TM 5-3805-280-10

TECHNICAL MANUAL

OPERATOR’S MANUAL

HYDRAULIC EXCAVATOR

JOHN DEERE

MODEL 230LCR

NSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILL

NSN 3805-01-463-0806

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

Reproduced by permission of Deere & Company, Moline, IL © 2000.

All rights reserved.

HEADQUARTERS, DEPARTMENT OF THE ARMY

15 FEBRUARY 2000
A

TM 5-3805-280-10

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LIST OF EFFECTIVE PAGES

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the page. Updates to wiring diagrams are indicated by shaded areas.

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Original .. 0 .. 15 February 2000

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i

TM 5-3805-280-10

Technical Manual

No. 5-3805-280-10 HEADQUARTERS,

 DEPARTMENT OF THE ARMY

 Washington, DC, 15 February 2000

OPERATOR’S MANUAL

HYDRAULIC EXCAVATOR

JOHN DEERE

MODEL 230LCR

NSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILL

NSN 3805-01-463-0806

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,

please let us know. Submit your DA Form 2028-2 (Recommended Changes to Equipment Technical Publications),

through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is

http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM”. The DA

Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on

SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the

DA Form 2028 program. You may also mail, fax or email your letter, DA Form 2028, or DA Form 2028-2 direct

to: Commander, U.S. Army Tank-automotive and Armaments Command, ATTN: AMSTA-LC-CI, Rock Island, IL

61299-7630. The email address is AMSTA-LC-CI@ria.army.mil. The fax number is DSN 793-0726 or

Commercial (309) 782-0726.

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

NOTE

As this operator manual is a commercial product supplemented to include Army specific

procedures, the manual may advise the operator to perform tasks that would normally not be

assigned to the operator level in a DATM. Always follow the limits established in the PMCS.

Also, references are made throughout the manual to see your authorized dealer or John Deere

dealer for repair or information. In those instances, notify your supervisor or next higher

maintenance level.

TABLE OF CONTENTS

Page

Introduction

Chapter 1 Safety and Safety Signs

John Deere Excavator Safety Features.......................................................................................1-1

Recognize Safety Information....................................................................................................1-2

Understand Signal Words...........................................................................................................1-2

Follow Safety Instructions .........................................................................................................1-2

Avoid Injury From: Loading Machine on a Trailer, Fastening Machine to

Trailer, and Unloading Machine From Trailer......................................................................1-3
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

ii

Avoid Injury From Backover Accidents ....................................................................................1-4

Avoid Injury From Rollaway Accidents ....................................................................................1-5

Inspect Machine .........................................................................................................................1-5

Use Handholds and Steps...........................................................................................................1-6

Use Seat Belt..............................................................................................................................1-6

Maintain Seat Belt......................................................................................................................1-7

Move and Operate Machine Safely ............................................................................................1-7

Operate Only From Operator’s Seat...........................................................................................1-8

Secondary Exits..........................................................................................................................1-8

Operate Machine Safely.............................................................................................................1-8

Dig With Caution .......................................................................................................................1-9

Operate With Caution.................................................................................................................1-9

Avoid Tipping ............................................................................................................................1-9

Avoid Power Lines.....................................................................................................................1-10

Drive Machine Safely.................................................................................................................1-10

Beware of Exhaust Fumes..........................................................................................................1-10

Park Machine Safely ..................................................................................................................1-11

Keep Riders Off Machine ..........................................................................................................1-11

Operate Attachment Safely ........................................................................................................1-12

Handle Fluids Safely—Avoid Fires ...........................................................................................1-12

Prepare for Emergencies ............................................................................................................1-13

Handle Starting Fluid Safely ......................................................................................................1-13

Clean Trash From Machine........................................................................................................1-14

Protect Against Flying Debris ....................................................................................................1-14

Wear Protective Clothing...........................................................................................................1-14

Protect Against Noise.................................................................................................................1-15

Handle Chemical Products Safely..............................................................................................1-15

Warn Others of Service Work....................................................................................................1-16

Stay Clear of Moving Parts ........................................................................................................1-16

Support Machine Properly .........................................................................................................1-17

Service Cooling System Safely ..................................................................................................1-17

Practice Safe Maintenance .........................................................................................................1-18

Remove Paint Before Welding or Heating.................................................................................1-19

Avoid Heating Near Pressurized Fluid Lines.............................................................................1-19

Avoid High-Pressure Fluids .......................................................................................................1-20

Prevent Battery Explosions ........................................................................................................1-20

Clean the Machine Regularly.....................................................................................................1-21

Store Attachments Safely...........................................................................................................1-21

Battery Terminals, Lifting Equipment, Dry Cleaning Solvent and Compressed Air .................1-22

Dispose of Waste Properly.........................................................................................................1-23

Drilling.......................................................................................................................................1-24

Rock Drill Maintenance .............................................................................................................1-24

Emergency Stops........................................................................................................................1-25

Safety Signs................................................................................................................................1-27

Chapter 2 Operator’s Station

Pedal, Levers and Panels....................................................................................................... .....2-1

Right Front Panel and Right Console Panel ...............................................................................2-2

Monitor Panel.............................................................................................................................2-3

Engine Coolant Temperature Gauge ..........................................................................................2-4

Warm-Up Indicator ....................................................................................................................2-4

Fuel Gauge .................................................................................................................................2-4

H/P (High Power) Mode Indicator .............................................................................................2-4

E (Economy) Mode Indicator.....................................................................................................2-5

Auto-Idle Indicator.....................................................................................................................2-5
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

iii

Hydraulic Oil Level Indicator ....................................................................................................2-5

Hydraulic Oil Filter Restriction Indicator (Model 230LCRD)...................................................2-6

Fuel Level Indicator ...................................................................................................................2-6

Air Filter Restriction Indicator...................................................................................................2-6

Engine Coolant Temperature Indicator ......................................................................................2-7

Charge Air Temperature Indicator .............................................................................................2-7

Engine Oil Pressure Indicator.....................................................................................................2-8

Alternator Voltage Indicator ......................................................................................................2-8

Engine Oil Level Indicator.........................................................................................................2-8

Coolant Level Indicator..............................................................................................................2-9

Switch Panel...............................................................................................................................2-10

Buzzer and Buzzer Stop Switch .................................................................................................2-11

Wiper Switch..............................................................................................................................2-11

Washer Switch............................................................................................................................2-12

Operating Lights Switch.............................................................................................................2-12

Operating Rear Lights Switch ....................................................................................................2-13

Cab Light....................................................................................................................................2-13

Overload Alarm and Indicator....................................................................................................2-13

Key Switch .................................................................................................................................2-14

Engine RPM Dial .......................................................................................................................2-14

Power Boost Switch ...................................................................................................................2-14

Horn ...........................................................................................................................................2-15

Hour Meter.................................................................................................................................2-15

Cab Heater and Air Conditioner.................................................................................................2-16

Control Panel Switches ..............................................................................................................2-17

Cab Heater Operation.................................................................................................................2-18

Air Conditioner Operation..........................................................................................................2-18

Defroster Operation....................................................................................................................2-19

Front Console .............................................................................................................................2-19

Operating the AM/FM Radio .....................................................................................................2-20

Setting the Clock ........................................................................................................................2-20

Cab Door Release Lever.............................................................................................................2-21

Secondary Exit Tool...................................................................................................................2-21

Opening Upper Front (Secondary Exit) Window.......................................................................2-21

Closing Upper Front Window ....................................................................................................2-22

Removing and Storing the Lower Front Window ......................................................................2-23

Opening Side Windows..............................................................................................................2-23

Opening and Closing the Roof Exit Cover.................................................................................2-24

Removing and Storing Fire Extinguisher (Model 230LCR) ......................................................2-24

Rock Drill Start—Stop Selection Control Box (Model 230LCRD) ..........................................2-25

Compressor Remote Instrument Control Panel (Model 230LCRD) ..........................................2-26

Removing and Storing Rifle.......................................................................................................2-26

J-Hooks ......................................................................................................................................2-27

Toolbox Security Hasp...............................................................................................................2-27

Decontamination Kit Bracket.....................................................................................................2-28

Vandal Protection Panel Storage................................................................................................2-28

Adjusting the Seat ......................................................................................................................2-29

Adjusting the Armrest ................................................................................................................2-30

Seat Belt .....................................................................................................................................2-30

Operator’s Manual Compartment...............................................................................................2-30

Chapter 3 Break-In

Engine Break-In Oil ...................................................................................................................3-1

Every 4 Hours.............................................................................................................................3-1
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

iv

Every 10 Hours or Daily ............................................................................................................3-2

After the First 50 Hours..............................................................................................................3-2

After the First 100 Hours............................................................................................................3-3

Chapter 4 Pre-Start Inspection

Inspect Machine Daily Before Starting ......................................................................................4-1

Chapter 5 Operating the Engine

Check Instruments Before Starting ............................................................................................5-1

Level Check................................................................................................................................5-1

Starting the Engine .....................................................................................................................5-2

Using Booster Batteries—24 Volt System .................................................................................5-3

Slave Receptacle—24 Volt System............................................................................................5-4

Starting Fluid (Cold Weather Starting Aid) ...............................................................................5-5

Using the Arctic Starter..............................................................................................................5-7

Starting the Arctic Starter...........................................................................................................5-8

Check Instruments After Starting...............................................................................................5-8

Warming the Machine................................................................................................................5-9

Cold Weather Warm-Up ............................................................................................................5-10

Stopping the Engine ...................................................................................................................5-11

Chapter 6 Driving the Machine

Steering the Machine Using Pedals....................................................................................6-1

Steering the Machine Using Levers ...........................................................................................6-3

Removing Propel Levers............................................................................................................6-5

Propel Speed Switch...................................................................................................................6-6

Travel Alarm and Travel Alarm Cancel Switch.........................................................................6-6

Parking the Machine...................................................................................................................6-7

Parking Machine During Freezing Weather...............................................................................6-8

Lock All Compartments .............................................................................................................6-8

Chapter 7 Operating the Machine

Control Levers............................................................................................................................7-1

Control Lever Pattern Conversion..............................................................................................7-3

Control Levers John Deere Pattern.............................................................................................7-5

Pilot Control Shut-Off Lever......................................................................................................7-6

Auto-Idle Switch ........................................................................................................................7-7

Mode Selection Switch...............................................................................................................7-8

Power Boost Switch ...................................................................................................................7-8

E (Economy) Mode ....................................................................................................................7-9

H/P (High Power) Mode ............................................................................................................7-10

Standard Mode ...........................................................................................................................7-10

Operating Tips............................................................................................................................7-11

Driving Machine ........................................................................................................................7-11

Driving on Slopes.......................................................................................................................7-12

Driving Down a Slope................................................................................................................7-12

Driving Up a Slope.....................................................................................................................7-12

Driving Up a Steep or Slippery Slope—Boom on Uphill End of Machine................................7-13

Driving Up a Steep or Slippery Slope—Boom on Downhill End of Machine...........................7-13

Moving Machine off an Embankment........................................................................................7-14

Leveling Machine.......................................................................................................................7-15

Using Quick-Disconnect Hitch...................................................................................................7-16

Two Way Hydraulic Thumb Foot Pedal (Model 230LCR)........................................................7-20

Using Hydraulic Thumb.............................................................................................................7-21

Using Bucket..............................................................................................................................7-23
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

v

Planning Spoil Piles ...................................................................................................................7-25

Trenching ...................................................................................................................................7-25

Backfilling..................................................................................................................................7-27

Truck Loading............................................................................................................................7-28

Operating in Water and Mud......................................................................................................7-29

Clean Track Frame Area ............................................................................................................7-29

Lifting.........................................................................................................................................7-30

Air Compressor - Operating Instructions ...................................................................................7-32

Using Quick-Coupler Type Attachments ...................................................................................7-37

Rock Drill Attachment (Model 230LCRD)................................................................................7-38

Install Rock Drill........................................................................................................................7-38

Remove Rock Drill.....................................................................................................................7-41

Operating the Rock Drill Attachment.........................................................................................7-43

Remote Control Operator’s Panel ..............................................................................................7-43

Rod Changer...............................................................................................................................7-45

Start Up ......................................................................................................................................7-49

Travelling ...................................................................................................................................7-50

Drilling .......................................................................................................................................7-51

Shut Down..................................................................................................................................7-53

Lower Boom With Engine Stopped ...........................................................................................7-54

Using Hydraulic Hand Tools Hose Reel ....................................................................................7-55

Using Hydraulic Hand Tools Flow Rate Valve and Switch .......................................................7-55

Using Hand Held Air Tools........................................................................................................7-55

Chapter 8 Transporting

Loading Machine on a Trailer ....................................................................................................8-1

Tiedowns....................................................................................................................................8-2

Fasten Machine to Trailer ..........................................................................................................8-3

Loading and Fastening Rock Drill on a Trailer..........................................................................8-6

Fasten Machine to Rail Car (Model 230LCR) ...........................................................................8-8

Fasten Machine and Rock Drill to Rail Car (Model 230LCRD)................................................8-10

Unloading Machine From Trailer...............................................................................................8-12

Towing Machine ........................................................................................................................8-13

Lifting the Machine....................................................................................................................8-14

Chapter 9 Fuels and Lubricants

Diesel Fuel .................................................................................................................................9-1

Lubricity of Diesel Fuels............................................................................................................9-1

Low Sulfur Diesel Fuel Conditioner ..........................................................................................9-2

Diesel Fuel Storage ....................................................................................................................9-2

Fuel Tank ...................................................................................................................................9-3

Do Not Use Galvanized Containers ...........................................................................................9-3

Diesel Engine and Pump Gearbox Oils ......................................................................................9-4

Hydraulic Oil..............................................................................................................................9-5

Swing Gearbox and Propel Gearbox Oils...................................................................................9-6

Track Roller, Front Idler, and Carrier Roller Oil .......................................................................9-6

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease...........9-7

Oil Filters ...................................................................................................................................9-7

Rock Drill Lubricants Specifications .........................................................................................9-8

Air Compressor Lubricants ........................................................................................................9-10

Lubricant Storage .......................................................................................................................9-11

Alternative and Synthetic Lubricants .........................................................................................9-11

Mixing of Lubricants..................................................................................................................9-12

Factory/Initial Fill Lubricants ....................................................................................................9-12
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

vi

Chapter 10 Periodic Maintenance—Excavator

Service Your Machine at Specified Intervals ...........................................................................10-1

Check the Hour Meter Regularly .............................................................................................10-1

Use Correct Fuels and Lubricants ............................................................................................10-1

Prepare Machine for Maintenance............................................................................................10-2

Open Access Doors for Service................................................................................................10-3

Open Hood for Service.............................................................................................................10-4

Chapter 11 Maintenance—As Required

Sampling Engine Oil (GRP NO. 0400) ....................................................................................11-1

Sampling Hydraulic Oil (GRP NO. 3360) ...............................................................................11-2

Clean Fuel Tank Inlet Screen (GRP NO. 0560) .......................................................................11-3

Drain Fuel Tank Sump (GRP NO. 0560) .................................................................................11-3

Clean Radiator Air Inlet Screens (GRP NO. 0511)..................................................................11-4

Drain Water Separator (GRP NO. 0560)..................................................................................11-4

Clean Air Cleaner Dust Unloader Valve (GRP NO. 0521) ......................................................11-5

Check Track Sag (GRP NO. 0132) ..........................................................................................11-5

Adjusting Track Sag (GRP NO. 0132).....................................................................................11-6

Windshield Washer Fluid Level...............................................................................................11-7

Chapter 12 Maintenance—Every 10 Hours or Daily

Check Engine Oil Level (GRP NO. 0400) ...............................................................................12-1

Check Recovery Tank Coolant Level (GRP NO. 0510)...........................................................12-2

Check Hydraulic Oil Level (GRP NO. 3360) ..........................................................................12-3

Chapter 13 Maintenance—Every 50 Hours

Grease Working Tool Pivots (GRP NO. 3302) ........................................................................13-1

Chapter 14 Maintenance—Every 250 Hours

Check Swing Gearbox Oil Level (GRP NO. 4351)..................................................................14-1

Drain Hydraulic Tank Sump (GRP NO. 3364) ........................................................................14-1

Check Pump Drive Gearbox Oil Level (GRP NO. 3361) ........................................................14-2

Change Engine Oil and Replace Filter (GRP NO. 0407) .........................................................14-3

Check Radiator Coolant Level .................................................................................................14-5

Check Battery Electrolyte Level and Terminals (GRP NO. 1671)...........................................14-6

Check Propel Gearbox Oil Level (GRP NO. 0250) .................................................................14-8

Clean Dusty Primary Element (GRP NO. 0521)......................................................................14-9

Inspect Element (GRP NO. 0521)............................................................................................14-10

Chapter 15 Maintenance—Every 500 Hours

Grease Swing Bearing (GRP NO. 4353)..................................................................................15-1

Grease Swing Bearing Gear (GRP NO. 4353) .........................................................................15-2

Replace Final Fuel Filter (GRP NO. 0420) ..............................................................................15-3

Replace Primary Fuel Filter (Water Separator) (GRP NO. 0560)............................................15-4

Check Air Intake Hoses (GRP NO. 0521)................................................................................15-5

Replace Hydraulic Oil Filter (GRP NO. 3360) ........................................................................15-6

Add Coolant Conditioner to Radiator (GRP NO. 0510) ..........................................................15-8

Chapter 16 Maintenance—Every 1000 Hours

Change Swing Gearbox Oil (GRP NO. 4351)..........................................................................16-1

Change Pilot Control Oil Filter (GRP NO. 3362) ....................................................................16-1

Change Pump Drive Gearbox Oil (GRP NO. 3360) ................................................................16-2

Clean the Engine Crankcase Ventilation Tube.........................................................................16-3

Check and Adjust Engine Valve Lash (Clearance) ..................................................................16-3

Firing Order 6-Cylinder Engine ...............................................................................................16-5
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

vii

Check Engine Speeds ...............................................................................................................16-6

Engine Speed Learning Procedure ...........................................................................................16-7

Change Air Cleaner Elements (GRP NO. 0521) ......................................................................16-7

Inspect Fan Belt (GRP NO. 0429)............................................................................................16-8

Replace Air Cleaner Dust Valve (GRP NO. 0521) ..................................................................16-8

Chapter 17 Maintenance—Every 2000 Hours

Drain Cooling System (GRP NO. 0510) ..................................................................................17-1

Diesel Engine Coolant (GRP NO. 0510)..................................................................................17-2

Cooling System Fill and Deaeration Procedure (GRP NO. 0510) ...........................................17-3

Change Propel Gearbox Oil .....................................................................................................17-4

Change Hydraulic Oil...............................................................................................................17-5

Chapter 18 Maintenance—Air Compressor

General .....................................................................................................................................18-1

Scheduled Maintenance............................................................................................................18-1

Compressor Oil Maintenance...................................................................................................18-1

Air Cleaner ...............................................................................................................................18-2

Gauges......................................................................................................................................18-3

Fuel Tank .................................................................................................................................18-3

Battery......................................................................................................................................18-3

Automatic Shutdown System ...................................................................................................18-3

Compressor Oil Cooler.............................................................................................................18-4

Radiator....................................................................................................................................18-4

Hoses........................................................................................................................................18-4

Compressor Oil Filters .............................................................................................................18-5

Fasteners...................................................................................................................................18-6

Compressor Oil ........................................................................................................................18-6

Receiver-Separator Systems.....................................................................................................18-6

Scavenge Line ..........................................................................................................................18-6

Cooling Fan Drive....................................................................................................................18-6

Oil Separator Element ..............................................................................................................18-7

Exterior Finish Care .................................................................................................................18-8

Lubrication ...............................................................................................................................18-10

Chapter 19 Maintenance—Rock Drill Attachment

First Oil Change .......................................................................................................................19-1

When Required.........................................................................................................................19-3

Adjustment of Drilling Automatisms .......................................................................................19-4

Replacing Rock Drill Dust Collector Filters ............................................................................19-8

Daily Maintenance Hydraulic Dust Collector ..........................................................................19-9

Daily.........................................................................................................................................19-10

Every 50 Hours.........................................................................................................................19-10

Every 1000 Hours.....................................................................................................................19-11

Every 2000 Hours.....................................................................................................................19-11

Drifter Maintenance .................................................................................................................19-12

Chapter 20 Maintenance

Do Not Service Injection Nozzles ............................................................................................20-1

Do Not Change Injection Pump ...............................................................................................20-1

Bleeding the Fuel System.........................................................................................................20-2

Precautions for Alternator and Regulator.................................................................................20-2

Service Batteries Carefully.......................................................................................................20-3

Checking Electrolyte Specific Gravity.....................................................................................20-5

Using Battery Charger..............................................................................................................20-6
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

viii

Replacing Batteries (GRP NO. 1671) ......................................................................................20-7

Removing Batteries (GRP NO. 1671)......................................................................................20-7

Welding on Machine ................................................................................................................20-8

Adding 12-Volt Accessories ....................................................................................................20-9

Replacing Fuses........................................................................................................................20-9

Fuse (Blade-Type) Color Codes...............................................................................................20-11

Checking Travel Alarm System (GRP NO. 1671) ...................................................................20-11

Replacing Bucket Teeth (GRP NO. 3302) ...............................................................................20-12

Removing the Bucket (GRP NO. 3302)...................................................................................20-13

Replacing Bucket Tooth Tip—Heavy-Duty Bucket (GRP NO. 3302) ....................................20-14

Do Not Service Control Valves, Cylinders, Pumps or Motors.................................................20-14

Track Sag General Information................................................................................................20-15

Hardware Torque Specifications ..............................................................................................20-15

Check Track Shoe Torque........................................................................................................20-16

Unified Inch Bolt and Cap Screw Torque Values ....................................................................20-17

Metric Bolt and Cap Screw Torque Values..............................................................................20-18

Additional Metric Cap Screw Torque Values ..........................................................................20-19

Check Oil Lines and Fittings....................................................................................................20-20

Service Recommendations for O-Ring Boss Fittings...............................................................20-21

Service Recommendations for Flat Face O-Ring Seal Fittings ................................................20-23

Service Recommendations for 37° Flare and 30° Cone Seat Connectors ................................20-24

Service Recommendations for Flared Connections—Straight or Tapered Threads.................20-25

Service Recommendations for Inch Series Four Bolt Flange Fittings......................................20-26

Service Recommendations for Metric Series Four Bolt Flange Fitting....................................20-28

Chapter 21 Operational Checkout

Operational Checkout...............................................................................................................21-1

Operator Station Checks—Key Switch On, Engine Off ..........................................................21-2

Operator Station Checks—Engine On......................................................................................21-4

Hydraulic System Checks ........................................................................................................21-8

Undercarriage Checks ..............................................................................................................21-15

Hydraulic Thumb Check ..........................................................................................................21-17

Quick-Disconnect Hitch Checks ..............................................................................................21-17

Accessories Checks ..................................................................................................................21-18

Air Conditioning Checks..........................................................................................................21-20

Seat, Doors, Windows, Latches, and Locks Checks.................................................................21-23

Coolant Checks ........................................................................................................................21-29

Chapter 22 Troubleshooting

Using Troubleshooting Charts..................................................................................................22-1

Engine ......................................................................................................................................22-2

Electrical System......................................................................................................................22-8

Hydraulic System .....................................................................................................................22-14

Chapter 23 Storage

Prepare Machine for Storage....................................................................................................23-1

Quick-Disconnect Hitch Storage Procedure.............................................................................23-2

Monthly Storage Procedure......................................................................................................23-3

Chapter 24 Specifications

230LCR/LCRD .................................................................................................................... ....24-1

230LCR/LCRD Working Ranges.............................................................................................24-3

230LCR/LCRD ........................................................................................................................24-4

230LCR/LCRD Drain and Refill Capacities............................................................................24-5
TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

ix

230LCR/LCRD Lift Capacity—KG (LB)................................................................................24-6

Rock Drill Attachment - Technical Specifications...................................................................24-7

Air Compressor General Data ..................................................................................................24-8

Appendix A Operator Preventive Maintenance Checks and Services (PMCS) .......................................A-1

Appendix B Components of End Item and Basic Issue Items List............................................................B-1

Appendix C References.................................................................................................................................C-1
TM 5-3805-280-10

x

WARRANTY

1. General. This section explains the contractor’s warranty for the Hydraulic Excavator (HYEX),

including all of its components and subassemblies. It also contains information, instructions, methods

and forms required to obtain services and/or supplies and for processing claims for items covered

under warranty for the HYEX. If additional warranty information is required for the HYEX, contact

your local Warranty Control Office/Officer (WARCO) or TACOM-WRN Logistics Assistance

Representative (LAR). If your WARCO or TACOM LAR is not available, contact TACOM-WRN.

The numbers at TACOM to call are DSN 786-7215/(810) 574-7215, DSN 786-7420/(810) 574-7420,

or DSN 786-8297/(810) 574-8297. The caller should be prepared to provide: (1) name, (2) telephone

number and/or electronic address, (3) complete unit designation, (4) identification of the vehicle to

include serial number(s) and (5) a brief description of the problem.

2. Coverage Specific. The information and data contained in this Technical Manual applies to the U.S.

Army’s Hydraulic Excavator (HYEX), model number 230LCR, NSN 3805-01-463-0804 and model

number 230LCRD, NSN 3805-01-463-0806. The HYEX is manufactured by Deere & Company,

Moline, IL under contract number DAAE07-98-D-S009.

3. Claim Procedures. DA Form 2407, along with information and instructions provided by the

contractor at time of delivery of the HYEX, shall be used to process warranty claims.

4. Claim Denial/Disputes. All denials or disputes will be handled by TACOM. The contact point for

warranty claim denials or disputes is:

Commander

U.S. Army Tank-Automotive and Armaments Command

ATTN: AMSTA-LC-CJBB

Warren, MI 48397-5000

Telephone: DSN 786-5314

 Commercial: (810) 574-5314

5. Local WARCO. Upon completion of warranty actions by the contractor, the WARCO shall complete

and provide a copy of DA Form 2407 to TACOM for information and warranty tracking purposes

only. NOTE: The DA Form 2407 shall be stamped or otherwise clearly marked "FOR

INFORMATION ONLY". Send the completed DA Form 2407 to:

Commander

U.S. Army Tank-Automotive and Armaments Command

ATTN: AMSTA-LC-CJCB

Warren, MI 48397-5000

Telephone: DSN 786-7215

 Commercial: (810) 574-7215

Forms may also be faxed to TACOM. Fax the forms to: DSN 786-5605, Commercial - (810) 574-

5605. Include ATTN: AMSTA-LC-CJCB on all related materials being faxed to TACOM.
TM 5-3805-280-10

xi

INTRODUCTION

READ THIS MANUAL carefully to learn how

to operate and service your machine

correctly. Failure to do so could result in

personal injury or equipment damage. This

manual and safety signs on your machine

may also be available in other languages.

(See your John Deere dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED

a permanent part of your machine and

should remain with the machine when you

sell it.

MEASUREMENTS in this manual are given

in both metric and customary U.S. unit

equivalents. Use only correct replacement

parts and fasteners. Metric and inch

fasteners may require a specific metric or

inch wrench.

RIGHT-HAND AND LEFT-HAND sides are

determined by facing in the direction of

forward travel.

GROUP NUMBERS (e.g., GRP NO. XXXX)

following maintenance task titles in the

Table of Contents refer to the John Deere

Functional Group Coding system.

WARRANTY is provided as part of John

Deere’s support program for customers who

operate and maintain their equipment as

described in this manual. The warranty is

explained on the warranty certificate, which

you should have received from your dealer.

This warranty provides you the assurance

that John Deere will back its products where

defects appear within the warranty period. In

some circumstances, John Deere also

provides field improvements, often without

charge to the customer, even if the product

is out of warranty. Should the equipment be

abused, or modified to change its

performance beyond the original factory

specifications, the warranty will become void

and field improvements may be denied.

Setting fuel delivery above specifications or

otherwise overpowering machines will result

in such action.

CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and

other reproductive harm.
TM 5-3805-280-10

BLANK

xii
CHAPTER 1

SAFETY AND SAFETY SIGNS

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
TX,05,DH5854 –19–15AUG97–1/1

T111123 –19–14AUG97

1-1
Safety

DX,ALERT –19–03MAR93–1/1

RECOGNIZE SAFETY INFORMATION

T81389 –UN–07DEC88

This is the safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the

potential for personal injury.

Follow recommended precautions and safe operating

practices.

DX,SIGNAL –19–03MAR93–1/1

UNDERSTAND SIGNAL WORDS

TS187 –19–30SEP88

A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the

most serious hazards.

DANGER or WARNING safety signs are located near

specific hazards. General precautions are listed on

CAUTION safety signs. CAUTION also calls attention to

safety messages in this manual.

TX,05,DY336 –19–15MAY96–1/1

FOLLOW SAFETY INSTRUCTIONS

TS201 –UN–23AUG88

Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good

condition. Replace missing or damaged safety signs. Be

sure new equipment components and repair parts include

the current safety signs.

Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without

instruction.

Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the

function and/or safety and affect machine life.

TM 5-3805-280-10

1-2
Safety

TX,05,FF1808 –19–28JUN90–1/1

AVOID INJURY FROM:

LOADING MACHINE ON A TRAILER,

FASTENING MACHINE TO TRAILER,

UNLOADING MACHINE FROM TRAILER

----------------------------------

ALWAYS USE CAUTION WHEN LOADING

AND UNLOADING MACHINES ON A TRAILER

----------------------------------

ALWAYS KNOW AND FOLLOW THE

RECOMMENDED PROCEDURES FOR THE

MACHINE, BECAUSE ALL MACHINES ARE

NOT LOADED, FASTENED, AND UNLOADED

THE SAME WAY

----------------------------------

ALWAYS KEEP BYSTANDERS CLEAR OF

THE AREA

T8513AB –UN–28JUN95 T7405BJ –UN–29NOV90

To avoid injury:

Keep the trailer bed clean.

Park the trailer on a firm, hard, level surface that will not

give way when the weight of the machine is on the trailer.

Put chock blocks against truck wheels.

Use a ramp or loading dock. Ramps must be strong

enough to adequately handle the load and have a low

angle and correct height.

If machine is equipped with a seatbelt, fasten it before

starting the engine.

Drive machine on or off the ramp slowly.

fasten chains or cables to machine tracks or track chain

links. Do not place chains or cable over or against

hydraulic lines or hoses.

TM 5-3805-280-10

1-3
Safety

TX,05,DY337 –19–15MAY96–1/1

AVOID INJURY FROM BACKOVER

ACCIDENTS

----------------------------------

BEFORE MOVING MACHINE, BE SURE ALL

PERSONS ARE CLEAR OF AREA

----------------------------------

ALWAYS BE ALERT FOR BYSTANDERS

MOVING INTO THE WORK AREA. USE HORN

OR OTHER SIGNAL TO WARN BYSTANDERS

BEFORE MOVING MACHINE

----------------------------------

WHEN USING A SIGNAL PERSON, KEEP

PERSON IN VIEW AT ALL TIMES, BE SURE

SIGNAL PERSON IS CLEAR BEFORE

BACKING UP

T7241AY –UN–21FEB90

To avoid backover accidents:

Always look around before you back up. Be sure that

everyone is in the clear.

Keep travel alarm in working condition.

Use a signal person when backing up if view is

obstructed. Always keep signal person in view.

Learn the meaning of all flags, signs, and markings used

on the job and who has the responsibility for signaling.

Keep windows, mirrors, and lights clean and in good

condition.

Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.

Read and understand the operating instructions in this

operator’s manual.

TM 5-3805-280-10

1-4
Safety

TX,05,FF2433 –19–22MAY91–1/1

AVOID INJURY FROM ROLLAWAY

ACCIDENTS

--------------------------------

TO PREVENT ROLLAWAY, ALWAYS MAKE

SURE MACHINE IS PROPERLY SECURED

BEFORE LEAVING OPERATOR’S SEAT

--------------------------------

DEATH OR SERIOUS INJURY MAY RESULT

IF YOU ATTEMPT TO MOUNT OR STOP A

MOVING MACHINE

T7241AZ –UN–21FEB90

To avoid rollaways:

Select level ground when possible to park machine.

