poor idle symptoms.
2. Observe monitor (WP 0005)

for warning lights and alarms.

cleaners. (WP 0087)
2. If any other warning lights and
alarms are present, notify Field
Maintenance.
3. If no warning lights and alarms
are present, proceed to
Malfunction 2.

2. Start engine. (WP 0007) 1. If engine idles properly,

2. If engine idles poorly, proceed
to Malfunction 3.
0051-1
TM 5-3805-294-10 0051
Table 1. Engine Idles Poorly - Continued.
3. Leaking Fuel Lines 1. Shut down engine. (WP 0009)

and Fittings.
2. Visually inspect fuel lines and 1. If fuel lines and fittings are
fittings for leakage. leaking, notify Field
Maintenance.
END OF WORK PACKAGE
0051-2
TM 5-3805-294-10 0052
AUTO-IDLE DOES NOT WORK
INITIAL SETUP:

WP 0005
WP 0009
Table 1. Auto-Idle Does Not Work.
1. Engine Speed Does 1. Turn engine speed dial to high

Not Lower With idle position (H). (WP 0004)
Auto-Idle (A. I.)
Turned ON.
2. Turn A.I. switch to ON 1. If engine speed lowers in 4 - 6

position. (WP 0004) seconds, proceed to
Malfunction 4.
2. If engine speed does not lower
in 4 - 6 seconds, proceed to
Malfunction 2.
2. Auto-Idle (A. I.) Verify A.I. indicator is 1. If A. I. indicator is not displayed

Indicator Not displayed on monitor. on monitor with A. I. switch in
Displayed On (WP 0005) ON position, shut down
Monitor. engine. (WP 0009) Notify
Field Maintenance.
2. If A. I. indicator is displayed on
monitor, proceed to
Malfunction 3.
3. Hydraulic Verify if hydraulic operations 1. If hydraulic operations are

Operations Being are being performed. being performed, cease any
Performed. (WP 0004) hydraulic operations being
performed, verify engine
speed adjusts to A. I. speed
within 4 - 6 seconds.
(WP 0004) If engine speed
does not adjust to A.I. speed
within 4 - 6 seconds, shut down
engine. (WP 0009) Notify
Field Maintenance.
0052-1
TM 5-3805-294-10 0052
Table 1. Auto-Idle Does Not Work - Continued.
2. If hydraulic operations are not

being performed, shut down
engine. (WP 0009) Notify
Field Maintenance.
4. Engine Speed Does Operate hydraulic functions. 1. If engine speed raises, no fault
Not Raise With (WP 0004) at this time. Shut down
Auto-Idle (A. I.) engine. (WP 0009)
Turned ON and
2. If engine speed does not raise,
Hydraulic
shut down engine. (WP 0009)
Functions Being
Notify Field Maintenance.
Performed.
END OF WORK PACKAGE
0052-2
TM 5-3805-294-10 0053
ENGINE NOT DEVELOPING FULL POWER
INITIAL SETUP:

WP 0005 WP 0077
WP 0009 WP 0087
Equipment Condition
Table 1. Engine Not Developing Full Power.


cleaners. (WP 0087)
Malfunction 2.
2. Exhaust Pipes Visually inspect exhaust pipes 1. If exhaust pipes are dented or
Dented or and muffler for dents and restricted, notify Field
Restricted. restrictions. (WP 0077) Maintenance.
2. If exhaust pipes are not dented
or restricted, proceed to
Malfunction 3.
3. Leaking Fuel Lines Visually inspect fuel lines and 1. If fuel lines and fittings are
or Fittings. fittings for leakage. leaking, notify Field
Maintenance.
END OF WORK PACKAGE
0053-1/2 blank
TM 5-3805-294-10 0054
ENGINE OIL PRESSURE LOW
INITIAL SETUP:

(WP 0009)
Table 1. Engine Oil Pressure Low.
Low Engine Oil Check engine oil level. 1. If engine oil level is low, service
Level. (WP 0077) machine. (WP 0077)
2. If engine oil level is full, notify
Field Maintenance.
END OF WORK PACKAGE
0054-1/2 blank
TM 5-3805-294-10 0055
ENGINE COOLANT TEMPERATURE ABOVE NORMAL
INITIAL SETUP:

(WP 0009)
Table 1. Engine Coolant Temperature Above Normal.
1. Engine Coolant Visually inspect engine coolant 1. If level is low, service radiator.
Level Low. level. (WP 0077) (WP 0077)
2. If level is not low, proceed to
Malfunction 2.
2. Engine Oil Level Visually inspect engine oil 1. If level is low, service engine.
Low. level. (WP 0077) (WP 0077)
2. If level is not low, proceed to
Malfunction 3.
3. Radiator Damaged Visually inspect radiator for 1. If radiator has foreign objects/
or Has Foreign damage, foreign objects and debris, remove foreign objects/
Objects/Debris. debris. (WP 0077) debris.
2. If radiator is damaged, notify
Field Maintenance.
3. If radiator does not have
foreign objects/debris or does
not have damage, proceed to
Malfunction 4.
4. Surge Tank Cap is Visually inspect surge tank cap 1. If cap is loose, secure cap.
Loose. for looseness or damage.
2. If cap is damaged, notify Field
(WP 0077)
Maintenance.
3. If cap is not damaged or loose,
END OF WORK PACKAGE
0055-1/2 blank
TM 5-3805-294-10 0056
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE
INITIAL SETUP:

WP 0009
WP 0087
Table 1. Engine Emits Excessive Black Or Gray Exhaust Smoke.
Air Cleaners Dirty 1. Observe monitor for air cleaner


cleaners. (WP 0087)
not displayed, notify Field
Maintenance.
END OF WORK PACKAGE
0056-1/2 blank
TM 5-3805-294-10 0057
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE
INITIAL SETUP:

WP 0009 (WP 0009)
WP 0077
Table 1. Engine Emits Excessive White Exhaust Smoke.
1. Oil Shows Signs Of Visually inspect engine oil 1. If oil dipstick shows signs of
Contamination. dipstick for coolant or fuel contaminants, notify Field
contaminants. (WP 0077) Oil Maintenance.
containing coolant will have a
2. If oil dipstick shows no signs of
creamy brown appearance or
contaminants, Malfunction 2.
oil containing fuel will be
diluted and smell like fuel.
2. White Exhaust 1. Operate engine to normal

Smoke Excessive at operating temperature.
Normal Operating (WP 0007)
Temperature.
2. Observe engine exhaust.
3. Shut down engine. (WP 0009) 1. If engine emits white exhaust,

2. If engine does not emit white
exhaust, no fault at this time.
END OF WORK PACKAGE
0057-1/2 blank
TM 5-3805-294-10 0058
NO HYDRAULIC FUNCTIONS
INITIAL SETUP:

WP 0004 WP 0077
WP 0009 WP 0088
Equipment Condition
Table 1. No Hydraulic Functions.
1. Pilot Shutoff Lever 1. Place pilot shutoff lever in

in LOCK (up) UNLOCKED (down) position.
Position. (WP 0004)
2. Operate control pedals and

levers. (WP 0004)
3. Shut engine off. (WP 0009) 1. If hydraulic functions operate,

2. If hydraulic functions do not
operate, proceed to
Malfunction 2.
2. Hydraulic Oil Level Check hydraulic oil level. 1. If hydraulic oil level is correct,
Low. (WP 0077) notify Field Maintenance.
2. If hydraulic oil level is not
correct, fill oil to proper level.
(WP 0088)
END OF WORK PACKAGE
0058-1/2 blank
TM 5-3805-294-10 0059
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER
INITIAL SETUP:

WP 0031 (WP 0009)
WP 0077
WP 0088
Table 1. Hydraulic Functions Are Slow or Have Little or No Power.
Low. (WP 0077) proceed to Malfunction 2.
(WP 0088)
2. Hydraulic Oil Cold. Perform operating in cold 1. If hydraulic functions operate

weather below 5°F (-15°C) properly, malfunction
(WP 0031) or operating in cold corrected.
weather 32° to 5°F (0° to
2. If hydraulic functions do not
-15°C). (WP 0030)
operate properly, proceed to
Malfunction 3.
3. Hydraulic Reservoir Visually inspect hydraulic 1. If damaged or missing

Fill Cap is Damaged reservoir fill cap for damage or hardware, notify Field
or Missing missing hardware. (WP 0077) Maintenance.
Hardware.
2. if not damaged or missing
hardware, notify Field
Maintenance.
END OF WORK PACKAGE
0059-1/2 blank
TM 5-3805-294-10 0060
POWER DIG DOES NOT WORK
INITIAL SETUP:

WP 0084 (WP 0009)
Table 1. Power Dig Does Not Work.
1. Solenoid Fuse 1. Remove F4 SOLENOID 10A

2. Visually inspect F4 1. If fuse blown, replace F4

SOLENOID 10A fuse for blown SOLENOID 10A fuse.
fuse. (WP 0084)
Malfunction 2.
2. Hydraulic Oil Hoses Visually inspect hydraulic oil 1. If damaged or leaking, notify
Damaged or Has hoses for damage and leaks. Field Maintenance.
Leaks. (WP 0077)
2. If not damaged or leaking,
END OF WORK PACKAGE
0060-1/2 blank
TM 5-3805-294-10 0061
HYDRAULIC OIL OVERHEATS
INITIAL SETUP:

WP 0088 (WP 0009)
Table 1. Hydraulic Oil Overheats.
1. Cooling Package Visually inspect cooling 1. If damaged, notify Field

Has Damage, package for damage, foreign Maintenance.
Foreign Objects/ objects/debris. (WP 0077)
2. If not damaged but has foreign
Debris.
objects/debris, remove foreign
objects/debris.
3. If not damaged and does not
have foreign objects/debris,
(WP 0088)
END OF WORK PACKAGE
0061-1/2 blank
TM 5-3805-294-10 0062
HYDRAULIC OIL FOAMS
INITIAL SETUP:

WP 0088 (WP 0009)
Table 1. Hydraulic Oil Foams.
Low. (WP 0077) proceed to Malfunction 2.
2. If hydraulic oil level is low, fill oil
to proper level. (WP 0088)
3. If hydraulic oil level is high,
2. Hydraulic Oil Hoses Visually inspect hydraulic oil 1. If hydraulic oil hoses are
are Damaged. hoses for damage. (WP 0077) damaged, notify Field
Maintenance.
2. If hydraulic oil hoses are not
damaged, notify Field
Maintenance.
END OF WORK PACKAGE
0062-1/2 blank
TM 5-3805-294-10 0063
NO SWING FUNCTION
INITIAL SETUP:

WP 0088 (WP 0009)
Table 1. No Swing Function.
Hydraulic Oil Level Check hydraulic oil level. 1. If hydraulic oil level is correct,
(WP 0088)
END OF WORK PACKAGE
0063-1/2 blank
TM 5-3805-294-10 0064
SWING FUNCTION IS JERKY
INITIAL SETUP:

LO 5-3805-294-13 (WP 0094) Machine safely parked and shut down.
(WP 0009)
Table 1. Swing Function Is Jerky.
Lack of Grease in Visually inspect swing bearing 1. If swing bearing lacks grease,
Swing Bearing. grease fittings (LO lubricate swing bearing grease
5-3805-294-13). (WP 0094) fittings (LO 5-3805-294-13).
(WP 0094)
2. If swing bearing does not lack
grease, notify Field
Maintenance.
END OF WORK PACKAGE
0064-1/2 blank
TM 5-3805-294-10 0065
SLOW TRAVEL SPEED ONLY
INITIAL SETUP:

WP 0084 (WP 0009)
WP 0088
Table 1. Slow Travel Speed Only.
1. Solenoid Fuse 1. Remove F4 SOLENOID 10A

2. Visually inspect F4 1. If fuse blown, replace F4

SOLENOID 10A fuse for blown SOLENOID 10A fuse.
fuse. (WP 0084)
Malfunction 2.
(WP 0088)
END OF WORK PACKAGE
0065-1/2 blank
TM 5-3805-294-10 0066
TRAVEL IS JERKY
INITIAL SETUP:

WP 0080 (WP 0009)
Table 1. Travel is Jerky.
1. Incorrect Track Check track chain sag. 1. If track chain sag is within
Chain Tension. (WP 0080) specification, proceed to
Malfunction 2.
2. If track chain sag is not within
specification, adjust track
chain tension. (WP 0080)
2. Debris in Track Visually inspect track frame for 1. If jammed with debris, remove
Frame. jammed debris. (WP 0077) debris.
2. If not jammed with debris,
END OF WORK PACKAGE
0066-1/2 blank
TM 5-3805-294-10 0067
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED
INITIAL SETUP:

WP 0008 (WP 0009)
WP 0086
Table 1. Engine Stops When Travel or Control Lever Actuated.
Fuel Filter/Water 1. Drain primary and final fuel

3. Move HYEX. (WP 0008) 1. If engine stops when either

control lever is actuated, notify
Field Maintenance.
2. If engine stops when travel is
actuated, notify Field
Maintenance.
3. If engine does not stop while
moving, malfunction
corrected.
END OF WORK PACKAGE
0067-1/2 blank
TM 5-3805-294-10 0068
QUICK LATCH DOES NOT OPERATE
INITIAL SETUP:

WP 0009 WP 0077
WP 0014 WP 0084
Equipment Condition
Table 1. Quick Latch Does Not Operate.
1. Quick Latch Switch 1. Set quick latch switch to

Does not Operate. UNLATCH position.
(WP 0014)
2. Observe quick latch warning

light and alarm.
3. Observe quick latch for 1. If warning light and alarm are

movement. off, notify Field Maintenance.
2. If warning light and alarm is on,
2. Safety Lock Pin Check quick latch safety lock 1. If in locked position, place
Lever in Locked pin lever position. (WP 0014) quick latch safety lock pin lever
Position. in unlocked position.
(WP 0014)
2. If in unlocked position, proceed
to Malfunction 3.
3. Quick Hitch Fuse 1. Shut down engine. (WP 0009)

Blown.
2. Remove F26 QUICK HITCH

5A fuse. (WP 0084)
3. Visually inspect F26 QUICK 1. If fuse blown, replace F26

HITCH 5A fuse for blown fuse. QUICK HITCH 5A fuse.
(WP 0084)
Malfunction 4.
0068-1
TM 5-3805-294-10 0068
Table 1. Quick Latch Does Not Operate - Continued.
4. Quick Latch Has Visually inspect quick latch for 1. If quick latch does have
Jammed Debris. jammed debris. (WP 0077) jammed debris, remove
jammed debris. (WP 0077)
2. If quick latch does not have
jammed debris, notify Field
Maintenance.
END OF WORK PACKAGE
0068-2
TM 5-3805-294-10 0069
COMPACTOR DOES NOT OPERATE
INITIAL SETUP:

WP 0020 (WP 0009)
Table 1. Compactor Does Not Operate.
1. Hydraulic Supply Visually inspect hydraulic 1. If quick disconnect is fully

Quick Disconnect supply quick disconnect. seated, proceed to Malfunction
Not Fully Seated. (WP 0077) 2.
2. If quick disconnect is not fully
seated, reconnect quick
disconnect properly.
(WP 0020)
3. If quick disconnect is
Maintenance.
2. Hydraulic Return Visually inspect hydraulic 1. If quick disconnect is fully

Quick Disconnect return quick disconnect. seated, proceed to Malfunction
(WP 0020)
Maintenance.
3. Compactor Has Visually inspect compactor for 1. If compactor does have

Jammed Debris. jammed debris. (WP 0077) jammed debris, remove
jammed debris. (WP 0077)
2. If compactor does not have
Maintenance.
END OF WORK PACKAGE
0069-1/2 blank
TM 5-3805-294-10 0070
BREAKER DOES NOT OPERATE
INITIAL SETUP:

WP 0077 (WP 0009)
Table 1. Breaker Does Not Operate.

(WP 0020)
Maintenance.