Pull pilot control shut-off lever to locked position.

Lower all equipment to ground.

Stop the engine.

Block all tracks if you must park on a grade. Position

machine to prevent rolling.

Park a reasonable distance from other machines.

Read and understand the operating instructions in this

operator’s manual.

T82,BHSA,CL –19–14MAR90–1/1

INSPECT MACHINE

T6607AQ –UN–18OCT88

Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection

Chapter.)

TM 5-3805-280-10

1-5
Safety

TX,05,DH832 –19–16MAR92–1/1

USE HANDHOLDS AND STEPS

T6981AN –UN–15JUN89

Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a

three point contact with the steps and handrails and face

the machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount or

dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.

TX,05,DH3732 –19–18AUG95–1/1

USE SEAT BELT

TS175 –UN–23AUG88

Always use the seat belt when operating your machine.

TM 5-3805-280-10

1-6
Safety

TX,05,DH3729 –19–09AUG95–1/1

MAINTAIN SEAT BELT

Keep the seat belt in good condition.

The complete seat belt assembly should be replaced

after three years of usage, regardless of appearance.

Between replacement intervals:

Carefully examine buckle, webbing, and attaching

hardware.

Be sure that the retractor, if equipped, locks to prevent

belt extension after latching buckle.

Be sure that attaching hardware is in place. Tighten, if

necessary.

Replace the seat belt if it does not operate properly, or if it

is damaged, worn, or deteriorated.

TX,05,FF1806 –19–05OCT90–1/1

MOVE AND OPERATE MACHINE SAFELY

T7273AL –UN–08JUN90

Bystanders can be run over. Know the location of

bystanders before moving, swinging, or operating the

machine.

Always keep the travel alarm in working condition. It

warns people when the machine starts to move.

Use a signal person when moving, swinging, or operating

the machine in congested areas. Coordinate hand signals

before starting the machine.

TM 5-3805-280-10

1-7
Safety

TX,05,FF1615 –19–14JUN90–1/1

OPERATE ONLY FROM OPERATOR’S SEAT

T6607AO –UN–18OCT88

Avoid possible injury or machine damage. Do not start

engine by shorting across starter terminals.

NEVER start engine while standing on ground. Start

engine only from operator’s seat.

TX,05,DH5848 –19–13AUG97–1/1

SECONDARY EXITS

Machines equipped with cabs are equipped with

secondary exits. For additional secondary exit information,

see the topics ”Secondary Exit Tool” and ’Opening Upper

Front (Secondary Exit) Window’ in chapter 10 of this

manual.

TX,05,DH3730 –19–09AUG95–1/1

OPERATE MACHINE SAFELY

T7252AL –UN–08JUN90

Clear all persons from area of operation and machine

movement.

Use your seat belt.

Make sure the work site footing has sufficient strength to

firmly support the machine. When working close to an

excavation, position machine with propel motors at the

rear.

Be cautious of tipping when working on frozen ground.

Temperature increases will cause ground to become soft,

making ground unstable.

When digging deep, avoid hitting bottom of boom or

bucket cylinder hoses against the ground.

Use the bucket only for digging. Do not use it as a jack

hammer or wrecking ball.

TM 5-3805-280-10

1-8
Safety

05,RR,592 –19–12JUN90–1/1

DIG WITH CAUTION

T7252AJ –UN–08JUN90

Before digging, check the location of cables, gas lines,

and water lines.

TX,05,RR,602 –19–26FEB91–1/1

OPERATE WITH CAUTION

T7286AJ –UN–08JUN90

Avoid contact of boom or arm and overhead obstacles

when you operate the machine.

TX,05,DH3731 –19–09AUG95–1/1

AVOID TIPPING

T7273AE –UN–08JUN90

Use your seat belt.

When operating on a slope, keep bucket low to ground

and close to machine. Point tracks uphill.

Avoid tipping the machine when swinging heavy loads.

Reduce swing speed as necessary.

Be cautious of tipping when working on frozen ground.

Temperature increases will cause ground to become soft

and make ground travel unstable.

TM 5-3805-280-10

1-9
Safety

TX,05,RR,594 –19–12JUN90–1/1

AVOID POWER LINES

T7273AD –UN–08JUN90

Serious injury or death can result from contact with

electric lines.

Never move any part of the machine or load closer to

electric line than 3 m (10 ft) plus twice the line insulator

length.

TX,05,DH3733 –19–09AUG95–1/1

DRIVE MACHINE SAFELY

T7273AG –UN–08JUN90

Use your seat belt.

Before moving machine, find out which way to move

propel pedals/levers for the direction you want to go.

Pushing down on the front of the propel pedals or pushing

the levers moves the machine towards the idlers.

Keep the bucket on the uphill side, approximately 30 cm

(12 in.) (A) above ground, when going up or down hill. If

machine starts to slip or become unstable, lower the

bucket immediately.

02T,05,J9 –19–07JAN91–1/1

BEWARE OF EXHAUST FUMES

T6458AO –UN–18OCT88

Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.

If you must operate in a building, be positive there is

adequate ventilation. Either use an exhaust pipe extension

to remove the exhaust fumes or open doors and windows

to bring enough outside air into the area.

TM 5-3805-280-10

1-10
Safety

TX,05,DH5002 –19–28MAY96–1/1

PARK MACHINE SAFELY

Before working on the machine:

• Park machine on a level surface.

• Lower bucket to the ground.

• Turn auto-idle switch off.

• Run engine with engine rpm dial at 1/3 position for 2

minutes.

• Move engine rpm dial to slow idle position.

• Turn key switch to OFF. Remove key from switch.

• Pull pilot control shut-off lever to locked position.

• Allow engine to cool.

TX,05,RR,560 –19–05OCT90–1/1

KEEP RIDERS OFF MACHINE

T7273AH –UN–08JUN90

Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the

machine. Riders also obstruct the operator’s view resulting

in the machine being operated in an unsafe manner.

TM 5-3805-280-10

1-11
Safety

TX,05,FF2883 –19–29OCT92–1/1

OPERATE ATTACHMENT SAFELY

An attachment may change the capabilities of your

machine in any or all of these ways:

• Safe range of motion

• Machine stability

• Hydraulic performance

• Engine performance

Read the attachment manual to learn how the attachment

works.

In an area free of bystanders and obstructions, carefully

operate the attachment to learn the available range of

motion. Anticipate how objects manipulated by the

attachment, or the attachment itself, may contact the

machine, especially the operator’s station. Consider

adding guards to the machine to protect the operator, and

if necessary, to prevent damage to machine.

See your dealer to match attachment demands to

machine performance.

TX,05,FF1622 –19–14JUN90–1/2

HANDLE FLUIDS SAFELY—AVOID FIRES

TS202 –UN–23AUG88

Handle fuel with care; it is highly flammable. Do not refuel

the machine while smoking or when near open flame or

sparks. Always stop engine before refueling machine. Fill

fuel tank outdoors.

Continued on next page

TM 5-3805-280-10

1-12
Safety

TX,05,FF1622 –19–14JUN90–2/2TS227 –UN–23AUG88

Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

spontaneously.

DX,FIRE2 –19–03MAR93–1/1

PREPARE FOR EMERGENCIES

TS291 –UN–23AUG88

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

DX,FIRE3 –19–16APR92–1/1

HANDLE STARTING FLUID SAFELY

TS1356 –UN–18MAR92

Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep

starting fluid away from batteries and cables.

To prevent accidental discharge when storing the

pressurized can, keep the cap on the container, and store

in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

TM 5-3805-280-10

1-13
Safety

02T,05,J33 –19–14MAR90–1/1

CLEAN TRASH FROM MACHINE

T6669AG –UN–18OCT88

Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.

Temperature in engine compartment may go up

immediately after engine is stopped. BE ON GUARD FOR

FIRES DURING THIS PERIOD.

Open access door(s) to cool the engine faster, and clean

engine compartment.

TX,05,FF1613 –19–14JUN90–1/1

PROTECT AGAINST FLYING DEBRIS

T6642DK –UN–18OCT88

Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.

DX,WEAR2 –19–03MAR93–1/1

WEAR PROTECTIVE CLOTHING

TS206 –UN–23AUG88

Wear close fitting clothing and safety equipment

appropriate to the job.

Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones

while operating machine.

TM 5-3805-280-10

1-14
Safety

DX,NOISE –19–03MAR93–1/1

PROTECT AGAINST NOISE

TS207 –UN–23AUG88

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or

uncomfortable loud noises.

TX,05,DH2500 –19–02OCT92–1/1

HANDLE CHEMICAL PRODUCTS SAFELY

TS1132 –UN–26NOV90

Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with

your machine include such items as lubricants, coolants,

paints, and adhesives.

A Material Safety Data Sheet (MSDS) provides specific

details on chemical products: physical and health hazards,

safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a

hazardous chemical. That way you will know exactly what

the risks are and how to do the job safely. Then follow

procedures and recommended equipment.

See your authorized dealer for MSDS’s on chemical

products used with your machine.

TM 5-3805-280-10

1-15
Safety

TX,05,RR,566 –19–23JUL91–1/1

WARN OTHERS OF SERVICE WORK

T7273AP –UN–08JUN90

Unexpected machine movement can cause serious injury.

Before performing any work on the machine, attach a ’Do

Not Operate’ tag on the right control lever.

TX,05,RR,572 –19–12JUN90–1/1

STAY CLEAR OF MOVING PARTS

T7273AS –UN–08JUN90

Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working around

rotating parts.

TM 5-3805-280-10

1-16
Safety

DX,LOWER –19–04JUN90–1/1

SUPPORT MACHINE PROPERLY

TS229 –UN–23AUG88

Always lower the attachment or implement to the ground

before you work on the machine. If you must work on a

lifted machine or attachment, securely support the

machine or attachment.

Do not support the machine on cinder blocks, hollow tiles,

or props that may crumble under continuous load. Do not

work under a machine that is supported solely by a jack.

Follow recommended procedures in this manual.

DX,RCAP –19–04JUN90–1/1

SERVICE COOLING SYSTEM SAFELY

TS281 –UN–23AUG88

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough

to touch with bare hands. Slowly loosen cap to first stop

to relieve pressure before removing completely.

TM 5-3805-280-10

1-17
Safety

TX,05,DH5001 –19–28MAY96–1/1

PRACTICE SAFE MAINTENANCE

TS218 –UN–23AUG88

Understand service procedure before doing work. Keep

area clean and dry.

Never lubricate or service machine while it is moving.

Keep hands, feet and clothing from power-driven parts.

Before servicing machine.

• Park machine on a level surface.

• Lower bucket to the ground.

• Turn auto-idle switch off.

• Run engine with engine rpm dial at 1/3 speed for 2

minutes.

• Move engine rpm dial to slow idle position.

• Turn key switch to OFF. Remove key from switch.

• Attach a ’Do Not Operate’ tag on the right side

controller lever.

• Pull pilot control shut-off lever to locked position.

• Allow engine to cool.

If maintenance procedure must be performed with engine

running, do not leave machine unattended.

Securely support any machine elements that must be

raised for service work. Never work under a machine

raised by the boom. If the machine must be raised, keep

a 90-110° angle between boom and arm.

Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before making

adjustments on electrical systems or welding on machine.

TM 5-3805-280-10

1-18
Safety

DX,PAINT –19–03MAR93–1/1

REMOVE PAINT BEFORE WELDING OR

HEATING

TS220 –UN–23AUG88

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area. Dispose of

paint and solvent properly.

Remove paint before welding or heating:

• If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

• If you use solvent or paint stripper, remove stripper with

soap and water before welding. Remove solvent or

paint stripper containers and other flammable material

from area. Allow fumes to disperse at least 15 minutes

before welding or heating.

DX,TORCH –19–03MAR93–1/1

AVOID HEATING NEAR PRESSURIZED FLUID

LINES

TS953 –UN–15MAY90

Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to

yourself and bystanders. Do not heat by welding,

soldering, or using a torch near pressurized fluid lines or

other flammable materials. Pressurized lines can be

accidentally cut when heat goes beyond the immediate

flame area.

TM 5-3805-280-10

1-19
Safety

DX,FLUID –19–03MAR93–1/1

AVOID HIGH-PRESSURE FLUIDS

X9811 –UN–23AUG88

Escaping fluid under pressure can penetrate the skin

causing serious injury.

Avoid the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten all

connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a

few hours or gangrene may result. Doctors unfamiliar with

this type of injury should reference a knowledgeable

medical source. Such information is available from Deere

& Company Medical Department in Moline, Illinois, U.S.A.

DX,SPARKS –19–03MAR93–1/1

PREVENT BATTERY EXPLOSIONS

TS204 –UN–23AUG88

Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object

across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).

TM 5-3805-280-10

1-20
Safety

TX,05,FF2787 –19–27JUL94–1/1

CLEAN THE MACHINE REGULARLY

T6642EJ –UN–18OCT88

Remove any grease, oil, fuel, or debris build-up to avoid

possible injury or machine damage.

High pressure washing [greater than 1379 kpa (13.8 bar)

(200 psi)] can damage freshly painted finishes. Paint

should be allowed to air dry for 30 days minimum after

receipt of machine before cleaning with high pressure.

Use low pressure wash operations until 30 days have

elapsed.

Do not spray oil cooler fins at an angle. Fins may bend.

TX,05,RR,576 –19–26APR90–1/1

STORE ATTACHMENTS SAFELY

TS219 –UN–23AUG88

Stored attachments such as buckets, hydraulic hammers,

and blades can fall and cause serious injury or death.

Securely store attachments and implements to prevent

falling. Keep playing children and bystanders away from

storage area.

TM 5-3805-280-10

1-21
Safety

CED,OUOE042,44 –19–19OCT99–1/1

BATTERY TERMINALS, LIFTING

EQUIPMENT, DRY CLEANING SOLVENT AND

COMPRESSED AIR

WARNING: Avoid possible injury. Disconnect the

negative terminal first and reconnect the negative

terminal last when disconnecting/reconnecting battery

terminals.

WARNING: When lifting equipment, ensure that the

lifting device is capable of supporting the desired

weights and the inspection date stamped on the lifting

device has not expired.

WARNING: Dry cleaning solvent PD-680 Type III is

toxic and flammable. Wear protective goggles and

gloves and use only in a well ventilated area. Avoid

contact with skin, eyes, and clothes and don’t breathe

vapors. Do not use near open flames or excessive

heat. The flash point is 200°F (93°C). If you become

dizzy while using solvent, get fresh air immediately

and get medical aid. If contact with eyes is made,

wash your eyes with water and get medical aid

immediately.

WARNING: Compressed air used for cleaning

purposes shall not exceed 30 psi. Use only with

effective chip guarding and personnel protective

equipment (goggles/shield/gloves, etc.).

TM 5-3805-280-10

1-22
Safety

TX,05,DH2502 –19–26AUG92–1/1

DISPOSE OF WASTE PROPERLY

TS1133 –UN–26NOV90

Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used

with your machine include such items as oil, fuel, coolant,

brake fluid, filters, and batteries.

Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone

into drinking from them.

Do not pour waste onto the ground, down a drain, or into

any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations

may require a certified air conditioning service center to

recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from

your authorized dealer.

TM 5-3805-280-10

1-23
Safety

DRILLING

Before starting work, the operator will make sure

there are no buried electrical, gas, water or other

pipes or lines.

Always be aware of previously drilled holes, and

where they are located : any open hole can cause severe injury to the operator or someone else. The loss

of tools, drill rods, drill bits or any other item can occur.


 $ "   !  #

 

   #   

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" 



When rising the guide, take care of any overhead

lines.

Always maintain a minimum distance of 25 Ft.

(7.6 m) distance between the machine and any

overhead lines during any operation.

The operator will make sure that everybody

stands clear from the machine in operation and stays

at a distance of 7 meters (25 ft.).

Nevertheless, some operations may need people

to enter the restricted area (checking of coupling temperature during feed thrust adjustment for instance).

On such an occasion :

 the operator must supervise, from the cabin,

the safety of the service man doing the work. He must

be ready to activate the cabin emergency stop if need

be.

 communication must be established in a reliable manner.

Make sure any hand signal will be perfectly

understood.

 the operator must make sure the following

safety decal is affixed on the drill guide to warn the

service man of risks incurred.



!     !

 #  


"#    ! 

     

#

 the service man must be informed about the

use of the emergency stop mounted on the guide.

Always have the cabin door closed and the dust

collector running when drilling to prevent respiratory

damage.

Keep all work areas clean and orderly.

ROCK DRILL MAINTENANCE

Keep hands, arms, legs and clothing away from

moving or rotating parts.

Only use genuine replacement parts.

 Stopping the drill for maintenance or bit change etc...

Prior to leaving the operators compartment, the

excavators hydraulic safety arm must be raised to

lock in the machines safety switch. This renders all

controls inoperable thus preventing any unwanted

movement.

Hydraulic cylinder

The hydraulic cylinder is equipped with 2 load–

sustaining valves.

The load–sustaining valves allow the disconnecting of the hydraulic hoses from the cylinder if they

need to be changed. But :

TM 5-3805-280-10

1-24
Safety



 Never disconnect a valve from the cylinder

without supporting the controlled element (drill

guide ...).

Burn prevention

At operating temperature, the hydraulic tank, circuit and components are hot and can be under pressure. Any contact can cause severe burns.

Always release the pressure and wait for cooling before intervening on the hydraulic circuit.

 	

	 	 

  

	  	

 	




Fire prevention

Fuel or hydraulic oil leaked or spilled onto hot surfaces or electrical components can cause a fire.

Repair immediately any leaks.

Regularly clean the machine to remove all flammable materials such as fuel, oil and other debris.

Always use approved safety solvent when cleaning parts or the machine.

Have all loose electrical wires connected and tight

before operating the machine.

Prior to any welding operation, make sure that the

surfaces and their environment are free of flammable

debris.

Respiratory damage prevention

Dust coming out from the dust collector fan indicates that one or several filter elements are damaged.

Change the damaged elements immediately.

Always dismount all the filters elements to check

the functioning of the automatic filter cleaning sequence.

Compressed air

Compressed air can be dangerous.

Never point an air hose at yourself or co–workers.

Be sure all hoses and fittings are tightly secured.

A loose hose not only leaks but can come completely off and while whipping under pressure, can

injure the operator and others in the area.

Never disconnect a pressurized air hose.



 	 	 


  	 	 	 

  
    
 




   


 	
 


  

EMERGENCY STOPS

The CPA remote control assembly incorporates

an emergency stops selector with allows to connect

the CPA emergency stops to the machine circuit.

 

– When the CPA is installed, place the selector on position A to have the CPA emergency stops

active.

– Place the selector on position B to refind the

normal excavator safety circuit when the CPA is not

used.

TM 5-3805-280-10

1-25
Safety

The CPA safety circuit incorporates 2 emergency

stops.

One mushroom type push–button is located in the

cabin on the remote control panel.

Pressing on this button shuts down the engine.

Unlock the knob by pulling it up to be in position to

restart the engine.

wire

The second emergency stop is located on the

guide rail, and stops the engine when pulling on the

wire attached along the guide.

To unlock the safety device and be in position to

restart the engine, press on the button.

WARNING: Take all necessary steps to safely

start the engine after emergency stop.

TM 5-3805-280-10

1-26
Safety Signs

TX,06,DH5564 –19–22MAR99–1/11

SAFETY SIGNS

T125071 –UN–28OCT99

Caution Decal (Model 230LCR)

T125070 –UN–28OCT99

Caution Decal (Model 230LCRD)

T125069 –UN–28OCT99

Caution Decal Location

Continued on next page

TM 5-3805-280-10

1-27
Safety Signs

TX,06,DH5564 –19–22MAR99–2/11

T7748CZ –19–14OCT92

T101484 –UN–27JUN96

A—Danger Decal Location

Continued on next page

TM 5-3805-280-10

1-28
Safety Signs

TX,06,DH5564 –19–22MAR99–3/11

T7748DA –19–14OCT92

T101485 –UN–27JUN96

A—Warning Decal Location

Continued on next page

TM 5-3805-280-10

1-29
Safety Signs

TX,06,DH5564 –19–22MAR99–4/11

T102888 –19–23AUG96

A-Caution Decal

T101483 –UN–27JUN96

A—Caution Decal Location

Continued on next page

TM 5-3805-280-10

1-30
Safety Signs

TX,06,DH5564 –19–22MAR99–5/11

T7972AP –19–22MAR93

T108112B –UN–27MAR97

Continued on next page

TM 5-3805-280-10

1-31
Safety Signs

TX,06,DH5564 –19–22MAR99–6/11

T7748DC –19–14OCT92

T8167AL –UN–06FEB94

A—Warning Decal Location

TX,06,DH5564 –19–22MAR99–7/11

T7748CX –19–14OCT92T7748DH –UN–15OCT92

Continued on next page

TM 5-3805-280-10

1-32
Safety Signs

TX,06,DH5564 –19–22MAR99–8/11

T7900AB –19–03DEC92

T7748DK –UN–22OCT92

TX,06,DH5564 –19–22MAR99–9/11

T101279 –19–14MAY96

T7869BZ –UN–05NOV92

A—Caution Decal Location

Continued on next page

TM 5-3805-280-10

1-33
Safety Signs

TX,06,DH5564 –19–22MAR99–10/11

T6888AC –19–06JAN89

Decal is located on top of each battery.

Continued on next page

TM 5-3805-280-10

1-34
Safety Signs

TX,06,DH5564 –19–22MAR99–11/11

T120457 –19–25MAR99

TM 5-3805-280-10

1-35
Safety Signs

Look for these signs on machine, which points out potential hazards to the safety of you and others. Read and

understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your

supervisor.

Indicates the presence of a hazard which WILL cause serious

injury, death or property damage, if ignored.

Indicates the presence of a hazard which CAN cause serious

injury, death or property damage, if ignored.

Indicates the presence of a hazard which WILL or can cause

injury or property damage, if ignored.

Indicates important set-up, operating or maintenance

information.

TM 5-3805-280-10

1-36
TM 5-3805-280-10

1-37
TM 5-3805-280-10

BLANK

1-38
CHAPTER 2

OPERATOR’S STATION

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Operator’s Station

CED,OUOE042,5058 –19–14APR99–1/1

PEDALS, LEVERS AND PANELS

T121034 –UN–29OCT99

A—Left Control Lever/Horn Switch (On Top of

Lever)

B—Left Travel Pedal

C—Left Travel Lever

D—Right Travel Lever

E—Right Travel Pedal

F—Right Control Lever/Power Boost Switch (On

Top of Lever)

G—Front Right Panel

H—Right Console Panel

I—Air Conditioner Panel—If Equipped

J—Cab Door Release Lever

K—Radio

L—Left Console Panel

M—Pilot Control Shut-Off Lever

N—Hydraulic Thumb Pedal (Model 230LCR)

O—Rock Drill Control Panel (Model 230LCRD)

TM 5-3805-280-10

2-1
Operator’s Station

TX,10,DH5708 –19–21APR97–1/1

RIGHT FRONT PANEL AND RIGHT CONSOLE

PANEL

T121035 –UN–14APR99

A—Monitor Panel

B—Switch Panel

C—Ash Tray

D—Cigar Lighter

E—Air Conditioner Panel-If Equipped

F—Engine RPM Dial

G—E (Economy) Mode Switch

H—H/P (High Power) Mode Switch

I—Key Switch

J—Rear Light Switch

K—Overload Alarm/Indicator

L—Arctic Heater Switch

M—Arctic Heater Indicator

TM 5-3805-280-10

2-2
Operator’s Station

CED,OUOE020,15 –19–03MAR99–1/1

MONITOR PANEL

T120386 –UN–25MAR99

A—Engine Coolant Temperature Gauge

B—Warm-up Indicator

C—Fuel Gauge

D—H/P (High Power) Mode Indicator

E—E (Economy) Mode Indicator

F—Auto-Idle Indicator

G—Hydraulic Oil Filter Restriction Indicator

(Model 230LCRD)

H—Hydraulic Oil Level Indicator

I—Fuel Level Indicator

J—Air Filter Restriction Indicator

K—Charge Air Temperature Indicator

L—Engine Coolant Temperature Indicator

M—Engine Oil Pressure Indicator

N—Alternator Voltage Indicator

O—Engine Oil Level Indicator

P—Engine Coolant Level Indicator

TM 5-3805-280-10

2-3
Operator’s Station

TX,10,DH5451 –19–25JUN96–1/1

ENGINE COOLANT TEMPERATURE GAUGE

T101569 –UN–11JUL96

IMPORTANT: If needle points to ’RED’ zone, idle

engine to bring back needle to ’GREEN’

zone before stopping engine. If needle

continues to rise, shut engine OFF.

TX,10,DH5453 –19–04MAR97–1/1

WARM-UP INDICATOR

T101574 –UN–11JUL96

Yellow indicator will turn off when the engine coolant

temperature reaches approximately 30°C (86°F).

TX,10,DH5454 –19–04JUN96–1/1

FUEL GAUGE

T101570 –UN–11JUL96

Fuel machine before needle reaches “E”.

TX,10,DH5455 –19–11JUL96–1/1

H/P (HIGH POWER) MODE INDICATOR

T101571 –UN–11JUL96

Green indicator will light when the H/P mode switch is

turned on.

TM 5-3805-280-10

2-4
Operator’s Station

TX,10,DH5456 –19–17JUN96–1/1

E (ECONOMY) MODE INDICATOR

T101572 –UN–11JUL96

Green indicator will light when the E mode switch is

turned on.

TX,10,DH5457 –19–17JUN96–1/1

AUTO-IDLE INDICATOR

T101573 –UN–11JUL96

Green indicator will light when the auto-idle switch is

turned on.

TX,10,DH5458 –19–04JUN96–1/1

HYDRAULIC OIL LEVEL INDICATOR

T101577 –UN–27JUN96

Park machine on level ground.

Position machine with arm cylinder fully retracted and

bucket cylinder fully extended.

Pressing the level check switch before starting the

machine will turn the indicator on if oil level is adequate

for operation.

NOTE: This check does NOT take the place of daily

inspection.

TM 5-3805-280-10

2-5
Operator’s Station

CED,OUOE020,16 –19–03MAR99–1/1

HYDRAULIC OIL FILTER RESTRICTION

INDICATOR (MODEL 230LCRD)

T8381AG –UN–03JAN95

IMPORTANT: Prevent possible hydraulic pump

damage. Change hydraulic oil filter as

soon as possible when a problem

occurs.

Indicator light will light and service required indicator light

will light when filter elements are restricted. Change filter

elements.

NOTE: Cold oil may cause hydraulic oil filter restriction

indicator light to light temporarily.

TX,10,DH5459 –19–25JUN96–1/1

FUEL LEVEL INDICATOR

T101578 –UN–27JUN96

When red fuel indicator lights, approximately 30 liters (8

gal.) of fuel remain.

TX,10,DH5460 –19–04JUN96–1/1

AIR FILTER RESTRICTION INDICATOR

T101580 –UN–27JUN96

Red indicator will light when the air filter elements are

clogged. Clean or replace elements.

TM 5-3805-280-10

2-6
Operator’s Station

TX,10,DH5461 –19–04JUN96–1/1

ENGINE COOLANT TEMPERATURE

INDICATOR

T101581 –UN–11JUL96

IMPORTANT: Do not stop engine when coolant

temperature light comes on or

temperature will rise further. Reduce

load and run engine at slow idle. If

temperature light continues to stay ON,

shut engine OFF.

Red indicator will light and buzzer will sound when the

engine coolant overheats. Reduce load immediately and

run engine at slow idle. Inspect for debris around radiator.

Check for low coolant level in the radiator recovery tank.

TX,10,DH5712 –19–21APR97–1/1

CHARGE AIR TEMPERATURE INDICATOR

T107672 –UN–27FEB97

IMPORTANT: Prevent possible engine damage. If

charge air indicator light comes on

while operating, stop engine.

Red indicator will light when air intake temperature is

excessively high. Stop engine. Check for debris on charge

air cooler inlet screens. Check fan for proper operation. A

clogged charge air system will reduce engine

performance.

TM 5-3805-280-10

2-7
Operator’s Station

TX,10,DH5462 –19–04JUN96–1/1

ENGINE OIL PRESSURE INDICATOR

T101579 –UN–27JUN96

IMPORTANT: If engine oil pressure light comes on

while operating, stop engine

immediately.

Red indicator will light and buzzer will sound when engine

oil pressure is low. Stop engine immediately.

NOTE: Cold oil, low oil level, or extreme off level

operation may cause indicator to light.

TX,10,DH5463 –19–09APR92–1/1

ALTERNATOR VOLTAGE INDICATOR

T101582 –UN–27JUN96

Indicator will light with no alternator output. Check

electrical system.

TX,10,DH5464 –19–18JUN96–1/1

ENGINE OIL LEVEL INDICATOR

T101575 –UN–27JUN96

Pressing the level check switch before starting the

machine will turn the indicator on if oil level is adequate

for operation.

NOTE: This check does NOT take the place of daily

inspection.

TM 5-3805-280-10

2-8
Operator’s Station

TX,10,DH5465 –19–04JUN96–1/1

COOLANT LEVEL INDICATOR

T101576 –UN–27JUN96

Pressing the level check switch before starting the

machine will turn the indicator on if coolant level is

adequate for operation.

NOTE: This check does NOT take the place of daily

inspection.

TM 5-3805-280-10

2-9
Operator’s Station

TX,10,DH5466 –19–27FEB97–1/1

SWITCH PANEL

T107673 –UN–27FEB97

A—Level Check Switch

B—Attachment Mode Indicator

C—Precision Mode Indicator

D—Grading Mode Indicator

E—Dig Mode Indicator

F—Work Mode Switch

G—Buzzer Stop Switch

H—Propel Speed Switch

I—Auto-idle Switch

J—Wiper Switch

K—Washer Switch

L—Operating Lights Switch

TM 5-3805-280-10

2-10
Operator’s Station

TX,10,DH5832 –19–24JUL97–1/1

BUZZER AND BUZZER STOP SWITCH

T107674 –UN–27FEB97

THE BUZZER SOUNDS WHEN:

• Engine oil pressure is low (indicator light (C ) will also

light). If engine oil pressure is low, stop the engine

immediately.

NOTE: The buzzer cannot be turned off when engine oil

pressure is low.

• Engine coolant overheats (indicator light (B) will also

light). If coolant temperature is high, push buzzer stop

switch (A), reduce load immediately, and run engine at

decreased engine speed. If high temperature continues,

stop the engine. Check fluid levels.

When the buzzer stop switch is pushed and released the

buzzer stops sounding and the buzzer function is

automatically reset for the engine coolant overheat

function.

TO RESET THE BUZZER:

Turn the key switch to OFF. The buzzer will not sound

more than once for the same problem unless the switch is

reset.

TX,10,DH5468 –19–18JUN96–1/1

WIPER SWITCH

T101626 –UN–20JUN96

Wiper switch (A) has three positions.

• INT position.......Wiper starts operating intermittently.

• ON position........Wiper operates continuously

• OFF position.......Wiper automatically stops operating.

NOTE: The wiper and washer do not operate unless the

upper front window is closed and the right-side

lock pin is installed.

TM 5-3805-280-10

2-11
Operator’s Station

TX,10,DH5469 –19–04JUN96–1/1

WASHER SWITCH

T101627 –UN–20JUN96

IMPORTANT: Washer motor may be damaged if

washer switch is held down for more

than 20 seconds, or continually

operated with no fluid in container.

Push switch (A) to squirt windshield washer fluid on

windshield. Do not hold down switch for more than 20

seconds.

CED,OUOE042,23 –19–05MAR99–1/1

OPERATING LIGHTS SWITCH

T101591 –UN–27JUN96 T120793 –UN–25MAR99

Turn light switch (A) to first position to turn on light (C).

Turn light switch to second position to turn on lights (B

and C).

TM 5-3805-280-10

2-12
Operator’s Station

CED,OUOE042,19 –19–03MAR99–1/1

OPERATING REAR LIGHTS SWITCH

T120402 –UN–25MAR99

Move switch (A) to turn the rear outside work lights on or

off.

TX,10,DH5471 –19–18JUN96–1/1

CAB LIGHT

T101592 –UN–27JUN96

Move switch (A) to turn the inside cab light on or off.

CED,OUOE020,18 –19–03MAR99–1/1

OVERLOAD ALARM AND INDICATOR

T120413 –UN–25MAR99

The overload alarm and indicator (A) will activate when

the digging capacity is exceeded, while the machine is

digging from the side.

TM 5-3805-280-10

2-13
Operator’s Station

TX,10,DH5472 –19–29MAY96–1/1

KEY SWITCH

T7396DS –UN–27JUN91

A—Engine Off

B—Accessory

C—Engine On

D—Start

Engine will stop when key switch is turned from ON to

ACC. Always turn key to OFF position to prevent batteries

from draining.

TX,10,DH5473 –19–19JUN96–1/1

ENGINE RPM DIAL

T101628 –UN–20JUN96

Use engine rpm dial (A) to adjust engine speed. Turn dial

clockwise to increase engine speed or counterclockwise to

decrease engine speed.

TX,10,DH5591 –19–22MAR97–1/1

POWER BOOST SWITCH

T101633 –UN–20JUN96

Power boost switch (A) is located on top of right control

lever.

TM 5-3805-280-10

2-14
Operator’s Station

TX,10,DH5475 –19–04JUN96–1/1

HORN

T101634 –UN–20JUN96

Horn switch (A) is located on top of left control lever.

TX,10,DH5476 –19–24JUN96–1/1

HOUR METER

T101639 –UN–26JUN96

The right hand number on the hour meter (A) indicates

tenths of an hour (six minutes).

TM 5-3805-280-10

2-15
Operator’s Station

TX,10,DH5480 –19–19JUN96–1/1

CAB HEATER AND AIR CONDITIONER

T101645 –UN–20JUN96

A—Control Panel

B—Front Vent

C—Defroster Vent

D—Foot Vent

E—Rear Vents

TM 5-3805-280-10

2-16
Operator’s Station

TX,10,DH5481 –19–19JUN96–1/1

CONTROL PANEL SWITCHES

T102753 –UN–05AUG96

A—Mode Switch

B—Mode Switch

C—Mode Switch

D—Air Conditioner Switch

E—Air Vent Switch

F—Fresh Air Vent Switch

G—Blower Switches

H—Blower OFF Switch

I—Temperature Control Switches

Mode Switches

(A) Air flows out of front vent and defroster vent.

(B) Air flows out of front and rear vents, and defroster

vent.

(C) Air flows out of foot vent only.

Temperature Control Switches

Eight indicators are situated just above the temperature

control switches (I). The indicators will turn red when the

right arrow switch is pressed, and green when the left

arrow switch is pressed. Air temperature is highest if all

indicators are red, and coolest if all indicators are green.

Either warm or cool air will flow out of vent(s) selected by

the mode switches.

Blower Switches

Press blower switches (G) to select desired blower speed.

Air conditioner will turn on when A/C switch (D) is pressed

and any of the blower indicators is on. When blower OFF

switch (H) is pressed, the blower and the air conditioner

will turn off. The blower will turn on if one of the blower

switches is pressed whether the air conditioner switch is

turned on or off.

Fresh Air Vent Switch

Press fresh air vent switch (F) to route outside air into the

cab. Press air vent switch (E) to close fresh air vent and

circulate air already in cab.

TM 5-3805-280-10

2-17
Operator’s Station

TX,10,DH5633 –19–26MAR97–1/1

CAB HEATER OPERATION

T102753 –UN–05AUG96

1. Press desired mode switch (A, B, or C).

2. Press right temperature control switch (I) until all

indicators are red.

3. Press blower switch (G to select desired blower speed.

4. Press air conditioner switch (D) to turn indicator off if

not already off.

5. Press temperature control switches and blower

switches to adjust cab temperature

TX,10,DH5483 –19–20JUN96–1/1

AIR CONDITIONER OPERATION

T102753 –UN–05AUG96

1. Press desired mode switch (A, B, or C).

2. Press left temperature control switch (I) until all

indicators are green.

3. Press blower switch (G) to select desired blower

speed.

4. Press air conditioner switch (D) to turn indicator green

if not already green.

5. Press temperature control switches and blower

switches to adjust cab temperature

TM 5-3805-280-10

2-18
Operator’s Station

TX,10,DH5484 –19–20JUN96–1/1

DEFROSTER OPERATION

T102753 –UN–05AUG96

1. Press front vent mode switch (A) or rear vent mode

switch (B).

2. Press temperature control switches (I) to select desired

air temperature.

3. Press fresh air vent switch (F).

4. Press blower switches (G) to select desired blower

speed.

5. Adjust the louvers on front vent and defroster vent as

required.

6. Press temperature control switches and blower

switches to adjust cab temperature.

7. Press air conditioner switch (F) on if windows become

clouded or if dehumidifying is required.

TX,10,DH5485 –19–20JUN96–1/1

FRONT CONSOLE

T101647 –UN–07AUG96

A—Radio/Clock

TM 5-3805-280-10

2-19
Operator’s Station

TX,10,DH5486 –19–06JUN96–1/1

OPERATING THE AM/FM RADIO

T101691 –UN–24JUN96

A—Power Switch/Volume Control Knob

B—Tone Adjustment Ring

C—AM/FM Switch

D—Tuning Switches

E—Display Mode Change Switch

F—Station Presets

G—Digital Display

H—Set Switch

I—Time Set Switches

Press power switch (A) to turn radio on, and repeatedly

press one of tuning switches (D) until desired station is

reached. To preset a station, select the desired station

using tuning switches. Press and hold station preset (F)

for more than 2 seconds until an electronic tone is heard.

The frequency of the preset station will be indicated on

digital display (G).

TX,10,DH5487 –19–06JUN96–1/1

SETTING THE CLOCK

T101692 –UN–24JUN96

A—Display Mode Change Switch

B—Digital Display

C—Time Set Switches

D—Set Switch

NOTE: In order to set the clock, digital display (B) must

be in the time display mode.

While pressing display mode change switch (A) use time

set switches (C) and set switch (D) to set the clock.

Press set switch to reset the minute display to “00”.

Press time set switch (H) to set correct hour.

Press time set switch (M) to set correct minute.

TM 5-3805-280-10

2-20
Operator’s Station

TX,10,DH5488 –19–04JUN96–1/1

CAB DOOR RELEASE LEVER

T101648 –UN–07AUG96

The cab door can be locked in the open position. Open

the door all the way until it locks in the latch on the side of

the cab.

To release the door from this locked position, push down

on lever (A).

TX,10,DH5967 –19–26NOV96–1/1

SECONDARY EXIT TOOL

T105379 –UN–26NOV96

IMPORTANT: FOR SECONDARY EXIT. Use tool (A) to

break window. Always keep tool in

machine.

TX,10,DH5489 –19–04JUN96–1/2

OPENING UPPER FRONT (SECONDARY

EXIT) WINDOW

T101649 –UN–26JUN96

NOTE: The washer and wiper cannot operate with the

upper front window opened.

1. Move lock pins (A) toward center of window.

Continued on next page

TM 5-3805-280-10

2-21
Operator’s Station

TX,10,DH5489 –19–04JUN96–2/2T101650 –UN–24JUN96

2. Pull window up and back until it catches in latch (B) for

convenient storage overhead.

CAUTION: Prevent possible injury from window

closing. DO NOT rely on latch (B) alone to hold

the window in the up position. Always lock the

pins in the cab frame boss holes.

3. Slide the two pins (C) into the cab frame boss holes

and turn to lock.

TX,10,DH5490 –19–21JUN96–1/2

CLOSING UPPER FRONT WINDOW

T101649 –UN–26JUN96

CAUTION: Prevent possible injury from window

closing. Upper front window comes down very

forcefully. Close window only when sitting on

operator’s seat. Guide window down slowly.

1. Pull out lock pins (A) to unlock window.

TX,10,DH5490 –19–21JUN96–2/2T101650 –UN–24JUN96

2. Push lever (B) to release latch.

3. Pull window down slowly.

4. Slide the two pins (C) into the cab frame boss holes

and turn to lock.

TM 5-3805-280-10

2-22
Operator’s Station

TX,10,DH5491 –19–27FEB97–1/2

REMOVING AND STORING THE LOWER

FRONT WINDOW

T101651 –UN–24JUN96

NOTE: Upper front window must be raised before lower

front window can be removed.

1. Pull in on lock pins (A) to unlock and remove window.

TX,10,DH5491 –19–27FEB97–2/2T105380 –UN–26NOV96

2. The window can be stored by inserting tabs on bottom

of window into brackets (B) and locking the pins into

holes (C) located below rear window in cab.

NOTE: In cold weather some operators may choose to

work with the top glass open and the bottom glass

in place. This provides excellent visibility and

tends to hold the heat being circulated around the

operator’s feet.

TX,10,DH5492 –19–04JUN96–1/1

OPENING SIDE WINDOWS

T101653 –UN–24JUN96

CAUTION: Avoid serious crushing injury from

boom. Never place any part of body beyond

window bar 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 or bars

are missing or broken, replace immediately.

Both right side window and cab door window can be

opened.

1. Right-rear side window: Unlatch the lock (A). Push joint

part of lock to open window.

2. Cab door window: Slide front pane to the rear and rear

pane to the front.

TM 5-3805-280-10

2-23
Operator’s Station

TX,10,DH5944 –19–01DEC97–1/1

OPENING AND CLOSING THE ROOF EXIT

COVER

T101654 –UN–24JUN96

Opening:

1. Move lock pins (A) toward center of roof exit cover.

2. Push on handle (B) to open roof exit cover.

Closing:

Hold handle and pull cover down until pins lock in

position.

TX,OUOE042,10 –19–19FEB99–1/1

REMOVING AND STORING FIRE

EXTINGUISHER (MODEL 230LCR)

T120368 –UN–25MAR99

A—Latch Assembly

NOTE: On model 230LCRD the fire extinguisher is

mounted in the battery compartment.

REMOVING

1. Pull the latch (A) outward.

2. Remove extinguisher.

STORING

1. Insert extinguisher into the seat.

2. Close latch assembly (A).

TM 5-3805-280-10

2-24
Operator’s Station

CED,OUOEBAS,1 –19–19JAN00–1/1

ROCK DRILL START—STOP SELECTION

CONTROL BOX (MODEL 230LCRD)

T125072 –UN–28OCT99

A—Rock Drill Start—Stop Selection Control Box

B—Selector Switch

Set the selector switch (B) to the B position for normal

excavator operation.

Set the selector switch (B) to the A position to activate the

electrical and hydraulic circuits for the rock drill. When set

to the A position, all pilot hydraulics for the excavator are

neutralized.

TM 5-3805-280-10

2-25
Operator’s Station

CED,OUOE042,47 –19–19OCT99–1/1

COMPRESSOR REMOTE INSTRUMENT

CONTROL PANEL (MODEL 230LCRD)

T125073 –UN–28OCT99

A—Compressor Remote Instrument Control Panel

TX,OUOE042,11 –19–19FEB99–1/1

REMOVING AND STORING RIFLE

T120371 –UN–25MAR99

A—Latch

REMOVING

1. Open latch (A) and remove barrel.

2. Lift rifle from saddle.

STORING

1. Insert rifle butt into saddle.

2. Snap barrel into latch (A).

TM 5-3805-280-10

2-26
Operator’s Station

TX,OUOE042,12 –19–19FEB99–1/1

J-HOOKS

T120374 –UN–25MAR99

A—J-Hooks

The J-Hooks (A) are used to hang the operator’s Load

Bearing Equipment (LBE) and individual chemical

equipment bag.

TX,OUOE042,16 –19–01MAR99–1/1

TOOLBOX SECURITY HASP

T120370 –UN–25MAR99

A—Toolbox Security Hasp

The toolbox security hasp (A) is located on the inside

corner of the toolbox. The hasp is used to secure the

toolbox.

TM 5-3805-280-10

2-27
Operator’s Station

TX,OUOE042,17 –19–01MAR99–1/1

DECONTAMINATION KIT BRACKET

T120373 –UN–28OCT99

A—Decontamination Kit Bracket

B—Strap

The decontamination kit bracket (A) is located between

the toolbox and the boom. The decontamination kit is

secured with a strap (B).

TX,OUOE042,20 –19–04MAR99–1/1

VANDAL PROTECTION PANEL STORAGE

T120414 –UN–25MAR99 T120415 –UN–25MAR99

A—Knob

B—Storage Box

The upper section of the windshield panel stores on the

left front access door of the machine. Use knob (A) to

secure the panel to the door. The remaining panels store

in the box (B) atop the machine.

TM 5-3805-280-10

2-28
Operator’s Station

TX,10,DH5494 –19–29JUL96–1/1

ADJUSTING THE SEAT

T102204 –UN–26JUL96

A—Weight Adjustment Knob

B—Seat Height And Angle Adjustment

C—Console And Seat Fore-Aft Adjustment Lever

D—Seat Fore-Aft Adjustment

E—Backrest Adjustment

Turn knob (A) to adjust seat to weight of operator. Weight

is displayed on knob.

Push down lever (B) while sitting on seat or while

standing and pulling up on seat to obtain desired height.

Release lever. Push down lever while sitting on seat to

adjust seat to desired angle. Release lever.

Push down lever (C) to adjust seat and both right and left

consoles to desired distance from travel pedals and

levers. Release lever to lock seat and consoles into

position.

Pull up lever (D) to unlock seat from both consoles. Slide

the seat to desired distance from control levers. Release

lever.

Pull up lever (E) to release backrest lock. Move backrest

to desired position and release lever.

TM 5-3805-280-10

2-29
Operator’s Station

TX,10,DH5412 –19–27FEB97–1/1

ADJUSTING THE ARMREST

T107760 –UN–27FEB97

A—Armrest

B—Dial

Pull up on armrest (A) to move armrest out of way when

exiting.

Turn dial (B) to adjust angle of armrest.

TX,10,DH3548 –19–22MAR99–1/1

SEAT BELT

T8415AA –UN–09FEB95

Seat belt and mounting hardware must be inspected

for wear or damage before operating the machine.

Replace the belt or mounting hardware if worn or

damaged.

Replace the complete seat belt assembly every three

years regardless of appearance. A date label, to

determine the age of the belt, is attached to each belt.

TX,10,DH5064 –19–24JUN96–1/1

OPERATOR’S MANUAL COMPARTMENT

Store operator’s manual behind the seat.

TM 5-3805-280-10

2-30
CHAPTER 3

BREAK-IN

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Break-In

CED,OUOE020,50 –19–13APR99–1/1

ENGINE BREAK-IN OIL

New engines are filled at the factory with John Deere

ENGINE BREAK-IN OIL. This is an SAE 5W-30

viscosity oil. During the break-in period (first 100

hours), add oil as needed to maintain the specified oil

level. (See Fuels and Lubricants chapter.)

If at any time during the break-in period, the engine is

exposed to air temperatures below -25°C (-13°F),

change the oil and filter using specified oil. (See Fuels

and Lubricants chapter.)

Change the oil and filter after the first 100 hours of

operation. Refill with specified oil. (See Fuels and

Lubricants chapter.)

• API Service Classification CE

• CCMC Specification D4

After the break-in period, use John Deere PLUS-50or

other diesel engine oil as recommended in this

manual.

IMPORTANT: Do not use John Deere PLUS-50 oil

or engine oils meeting API CG4, API

CF4, or CCMC D5 performance levels

during the first 100 hours of

operation of a new or rebuilt engine.

These oils will not allow the engine

to break-in properly.

PLUS-50 is a trademark of Deere & Company.

TX,15,DH5496 –19–12JUL96–1/1

EVERY 4 HOURS

Lubricate boom, arm, and bucket linkage every 4 hours

for the first 20 hours of operation. (See Maintenance—

Every 50 Hours chapter.)

TM 5-3805-280-10

3-1
Break-In

TX,15,DH5497 –19–12JUL96–1/1

EVERY 10 HOURS OR DAILY

1. Perform 10 hours or daily service. (See Maintenance—

Every 10 Hours or Daily chapter.)

2. Watch for fluid leaks.

3. Lubricate working tool pivots every 10 hours during the

first 30—100 hours of operation and when working in

mud or water. (See Maintenance—Every 50 Hours

chapter.)

TX,15,DH5498 –19–06JUL94–1/1

AFTER THE FIRST 50 HOURS

1. Perform 10 hours or daily and 50 hour service. (See

Maintenance—Every 10 Hours or Daily and

Maintenance—Every 50 Hours chapters.)

2. Change hydraulic oil filter (See Maintenance—Every

500 Hours chapter) and pilot filter (See Maintenance—

Every 1000 Hours chapter).

3. Check accessible hardware torque. (See Hardware

Torque Specifications in Maintenance chapter.)

TM 5-3805-280-10

3-2
Break-In

TX,15,DH5499 –19–06JUL94–1/1

AFTER THE FIRST 100 HOURS

1. Perform 10 hour or daily and 50 hour service. (See

Maintenance—Every 10 Hours or Daily and

Maintenance—Every 50 Hours chapters.)

2. Change engine oil and filter. (See Maintenance—Every

250 Hours chapter.)

3. Change fuel filter. (See Maintenance—Every 500

Hours chapter.)

TM 5-3805-280-10

3-3
TM 5-3805-280-10

BLANK

3-4
CHAPTER 4

PRE-START INSPECTION

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Pre-Start Inspection

TX,20,DH5500 –19–25NOV96–1/1

INSPECT MACHINE DAILY BEFORE

STARTING

T105341 –UN–25NOV96

Do periodic service checks in the Maintenance—Every 10

Hours or Daily chapter.

A—Check pedals and levers for freedom of movement.

Clean operator’s station.

B—Check hydraulic reservoir oil level.

C—Check engine oil level.

D—Check coolant level at recovery tank.

E—Clean radiator and oil cooler fins.

ELECTRICAL SYSTEM: Check for worn or frayed wires

and loose or corroded connections.

BOOM, BUCKET, SHEET METAL, TRACKS: Check for

bent, broken, loose, or missing parts.

HARDWARE: Check for loose or missing parts.

FUEL SYSTEM: Drain fuel filter and fuel tank sump.

HYDRAULIC SYSTEM: Check for leaks, missing or loose

clamps, kinked hoses, and lines or hoses that rub against

each other or other parts.

LUBRICATION: Check lubrication points on Periodic

Maintenance chart.

PROTECTIVE DEVICES: Check guards, shields, covers.

SAFETY: Walk around machine to clear all persons from

machine area.

TM 5-3805-280-10

4-1
TM 5-3805-280-10

BLANK

4-2
CHAPTER 5

OPERATING THE ENGINE

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Operating the Engine

TX,25,DH5501 –19–29MAY96–1/1

CHECK INSTRUMENTS BEFORE STARTING

T7396DS –UN–27JUN91

Turn key switch to ON position. All indicator lights will stay

on for approximately 3 seconds.

The indicator lights will also stay on for approximately 3

seconds when the key switch is turned to START position.

If any lamp fails to light, the bulb may be burned out.

The fuel gauge will show the fuel level.

The coolant gauge should NOT go to the red zone.

TX,25,DH5405 –19–27FEB97–1/1

LEVEL CHECK

T107675 –UN–27FEB97

1. Turn key switch to ON position.

2. Press level check switch (A).

3. Hydraulic oil level (B) engine coolant level (C) and

engine oil level (D) indicators will light if levels are

adequate for operation.

IMPORTANT: The level check does NOT take the

place of daily checks at hydraulic oil

level window, engine coolant recovery

tank, and engine oil level dipstick.

TM 5-3805-280-10

5-1
Operating the Engine

TX,OUOE042,5 –19–17DEC99–1/1

STARTING THE ENGINE

T101749 –UN–27JUN96

IMPORTANT: Before starting the engine in extreme

cold, unit must be prepared with proper

grade lubricants.

1. Move engine rpm dial (A) to slow idle position.

IMPORTANT: Prevent starter damage. Never operate

starter for more than 30 seconds at a

time. If engine fails to start, return key

switch to OFF. Wait for about 2

minutes, then try again. After a false

start, do not turn key switch until

engine stops.

2. Sound horn to alert persons nearby.

3. Turn key switch to START. Release key; switch will

return to ON position.

TM 5-3805-280-10

5-2
Operating the Engine

CED,OUOE012,142 –19–18MAR99–1/1

USING BOOSTER BATTERIES—24 VOLT

SYSTEM

T6713AH1 –UN–24OCT91

Two Battery Application

A—Machine Batteries

B—Booster Batteries

Before boost starting, machine must be properly shut

down to prevent unexpected machine movement when

engine starts.

CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep

flames or sparks away from the battery area.

Make sure the batteries are charged in a well

ventilated area.

IMPORTANT: The machine electrical system is a

24-volt negative (-) ground. Connect two

12-volt booster batteries together in

series as shown for 24 volts.

1. Connect one end of the positive cable to the positive

terminal of the machine batteries and the other end to

the positive terminal of the booster batteries.

2. Connect one end of the negative cable to the negative

terminal of the booster batteries. Connect other end of

the negative cable to the machine frame as far away

from the machine batteries as possible.

3. Start engine. (See procedure on previous page.)

4. Immediately after starting engine disconnect end of the

negative cable from the machine frame. Then

disconnect the other end of the negative cable from the

negative terminal of the booster batteries.

5. Disconnect positive cable from booster batteries and

machine batteries.

TM 5-3805-280-10

5-3
Operating the Engine

CED,OUOE042,62 –19–07APR99–1/1

SLAVE RECEPTACLE—24 VOLT SYSTEM

T120369 –UN–25MAR99

Before boost starting, machine must be properly shut

down to prevent unexpected machine movement when

engine starts.

CAUTION: An explosive gas is produced while

batteries are in use or being charged. Keep

flames or sparks away from the battery area.

Make sure the batteries are charged in a well

ventilated area.

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 other equipment.

TM 5-3805-280-10

5-4
Operating the Engine

TX,OUOE042,7 –19–17FEB99–1/2

STARTING FLUID (COLD WEATHER

STARTING AID)

T120333 –UN–25MAR99

A—Starting Aid Switch

CAUTION: Prevent possible injury from

exploding container. Starting fluid is highly

flammable. Keep container away from heat,

sparks, and open flame. Contents are

pressurized. Do not puncture or incinerate

container from machine if engine does not need

starting fluid.

IMPORTANT: Prevent damage to engine. Use starting

aid when temperatures are below 4.4°C

(40°F) and only when engine is COLD.

USING STARTING FLUID

1. Move engine rpm dial to the slow idle position.

2. Turn key switch clockwise to the START position.

3. As soon as the engine starts cranking you must

depress the starting aid switch (A).

IMPORTANT: Excess starting fluid could damage

engine; push starting aid button only

when engine is cold and cranking.

Starting aid fluid is being injected into

engine as long as you push switch.

4. If engine is cranking but no cylinders are firing you

must crank the engine for a maximum of 30 seconds.

Then release the starting aid switch (A) and turn the

key switch to the OFF position.

5. If the engine is cranking and some cylinders are firing,

continue cranking and pushing the starting aid switch

(A) for a maximum of 50 seconds. Or until the engine

is running.

Continued on next page

TM 5-3805-280-10

5-5
Operating the Engine

TX,OUOE042,7 –19–17FEB99–2/2T120335 –UN–25MAR99 T120336 –UN–25MAR99

B—Clamp

C—Container

D—Dust Cap

REPLACING STARTING AID CAN

1. Remove clamp (B) from container.

2. Turn container (C) counterclockwise to remove.

3. Turn container clockwise to install.

IMPORTANT: Protect starting aid components from

possible damage. Install dust cap (D) on

the starting valve when cylinder is not

installed in starting valve.

TM 5-3805-280-10

5-6
Operating the Engine

CED,OUOE020,11 –19–26FEB99–1/1

USING THE ARCTIC STARTER

The arctic starter is a fuel fired coolant heater located

between the engine and the rear counterweight. The

exhaust pipe comes out the bottom of the heater box and

can be accessed by removing the lower bottom cover at

the rear of the vehicle.

CAUTION: Prevent possibility of fire by keeping

the area around the arctic starter exhaust pipe

clean and free of debris. The exhaust pipe

outlet must be directed away from electrical

wiring, hydraulic hoses, fuel lines, and cold

weather starting aid lines.

Prevent asphyxiation. Exhaust fumes from

operating the arctic starter can cause sickness

or death. Never operate in an enclosed area or

building unless there is adequate ventilation to

expel the exhaust fumes.

The arctic starter must be used when the engine has

been off for at least eight hours at ambient temperatures

below -32°C (-25°F) and is recommended at temperatures

below -23°C (-10°F). Ignite the arctic starter and allow to

run for 45 minutes. Then shut the arctic starter OFF and

start the engine. (See Starting The Engine in this manual.)

NOTE: The arctic starter may not ignite at ambient

temperatures below -40°C (-40°F).

The arctic starter does not preheat any oils. All

oils must be of the proper viscosity depending

upon the ambient air temperature. (See Fuels And

Lubricants in this manual.)

TM 5-3805-280-10

5-7
Operating the Engine

CED,OUOE020,14 –19–01MAR99–1/1

STARTING THE ARCTIC STARTER

T125068 –UN–28OCT99

A—Heater Switch

B—LED Light

Move switch (A) to ON position.

A continuous green on the LED light (B) indicates the

system is operating properly. There is a normal delay of

up to 90 seconds before actual ignition of the heater

burner.

If the LED light (B) flashes green something in the system

sequence did not occur properly and default sensors have

shut down the heater start-up. If this occurs, move switch

(A) to OFF position for 15 seconds and then move switch

to ON position.

If the LED light (B) does not stay a continuous green after

four consecutive tries, move switch (A) to OFF position

and contact maintenance shop.

NOTE: Move switch (A) to ON position for two minutes

with a continuous green LED light (B) once a

month when it is not used. This will prevent the

water pump and combustion engine from seizing.

TX,25,DH3613 –19–27JUN95–1/1

CHECK INSTRUMENTS AFTER STARTING

IMPORTANT: Prevent possible damage to engine. If

indicator lights do not go out after

starting engine, IMMEDIATELY STOP

THE ENGINE. Find and correct the

problem.

After the engine is started, the indicator lights should go

out. If they do not, stop the engine immediately. Find and

correct the problem.

TM 5-3805-280-10

5-8
Operating the Engine

TX,25,DH5503 –19–24JUN96–1/1

WARMING THE MACHINE

1. Start engine. Run engine at 1/3 speed for 30 seconds.

Do not run engine at fast or slow idle. Do not

accelerate rapidly during warm up.

2. Operate machine at less-than-normal loads and

speeds until engine is at normal operating temperature.

TM 5-3805-280-10

5-9
Operating the Engine

TX,25,DH5504 –19–21JUN95–1/1

COLD WEATHER WARM-UP

CAUTION: Prevent possible injury from

unexpected machine movement. If hydraulic

oil is cold, hydraulic functions move slowly.

DO NOT attempt normal machine operation

until hydraulic functions move at

close-to-normal cycle times.

In extremely cold conditions, an extended warm-up

period will be necessary. Under such conditions, the

radiator and oil cooler should be covered to maintain

correct operating temperature.

Avoid sudden operation of all functions until the engine

and hydraulic oil are thoroughly warm.

1. Run engine at 1/2 speed for 5 minutes. Do not run

at fast or slow idle.

CAUTION: Prevent possible injury from

unexpected machine movement. Clear the

area of all persons before running your

machine through the warm-up procedure. If

machine is inside a building, warm the

propel circuit first and move the machine to

a clear area outside. Cold oil will cause

machine functions to respond slowly.

2. Exercise propel and swing functions slowly, initially

moving only short distances.

3. Operate boom, arm, and bucket functions by

moving cylinders a short distance each direction for

the first time.

4. Continue cycling cylinders by increasing the travel

each cycle until full stroke is obtained.

5. Swing upperstructure so boom is perpendicular to

tracks.

CAUTION: Prevent possible injury from

machine sliding backwards. Keep angle

between boom and arm 90—110°.

6. Keeping the angle between boom and arm 90—

110°, fully actuate bucket close function (cylinder

extend) and lower bucket to raise track off ground.

IMPORTANT: Holding function actuated for more

than 10 seconds can cause damage

from hot spots in the control valve.

7. While rotating raised track in forward direction,

actuate bucket curl function (cylinder extend) for 10

seconds and release for 5 seconds for a period of

2-1/2 minutes.

8. Repeat procedure with track rotating in reverse

direction.

9. Lower machine to ground.

10. Repeat steps 5—9 on opposite track.

11. Operate all hydraulic functions to distribute warm

oil in all cylinders, motors, and lines.

12. If hydraulic functions still move slowly, repeat

steps 6 and 7.

TM 5-3805-280-10

5-10
Operating the Engine

TX,25,DH5505 –19–29MAY96–1/1

STOPPING THE ENGINE

IMPORTANT: Prevent possible engine damage. If

engine stops when operating under

load, remove load. Restart engine

immediately. Run 30 seconds at 1/2

speed before adding load.

1. Park machine on a level surface.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Turn key switch to OFF. Remove key from switch.

7. Pull pilot control shut-off lever to locked position.

TM 5-3805-280-10

5-11
TM 5-3805-280-10

BLANK

5-12
CHAPTER 6

DRIVING THE MACHINE

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Driving the Machine

TX,10,FF2292 –19–28OCT91–1/3

STEERING THE MACHINE USING PEDALS

T7405CO –UN–08APR91

Steering with Pedals

T7405CP –UN–08APR91

Right Turn

Continued on next page

TM 5-3805-280-10

6-1
Driving the Machine

TX,10,FF2292 –19–28OCT91–2/3T7405CQ –UN–08APR91

Short Turn (Counterrotate)

T7405CN –UN–08APR91

Long Distance Travel

CAUTION: Keep bystanders clear of machine

when traveling. Before moving machine,

determine which way to press propel pedals.

Keep bystanders clear of machine when traveling.

The instructions below apply when the propel motors (E)

are to the rear of the machine. If the propel motors are to

the front of the machine, the machine moves OPPOSITE

to the direction described.

FORWARD TRAVEL: Push down on front (A) of both

pedals.

REVERSE TRAVEL: Push down on rear (C) of both

pedals.

NEUTRAL POSITION (B): Propel brakes will automatically

stop and/or hold the machine.

RIGHT TURN: Push down on front of left pedal.

LEFT TURN: Push down on front of right pedal.

SHORT TURN (COUNTERROTATE): Push down the front

of one pedal and the rear of the other.

IMPORTANT: When traveling over long distances,

swing upperstructure so propel motors

are to the rear.

LONG DISTANCE TRAVEL: When traveling over long

distances, swing upperstructure so propel motors are to

the rear. Push down on pedal tabs (D) and rest feet on

footrests.

CAUTION: Prevent possible injury from machine

tipping. Operate control pedals slowly when

traveling down a slope.

TRAVELING DOWN A SLOPE: Operate control pedals

slowly when traveling down a slope.

Continued on next page

TM 5-3805-280-10

6-2
Driving the Machine

TX,10,FF2292 –19–28OCT91–3/3

COLD WEATHER OPERATION: Propel pedal dampers

are provided for smooth control. In extremely cold

weather, pedal effort will increase. Operate pedal several

times with pilot control shut-off lever in locked position.

TX,10,FF2293 –19–15MAY92–1/2

STEERING THE MACHINE USING LEVERS

T7405CK –UN–08APR91

Steering With Levers

T7405CL –UN–08APR91

Right Turn

Continued on next page

TM 5-3805-280-10

6-3
Driving the Machine

TX,10,FF2293 –19–15MAY92–2/2T7405CM –UN–08APR91

Short Turn (Counterrotate)

T7405CN –UN–08APR91

Long Distance Travel

CAUTION: Keep bystanders clear of machine

when traveling. Before moving machine,

determine which way to move propel levers.

Keep bystanders clear of machine when traveling.

The instructions below apply when the propel motors (E)

are to the rear of the machine. If the propel motors are to

the front of the machine, the machine moves OPPOSITE

to the direction described.