(WP 0020)
Maintenance.
3. Breaker Has Visually inspect breaker for 1. If breaker does have jammed
Jammed Debris. jammed debris. (WP 0077) debris, remove jammed
debris. (WP 0077)
2. If breaker does not have
Maintenance.
END OF WORK PACKAGE
0070-1/2 blank
TM 5-3805-294-10 0071
BREAKER OPERATES SLOWLY
INITIAL SETUP:

WP 0009 WP 0077
WP 0018 WP 0088
Equipment Condition
Table 1. Breaker Operates Slowly.
1. Breaker Check attachment selection on 1. If breaker attachment is

Attachment Not monitor. (WP 0018) selected, proceed to
Selected. Malfunction 2.
2. If breaker attachment is not
selected, select breaker
attachment on monitor.
(WP 0018)
2. Hydraulic Supply 1. Shut down engine. (WP 0009)

Hose is Damaged or
Has Leaks.
2. Visually inspect hydraulic 1. If hydraulic supply hose is

supply hose. (WP 0077) damaged or leaking, notify
Field Maintenance.
2. If hydraulic supply hose is not
damaged or leaking, proceed
to Malfunction 3.
3. Hydraulic Return Visually inspect hydraulic 1. If hydraulic return hose is

Hose is Damaged or return hose. (WP 0077) damaged or leaking, notify
Has Leaks. Field Maintenance.
2. If hydraulic return hose is not
damaged or leaking, proceed
to Malfunction 4.
0071-1
TM 5-3805-294-10 0071
Table 1. Breaker Operates Slowly - Continued.
(WP 0088)
END OF WORK PACKAGE
0071-2
TM 5-3805-294-10 0072
CRUSH-ALL DOES NOT OPERATE
INITIAL SETUP:

WP 0077 (WP 0009)
WP 0084
Table 1. Crush-All Does Not Operate.
1. 12-Volt Power 1. Remove F6 OPT.2 (ALT) 10A

Outlet Fuse Blown. fuse. (WP 0084)
2. Visually inspect F6 OPT.2 1. If fuse blown, replace F6 OPT.

(ALT) 10A fuse for blown fuse. 2 (ALT) 10A fuse. (WP 0084)
Malfunction 2.

(WP 0020)
Maintenance.

(WP 0020)
Maintenance.
0072-1
TM 5-3805-294-10 0072
Table 1. Crush-All Does Not Operate - Continued.
4. Crush-All Has Visually inspect crush-all for 1. If crush-all does have jammed
Jammed Debris. jammed debris. (WP 0077) debris, remove jammed
debris. (WP 0077)
2. If crush-all does not have
Maintenance.
END OF WORK PACKAGE
0072-2
TM 5-3805-294-10 0073
BARRIER GRAPPLE DOES NOT HOLD LOAD
INITIAL SETUP:

(WP 0009)
Table 1. Barrier Grapple Does Not Hold Load.
Grip pads worn. Visually inspect grip pads. 1. If grip pads worn, notify Field
2. If grip pads not worn, notify
Field Maintenance.
END OF WORK PACKAGE
0073-1/2 blank
TM 5-3805-294-10 0074
DEEP DIG DOES NOT OPERATE
INITIAL SETUP:

WP 0009 WP 0077
WP 0023 WP 0084
Equipment Condition
Table 1. Deep Dig Does Not Operate.
1. Deep Dig Control Check deep dig control pattern 1. If switch is OFF, set deep dig
Pattern Switch is switch position. (WP 0023) control pattern switch to ON.
OFF. (WP 0023)
2. If switch is ON, proceed to
Malfunction 2.
2. Cab Auxiliary 1. Shut down engine. (WP 0009)

Power Connector
One Fuse Blown.
2. Remove F13 AUX 10A fuse.

(WP 0084)
3. Visually inspect F13 AUX 10A 1. If fuse blown, replace F13 AUX
Malfunction 3.
3. Hydraulic Supply 1. Visually inspect hydraulic

Quick Disconnect supply quick disconnect.
Not Fully Seated. (WP 0077)
2. Visually inspect hydraulic

return quick disconnect.
(WP 0077)
3. Visually inspect hydraulic

supply hose for damage.
(WP 0077)
0074-1
TM 5-3805-294-10 0074
Table 1. Deep Dig Does Not Operate - Continued.
4. Visually inspect hydraulic 1. If quick disconnect(s) is not

return hose for damage. fully seated, reconnect quick
(WP 0077) disconnect properly.
(WP 0023)
2. If quick disconnect(s) is
Maintenance.
3. If hose(s) is damaged, notify
Field Maintenance.
4. If quick disconnects are fully
seated and hoses are not
Maintenance.
END OF WORK PACKAGE
0074-2
TM 5-3805-294-10 0075
HYDRAULIC HOSE REEL DOES NOT OPERATE
INITIAL SETUP:

WP 0009 WP 0077
WP 0026 WP 0084
Equipment Condition
Table 1. Hydraulic Hose Reel Does Not Operate.
1. Hand Held Check hand held hydraulic tool 1. If switch is OFF, set hand held
Hydraulic Tool circuit switch position. hydraulic tool circuit switch to
Circuit Switch is (WP 0026) ON. (WP 0026)
OFF.
2. If switch is ON, proceed to
Malfunction 2.
2. Cab Auxiliary 1. Shut down engine. (WP 0009)

Power Connector
One Fuse Blown.
2. Remove F13 AUX 10A fuse.

(WP 0084)
3. Visually inspect F13 AUX 10A 1. If fuse blown, replace F13 AUX
Malfunction 3.

(WP 0026)
Maintenance.
0075-1
TM 5-3805-294-10 0075
Table 1. Hydraulic Hose Reel Does Not Operate - Continued.

(WP 0026)
Maintenance.
5. Hydraulic Tool Visually inspect hydraulic tool 1. If hose is not damaged,

Supply Hose Has supply hose for damage. proceed to Malfunction 6.
Damage. (WP 0077)
2. If hose is damaged, notify Field
Maintenance.
6. Hydraulic Tool Visually inspect hydraulic tool 1. If hose is not damaged, notify
Return Hose Has return hose for damage. Field Maintenance.
Damage. (WP 0077)
2. If hose is damaged, notify Field
Maintenance.
END OF WORK PACKAGE
0075-2
TM 5-3805-294-10
CHAPTER 4
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND

SERVICES (PMCS)
NSN 3805-01-573-0677
TM 5-3805-294-10 0076
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
PREVENTIVE MAINTENANCE CHECKS AND SERVICES
NOTE
• If the machine has reached the initial 250 hours of operation, contact field level
maintenance to perform the initial 250 hour service.
• Tools supplied on the machine are to be used for Preventive Maintenance Checks and
Services (PMCS). Rags are also required for removing dirt and grease.
• PMCS intervals should be performed more frequently when operating under unusual
conditions.
• Perform PMCS on attachments only if they are to be used for the current mission.
This section contains operator level PMCS requirements for the Hydraulic Excavator (HYEX). The PMCS tables
contain checks and services necessary to ensure that the machine is ready for operation. Maintenance is performed
at specified intervals using the PMCS tables.
Inspecting for good condition is generally a visual inspection to determine if components are safe or serviceable.
Components in good condition are: not bent or twisted, chafed or burned, broken, or cracked. There should be no
signs of wear, fraying, dents, collapsing, tears, cuts, or deterioration.
Damage is any condition that affects safety or prevents a part or assembly from functioning normally or would render
the machine unserviceable for mission requirements.
MAINTENANCE RECORDS AND FORMS
Every mission begins and ends with paperwork. There is not much of it, but it must be kept up. The completed forms
and records have several uses. They are a permanent record of services, repairs, and modifications made to the
machine. They are reports to maintenance personnel, and to the Commander. They serve as a checklist to track
previous machine malfunctions and repair actions. Record results of PMCS on DA Form 2404, Equipment Inspection
and Maintenance Worksheet, or DA Form 5988-E, Equipment Inspection and Maintenance (Electronic) Worksheet.
For the information needed on forms and records, refer to DA PAM 750-8 The Army Maintenance Management
System (TAMMS) Users Manual.
GENERAL MAINTENANCE PROCEDURES
• Cleanliness: Dirt, grease, oil, and debris can conceal serious problems. Use solvent cleaning compound
on all metal surfaces and soapy water on rubber or plastic surfaces.
• Bolts, Nuts, and Screws: Check for loose bolts, nuts, and screws, as well as for those that are missing,
bent, or broken. Tighten or replace as necessary. If parts cannot be checked with a tool, look for signs of
chipped paint, bare metal, or rust around bolt heads.
• Welds: Look for loose or chipped paint, rust, or gaps where parts are welded together. If a damaged weld
is discovered, notify Field Level Maintenance.
• Electric Wires and Connectors: Look for cracked or broken insulation, exposed wires, and loose or broken
connectors. Tighten loose connectors and ensure wires are in good shape.
• Fluid Hoses, Tubes, and Fittings: Look for wear, damage, or leaks. Ensure clamps and fittings are tight.
Wet spots show leaks, but a stain around a fitting or connector may also indicate a leak. If connectors or
fittings are loose or if hoses, tubes, or fittings are broken or worn out, notify Field Level Maintenance.
0076-1
TM 5-3805-294-10 0076
WARNINGS AND CAUTIONS
Always observe the warnings and cautions appearing in your PMCS table. Warnings and cautions appear before
the applicable procedure. You must observe these warnings and cautions to prevent serious injury to personnel or
to prevent damage to the equipment.
ARMY OIL ANALYSIS PROGRAM (AOAP)
The engine and hydraulic oil and filters replacement are governed by the AOAP program. Samples for the engine
are taken every 90 days and once yearly for the hydraulic system. If sampling is not feasible due to mission, then
hard time intervals apply for oil and filter changes.
LUBRICATION INSTRUCTIONS
• During adverse weather or unusually dusty conditions, lubrication may be required on a daily basis.
• After fording operations, lubricate all lubrication points below fording line.
• For detailed lubrication instructions, refer to: LO 5-3805-294-13 Lubrication Instructions for the Hydraulic
Excavator (HYEX).
PMCS COLUMN DESCRIPTION
The PMCS table columns are described as follows:
Item Number
The order that the PMCS should be performed. Use the item number when recording results on the DA Form 2404,
Equipment Inspection and Maintenance Worksheet or the DA Form 5988-E, Equipment Inspection and Maintenance
(Electronic) Worksheet.
Interval
Lists the interval at which the check or service is to be performed.
Item to be Inspected
Lists the item being checked or serviced.
Procedures
Describes the procedure for the check or service.
Equipment Not Ready or Available If
Describes a condition that renders the machine not mission capable.
0076-2
TM 5-3805-294-10 0076
Types of Preventive Maintenance Checks and Services (PMCS)
For each service interval, perform all checks and services listed and all checks and services associated with any
lower service interval.
• Before: Do the Before (B) PMCS before operating the machine. Pay attention to the WARNINGS and
CAUTIONS.
• During: Do the During (D) PMCS while machine or its components are in operation. Pay attention to the
WARNINGS and CAUTIONS.
• After: Do the After (A) PMCS after operating the machine. Pay attention to the WARNINGS and CAUTIONS.
• Monthly: Do the Monthly (M) PMCS once a month on the machine. Pay attention to the WARNINGS and
CAUTIONS.
Always perform PMCS in the same order, every time. Once practiced, problems can be spotted quickly. If an item
or component being inspected is inoperable or damaged, either troubleshoot by following instructions in the
Troubleshooting Section of this manual or repair and/or replace as described in the related maintenance task. If
there appears to be a malfunction that cannot be repaired immediately, complete either DA Form 2404,or DA Form
5988-E.
FLUID LEAKAGE
• Class I: Seepage of fluid (as indicated by wetness or discoloration) not sufficient enough to form drops.
• Class II: Leakage of fluid sufficient enough to form drops, but not sufficient enough to cause the drops to
drip from the item being inspected.
• Class III: Leakage of fluid sufficient enough to form drops that fall from the item being inspected.
END OF WORK PACKAGE
0076-3/4 blank
TM 5-3805-294-10 0077
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
INITIAL SETUP:
Materials/Parts References (cont.)

Antifreeze, Arctic Type TM 5-3805-295-13&P (WP 0094)
(WP 0097, Table 1, Item 1) WP 0007
Antifreeze (WP 0097, Table 1, Item 2) WP 0009
Engine Oil (WP 0097, Table 1, Item 13) WP 0034
Gloves (WP 0097, Table 1, Item 10) WP 0080
Goggles (WP 0097, Table 1, Item 10) WP 0085
Grease (WP 0097, Table 1, Item 10) WP 0087
Penetrating Oil (WP 0097, Table 1, Item 14) WP 0088
Rags, Wiping (WP 0097, Table 1, Item 15) WP 0089
WP 0090
WP 0091
References
WP 0094
LO 5-3805-294-13 (WP 0094)
Table 1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES
EQUIPMENT NOT
ITEM ITEM TO BE CHECKED READY/
NO. INTERVAL OR SERVICED PROCEDURE AVAILABLE IF:
WARNING
Personnel hearing can be

permanently damaged if ex-
posed to constant high noise
levels of 85 dB or greater.
Failure to comply may result
in injury to personnel.
WARNING
Unless otherwise specified,

perform all maintenance
procedures with all attach-
ments lowered to the
ground, pilot shutoff lever in
0077-1
TM 5-3805-294-10 0077
Table 1. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES - Continued
EQUIPMENT NOT
the up position, and engine
shut off. Failure to comply
may result in injury or death
to personnel.
WARNING
Ensure electrical power is

off prior to working on all
electrical connections. Re-
move all jewelry such as
rings, ID tags, bracelets,
etc., prior to working on or
around vehicle. Jewelry and
tools can catch on equip-
ment, contact positive elec-
trical circuits, and cause a
direct short, severe burns, or
electrical shock. Failure to
comply may result in injury
CAUTION
New machine break-in
maintenance is required at
250 hours. Contact Field
Maintenance to avoid early
wear or damage to the ma-
chine. Failure to comply may
result in voidance of warran-
ty and damage to the ma-
chine.
NOTE
Perform Operator's Before
PMCS checks if:
• You are the assigned
operator but have not
operated the machine
since the last PMCS
was performed.
0077-2
TM 5-3805-294-10 0077
EQUIPMENT NOT
• You are operating the
machine for the first
time.
• Only perform PMCS on
attachments if they are
to be operated for
current mission.
• The lubrication order is
to be used in
conjunction with the
PMCS.
• For Armored Cab
PMCS, refer to
TM 5-3805-295-13&P.
1 Before Exterior of Machine Perform walk-around inspection of Class III oil or

the machine exterior. Check on coolant leaks.
ground under machine (Figure 1, Any fuel leak-
Item 1) for evidence of fluid leakage age is evident.
such as oil, coolant, or fuel.
Check machine (Figure 1, Item 1) Damage that

for obvious damage that would would impair
impair operation. operation is evi-
dent.
4 2 HYEX01001
Figure 1. Exterior of Machine.
0077-3
TM 5-3805-294-10 0077
EQUIPMENT NOT
2 Before Left and Right Track Check for loose or missing track Loose or miss-
Chain and Rollers shoe (Figure 2, Item 2) and track ing track shoe.
bolts. One or more
bolts missing
from track shoe.
4 2 HYEX01001
Figure 2. Exterior of Machine Continued.
Check for oil leakage from carrier Oil leaking from

roller (Figure 2, Item 3) or support carrier roller or
rollers (Figure 2, Item 4). support roller.
3 Before Coolant Surge Tank Check that coolant is at the MIN Coolant level
COLD line (Figure 3, Item 5) on the below MIN
surge tank (Figure 3, Item 6). COLD level.
0077-4
TM 5-3805-294-10 0077
EQUIPMENT NOT
6 5 HYEX01002
Figure 3. Coolant Level.
If coolant is low, remove surge tank

cap (Figure 3, Item 7) and fill as
required.
Check that the surge tank (Figure 3, Surge tank has

Item 6) is not damaged. a Class III leak.
Check that surge tank cap (Figure Cap is missing

3, Item 7) is present and is not or is unservice-
broken or cracked. able.
4 Before Engine Oil Level Check oil level on the dipstick Engine oil level
(Figure 4, Item 8) and ensure that it below the ADD
is between the ADD and FULL mark or engine
marks. oil is overfull.
0077-5
TM 5-3805-294-10 0077
EQUIPMENT NOT
HYEX01003
Figure 4. Engine Oil.
If engine oil is low, remove cap

(Figure 4, Item 9) and add oil as
required (LO 5-3805-294-13).
(WP 0094)
5 Before Engine Compartment Check engine compartment for Any damage

obvious damage or leaks in hoses that would im-
or lines. pair safe opera-
tion of the ma-
chine.
6 Before Exhaust Components Check exhaust components for Loose, leaking,

leaks, loose parts, dents, or or damaged
damage. components.
0077-6
TM 5-3805-294-10 0077
EQUIPMENT NOT
HYEX03409
Figure 5. Exhaust Components.
7 Before Hydraulic Reservoir Cap Press button (Figure 6, Item 10) on Hydraulic reser-
hydraulic reservoir cap (Figure 6, voir cap is bro-
Item 11) to ensure that it is ken, missing, or
operational and that cap is not button cannot
broken. be pressed.
11 10
HYEX01004
Figure 6. Hydraulic Reservoir Cap.
8 Before Fuel Tank Check fuel tank (Figure 7, Item 12) Any signs of
for evidence of leaks. leaks from fuel
tank.
0077-7
TM 5-3805-294-10 0077
EQUIPMENT NOT
14
13
12
HYEX01005
Figure 7. Fuel Tank and Fuel Level.
Ensure fuel tank is full.
To fill fuel tank:

• Remove fuel cap (Figure
7, Item 13).
• Fill fuel tank (Figure 7,
Item 12) until band (Figure
7, Item 14) is visible.
• Install fuel cap (Figure 7,
Item 13).
9 Before Fuel Filters Check primary fuel filter (Figure 8, Any fuel leak.
Item 15), fuel/water separator
(Figure 8, Item 16), and fuel lubricity
filter (Figure 8, Item 17) for
evidence of leaks.
0077-8
TM 5-3805-294-10 0077
EQUIPMENT NOT
16 15
18
17
HYEX01006
Figure 8. Fuel Filters.
10 Before Hydraulic Oil Filter Check hydraulic oil filter (Figure 8, Any Class III
Item 18) for evidence of leaks. leak.
11 Before Hydraulic Pump Check hydraulic pump Any damage

Compartment compartment for obvious damage that would im-
or leaks in lines or hoses. pair safe opera-
tion of machine.
12 Before Engine Oil Filter Check engine oil filter (Figure 9, Any Class III
Item 19) for evidence of leaks. leak.
19
HYEX01007
Figure 9. Engine Oil Filter.
0077-9
TM 5-3805-294-10 0077
EQUIPMENT NOT
13 Before Boom, Arm, Quick Latch, Check boom (Figure 10, Item 20), Damage that
Hydraulic Thumb arm (Figure 10, Item 21), quick impairs proper
latch (Figure 10, Item 22), and operation.
hydraulic thumb (Figure 10, Item
23) for damage that would impair
operation.
24 27
20
25
26
23
21
24
26
24
24 22 HYEX01008
Figure 10. Boom, Arm, Quick Latch, and Hydraulic Thumb.
Check cylinders (Figure 10, Item Any Class III

24) for leaks. leak.
Check hydraulic lines (Figure 10, Any Class III

Item 25) and hoses (Figure 10, Item leak.
26) for leaks.
Check for presence of hydraulic

thumb pin (Figure 10, Item 27).
14 Before Bucket NOTE

Only check bucket or attach-
ment to be used for current
mission.
Check bucket (Figure 11, Item 28)

for cracks and missing teeth.
0077-10
TM 5-3805-294-10 0077
EQUIPMENT NOT
Replace teeth as required.
(WP 0085)
28
HYEX01009
Figure 11. Bucket and Teeth.
Check bucket for loose, broken, or Loose, broken,

missing hardware or mounting or missing hard-
bracket damage. ware or mount-
ing bracket is
cracked.
15 Before Primary and Secondary Inspect and clean primary and Primary and
Air Cleaner Housing secondary air cleaner housing secondary air
(Figure 12, Item 29) for damage or cleaner housing
missing parts. (WP 0087) cracked or cov-
er missing.
0077-11
TM 5-3805-294-10 0077
EQUIPMENT NOT
29
30
33
32
31
HYEX01395
Figure 12. Air Cleaner Housing and Hose Reel.
Squeeze ejector (Figure 12, Item

30) to remove dust.
16 Before Hose Reel, Hoses, Deep Check deep dig control pattern Any lines are
Dig Control Switch, and switch (Figure 12, Item 31) to cracked, frayed,
Hand Held Hydraulic ensure it is in the OFF position. If or broken.
Switch deep dig arm is installed, ensure
that deep dig control pattern switch
(Figure 12, Item 31) is in the ON
position.
Check hydraulic hand held tool

circuit switch (Figure 12, Item 32) to
ensure it is in the OFF position.
Check hydraulic hose reel and Any class III

hoses (Figure 12, Item 33) for leak.
damage and leaks.
0077-12
TM 5-3805-294-10 0077
EQUIPMENT NOT
17 Before Batteries WARNING
LEAD-ACID BATTERIES
Remove four wing nuts (Figure 13,

Item 34), washers (Figure 13, Item
35), and two covers (Figure 13,
Item 36) from batteries (Figure 13,
Item 37).
Check batteries (Figure 13, Item Batteries show

37) for leaks or cracks. signs of leaking
or have cracks.
40
41
36
34, 35 37 38 39 HYEX01011
Figure 13. Batteries.
Check battery cables (Figure 13, Battery cables

Item 38) for looseness. are loose.
Install two covers (Figure 13, Item

36) to batteries (Figure 13, Item 37)
with four wing nuts (Figure 13, Item
0077-13
TM 5-3805-294-10 0077
EQUIPMENT NOT
34) and washers (Figure 13, Item
35).
18 Before Cooling Package Check cooling package (Figure 13, Any Class III
Item 39) for leaks and damage. coolant leak.
19 Before Fuel Cooler Check fuel cooler (Figure 14, Item Any fuel leak.
40) and fuel lines for leaks.
40
41
36
34, 35 37 38 39 HYEX01011
Figure 14. Batteries Continued.
Check windshield washer reservoir

(Figure 14, Item 41) for fluid and
damage. Fill as required.
Check cooling compartment for Any damage

obvious damage or leaks. that would im-
pair safe opera-
tion of the ma-
chine.
Any fuel leak or
class III fluid
leaks.
20 Before Cab Glass Check cab glass (Figure 15, Item Any broken
42) for cracks or chips. glass that im-
pairs the opera-
tors vision. Any
glass missing.
0077-14
TM 5-3805-294-10 0077
EQUIPMENT NOT
42
42
42
42
HYEX01012
Figure 15. Cab Glass.
21 Before Mirrors, Wiper, and Check that mirrors (Figure 16, Item
Operator Protection 43) are present and serviceable.
Guard
43
43
45
44
HYEX01396
Figure 16. Mirrors and Wiper Arm.
Check that operator protection Operator pro-

guard (Figure 16, Item 44) is tection guard
present and serviceable. missing.
0077-15
TM 5-3805-294-10 0077
EQUIPMENT NOT
Check that wiper arm and blade

(Figure 16, Item 45) are
serviceable.
22 Before Door, Door Hinges, and Check that hinges (Figure 17, Item Door is difficult
Latches 46) allow door (Figure 17, Item 47) to open or close.
to swing freely.
46
47
48
48
46 HYEX03430
Figure 17. Cab Door, Hinges, and Latches.
Check that door (Figure 17, Item Door fails to

47) and latches (Figure 17, Item 48) latch or latches
lock and release in open and closed fail to release.
positions.
23 Before Fire Extinguisher Check that fire extinguisher (Figure Fire extinguish-
18, Item 49) is present and is fully er is missing,
charged. has been dis-
charged, or has
an expired date
of service.
0077-16
TM 5-3805-294-10 0077
EQUIPMENT NOT
49
HYEX01013
Figure 18. Fire Extinguisher.
24 Before Cab Pedals and Levers Check that left and right travel pedal Left or right trav-
and lever (Figure 19, Item 50) move el pedal or lever
freely through their full range of are binding or
travel. do not move
freely through
full range of
travel.
0077-17
TM 5-3805-294-10 0077
EQUIPMENT NOT
50 50 50 50 51 52
HYEX01399
Figure 19. Pedals and Levers.
Check that attachment pedal Attachment

(Figure 19, Item 51) moves freely pedal does not
through range of travel and move freely or
attachment pedal lock (Figure 19, attachment
Item 52) is operational. pedal lock does
not operate.
25 Before Pilot Control Levers Check left (Figure 20, Item 53) and Left or right pilot
right (Figure 20, Item 54) pilot control lever
control levers to ensure that they binds or will not
move freely through full range of move through
motion. full range of mo-
tion.
0077-18
TM 5-3805-294-10 0077
EQUIPMENT NOT
54
53
HYEX01397
Figure 20. Pilot Control Levers.
26 Before Horn Press horn button to ensure horn Horn does not
sounds. sound.
27 Before Seat Belt Check that seat belt (Figure 21, Seat belt is
Item 55) is not frayed and fastens frayed or will not
together. fasten together.
0077-19
TM 5-3805-294-10 0077
EQUIPMENT NOT
55
HYEX01398
Figure 21. Seat Belt.
28 Before Monitor Turn ignition switch (Figure 22, Item

56) to ON position.
56
HYEX01014
Figure 22. Ignition Switch.
0077-20
TM 5-3805-294-10 0077
EQUIPMENT NOT
NOTE
If default screen is not dis-
played after start up screen,
wait 10 seconds to ensure
default screen will be dis-
played.
Check that monitor (Figure 23, Item Monitor does

57) comes on, then goes to default not come on.
screen. Monitor does
not go to default
screen.
57
System Starting...
1 2 3 4 5
6 7 8 9 0
F1 F2 F3 F4
HYEX01015
Figure 23. Monitor.
29 Before Starter Start engine. (WP 0007) Engine does not

start or starter
makes unusual
noises.
30 Before Lights Check that all lights operate. Lights do not

operate.
31 Before Wipers and Washer Fluid Check that wipers and washer Wipers do not
pump works and has fluid. operate.
32 Before Hydraulic Oil Level To check hydraulic oil level: Sight glass has
• Fully extend arm (Figure class III leak.
24, Item 58).
0077-21
TM 5-3805-294-10 0077
EQUIPMENT NOT
• Curl bucket (Figure 24,
Item 59).
• Lower boom (Figure 24,
Item 60) until bucket is
resting on the ground.
60
58
59 HYEX01016
Figure 24. Position Boom and Arm.
61
HYEX01017
Figure 25. Hydraulic Oil Level Check.
To fill hydraulic reservoir: Reservoir is

• Open right door and empty.
ensure that hydraulic oil is Sight glass is
between marks on sight broken or dam-
glass (Figure 25, Item 61). aged.
Fill as required. Any Class III
•Shut down engine. leaks.
(WP 0009)
•Service hydraulic
reservoir. (WP 0088)
0077-22
TM 5-3805-294-10 0077
EQUIPMENT NOT
33 Before Breaker NOTE

Only perform PMCS on at-
tachments that are required
for current mission.
Check breaker (Figure 26, Item 62) Loose, broken,

for loose, broken, or missing or missing hard-
hardware or mounting bracket ware or mount-
damage. ing bracket is
cracked.
63
HYEX01018
62
Figure 26. Breaker.
Check breaker hydraulic hoses Any class III

(Figure 26, Item 63) for leaks and leak.
breaker for problems that would
impair operation.
34 Before Compactor Check compactor (Figure 27, Item Loose, broken,

64) for loose, broken, or missing or missing hard-
cracked.
0077-23
TM 5-3805-294-10 0077
EQUIPMENT NOT
65
64
HYEX01019
Figure 27. Compactor.
Check compactor hydraulic hoses Any class III

(Figure 27, Item 65) for leaks and leak.
compactor for problems that would
impair operation.
35 Before Crush-All Check crush-all (Figure 28, Item Loose, broken,

66) for loose, broken, or missing or missing hard-
cracked.
0077-24
TM 5-3805-294-10 0077
EQUIPMENT NOT
66 67 HYEX01020
Figure 28. Crush-All.
Check hydraulic hoses (Figure 28, Any class III

Item 67) for leaks and crush-all for leak.
problems that would impair
operation.
36 Before Lubricate Lubricate crush-all daily before

each use (LO 5-3805-294-13).
(WP 0094)
37 Before Barrier Grapple Check barrier grapple (Figure 29, Loose, broken,
Item 68) for loose, broken, or or missing hard-
missing hardware or mounting ware or mount-
bracket damage. ing bracket is
cracked.
0077-25
TM 5-3805-294-10 0077
EQUIPMENT NOT
69
68 HYEX02987
Figure 29. Barrier Grapple.
Check barrier grapple for missing or Barrier grapple

damaged pads. pad missing or
damaged.
Check that barrier grapple lifting Barrier grapple

device (Figure 29, Item 69) does cable is kinked
not have broken strands. or three or more
strands are bro-
ken.
38 Before Barrier Grapple Actuator Lubricate actuator before use with

penetrating oil.
39 Before Deep Dig Arm Check deep dig arm (Figure 30, Any loose, bro-
Item 70) for loose, broken, or ken, or missing
missing hardware or damage. hardware or
damage.
0077-26
TM 5-3805-294-10 0077
EQUIPMENT NOT
72
71
70
HYEX01306
Figure 30. Deep Dig Arm and Bucket.
Check deep dig arm hydraulic Any class III

hoses (Figure 30, Item 71) for leak.
leaks, damage, or fraying.
Check deep dig ditch cleaning Loose, broken,

bucket (Figure 30, Item 72) for or missing hard-
loose, broken, or missing hardware ware or mount-
or mounting bracket damage. ing bracket is
cracked.
40 Before Deep Dig Bucket Check bucket (Figure 31, Item 73)
for cracks and missing teeth.
Replace teeth as required.
(WP 0085)
0077-27
TM 5-3805-294-10 0077
EQUIPMENT NOT
73 HYEX01307
Figure 31. Deep Dig Bucket.
Check bucket (Figure 31, Item 73) Loose, broken,

cracked.
41 Before Ditch Cleaning Bucket Check bucket (Figure 32, Item 74) Loose, broken,
cracked.
0077-28
TM 5-3805-294-10 0077
EQUIPMENT NOT
74
HYEX01308
Figure 32. Ditch Cleaning Bucket.
42 During Monitor Check monitor during operation for Any alarm

any alarm. If alarm sounds or is sounds or is dis-
displayed on monitor, perform played on moni-
corrective procedures as needed or tor.
shut down engine. (WP 0009)
43 During Engine speed Dial Turn engine speed dial and ensure Engine speed
engine speed increases. dial does not op-
erate.
44 During Right-Hand Console Operate right-hand console Switches do not

Switches switches. operate.
45 During Hydraulic Cylinders Check that all hydraulic cylinders Hydraulic cylin-
operate smoothly and through full ders do not op-
range of travel. erate normally
or have class III
leak.
46 During Travel Motor, Steering, Travel machine forward a short If machine

and Brakes distance and ensure that: doesn't travel in
• Machine travels in a a straight line.
straight line. Machine does
•Steers left and right. not steer left or
•Track chain does not right.
make any unusual or Track chain
popping noises. makes unusual
0077-29
TM 5-3805-294-10 0077
EQUIPMENT NOT
•When travel levers or or popping
pedals are released noises.
machine stops. Machine does
•Travel levers and pedals not stop when
return to center when travel levers or
released. pedals are re-
leased.
Travel levers or
pedals do not
return to center
when released.
47 During Travel Alarm Ensure travel alarm operates when Travel alarm
machine is moved. does not oper-
ate.
48 During Swing Motor and Swing Swing upperstructure left or right Upperstructure
Brake approximately 90 degrees then does not stop or
release pilot control levers and drifts.
ensure upperstructure stops.
49 During Air Conditioner/Heater Ensure air conditioner/heater Blower motor

blower motor operates. does not oper-
ate when turned
on.
50 During Breaker CAUTION

Breaker must be lubricated
every 2 hours of use and ev-
ery hour during dusty condi-
tions. Failure to comply may
result in damage to the at-
tachment.
During extreme dusty conditions,

lubricate breaker after every hour of
use LO 5-3805-294-13.
(WP 0094)
51 After Hydraulic Oil Level To check hydraulic oil level: Sight glass has
• Fully extend arm (Figure class III leak.
33, Item 58).
• Curl bucket (Figure 33,
Item 59).
• Lower boom (Figure 33,
Item 60) until bucket is
resting on the ground.
• Open right door and
ensure that hydraulic oil is
0077-30
TM 5-3805-294-10 0077
EQUIPMENT NOT
between marks on sight
glass (Figure 34, Item 61).
Fill as required.
60
58
59 HYEX01016
Figure 33. Position Boom and Arm.
61
HYEX01017
Figure 34. Hydraulic Oil Level Check.
To fill hydraulic reservoir:

•Shut down engine.
(WP 0009)
•Service hydraulic
reservoir. (WP 0088)
•Start engine. (WP 0007)
•Safely park and shut down
engine. (WP 0009)
52 After Fuel Tank and Strainer Check fuel tank and strainer (Figure Any signs of
35, Item 12) for evidence of leaks or leaks or dam-
damage. age to fuel tank
or strainer, or
strainer is miss-
ing.
0077-31
TM 5-3805-294-10 0077
EQUIPMENT NOT
14
13
12
HYEX01005
Figure 35. Fuel Tank and Fuel Level Check.
Ensure fuel tank is full.
To fill fuel tank:

• Remove fuel cap (Figure
35, Item 13).
• Fill fuel tank (Figure 35,
Item 12) until band (Figure
35, Item 14) is visible.
• Install fuel cap (Figure 35,
Item 13).
53 After Engine Oil Level CAUTION

chine.
Check oil level on the dipstick

(Figure 36, Item 8) and ensure that
it is between the ADD and FULL
marks.
0077-32
TM 5-3805-294-10 0077
EQUIPMENT NOT
HYEX01003
Figure 36. Engine Oil Check.
If engine oil is low, remove cap

(Figure 36, Item 9) and add oil as
required.
54 After Engine Compartment, Check engine compartment for Any damage

Belts, and Hoses obvious damage or leaks in hoses that would im-
or lines. Check belts for cuts or pair safe opera-
frays. tion of the ma-
chine.
HYEX03410
Figure 37. Engine Compartment.
0077-33
TM 5-3805-294-10 0077
EQUIPMENT NOT
55 After Exterior of Machine Perform walk-around inspection of Class III oil or

the machine exterior. Check on coolant leaks.
ground under machine (Figure 38, Any fuel leak-
Item 1) for evidence of fluid leakage age is evident.
such as oil, coolant, or fuel.
Check machine (Figure 38, Item 1) Damage that

for obvious damage that would would impair
impair operation. operation is evi-
dent.
2 HYEX01400
Figure 38. Exterior of Machine Check.
Check left and right track chains Any missing

(Figure 38, Item 2) for missing track shoes or
shoes and mounting hardware. mounting hard-
ware.
56 Monthly Swing Gearbox Oil CAUTION

chine.
0077-34
TM 5-3805-294-10 0077
EQUIPMENT NOT
Check that swing gearbox oil is Oil level is not

between marks on dipstick (Figure on dipstick.
39, Item 75).
76 75
HYEX01410
Figure 39. Swing Gearbox Oil Level Check.
To add oil:
• Remove cap (Figure 39,
Item 76).
• Add oil until it is between
the marks on the dipstick
• Install cap (Figure 39,
Item 76).
57 Monthly Hydraulic Pump Gearbox Check hydraulic pump gearbox oil Oil level is be-
Oil level on dipstick (Figure 40, Item low the "L"
77). mark.
0077-35
TM 5-3805-294-10 0077
EQUIPMENT NOT
78
77
H
HYEX01409
Figure 40. Hydraulic Pump Oil Level Check.
To add oil:
• Remove cap (Figure 40,
Item 78).
• Add oil until it reaches the
"H" mark on the dipstick
• Install cap (Figure 40,
Item 78).
58 Monthly Primary and Final Fuel Service primary and final fuel filter/
Filter/Water Separators water separators. (WP 0086)
59 Monthly Fuel Tank Drain sediment from fuel tank.