FORWARD TRAVEL: Push both levers forward (A).

REVERSE TRAVEL: Pull both levers rearward (B).

NEUTRAL POSITION (C): Propel brakes automatically will

stop and/or hold the machine.

RIGHT TURN: Push left lever forward.

LEFT TURN: Push right lever forward.

SHORT TURN (COUNTERROTATE): Push one lever

forward and pull the other rearward.

IMPORTANT: When traveling over long distances,

swing upperstructure so propel motors

are to the rear.

LONG DISTANCE TRAVEL: When traveling over long

distances, swing upperstructure so propel motors are to

the rear.

CAUTION: Prevent possible injury from machine

tipping. Operate control levers slowly when

traveling down a slope.

TRAVELING DOWN A SLOPE: Operate control levers

slowly when traveling down a slope.

COLD WEATHER OPERATION: Propel lever dampers

are provided for smooth control. In extremely cold

weather, lever effort will increase. Operate lever several

times with pilot control shut-off lever in locked position.

TM 5-3805-280-10

6-4
Driving the Machine

TX,90,FF2018 –19–14NOV91–1/1

REMOVING PROPEL LEVERS

T7396EA –UN–12NOV91

A—Lever

B—Cap Screw

Propel levers may be removed if desired.

Remove cap screws (B) (two on each lever) to remove

levers (A) from brackets.

TM 5-3805-280-10

6-5
Driving the Machine

TX,30,DH5608 –19–25MAR97–1/1

PROPEL SPEED SWITCH

T101589 –UN–27JUN96

Fast speed or slow speed travel can be selected in each

working mode by turning the propel speed switch (A).

To lower travel speed, such as traveling on a slope or

moving in a tight space, turn switch to slow speed.

TX,30,DH5507 –19–24JUN96–1/1

TRAVEL ALARM AND TRAVEL ALARM

CANCEL SWITCH

T102893 –UN–07AUG96

The travel alarm sounds when a propel pedal is

depressed and will continue as long as the tracks are

moving. When travel motion stops, the travel alarm switch

is reset.

After the initial 12 second alarm, alarm can be silenced by

depressing the travel alarm cancel switch (A).

TM 5-3805-280-10

6-6
Driving the Machine

TX,30,DH5508 –19–06JUN96–1/1

PARKING THE MACHINE

1. Park machine on a level surface.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Turn key switch to OFF. Remove key from switch.

7. Pull pilot control shut-off lever to locked position.

IMPORTANT: Prevent cab electrical component

damage from bad weather. Always

close windows, roof vent, and cab door.

8. Close windows, roof vent, and cab door.

9. Lock all access doors and compartments.

TM 5-3805-280-10

6-7
Driving the Machine

TX,30,DH5509 –19–06AUG91–1/1

PARKING MACHINE DURING FREEZING

WEATHER

IMPORTANT: Prevent damage to undercarriage.

During freezing weather, park machine

on a hard surface to prevent tracks

from freezing to the ground. Clean

debris from tracks and track frames.

If tracks are frozen to the ground, raise

tracks using boom. Move machine

carefully to prevent damage to drive

train and tracks.

During freezing weather, park machine on a hard surface.

Clean debris from tracks and track frames.

If tracks are frozen to the ground, raise the tracks using

boom. Move machine carefully.

TX,30,DH5510 –19–09APR92–1/1

LOCK ALL COMPARTMENTS

Your machine is equipped with locks on the side shields,

fuel cap, hood, cab door, access door in hood, tool box,

and vandal shields (if equipped). One key will fit all locks.

The battery compartment has a lockable door. Use these

locks to help safeguard your machine.

TM 5-3805-280-10

6-8
CHAPTER 7

OPERATING THE MACHINE

TM 5-3805-280-10 TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Operating the Machine

TX,35,DH5511 –19–13AUG91–1/2

CONTROL LEVERS

CAUTION: 230LCR:

Single hearing protection is required by ground

personnel within 8 feet of the 230LCR vehicle at

high idle.

Operators are required to wear single hearing

protection when operating the vehicle with the

cab windows or door open.

230LCRD:

Operators are required to wear single hearing

protection when performing drilling operations

with cab windows or door open.

Ground personnel are required to wear single

hearing protection within 98 feet of the drill bit

and double hearing protection when within 10

feet of the drill bit.

Single hearing protection is required by ground

personnel within 8 feet of the 230LCRD vehicle

at high idle.

When both engines are operating, single

hearing protection is required within 12 feet of

the vehicle at high idle.

CAUTION: Never place any part of body beyond

window frame. It could be crushed by the boom

if boom control lever is accidentally bumped or

otherwise engaged. If window is missing or

broken, replace immediately.

Prevent possible injury from unexpected

machine movement. Make sure you know the

location and function of each control before

operating.

Never place any part of the body beyond the window

frame. Replace missing or broken windows immediately.

Continued on next page

TM 5-3805-280-10

7-1
Operating the Machine

TX,35,DH5511 –19–13AUG91–2/2T7364AT –UN–10OCT90 T6811AC –UN–18OCT88

A—Arm Out

B—Arm In

C—Swing Left

D—Swing Right

E—Boom Down

F—Boom Up

G—Bucket Load

H—Bucket Dump

The machine is factory equipped with the control pattern

shown.

IMPORTANT: Prevent possible machine damage.

When digging, avoid contacting tracks

with boom cylinders or bucket.

When digging over the end of the

tracks, propel motors should be at the

rear to minimize chain and sprocket

wear and to maximize machine stability

and lift capacity.

NOTE: With this control pattern, functions must

correspond to the black-on-white labels located on

the control console.

Do not contact tracks with boom cylinders or bucket.

When digging over the end of tracks, propel motors

should be at the rear of machine.

When a lever is released, it will return to neutral. The

machine will remain positioned.

TM 5-3805-280-10

7-2
Operating the Machine

TX,35,DH5038 –19–06JUN96–1/2

CONTROL LEVER PATTERN CONVERSION

To change your machine pilot control levers from the

standard pattern to a John Deere pattern:

1. Lower bucket to the ground. Turn auto-idle switch off.

2. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

3. Move engine rpm dial to slow idle position, and turn

key switch to OFF to stop engine. Remove key from

switch.

4. Move pilot control shut-off lever to locked position.

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug. Release

pressure by loosening vent plug.

5. Loosen vent plug to relieve air pressure.

6. Open door on storage compartment behind cab.

7. Remove cover above flow regulator valve.

Continued on next page

TM 5-3805-280-10

7-3
Operating the Machine

TX,35,DH5038 –19–06JUN96–2/2T102684 –UN–07AUG96

A—Hose

B—Hose

C—Hose

D—Hose

NOTE: DO NOT use manufacturer’s line tags or markings

on line ends to identify lines for this conversion

procedure. The conversion must be done on the

front (cab side) of the flow regulator valve.

• Switch hose (A) with hose (C).

• Switch hose (B) with hose (D).

CAUTION: Prevent injury from unexpected

control lever function. Install new decals on

control consoles.

8. Install new decals (black on yellow) on control

consoles near the base of control levers. Decals are

enclosed in Operator Manual package. Additional

decals can be purchased from your John Deere dealer.

TM 5-3805-280-10

7-4
Operating the Machine

TX,35,DH5512 –19–13AUG91–1/1

CONTROL LEVERS JOHN DEERE PATTERN

T7364AT –UN–10OCT90 T6811AD –UN–18OCT88

A—Boom Down

B—Boom Up

C—Swing Left

D—Swing Right

E—Arm Out

F—Arm In

G—Bucket Load

H—Bucket Dump

CAUTION: Avoid serious crushing injury from

boom. Never place any part of body beyond

window frame. It could be crushed by the boom

if boom control lever is accidentally bumped or

otherwise engaged. If window is missing or

broken, replace immediately.

Prevent possible injury from unexpected

machine movement. Make sure you know the

location and function of each control before

operating.

Never place any part of the body beyond the window

frame. Replace missing or broken windows immediately.

A conversion kit is available from your John Deere dealer

to change your controls to the pattern shown.

IMPORTANT: Prevent possible machine damage.

When digging, avoid contacting tracks

with boom cylinders or bucket.

When digging over the end of the

tracks, propel motors should be at the

rear to minimize chain and sprocket

wear and to maximize machine stability

and lift capacity.

NOTE: With this control pattern, functions must

correspond to the black-on-yellow labels located

on the control console.

Do not contact tracks with boom cylinders or bucket.

When digging over the end of tracks, propel motors

should be at the rear of machine.

When a lever is released, it will return to neutral. The

machine will remain positioned.

TM 5-3805-280-10

7-5
Operating the Machine

TX,35,DH5039 –19–07JUN96–1/1

PILOT CONTROL SHUT-OFF LEVER

T101635 –UN–26JUN96

The pilot control shut-off lever (A) shuts off hydraulic pilot

pressure to all pilot control valves. When pilot control

shut-off lever is in locked position, the machine will not

move if a lever or pedal is accidentally moved.

Always pull pilot control shut-off lever to locked position

when you stop the engine or leave the operator’s station.

TM 5-3805-280-10

7-6
Operating the Machine

TX,35,DH5406 –19–27FEB97–1/1

AUTO-IDLE SWITCH

T107692 –UN–27FEB97

The auto-idle circuit automatically reduces engine speed

after 4 seconds when control levers are placed in neutral

position. Press switch (A) to turn circuit ON.

CAUTION: Turn auto-idle switch OFF when

automatic acceleration of engine speed is not

desired, and when stopping engine.

Always check auto-idle switch before operating

any control levers. When ON, the engine speed

lowers to auto-idle speed (regardless of the

position of the engine speed control lever)

approximately 4 seconds after the control

levers are returned to neutral. By operating the

control levers, the engine speed increases to

the engine rpm dial setting.

Starting engine when auto-idle is ON:

1. When key switch is turned ON, buzzer will sound

briefly.

2. The engine will run at the engine rpm dial setting for 4

seconds after turning the key switch ON. The auto-idle

system will then slow the engine to auto-idle engine

speed.

3. Engine speed increases to engine rpm dial setting

when any control lever is operated.

4. Four seconds after control levers are returned to

neutral, the engine speed is reduced automatically to

auto-idle level. Engine will run at auto-idle speed if

engine is started more than 4 seconds after turning key

switch ON.

When the auto-idle switch is turned OFF, the engine

speed is controlled by the engine rpm dial.

Indicator (B) will light when auto-idle is ON.

Turn auto-idle switch OFF and set engine rpm dial to

improve machine control in difficult work areas,

loading, and unloading.

TM 5-3805-280-10

7-7
Operating the Machine

TX,35,DH5041 –19–10JUN96–1/1

MODE SELECTION SWITCH

T101585 –UN–11JUL96

Select operating modes by pressing the mode selection

switch (A). In each mode, a microcomputer automatically

selects the best combination of engine speed and pump

flow rate that fits the working load. The dig mode (B) is

automatically selected when the engine is started.

Use the following as a guide:

• Dig Mode (B)—Designed for general digging and truck

loading.

• Grading Mode (C)—Arm roll-in is slower for grading and

finishing work.

• Precision Mode (D)—For work that requires precision

front movement.

• Attachment Mode (E)—When using attachments other

than the bucket.

TX,35,DH5156 –19–12AUG96–1/1

POWER BOOST SWITCH

T101633 –UN–20JUN96

Push power boost switch (A) on top of right control lever

for an 8 second, 6% increase in hydraulic power. Release

switch to reset power boost function.

TM 5-3805-280-10

7-8
Operating the Machine

TX,35,DH5407 –19–27FEB97–1/1

E (ECONOMY) MODE

T101632 –UN–01JUL96 T107693 –UN–27FEB97

Use E mode to improve fuel efficiency and reduce noise

level with a small difference in engine speed. E mode is

effective when the dig mode is selected as the work

mode.

Push down E mode switch (A). The switch will stay down

and E mode indicator (B) will light. Push the E mode

switch again. The switch will return to original position and

will deactivate the E mode.

TM 5-3805-280-10

7-9
Operating the Machine

TX,35,DH5408 –19–27FEB97–1/1

H/P (HIGH POWER) MODE

T101630 –UN–01JUL96 T107694 –UN–27FEB97

NOTE: With both the H/P and E modes turned on, the

digging power increases while achieving low fuel

consumption.

Use H/P mode when extra horse power is needed for

rolling in the arm in excavation work. The H/P mode is

effective when the dig mode is selected as the work

mode. H/P mode can also be used with the E mode

turned on.

The H/P mode will be activated, automatically increasing

the engine speed when:

• H/P mode switch (A) is pushed down.

• Engine speed is set to 1600 rpm or higher.

• Arm roll-in is operated.

• A load heavier than a specified amount is applied.

Push down H/P mode switch (A). The switch will stay

down and H/P mode indicator will light. Push the H/P

mode switch again. The switch will return to original

position and will deactivate the H/P mode.

TX,35,DH5135 –19–03AUG96–1/1

STANDARD MODE

The engine is in standard mode when no switches are

pushed down and no indicator lights are on.

TM 5-3805-280-10

7-10
Operating the Machine

TX,35,DH5070 –19–27JUN96–1/1

OPERATING TIPS

Before starting work, walk the site to uncover hazards and

to plan the job. Check for buried utility lines and pipes,

and for gas and oil pipelines

Keep site clean and level to maximize machine stability,

reduce operator fatigue, and increase productivity.

Do not knock down stakes or grade markers. If you lose

sight of your guides, you may have to re-work the job.

TX,35,DH5784 –19–04JUN97–1/1

DRIVING MACHINE

T7527DS –UN–15JUL91

Use your seat belt.

Select a route that is as flat as possible. Steer machine as

straight as possible making small, gradual changes in

direction.

When driving over rough terrain, reduce speed to lessen

possibility of undercarriage damage. Reduce speed when

carrying a heavy load, or working in a congested area.

When possible, avoid obstacles, rough terrain, rocks,

curbs, and ditches. In general, decreasing speed

increases control.

When driving, carry bucket or attachment low for good

visibility and machine stability and to avoid overhead

obstacles. Visibility may also be improved by rotating

upperstructure slightly.

TM 5-3805-280-10

7-11
Operating the Machine

TX,35,FF2441 –19–13AUG91–1/1

DRIVING ON SLOPES

Use your seat belt.

CAUTION: Prevent possible injury from machine

rollover. Do not turn machine on a slope.

Do not turn machine on a slope.

TX,35,FF2322 –19–02JUL91–1/1

DRIVING DOWN A SLOPE

T7527CQ –UN–10JUL91

• Use your seat belt.

• Lower bucket near to ground as shown.

• Angle of boom to arm should be 90 degrees.

• Drive down slope with boom on the downhill end of the

machine.

• If machine begins to slide, lower boom, placing bucket

against or in the ground to slow the machine.

TX,35,FF2337 –19–13AUG91–1/1

DRIVING UP A SLOPE

T7273AG –UN–08JUN90

• Use your seat belt.

• Position undercarriage so propel motors will be on uphill

end of machine.

• Keep the bucket on the uphill side, approximately 30 cm

(12 in.) (A) above ground.

• If machine starts to slip or become unstable, lower the

bucket immediately.

TM 5-3805-280-10

7-12
Operating the Machine

TX,35,FF2338 –19–13AUG91–1/1

DRIVING UP A STEEP OR SLIPPERY

SLOPE—BOOM ON UPHILL END OF

MACHINE

T7527CS –UN–10JUL91

CAUTION: Prevent possible injury from machine

rollover. Use this technique only on a short

slope. Machine depends on support of

boom/arm/bucket during entire procedure until

machine reaches top of slope. Repositioning

the bucket during this procedure is NOT

recommended. Do not swing upperstructure

during this procedure.

• Use your seat belt.

• Position undercarriage so propel motors will

be on uphill end of machine.

• Push bucket into the ground.

• Drive up slope. Pull machine using boom and

arm cylinders to help propel motors. DO NOT

reposition bucket during this procedure.

TX,35,FF2339 –19–13AUG91–1/1

DRIVING UP A STEEP OR SLIPPERY

SLOPE—BOOM ON DOWNHILL END OF

MACHINE

T7527CT –UN–10JUL91

CAUTION: Prevent possible injury from machine

rollover. Use this technique only on a short

slope. Machine depends on support of

boom/arm/bucket during entire procedure until

machine reaches top of slope. Repositioning

the bucket during this procedure is NOT

recommended. Do not swing upperstructure

during this procedure.

• Use your seat belt.

• Position undercarriage so propel motors will

be on uphill end of machine.

• Push bucket into the ground.

• Drive up slope. Push machine using boom

and arm cylinders to help propel motors. Do

NOT reposition bucket during this procedure.

TM 5-3805-280-10

7-13
Operating the Machine

TX,35,DH5639 –19–26MAR97–1/3

MOVING MACHINE OFF AN EMBANKMENT

T7527DJ –UN–05JUN91

1. To move machine over edge of embankment, position

bucket with flat surface resting on ground. Angle (A) of

arm to boom should be 90°.

Bucket must be on ground before machine begins to

tip.

TX,35,DH5639 –19–26MAR97–2/3T7527DK –UN–05JUN91

IMPORTANT: To prevent machine damage, do not

allow machine to impact ground with

bucket absorbing force of the fall.

2. As machine moves forward, raise the boom and retract

arm until front of tracks reaches the lower ground level.

3. Raise bucket off the ground. Rotate upperstructure

180°.

TX,35,DH5639 –19–26MAR97–3/3T7527DL –UN–05JUN91

4. Position bucket on ground with flat surface of bucket

resting on ground. Angle (A) of arm to boom should be

90°.

5. Lower boom slightly and propel machine towards lower

level as the arm is extended.

6. When tracks clear embankment, raise boom to lower

undercarriage on lower ground level.

7. To move machine onto an embankment, reverse

procedure.

TM 5-3805-280-10

7-14
Operating the Machine

TX,35,FF2324 –19–13FEB92–1/2

LEVELING MACHINE

T7527CU –UN–15JUL91

A—Quick-Disconnect Hitch Switch

Operating on a firm, level surface optimizes machine

stability.

To create a level surface:

• Counterrotate tracks 30° to each side.

TX,35,FF2324 –19–13FEB92–2/2T7527DE –UN–15JUL91

• Use bucket to add or remove material to level the

worksite. When adding material to the worksite, drive

over new material to compact it until the worksite feels

stable.

TM 5-3805-280-10

7-15
Operating the Machine

CED,OUOE042,65 –19–09DEC99–1/8

USING QUICK-DISCONNECT HITCH

T121059 –UN–28OCT99

A—Quick-Disconnect Hitch Switch

1. The cylinder in the Quick-Disconnect Hitch is powered

by hydraulic oil from the excavator bucket cylinder

which is diverted to the Quick-Disconnect by an electric

solenoid valve. The switch is located on the left side

rear cab glass.

NOTE: The solenoid coil is energized only in the unlatch

position.

2. To attach the Quick-Disconnect Hitch to an attachment

manually lift and rotate the safety lock pin lever on the

top rear of the Quick-Disconnect Hitch. Fully extend

the bucket cylinder and set the Quick-Disconnect Hitch

switch (A) to the unlatch position. Extend the bucket

cylinder again to place the oil over relief (except for

rock drill attachment). This will activate the cylinder to

the open position.

CED,OUOE042,65 –19–09DEC99–2/8T120310 –UN–25MAR99

3. Operate the excavator to position the Quick-Disconnect

Hitch in the vertical position (B). The attachment must

be level and resting on the ground.

Continued on next page

TM 5-3805-280-10

7-16
Operating the Machine

CED,OUOE042,65 –19–09DEC99–3/8T120311 –UN–25MAR99

4. Position the Quick-Disconnect Hitch to engage the

front hook of the attachment (C).

CED,OUOE042,65 –19–09DEC99–4/8T120312 –UN–25MAR99

5. Rotate the Quick-Disconnect Hitch to seat the rear of

the latch over the rear attachment pins (D).

CAUTION: Do not raise the attachment without

acceptable wedge engagement. The attachment

can fall causing possible injury to people in the

vicinity of attachment.

6. Move the latch switch to the latch position and move

the control in order to carefully curl the

Quick-Disconnect Hitch and the attachment to full

extension of the bucket cylinder. This will place oil over

relief and divert oil to the hydraulic latch cylinder in

order to engage the wedge into the attachment.

NOTE: Keep the attachment close to the ground during

all latch and unlatch operations.

CAUTION: Wedge must be engaged into

attachment.

Continued on next page

TM 5-3805-280-10

7-17
Operating the Machine

CED,OUOE042,65 –19–09DEC99–5/8T120313 –UN–25MAR99

IMPORTANT: The safety lock pin is a safety device to

mechanically secure the attachment in

the event of hydraulic system failure.

The machine should not be operated

without the safety lock pin in the locked

position (E).

7. The safety lock pin lever is at the rear of the

Quick-Disconnect Hitch. Carefully rotate the spring

loaded safety lock pin lever toward the excavator to

engage the lock pin.

CED,OUOE042,65 –19–09DEC99–6/8T120314 –UN–25MAR99

QUICK-DISCONNECT ATTACHMENT REMOVAL

1. Fully extend arm and curl bucket in. Place the

attachment on the ground.

2. Manually lift and rotate the safety lock pin lever from its

locked position and install it in the unlocked position

(F).

NOTE: Alarm will sound when switch is in unlocked

position.

3. To unlatch the Quick-Disconnect Hitch from an

attachment fully extend the bucket cylinder. Move the

Quick-Disconnect Hitch switch (A) in the operators cab

to the unlatch position. Move the control to extend the

bucket cylinder again to place hydraulic oil over relief

(except for rock drill attachment). This will activate the

latch cylinder to the open position.

Continued on next page

TM 5-3805-280-10

7-18
Operating the Machine

CED,OUOE042,65 –19–07APR99–7/8T120315 –UN–25MAR99

4. Operate the excavator to rotate the Quick-Disconnect

Hitch in the vertical position (G).

CED,OUOE042,65 –19–07APR99–8/8T120316 –UN–25MAR99

5. Remove the Quick-Disconnect Hitch from the hook on

the front of the attachment (H).

TM 5-3805-280-10

7-19
Operating the Machine

TX,OUOE042,30 –19–09MAR99–1/1

TWO WAY HYDRAULIC THUMB FOOT

PEDAL (MODEL 230LCR)

T120459 –UN–25MAR99

A—Foot Pedal

B—Top of Pedal

C—Bottom of Pedal

The Model 230LCR machine is equipped with a third foot

pedal (A). This pedal controls the movement of the

hydraulic thumb.

To close the hydraulic thumb, push down the top of the

pedal (B).

To open the hydraulic thumb, push down the bottom of

the pedal (C).

TM 5-3805-280-10

7-20
Operating the Machine

CED,OUOE042,15 –19–01MAR99–1/2

USING HYDRAULIC THUMB

T120317 –UN–25MAR99

The hydraulic thumb was designed to be used for the

following procedures.

• Clamping and lifting

• Medium duty scrap handling

• Demolition of wood and brick structures

• Medium duty land clearing/grubbing

• Bulky loose materials

• Logging

Do not use the hydraulic thumb for the following

procedures.

• Ripping-up concrete and asphalt

• Quarry applications

• Heavy scrap handling

• Heavy land clearing

• Heavy grubbing

• Breaking ledge rock

Clamping with Bucket

From the stored position actuate and locate the hydraulic

thumb near the object to be picked up. Curl-in the bucket

(A) to the point where it begins to grasp and force the

object being picked up into the face of the hydraulic

thumb. The thumb is capable of large clamping forces and

could crush the object. To prevent the bucket and thumb

from crushing the object, “feather” the bucket control to

the point where the object can be picked up but not

crushed.

Continued on next page

TM 5-3805-280-10

7-21
Operating the Machine

CED,OUOE042,15 –19–01MAR99–2/2T120318 –UN–25MAR99

Clamping with Hydraulic Thumb

CAUTION: This method is less precise and

should only be used where there is no concern

about crushing the object to be clamped.

Retract the hydraulic thumb to the store position (B). This

allows better operator visibility. Position the bucket behind

and curl it in until it is near or in contact with the object

being picked up. Actuate the hydraulic thumb and allow it

to grasp and clamp. This method of grasping is usually

less precise and objects may be crushed.

Lifting Objects

CAUTION: Always use caution when lifting and

transporting objects with the hydraulic thumb

and bucket. Excavators can lift heavy objects

that are closer to the excavator. As heavy

objects are moved further away from the

machine via boom and arm actuation, the

possibility of making the machine unstable

exists. Use caution when lifting, moving and

rotating heavy objects away from the

excavator’s main body.

Never lift clamped objects over people. The

possibility always exists that the lifted objects

could drop.

Releasing Clamped Objects

CAUTION: Always look before you release a

clamped load. Never release a clamped load

while moving or turning. Objects clamped in the

jaws should be released one of two ways.

Retract the material clamp or retract the bucket.

TM 5-3805-280-10

7-22
Operating the Machine

TX,35,FF2325 –19–28JAN92–1/3

USING BUCKET

T7527CV –UN–10JUL91

ARM DIGGING: For most general excavating, leveling

material, and digging trenches.

To begin excavating, position arm in vertical position and

then move it away from machine approximately 0.61 m (2

ft).

Using mainly the arm cylinder (A), retract the arm. As the

bucket fills, curl the bucket while retracting the arm. The

first cut should be approximately 1.2 m (4 ft) long and

75—100 mm (3—4 in.) deep. Remaining cuts should be

approximately 1.2 m (4 ft) long and 100—150 mm (4-6 in.)

deep.

Continued on next page

TM 5-3805-280-10

7-23
Operating the Machine

TX,35,FF2325 –19–28JAN92–2/3T7527CW –UN–10JUL91

BUCKET DIGGING: For power digging and for working in

a small or cramped excavation. Use the bucket cylinder

(A) for digging.

Lower bucket to the digging area and use boom to force

the bucket into the ground. Work two functions at once;

retracting the arm, and curling the bucket until the bucket

is full.

If the bucket stalls, raise the boom slightly and continue to

curl bucket.

If arm stalls, roll back bucket to break out.

IMPORTANT: To avoid damaging cylinder(s), do not

strike ground with bucket or use bucket

for tamping when bucket cylinder is

fully extended (bucket completely

curled under).

When bucket cylinder is fully extended, do not strike the

ground with the bucket or use the bucket for tamping.

Do not use the bucket as a hammer or pile driver. Do not

attempt to shift rocks and break walls using swing motion.

Do not sideload bucket. For example, do not swing bucket

to level material or do not strike objects from the side with

the bucket.

Match bucket, bucket teeth, or attachment to type of

material being handled.

Loose, fragmented material dumps quickly from the

bucket. To break up material as it enters the bucket,

excavate material in thin layers rather than jamming it into

the bucket. This is especially important with sticky

materials.

If you clean the bucket by rapping it against the stop, to

prevent cylinder damage, use the MINIMUM amount of

force. Clean the bucket by hand if rapping bucket lightly

does not work. Do not try to remove material from bucket

by striking bucket against the ground or another object.

Continued on next page

TM 5-3805-280-10

7-24
Operating the Machine

TX,35,FF2325 –19–28JAN92–3/3T7527CX –UN–10JUL91

To prevent cave-in’s:

• Work perpendicular to or at an angle to excavation, with

propel motors to the rear of the machine.

• Do not drive near the edge of an excavation or trench.

• Do not dig under the machine.

TX,35,FF2323 –19–13AUG91–1/1

PLANNING SPOIL PILES

T7527CY –UN–10JUL91

To prevent cave-in’s, place spoil pile at least 1 m (3 ft)

away from excavation. The deeper the excavation the

further the spoil pile should be placed from the

excavation. Place spoil piles for convenient truck loading

or backfilling.

On slopes, place spoil piles on the upper side of the slope

for improved machine stability and easier backfilling.

TX,35,FF2327 –19–13AUG91–1/4

TRENCHING

T7527CZ –UN–10JUL91

Before starting work, walk the site to uncover hazards and

to plan the job. Check for buried utility lines and pipes and

for gas and oil pipelines.

To prevent cave-in’s, dig a ’V’ shaped trench and place

spoil piles at least 1 m (3 ft) away from trench. The

deeper the trench, the further the spoil pile should be

placed from it.

Continued on next page

TM 5-3805-280-10

7-25
Operating the Machine

TX,35,FF2327 –19–13AUG91–2/4T7527DA –UN–10JUL91

If you have to clean up a cave-in and cannot reach it from

machine’s present position, DO NOT back over the

trench. Drive the machine beside the trench to the

cave-in. Park the machine at a 90° angle to trench, with

propel motors to the rear of the machine. Clean cave-in

from the side of the trench.

TX,35,FF2327 –19–13AUG91–3/4T7527DB –UN–10JUL91

When trenching across a slope, level the machine so that

bottom of trench will be level. Level machine by

counterrotating tracks or by digging a shelf.

Place the spoil pile on the upper side of the trench. The

machine is more stable and backfilling is easier.

TX,35,FF2327 –19–13AUG91–4/4T6879AU –UN–06DEC88

For straight line trenching, drive two stakes in at the

beginning of the trench. Drive the first stake in

immediately behind the starting point and the second

stake approximately 9 m (30 ft) behind the first (A).

Use the stakes as a sight gauge. They are especially

helpful if the machine is moved often.

TM 5-3805-280-10

7-26
Operating the Machine

TX,35,FF2331 –19–02JUL91–1/1

BACKFILLING

T7527DC –UN–10JUL91

When backfilling, position machine at a 90° angle to the

excavation, with propel motors to the rear of the machine.

To prevent machine damage DO NOT use the side of the

bucket to backfill.

The bucket side can be used for finish grading.

Extra material can be backfilled around foundations to

allow for settling.

TM 5-3805-280-10

7-27
Operating the Machine

TX,35,FF2332 –19–02JUL91–1/1

TRUCK LOADING

T7527DD –UN–15JUL91

Level loading area during wait time between trucks to

maximize machine stability, decrease operator fatigue,

and increase productivity.

Know location of all persons in working area, including

truck driver. Do not load the truck unless the truck driver

is in a safe place.

If possible, park truck where wind will be behind operator

to keep dust of the dumped load out of operator’s eyes

and out of engine air cleaner.

Raise the bucket while swinging toward the truck.

Drop first load into truck from a minimum height to lessen

the stress on the truck. The first material in the box will

cushion following loads. Dump load into truck at a steady

pace (rather than abruptly) to minimize stress on truck.

Load truck box from center front to center rear.

If loading large rock, first place a load of smaller rock into

truck to cushion impact of large rock in truck.

Move bucket to excavation level while swinging away from

the truck.

Do not swing the bucket over the cab.

TM 5-3805-280-10

7-28
Operating the Machine

TX,35,FF2007 –19–06JUL94–1/1

OPERATING IN WATER AND MUD

T6274AR –UN–20APR89

Be careful not to operate the machine in water or mud

above the upper deck surface of the undercarriage,

causing the swing bearing and rotary manifold to be

submerged.

If the swing bearing and rotary manifold are submerged,

remove cover from underneath center of machine.

Remove drain plug (A) to drain water and mud.

Clean swing gear area. Install plug and cover. Lubricate

swing gear and swing bearing. (See Maintenance—Every

500 Hours chapter.)

TX,35,DH5513 –19–06AUG91–1/1

CLEAN TRACK FRAME AREA

T6879AT –UN–06DEC88

1. Swing upperstructure 90°.

CAUTION: Prevent possible injury from machine

sliding backwards. Keep angle between boom

and arm 90-110°.

2. Lower bucket (round side down) to raise track off

ground, keeping angle (A) between boom and arm

90-110°.

3. Run track back and forth to remove mud and dirt.

4. Turn engine off.

CAUTION: Prevent possible injury from

unexpected machine movement. Place blocks

under machine frame to support machine while

cleaning track frame area when track is

stationary.

5. Place blocks under machine frame if further cleaning of

track frame area is performed while track is stationary.

Clean track often during cold weather to prevent

damage to track components.