(WP 0091)
60 Monthly Coolant Heater Run coolant heater (WP 0034) for

5 minutes to keep water pump from
seizing.
0077-36
TM 5-3805-294-10 0077
EQUIPMENT NOT
61 Monthly Primary and Secondary Service primary and secondary air

Air Cleaner cleaner. (WP 0087)
62 Monthly Serpentine Belt Check serpentine belt (Figure 41, Serpentine belt
Item 79) for cracks, cuts and frays. is cut, broken, or
frayed.
79
HYEX01401
Figure 41. Serpentine Belt Check.
63 Monthly Air Conditioner Belt Check air conditioner belt (Figure Air conditioner
42, Item 80) for cracks and cuts. belt is cut or bro-
ken.
0077-37
TM 5-3805-294-10 0077
EQUIPMENT NOT
80
HYEX01402
Figure 42. Air Conditioner Belt Check.
64 Monthly Fan Check fan (Figure 43, Item 81) for Any damage
damage, debris, and hydraulic that would im-
leaks. pair safe opera-
tion of machine.
Any debris that
would block air
flow through ra-
diator.
Any class III hy-
draulic leak.
0077-38
TM 5-3805-294-10 0077
EQUIPMENT NOT
81
HYEX01403
Figure 43. Fan Check.
65 Monthly Track Sag Check track sag. (WP 0080)
66 Monthly Fresh Air Filter Service fresh air filter. (WP 0089)
67 Monthly Air Conditioner/Heater Service air conditioner/heater

Filter Service filter. (WP 0090)
68 Monthly Lubrication Perform 100 lubrication in

accordance with, LO
5-3805-294-13. (WP 0094)
END OF TASK
END OF WORK PACKAGE
0077-39/40 blank
TM 5-3805-294-10
CHAPTER 5
OPERATOR MAINTENANCE INSTRUCTIONS

NSN 3805-01-573-0677
TM 5-3805-294-10 0078
GENERAL MAINTENANCE INSTRUCTIONS
INITIAL SETUP:
Not Applicable
GENERAL MAINTENANCE
NOTE
Instructions in this section provide general procedures to be followed for maintenance
authorized at the operator level. Specific instructions are found in the operator maintenance
section of this manual.
This section covers general maintenance instructions for the machine. Read all CAUTIONS and WARNINGS that
apply to all maintenance instructions.
Follow these maintenance practices when working on the machine.
Prior to starting any inspection or maintenance procedure, ensure that machine is safely parked and shut down.
INSPECTION
Electrical Parts. Inspect wiring harnesses for cracked, broken, chafed, bare, and burned insulation, or bare wires.
Inspect all terminal connectors for loose connections and broken parts. Inspect connectors for corrosion or signs of
sparking. This is an indication of a malfunction within the terminal. Notify Field Level maintenance of any part found
to be defective.
Tubing and Hosing. Check all hose surfaces for wear, damage, broken, or frayed coverings, and leaks. Check for
breaks and wet or worn spots caused by kinking or rubbing against other parts of the machine. Wet spots show
leaks, but a stain around a fitting or connector may also indicate a leak. If a connector or fitting is loose, broken, or
worn out, notify Field Level maintenance.
Metal Parts. Check bolts, nuts, and screws for obvious looseness. Also check for missing, bent, or broken pieces.
They cannot all be checked with a tool, but look for chipped paint, bare metal, or rust around bolt heads. Look for
loose or chipped paint, rust, or gaps where parts are welded together. If a bad weld is found, have it repaired. Visually
inspect all castings and weldments for cracks.
0078-1
TM 5-3805-294-10 0078
CLEANING
WARNING
Never use fuel to clean parts. Fuel is highly flammable. Failure to comply may result in injury
Rubber Parts. Do not clean rubber parts in solvent cleaning compound. Wipe parts clean with a dry, cleaning
cloth.
Machine Exterior. Steam clean all exterior parts thoroughly. If pressurized water is not available, wash
painted surfaces of machine with solution of 1/4 cup of soap chips, to 1 gallon (4 L) of water.
Electrical Parts. Electrical parts such as coils, junction blocks, switches, and electrical parts that contain
insulation materials should not be soaked or sprayed with cleaning solutions. Clean these parts with a
cleaning cloth moistened with cleaning compound. Clean rubber parts with hot, soapy water and soft cloths.
Do not clean with solvents.
END OF TASK
END OF WORK PACKAGE
0078-2
TM 5-3805-294-10 0079
TAKING ENGINE OIL SAMPLE
INITIAL SETUP:

Bottle, Oil Sample (WP 0097, Table 1, Item 3) Engine running. (WP 0007)
Time to Complete
Personnel Required 0.2 Hour(s)
References
DA FORM 5988-E or DA FORM 2404 (WP 0094)
SAMPLING ENGINE
1. Clean dirt from around cap (Figure 1, Item 1).
1
3
HYEX00909
Figure 1. Engine Oil Sampling Valve.
2. Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).
3. Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.
4. Release valve (Figure 1, Item 3).
5. Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).
END OF TASK
END OF WORK PACKAGE
0079-1/2 blank
TM 5-3805-294-10 0080
TRACK SAG CHECK
INITIAL SETUP:

Measuring Tape (WP 0095, Table 2, Item 10) WP 0007
WP 0009
WP 0081
Materials/Parts
WP 0082
Grease (WP 0097, Table 1, Item 10)
Equipment Condition
Personnel Required
Time to Complete
0.5 Hour(s)
References
RAISING MACHINE
NOTE
Sag for left and right side tracks is checked the same way.
3
4
5 2 HYEX00383

END OF TASK
0080-1
TM 5-3805-294-10 0080
TRACK SAG CHECK
1. Mark track (Figure 2, Item 5) to measure two full rotations of track in each direction.
5 HYEX00491
Figure 2. Rotate Track.

2. Rotate track (Figure 2, Item 5) forward two full rotations and in reverse two full rotations.
3. Move pilot shutoff lever (Figure 3, Item 6) to locked (up) position.
0080-2
TM 5-3805-294-10 0080
TRACK SAG CHECK - Continued
HYEX01309
6
Figure 3. Shut Machine Off.
4. Turn key switch (Figure 3, Item 7) to OFF position.

5. Measure for a distance of 11.8-13.2 in. (300-335 mm) between surface of track (Figure 4, Item 5) and bottom
of track frame (Figure 4, Item 8) at middle track roller (Figure 4, Item 9).
0080-3
TM 5-3805-294-10 0080
TRACK SAG CHECK - Continued
8 9
HYEX00838
5
Figure 4. Measure Track Sag.

6. If track sag is more than 13.2 in. (335 mm), Tighten Track Tension. (WP 0081)
7. If track sag is less than 11.8 in. (300 mm), Loosen Track Tension. (WP 0082)
8. If track sag is within limits, go to Lowering Machine task in this work package.
END OF TASK
LOWERING MACHINE
1. Turn key switch (Figure 5, Item 7) to ON position and start engine.
0080-4
TM 5-3805-294-10 0080
LOWERING MACHINE - Continued
HYEX01309
6
Figure 5. Start Machine.
2. Move pilot shutoff lever (Figure 5, Item 6) to unlocked (down) position.

3. Slowly raise boom (Figure 6, Item 3) until track (Figure 6, Item 5) is resting on ground.
3
4
5 2 HYEX00383
Figure 6. Lower Machine.
0080-5
TM 5-3805-294-10 0080
LOWERING MACHINE - Continued
4. Raise boom (Figure 6, Item 3), arm (Figure 6, Item 4), and bucket (Figure 6, Item 2) off ground.
END OF TASK
END OF WORK PACKAGE
0080-6
TM 5-3805-294-10 0081
TIGHTENING TRACK TENSION
INITIAL SETUP:
Tools and Special Tools References

Grease Gun (WP 0095, Table 2, Item 4) DA FORM 5988-E or DA FORM 2404 (WP 0094)
WP 0080
Materials/Parts
Grease (WP 0097, Table 1, Item 10) Equipment Condition
Rags, Wiping (WP 0097, Table 1, Item 15) Track sag checked. (WP 0080)
Personnel Required Time to Complete

Horizontal Construction Engineer 12N 0.1 Hour(s)
TIGHTENING TRACK
1. Add a small amount of grease to grease fitting (Figure 1, Item 1).
1 HYEX00384
Figure 1. Tighten Track.

2. Check track sag. (WP 0080)
END OF TASK
END OF WORK PACKAGE
0081-1/2 blank
TM 5-3805-294-10 0082
LOOSENING TRACK TENSION
INITIAL SETUP:

Wrench, Open End, 24 mm DA FORM 5988-E or DA FORM 2404 (WP 0094)
(WP 0095, Table 2, Item 4) WP 0007

Rags, Wiping (WP 0097, Table 1, Item 15) Track sag checked. (WP 0080)

Horizontal Construction Engineer 12N 0.1 Hour(s)
LOOSENING TRACK TENSION
1. Loosen nut (Figure 1, Item 1) and allow a small amount of grease to escape.
HYEX00385
Figure 1. Loosen Track.

2. Tighten nut (Figure 1, Item 1).
3. Check track sag. (WP 0080)
END OF TASK
END OF WORK PACKAGE
0082-1/2 blank
TM 5-3805-294-10 0083
TAKING HYDRAULIC OIL SAMPLE
INITIAL SETUP:

Bottle, Oil Sample (WP 0097, Table 1, Item 3) Engine running. (WP 0007)
Time to Complete
References
SAMPLING HYDRAULIC OIL
1. Clean dirt from around cap (Figure 1, Item 1).
3 1
HYEX00908
Figure 1. Hydraulic Oil Sampling Valve.
2. Remove cap (Figure 1, Item 1) from sampling valve (Figure 1, Item 2).
3. Turn valve (Figure 1, Item 3) and fill sampling bottle until it is at least 3/4 full.
4. Release valve (Figure 1, Item 3).
5. Install cap (Figure 1, Item 1) to sampling valve (Figure 1, Item 2).
END OF TASK
END OF WORK PACKAGE
0083-1/2 blank
TM 5-3805-294-10 0084
CAB FUSE REPLACEMENT
INITIAL SETUP:

Horizontal Construction Engineer 12N (1) 0.2 Hour(s)
References
Equipment Condition
(WP 0009)
REMOVAL
NOTE
• All fuses from both main and auxiliary fuse boxes are removed the same way. Main fuse
box shown.
• Spare fuses are located in the fuse box. After using a spare fuse, notify Field maintenance
to get a replacement fuse.
1. Remove fuse box access cover (Figure 1, Item 1) from cab rear tray (Figure 1, Item 2).
0084-1
TM 5-3805-294-10 0084
REMOVAL - Continued
2
1
HYEX00089
Figure 1. Fuse Box Access Cover Removal.

2. Remove main fuse box cover (Figure 2, Item 3) from main fuse box (Figure 2, Item 4).
0084-2
TM 5-3805-294-10 0084
REMOVAL - Continued
HYEX00097
Figure 2. Main Fuse Box Cover Removal.

3. Locate fuse in question using key found on fuse box cover (Figure 2, Item 3).
4. Remove fuse (Figure 3, Item 5) from main fuse box (Figure 3, Item 4).
0084-3
TM 5-3805-294-10 0084
REMOVAL - Continued
HYEX00098
Figure 3. Fuse Removal.
END OF TASK
INSTALLATION
CAUTION
Use only a fuse having the same amperage as noted on fuse box cover. Using a fuse with
higher amperage than specified could cause damage to the electrical system. Failure to
NOTE
All fuses from both main and auxiliary fuse boxes are installed the same way. Main fuse box
shown.
1. Install fuse (Figure 4, Item 5) to main fuse box (Figure 4, Item 4).
0084-4
TM 5-3805-294-10 0084
INSTALLATION - Continued
HYEX00098
Figure 4. Fuse Installation.

2. Install main fuse box cover (Figure 5, Item 3) to main fuse box (Figure 5, Item 4).
0084-5
TM 5-3805-294-10 0084
HYEX00097
Figure 5. Main Fuse Box Cover Installation.

3. Install fuse box access cover (Figure 6, Item 1) to cab rear tray (Figure 6, Item 2).
0084-6
TM 5-3805-294-10 0084
2
1
HYEX00089
Figure 6. Fuse Box Access Cover Installation.
END OF TASK
END OF WORK PACKAGE
0084-7/8 blank
TM 5-3805-294-10 0085
BUCKET TEETH REPLACEMENT
INITIAL SETUP:

Hammer, Hand, 3 lb (WP 0095, Table 2, Item 5) Machine safely parked and shut down.
Punch, Pin (WP 0095, Table 2, Item 9) (WP 0009)

References
HEAVY DUTY BUCKET TOOTH REMOVAL
1. Using hammer and pin punch, drive out pin (Figure 1, Item 1) from tooth (Figure 1, Item 2) and shank (Figure
1, Item 3).
3 1 2 HYEX01282
Figure 1. Tooth Removal.
2. Remove tooth (Figure 1, Item 2) from shank (Figure 1, Item 3).
END OF TASK
0085-1
TM 5-3805-294-10 0085
HEAVY DUTY BUCKET TOOTH INSTALLATION
1. Position tooth (Figure 2, Item 2) on shank (Figure 2, Item 3).
3 1 2 HYEX01282
Figure 2. Tooth Installation.
2. Using hammer, drive pin (Figure 2, Item 1) to tooth (Figure 2, Item 2) and shank (Figure 2, Item 3) until seated.
END OF TASK
DEEP DIG BUCKET TOOTH REMOVAL
1. Using hammer and pin punch, drive out pin (Figure 3, Item 4) from tooth (Figure 3, Item 5) and shank (Figure
3, Item 6).
4
5
6
HYEX01281
Figure 3. Bucket Tooth Removal.
0085-2
TM 5-3805-294-10 0085
DEEP DIG BUCKET TOOTH REMOVAL - Continued
2. Remove tooth (Figure 3, Item 5) from shank (Figure 3, Item 6).
END OF TASK
DEEP DIG BUCKET TOOTH INSTALLATION
1. Position tooth (Figure 4, Item 5) on shank (Figure 4, Item 6).
4
5
6
HYEX01281
Figure 4. Bucket Tooth Installation.
2. Using hammer, drive pin (Figure 4, Item 4) to tooth (Figure 4, Item 5) and shank (Figure 4, Item 6) until seated.
END OF TASK
END OF WORK PACKAGE
0085-3/4 blank
TM 5-3805-294-10 0086
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE
INITIAL SETUP:

Pan, Drain Machine safely parked and shut down (WP 0009)

DRAIN FUEL FILTER/WATER SEPARATORS
WARNING
DIESEL FUEL
1. Disconnect wiring harness connector D01 (Figure 1, Item 1) from water in fuel (WIF) sensor (Figure 1, Item
2).
1 4 5 HYEX00103
Figure 1. Drain Fuel Filter/Water Separators.
0086-1
TM 5-3805-294-10 0086
DRAIN FUEL FILTER/WATER SEPARATORS - Continued
NOTE
Place drain pan under fuel/water separators prior to draining.
2. Loosen, but do not remove WIF sensor (Figure 2, Item 2), and drain water/sediment from primary fuel filter/
water separator (Figure 2, Item 3) for approximately 30 seconds.
1 4 5 HYEX00103
Figure 2. Drain Fuel Filter/Water Separators Continued.

3. Tighten WIF sensor (Figure 2, Item 2).
4. Connect wiring harness connector D01 (Figure 2, Item 1) to WIF sensor (Figure 2, Item 2).
5. Loosen, but do not remove valve (Figure 2, Item 4), and drain water/sediment from final fuel filter/water
separator (Figure 2, Item 5) for approximately 30 seconds.
6. Tighten valve (Figure 2, Item 4).
END OF TASK
END OF WORK PACKAGE
0086-2
TM 5-3805-294-10 0087
PRIMARY AND SECONDARY AIR CLEANER SERVICE
INITIAL SETUP:

Rag, Wiping (WP 0097, Table 1, Item 15) Engine off. (WP 0009)

REMOVAL
1. Lift lever (Figure 1, Item 1) and rotate cover (Figure 1, Item 2) counterclockwise.
HYEX00073
Figure 1. Cover Removal.
2. Remove cover (Figure 1, Item 2) from air cleaner housing (Figure 1, Item 3).
3. Remove primary air cleaner (Figure 2, Item 4) from air cleaner housing (Figure 2, Item 3).
0087-1
TM 5-3805-294-10 0087
REMOVAL - Continued
HYEX00074
Figure 2. Primary Air Cleaner Removal.
4. Remove secondary air cleaner (Figure 3, Item 5) from air cleaner housing (Figure 3, Item 3).
5
3
HYEX00075
Figure 3. Secondary Air Cleaner Removal.
END OF TASK
0087-2
TM 5-3805-294-10 0087
SERVICING AIR CLEANERS
WARNING
Particles blown by compressed air are hazardous. Ensure air stream is directed away from
user and any personnel in the area. Use a maximum of 30 psi (2.0 bar) when compressed
air is used to clean parts. Always wear safety glasses when using compressed air. Failure to
NOTE
• Contact field level maintenance for an air hose and air nozzle to service the air cleaner.
• Secondary air cleaner does not require servicing, only replacement.
1. Lightly tap primary air cleaner (Figure 4, Item 4) to remove major amount of dirt from primary air cleaner.
HYEX00076
Figure 4. Primary Air Cleaner Service.
2. Start from inside, top of primary air cleaner (Figure 4, Item 4), blow remainder of debris out of primary air
cleaner.
3. Work around and inward of primary air cleaner (Figure 4, Item 4) until primary air cleaner has been completely
blown out.
4. Wipe out air cleaner housing (Figure 5, Item 3) with a clean rag.
0087-3
TM 5-3805-294-10 0087
SERVICING AIR CLEANERS - Continued
HYEX00077
Figure 5. Air Cleaner Housing Service.

5. Wipe inside of cover (Figure 6, Item 2) with a clean rag and squeeze dust boot (Figure 6, Item 6) to remove
dust.
2
HYEX00078
Figure 6. Cover and Dust Boot Service.
END OF TASK
INSTALLATION
NOTE
Dust valve will be at the 6 O'clock position when air cleaner cover is installed.
1. Install secondary air cleaner (Figure 7, Item 5) to air cleaner housing (Figure 7, Item 3).
0087-4
TM 5-3805-294-10 0087
3 5
HYEX00084
Figure 7. Secondary Air Cleaner Installation.
2. Install primary air cleaner (Figure 8, Item 4) to air cleaner housing (Figure 8, Item 3).
HYEX00074
Figure 8. Primary Air Cleaner Installation.
3. Position cover (Figure 9, Item 2) on air cleaner housing (Figure 9, Item 3).
0087-5
TM 5-3805-294-10 0087
1
HYEX00083
Figure 9. Cover Installation.
4. Rotate cover (Figure 9, Item 2) clockwise until lever (Figure 9, Item 1) locks.
END OF TASK
END OF WORK PACKAGE
0087-6
TM 5-3805-294-10 0088
HYDRAULIC RESERVOIR SERVICE
INITIAL SETUP:

Wrench, Allen 5 mm (0.196 in.) LO 5-3805-294-13 (WP 0094)
Equipment Condition
Materials/Parts Machine safely parked and shut down.
Lubricating Oil, Engine (WP 0009)
Time to Complete
FILLING HYDRAULIC RESERVOIR
WARNING
Hydraulic system operates at high pressures and temperatures. Always allow hydraulic oil to
cool and relieve pressure in hydraulic reservoir before working on hydraulic system. Wear
eye protection and gloves to prevent injury. Open lines and hoses slowly and wait for any
residual pressure to relieve before continuing to open lines and hoses. Failure to comply may
1. Press button (Figure 1, Item 1) to relieve pressure from hydraulic reservoir (Figure 1, Item 2).
1 3
4
2
HYEX00085
Figure 1. Hydraulic Reservoir Cover Removal.

2. Remove four screws (Figure 1, Item 3) and hydraulic reservoir cover (Figure 1, Item 4) from hydraulic reservoir
(Figure 1, Item 2).
0088-1
TM 5-3805-294-10 0088
FILLING HYDRAULIC RESERVOIR - Continued
WARNING
LUBRICATING OIL
3. Fill hydraulic reservoir (Figure 2, Item 2) until oil is between marks (Figure 2, Item 5) on sight glass (Figure 2,
Item 6). LO 5-3805-294-13 (WP 0094)
2
6
HYEX00086
Figure 2. Hydraulic Reservoir Sight Glass.
4. Ensure O-ring (Figure 3, Item 7) is present and is not damaged. If O-ring is missing or damaged, notify field
maintenance.
0088-2
TM 5-3805-294-10 0088
FILLING HYDRAULIC RESERVOIR - Continued
4
3
2 HYEX00087
Figure 3. Hydraulic Reservoir Cover Installation.
5. Install hydraulic reservoir cover (Figure 3, Item 4) to hydraulic reservoir (Figure 3, Item 2) with four screws
(Figure 3, Item 3).
END OF TASK
END OF WORK PACKAGE
0088-3/4 blank
TM 5-3805-294-10 0089
FRESH AIR FILTER SERVICE
INITIAL SETUP:

Rag, Wiping (WP 0097, Table 1, Item 15) Machine safely parked and shut down.
(WP 0009)
Personnel Required
Horizontal Construction Engineer 12N (1) Time to Complete
0.2 Hour(s)
References
TM 5-3805-295-13&P (WP 0094)
REMOVAL
NOTE
After the fresh air filter has been serviced three times, it must be replaced by Field
Maintenance.
1. Move two tabs (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).
1 1
3 2 HYEX00168
Figure 1. Filter Removal.

2. Inspect seal (Figure 2, Item 4) on filter (Figure 2, Item 2).
0089-1
TM 5-3805-294-10 0089
REMOVAL - Continued
2 4 HYEX00169
Figure 2. Inspect Seal.

3. If seal (Figure 2, Item 4) is damaged, contact field maintenance.
END OF TASK
SERVICE
WARNING
NOTE
• Contact field level maintenance for an air hose and air nozzle to service the air filter.
• If HYEX is equipped with a Supplemental Armor Set, refer to and use procedure found
in TM 5-3805-295-13&P.
1. Lightly tap filter (Figure 3, Item 2) with hand.
0089-2
TM 5-3805-294-10 0089
SERVICE - Continued
2 HYEX00170
Figure 3. Clean Filter.
CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
2. Blow remainder of debris from filter (Figure 3, Item 2).
3. Wipe inside of housing (Figure 4, Item 3) with clean rag.
HYEX00171
Figure 4. Clean Housing.
END OF TASK
0089-3
TM 5-3805-294-10 0089
INSTALLATION
1. Install filter (Figure 5, Item 2) to housing (Figure 5, Item 3).
1 1
3 2 HYEX00168
Figure 5. Filter Installation.
2. Ensure tabs (Figure 5, Item 1) lock.
END OF TASK
END OF WORK PACKAGE
0089-4
TM 5-3805-294-10 0090
AIR CONDITIONER/HEATER FILTER SERVICE
INITIAL SETUP:

Rag, Wiping (WP 0097, Table 1, Item 15) Engine OFF. (WP 0009)

REMOVAL
NOTE
After air conditioner/heater has been serviced three times it must be replaced by Field
Maintenance.
1. Move tab (Figure 1, Item 1) inward and remove filter (Figure 1, Item 2) from housing (Figure 1, Item 3).
2 3 1 HYEX00187
Figure 1. Filter Removal.
2. Check tab (Figure 1, Item 1) on filter (Figure 1, Item 2) and replace filter if tab broken.
END OF TASK
SERVICE
NOTE
Contact Field level maintenance for an air hose and air nozzle to service the air cleaner.
1. Lightly tap filter (Figure 2, Item 2) with hand.
0090-1
TM 5-3805-294-10 0090
SERVICE - Continued
HYEX00188
2
Figure 2. Clean Filter.
WARNING
CAUTION
Always blow compressed air from the inside to the outside of the air cleaner when servicing.
Blowing compressed air from the outside to the inside could damage the air cleaner. Failure
2. Blow remainder of debris from filter (Figure 2, Item 2).
3. Wipe inside of housing (Figure 3, Item 3) with clean rag.
0090-2
TM 5-3805-294-10 0090
SERVICE - Continued
HYEX00190
3
Figure 3. Clean Housing.
END OF TASK
INSTALLATION
1. Install filter (Figure 4, Item 2) to housing (Figure 4, Item 3).
2 3 1 HYEX00187
Figure 4. Filter Installation.
2. Ensure tab (Figure 4, Item 1) locks.
END OF TASK
END OF WORK PACKAGE
0090-3/4 blank
TM 5-3805-294-10 0091
DRAINING WATER AND SEDIMENT FROM FUEL TANK
INITIAL SETUP:

Pan, Drain Machine safely parked and shut down
(WP 0009)
Materials/Parts
Rags, Wiping (WP 0097, Table 1, Item 15) Time to Complete
0.2 Hour(s)
Personnel Required
References
DRAINING WATER AND SEDIMENT
NOTE
Contact Field Maintenance for drain pan.
1. Remove fuel tank fill cap (Figure 1, Item 1).
HYEX01298
Figure 1. Remove Fuel Cap.

2. Position drain pan under drain hose (Figure 2, Item 2).
0091-1
TM 5-3805-294-10 0091
DRAINING WATER AND SEDIMENT - Continued
HYEX00914
Figure 2. Drain Hose.
3. Open drain valve (Figure 3, Item 3) and drain water and sediment until a clear stream of fuel comes out.
0091-2
TM 5-3805-294-10 0091
HYEX00915
Figure 3. Drain Valve.
4. Close drain valve (Figure 3, Item 3).

5. Dispose of waste properly.
6. Install fuel tank fill cap (Figure 4, Item 1).
0091-3
TM 5-3805-294-10 0091
HYEX01298
Figure 4. Install Fuel Cap.
END OF TASK
END OF WORK PACKAGE
0091-4
TM 5-3805-294-10 0092
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT
INITIAL SETUP:

Wrench 2-1/4 Machine safely parked and shut down
Wrench 2-1/2 (WP 0095, Table 2, Item 15) (WP 0009)

References
DISCHARGE ADJUSTMENT
WARNING
Unless otherwise specified, perform all maintenance procedures with all attachments lowered
to the ground, pilot shutoff lever in the up position, and engine shut off. Failure to comply may
NOTE
• Ensure curtain is set to desired discharge size before Crush-All operation.
• There are no disassembly requirements to perform discharge adjustments. Adjustment
points are on the outside of the machine.
• There are two adjustment points for lower curtain. Adjustment procedure is identical for
both points and must be adjusted at same time.
• Raise curtain to increase discharge size.
• Lower curtain to decrease discharge size.
• To reduce dust, increase discharge size.
• Repeat steps for opposite side.
1. Loosen nut (Figure 1, Item 1) on nut (Figure 1, Item 2) and rod (Figure 1, Item 3).
0092-1
TM 5-3805-294-10 0092
DISCHARGE ADJUSTMENT - Continued
6
7, 8, 9
10
11
2
1
HYEX03092
Figure 1. Curtain Adjustment.

2. Loosen nut (Figure 1, Item 2) on rod (Figure 1, Item 3) to release tension from spring (Figure 1, Item 4).
3. Using wrench provided with crush-all loosen nut (Figure 1, Item 5) on nut (Figure 1, Item 6) and rod (Figure 1,
Item 3).
4. Remove bolt (Figure 1, Item 7), lockwasher (Figure 1, Item 8), and washer (Figure 1, Item 9) from clamp (Figure
1, Item 10) and plate (Figure 1, Item 11).
5. Remove clamp (Figure 1, Item 10) from nut (Figure 1, Item 6) and plate (Figure 1, Item 11).
6. Turn nut (Figure 2, Item 6) to raise or lower curtain (Figure 2, Item 12).
0092-2
TM 5-3805-294-10 0092
12
14
13
HYEX03093
Figure 2. Clearance Check.
CAUTION
Ensure surface of blow bar does not touch curtain. Failure to comply may result in damage
to equipment.
7. Turn rotor (Figure 2, Item 13) manually. Verify curtain (Figure 2, Item 12) does not touch rotor (Figure 2, Item
13) or blow bars (Figure 2, Item 14).
8. Position clamp (Figure 3, Item 10) on nut (Figure 3, Item 6) and plate (Figure 3, Item 11).
0092-3
TM 5-3805-294-10 0092
7, 8, 9 11
10
HYEX03094
Figure 3. Clamp Installation.

9. Install clamp (Figure 3, Item 10) on plate (Figure 3, Item 11) with bolt (Figure 3, Item 7), lockwasher (Figure 3,
Item 8), and washer (Figure 3, Item 9).
10. Using wrench provided with crush-all tighten nut (Figure 3, Item 5) against nut (Figure 3, Item 6) on rod (Figure
3, Item 3).
11. Tighten nut (Figure 4, Item 2) and compress spring (Figure 4, Item 4) to align marks (Figure 4, Item 15) and
0092-4
TM 5-3805-294-10 0092
16
15
HYEX03095
Figure 4. Spring Compression.