TM 5-3805-280-10

7-29
Operating the Machine

TX,35,DH5145 –19–10AUG96–1/2

LIFTING

T6589AA –UN–18OCT88

Without Bucket Loop

CAUTION: Prevent possible injury. Never move

the load suddenly. Never move load over a

person’s head. Do not allow any persons near

load.

Keep all persons away from raised load until

blocks are supporting it or load is sitting on the

ground.

Check chart on the right window or lifting

capacity specification of this manual before

lifting with machine. Position upperstructure so

track sprockets are at the rear.

Do not attach sling/chain to bucket teeth. Do

not lift with damaged or worn sling, chain, or

bucket.

1. Secure sling/chain tightly to load being lifted.

2. Without bucket loop: Fasten chain/sling to pivot pin on

machine, bucket curled, and arm retracted

Continued on next page

TM 5-3805-280-10

7-30
Operating the Machine

TX,35,DH5145 –19–10AUG96–2/2T6866AC –UN–19OCT88

With Bucket Loop

With bucket loop: Fasten sling/chain to bucket loop (A),

bucket curled and arm retracted.

3. Coordinate hand signals with your signal man before

starting.

4. Know location of all persons in working area.

5. Attach a hand line to load and make sure person

holding it is away from load.

6. Before starting job, test your load.

• Park your machine close to load.

• Attach load to machine.

• Raise load 50 mm (2 in.) above the ground.

• Swing the load all the way to one side.

• While keeping load close to the ground, move it

away from machine.

• If there is any indication of reduced stability of your

machine, lower load to the ground.

7. Lift load only as high as necessary.

TM 5-3805-280-10

7-31
AIR COMPRESSOR - OPERATING INSTRUCTIONS

CONTROL PANEL

DIAGNOSTICS/AUTO SHUTDOWN

1. High Compressor Temperature -

248°F (120°C) or more.

2. Low Engine Oil Pressure - 12 psi or less

3. High Engine Temperature -

Coolant above 220°F (104°C).

4. Low Coolant Level -

Must add coolant.

5. Air Filter Service Indicators -

Indicates when air filter elements need to be 

replaced.

6. Heater Switch - Flip “ON” in cold weather to 

activate control system heaters.

7. Heater Indicator - Indicates heaters are “ON” 

when lighted.

8. Compressor Discharge Pressure Gauge -

Indicates pressure in receiver tank, psi (kPa).

9. Hourmeter -

Records running time for maintenance.

CONTROLS

10. Panel Light (PL1) -

When illuminated, indicates power is on. 

When not illuminated, indicates power is off.

11. Panel Light (PL2) -

When illuminated along with PL1, indicates unit

is ready to start. When not illuminated, but PL1

is, indicates compressor is operating at full 

pressure.

12. Toggle Switch (SW1) -

Flip “ON” to activate systems prior to starting. 

Flip “OFF” to stop engine.

13. Toggle Switch (SW2) -

Flip “ON” to activate systems prior to starting.

Flip “OFF” after warmup to provide full air

pressure.

14. Start Button -

Push to start engine.

15. Ether Inject Button -

Push to inject metered amount of ETHER to

help start engine in cold weather. USE

SPARINGLY.

Note: Items 6, 7 and 10-15 are also remote mounted

in the excavator cab.

 ENGINE 

AIR FILTER

COMPRESSOR 

 AIR FILTER

 DISCHARGE 

 AIR PRESSURE

HOURMETER

PL1 SW1 START

PL2 SW2 ETHER 

 INJECT

+ + +

+ + +

10 12 14

11 13 15

9

+ +

43208859

HIGH COMPRESSOR

TEMPERATURE 1

LOW ENGINE

OIL PRESSURE 2

HIGH ENGINE

TEMPERATURE 3

LOW COOLANT 

LEVEL 4

5

5

LAMP TEST - WITH ENGINE 

OFF, TURN POWER SWITCH 

TO •OFF", THEN TO •ON". 

ALL LAMPS SHOULD LIGHT.

8

7

6

TM 5-3805-280-10

7-32
36518066

Speed and Pressure Regulation Adjusting Instructions

Normally, regulation requires no adjusting, but if

proper adjustment is lost, proceed as follows:

Note: Refer to general data for machine rated

speeds and pressure.

Before Starting Unit:

1. Atop separator tank cover at pressure valve,

loosen locknut counterclockwise. Turn adjustment

screw and locknut counterclockwise until no

tension is felt at the screw. turn screw clockwise

one full revolution.

After Starting Unit:

2. Allow unit to warm up. Then at control panel,

push “Service Air” Button, if equipped.

3. Open and adjust service valve (on outside of the

unit) to obtain the rated operating pressure on the

discharge pressure gauge.

Note: If the rated operating pressure cannot be

maintained with engine at full load speed and rod

(A) of air cylinder (B) fully retracted, turn regulator

adjustment screw clockwise until throttle air (C)

moves against full speed governor stop (D).

4. Insure that pressure is maintained at rated

pressure, then turn regulator adjustment screw

counterclockwise until throttle arm (C) just begins

to move.

Note: Turning regulator adjustment screw

clockwise will raise pressure at full speed.

5. Close service valve (engine will slow to idle

speed). Loosen jam nut (E) on rod (A). Rotate rod

(A) to adjust speed to obtain idle rpm.

6. If necessary, repeat steps 3 and 4.

7. At pressure regulator, tighten lock nut.

8. Limit full load engine speed by loosening jam

nut (F) and (G) and rotating rod (H). When proper

speed is reached, tighten jam nuts.

9. To obtain maximum CFM at any pressure

between 80 PSI (550kPa) and the rated operating

pressure, turn adjustment screw of pressure

regulator to obtain desired discharge pressure at

full load engine speed. Always lock pressure

setting of adjusting screw.

TM 5-3805-280-10

7-33
BEFORE STARTING

CAUTION

Do not connect the air discharge on this unit into a

common header with any other unit of any

description, or any other source of compressed air,

without first making sure a check valve is used

between the header and the unit. If this unit is

connected in parallel with another unit of higher

discharge pressure and capacity, a safety hazard

could occur in a back-flow condition.

WARNING

Unrestricted air flow from a hose will result in

a whipping motion of the hose which can cause

severe injury or death. A safety device must be

attached to the hose at the source of supply to

reduce pressure in case of hose failure or other

sudden pressure release. Reference: OSHA

regulation 29 CFR Section 1926.302 (b).

• Open manual blowdown valve to ensure

pressure is relieved in receiver-separator system.

Close valve in order to build up full air pressure

and ensure proper oil circulation.

.• Check battery for proper connections and

condition.

• Check the compressor lubricating oil level. The

proper oil level is mid-way on the sight gauge. Add

oil if the level falls to the bottom of the sight gauge.

Do not overfill.

• Check the engine lubricating oil level. Add oil if

low on dipstick.

WARNING

Do not remove the cap from a HOT engine

radiator. The sudden release of pressure from

a heated cooling system can cause severe

injury or death.

CAUTION

The use of water alone in this engine can result

in major engine failure.

• At overflow reservoir ( plastic bottle )

check coolant level and, if necessary, top off

to “cold” mark.

• Roof access door has retaining pins on each

side. After servicing cooling system, pins must

be replaced for proper operation.

• Check the fuel level. Add only CLEAN DIESEL

fuel for maximum service from the engine.

Note: To minimize condensation (water) in the fuel

tank, fill the tank at the end of each day.

WARNING

This machine produces loud noise with doors

open. Extended exposure to loud noise can

cause hearing loss. Wear hearing protection

when doors or valve (s) are open.

Close the side doors to maintain a cooling air path

and to avoid recirculation of hot air. This will

maximize the life of the engine and compressor

and protect the hearing of surrounding personnel.

Be sure no one is IN or ON the compressor unit.

STARTING

WARNING

Do NOT operate machine with guards removed.

CAUTION

Do NOT operate machine with safety shutdown

switches by-passed.

CAUTION

When attempting to start or stop the unit from

the remote location, the operator should first

use caution to assure no one is performing

maintenance or inspecting the machine.

TM 5-3805-280-10

7-34
Low Ambient Temperature Operation

Two 24 volt DC heaters are provided at critical

control system locations to prevent ice formation in

the compressor capacity control system. One

heater is attached to the surface of the pressure

control valve. The other heater is attached to the

bleed orifice connected to the compressor

unloader valve. The heaters are turned on and off

using the toggle switches located on either the

local or remote compressor control panels.

Below 40 degrees Fahrenheit

Energize the heaters prior to starting the

compressor drive engine. Allow the heaters to

operate continuously during compressor operation.

Below -25 degrees Fahrenheit

Energize the heaters and wait 60 seconds prior to

starting the excavator drive engine. Allow the

heaters to operate continuously during compressor

operation.

CAUTION

Ether is an extremely volatile, highly flammable

gas. Use sparingly! If too much is injected, the

uncontrolled explosion may result in costly

damage to the engine.

Flip SW1 and SW2 until both panel lights are

illuminated. All DIAGNOSTICS lamps will light

(glow) for two (2) seconds. Then all lamps should

go off except for ALTERNATOR NOT CHARGING

and LOW ENGINE OIL PRESSURE.

In cold weather, open manual blow down valve

and, press the ETHER INJECT button once and

release. Then, while cranking, press release

button once every five (5) seconds. This injects a

measured amount of ether to the engine.

Press the START button to crank the engine. DO

NOT OPERATE THE STARTER MOTOR FOR

MORE THAN TEN (10) SECONDS WITHOUT

ALLOWING AT LEAST ONE MINUTE COOLING

TIME BETWEEN START ATTEMPTS.

Release the START button when the engine

starts and sustains running. If the engine does not

start after a couple of attempts, refer to Trouble

Shooting Section.

All Diagnostic lamps should be off. If not, stop the

machine and investigate. If opened above, close

manual blowdown valve.

Allow the unit to warm up for at least (2) two

minutes.

Flip switch SW2 to the opposite position. Panel

light PL2 will go out. The engine should go to full

speed and the discharge pressure rise to slightly

over rated pressure. The compressor will unload

(intake be throttled or closed) and the engine

speed will drop to the idle speed.

Compressor is now ready to furnish air when the

service valve is opened.

STOPPING

Close air service valve (s).

Allow the unit to run at “no load” for 3 to 5 minutes

to reduce the engine temperatures.

The unit may be stopped from either the local

panel on the compressor or the optional start/stop

panel if so equipped.

Flip both toggle switches (SW1 and SW2) to the

opposite position until both panel lights (PL1 and

PL2) go out. Power is now off.

Note: Once the engine stops, the automatic

blowdown valve will begin to relieve all

pressure from the receiver-separator system.

CAUTION

Never allow the unit to sit stopped with

pressure in the receiver-separator system. As

a precaution, after the automatic blowdown

period (2 minutes), open the manual blowdown

valve.

EQUIPMENT PROTECTION

Note: Do NOT wire around or bypass a

shutdown sensor or switch.

This unit is protected by sensors or switches at

the following locations:

(1) High engine COOLANT temperature in the

engine.

(2) Low engine oil pressure, in the engine.

(3) Low Fuel Level.

High Discharge AIR Temperature -

(4) At the airend outlet.

(5) In the safety valve connection on the separator

tank.

TM 5-3805-280-10

7-35
AUTOMATIC SHUTDOWN / DIAGNOSTICS

 Should any of these problem situations occur, the

unit will automatically shutdown and stop.

BEFORE restarting the unit or flipping the POWER

switch to “Off”, check the DIAGNOSTICS area on

the instrument panel.

The upper four (4) lamps are electronically

“latched” to only respond to the first or primary

signal for a shutdown. In other words, if the

automatic shutdown is the result of one of these

four problems, only that particular problem lamp

will be lit. And the lamp will remain lit as long as

the batteries provide power.

Refer to OPERATING CONTROLS AND

INSTRUMENTS, for the various problem signal

criteria (°F, psi, etc.). The indicated problem area

should be inspected for a physical cause (low fluid,

broken fan belt, evidence of excessive heat, etc.)

and corrections made.

The shutdown will automatically reset when the

problem condition is corrected.

Other possible causes for an unexpected

shutdown are listed on the Trouble Shooting Chart.

TM 5-3805-280-10

7-36
Operating the Machine

CED,OUOE020,17 –19–09DEC99–1/1

USING QUICK-COUPLER TYPE

ATTACHMENTS

T120404 –UN–25MAR99

GENERAL OPERATING TIPS

IMPORTANT: To avoid damaging machine cylinder(s),

do not strike ground with attachment or

operate with cylinders fully extended or

retracted.

• Do not operate the attachment with the hydraulic

cylinder rods fully extended or fully retracted.

• Do not strike the ground or other objects with the

attachment.

KEEPING HYDRAULIC SYSTEM CLEAN

IMPORTANT: To prevent damage to hydraulic

components, keep contamination from

entering hydraulic system.

Use wrench to loosen connectors when connecting and

disconnecting hydraulic lines to attachment.

While attaching or detaching attachments, the hydraulic

lines are open. Contamination can enter the hydraulic

system at this time, causing machine damage. If

attachments are changed frequently, there are more

opportunities for contamination to enter the hydraulic

system. To keep hydraulic oil contamination to a

minimum:

• Clean connectors before disconnecting hydraulic lines.

• Install caps and plugs on hydraulic lines as soon as

possible.

• Change hydraulic return filter at half the normal interval

(250 hours).

• Sample hydraulic oil every 500 hours. (See OILSCAN

PLUS in Periodic Maintenance chapter.) Follow

OILSCAN PLUS recommendations for oil change

interval, but never change the oil less frequently than

recommended for the machine.

OILSCAN PLUS is a trademark of Deere & Company.

TM 5-3805-280-10

7-37
Operating the Machine

TX,35,FF2664 –19–13MAY93–1/1

ROCK DRILL ATTACHMENT (MODEL

230LCRD)

Rock drill operation subjects the machine’s hydraulic

system to possible contamination and accelerated

deterioration. The hydraulic return filter and hydraulic oil

must be replaced more often to prevent damage to

hydraulic pumps and other hydraulic components. Change

the hydraulic return filter and oil at the intervals

recommended below based on the amount of machine

operating time the attachment is used.

Percentage of Operating Time Hydraulic Return Filter Hydraulic Oil Change

Rock Drill Used Change Interval (Hours) Interval (Hours)

100 100 600

60 150 800

40 200 1000

20 300 1300

CED,OUOESLH,6 –19–09DEC99–1/3

INSTALL ROCK DRILL

1. Ensure that rock drill is level and legs are resting on

ground.

NOTE: See Using Quick-Disconnect Hitch in this chapter

for additional information when performing steps 2

through 7.

2. Manually place hitch safety lock pin in unlocked

position.

3. Fully extend bucket cylinder and set quick-disconnect

switch in cab to unlatch position.

Continued on next page

TM 5-3805-280-10

7-38
Operating the Machine

CED,OUOESLH,6 –19–09DEC99–2/3T126622 –UN–17DEC99

4. Operate excavator to position hitch in vertical position

and engage front hooks of rock drill adapter (A).

5. Rotate hitch downward to seat hitch and engage

wedge into rock drill adapter (B).

CAUTION: Do not raise the rock drill without

acceptable wedge engagement. The rock drill

can fall causing possible injury to people in the

vicinity of rock drill.

6. Set quick-disconnect switch in cab to latch position.

Rotate hitch downward a small amount to engage

wedge bar.

7. Check for wedge engagement and manually engage

hitch safety lock pin.

NOTE: See Using Quick-Coupler Type Attachments in

this chapter for general operation tips and

information on keeping the hydraulic system clean

when connecting attachments.

8. Remove cap from quick-disconnect fitting of high

pressure hose on left side of excavator arm and plug

from quick-disconnect fitting of low pressure hose on

right side of excavator.

Continued on next page

TM 5-3805-280-10

7-39
Operating the Machine

CED,OUOESLH,6 –19–09DEC99–3/3T126624 –19–17DEC99

9. Connect high pressure hydraulic hose, grease hose,

and electrical cable from rock drill to corresponding

hoses and electrical connector on left side of excavator

arm.

10. Connect low pressure hydraulic hose, vent hose, and

air hose to corresponding hoses on right side of

excavator arm.

TM 5-3805-280-10

7-40
Operating the Machine

CED,OUOESLH,7 –19–09DEC99–1/2

REMOVE ROCK DRILL

1. Operate excavator and position rock drill with legs on

level ground.

2. Clean and disconnect three hydraulic hoses, one air

hose, one grease hose, and one electrical cable from

left and right sides of excavator arm. Cap and plug

fittings to prevent contamination of hydraulic, air, and

grease systems. Close cover over electrical connector.

(See Using Quick-Coupler Type Attachments in this

chapter.)

3. Install plug and cap on quick-disconnect fittings on

excavator arm.

NOTE: See Quick-Disconnect Attachment Removal in this

chapter for additional information when performing

steps 4 through 7.

4. Manually place lock pin in unlocked position.

5. Set quick-disconnect hitch switch in cab to unlatch

position.

6. Extend bucket cylinder slowly but do not extend bucket

cylinder too far and cause rock drill to move. This will

activate the wedge bar to the open position.

Continued on next page

TM 5-3805-280-10

7-41
Operating the Machine

CED,OUOESLH,7 –19–09DEC99–2/2T126623 –UN–17DEC99

7. When latch bar is retracted, hitch can be rotated

upward away from rock drill (A). The excavator arm

can then be moved toward excavator (B) to completely

disengage hitch from hooks of rock drill adapter.

TM 5-3805-280-10

7-42
Remote control operator’s panel

OPERATING THE ROCK DRILL ATTACHMENT - REMOTE CONTROL OPERATOR’S PANEL

   

 	 
 





A ) Guide swing control

B ) Feed control

C ) Drifter control

D ) Drilling hourmeter

E ) Hydraulic centralizer control

F ) Air flushing switch

G ) Dust hood control

H ) Thread loosening button (percussion)

I ) HP / Dust collector selector

J ) Emergency stop button

K ) Rod changer control

Guide swing

This control allows operation of the CPA swing.

Swing the lever to the left to move the CPA foot

piece to the left.

Swing the lever to the right to move the CPA foot

piece to the right.

Feed control

This is a four–way lever with a push button on top.

 







B1 ) Pull the lever to operate the feed forward.

The lever is locked in position. This is the normal position when drilling.

B2 ) Push the lever to operate reverse feed. The

lever must be held in position.

B3 ) Swing the lever in this direction to operate

fast feed forward. The lever must be held in position.

B4 ) Swing the lever in this direction to operate

fast reverse feed. The lever must be held in position.

B5 ) Pressing this button when the lever is pulled

in B1 position operates the reduced feed for collaring.

TM 5-3805-280-10

7-43
Remote control operator’s panel

Drifter control

This is a four–way lever.

 





C1 ) Pull the lever to operate normal rotation

only.

C2 ) Push the lever to operate reverse rotation

only.

Note : these two functions are never used for

thread coupling or uncoupling.

C3 ) Swing the lever in this direction to drill with

automatic control.

This is the normal lever position when drilling.

The lever is locked in position.

C4 ) Swing the lever in this position to drill on

manual.

In this specific position, the drilling automatics are

inoperative.

This lever position is exceptionally used to get full

reverse percussion (if the drifter is so equipped), or to

force the drilling when encountering faults by over–

riding the anti–jamming.

in such an occasion, rod jamming is risky.

Carefully reduce the feed speed by switching the

feed control in collaring position.

Drifter hourmeter

The drifter hourmeter indicates the total operating

of the drifter.

It should be used to determine service maintenance.

Hydraulic centralizer control

Pull the lever to open the centralizer.

Push the lever to close the centralizer.

Air flushing

Pull the lever to operate air flushing.

Dust hood control

Pull the lever to slide the dust hood down.

Push the lever to slide the dust hood up.

Thread loosening button



Depress this button to operate drifter percussion

only. By successive impulses to the drifter control in

C2 direction operate reverse rotation to break loose

the threaded joints.

HP / Dust collector switch

This is a 3 positions switch.







J0) Down, HP flow is diverted to tank.

J1) Middle, HP pressure built up to allow movements or auxiliaries.

J2) Up, the dust collector is activated.

Emergency stop button

Press the button to switch down the engine in case

of emergency only.

The emergency stops selector must be placed

on CPA position (refer to safety).

TM 5-3805-280-10

7-44
Rod changer

ROD CHANGER

The rod changer is a semi–automatic device

which allows:

• the storage of 6 x 12’ extension rods in a

carousel.

• the handling of the rod to and from the drill

guide.

• automatic operations for rod coupling and

uncoupling. The synchronized drifter rotation and displacement are operated by a single lever.

When male/male extension rods are used, the

upper rod clamp prevents hazardous sleeve loosening which might occur during drifter shank uncoupling.

Thread lubrication is also controlled from the

operator’s station.

CONTROL PANEL









 	

K) Rod changer control lever

The safety trigger located on the back of the

lever must be depressed to allow any operation.

L) Indicator light

This indicator is alight when the carousel is well

positioned for adding or removing a rod.

S) Mode selector :

S0) Manual mode.

S1) Automatic mode for rod adding.

S2) Automatic mode for rod removing.

When an automatic mode is selected, the different

movements of the rod clamps arms and those of the

carousel are controlled automatically. This makes the

different operations easiest and reduces the cycle

time.

Functions





















 

Depressed the indicated pushed button to operate :

M1 Rod clamps closing (upper and lower).

M2 Carousel rotation (manual mode only).

M3 Rod / drifter shank threads lubrication.

M4 Rod clamps opening (upper and lower).

M5 Carousel rotation (manual mode only).

M1 + M4 Lower rod clamp closing, upper rod

clamp opening (manual mode only).

Move the rod changer control lever in the indicated

direction to operate :

K1) Rod clamp arms swing towards the guide.

K2) Rod coupling.

K3) Rod clamp arms swing into the carousel.

K4) Rod uncoupling.

TM 5-3805-280-10

7-45
 Rod changer

LOADING THE CAROUSEL (MANUAL MODE S0)



	

	

	











	 	









Loading the carousel with rods necessitates the

presence of 1 or 2 assistants depending on the rods

weight.

Make sure that any hand signal will be perfectly understood.

The CPA should be lowered in its rest position to

load the rod.

1) Place the HP / Dust collector switch on position J1 (middle).

2) Select the manual mode (mode selector in

S0 position).

3) Check the indicator (L) is alight. If not,

depress M2 or M5 button to rotate the carousel.

Release the button when the indicator (L) is

alight.

4) Swing the rod clamp arms towards the

guide (rod changer lever in K1 direction).

5) Open the rod clamps (depress M4 button).

6) Mount a coupling on the rod to be loaded. 

Place the rod into the rod clamps.

7) Close the rod clamps onto the rod (depress

M1 button).

8) Swing the rod clamp arms into the carousel

(rod changer lever in K3 position).

9) Open the rod clamps (depress M4 button).

10) Depress M5 button to rotate the carousel.

Release the button when the indicator

(L) is alight.

11) Perform steps 4 through 10 until the carousel is loaded with 4 extension rods (do not perform

steps 9 and 10 after loading the last extension rod).

12) Make sure the centralizer is open (switch

E).

13) Raise the dusthood (switch G).

14) Place the starter rod with a coupling into the

centralizer. Close the centralizer onto the coupling

(switch E).

15) Feed the drifter down to the centralizer end

of the drill guide (feed lever in B3 direction).

16) Screw the drifter shank into the coupling

(rod changer lever in K2 direction).

17) Open the centralizer (switch E). Feed the

drifter back (feed lever in B2 direction) until the coupling is above the centralizer. Close the centralizer

(switch E).

18) Feed the drifter back (feed lever in B4 direction) until the rod threads are bellow the dust hood.

Screw on a bit to the rod. Retract the drifter so that the

bit enters inside the dusthood (feed lever in B2 direction).

TM 5-3805-280-10

7-46
Rod changer 

ADDING A ROD (AUTO MODE S1)











	









 



	



Make sure : 

the carousel is properly positioned i.e. a

rod housing is in front of the opening of the rod

catcher (the indicator L is then alight).

the rod clamp arms are swung into the rod

changer.

the rod clamps are closed onto a rod.

the mode selector is on S1 position.

1) When drilling with the first rod is completed,

close the centralizer onto the coupling (switch E).

2) Break loose the drifter shank (depress the

thread loosening button H and pull back the drifter

control lever in C2 direction to reverse the rotation).

The rotation of the shank must be visible when looking

at the connection, air flows from the connection.

Stop air flushing (switch F).

3) Unscrew the drifter shank from the coupling

(lever in K4 position).

4) After the drifter shank has been disconnected from the coupling, depress M3 button to lubricate the shank threads.

5) Raise the drifter to the top of the drill guide

(feed lever in B4 direction).

6) Swing the next extension rod towards the

drill guide (rod changer lever in K1 direction. Hold the

position for 1 second.)

7) Depress M3 button to lubricate the rod

threads.

8) Screw the drifter shank into the top coupling

(rod changer lever in K2 direction).

9) Depress M4 button while keeping the lever

in K2 direction to screw the rod into the bottom coupling.

10) Swing the rod changer lever in K3 direction.

Hold the position for 1 second (the rod clamps open

and the rod clamp arms swing into the carousel). #

11) Open the hydraulic centralizer (switch E).

12) Start air flushing (switch F) and drilling

(drifter lever in C3 position).

# The cycle will then end automatically : the carousel rotates to bring the following rod into the rod

clamps, the rod clamps close onto the rod.

TM 5-3805-280-10

7-47
Rod changer

REMOVING A ROD (AUTO MODE S2)



















 









Make sure : 

 the carousel is properly positioned i.e. a

rod housing is in front of the opening of the rod

catcher (the indicator L is then alight).

 the rod clamp arms are swung into the rod

changer.

 the rod clamps are closed.

 the mode selector is on S2 position.

1) While drilling the end of the last rod and if

the drifter has not reached its front end position, start

to break loose the drifter shank (depress the thread

loosening button H and pull back the drifter control

lever in C2 direction to reverse the rotation).

Stop drilling.

2) Feed the drifter back (feed lever in B4 direction) until the bottom coupling is in the centralizer.

 Close the centralizer onto the coupling

(switch E)

3) Break loose the rod (depress the thread

loosening button H and pull back the drifter control

lever in C2 direction to reverse the rotation). The rotation of the rod must be visible when looking at the connection, air flows from the connection.

Stop air flushing (switch F).

4) Swing the rod changer lever in K1 direction.

Hold the position for 1 second (the rod clamps open,

the carousel rotate, the rod clamp arms swing

towards the guide and the clamps close onto the rod).

5) Tighten the upper coupling onto the rod (rod

changer lever in K2 direction, hold the position for few

seconds).

6) Unscrew the rod from the bottom coupling

(rod changer lever in K4 direction).

note : If during this sequence, the drifter

shank or the upper coupling uncouples, returns to

point 5).

7) After the rod has been disconnected from

the bottom coupling and is high enough to enter into

the carousel, close the clamps onto the rod : the

drifter shank unscrews from the top coupling (depress

M1 button while changer lever in K4 direction).

8) After the drifter shank has been disconnected from the top coupling swing the rod into the

carousel (changer lever in K3 direction).

note : If the rod abuts against the rod holder

plate, 

– swing the rod toward the guide (changer

lever in K1 direction).

– screw the drifter shank into the coupling

(changer lever in K2 direction).

– depress M4 button to open the clamps

and keeping M4 button depressed, adjust the position

of the rod by acting on the feed control lever.

– swing the rod into the carousel (changer

lever in K3 direction).

9) Feed the drifter down to the centralizer end

of the drill guide (feed lever in B3 direction).

10) Screw the drifter shank into the coupling

(rod changer lever in K2 direction).

11) Perform steps 2 through 10 to remove more

rod.

TM 5-3805-280-10

7-48
Starting operation

START UP

– Make a walk–around inspection before

mounting the machine and starting the engine.

– Look around and under the machine for

loose bolts, broken or worn parts. Have the machine

repaired before starting.

– Check engine oil and coolant, hydraulic and

compressor oil levels. Refill if necessary.

– Check the emergency stop selector is

placed on CPA position.

CPA

– Check all electric cables of the remote control are properly connected.

– Check excavator safety switch is in lock

position.

– Check compressor is off.

– Start engine and warm by carrier manufacturer handbook.

– Set engine R.P.M mode.

– Set the guide in toe holes drilling position, to

inspect the guide chains and wire rope. (#)

 (#) refer to maintenance section for further information.

TM 5-3805-280-10

7-49
Travelling

TRAVELLING

– Excavator safety switch to unlock.

– Boom up, CPA vertical to 1.5 meter from

ground.

– Base of CPA close but clear of tracks.

– Travel at a speed suitable to ground conditions.

– Be careful when tramming over rough terrain to prevent tipping or any hazardous conditions.

– Never use CPA to assist with slewing.

TRAVELLING HOLE TO HOLE

– Turn off CPA and compressor.

– Be sure of side and rear clearance from batters and machinery.

– Lift mast base clear of ground.

– Slew and travel slowly. Do not extend dipper to full length to reach hole.

TM 5-3805-280-10

7-50


DRILLING

POSITION FOR DRILLING

– Do not over reach.

– Position base of mast over top of hole..

– Place mast base on ground slowly.

– Do not jack machine off ground.

– Do not re–position boom or mast whilst

resting on ground.

START UP DRILLING

– Check engine R.P.M mode setting.

– Start compressor.

– Close centralizer.

– Dust hood up.

START DRILLING

– Flush air to collar position and dust collector

on.

– Rotation only feed bit to just above ground.

– Move drill lever to “AUTO” position.

– Depress button / Flick feed lever forward

and stop several times till bit travels without deflection.

If not straight start new hole

– With bit straight hold lever forward and button depressed to complete collaring to required

depth.

Use water if required but dust collector must be off

(if machine is so equipped).

– Move feed up and down the collar with air

off to solidify wall of hole.

TM 5-3805-280-10

7-51


DRILLING

– Dust collector on. Dust hood down.

– Flushing air on.

– Feed down without hammering till reaching

end of collar (solid ground).

– Move drill lever to auto and start drilling.

– When sampling or completion of hole, turn

dust collector off to purge filters (if machine is so

equipped).

SETTING OF BIT ROTATION

The bit rotation speed can not be adjusted directly

from the operator’s control panel.

To modify the bit rotation, it is necessary to act on

the rotation flow regulator.


 
		 

TM 5-3805-280-10

7-52
WATER POCKETS

As soon as the operator observes water going into

the dust collector, shut it down. If shutdown was

immediate and operator is sure that no water has

entered the dust collector, drilling may be resumed

until dust smoke is observed coming from the

hole. Then the dust collector can be started again.

If water has entered the dust collector, or in case

of doubt, stop drilling and retract the drifter (do not

stay in the water pocket). Wait 5 to 10 minutes

with the dust collector running and air flushing so

as to dry the filter cartridges. Then do 10 cycles of

stopping, flushing and starting the dust collector

again to clean the dry mud from the filter cartridge.

Restart drilling with the dust collector shut off as

long as no dust smoke is coming from the hole.

Mud inside the hood and plastic hose has to be

removed manually.

ROD CHANGING

Refer to Changing a Rod.

SHUT DOWN

— Switch off drill and compressor.

— Move carrier to park site.

— Position CPA vertical. mast base on ground.

— Position excavator safety switch to lock.

— Idle down engine to manufacturer

specifications.

TM 5-3805-280-10

7-53
Operating the Machine

CED,OUOEBAS,2 –19–19JAN00–1/1

LOWER BOOM WITH ENGINE STOPPED

X9811 –UN–23AUG88 T127544 –UN–19JAN00

A—Relief Valve

B—Boom Cylinder

When an engine stops during operation, the boom cannot

be lowered using the pilot controller because there is no

pilot pressure oil to move the boom valve spool or to

unlatch the boom load lowering valves.

CAUTION: Prevent possible injury from

unexpected machine movement. Clear all

persons from the area before lowering the

boom with the engine stopped.

To avoid injury from escaping fluid under

pressure, stop engine and relieve the pressure

in the system before disconnecting or

connecting hydraulic or other lines. Tighten all

connections before applying pressure.