12. Tighten nut (Figure 4, Item 1) against nut (Figure 4, Item 2) on rod (Figure 4, Item 3).
END OF TASK
END OF WORK PACKAGE
0092-5/6 blank
TM 5-3805-294-10 0093
MAINTENANCE AFTER FORDING
INITIAL SETUP:

Grease Gun (WP 0095, Table 2, Item 4) LO 5-3805-294-13 (WP 0094)
Wrench 17 mm (WP 0095, Table 2, Item 17) DA FORM 5988-E or DA FORM 2404 (WP 0094)

Grease, Automotive and Artillery Machine safely parked and shut down.
(WP 0097, Table 1, Item 10) (WP 0094)

DRAINING MUD OR WATER
1. Remove two bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from cover (Figure 1, Item 3).
1, 2 3, 4
HYEX03286
Figure 1. Draining Mud or Water.
2. Remove cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from machine (Figure 1, Item 5) and allow mud
or water to completely drain.
3. Remove any contaminated grease.
4. Install cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) to machine (Figure 1, Item 5) with two bolts (Figure
1, Item 1) and washers (Figure 1, Item 2).
0093-1
TM 5-3805-294-10 0093
DRAINING MUD OR WATER - Continued
5. If grease was removed, notify field level maintenance to service swing gear and swing bearing.
END OF TASK
END OF WORK PACKAGE
0093-2
TM 5-3805-294-10
CHAPTER 6
OPERATOR SUPPORTING INFORMATION

NSN 3805-01-573-0677
TM 5-3805-294-10 0094
REFERENCES
SCOPE
This work package lists all field manuals, forms, technical manuals, and miscellaneous publications referenced in
this manual.
ARMY REGULATIONS
AR 25-52 Authorized Abbreviations and Brevity Codes

AR 310-25 Dictionary of United States Army Terms
AR 385-40 Accident Reporting and Records
AR 385-55 Prevention of Motor Vehicle Accidents
AR 700-138 Army Logistics Readiness and Sustainability
DEPARTMENT OF ARMY PAMPHLETS (DA PAM)
DA PAM 25-30 Consolidated Index of Army Publications and Blank Forms

DA PAM 750-8 The Army Maintenance Management System (TAMMS)
Users Manual
FIELD MANUALS
FM 1-02 Military Symbols

FM 3-11.5 Chemical, Biological, Radiological, and Nuclear
Decontamination
FM 3-97.6 Mountain Operations
FM 4-25.11 First Aid
FM 7-1 Military Training Management
FM 9-207 Operation and Maintenance of Ordnance Material in Cold
Weather (0°F to -65°F)
FM 20-3 Camouflage
FM 21-305 Manual for Wheeled Vehicle Driver
FM 31-70 Basic Cold Weather
FM 31-71 Northern Operations
FM 38-700 & 701 Preservation and Packing of Military Supplies and Equipment
FM 55-15 Transportation Reference Data
FM 90-3 Desert Operations
0094-1
TM 5-3805-294-10 0094
FORMS
DA Form 2404 Equipment Inspection and Maintenance Worksheet

DA Form 2408-9 Equipment Control Record
DA Form 5988-E Equipment Inspection and Maintenance (Electronic)
Worksheet
DD Form 1149 Requisition and Invoice/Shipping Document
DD Form 1266 Request for Special Hauling Permit
DD Form 250 Material Inspection and Receiving Report
SF 368 Product Quality Deficiency Report
MILITARY HANDBOOK (MIL-HDBK)
MIL-HDBK-1791 Designing for Internal Aerial Delivery in Fixed Winged Aircraft
MILITARY STANDARD (MIL-STD)
MIL-STD-810 Enviromental Test Methods and Engineering Guidelines

MIL-STD-1366 Interface Standard for Transportability Criteria
TECHNICAL BULLLITENS
TB 5-3805-294-13 Warranty Program for Hydraulic Excavator 240D LC

TB 9-2300-281-35 Standards for Overseas Shipment or Domestic Issue of
Special Purpose Vehicles
TB 43-0209 Color, Marking, and Camouflage Painting of Military Vehicles,
Construction Equipment, and Materials Handling Equipment
TB 43-0216 Safety and Hazard Warnings for Operation and Maintenance
of TACOM Equipment
TB 55-45 Certification of Military Equipment for Transport in AMC/
CRAF Aircraft
TB 740-97-2 Preservation of USAMECOM Mechanical Equipment for
Shipment and Storage
TECHNICAL MANUALS
LO 5-3805-294-13 Lubrication Instructions for the Hydraulic Excavator (HYEX)

TM 5-3805-295-13&P Operator's and Field Level Maintenance Manual for
Supplemental Armor Set for Hydraulic Excavator (HYEX)
(John Deere 240D LCR)
0094-2
TM 5-3805-294-10 0094
TECHNICAL MANUALS - Continued
TM 9-2330-381-13 Operator and Field Maintenance Manual for the Semitrailer,

Transporter, Heavy Equipment
TM 21-40 Chemical, Biological, Radiological, and Nuclear Defense
TM 38-250/AFR 71-4 Preparation of Hazardous Materials for Military Air Shipment
TM 55-2200-001-12 Transportability Guidance for Application of Blocking, Bracing
and Tiedown Materiels for Rail Transport
TM 750-244-6 Procedures for Destruction of Tank-Automotive Equipment to
Prevent Enemy Use
END OF WORK PACKAGE
0094-3/4 blank
TM 5-3805-294-10 0095
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS
INTRODUCTION
Scope
This work package lists COEI and BII for the Hydraulic Excavator (HYEX) to help you inventory items for safe
operation of the equipment.
General
The COEI and BII information is divided into the following lists:
Components of End Item (COEI). This list is for information purposes only and is not authority to requisition
replacements. These items are part of the HYEX. As part of the end item, these items must be with the end item
whenever it is issued or transferred between property accounts. Items of COEI are removed and separately
packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify
the items.
Basic Issue Items (BII). These essential items are required to place the (HYEX) in operation, operate it, and to do
emergency repairs. Although shipped separately packaged, BII must be with the Hydraulic Excavator during
operation and when it is transferred between property accounts. Listing these items is your authority to request/
requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished
to help you find and identify the items.
Explanation of Columns in the COEI List and BII List
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Stock Number shown in column (2).
Column (6) Qty Rqr. Indicates the quantity required.
0095-1
TM 5-3805-294-10 0095
Table 1. COMPONENTS OF END ITEM
(1) (2) (3) (4) (5) (6)
ITEM NATIONAL STOCK NUMBER DESCRIPTION, PART USABLE QTY

NUMBER (NSN) AND ILLUSTRATION NUMBER/(CAGEC) ON CODE U/I RQR
1 Ditch Cleaning Bucket EA 1
C909323-623315 (8U941)
HYEX01340
2 2540-01-478-1207 Quick Latch EA 1

C909332(1J955)
HYEX01359
3 Rock Bucket, 42 in. EA 1

909325-623327(8U941)
HYEX01341
4 Hydraulic Thumb EA 1
70N0013(3PSD7)
HYEX01360
0095-2
TM 5-3805-294-10 0095
Table 1. COMPONENTS OF END ITEM - Continued
(1) (2) (3) (4) (5) (6)

5 2590-01-474-7812 Vandal Protection Kit EA 1
AP33356 (75755)
HYEX01342
0095-3
TM 5-3805-294-10 0095
Table 2. BASIC ISSUE ITEMS
(1) (2) (3) (4) (5) (6)

1 Bag, Mason EA 1
204900 (3PSD7)
HYEX03287
2 Cap EA 4
811438500 (1BVQ2)
HYEX03288
3 Cap, Pin EA 4
U42984 (3PSD7)
HYEX03289
4 Gun, Grease, Lever Action, 12 EA 1

in. (304.8 mm)
HYEX01349 7Y26518 (3PSD7)
5 Hammer, Hand, 3 lb (1.36 kg) EA 1
B3-3LB(72987)
HYEX03327
6 Operator's Manual TM EA 1
TM 5-3805-294-10 5-3805-294-10
TECHNICAL MANUAL
OPERATOR'S MANUAL
FOR
HYDRAULIC EXCAVATOR (HYEX)

(JOHN DEERE 240D LCR)
TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH
NSN 3805-01-573-0677 (EIC : ALL)
DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY

XXXX XXXX
HYEX01339
7 Plug, Hex 37 Degree Flare, -12 EA 4

205324(1BVQ2)
HYEX03290
8 Plug, Hex 37 Degree Flare, -6 EA 4

R39783 (3PSD7)
HYEX03291
0095-4
TM 5-3805-294-10 0095
Table 2. BASIC ISSUE ITEMS - Continued
(1) (2) (3) (4) (5) (6)

9 5120 -01-434-9835 Punch, Drift EA 1
70-195(08292)
HYEX03325
10 5210-01-434-9515 Tape, Measuring 25 FT EA 1

68-445 (08292)
HYEX03326
11 5120 -01-434-9171 Screwdriver, Pry Bar, 12 in. EA 1

(305 mm) Long
B107.60 (05047)
HYEX01348
12 3815-01-475-0710 Tooth, Surface Ripping EA 5

TX400 (1J955)
HYEX03292
13 Vice Grips EA 1
67-460 (08292)
HYEX01355
14 Wrench, Open End, 3 in. (76 EA 1

mm)
T183966 (75755)
HYEX01346
0095-5
TM 5-3805-294-10 0095
Table 2. BASIC ISSUE ITEMS - Continued
(1) (2) (3) (4) (5) (6)

15 Wrench, Open End, 2 1/2 in. EA 2
(63.5 mm)
AT189507 (75755)
HYEX01345
16 5120-01-045-4889 Wrench, Allen, 5 mm (0.196 EA 1

in.)
B18.3.2M (05047)
HYEX01344
17 Wrench, Open End, 17 mm EA 1

52-217 (08292)
HYEX01356
18 5120 - 01-581-3318 Wrench, Open End, 24 mm EA 1

52-224 (08292)
HYEX01356
19 5120-00-240-5328 Wrench, Open End, EA 1

Adjustable, 0.95 in. (24 mm)
Jaw Opening, 15 in. (381 mm)
Long
11655778-3 (19207)
HYEX01343
END OF WORK PACKAGE
0095-6
TM 5-3805-294-10 0096
ADDITIONAL AUTHORIZATION LIST (AAL)
INTRODUCTION
SCOPE
This work package lists additional items you are authorized for the support of the Hydraulic Excavator (HYEX).
GENERAL
This list identifies items that do not have to accompany the HYEX and that do not have to be turned in with it. These
items are all authorized to you by CTA, MTOE, TDA, or JTA.
Explanation of Columns in the AAL
Column (1) - National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning
purposes.
Column (2) - Description, Part Number/(CAGEC). Identifies the Federal item name (in Initial capital letters) followed
by a minimum description when needed. The last line below the description is the part number and the Commercial
and Government Entity Code (CAGEC) (in parentheses).
Column (3) - Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment.
Column (4) - Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Column (5) - Quantity Recommended (Qty Recom). Indicates the quantity recommended.
Table 1. Additional Authorization List.
(1) (2) (3) (4) (5)
NATIONAL STOCK DESCRIPTION, PART NUMBER/ USABLE ON

NUMBER (NSN) (CAGEC) CODE U/I QTY RECOM
Compactor EA 1
IHC 00130FT (1N0L6)
END OF WORK PACKAGE
0096-1/2 blank
TM 5-3805-294-10 0097
EXPENDABLE AND DURABLE ITEMS LIST
Introduction
Scope
This work package lists expendable/durable supplies and materials you will need to operate and maintain the
Hydraulic Excavator (HYEX). This list is for information only and is not authority to requisition the listed items. These
items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and
Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical
Department Expendable/Durable Items.
Explanation of Columns in the Expandable/Durable Items List
Column (1) - Item Number
This number is assigned to the entry in the listing and is referenced in the initial setup narrative instructions to identify
the material.
Column (2) - Level
This column identifies the lowest level of maintenance that requires the listed item.
• C -- Operator/Crew
• F -- Field
• H -- Below Depot
• D -- Depot
Column (3) - National Stock Number (NSN)
This is the NSN assigned to the item which you can use to requisition it.
Column (4) Item Name, Description, Commercial and Government Entity Code (CAGEC), and Part Number
(P/N)
This column provides the other information you need to identify the item. The last line below the description is the
part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).
Column (5) - Unit of Issue (U/I)
Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.
Table 1. Expendable and Durable Items List
(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION, PART NUMBER/
NO. LEVEL NUMBER (NSN) (CAGEC) U/I
1 C 6850-01-441-3248 Antifreeze, Permanent, Type: Arctic Grade 55-Gallon DR
Drum
A-A-52624 (58536)
0097-1
TM 5-3805-294-10 0097
Table 1. Expendable and Durable Items List - Continued
(1) (2) (3) (4) (5)

ITEM NATIONAL STOCK ITEM NAME, DESCRIPTION, PART NUMBER/
NO. LEVEL NUMBER (NSN) (CAGEC) U/I
2 C 6850-01-441-3257 Antifreeze, Permanent, Ethylene Glycol, Inhibited 5- CO
Gallon Can
A-A-52624 (58536)
3 C 8125-01-193-3440 Bottle, Oil Sample BX
M44054 TYPE III (81349)
4 C 6850-00-926-2275 Cleaning Compound, Windshield 1-pt Can BX
0854-000 (0FTT5)
5 C 9130-01-031-5816 Fuel, JP8 Bulk GL
MILT83133 GR JP8 (81349)
6 C 9140-01-413-7511 Fuel, DF-2, Regular Bulk GL
W-F-800 (81348)
7 C 9140-00-286-5294 Fuel, DF-2, Regular Bulk GL
ASTM D 975 (58536)
8 C 9140-01-412-1311 Fuel, DF-1, Winter Bulk GL
W-F-800 (81348)
9 C 9140-00-286-5286 Fuel, DF-1, Winter Bulk GL
AA52557-1 (58536)
10 C 9150-01-197-7688 Grease, Automotive and Artillery, GAA 2-1/4-oz Tube TU
M-10924-A (81349)
11 C 9150-00-111-6256 Lubricating Oil, OEA Ice, Subzero 1-qt Can QT
MIL-PRF-46170 (81349)
12 C 9150-00-111-6255 Lubricating Oil, OEA Ice, Subzero 5-gal Can GL
MIL-PRF-46170 (81349)
13 C 9150-01-438-6076 Lubricating Oil, Engine OE/HDO 15W-40 1-qt Can QT
MIL-PRF-2104 (81349)
14 C 9150-00-973-9504 Penetrating Oil Can, 8 oz Can CN
L3 (77628)
15 C 7920-00-148-9666 Rag, Wiping BE
7920-00-148-9666 (80244)
END OF WORK PACKAGE
0097-2
TM 5-3805-294-10 0098
SPECIAL PURPOSE KITS (SPK) LIST
SCOPE
This work package lists the Special Purpose Kits (SPKs) for support of the Hydraulic Excavator (HYEX) Type 1.
Where to find operation instructions and troubleshooting procedures for the SPKs are also provided.
OPERATION INSTRUCTIONS FOR SPKS
For instructions on how to select the SPKs on the operators monitor, go to Selecting an Attachment On the
Monitor (WP 0018).
To operate the SPKs go to Operating the Barrier Grapple (WP 0022), Installing and Operating the Compactor and
Breaker (WP 0020), or Installing and Operating the Crush-All (WP 0019).
The Deep Dig Arm and associated Excavator Bucket or Scoop Type Loader Bucket must be installed on the HYEX
Type 1 by Field Maintenance. To operate the Deep Dig Arm, go to Operating the Deep Dig Arm (WP 0023).
TROUBLESHOOTING PROCEDURES FOR SPKS
To find troubleshooting procedures for the SPK items, go to the Troubleshooting Index (WP 0037).
INTRODUCTION TO THE SPECIAL PURPOSE KITS LIST
Special Purpose Kits (SPK) listed in Table 1 are for information purposes only and are not the authority to requisition
replacements. These items are part of the HYEX Type 1, but they are removed and separately packaged for
transportation or shipment. As part of the end item, these items must be with the end item whenever it is issued or
transferred between property accounts. Illustrations are furnished to help you find and identify the items.
EXPLANATION OF COLUMNS IN TABLE 1
Column (1) Item Number. Gives you the reference number of the item listed.
Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for
requisitioning purposes and provides an illustration of the item.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name followed by a minimum description
when needed. The last line below the description is the part number and the Commercial and Government Entity
Code (CAGEC) (in parentheses).
Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different
models of equipment. There are no usable on codes for this equipment.
Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the National
Column (6) QTY RQD. Indicates the quantity required.
0098-1
TM 5-3805-294-10 0098
SCOPE - Continued
SPECIAL PURPOSE KITS
Table 1. Special Purpose Kits.
(1) (2) (3) (4) (5) (6)

ITEM NATIONAL STOCK NUMBER DESCRIPTION, USABLE U/I QTY
NO. PART NUMBER/(CAGEC) ON CODE RQD
1 Arm, Long Reach EA 1

502113 (1BVQ2)
HYEX02525
2 Barrier Grapple EA 1
KL16000-1 (1V7ZO)
HYEX02522
3 3830-01-585-2734 Breaker, Impact EA 1

205146 (1BVQ2)
HYEX02520
4 Counterweight EA 1
305156 (1BVQ2)
HYEX02526
0098-2
TM 5-3805-294-10 0098
SCOPE - Continued
Table 1. Special Purpose Kits - Continued.
5 Crush-All EA 1
502063 (1BVQ2)
HYEX02521
6 Excavator Bucket (Deep Dig) EA 1

70G0001 (3PSD7)
HYEX02523
7 Bucket, Scoop Loader (Deep Dig) EA 1

70G0002 (3PSD7)
HYEX02524
END OF WORK PACKAGE
0098-3/4 blank
TM 5-3805-294-10 0099
TROUBLESHOOTING NOTES
Troubleshooting Notes
This paragraph contains troubleshooting information for locating and correcting some operating troubles which may
develop in the HYEX. This manual cannot list all possible malfunctions that may occur, nor can it include all tests,
inspections, and corrective actions. Notify field maintenance personnel if a malfunction is not listed, unless a
malfunction and cause are obvious or the malfunction can be corrected by a corrective action that is already listed.
Procedures. The troubleshooting symptom index lists possible malfunctions that may be experienced during
operation of machine or components. Each malfunction for an individual component, unit, or system is followed by
a list of tests or inspections and corrective actions.
Lubrication. When instructions to lubricate, grease, oil, or add oil appear in the troubleshooting table, refer to Operator
Preventive Maintenance Checks and Services. (WP 0077)
END OF WORK PACKAGE
0099-1/2 blank
TM 5-3805-294-10 0100
HYEX TRANSPORTABILITY INSTRUCTIONS
HYEX TRANSPORTABILITY INSTRUCTIONS.
The HYEX can be transported via highway, rail, marine, C-5, and C-17 air transport and meets all weight and
dimensional requirements while in its standard configuration with no reduction or sectionalization required.
TRANSPORTABILITY RELATED PUBLICATIONS.
Additional information on transport procedures can be found in:

1. TB 9-2300-281-35, Standards for Overseas Shipment or Domestic Issue of Special Purpose Vehicles
WP 0094.
2. TM 38-250/AFR 71-4, Preparation of Hazardous Materials for Military Air Shipment WP 0094.
TRANSPORTABILITY RELATED DEFINITIONS.
Technical terms that may be helpful while preparing the HYEX for transportation are:
1. Center of Gravity (CG). The balance point of a suspended item. The HYEX counterweight is used to shift
CG to the rear.
2. Curb Weight (CW). Total weight of operational HYEX including fuel, all system fluids, and on-vehicle Basic
Issue Items (BII). CW does not include crew weight, which in this case, is less than one percent of the gross
vehicle weight.
3. Gross Vehicle Weight (GVW). CW plus payload. For transport purposes, there is no payload. Therefore, the
GVW equals the CW.
MILITARY LOAD CLASSIFICATION.
The Military Load Classifications (MLC) for the HYEX are as follows:
1. HYEX Standard Cab System - MLC 32
2. HYEX Armored Cab System - MLC 34
HYEX03197
Figure 1. Military Load Classification.
0100-1
TM 5-3805-294-10 0100
HYEX SHIPPING WEIGHT.
1. HYEX with Standard Cab shipping weight, without bucket or attachment = 58,900 lbs
2. HYEX with Armored Cab shipping weight without bucket or attachment = 63,000 lbs
HYEX HIGHWAY TRANSPORTABILITY.
NOTE
• The HYEX is self-propelled at speeds up to 3.4 mph.
• The unit transportation officer must contact local authorities to ensure the HYEX is not
required to have special permits prior to highway transporting.
The HYEX transport height is 10 feet 1 inch so it is capable of normal highway transport on trailers that have a bed
height of 40 inches or less. HYEX is transportable on common military trailers, especially the M870A1 and M870A3.
The HYEX is outfitted with a hydraulic quick latch for rapid exchange of attachments. HYEX can normally be
transported over the road with any of the standard buckets attached. Attaching the Crush-All for shipment may cause
the HYEX to exceed the 13 feet 6 inches transport height requirement.
33 FT. 4 IN. [10.15 M]

11 FT. 1 IN. [3.39 M]
10 FT. 1 IN. [3.07 M]
HYEX01365
Figure 2. HYEX Dimensions.
HYEX RAIL TRANSPORTABILITY.
Due to the 30 inch track shoe requirement, the HYEX will have to be subjected to restrictive routes for rail movements.
The HYEX may easily be rail transported via routes subjected to DOD clearance diagrams. HYEX can be transported
via rail with any of the standard buckets attached.
HYEX MARINE TRANSPORTABILITY.
The HYEX can be shipped as roll-on/roll-off, LASH, SEABEE, water-way barge, or boat. On deck storage is
permissible with some protection for cylinder rods. The HYEX height of 10 feet 1 inch allows the sea shipment within
the LASH lighter.
0100-2
TM 5-3805-294-10 0100
HYEX LIFTING AND TIE DOWN PROVISIONS.
HYEX Transportation Data Plate shows location of the lifting points, tie down points, and machine center of gravity
(CG).
TRANSPORTATION DATA
GROSS WEIGHT - 60,000 LB.
-
EQUIPMENT TIEDOWN DESIGN LIMIT LOAD
LIFTING DESIGN LIMIT LOAD -
NO. OF SLINGS REQUIRED - 4

LENGTH OF SLINGS - 12 FT.
EQUIPMENT TIEDOW PROVISIONS

LIFTING PROVISIONS
SWING CENTERLINE CENTER OF

GRAVITY
44 MM [1.7 IN.] 1212 MM [47.5 IN.]

HYEX03192
Figure 3. HYEX Transportation Data Plate.
The following values are the HYEX Design Load Capabilities:

1. TieDown Provisions 1 and 2;
a. Longitudinal = 92,250 lbs
b. Vertical = 124,200 lbs
2. Tie Down Provisions 3 and 4;
a. Longitudinal = 110.250 lbs
b. Vertical = 110,250 lbs
3. Lift Provisions;
a. Rated design limit = 60,000 lbs, each shackle
b. Ultimate design factor 5:1
0100-3
TM 5-3805-294-10 0100
HYEX LIFTING AND TIE DOWN PROVISIONS - Continued.
HYEX LIFT AND TIE DOWN PROVISIONS
TIE TIE TIE CAB TIE

DOWN DOWN DOWN DOWN
2 4 3 1
LIFT POINTS
=TIE DOWN 1
=TIE DOWN 2
=TIE DOWN 3
=TIE DOWN 4
HYEX03063
Figure 4. HYEX Lifting and Tie Down Points.
Table 1. HYEX Lift and Tie Down Information.
Provision QTY Location (Relative to CG) Lateral
1 - Tie Down 2 39 in. forward 30 in. below 56 in.
2 - Tie Down 2 26 in. forward 25 in. below 7 in.
3 - Tie Down 2 43 in. aft 30 in. below 56 in.
4 - Tie Down 2 30 in. aft 25 in. below 7 in.
Lift Points 4 120 in. aft 5 in. below 15 in.
0100-4
TM 5-3805-294-10 0100
HIGHWAY:
Figure (5) shows the HYEX on an M870 semi trailer. The top view also shows a possible M870 tie down configuration.
The front view shows the HYEX is at or below the maximum height restriction for highway transport.
1 FOOT EXTENSION A A
BOTH SIDES
13 FT. 6 IN. HEIGHT CLEARANCE LINE
M870
TRAILER
SECTION A-A
HYDRAULIC EXCAVATOR, CRAWLER MOUNTED, TYPE I

JOHN DEERE MODEL 240D LCR HYEX03073
Figure 5. M870 Loading.
0100-5
TM 5-3805-294-10 0100
HIGHWAY: - Continued
Figure (6) shows the HYEX on an M870A1 semi trailer. The top view also shows a possible M870A1 tie down
configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.
A A
1 FOOT EXTENSION
BOTH SIDES
M870A1
TRAILER
SECTION A-A

JOHN DEERE MODEL 250D LCR HYEX03072
Figure 6. M870A1 Loading.
0100-6
TM 5-3805-294-10 0100
Figure (7) shows the HYEX on an M870A3 semi trailer. The top view also shows a possible M870A3 tie down
configuration. The front view shows the HYEX is at or below the maximum height restriction for highway transport.
A A
M870A3
TRAILER
SECTION A-A

JOHN DEERE MODEL 240D LCR
HYEX03069
Figure 7. M870A3 Loading.
0100-7
TM 5-3805-294-10 0100
RAIL:
HYEX is equipped with 30 inch track shoes, which require the HYEX to have special rail routing. The armored HYEX
has the same exterior dimensions as the standard cab model, so the armored cab version was not shown in the GIC
envelope. The HYEX requires special routing for rail systems requiring the GIC dimensions. Figures (8), (9), and
(10) show the HYEX modeled in various rail envelopes.
HYEX RAIL DIAGRAM
51.4 INCH
HIGH
RAILCAR
GIC RAIL CLEARANCE

WITH STANDARD CAB HYEX03078
Figure 8. GIC Rail Clearance.
0100-8
TM 5-3805-294-10 0100
RAIL: - Continued
HYEX RAIL DIAGRAMS
AAR RAIL CLEARANCE DOD RAIL CLEARANCE

WITH STANDARD CAB WITH STANDARD CAB
HYEX03080
Figure 9. Standard Cab Clearance.
0100-9
TM 5-3805-294-10 0100
RAIL: - Continued
HYEX RAIL DIAGRAMS
AAR RAIL CLEARANCE DOD RAIL CLEARANCE

WITH ARMORED CAB WITH ARMORED CAB
HYEX03064
Figure 10. Armored Cab Clearance.
Figures (11) and (12) show the proposed HYEX tie down configurations on the HTTX railcar.
HYEX01370
Figure 11. HTTX Railcar Loading Overhead View.
0100-10
TM 5-3805-294-10 0100
RAIL: - Continued
HYEX01371
Figure 12. HTTX Railcar Loading Side View.
AIR:
The HYEX meets the requirements of MIL-HDBK-1791, Designing for Internal Aerial Delivery in Fixed Winged
Aircraft (WP 0094) for transport on C-17 and C-5 aircraft.
Figure (13) shows model of the HYEX, both standard and armored cab, inside the C-5 aircraft design envelope. The
model shows that the HYEX does not require disassembly for transportation on the C-5 aircraft.
HYEX DIAGRAMS INSIDE C-5 AIRCRAFT
STANDARD CAB ARMORED CAB
LOAD RAMP CLEARANCE
GROUND
PLANE
BOOM RAISED 152.4mm (6 inches) BOOM RAISED 152.4mm (6 inches)

ABOVE GROUND PLANE ABOVE GROUND PLANE HYEX03066
Figure 13. C-5 Aircraft Loading.
0100-11
TM 5-3805-294-10 0100
AIR: - Continued
Figure (14) shows model of the HYEX, both standard and armored cab, inside the C-17 aircraft design envelope.
The model shows that the HYEX does not require any disassembly for transportation on the C-17 aircraft.
HYEX DIAGRAMS INSIDE C-17 AIRCRAFT
STANDARD CAB ARMORED CAB
LOAD RAMP CLEARANCE LOAD RAMP CLEARANCE
GROUND
PLANE
BOOM RAISED 152.4mm (6 inches) BOOM RAISED 152.4mm (6 inches)

ABOVE GROUND PLANE ABOVE GROUND PLANE
HYEX03065
Figure 14. C-17 Aircraft Loading.
MARINE:
Marine tie-down restraint depends on the size of the ship (decreasing on larger vessels), the expected sea state to
be encountered, and the stow location of a given ship. Generally, the restraint required will increase for locations
high and forward (or aft) in the ship. The most severe conditions will occur on exposed "weather decks," where strong
wind and wet conditions add to the problem. A ship’s crew may require additional lashing on exposed decks. Below-
deck locations that are closer to the vessel’s center of gravity and rotation will experience less severe motion.
HYEX01372
Figure 15. Marine Loading.
0100-12
TM 5-3805-294-10 0100
HYEX STANDARD BUCKET AND SPECIAL PURPOSE KITS (SPK) TRANSPORTABILITY.
All HYEX attachments have lifting and tie-down provisions included for ease in preparing for transport. The standard
HYEX quick latch system enables ease in changing attachments. The HYEX attachments can be directly chained
down to railcar/trailer for transport.
HYEX Attachments Weights are as follows:
1. Standard Rock Bucket, 42 in. = 3,000 lb (1361 kg)
2. Standard Ditch Cleaning Bucket = 2,337 lb (1060 kg)
3. Impact Breaker = 4,970 lb (2254 kg)
4. Crush-All = 7,450 lb (3379 kg)
5. Barrier Grapple = 870 lb (395 kg)
6. Plate Compactor = 2,200 lb (998 kg)
7. Deep Dig Arm = 3,440 lb (1560 kg)
STANDARD BUCKET TIE DOWN PROVISIONS.
Figure (16) shows the Standard Rock Bucket lifting and tie-down provisions.
TIE DOWN PROVISIONS
HYEX03083
Figure 16. Standard Rock Bucket.
0100-13
TM 5-3805-294-10 0100
STANDARD BUCKET TIE DOWN PROVISIONS - Continued.
Figure (17) shows the Standard Ditch Cleaning Bucket lifting and tie-down provisions.
TIE DOWN PROVISIONS HYEX03087
Figure 17. Standard Ditch Cleaning Bucket.
HIGHWAY:
Figure (18) shows the Standard Buckets on an M870A1 semi trailer. The top view also shows a possible M870A1
tie down configuration.
0100-14
TM 5-3805-294-10 0100
HYEX STANDARD BUCKETS

ON M870A1 TRAILER
HYEX03071
Figure 18. Standard Buckets Loaded On M870A1.
Figure (19) shows the Standard Buckets on an M870A3 semi trailer. The top view also shows a possible M870A3
tie down configuration.
HYEX STANDARD BUCKETS

ON M870A3 TRAILER
HYEX03068
Figure 19. Standard Buckets Loaded On M870A3.
0100-15
TM 5-3805-294-10 0100
SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS.
Figure (20) shows the Deep Dig Arm lifting and tie-down provisions.
TIE DOWN PROVISIONS
HYEX03089
Figure 20. Deep Dig Arm.
Figure (21) shows the Deep Dig Bucket lifting and tie-down provisions.
Figure 21. Deep Dig Bucket.
Figure (22) shows the Deep Dig Ditch Cleaning Bucket lifting and tie-down provisions.
0100-16
TM 5-3805-294-10 0100
SPECIAL PURPOSE KITS (SPK) LIFTING AND TIE DOWN PROVISIONS - Continued.
TIE DOWN PROVISIONS
HYEX03085
Figure 22. Deep Dig Ditch Cleaning Bucket.
0100-17
TM 5-3805-294-10 0100
Figure (23) shows the Crush-All lifting and tie-down provisions.
TIE DOWN PROVISIONS
HYEX03084
Figure 23. Crush-All.
Figure (24) shows the Compactor lifting and tie-down provisions.
Figure 24. Compactor.
0100-18
TM 5-3805-294-10 0100
Figure (25) shows the Impact Breaker lifting and tie-down provisions.
Figure 25. Impact Breaker.
Figure (26) shows the Barrier Grapple lifting and tie-down provisions.
Figure 26. Barrier Grapple.
0100-19
TM 5-3805-294-10 0100
CRUSH-ALL TIE DOWNS FOR HIGHWAY TRANSPORT.
Figure (27) shows the Crush-All loaded on M870A1 semi trailer. The top view also shows possible M870A1 tie down
configuration.
HYEX CRUSH-ALL ATTACHMENTS

ON M870A1 TRAILER
HYEX03070
Figure 27. Crush-All On M870A1.
Figure (28) shows the Crush-All loaded on M870A3 semi trailer. The top view also shows possible M870A3 tie down
configuration.
HYEX CRUSH-ALL
ON M870A3 TRAILER
HYEX03067
Figure 28. Crush-All On M870A3.
0100-20
TM 5-3805-294-10 0100
TRANSPORTING ON RAIL.
Figures (29) through (32) shows the Standard Buckets and Special Purpose Kits loading and tie downs on a HTTX
railcar. The top view also shows possible HTTX railcar tie down configurations.
BUCKETS
ON HTTX RAILCAR
HYEX03077
Figure 29. Standard Buckets Loaded On HTTX Railcar.
HYEX CRUSH-ALL ATTACHMENT

ON HTTX RAILCAR
HYEX03076
Figure 30. Crush-All Loaded On HTTX Railcar.
0100-21
TM 5-3805-294-10 0100
TRANSPORTING ON RAIL - Continued.
HYEX IMPACT BREAKER, COMPACTOR, AND BARRIER GRAPPLE

ON HTTX RAILCAR
HYEX03074
Figure 31. Impact Breaker, Compactor, and Barrier Grapple Loaded On HTTX Railcar.
HYEX DEEP DIG ATTACHMENTS