1. Loosen jam nut on relief valve (A). Back off relief valve

set screw, counting number of turns, until boom starts

to lower slowly.

2. After bucket is on ground, reset relief valve (A) by

turning set screw clockwise the same number of turns

noted in step 1 and lock jam nut.

TM 5-3805-280-10

7-54
Operating the Machine

TX,OUOE042,21 –19–04MAR99–1/1

USING HYDRAULIC HAND TOOLS HOSE

REEL

T120425 –UN–25MAR99

A—Male Hose End

B—Female Hose End

KEEPING HYDRAULIC SYSTEM CLEAN

IMPORTANT: To prevent damage to hydraulic

components, keep contamination from

entering hydraulic system.

Connect tool to corresponding hose ends (A and B).

TX,OUOE042,22 –19–04MAR99–1/1

USING HYDRAULIC HAND TOOLS FLOW

RATE VALVE AND SWITCH

T120426 –UN–25MAR99

Once tool is connected to hose ends, turn on switch (B).

Set flow rate valve (A) to flow rate required to operate

tool.

CED,OUOE012,186 –19–24MAY99–1/1

USING HAND HELD AIR TOOLS

T121502 –UN–02JUN99

CAUTION: Make sure the air tool outlet shutoff

lever is in the Off position before attempting to

remove the outlet cover or disconnecting hand

tools.

1. Remove air tool outlet cover (A) and connect air tool

hose to outlet.

2. Move outlet shutoff lever (B) to On.

TM 5-3805-280-10

7-55
TM 5-3805-280-10

BLANK

7-56
CHAPTER 8

TRANSPORTING

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Transporting

TX,40,DH5074 –19–01JUL96–1/2

LOADING MACHINE ON A TRAILER

T7405BI –UN–29NOV90

WARNING: The M870 and M870A1 trailers may

be used to haul/transport the John Deere

Hydraulic Excavators (Model Numbers 230LCR

and 230LCRD) providing the following

precautions are adhered to:

• Position the longitudinal centerline of the

hydraulic excavator as near as possible over

the longitudinal centerline of the trailer, i.e.,

overhang of the hydraulic excavator tracks to

be equal on both left and right outriggers.

• An M870 or M870A1 trailer shall be limited to

primary and secondary roads (paved and

gravel) when hauling a hydraulic excavator.

• The truck/tractor shall reduce its top speed

by 50% when hauling an M870 or M870A1

trailer loaded with a hydraulic excavator.

• An M870 or M870A1 trailer loaded with a

hydraulic excavator shall not be operated on

roads with side slopes greater than 10%.

1. Keep trailer bed clean.

2. Put chocks against trailer wheels.

3. Use a ramp or loading dock. Ramps must be strong

enough and have a low angle of 10—15°.

CAUTION: Prevent possible injury from

unexpected machine movement. Turn auto-idle

switch off and turn H/P mode switch off when

loading or unloading the machine.

4. Turn auto-idle switch off and turn H/P mode switch off.

5. Load and unload machine on a level surface.

6. Drive machine onto ramps slowly.

7. The centerline of the machine should be over the

centerline of the trailer.

8. Position bucket with flat surface resting on trailer.

Angle (A) of arm to boom should be 90°.

Continued on next page

TM 5-3805-280-10

8-1
Transporting

TX,40,DH5074 –19–01JUL96–2/2

IMPORTANT: To prevent machine or trailer damage,

do not allow machine to impact trailer

with bucket.

9. Bucket must be resting on trailer before machine

begins to tip forward onto trailer.

TX,OUOE042,18 –19–02MAR99–1/1

TIEDOWNS

T121038 –UN–14APR99

Tiedown loops (A) are located on the front and rear frame

of the machine. The tiedown are used to secure the

machine to the transport medium.

TM 5-3805-280-10

8-2
Transporting

TX,40,DH5642 –19–26MAR97–1/3

FASTEN MACHINE TO TRAILER

T125167 –19–28OCT99

Continued on next page

TM 5-3805-280-10

8-3
Transporting

TX,40,DH5642 –19–26MAR97–2/3

T125168 –19–28OCT99

Before leaving the operator’s seat, perform steps 1—9.

1. Position machine on trailer so that dimension (A) is

1372 mm (54 in.).

2. Extend bucket cylinder fully.

3. Extend arm cylinder fully.

4. Lower the boom.

If machine cannot be transported with arm fully

retracted, remove bucket or attachment and retract

arm.

5. Lower bucket onto blocks.

Continued on next page

TM 5-3805-280-10

8-4
Transporting

TX,40,DH5642 –19–26MAR97–3/3

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

6. Run engine at 1/2 speed without load for 2 minutes.

7. Move engine speed rpm dial to slow idle position.

8. Turn key switch to OFF. Remove key from switch.

9. Pull pilot control shut-off lever to locked position.

IMPORTANT: Prevent cab electrical component

damage from bad weather. Always

close windows, roof vent, and cab

door.

10. Close windows, roof vent, and cab door.

11. Cover exhaust opening to prevent entry of wind

and water.

IMPORTANT: Prevent possible damage to

hydraulic lines, rods, and hoses.

Fasten chains to machine frame.

12. Install chock blocks and 2 transport brackets over

track shoes. Fasten machine to trailer with chains

and nylon strap.

TM 5-3805-280-10

8-5
Transporting

CED,OUOE042,48 –19–19OCT99–1/2

LOADING AND FASTENING ROCK DRILL ON A TRAILER

T125169 –19–03NOV99

Rock Drill on M870 Trailer

1. Keep trailer bed clean. 2. Put chocks against trailer wheels.

Continued on next page

TM 5-3805-280-10

8-6
Transporting

CED,OUOE042,48 –19–19OCT99–2/2T125560 –UN–03NOV99

A—Rock Drill Dust Collector Blocking

3. Load and unload rock drill on a level surface.

CAUTION: Ensure that the lifting device is

capable of supporting the rock drill. The

approximate weight of the rock drill is 4536 kg

(10,000 lb). Keep all people clear of raised load.

4. Load rock drill onto trailer.

5. Install blocking (A) under rock drill dust collector.

6. Fasten rock drill to trailer with chains.

TM 5-3805-280-10

8-7
Transporting

CED,OUOE042,49 –19–19OCT99–1/2

FASTEN MACHINE TO RAIL CAR (MODEL 230LCR)

T125165 –19–28OCT99

Before leaving the operator’s seat, perform steps 1—6.

1. Extend bucket cylinder fully.

2. Extend arm cylinder fully.

3. Lower the deck.

If machine cannot be transported with arm fully

retracted, remove bucket or attachment and retract

arm.

4. Lower bucket onto deck.

Continued on next page

TM 5-3805-280-10

8-8
Transporting

CED,OUOE042,49 –19–19OCT99–2/2

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine at 1/2 speed without load for 2 minutes.

6. Move engine speed rpm dial to slow idle position.

7. Turn key switch to OFF. Remove key from switch.

8. Pull pilot control shut-off lever to locked position.

IMPORTANT: Prevent cab electrical component

damage from bad weather. Always

close windows, roof vent, and cab

door.

9. Close windows, roof vent, and cab door.

10. Cover exhaust opening to prevent entry of wind

and water.

IMPORTANT: Prevent possible damage to

hydraulic lines, rods, and hoses.

Fasten chains to machine frame.

11. Fasten machine to rail car with 16 chains and

nylon strap.

TM 5-3805-280-10

8-9
Transporting

CED,OUOE042,50 –19–19OCT99–1/3

FASTEN MACHINE AND ROCK DRILL TO RAIL CAR (MODEL 230LCRD)

T125166 –19–11JAN00

Before leaving the operator’s seat, perform steps 1—6.

1. Extend bucket cylinder fully.

2. Extend arm cylinder fully.

3. Lower the boom.

If machine cannot be transported with arm fully

retracted, remove bucket or attachment and retract

arm.

4. Lower bucket onto deck.

Continued on next page

TM 5-3805-280-10

8-10
Transporting

CED,OUOE042,50 –19–19OCT99–2/3

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine at 1/2 speed without load for 2 minutes.

6. Move engine speed rpm dial to slow idle position.

7. Turn key switch to OFF. Remove key from switch.

8. Pull pilot control shut-off lever to locked position.

IMPORTANT: Prevent cab electrical component

damage from bad weather. Always

close windows, roof vent, and cab

door.

9. Close windows, roof vent, and cab door.

10. Cover exhaust opening to prevent entry of wind

and water.

IMPORTANT: Prevent possible damage to

hydraulic lines, rods, and hoses.

Fasten chains to machine frame.

11. Fasten machine to rail car with 16 chains and

nylon strap.

CED,OUOE042,50 –19–19OCT99–3/3T125560 –UN–03NOV99

CAUTION: Ensure that the lifting device is

capable of supporting the rock drill. The

approximate weight of the rock drill is 4536 kg

(10,000 lb). Keep all people clear of raised load.

12. Load rock drill onto rail car.

13. Install blocking (A) under rock drill dust collector.

14. Fasten rock drill to rail car with chains and nylon

strap.

TM 5-3805-280-10

8-11
Transporting

TX,40,DH5146 –19–10AUG96–1/3

UNLOADING MACHINE FROM TRAILER

T7405BJ –UN–29NOV90

CAUTION: Prevent possible injury from

unexpected machine movement. Turn auto-idle

switch off and turn H/P mode switch off when

loading or unloading the machine.

1. Turn auto-idle switch off, turn H/P mode switch off, and

move propel speed switch to slow speed.

CAUTION: Prevent possible injury from machine

tipping while upperstructure is rotating. Keep

arm tucked under and rotate upperstructure

slowly for best stability.

2. Raise bucket slightly off trailer. Keeping arm tucked

under, slowly rotate upperstructure 180°.

TX,40,DH5146 –19–10AUG96–2/3T7405BK –UN–29NOV90

IMPORTANT: Prevent possible damage to front-end

attachment. Always position arm at 90°

to boom when unloading machine.

Unloading machine with arm tucked

may cause machine damage.

3. To move machine over end of trailer onto ramp,

position bucket on ground with flat surface of bucket

resting on ground. Angle (A) of arm to boom should be

90°.

Continued on next page

TM 5-3805-280-10

8-12
Transporting

TX,40,DH5146 –19–10AUG96–3/3T7405BL –UN–29NOV90

IMPORTANT: Prevent possible damage to hydraulic

cylinders. Do not allow machine to

impact ground with bucket.

4. Bucket must be on ground before machine begins to

tip forward.

5. As machine moves forward, raise the boom and extend

arm until machine is completely off ramp.

TX,40,FF2193 –19–06JUL94–1/1

TOWING MACHINE

T6879EG –UN–06DEC88

CAUTION: Prevent possible injury from

unexpected machine movement. Block both

tracks when disconnecting propel gearboxes.

When propel gearboxes are disconnected,

machine has no brakes and can move. The

machine will roll free on a slope or while being

towed.

1. Block tracks.

2. Drain oil from each propel gearbox. (See Change

Propel Gearbox Oil in Maintenance—Every 2000 Hours

chapter.)

3. Remove cover from each gearbox.

4. Remove sun gear (A) from each gearbox.

5. Install cover. Fill gearbox with oil.

TM 5-3805-280-10

8-13
Transporting

CED,OUOESLH,9 –19–14DEC99–1/1

LIFTING THE MACHINE

T120447 –UN–25MAR99

Use all four lifting rings (A) to lift the machine.

CAUTION: Prevent possible injury from

unexpected machine movement when lifting the

machine. Check lifting capacity of crane before

lifting the excavator. Lift load only as high as

necessary.

Keep all people clear of raised load.

Approximate weight of machine, less bucket, is as follows:

230LCR

24 712 kg (54,480 lb)

230LCRD

25 056 kg (55,240 lb)

TM 5-3805-280-10

8-14
CHAPTER 9

FUELS AND LUBRICANTS

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Fuels and Lubricants

CED,OUOE020,2 –19–11FEB99–1/1

DIESEL FUEL

Consult your local fuel distributor for properties of the

diesel fuel available in your area.

In general, diesel fuels are blended to satisfy the low

temperature requirements of the geographical area in

which they are marketed.

Diesel fuels specified to A-A-52557, EN 590 or ASTM

D975 are recommended.

In all cases, the fuel shall meet the following

properties:

• Cetane Number 40 minimum. Cetane number

greater than 50 is preferred, especially for

temperatures below -20°C (-4°F) or elevations above

1500 m (5000 ft).

• Cold Filter Plugging Point(CFPP) below the

expected low temperature OR Cloud Point at least

5°C (9°F) below the expected low temperature.

• Fuel Lubricity should pass a minimum of 3100

gram load level as measured by the SL BOCLE

scuffing test.

• Sulfur content:

• Sulfur content should not exceed 0.5% Sulfur

content less than 0.05% is preferred.

• If diesel fuel with sulfur content greater than 0.5%

sulfur content is used, reduce the service interval

for engine oil and filter by 50%.

• DO NOT use diesel fuel with sulfur content greater

than 1.0%.

Bio-diesel fuels with properties and meeting DIN 51606

or equivalent specifications may be used.

Aviation fuel Grade JP-8 may be used.

DO NOT mix used engine oil or any other type of

lubricant with diesel fuel.

TX,45,JC1771 –19–08JAN97–1/1

LUBRICITY OF DIESEL FUELS

Diesel fuel must have adequate lubricity to ensure

proper operation and durability of fuel injection system

components.

Diesel fuels for highway use in the United States and

Canada now require sulfur content less than 0.05%.

Diesel fuel in the European Union will require sulfur

content less than 0.05% by 1 October 1996.

Experience shows that some low sulfur diesel fuels

may have inadequate lubricity and their use may

reduce performance in fuel injection systems due to

inadequate lubrication of injection pump components.

The lower concentration of aromatic compounds in

these fuels also adversely affects injection pump seals

and may result in leaks.

Use of low lubricity diesel fuels may also cause

accelerated wear, injection nozzle erosion or corrosion,

engine speed instability, hard starting, low power, and

engine smoke.

Fuel lubricity should pass a minimum of 3100 gram

load level as measured by the SL BOCLE scuffing

test.

A-A-52557, ASTM D975 and EN 590 specifications do

not require fuels to pass a fuel lubricity test.

If fuel of low or unknown lubricity is used, add John

Deere PREMIUM DIESEL FUEL CONDITIONER or

Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble

(MIL-PRF-25017) at the recommended concentration.

John Deere PREMIUM DIESEL FUEL CONDITIONER

is available in winter and summer formulas. Consult

your John Deere engine distributor or servicing dealer

for more information.

TM 5-3805-280-10

9-1
Fuels and Lubricants

TX,45,DH5857 –19–15AUG97–1/1

LOW SULFUR DIESEL FUEL CONDITIONER

When possible, use existing fuel formulations for engines

used off-highway. This fuel will not require any additives

to provide good performance and engine reliability.

However, many local fuel distributors will not carry both

low and regular sulfur diesel fuels.

If only low sulfur fuel is available, Inhibitor,

Corrosion/Lubricity Improver, Fuel Soluble should be

added at the recommended concentration

(MIL-PRF-25017). Nearly all other diesel fuel conditioners

only improve cold weather flow and stabilize long-term

fuel storage. They do not contain the lubrication additives

needed by rotary fuel injection pumps.

TX,45,JC1772 –19–08JAN97–1/1

DIESEL FUEL STORAGE

Proper fuel storage is critically important. Use clean

storage and transfer tanks. Periodically drain water

and sediment from bottom of tank. Store fuel in a

convenient place away from buildings.

IMPORTANT: DO NOT store diesel fuel in

galvanized containers. Diesel fuel

stored in galvanized containers

reacts with zinc coating on container

to form zinc flakes. If fuel contains

water, a zinc gel will also form. The

gel and flakes will quickly plug fuel

filters, damage injection nozzles and

injection pump.

DO NOT use brass-coated containers

for fuel storage. Brass is an alloy of

copper and zinc.

Store diesel fuel in plastic, aluminum, and steel

containers specially coated for diesel fuel storage.

Avoid storing fuel over long periods of time. If fuel is

stored for more than a month prior to use, or there is a

slow turnover in fuel tank or supply tank, add a fuel

conditioner such as John Deere PREMIUM DIESEL

FUEL CONDITIONER or fuel conditioner meeting

MIL-S-53021 to stabilize the fuel and prevent microbial

growth in the fuel. John Deere PREMIUM DIESEL

FUEL CONDITIONER is available in winter and

summer formulas. Fuel conditioner also reduces fuel

gelling and controls wax separation during cold

weather.

Consult your John Deere engine distributor or servicing

dealer for recommendations and local availability.

Always follow manufacturer’s directions on label.

TM 5-3805-280-10

9-2
Fuels and Lubricants

CED,TX14740,6018 –19–28JAN98–1/1

FUEL TANK

CAUTION: Handle fuel carefully. If the engine is

hot or running, do not fill the fuel tank. Do not

smoke while you fill fuel tank or work on fuel

system.

To avoid condensation, fill the fuel tank at the end of each

day’s operation. Capacity is 560 L (148 gal).

Fuel Tank—Specification

Capacity............................................................................. 560 L (148 gal)

DX,FLBT,C –19–04JUN90–1/1

DO NOT USE GALVANIZED CONTAINERS

IMPORTANT: Diesel fuel stored in galvanized

containers reacts with zinc coating

on the container to form zinc flakes.

If fuel contains water, a zinc gel will

also form. The gel and flakes will

quickly plug fuel filters and damage

fuel injectors and fuel pumps.

DO NOT USE a galvanized container to store diesel

fuel.

Store fuel in:

• plastic containers.

• aluminum containers.

• specially coated steel containers made for diesel

fuel.

DO NOT USE brass-coated containers: brass is an

alloy of copper and zinc.

TM 5-3805-280-10

9-3
Fuels and Lubricants

CED,OUOE020,3 –19–12FEB99–1/1

DIESEL ENGINE AND PUMP GEARBOX OILS

T125427 –19–28OCT99

Use oil viscosity based on the expected air

temperature range during the period between oil

changes.

Other oils may be used if they meet one or more of

the following:

• MIL-PRF-2104G

• MIL-L-46167B

• MIL-PRF-46167C

• API CG-4

• API CF-4

Multi-viscosity diesel engine oils are preferred.

If diesel fuel with sulfur content greater than 0.5% is

used, reduce the service interval by 50%.

TM 5-3805-280-10

9-4
Fuels and Lubricants

CED,OUOE020,4 –19–12FEB99–1/1

HYDRAULIC OIL

T125428 –19–17NOV99

Depending upon the expected air temperature range

between oil changes, use oil viscosity shown on the

temperature chart above.

Use oils meeting one or more of the following:

• MIL-PRF-2104G1

• MIL-L-46167B

• MIL-PRF-46167C

• API CG-41

• API CF-41

1Must contain a minimum zinc additive of 0.09 percent.

TM 5-3805-280-10

9-5
Fuels and Lubricants

CED,OUOE020,5 –19–12FEB99–1/1

SWING GEARBOX AND PROPEL GEARBOX OILS

T125429 –19–17NOV99

Depending upon the expected air temperature range

between oil changes, use oil viscosity shown on the

temperature chart above.

The following oils are recommended:

• Oils meeting MIL-PRF-2105. MIL-PRF-2105E is

updated.

• Oils meeting API Service GL-5 (MIL-L-2105E).

CED,OUOE020,6 –19–12FEB99–1/1

TRACK ROLLER, FRONT IDLER, AND

CARRIER ROLLER OIL

Use oil viscosity based on the expected air temperature

range during the period between oil changes.

The following oils are recommended:

• MIL-PRF-2105E (80W90).

• API Service Classification GL-5 gear oil (SAE 80W90).

• Arctic oil such as MIL-PRF-2105E (75W) should be

used at temperatures below -30°C (-11°F).

TM 5-3805-280-10

9-6
Fuels and Lubricants

CED,OUOE020,7 –19–12FEB99–1/1

TRACK ADJUSTER, WORKING TOOL PIVOT, SWING BEARING, AND SWING BEARING

GEAR GREASE

T120320 –19–25MAR99

Use grease based on NLGI consistency numbers and

the expected air temperature range during the service

interval.

Use greases meeting MIL-PRF-10924G.

Lithium complex grease containing high temperature,

extreme pressure properties with 3-5 percent

molybdenum disulfide is preferred, although those

without the molybdenum disulfide are acceptable.

DX,FILT –19–18MAR96–1/1

OIL FILTERS

Filtration of oils is critical to proper operation and

lubrication. Always change filters regularly as specified in

this manual.

Use filters meeting John Deere performance

specifications.

TM 5-3805-280-10

9-7
Lubricant specifications

ROCK DRILL LUBRICANTS SPECIFICATIONS

We recommend the use of the MOBIL lubricants.

These are selected to get the best performances out

of our equipments.

If the MOBIL products are not available, our warranty will apply only if high quality lubricants are used

according to the following specifications and under

the responsability of your supplier.

HYDRAULIC CIRCUIT

 Oil ISO VG 32 (ISO VG 46 when 10oC <t<45o C)

with stabilized anti–wear additive

Specifications :

Viscosity at 40oC: 30 to 33 cSt (46 cSt)

Viscosity index VI: 150 (140)

Pour point: < – 40oC

De airing:  5 mn

Performances :

Homologation: DENISON HFO

Anti wear: FZG 12

VICKERS 35 VQ 25 : total wear < 50 mg

ASTM D 130 : cotation 1 a

Anti corrosion: CINCINNATI P 70 – pass

Filterability: DENISON TP 02–100 :

 t < 200 seconds with water 2%

Oxydation stability NFT 60150 t > 2200 h

for 1 a  2 ASTM D 943

Performances :

specifications: MIL-PRF-2105E

PNEUMATIC CIRCUIT

Anti wear oils for pneumatic equipment

ISO VG 46 for : t  0oC

ISO VG 100 for : t > 0oC

Performances :

film resistance

reinforced anti–wear

anti–corrosion

anti–freeze (for : t  OoC)

Specifications :

Pour point <–24o C

Flash point 218o C

Viscosity at 40o C: 150 cSt

Viscosity index Vi: 140

GEAR BOX

High pressure oil SAE 80 W 90 for transmissions.

Performances :

specifications: MIL-PRF-2105E

GREASE

MIL-PRF-10924G

TM 5-3805-280-10

9-8
SECTOR 0°C to -45°C

PRODUCT

+30°C to -20°C

PRODUCT

+45°C to +10°C

PRODUCT

Hydraulic MOBIL SHC 524 MOBIL DTE 13 M MOBIL DTE 15 M

Pneumatic MOBIL SHC 524 MOBIL

ALMO 527 (t > 0°C)

ALMO 325 (t < 0°C)

ALMO 527

Grease MOBILTEMP

SHC 100 SPECIAL

MOBILGREASE

SPECIAL

MOBILGREASE

SPECIAL

GCL/GCX reducer MOBIL SHC 630 MOBIL SHC 630 MOBILGEAR 629

MOBIL SHC 630

TM 5-3805-280-10

9-9
AIR COMPRESSOR LUBRICANTS

FLUIDS AND LUBRICANTS TABLE

ITEM FLUID AMBIENT TEMP. SPECIFICATION

Compressor Models:

VHP - (200 + psi)

 HP - (150 psi)

 XP - (125 psi)

 P - (100 psi)

Airend

Lubricant -10°F to 125°F

(-23°C to 52°C)

 IR Pro-TecTM

MIL-PRF-2104G

• A-A-52039

 SAE 10W

 -40°F to 125°F

(-40°C to 52°C)

 IR Performance 500

 -40°F to 65°F

(-40°C to 18°C)

• MIL-PRF-46167

 NXP (Oil Free) Refer to Operator’s Manual

 Recommended Ingersoll-Rand Fluids -

Use of these fluids with original I-R filters can extend airend warranty. Refer to operator’s manual warranty

section for details or contact your I-R representative.

Recommended Fluid 1 Gal. (3.8 litre) 5 Gal. (19.0 litre) 55 Gal. (208.2 litre)

IR Pro-TecR 36899698 36899706 36899714

IR Performance 500 35382928 35382936 35382944

DexronR - Reg. T.M. of General Motors Corp. Pro-TecTM - T.M. of Ingersoll-Rand

For Parts, Service & nearest Distributor call 1-800-633-5206

TM 5-3805-280-10

9-10
Fuels and Lubricants

DX,LUBST –19–18MAR96–1/1

LUBRICANT STORAGE

Your equipment can operate at top efficiency only

when clean lubricants are used.

Use clean containers to handle all lubricants.

Whenever possible, store lubricants and containers in

an area protected from dust, moisture, and other

contamination. Store containers on their side to avoid

water and dirt accumulation.

Make certain that all containers are properly marked to

identify their contents.

Properly dispose of all old containers and any residual

lubricant they may contain.

DX,ALTER –19–18MAR96–1/1

ALTERNATIVE AND SYNTHETIC

LUBRICANTS

Conditions in certain geographical areas may require

lubricant recommendations different from those printed in

this manual. Some John Deere brand coolants and

lubricants may not be available in your location. Consult

your John Deere dealer to obtain information and

recommendations.

Synthetic lubricants may be used if they meet the

performance requirements as shown in this manual.

The temperature limits and service intervals shown in this

manual apply to both conventional and synthetic oils.

Re-refined base stock products may be used if the

finished lubricant meets the performance requirements.

TM 5-3805-280-10

9-11
Fuels and Lubricants

DX,LUBMIX –19–18MAR96–1/1

MIXING OF LUBRICANTS

In general, avoid mixing different brands or types of oil.

Oil manufacturers blend additives in their oils to meet

certain specifications and performance requirements.

Mixing different oils can interfere with the proper

functioning of these additives and degrade lubricant

performance.

Consult your John Deere dealer to obtain specific

information and recommendations.

CED,OUOE020,51 –19–13APR99–1/1

FACTORY/INITIAL FILL LUBRICANTS

The acceptable air temperature ranges for the initial fill

lubricants are as follows:

Engine ................................................... -25°C (-13°F) to 40°C (104°F)

Pump Gearbox ...................................... -25°C (-13°F) to 50°C (122°F)

Hydraulic Oil .......................................... -29°C (-20°F) to 50°C (122°F)

Swing and Propel Gearbox ..................... -20°C (-4°F) to 50°C (122°F)

TM 5-3805-280-10

9-12
TM 5-3805-280-10

CHAPTER 10

PERIODIC MAINTENANCE—EXCAVATOR
TM 5-3805-280-10

BLANK
Periodic Maintenance

TX,50,DH5147 –19–10AUG96–1/1

SERVICE YOUR MACHINE AT SPECIFIED

INTERVALS

T102298 –UN–30JUL96

Lubricate, make service checks, and make adjustments at

intervals shown on the periodic maintenance chart (A) and

on the following pages.

Perform service on items at multiples of the original

requirement. For example, at 500 hours also service those

items (if applicable) listed under 250 hours, 100 hours, 50

hours and 10 hours or daily.

TX,50,DH5063 –19–24JUN96–1/1

CHECK THE HOUR METER REGULARLY

T101639 –UN–26JUN96

Check the hour meter (A) to determine when your

machine needs periodic maintenance.

Intervals on the periodic maintenance chart are for

operating in normal conditions. If you operate your

machine in difficult conditions, you should service it at

SHORTER INTERVALS.

TX,50,DH5112 –19–12JUL96–1/1

USE CORRECT FUELS AND LUBRICANTS

IMPORTANT: To prevent machine damage, when

servicing your machine use correct

fuels and lubricants. (See Fuels and

Lubricants chapter.)

TM 5-3805-280-10

10-1
Periodic Maintenance

TX,50,DH5079 –19–02JUL96–1/1

PREPARE MACHINE FOR MAINTENANCE

Before performing maintenance procedures given in the

following chapters and before leaving the operator’s seat,

park the machine as described below unless another

position is specified in the procedure.

1. Park machine on a level surface.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Turn key switch to OFF. Remove key from switch.

7. Pull pilot control shut-off lever to locked position.

TM 5-3805-280-10

10-2
Periodic Maintenance

TX,50,DH5095 –19–08JUL96–1/1

OPEN ACCESS DOORS FOR SERVICE

T102125 –UN–26JUL96

Right Side Access Door

T102126 –UN–26JUL96

Front Left Side Access Door

T102127 –UN–26JUL96

Rear Left Side Access Door

CAUTION: Prevent possible injury from door

closing. Secure door in the OPEN position.

To hold door open, remove rod from stored position (A)

and insert in tab (B) on door.

TM 5-3805-280-10

10-3
Periodic Maintenance

TX,50,DH5439 –19–03MAR97–1/1

OPEN HOOD FOR SERVICE

T107777 –UN–03MAR97

Engine Hood

CAUTION: Prevent possible injury. Unlock latch.

Pull open latches to unlock hood. Raise the

hood until the end of the bar is securely locked

into catch.

Raise hood using handle on hood until the end of the rod

is securely locked into catch (A).

TM 5-3805-280-10

10-4
TM 5-3805-280-10

CHAPTER 11

MAINTENANCE—AS REQUIRED
TM 5-3805-280-10

BLANK
Maintenance—As Required

CED,OUOE020,19 –19–17DEC99–1/1

SAMPLING ENGINE OIL

T125092 –UN–28OCT99

NOTE: Sample engine oil every 50 hours or 90 days.

1. Run engine to warm oil.

2. Park machine on a level surface.

3. Lower bucket to the ground.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Attach a “Do Not Operate” tag on the right control

lever.

7. Pull pilot control shut-off lever to locked position.

8. Open engine hood and secure hood in open position.

9. Clean valve (A) and use to sample engine oil.

TM 5-3805-280-10

11-1
Maintenance—As Required

CED,OUOE042,42 –19–17DEC99–1/1

SAMPLING HYDRAULIC OIL

T127009 –UN–23DEC99

IMPORTANT: Prevent damage to hydraulic system

components. DO NOT run engine

without oil in hydraulic tank.

NOTE: Sample hydraulic oil once a year.

1. Park machine on a level surface.

2. Position machine with arm cylinder fully retracted and

bucket cylinder fully extended.

3. Lower bucket to the ground.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Attach a “Do Not Operate” tag on the right control

lever.

7. Pull pilot control shut-off lever to locked position.

8. Open rear right side access door and secure door in

open position.

9. Clean valve (A), located on pilot filter housing

assembly, and use to sample hydraulic oil.

TM 5-3805-280-10

11-2
Maintenance—As Required

TX,55,DH5138 –19–08AUG96–1/1

CLEAN FUEL TANK INLET SCREEN

T102894 –UN–07AUG96

Clean screen (A) to remove any debris. Use solvent or

diesel fuel.

Replace screen if damaged.

TX,55,DH5081 –19–02JUL96–1/1

DRAIN FUEL TANK SUMP

T7396CI –UN–18OCT90

1. Park machine on a level surface. Rotate upperstructure

90° for easier access.

2. Remove fuel tank fill cap.

NOTE: Plug is installed in drain cock to prevent

vandalism.

3. Remove plug (A) and open drain cock (B) for several

seconds to drain water and sediment into a container.

Dispose of waste properly. Close drain cock.

4. Install and tighten plug.

5. Install fill cap.

TM 5-3805-280-10

11-3
Maintenance—As Required

TX,55,DH5565 –19–02JUL96–1/1

CLEAN RADIATOR AIR INLET SCREENS

T108113B –UN–27MAR97

Remove wing nut (A) and pull up on handles (B) to slide

screens up for cleaning. Use pressurized air (30 psi max.)

or low pressure water.

TX,55,DH5083 –19–02JUL96–1/1

DRAIN WATER SEPARATOR

T102299 –UN–30JUL96

1. Open right access door to access water separator.

2. Open drain valve (A) and press pump (B) to extract

water from fuel system. Collect waste in a container

and dispose of it properly.

3. Close drain valve.

TM 5-3805-280-10

11-4
Maintenance—As Required

TX,55,DH5084 –19–02JUL96–1/1

CLEAN AIR CLEANER DUST UNLOADER

VALVE

T101488 –UN–15JUL96

IMPORTANT: A missing, damaged, or hardened dust

unloader valve will make the dust cup

precleaner ineffective, causing very

short element life. Valve should suck

closed above 1/3 engine speed.