ON HTTX RAILCAR
HYEX03075
Figure 32. Deep Dig Arm and Buckets Loaded On HTTX Railcar.
END OF WORK PACKAGE
0100-22
TM 5-3805-294-10
INDEX
Subject WP Sequence No.-Page No.
A
ADDITIONAL AUTHORIZATION LIST (AAL).......................................................................... WP 0096-1
ADJUSTING THE OPERATOR'S SEAT................................................................................. WP 0006-1
AIR CONDITIONER DOES NOT OPERATE.......................................................................... WP 0045-1
AIR CONDITIONER/HEATER FILTER SERVICE................................................................... WP 0090-1
AUTO-IDLE DOES NOT WORK............................................................................................. WP 0052-1
B
BARRIER GRAPPLE DOES NOT HOLD LOAD..................................................................... WP 0073-1
BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE....................................................... WP 0041-1
BREAKER DOES NOT OPERATE......................................................................................... WP 0070-1
BREAKER OPERATES SLOWLY........................................................................................... WP 0071-1
BUCKET TEETH REPLACEMENT......................................................................................... WP 0085-1
C
CAB DOME LIGHT DOES NOT OPERATE............................................................................ WP 0040-1
CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................ WP 0042-1
CAB FUSE REPLACEMENT................................................................................................... WP 0084-1
CAB REAR WORK LIGHTS DO NOT OPERATE................................................................... WP 0043-1
COMPACTOR DOES NOT OPERATE................................................................................... WP 0069-1
COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS................... WP 0095-1
CRUSH-ALL DISCHARGE MATERIAL SIZE ADJUSTMENT................................................. WP 0092-1
CRUSH-ALL DOES NOT OPERATE...................................................................................... WP 0072-1
D
DECAL LOCATION GUIDE..................................................................................................... WP 0027-1
DEEP DIG DOES NOT OPERATE......................................................................................... WP 0074-1
DESCRIPTION AND USE OF MONITOR AND ALARMS....................................................... WP 0005-1
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS....................... WP 0004-1
DRAINING WATER AND SEDIMENT FROM FUEL TANK.................................................... WP 0091-1
E
ENGINE COOLANT TEMPERATURE ABOVE NORMAL...................................................... WP 0055-1
ENGINE CRANKS BUT DOES NOT START OR HARD TO START...................................... WP 0046-1
ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE................................... WP 0056-1
ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE..................................................... WP 0057-1
ENGINE IDLES POORLY....................................................................................................... WP 0051-1
ENGINE NOT DEVELOPING FULL POWER......................................................................... WP 0053-1
ENGINE OIL PRESSURE LOW.............................................................................................. WP 0054-1
ENGINE RUNS POORLY........................................................................................................ WP 0048-1
ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED................................ WP 0067-1
ENGINE WILL NOT CRANK................................................................................................... WP 0047-1
EQUIPMENT DESCRIPTION AND DATA.............................................................................. WP 0002-1
EXCESSIVE FUEL CONSUMPTION...................................................................................... WP 0049-1
EXCESSIVE OIL CONSUMPTION......................................................................................... WP 0050-1
EXPENDABLE AND DURABLE ITEMS LIST......................................................................... WP 0097-1
Index-1
TM 5-3805-294-10
INDEX - Continued
F
FORDING THE HYEX............................................................................................................. WP 0036-1
FRESH AIR FILTER SERVICE............................................................................................... WP 0089-1
G
GENERAL INFORMATION..................................................................................................... WP 0001-1
GENERAL MAINTENANCE INSTRUCTIONS........................................................................ WP 0078-1
GENERAL MONITOR OPERATION....................................................................................... WP 0013-1
H
HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO POWER........................ WP 0059-1
HYDRAULIC HOSE REEL DOES NOT OPERATE................................................................ WP 0075-1
HYDRAULIC OIL FOAMS....................................................................................................... WP 0062-1
HYDRAULIC OIL OVERHEATS.............................................................................................. WP 0061-1
HYDRAULIC RESERVOIR SERVICE..................................................................................... WP 0088-1
HYEX TRANSPORTABILITY INSTRUCTIONS...................................................................... WP 0100-1
I
INSTALLING AND OPERATING THE COMPACTOR............................................................ WP 0021-1
INSTALLING AND OPERATING THE CRUSH-ALL............................................................... WP 0019-1
INSTALLING AND OPERATING THE IMPACT BREAKER.................................................... WP 0020-1
INTRODUCTION - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...... WP 0076-1
L
LIFTING WITH HYEX.............................................................................................................. WP 0015-1
LOOSENING TRACK TENSION............................................................................................. WP 0082-1
LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE................................................. WP 0044-1
LOWERING BOOM WITHOUT HYDRAULIC PRESSURE..................................................... WP 0029-1
M
MAINTENANCE AFTER FORDING........................................................................................ WP 0093-1
MOVING MACHINE ON/OFF AN EMBANKMENT................................................................. WP 0024-1
MOVING THE HYEX............................................................................................................... WP 0008-1
MOVING UP/DOWN STEEP OR SLIPPERY SLOPES.......................................................... WP 0035-1
N
NO HYDRAULIC FUNCTIONS............................................................................................... WP 0058-1
NO SWING FUNCTION.......................................................................................................... WP 0063-1
O
OPENING AND CLOSING WINDOWS................................................................................... WP 0011-1
OPERATING IN COLD WEATHER 32°TO 5°F (0°TO -15°C)................................................. WP 0030-1
OPERATING IN COLD WEATHER 5°F (-15°C) OR COLDER .............................................. WP 0031-1
OPERATING TECHNIQUES................................................................................................... WP 0016-1
OPERATING THE BARRIER GRAPPLE................................................................................ WP 0022-1
OPERATING THE COOLANT HEATER................................................................................. WP 0034-1
OPERATING THE DEEP DIG ARM........................................................................................ WP 0023-1
Index-2
TM 5-3805-294-10
INDEX - Continued
O
OPERATING THE HYDRAULIC HOSE REEL........................................................................ WP 0026-1
OPERATING THE HYDRAULIC THUMB................................................................................ WP 0017-1
P
POWER DIG DOES NOT WORK............................................................................................ WP 0060-1
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)..................................... WP 0077-1
PRIMARY AND FINAL FUEL FILTER/WATER SEPARATORS SERVICE............................ WP 0086-1
PRIMARY AND SECONDARY AIR CLEANER SERVICE...................................................... WP 0087-1
Q
QUICK LATCH DOES NOT OPERATE.................................................................................. WP 0068-1
R
REFERENCES........................................................................................................................ WP 0094-1
REMOVING AND INSTALLING BUCKET............................................................................... WP 0014-1
S
SELECTING AN ATTACHMENT ON THE MONITOR............................................................ WP 0018-1
SHUTTING DOWN THE HYEX............................................................................................... WP 0009-1
SHUTTING DOWN THE HYEX WITH THE DEEP DIG ARM INSTALLED............................. WP 0010-1
SKYLIGHT WINDOW (SECONDARY EXIT) AND REAR WINDOW (EMERGENCY
EXIT)....................................................................................................................................... WP 0033-1
SLAVE STARTING.................................................................................................................. WP 0032-1
SLOW TRAVEL SPEED ONLY............................................................................................... WP 0065-1
SPECIAL PURPOSE KITS (SPK) LIST................................................................................... WP 0098-1
STARTING THE ENGINE....................................................................................................... WP 0007-1
SWING FUNCTION IS JERKY................................................................................................ WP 0064-1
T
TAKING ENGINE OIL SAMPLE.............................................................................................. WP 0079-1
TAKING HYDRAULIC OIL SAMPLE....................................................................................... WP 0083-1
THEORY OF OPERATION..................................................................................................... WP 0003-1
TIGHTENING TRACK TENSION............................................................................................ WP 0081-1
TOWING THE HYEX............................................................................................................... WP 0028-1
TRACK SAG CHECK ............................................................................................................. WP 0080-1
TRAVEL ALARM DOES NOT OPERATE............................................................................... WP 0038-1
TRAVEL IS JERKY.................................................................................................................. WP 0066-1
TROUBLESHOOTING NOTES............................................................................................... WP 0099-1
TROUBLESHOOTING SYMPTOM INDEX - OPERATOR MAINTENANCE........................... WP 0037-1
U
USING THE RIFLE MOUNT.................................................................................................... WP 0012-1
USING THE VANDAL PROTECTION KIT.............................................................................. WP 0025-1
W
WINDSHIELD WIPER AND WASHER DO NOT OPERATE................................................... WP 0039-1
Index-3/4 blank
RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Date you filled out
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4. this form.
TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS Your mailing address
6501 E. 11 Mile Road, Warren, MI 48397-5000
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE Title
2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU
TM 0DUFK +<(;7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO. (Provide exact wording of recommended changes, if possible).
*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature
Your Signature
Your Name
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U. S. Army TACOM Life Cycle Management Command Your address Date you filled out this
ATTN: AMSTA-LCL-MPP/TECH PUBS form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU
PUBLICATION NUMBER DATE
TM 0 MarFK +<(;7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS RECOMMENDED ACTION
SUPPORTED
SAMPLE
PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE
Your Name Your Signature

USAPPC V3.00
For use of this form, see AR 25-30; the proponent agency is ODISC4.
FROM: (Activity and location) (Include ZIP Code)

TO: (Forward to proponent of publication or form)(Include ZIP Code)
ATTN: AMSTA-LCL-MPP/TECH PUBS
6501 East 11 Mile Road, Warren, MI 48397-5000
PUBLICATION/FORM NUMBER DATE TITLE 2SHUDWRU
V0DQXDO)RU+\GUDXOLF([FDYDWRU+<(;
TM 0 MarFK 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE

EXTENSION
U. S. Army TACOM Life Cycle Management Command
PUBLICATION NUMBER DATE TITLE2SHUDWRU
TM 0 MarFK 0 7\SH:LWK+\GUDXOLF7KXPE 4XLFN/DWFK
TOTAL NO.
SUPPORTED
USAPPC V3.00


EXTENSION
TOTAL NO.
SUPPORTED
USAPPC V3.00


EXTENSION
TOTAL NO.
SUPPORTED
USAPPC V3.00


EXTENSION
TOTAL NO.
SUPPORTED
USAPPC V3.00
By Order of the Secretary of the Army:
Official: GEORGE W. CASEY, JR.

General, United States Army
Chief of Staff
JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
1103409
Distribution:
To be distributed in accordance with the Initial Distribution Number (IDN) 257856

requirements for TM 5-3805-294-10.
THE METRIC SYSTEM AND EQUIVALENTS
LINEAR MEASURE SQUARE MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.386 Sq Miles
WEIGHTS CUBIC MEASURE

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Cu Centimeter = 1000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Lb 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
TEMPERATURE
LIQUID MEASURE 5/9 ( F - 32) = C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212 Fahrenheit is equivalent to 100 Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 90 Fahrenheit is equivalent to 32.2 Celsius
32 Fahrenheit is equivalent to 0 Celsius
9/5 C + 32 = F
APPROXIMATE CONVERSION FACTORS
0
TO CHANGE TO MULTIPLY BY
INCHES
1 CM 2
Inches . . . . . . . . . . . . . . . . . Centimeters . . . . . . . . . . . . . . . . . . 2.540
Feet . . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . 0.305
Yards . . . . . . . . . . . . . . . . . . Meters . . . . . . . . . . . . . . . . . . . . . . . 0.914
Miles . . . . . . . . . . . . . . . . . . Kilometers . . . . . . . . . . . . . . . . . . . . 1.609
Square Inches . . . . . . . . . . Square Centimeters . . . . . . . . . . . 6.451
1
Square Feet . . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . 0.093
Square Yards . . . . . . . . . . . Square Meters . . . . . . . . . . . . . . . . 0.836
3
Square Miles . . . . . . . . . . . Square Kilometers . . . . . . . . . . . . . 2.590
Acres . . . . . . . . . . . . . . . . . . Square Hectometers . . . . . . . . . . . 0.405
Cubic Feet . . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . 0.028
4
Cubic Yards . . . . . . . . . . . . Cubic Meters . . . . . . . . . . . . . . . . . 0.765
Fluid Ounces . . . . . . . . . . . Milliliters. . . . . . . . . . . . . . . . . . . . . . 29.573
Pints . . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . 0.473
Quarts . . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . 0.946
5
2
Gallons. . . . . . . . . . . . . . . . . Liters . . . . . . . . . . . . . . . . . . . . . . . . 3.785
Ounces . . . . . . . . . . . . . . . . Grams . . . . . . . . . . . . . . . . . . . . . . . 28.349
Pounds . . . . . . . . . . . . . . . . Kilograms . . . . . . . . . . . . . . . . . . . . 0.454
6
Short Tons . . . . . . . . . . . . . Metric Tons . . . . . . . . . . . . . . . . . . . 0.907
Pound-Feet . . . . . . . . . . . . Newton-Meters . . . . . . . . . . . . . . . . 1.356
Pounds/Sq Inch . . . . . . . . . Kilopascals . . . . . . . . . . . . . . . . . . . 6.895
7
Miles per Gallon . . . . . . . . Kilometers per Liter . . . . . . . . . . . . 0.425
Miles per Hour . . . . . . . . . . Kilometers per Hour . . . . . . . . . . . 1.609
3
8
TO CHANGE TO MULTIPLY BY
9
Centimeters . . . . . . . . . . . . Inches . . . . . . . . . . . . . . . . . . . . . . . 0.394

Meters . . . . . . . . . . . . . . . . . Feet . . . . . . . . . . . . . . . . . . . . . . . . . 3.280
Meters. . . . . . . . . . . . . . . . . . Yards . . . . . . . . . . . . . . . . . . . . . . . . 1.094
10
4
Kilometers . . . . . . . . . . . . . Miles. . . . . . . . . . . . . . . . . . . . . . . . . 0.621

Sq Centimeters . . . . . . . . . Square Inches . . . . . . . . . . . . . . . . 0.155
Square Meters . . . . . . . . . . Square Feet . . . . . . . . . . . . . . . . . . 10.764
11
Square Meters . . . . . . . . . . Square Yards . . . . . . . . . . . . . . . . . 1.196

Square Kilometers . . . . . . Square Miles . . . . . . . . . . . . . . . . . 0.386
Sq Hectometers . . . . . . . . Acres . . . . . . . . . . . . . . . . . . . . . . . . 2.471
12
Cubic Meters ............. Cubic Feet . . . . . . . . . . . . . . . . . . . 35.315

Cubic Meters . . . . . . . . . . . Cubic Yards . . . . . . . . . . . . . . . . . . . 1.308
Milliliters . . . . . . . . . . . . . . . Fluid Ounces . . . . . . . . . . . . . . . . . 0.034
5
Liters . . . . . . . . . . . . . . . . . . Pints . . . . . . . . . . . . . . . . . . . . . . . . . 2.113

13
Liters . . . . . . . . . . . . . . . . . . Quarts . . . . . . . . . . . . . . . . . . . . . . . 1.057

Liters . . . . . . . . . . . . . . . . . . Gallons . . . . . . . . . . . . . . . . . . . . . . 0.264
Grams . . . . . . . . . . . . . . . . . Ounces . . . . . . . . . . . . . . . . . . . . . . 0.035
14
Kilograms . . . . . . . . . . . . . . Pounds. . . . . . . . . . . . . . . . . . . . . . . 2.205

Metrication . . . . . . . . . . . . . Short Tons . . . . . . . . . . . . . . . . . . . . 1.102
Newton-Meters . . . . . . . . . Pound-Feet . . . . . . . . . . . . . . . . . . . 0.738
15
Kilopascals . . . . . . . . . . . . . Pounds per Sq Inch . . . . . . . . . . . . 0.145

6
Km per Liter . . . . . . . . . . . . Miles per Gallon . . . . . . . . . . . . . . . 2.354

Km per Hour. . . . . . . . . . . . Miles per Hour . . . . . . . . . . . . . . . . 0.621
PIN 086698-000

Excavator John Deree

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TM 5-3805-294-10

HYDRAULIC EXCAVATOR (HYEX)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - Electrical wire to hand with electricity symbol running through

WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued

WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued

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

WARNING SUMMARY - Continued

WARNING SUMMARY - Continued

WARNING SUMMARY - Continued

WARNING SUMMARY - Continued

2. DO NOT idle engine without adequate ventilation.

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Date of issue for the original manual is:

Original 07 March 2011

Front Cover 0 WP0033 (2 pgs) 0

LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued

WP0072 (2 pgs) 0 WP0087 (6 pgs) 0

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

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

How to Use this Manual

Chapter 1 - OPERATOR GENERAL INFORMATION

GENERAL INFORMATION.......................................................................................................................... WP 0001

Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2

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

Figure 1. Right View of HYEX............................................................................................................. 0002-3

Table 1. Right View of HYEX............................................................................................................. 0002-3

Figure 2. Left View of HYEX................................................................................................................ 0002-4

Table 2. Left View of HYEX................................................................................................................ 0002-4

Figure 3. Data Plates........................................................................................................................... 0002-5

Table 3. Data Plates........................................................................................................................... 0002-5

Table 4. Equipment Data.................................................................................................................... 0002-6

Figure 4. HYEX Specifications............................................................................................................ 0002-7

Table 5. HYEX Specification.............................................................................................................. 0002-7

Figure 5. HYEX Working Ranges........................................................................................................ 0002-8

Table 6. HYEX Working Ranges........................................................................................................ 0002-9

Table 7. Front Lift Capacities........................................................................................................... 0002-10

Table 8. Side Lift Capacities............................................................................................................. 0002-11

Table 9. HYEX Weights With Attachments...................................................................................... 0002-12

Table 10. Deep Dig Arm Weights....................................................................................................... 0002-12

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

Figure 1. Electrical System Components............................................................................................ 0003-2

Table 1. Electrical System Components............................................................................................ 0003-2

Figure 2. Hydraulic System Components............................................................................................ 0003-3

Table 2. Hydraulic System Components............................................................................................ 0003-3

Figure 3. Hydraulic System Components Continued........................................................................... 0003-4

Table 3. Hydraulic System Components Continued........................................................................... 0003-4

TABLE OF CONTENTS - Continued

Figure 4. Powertrain Components....................................................................................................... 0003-5

Table 4. Powertrain Components....................................................................................................... 0003-5

Figure 5. Fuel System Components.................................................................................................... 0003-6

Table 5. Fuel System Components.................................................................................................... 0003-6

Figure 6. High-Pressure Pump and Injectors...................................................................................... 0003-7

Table 6. High-Pressure Pump and Injectors...................................................................................... 0003-7

Figure 7. Cooling Package.................................................................................................................. 0003-8

Table 7. Cooling Package.................................................................................................................. 0003-8

Figure 8. Cooling System Components............................................................................................... 0003-9

Table 8. Cooling System Components............................................................................................... 0003-9

Chapter 2 - OPERATOR INSTRUCTIONS