Squeeze dust valve (A) to remove dust from the air

cleaner.

If operating in high dust conditions, squeeze dust valve

every couple of hours of operation to release dust.

TX,55,DH5447 –19–04MAR97–1/2

CHECK TRACK SAG

T6879AT –UN–06DEC88

1. Swing upperstructure 90° and lower bucket to raise

track off ground.

2. Keep the angle (A) between boom and arm 90—110°

and position the bucket’s round side on the ground.

CAUTION: Prevent possible injury from

unexpected machine movement. Place blocks

under machine frame to support machine while

measuring track sag.

3. Place blocks under machine frame to support machine.

4. Rotate track forward two full rotations and then in

reverse two full rotations.

Continued on next page

TM 5-3805-280-10

11-5
Maintenance—As Required

TX,55,DH5447 –19–04MAR97–2/2T7869AP –UN–22OCT92

5. Measure distance (A) at middle track roller from bottom

of track frame to top surface of track shoe.

Normal Ground Condition—Specification

Track Sag 300—335 mm

(11-13/16—13-3/16 in.)

.............................................................................

For general information on track sag, see Maintenance

chapter.

TX,55,FF2991 –19–29OCT92–1/1

ADJUSTING TRACK SAG

T7396DZ –UN–28NOV90 T7869AQ –UN–22OCT92

A—Grease Fitting

B—Nut

C—Bleed Hole

D—Access Hole

IMPORTANT: Prevent possible damage to track

components. DO NOT use the grease

fitting on the track adjusting cylinder

for lubrication. Use this fitting ONLY for

track adjustment.

To tighten track, connect a grease gun to grease fitting

(A) (located through access hole (D) in track frame. Add

grease until sag is within recommended limits.

CAUTION: Prevent possible injury from high

pressure grease. Do not remove grease fitting

(A) from nut (B).

To loosen, slowly turn nut (B) counterclockwise; grease

will escape through the bleed hole (C).

Nut—Specification

Torque ......................................................................... 147 N•m (108 lb-ft)

When amount of track sag is satisfactory, turn nut

clockwise to tighten.

TM 5-3805-280-10

11-6
Maintenance—As Required

TX,55,DH5086 –19–02JUL96–1/1

WINDSHIELD WASHER FLUID LEVEL

T101489 –UN–15JUL96

Check fluid in windshield washer tank (A). If necessary,

remove fill cap to add fluid.

During winter season, use all season windshield washer

fluid which will not freeze.

TM 5-3805-280-10

11-7
TM 5-3805-280-10

BLANK

11-8
TM 5-3805-280-10

CHAPTER 12

MAINTENANCE—EVERY 10 HOURS OR DAILY
TM 5-3805-280-10

BLANK
Maintenance—Every 10 Hours or Daily

TX,60,DH5572 –19–10AUG96–1/1

CHECK ENGINE OIL LEVEL

T108260B –UN–27MAR97 RG5421 –UN–15DEC88

IMPORTANT: Prevent engine damage. Do not run

engine when oil level is below the ADD

mark.

The most accurate oil level reading is obtained when the

engine is cold before starting the engine for the day’s

operation.

1. Make sure dipstick (A) is fully seated.

2. Remove dipstick to check oil level.

BEFORE THE ENGINE IS STARTED: The engine is

full when oil level is in the cross hatch area (C). It is

acceptable to run the engine when the oil level is

above the ADD mark.

AFTER THE ENGINE HAS BEEN RUN: Allow the oil

to drain into the oil pan for 10 minutes before checking

the oil level. Ten minutes after shutdown the engine oil

level must be above the ADD mark.

3. If necessary, remove filler cap (B) to add oil. (See

Fuels and Lubricants chapter.)

TM 5-3805-280-10

12-1
Maintenance—Every 10 Hours or Daily

TX,60,DH5566 –19–17SEP96–1/1

CHECK RECOVERY TANK COOLANT LEVEL

T108115B –UN–27MAR97 T6274AQ –UN–18OCT88

With the engine cold, coolant level must be at the FULL

mark on the recovery tank (A).

If coolant is below the FULL mark, add coolant to the

recovery tank.

CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove radiator filler

cap unless engine is cool. Then turn cap slowly

to the stop. Release all pressure before you

remove cap.

If recovery tank is empty, check for leaks. Repair as

required. Add coolant to the radiator and the recovery

tank.

NOTE: If recovery tank is full and radiator is low, check

for leaks in radiator cap and hose connections

between radiator and coolant recovery tank.

Coolant level must be at bottom of the filler neck.

TM 5-3805-280-10

12-2
Maintenance—Every 10 Hours or Daily

TX,60,DH5096 –19–08JUL96–1/5

CHECK HYDRAULIC OIL LEVEL

T6811AI –UN–18OCT88

IMPORTANT: Prevent damage to hydraulic system

components. DO NOT run engine

without oil in hydraulic tank.

1. Park machine on a level surface.

2. Position machine with arm cylinder fully retracted and

bucket cylinder fully extended.

3. Lower bucket to the ground.

4. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

6. Move engine rpm dial to slow idle position.

7. Turn key switch to OFF. Remove key from switch.

8. Attach a ’Do Not Operate’ tag on the right control lever.

9. Pull pilot control shut-off lever to locked position.

TX,60,DH5096 –19–08JUL96–2/5T102301 –UN–30JUL96

10. Check oil level window (A) on hydraulic tank. Oil must

be between marks on window.

If necessary, add oil. (See Fuels and Lubricants

chapter.)

To add oil:

Continued on next page

TM 5-3805-280-10

12-3
Maintenance—Every 10 Hours or Daily

TX,60,DH5096 –19–08JUL96–3/5T7869AT –UN–12NOV92

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

11. Loosen vent plug (A) to release hydraulic pressure.

TX,60,DH5096 –19–08JUL96–4/5T6457EI –UN–18OCT88

A—Cap

B—Aligning Marks

C—Case Assembly

D—Hex Wrench

E—Hole

12. Insert 4 mm (0.15 in.) hex wrench (D) into hole (E)

and turn counterclockwise.

13. Slowly turn cap (A) counterclockwise. Remove cap.

14. Add oil. (See Fuels and Lubricants chapter.)

15. Install cap to case assembly (C) by aligning marks (B)

and turning cap clockwise to lock position.

Continued on next page

TM 5-3805-280-10

12-4
Maintenance—Every 10 Hours or Daily

TX,60,DH5096 –19–08JUL96–5/5T7869AT –UN–12NOV92

16. Tighten plug (A).

TM 5-3805-280-10

12-5
TM 5-3805-280-10

BLANK

12-6
TM 5-3805-280-10

CHAPTER 13

MAINTENANCE—EVERY 50 HOURS
TM 5-3805-280-10

BLANK
Maintenance—Every 50 Hours

TX,OUOE042,31 –19–17DEC99–1/3

GREASE WORKING TOOL PIVOTS

Grease working tool pivots (20 points, 230LCRD) (24

points, 230LCR) until grease escapes from joints.

Grease every 4 hours for first 20 hours. Grease every

10 hours during first 30—100 hours and when working

in mud and water. (See Fuels and Lubricants chapter.)

Continued on next page

TM 5-3805-280-10

13-1
Maintenance—Every 50 Hours

TX,OUOE042,31 –19–17DEC99–2/3

T7869AX –UN–22OCT92

Three Points

T7869AZ –UN–22OCT92

Three Points

T7869AY –UN–22OCT92

Two Points

T120466 –UN–25MAR99

One Point

T126586 –UN–17DEC99

Four Points (230LCR)

Continued on next page

TM 5-3805-280-10

13-2
Maintenance—Every 50 Hours

TX,OUOE042,31 –19–10MAR99–3/3

T7869BD –UN–22OCT92

Three Points, A—Left Side Shown

T7869BC –UN–22OCT92

Five Points

T7869BA –UN–22OCT92

One Point

T101490 –UN–15JUL96

Two Points

TM 5-3805-280-10

13-3
TM 5-3805-280-10

BLANK

13-4
TM 5-3805-280-10

CHAPTER 14

MAINTENANCE—EVERY 250 HOURS
TM 5-3805-280-10

BLANK
Maintenance—Every 250 Hours

TX,75,DH5088 –19–03JUL96–1/1

CHECK SWING GEARBOX OIL LEVEL

T101491 –UN–15JUL96

1. Park machine on a level surface.

2. Remove dipstick (A). Oil must be in the operating

range.

3. If oil is needed, remove filler cap (B) and add oil. (See

Fuels and Lubricants chapter.)

4. Check oil level.

TX,75,DH5108 –19–11JUL96–1/2

DRAIN HYDRAULIC TANK SUMP

T7869AT –UN–12NOV92

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

1. Loosen vent plug (A) to release hydraulic pressure.

TX,75,DH5108 –19–11JUL96–2/2T7869BN –UN–05NOV92

2. Loosen plug (F) for several seconds to drain water and

sediment into a container. Do not remove plug

completely. Dispose of waste properly.

3. Tighten sump plug and vent plug.

TM 5-3805-280-10

14-1
Maintenance—Every 250 Hours

TX,75,DH5679 –19–03JUL96–1/1

CHECK PUMP DRIVE GEARBOX OIL LEVEL

T101493 –UN–15JUL96

To check oil:

1. Remove dipstick (A) to release air pressure.

2. Wipe dipstick clean and insert completely into tube.

3. Pull dipstick.

4. Oil must be approximately halfway below the ’H’ (level)

mark.

To add oil:

1. Remove filler cap (B).

2. Add oil. (See Fuels and Lubricants chapter.)

3. Install filler cap.

TM 5-3805-280-10

14-2
Maintenance—Every 250 Hours

TX,OUOE042,26 –19–08MAR99–1/2

CHANGE ENGINE OIL AND REPLACE

FILTER

IMPORTANT: If fuel sulfur content exceeds 0.5

percent, change the engine oil at 1/2 the

normal interval.

NOTE: If engine has not run 250 hours before the season

changes, change oil.

1. Run engine to warm oil.

2. Park machine on a level surface.

3. Lower bucket to the ground.

4. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

6. Move engine rpm dial to slow idle position.

7. Turn key switch to OFF. Remove key from switch.

8. Attach a ’Do Not Operate’ tag on the right control lever.

9. Pull pilot control shut-off lever to locked position.

Continued on next page

TM 5-3805-280-10

14-3
Maintenance—Every 250 Hours

TX,OUOE042,26 –19–08MAR99–2/2T120417 –UN–25MAR99 T108262B –UN–27MAR97

A—Drain Hose

B—Filter

C—Fill Cap

10. Remove cover from under the engine. Remove drain

plug (A) from bottom of engine oil pan, or open drain

valve on side of engine oil pan. Allow oil to drain into

a container. Dispose of waste oil properly.

11. Turn filter (B) counterclockwise to remove. Clean

mounting surface on base.

12. Apply thin film of oil to rubber gasket of new filter.

13. Install new filter. Turn filter clockwise by hand until

gasket touches mounting surface.

14. Tighten filter 1/2—3/4 turn more.

15. Install drain plug or close drain valve.

16. Remove fill cap (C).

Oil—Specification

Capacity with Filter Change .................................................... 19 L (20 qt)

17. Fill engine with oil. (See Fuels and Lubricants

chapter.)

18. Install fill cap.

19. Start engine.

Engine oil pressure indicator on monitor must go out

within 15-20 seconds. If not, stop engine immediately

and find the cause.

20. Stop engine. Check oil level.

21. Check for any leakage at filter. Tighten filter just

enough to stop leakage.

22. Install cover from under the engine.

TM 5-3805-280-10

14-4
Maintenance—Every 250 Hours

TX,75,DH3501 –19–29NOV94–1/1

CHECK RADIATOR COOLANT LEVEL

T6642EK –UN–01NOV88

CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove radiator filler

cap unless engine is cool. Then turn cap slowly

to the stop. Release air to relieve all pressure

before you remove cap.

1. Slowly remove cap. Coolant level must be at bottom of

the filler neck.

NOTE: If radiator coolant level is low, check for leaks on

radiator cap, and hose connections between

radiator and coolant recovery tank.

2. Add coolant, if necessary.

3. Install filler cap.

TM 5-3805-280-10

14-5
Maintenance—Every 250 Hours

TX,75,DH5594 –19–05MAY94–1/3

CHECK BATTERY ELECTROLYTE LEVEL

AND TERMINALS

TS203 –UN–23AUG88

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a

flashlight to check battery electrolyte level.

NEVER check battery charge by placing a metal

object across the posts. Use a voltmeter or

hydrometer.

ALWAYS remove grounded (-) battery clamp

first and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in

clothing, and cause blindness if splashed into

eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is

added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize

the acid.

3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do

not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

IMPORTANT: If water is added to batteries during

freezing weather, batteries must be

charged after water is added to prevent

batteries from freezing. Charge battery

using a battery charger or by running

the engine.

1. Remove hold-down clamps and battery covers.

Continued on next page

TM 5-3805-280-10

14-6
Maintenance—Every 250 Hours

TX,75,DH5594 –19–05MAY94–2/3T6996DB –UN–10FEB89 T6996DA –UN–10FEB89

A—Battery Post

B—Fill Tube

C—Electrolyte Level Range

2. Fill each cell to within specified range with distilled

water. DO NOT overfill.

CAUTION: Avoid possible injury. Always

remove grounded (-) battery clamp first and

replace it last.

3. Disconnect battery clamps, grounded clamp first.

TX,75,DH5594 –19–05MAY94–3/3T6758AA –UN–21OCT88

4. Clean battery terminals (A) and clamps with a stiff

brush.

5. Apply lubricating grease (B) around battery terminal

base only.

6. Install and tighten clamps, grounded clamp last.

7. Install battery covers and hold-down clamps.

TM 5-3805-280-10

14-7
Maintenance—Every 250 Hours

TX,75,DH5098 –19–08JUL96–1/2

CHECK PROPEL GEARBOX OIL LEVEL

1. Park the machine on level ground rotating propel

gearbox until bottom of the oil level check plug is even

with the horizontal centerline.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Turn key switch to OFF. Remove key from switch.

7. Attach a ’Do Not Operate’ tag on the right control lever.

8. Pull pilot control shut-off lever to locked position.

Continued on next page

TM 5-3805-280-10

14-8
Maintenance—Every 250 Hours

TX,75,DH5098 –19–08JUL96–2/2T7396CG –UN–18OCT90

A—Fill Plug

B—Check Plug

C—Drain Plug

D—Horizontal Centerline

CAUTION: High pressure release of fluids from

pressurized system can cause serious burns.

Wait for propel gearbox oil to cool. Keep body

and face away from check plug. Gradually

loosen check plug to release air to relieve

pressure.

9. After propel gearbox has cooled, slowly loosen check

plug (B) to release air to relieve pressure.

10. Remove check plug. Oil must be to bottom of hole.

11. If necessary, add oil until oil flows out of oil level

check plug hole. (See Fuels and Lubricants chapter.)

12. Wrap threads of plug with sealing-type tape. Install

plug. Tighten plug to 49 N•m (36 lb-ft).

13. Check second propel gearbox oil level.

03T,55,MM11 –19–18NOV92–1/1

CLEAN DUSTY PRIMARY ELEMENT

T47764 –UN–09NOV88

1. Tap element with the palm of your hand, NOT ON A

HARD SURFACE.

CAUTION: Prevent possible injury from flying

chips if compressed air is more than 210 kPa

(2.1 bar) (30 psi). Reduce compressed air to

less than 210 kPa (2.1 bar) (30 psi) when using

for cleaning purposes. Clear area of bystanders,

guard against flying chips, and wear personal

protection equipment including eye protection.

2. If this does not remove dust, use compressed air under

210 kPa (2.1 bar) (30 psi).

3. Direct air up and down the pleats from inside to

outside. Be careful not to make a break in the element.

TM 5-3805-280-10

14-9
Maintenance—Every 250 Hours

03T,55,C67 –19–24JUL91–1/1

INSPECT ELEMENT

T90684 –UN–10NOV88

IMPORTANT: A damaged or dirty element may cause

engine damage.

Install a new primary element:

1. If the element shows damage.

2. If element will not clean.

3. After 1000 hours service or annually.

Install a new secondary element:

1. If the primary element is damaged

and needs to be replaced.

2. If the element is visibly dirty.

3. After 1000 hours service or annually.

DO NOT clean a secondary element.

Install a new element carefully centering

it in the canister.

1. Inspect element and gasket for damage.

2. Air restriction indicator will not signal correctly if an

element has a break or is not correctly sealed in air

cleaner housing. Throw away element that has the

slightest damage. If gasket is broken or missing, install

a new element.

TM 5-3805-280-10

14-10
TM 5-3805-280-10

CHAPTER 15

MAINTENANCE—EVERY 500 HOURS
TM 5-3805-280-10

BLANK
Maintenance—Every 500 Hours

TX,80,DH5099 –19–08JUL96–1/1

GREASE SWING BEARING

T7869BM –UN–22OCT92

CAUTION: Prevent possible injury from

unexpected machine movement if controls are

moved by another person. Lubricating swing

bearing and rotating the upperstructure must be

done by one person. Before you lubricate swing

bearing, clear the area of all persons.

1. Park machine on a level surface.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

5. Move engine rpm dial to slow idle position.

6. Turn key switch to OFF. Remove key from switch.

7. Attach a ’Do Not Operate’ tag on the right control lever.

8. Pull pilot control shut-off lever to locked position.

9. Lubricate swing bearing with ten shots of grease at

both grease fittings. (See Fuels and Lubricants

chapter.)

10. Start engine. Raise bucket several inches off the

ground and turn upperstructure 45 degrees.

11. Repeat steps 2—9 three times.

NOTE: It is not necessary to start the engine the last

time.

TM 5-3805-280-10

15-1
Maintenance—Every 500 Hours

TX,80,DH5440 –19–03MAR97–1/1

GREASE SWING BEARING GEAR

T107788 –UN–03MAR97 T8156AE –UN–13JAN94

CAUTION: Prevent possible injury from

unexpected machine movement if controls are

moved by another person. Lubricating swing

bearing gear and rotating the upperstructure

must be done by one person.

1. Remove access cover (A) to swing gear.

2. Grease must be 13—25 mm (1/2—1 in.) (B) deep

measured from the bottom of the ring gear. The grease

must also be free of contamination by dirt and water.

If the grease is contaminated, remove grease and

replace with clean grease.

IMPORTANT: If water or mud is found in swing gear

area, see Operating in Water and Mud in

Operating the Machine chapter.

3. Add grease as required (approximately 0.113 kg (1/4

lb) every 90°). (See Fuels and Lubricants chapter.)

IMPORTANT: Excessive grease can damage the

swing gearbox seal.

4. Remove excessive grease that extrudes over the top of

the swing drive pinion.

5. Install access cover.

TM 5-3805-280-10

15-2
Maintenance—Every 500 Hours

TX,80,DH5574 –19–19JUL96–1/1

REPLACE FINAL FUEL FILTER

T108260C –UN–27MAR97

1. Turn retaining ring (A) clockwise to remove filter. Allow

sediment to drain into a container. Dispose of waste

properly.

2. Clean filter base.

3. Install new filter. Follow instructions on filter.

4. Bleed fuel system. (See Bleeding Fuel System in

Maintenance chapter

TM 5-3805-280-10

15-3
Maintenance—Every 500 Hours

TX,80,DH5123 –19–26JUL96–1/2

REPLACE PRIMARY FUEL FILTER (WATER

SEPARATOR)

T102466 –UN–30JUL96 T8387AE –UN–17DEC94

1. Turn retaining ring (A) counterclockwise to remove filter

(B). Allow sediment to drain into a container. Dispose

of waste properly.

2. Turn sediment bowl (C) counterclockwise to remove

from filter assembly. Clean bowl.

3. Remove hand primer from fuel filter base. Disassemble

hand primer assembly.

Continued on next page

TM 5-3805-280-10

15-4
Maintenance—Every 500 Hours

TX,80,DH5123 –19–26JUL96–2/2T8387AD –UN–17DEC94

4. Remove fuel inlet line (A) and plug (C).

5. Flush any debris from filter base (B).

6. Install fuel inlet plug and fuel inlet line.

7. Assemble primer assembly and install onto fuel filter

base.

8. Install new filter. (Follow instructions on filter.)

9. Install sediment bowl.

10. Bleed fuel system. (See Bleeding Fuel System in

Maintenance chapter.)

TX,80,DH5575 –19–25JUL96–1/1

CHECK AIR INTAKE HOSES

T108267B –UN–27MAR97

Check hoses (A) for cracks. Replace as necessary.

Tighten clamps.

TM 5-3805-280-10

15-5
Maintenance—Every 500 Hours

TX,80,DH5100 –19–08JUL96–1/4

REPLACE HYDRAULIC OIL FILTER

1. Park machine on a level surface.

2. Position machine with arm cylinder fully retracted and

bucket cylinder fully extended.

3. Lower bucket to the ground.

4. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine with engine rpm dial at 1/3 position without

load for 2 minutes.

6. Move engine rpm dial to slow idle position.

7. Turn key switch to OFF. Remove key from switch.

8. Attach a ’Do Not Operate’ tag on the right control lever.

9. Pull pilot control shut-off lever to locked position.

TX,80,DH5100 –19–08JUL96–2/4T7869AT –UN–12NOV92

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

10. Loosen vent plug (A) to release hydraulic pressure.

Continued on next page

TM 5-3805-280-10

15-6
Maintenance—Every 500 Hours

TX,80,DH5100 –19–08JUL96–3/4T7869AL –UN–12NOV92

11. Hold down filter cover (C) against light spring load

when removing the last two cap screws.

TX,80,DH5100 –19–08JUL96–4/4T6457ED –UN–18OCT88

A—Cover

B—Cap Screw

C—Spring

D—Element

E—Valve

F—O-Ring

12. Remove spring (C), valve (E), and element (D).

13. Remove filter case and discard element and O-ring

(F).

CAUTION: Prevent possible injury from flying

chips if compressed air is more than 210 kPa

(2.1 bar) (30 psi). Reduce compressed air to

less than 210 kPa (2.1 bar) (30 psi) when using

for cleaning purposes. Clear area of bystanders,

guard against flying chips, and wear personal

protection equipment including eye protection.

NOTE: Remove element and inspect for metal particles

and debris in bottom of filter can. Excessive

amounts of brass and steel particles can indicate

a hydraulic pump, motor, or valve malfunction, or

a malfunction in process. A rubber type of

material can indicate cylinder packing problem.

14. Clean filter case with diesel fuel and dry with

compressed air.

15. Install filter case, valve (E), and spring (C) in

reservoir.

16. Install cover (A) and tighten cap screws (B).

Cover Cap Screw—Specification

Torque ............................................................................. 49 N•m (36 lb-ft)

17. Tighten vent plug.

TM 5-3805-280-10

15-7
Maintenance—Every 500 Hours

TX,OUOE042,27 –19–08MAR99–1/1

ADD COOLANT CONDITIONER TO

RADIATOR

Coolant conditioner prevents rust, scale, and liner

cavitation.

CAUTION: Prevent possible injury from hot

spraying water. Do not remove radiator cap

unless the engine is cool.

Turn cap slowly to the stop to release air to

relieve pressure before removing cap.

1. Turn cap slowly to the stop to release pressure. Then

remove radiator cap.

2. Add TY16004 John Deere Coolant Conditioner or

equivalent non-chromate conditioner/rust inhibitor,

following instructions on container.

Cooling System—Specification

Capacity...................................................................... Approx. 22 L (6 gal)

NOTE: Check coolant every 500 hours or 6 months, or if

you replace 1/3 or more of coolant.

John Deere Liquid Coolant Conditioner does not

protect against freezing.

TM 5-3805-280-10

15-8
TM 5-3805-280-10

CHAPTER 16

MAINTENANCE—EVERY 1000 HOURS
TM 5-3805-280-10

BLANK
Maintenance—Every 1000 Hours

TX,85,DH5441 –19–03MAR97–1/1

CHANGE SWING GEARBOX OIL

T102305 –UN–30JUL96

1. Remove plug (A) mounted on end of drain pipe to

drain oil into a container. Dispose of waste oil properly.

Swing gearbox oil—Specification

Capacity................................................................................... 13 L (14 qt)

2. Install plug.

3. Remove filler cap (B) and add oil.

4. Install filler cap.

5. Check oil level on dipstick.

TX,85,DH5150 –19–10AUG96–1/3

CHANGE PILOT CONTROL OIL FILTER

T7869AT –UN–12NOV92

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

1. Loosen vent plug (A) to relieve air pressure.

TX,85,DH5150 –19–10AUG96–2/3T101495 –UN–15JUL96

2. Remove filter case (A).

Continued on next page

TM 5-3805-280-10

16-1
Maintenance—Every 1000 Hours

TX,85,DH5150 –19–10AUG96–3/3T6457ES –UN–19OCT88

3. Unscrew filter element (B).

4. Remove O-ring (C)

5. Install new O-ring and filter element.

Filter case—Specification

Torque ................................................................... 20-30 N•m (15-22 lb-ft)

6. Install filter case (A).

7. Tighten vent plug.

TX,85,DH5685 –19–03MAR97–1/1

CHANGE PUMP DRIVE GEARBOX OIL

T101494 –UN–15JUL96

1. Remove plastic cap and filler plug (A).

2. Remove drain plug (B). Allow oil to drain into a

container. Dispose of waste oil properly.

3. Apply Liquid TEFLON Pipe Thread Sealant to drain

plug. Install plug.

4. Add oil. (See Fuels and Lubricants chapter.)

Pump Gearbox—Specification

Capacity................................................................................. 1.0 L (1.1 qt)

5. Pull dipstick (C) and check oil level. Oil level must be

approximately halfway below ’H’ (level) mark.

6. Install filler cap. Install dipstick.

TM 5-3805-280-10

16-2
Maintenance—Every 1000 Hours

TX,85,DH5580 –19–10AUG96–1/1

CLEAN THE ENGINE CRANKCASE

VENTILATION TUBE

T108260D –UN–27MAR97

Clean the engine crankcase ventilation tube (A) when you

measure and adjust engine valve clearance (lash).

TX,86,DH5104 –19–09JUL96–1/2

CHECK AND ADJUST ENGINE VALVE LASH

(CLEARANCE)

RG7408 –UN–06AUG96

CAUTION: Prevent accidental starting of engine

while performing valve adjustments. Always

disconnect NEGATIVE (-) battery terminal.

IMPORTANT: Valve clearance MUST BE checked and

adjusted with engine COLD.

1. Remove rocker arm cover and engine crankcase

ventilation tube. Clean tube with solvent or diesel fuel.

Check that O-ring in rocker arm cover is in good

condition.

IMPORTANT: Visually inspect contact surfaces of

valve tips and rocker arm wear pads.

Check all parts for excessive wear,

breakage, or cracks. Replace parts that

show visible damage.

Rocker arms that exhibit excessive

valve clearance should be inspected

more thoroughly to identify damaged

parts.

2. Remove plug (A). Install JDG820 Flywheel Turning

Tool. Remove cap screw (B). Install JDE-81-4 Timing

Pin.

Continued on next page

TM 5-3805-280-10

16-3
Maintenance—Every 1000 Hours

TX,86,DH5104 –19–09JUL96–2/2 RG7409 –UN–06AUG96

3. Turn flywheel until timing pin goes into hole in flywheel.

4. Using engine rotation tool, rotate engine flywheel in

running direction (clockwise viewed from front) until No.

1 cylinder is at “TDC” Compression stroke.

If No. 1 cylinder rocker arms are loose, the engine is at

No. 1 “TDC” Compression. If No. 1 cylinder rocker

arms are not loose, rotate engine one full revolution

(360°) to No. 1 “TDC” Compression

To change piston position, remove timing pin and

rotate flywheel.

5. Check and adjust valve clearance to specifications as

directed in the following procedures.

6. Loosen jam nut (A) and adjust clearance with a

screwdriver, as shown.

TM 5-3805-280-10

16-4
Maintenance—Every 1000 Hours

CED,OUOE042,28 –19–08MAR99–1/1

FIRING ORDER 6—CYLINDER ENGINE:

T6872AG –UN–18MAY94

A—No. 1 TDC Compression Stroke

B—No. 1 TDC Exhaust Stroke

C—Fan End of Engine

NOTE: Firing order is 1-5-3-6-2-4.

1. Adjust No. 1, 3, and 5 exhaust valves and No. 1, 2,

and 4 intake valves.

Exhaust Valves (E)—Specification

Clearance ................................................................... 0.46 mm (0.018 in.)

Intake Valves (I)—Specification

Clearance ................................................................... 0.36 mm (0.014 in.)

2. Rotate engine 360° and repeat step 1 for the remaining

intake and exhaust valves.

3. Tighten jam nut to 27 N•m (20 lb-ft).

4. Clean cylinder head and rocker arm cover mating

surfaces.

5. Install rocker arm cover gasket. Do not use sealant on

the gasket.

6. Install rocker arm cover. Tighten screws to 35 N•m (26

lb-ft). Do not over tighten cap screws.

7. Remove turning tool and timing pin.

8. Install parts. Center muffler to turbocharger inlet tube

before fastening muffler into place.

TM 5-3805-280-10

16-5
Maintenance—Every 1000 Hours

TX,85,DH5726 –19–28APR97–1/1

CHECK ENGINE SPEEDS

1. Warm engine to normal operating temperature.

Slow idle—Specification

Speed .................................................................................. 900 ± 25 rpm

Fast idle in Standard Mode—Specification

Speed ................................................................................. 2180 ± 25 rpm

2. Connect a tachometer to check engine speeds

NOTE: Turn engine RPM dial to slow idle to check slow

idle speed

Turn engine RPM dial to fast idle to check fast

idle speed.

If engine speeds need adjustment, see your authorized

dealer.

TM 5-3805-280-10

16-6
Maintenance—Every 1000 Hours

TX,85,DH5728 –19–28APR97–1/1

ENGINE SPEED LEARNING PROCEDURE

T103674 –UN–11SEP96

1. Stop engine.

2. Push engine learning switch (C) up to top position. The

switch is a three position switch. Make sure it is in the

top position.

3. Turn key switch ON. Wait for 5 seconds.

4. Turn key switch OFF. Wait for 5 seconds.

5. Push engine learning switch to middle position.

6. Check engine speeds.

Slow Idle—Specification

Speed ................................................................................... 900 ± 25 rpm

Auto-Idle—Specification

Speed ................................................................................. 1200 ± 25 rpm

E (Economy) Mode—Specification

Speed ................................................................................. 1980 ± 25 rpm

Fast Idle in Standard Mode—Specification

Speed ................................................................................. 2180 ± 25 rpm

NOTE: If engine RPM is not to specifications, see your

authorized dealer.

TX,85,FF2318 –19–01NOV91–1/2

CHANGE AIR CLEANER ELEMENTS

T6119AF –UN–01NOV88

1. Open left front service door.

2. Loosen wing nut to remove cover.

3. Remove wing nut and primary element (A).

Continued on next page

TM 5-3805-280-10

16-7
Maintenance—Every 1000 Hours

TX,85,FF2318 –19–01NOV91–2/2T6119AG –UN–01NOV88

4. Remove wing nut and secondary element (B).

5. Install elements, making sure the secondary element is

centered in canister.

6. Install cover.

TX,85,DH5557 –19–17DEC96–1/1

INSPECT FAN BELT

T108219 –UN–25MAR97

1. Check belt regularly for wear, especially for cracks at

the bottom of grooves and for frayed edges.

2. If necessary, replace belt.

3. Install a 15 mm wrench to the TOP pulley (A) of belt

tension adjuster. Turn wrench counterclockwise to pull

tension adjuster pulley away from belt, releasing belt

tension.

4. Hold tension adjuster away from belt while removing

old belt and installing new belt.

5. Slowly release wrench tension to allow tension adjuster

to move clockwise against new belt. Tension is

automatically adjusted.

6. Remove wrench.

TX,85,DH5094 –19–08JUL96–1/1

REPLACE AIR CLEANER DUST VALVE

T101488 –UN–15JUL96

NOTE: A missing, damaged, or hardened dust valve will

cause the air filter elements to be ineffective.

Replace dust valve (A).

TM 5-3805-280-10

16-8
TM 5-3805-280-10

CHAPTER 17

MAINTENANCE—EVERY 2000 HOURS
TM 5-3805-280-10

BLANK
Maintenance—Every 2000 Hours

CED,OUOE042,72 –19–07APR99–1/3

DRAIN COOLING SYSTEM

T102676 –UN–02AUG96

Drain and flush cooling system using commercial

products, replace thermostats, radiator cap, and refill with

new coolant.

1. Check coolant hoses (A) for cracks and leaks. Replace

if necessary.

2. Tighten clamps.

3. Check radiator and oil cooler for dirt, grease, leaks,

and loose or broken mountings. Clean radiator and oil

cooler fins.

CAUTION: Prevent possible injury from hot

spraying water. DO NOT remove radiator filler

cap unless engine is cool. Then turn cap slowly

to the stop.

4. Release air to relieve pressure. Remove filler cap.

CED,OUOE042,72 –19–07APR99–2/3T121079 –UN–14APR99

5. Turn radiator petcock (A) counterclockwise to open

valve. Allow coolant to drain into a container. Dispose

of waste coolant properly.

CED,OUOE042,72 –19–07APR99–3/3T102677 –UN–02AUG96

6. Turn engine block drain cock (A) counterclockwise to

drain engine block. Drain coolant into a container.

Dispose of waste properly.

TM 5-3805-280-10

17-1
Maintenance—Every 2000 Hours

CED,OUOESLH,8 –19–09DEC99–1/1

DIESEL ENGINE COOLANT

The engine cooling system is filled to provide

year-round protection against corrosion and cylinder

liner pitting, and winter freeze protection to -37°C

(-34°F).

The following engine coolant is preferred for service:

• CID A-A-52624 Type 1 is a fully formulated ethylene

glycol-based engine coolant concentrate.

• CID A-A-52624 Type 1P is a prediluted (60% by vol.

Glycol) fully formulated ethylene glycol-based engine

coolant.

• CID A-A-52624 Type 11 is a fully formulated

propylene glycol-based engine coolant concentrate.

• CID A-A-52624 Type 1 and Type 11 require dilution

with water before use.

• CID A-A-52624 Type 1P is ready to use as

packaged.

• John Deere PREDILUTED ANTIFREEZE/SUMMER

COOLANT.

• John Deere COOL-GARD, where available.

John Deere ANTIFREEZE/SUMMER COOLANT

CONCENTRATE in a 40 to 60% mixture of

concentrate with quality water is also recommended.

Other low silicate ethylene glycol base coolants for

heavy-duty engines may be used if they meet one of

the following specifications:

• ASTM D6210 (prediluted coolant)

• ASTM D6211 (coolant concentrate) in a 40 to 60%

mixture of concentrate with quality water

Coolants meeting these specifications require use of

supplemental coolant additives, formulated for

heavy-duty diesel engines, for protection against

corrosion and cylinder liner erosion and pitting.

A 50% mixture of ethylene glycol engine coolant in

water provides freeze protection to -37°C (-34°F). If

protection at lower temperatures is required, consult

your John Deere dealer for recommendations.

Water quality is important to the performance of the

cooling system. Distilled, deionized, or demineralized

water is recommended for mixing with ethylene glycol

base engine coolant concentrate.

IMPORTANT: Do not use cooling system sealing

additives or antifreeze that contains

sealing additives.

Coolant drain intervals

Drain and flush the cooling system and refill with fresh

coolant every 24 months.

When John Deere PREDILUTED

ANTIFREEZE/SUMMER COOLANT is used, the

service interval may be extended to 36 months.

COOL-GARD is a trademark of Deere & Company.

TM 5-3805-280-10

17-2
Maintenance—Every 2000 Hours

TX,86,DH5113 –19–15JUL96–1/1

COOLING SYSTEM FILL AND DEAERATION

PROCEDURE

IMPORTANT: Use only permanent-type low silicate

ethylene glycol base antifreeze in

coolant solution. Other types of

antifreeze may damage cylinder seals.

FREEZING TEMPERATURES: Fill with permanent-type,

low silicate, ethylene glycol antifreeze (without stop-leak

additive) and clean, soft water.

FILL

Fill radiator to the bottom of the radiator fill neck.

Cooling System—Specification

Capacity...................................................................... Approx. 22 L (6 gal)

Fill the recovery tank to FULL mark.

DEAERATION

The cooling system requires several warm-up and cool

down cycles to deaerate. It will NOT deaerate during

normal operation. Only during warm-up and cool down

cycles will the system deaerate.

1. Start engine. Run engine until coolant reaches a warm

temperature.

2. Stop engine. Allow coolant to cool.

3. Check coolant level at recovery tank.

4. Repeat Steps 1—3 until recovery tank coolant level is

repeatedly at the same level (stabilized).

NOTE: The level of the coolant in the cooling system

MUST BE repeatedly checked after all drain and

refill procedures to insure that all air is out of the

system which allows the coolant level to stabilize.

Check coolant level only when the engine is cold.

5. If necessary, fill recovery tank to FULL mark.

6. Install recovery tank and radiator caps.

TM 5-3805-280-10

17-3
Maintenance—Every 2000 Hours

TX,86,DH5152 –19–10AUG96–1/2

CHANGE PROPEL GEARBOX OIL

T7396CG –UN–18OCT90

A—Fill Plug

B—Check Plug

C—Drain Plug

D—Horizontal Centerline

1. Park the machine on level ground rotating propel

gearbox until bottom of the oil level check plug (B) is

even with the horizontal centerline.

2. Lower bucket to the ground.

3. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

4. Run engine with engine RPM dial at 1/3 position

without load for 2 minutes.

5. Move engine RPM dial to slow idle and turn key switch

to OFF. Remove key from switch.

6. Attach a ’Do Not Operate’ tag on the right control lever.

7. Pull pilot control shut-off lever to locked position.

CAUTION: High pressure release of fluids from

pressurized system can cause serious burns.

Wait for propel gearbox oil to cool. Keep body

and face away from check plug. Gradually

loosen check plug to release pressure.

8. After propel gearbox has cooled, slowly loosen check

plug to release pressure.

Propel Gearbox Oil—Specification

Capacity....................................................................... Approx. 6 L (6.5 qt)

9. Remove drain plug (C). Allow oil to drain into a

container. Dispose of waste oil properly.

10. Wrap threads of drain plug with a sealing-type tape.

Install plug. Tighten plug to 49 N•m (430 lb-in.).

11. Remove oil fill plug (A).

12. Add oil until oil flows out of oil level check plug hole.

(See Fuels and Lubricants chapter.)

Continued on next page

TM 5-3805-280-10

17-4
Maintenance—Every 2000 Hours

TX,86,DH5152 –19–10AUG96–2/2

13. Wrap threads of check plug and fill plug with

sealing-type tape. Install plugs. Tighten plugs to 49

N•m (36 lb-ft).

14. Change oil of second propel gearbox.

TX,OUOE042,29 –19–08MAR99–1/7

CHANGE HYDRAULIC OIL

T6811AJ –UN–18OCT88

IMPORTANT: DO NOT run engine without oil in the

tank.

1. Park machine on level surface with upperstructure

rotated 90° for easier access.

2. Position machine with arm cylinder fully retracted and

bucket cylinder fully extended.

3. Lower bucket to the ground.

4. Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if

engine is not properly shut down.

5. Run engine with engine RPM dial at 1/3 position

without load for 2 minutes.

6. Move engine RPM dial to slow idle position.

7. Turn key switch to OFF to stop engine. Remove key

from switch.

8. Pull pilot control shut-off lever to locked position.

Continued on next page

TM 5-3805-280-10

17-5
Maintenance—Every 2000 Hours

TX,OUOE042,29 –19–08MAR99–2/7T7869AT –UN–12NOV92

CAUTION: High pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

9. Loosen vent plug (A) to relieve air pressure.

TX,OUOE042,29 –19–08MAR99–3/7T6457EI –UN–18OCT88

A—Cap

B—Aligning Marks

C—Case Assembly

D—Hex Wrench

E—Hole

10. Insert 4 mm (0.15 in.) hex wrench (D) into hole (E)

and turn counterclockwise.

11. Slowly turn cap (A) counterclockwise. Remove cap.

Hydraulic Tank Oil—Specification

Capacity............................................................................... 148 L (39 gal)

Continued on next page

TM 5-3805-280-10

17-6
Maintenance—Every 2000 Hours

TX,OUOE042,29 –19–08MAR99–4/7T120418 –UN–25MAR99

12. Remove drain plug (F). Allow oil to drain into a

container. Dispose of waste oil properly.

TX,OUOE042,29 –19–08MAR99–5/7T7869BP –UN–12NOV92

13. Remove cover (A) with suction filter.

14. Clean inside of tank and suction filter.

15. Change hydraulic oil filter. (See Maintenance-Every

500 Hours chapter.)

16. Change pilot control oil filter. (See Maintenance-Every

1000 Hours chapter.)

Continued on next page

TM 5-3805-280-10

17-7
Maintenance—Every 2000 Hours

TX,OUOE042,29 –19–08MAR99–6/7T108541 –UN–24MAR97

17. Install suction screen with cover. Suction screen must

seal against outlet pipe in bottom of tank. If

necessary, loosen nut (B) to adjust rod length

Suction Screen Rod—Specification

Length (A)...................................................................... 670 mm (26.4 in.)

Suction Screen Rod Nut—Specification

Torque (A) .................................................. 17 N•m (12.5 lb-ft) (150 lb-in.)

Top of Rod to Top of Rod Nut—Specification

Length (C) ......................................................................... 20 mm (0.8 in.)

Cover Cap Screw—Specification

Torque ............................................................................. 49 N•m (36 lb-ft)

18. Install tank drain plug and bottom guard.

19. Add oil until it is between marks on sight glass. (See

Fuels and Lubricants chapter.)

TX,OUOE042,29 –19–08MAR99–7/7T101875 –UN–15JUL96

IMPORTANT: If the hydraulic pump is not filled with

oil, it will be damaged when the engine

is started.

20. Remove air bleed plugs (C) from hydraulic pump until

oil flows from bleed holes.

21. Install air bleed plugs in hydraulic pump.

22. Check oil level in sight glass. Add oil, if necessary.

Install tank cap. Tighten vent plug.

23. Purge air from cylinders and swing motor by cycling

hydraulic functions.

TM 5-3805-280-10

17-8
TM 5-3805-280-10

CHAPTER 18

MAINTENANCE—AIR COMPRESSOR
TM 5-3805-280-10

BLANK
MAINTENANCE – AIR COMPRESSOR

GENERA L

In addition to periodic inspections, many of the

components in these units require periodic

servicing to provide maximum output and

performance. Servicing may consist of preoperation and post-operation procedures to be

performed by the operating or maintenance

personnel. The primary function of preventive

maintenance is to prevent failure, and consequently,

the need for repair. Preventive maintenance is the

easiest and the least expensive type of

maintenance. Maintaining your unit and keeping it

clean at all times will facilitate servicing.

Correct engine speed is critical to the operation of

this machine. Check the idle and full load rpm every

three months and adjust in accordance with the

speed and pressure adjustment instructions in this

manual and included on a decal on the machine.

Correct speeds are on the general data decal.

SC HEDULED MAINTENANCE

The maintenance schedule is based on normal

operation of the unit. This page can be reproduced

and used as a checklist by the service personnel. In

the event unusual environmental operating

conditions exist, the schedule should be adjusted

accordingly.

COMPRESSOR OIL LEVEL

The oil level is most consistent when the unit is

RUNNING AT FULL LOAD and should be checked

at this time.The optimum operating level is midway

of the sight tube on the side of the receiver tank.

See the decal beside the sight tube. If the oil level is

not in the “OK” range, make appropriate corrections

(Add or Drain). A totally filled sight tube in which the

level is not visible indicates an over-full condition

and requires that oil be drained.

Compressor Oi l

This machine was factory filled with Ingersoll-Rand

Pro TecR Compressor Fluid (Ingersoll-Rand

XHP505 for XHP900 models).

TM 5-3805-280-10

18-1
The compressor oil must be replaced every 500 hours of operation or six (6) months, whichever comes first for

models HP600 - P1600.

Refer to the fluids and lubricants chart for ambient temperature ranges and specifications, in the lubrication

section of this manual.

The compressor oil must be replaced every 500 hours of operation or six (6) months, whichever comes first for

models P100-P600. The compressor oil must be replaced every 1000 hours of operation or six (6) months,

whichever comes first for models HP600-P1600.

Refer to the fluids and lubricants chart for ambient temperature ranges and specifications in the lubrication

section of this manual.

AIR CLEANER 

The Model XP330SCU is equipped with air cleaner

service indicators mounted on the main

instrument/control panel.

Inspect daily the air cleaner service indicator. Never

guess about restriction in the air cleaner. Always

know what condition your air cleaner is in with the

assistance of the service indicator. If it is not

working properly, or is missing, replace it.

Maximum compressor and engine protection against

the ravages of dust is possible only if the air cleaner

is serviced at regular intervals or whenever the

service indicator shows red.

Visually inspect the position of the flag in the air

cleaner restriction indicator. Normally, the flag in a

service indicator shows green, indicating the filter

element is still serviceable. If the flag shows red

when the unit is operating at full speed or stopped, it

is an indication that proper servicing of the filter

element is necessary.

Also weekly squeeze the rubber valve (precleaner

dirt dump) on each air cleaner housing to ensure

that they are not clogged. NOTICE: Holes or cracks

downstream of the air cleaner housing will cause the

restriction indicators to be ineffective.

The air filters restricted sensor will automatically

reset after the main power switch is flipped to “OFF.”

To service the air cleaners on all units proceed

as follows:

1. Loosen outer wing nut and remove with outer

element. Inspect red window on special inner

wing nut to find small dot. If dot is not visible,

remove cotter pin and special wing nut and

inner (safety) element.

2. Inspect air cleaner housing for any condition

that might cause a leak and correct as

necessary.

3. Wipe inside of air cleaner housing with a

clean, damp cloth to remove any dirt

accumulation, especially in the area where

the element seals against the housing.

4. Inspect element by placing a bright light

inside and rotating slowly. If any holes or

tears are found in the paper, discard this

element. If no ruptures are found, the

element can be cleaned by one of the

following procedures.

5. If a new air filter element is to be used check

it closely for shipping damage. To reset the

signal indicator in the special wing nut, apply

suction to the red window.

6. Install cleaned or new elements in the

reverse order to the above. Tighten wing nuts

firmly and replace cotter pin.

7. Inspect to ensure that the end cap seals

tightly 360 degrees around the air cleaner

body.

TM 5-3805-280-10

18-2
In the event the element is contaminated with dry

dirt, oil or greasy dirt deposits, and a new element

is not available, cleaning can be accomplished

by washing, using the air cleaner element

manufacturer’s recommendations.

NOTICE

To prevent damage to the element, never exceed

a maximum air pressure of 100 psi (700 kPa).

NOTICE

It is highly recommended that new replacement

elements be installed in the unit immediately in

order that the unit be returned to service in the

shortest possible time. In this manner, the

elements just removed for cleaning can be

washed and stored as future replacement

elements.

In addition, the air cleaner system (housing and

piping) should be inspected every month for any

leakage paths or inlet obstructions. Make sure the

air cleaner mounting bolts and clamps are tight.

Check the air cleaner housing for dents or damage

which could lead to a leak. Inspect the air transfer

tubing from the air cleaner to the compressor and

the engine for holes. Make sure that all clamps and

flange joints are tight.

GAUGE S

The instruments or gauges are essential for safety,

maximum productivity and long service life of the

machine. Inspect the gauges and test any

diagnostic lamps prior to start-up. During operation

observe the gauges and any lamps for proper

functioning. Refer to Operating Controls, for the

normal readings.

FUEL TAN K

This unit is supplied with diesel fuel from an

external, customer supplied fuel tank. Using clean

fuel in the fuel tanks is vitally important and every

precaution should be taken to ensure that only clean

fuel is either poured or pumped into the tank. When

filling the fuel tank on this unit, by methods other

than a pump and hose, use a CLEAN non-metallic

funnel.

Every six months the drain plugs should be removed

from the tanks so that any sediment or accumulated

condensate may be drained. When replacing the

drain plugs, make sure they are tightened securely.

BATTE RY

Electrical power to this unit is supplied from

externally mounted batteries.

Keep the battery posts-to-cable connections clean,

tight and lightly coated with a grease. Also the

electrolyte level in each cell should cover the top of

the plates. If necessary, top-up with clean distilled

water.

AUTOMATIC SHUTD OWN SYSTEM

The high discharge air temperature switches will

require approximately 248°F (120°C) to actuate. The

engine coolant temperature switch will require

approximately 220° F (104° C) to actuate. Replace

any defective switch before continuing to operate

the unit.

A low oil pressure switch may be tested by removing

it and connecting it to a source of controlled

pressure while monitoring an ohmmeter connected

to the switch terminals. As pressure is applied

slowly from the controlled source, the switch should

close at 12 psi (.84 kgf per cm2) and show

continuity through the contacts. As the pressure is

slowly decreased to 8 psi (0.56 kgf per cm2) the

contacts should open and the ohmmeter should

show lack of continuity (infinite ohms) through the

contacts. Replace a defective switch before

continuing to operate the unit.

TM 5-3805-280-10

18-3
COMPRESSOR OIL COOLER 

The compressor lubricating and cooling oil is cooled

by means of the fin and tube-type oil cooler, located

beside the radiator. The lubricating and cooling oil,

flowing internally through the core section, is cooled

by the air stream from the cooling fan flowing past

the core section. When grease, oil and dirt

accumulate on the exterior surfaces of the oil cooler,

its efficiency is impaired.

Each month it is recommended that the oil cooler

be cleaned by directing compressed air which

contains a nonflammable safety solvent through the

core of the oil cooler. This should remove the

accumulation of grease, oil and dirt from the exterior

surfaces of the oil cooler core so that the entire

cooling area can transmit the heat of the lubricating

and cooling oil to the air stream.

In the event foreign deposits, such as sludge and

lacquer, accumulate in the oil cooler to the extent

that its cooling efficiency is impaired, a resulting

high discharge air temperature is likely to occur,

causing shut down of the unit.

To correct this situation it will be necessary to clean

it using a cleaning compound in accordance with the

manufacturer’s recommendations. Use only a

dependable cleaning compound. This is of prime

importance because different cleaners vary in

concentration and chemical composition. After

completing the cleaning procedure, the oil cooler

must be flushed before returning to service.

RADIATOR 

WARNING

Do not remove the cap from a HOT engine

radiator. The sudden release of pressure from a

heated cooling system can result in a loss of

coolant and possible severe personal injury.

The engine cooling system is filled at the factory

with a 50/50 mixture of water and ethylene glycol.

This permanent type antifreeze contains rust

inhibitors and provides protection to -35° F (-37°C).

The use of such a mixture is recommended for both

summer and winter operation. When using water

alone, be sure to add a reputable brand of rust

inhibitor to prevent internal corrosion.

It is recommended to test the freezing protection of

the coolant every six months or prior to freezing

temperatures. Replenish with a fresh mixture every

twelve months. A drain for the system is located in

the bottom radiator tank. An alternate method

would be to disconnect a bottom radiator hose.

Each month, inspect the radiator exterior for

obstructions (dirt, bugs, etc.). If present, blow water

or compressed air containing a nonflammable

solvent between the fins in a direction opposite the

normal air flow. Should the radiator be clogged

internally, standard automotive practices should be

followed.

HOSES 

Each month it is recommended that all of the intake

lines to and from the air cleaners, the engine cooling

system hoses and all of the flexible hoses used for

air, oil, and fuel be inspected.

To ensure freedom from air leaks, all rubber hose

joints and the screw-type hose clamps must be

absolutely tight. Regular inspection of these

connections for wear or deterioration is a definite

“must” if regulator servicing of the air cleaners is not

to prove futile.

 Premature wear of both the engine and compressor

is ASSURED whenever dust-laden air is permitted

to enter the engine’s combustion chamber or the

compressor intake practically unfiltered.

The flexible hoses used in the fuel, oil and air lines

on these units are primarily used for their ability to

accommodate relative movement between

components. It is extremely important they be

periodically inspected for wear and deterioration.

Clamps are used to prevent hose cover abrasion

through vibration. This abrasion may occur when

two hose lines cross, or when a hose line rubs

against a fixed point; therefore, it is necessary that

all clamps be replaced if missing. It is also

important the operator does not use the hoses as

convenient hand hold or steps. Such use can cause

early cover wear and hose failure.

TM 5-3805-280-10

18-4
NOTICE

Piping systems operating at less than 150 psi

(1050 kPa) may use a special nylon tubing. The

associated fittings are also of a special “pushin” design. If so, features are as follows:

Pulling on the tubing will cause the inner sleeve to

withdraw and compress, thus tightening the

connection. The tubing can be withdrawn only while

holding the sleeve against the fitting. The tubing

can be removed and replaced numerous times

without losing its sealing ability.

To install the nylon tubing, make a mark (with tape

or grease pencil) approximately 7/8 inch from the

end of the tubing. Insert the tubing into the sleeve

and “push-in” past the first resistance to the bottom.

The mark should be approximately 1/16 inch from

the sleeve, for the 3/8 inch O.D. tubing; 1/8 inch for

the 0.25 inch O.D. tubing. This will ensure that the

tubing is fully engaged in the sealing mechanism.

COMPRESSOR OIL FILTERS 

The compressor lubrication and cooling oil system

includes dual spin-on, throw away type oil filters,

each with an internal bypass valve. With a clean,

new filter element, all of the oil flows through the full

element area, from the outside/inside. As each

element becomes contaminated with dirt, a pressure

differential is created in the filter housing between

the oil inlet and outlet ports. As this differential

approaches 25 psi (175 kPa), the bypass valve

starts to open, thus permitting a small quantity of oil

to bypass the filter. As the contaminants continue to

build up, more and more of the oil bypasses the filter

media itself.

This bypass does not provide any filtration but does 

allow a maximum flow of compressor lubricating and

cooling oil to preclude any possible damage from

loss of oil. Also the design of the filter prevents any

washing-off of any dirt during oil bypassing.

NOTICE

The oil filter must be replaced every 500 hours

of operation. On new or overhauled units,

replace the element after the first 50 and 150

hours of operation; thereafter, service the oil

filter every 500 hours.

To service the oil filters it will first be necessary to

shut the unit down. Wipe off any external dirt and oil

from the exterior of the filter to minimize any

contamination from entering the lubrication system.

Proceed as follows:

WARNING

High pressure air can cause severe injury or

death from hot oil and flying parts. Always

relieve pressure before removing caps, plugs,

covers or other parts from pressurized air

system.

1. Open the service air valve(s) to ensure that

system is relieved of all pressure. Close the

valve(s).

2. Turn the spin-on filter element counterclockwise

to remove it from the filter housing. Inspect the filter

element and then discard.

Note: If there is any indication of formation of

varnishes, shellacs or lacquers on the oil filter

element, it is a warning the compressor lubricating

oil has improper characteristics and should be

immediately changed.

3. Inspect the oil filter head to be sure the gasket

was removed with the oil filter element. Clean the

gasket seal area on the oil filter head.

Installing a new oil filter element when the old

gasket remains on the oil filter head will cause an oil

leak and can cause property damage.

4. Lubricate the new filter gasket with the same oil

being used in the machine.

5. Install new filter by turning element clockwise

until gasket makes initial contact. Tighten an

additional 1/2 to 3/4 turn.

6. Start unit and allow to build up to rated

pressure. Check for leaks before placing unit back

into service.

TM 5-3805-280-10

18-5
FASTE NERS

Visually check entire unit in regard to bolts, nuts and

screws being properly secured. Spot check several

capscrews and nuts for proper torque. If any are

found loose, a more thorough inspection must be

made. Take corrective action.

COMPRESSOR OI L

Refer to Maintenance Schedule.

RE CEIVER-SEPARATOR SYSTEMS

WARNING

High pressure air can cause severe injury or

death from hot oil and flying parts. Always

relieve pressure before removing caps, plugs,

covers or other parts from pressurized air

system.

* Open service valve at end of machine.

* Ensure pressure is relieved, with BOTH:

 - Discharge air pressure gauge reads zero (0).

 - No air discharging from service valve.

* When draining oil, remove and replace (make

tight) plug at bottom of separator tank.

* When adding oil, remove and replace (make tight)

plug on side of separator tank.

In the compressor lubricating and cooling system,

separation of the oil from the compressed air takes

place in the receiver-separator tank. As the

compressed air enters the tank, the change in

velocity and direction drop out most of the oil from

the air.

Additional separation takes place in the oil

separator element which is located in the top of the

tank.

Any oil accumulation in this separator element is

continuously drained off by means of a scavenge

tube which returns the accumulated oil to the

system.

SC AVENGE LINE

WARNING

High pressure air can cause severe injury or

death from hot oil and flying parts. Always

relieve pressure before removing caps, plugs,

covers or other parts from pressurized air

system.

The scavenge line originates at the receiverseparator tank cover and terminates at the

compressor airend through an orifice (.063 inch/1.6

mm). Once a year or every 2000 hours of operation,

whichever comes first, remove this line and any

orifice, thoroughly clean, then reassemble.

NOTICE

Excessive oil carry-over may be caused by an

oil-logged separator element. Do not replace

element without first performing the following

maintenance procedure:

1. Check oil level. Maintain as indicated earlier in

this section.

2. Thoroughly clean scavenge line, any orifice and

check valve.

3. Assure minimum pressure valve (if so

equipped) has proper setting.

4. Run unit at rated operating pressure for 30 to

40 minutes to permit element to clear itself.

COOLING FAN DRIV E

The heat exchanger or cooling fan is driven by a

multiple V-belt arrangement from the engine.

Inspect the cooling fan belts weekly or at 50 hour

intervals. These V-belts should be maintained at

the proper tension. Fan belts that are too tight

impose an undue load on the fan shaft bearings and

shorten the life of the belts. Fan belts that are too

loose allow slippage and lower the fan speed, cause

excessive belt wear, and can lead to overheating of

the cooling systems.

TM 5-3805-280-10

18-6
OIL SEPARATO R ELEMENT

The life of the oil separator element is dependent

upon the operating environment (soot, dust, etc.)

and should be replaced every twelve months or

2000 hours. To replace the element proceed as

follows:

* Ensure the tank pressure is zero.

* Disconnect the hose from the scavenge tube.

* Remove scavenge tube from tank cover.

* Disconnect service line from cover.

* Remove (16) cover mounting screws.

* Remove cover, element and inner shell.

* Remove any gasket material left on cover or tank.

* Install new gasket, inner shell and new element.

*Place a straightedge across top of element and

measure from bottom of straightedge to bottom of

element (See Fig. 1).

*Replace scavenge tube in cover (cover is still off of

tank).

*Measure from bottom of cover to end of

scavenge tube (See Fig. 2). Measurement

should be from 1/8” to 1/4” less than the

element measurement. If not, cut to size.

*Remove scavenge tube.

*Reposition cover (use care not to damage

gaskets). *Replace cover mounting screws:

tighten in a crisscross pattern to 100 lbs.-ft.

*Reconnect service line. Replace scavenge tube.

Reconnect hose.

*Close service valve. Start unit and look for leaks.

When replacing the element, the scavenge lines,

orifice, filter, and check valve should be thoroughly

cleaned and the oil changed.

Note: Do not remove staples from the

element/gasket connection.

cut line if necessary

Figure No. 1 Element Measurement Figure No. 2 Tube Measurement

TM 5-3805-280-10

18-7
EX TERIOR FINISH CARE

This unit was painted and heat cured at the

factory with a high quality, thermoset

polyester powder coating. The following

care will ensure the longest possible life

from this finish.

1. If necessary to remove dust, pollen,

etc. from housing, wash with water

and soap or dish washing liquid

detergent. Do not scrub with a

rough cloth, pad, etc.

2. If grease removal is needed, a fast

evaporating alcohol or chlorinated

solvent can be used. Note: This

may cause some dulling of the paint

finish.

3. If the paint has faded or chalked, the

use of a commercial grade, nonabrasive car wax may partially

restore the color and gloss.

 Field Repair of Texture Paint

1. The sheet metal should be washed

and clean of foreign material and

then thoroughly dried.

2. Clean and remove all grease and

wax from the area to be painted

using Duponts 3900S Cleaner prior

to sanding.

3. Use 320 grit sanding paper to

repair any scratches or defects

necessary.

4. Scuff sand the entire area to be

painted with a red scotch brite

pad.

5. Wipe the area clean using Duponts

3900S.

6. Blow and tack the area to be

painted.

7. Apply a smooth coat of Duponts

1854S Tuffcoat Primer to all bare

metal areas and allow to dry.

8. Apply 2 medium - wet coats of

Duponts 222S Adhesion Promoter

over the entire area to be painted,

with a 5 minute flash in between

coats.

9. To apply the texture coat, use

Duponts 1854S Tuffcoat Primer.

The proper technique to do this is

to spray the Tuffcoat Primer using

a pressure pot and use about 2-5

pounds of air pressure. This will

allow the primer to splatter

causing the textured look. Note:

you must be careful not to put too

much primer on at one time, this

will effect the amount of texture

that you are trying to achieve.

Allow the texture coat to flash for

20 minutes or until dry to touch.

10. Apply any of Duponts Topcoat

Finishes such as ImronTM or

CentariTM according to the label

instructions.

Note: To re-topcoat the textured surfaces

when sheet metal repairs are not

necessary, follow steps 1, 2, 4, 5,

6, 8 and 10.

CAUTION

• Any unauthorized modification or failure to

maintain this equipment may make it unsafe

and out of factory warranty.

• If performing more than visual inspections,

disconnect battery cables and open manual

blowdown valve.

• Use extreme care to avoid contacting hot

surfaces (engine exhaust manifold and

piping, air receiver and air discharge piping,

etc.).

• Never operate this machine with any

guards removed.

TM 5-3805-280-10

18-8
• Inch and metric hardware was used in the

design and assembly of this unit. Consult

the parts manual for clarification of usage.

Notice: Disregard any maintenance

pertaining to components not provided on

your machine.

TM 5-3805-280-10

18-9
AIR COMPRESSOR - LUBRICATION

GENERAL INFORMATION 

Lubrication is an essential part of preventive

maintenance, affecting to a great extent the

useful life of the unit. Different lubricants are

needed and some components in the unit

require more frequent lubrication than

others. Therefore, it is important that the

instructions regarding types of lubricants

and the frequency of their application be

explicitly followed. Periodic lubrication of the

moving parts reduces to a minimum the

possibility of mechanical failures.

The Preventive Maintenance Schedule

shows those items requiring regular service

and the interval in which they should be

performed. A regular service program

should be developed to include all items and

fluids. These intervals are based on

average operating conditions. In the event

of extremely severe (hot, cold, dusty or wet)

operating conditions, more frequent

lubrication than specified may be necessary.

Details concerning lubrication of the running

gear are in Maintenance Section.

All filters and filter elements for air and

compressor lubricant must be obtained

through Ingersoll-Rand to assure the proper

size and filtration for the compressor.

COMPRESSOR OIL CHANGE 

These units are normally furnished with an

initial supply of oil sufficient to allow

operation of the unit for approximately 6

months or 1000 hours, whichever comes

first. If a unit has been completely drained

of all oil, it must be refilled with new oil

before it is placed in operation. Refer to

specifications in Lubrication Table.

NOTICE

Some oil types are incompatible when mixed

and result in the formation of varnishes,

shellacs, or lacquers which may be

insoluble. Such deposits can cause serious

troubles including clogging of the filters.

Where possible, do NOT mix oils of different

types and avoid mixing different brands. A

type or brand change is best made at the

time of a complete oil drain and refill.

If the unit has been operated for the time/

hours mentioned above, it should be

completely drained of oil. If the unit has

been operated under adverse conditions, or

after long periods in storage, an earlier

change period may be necessary as oil

deteriorates with time as well as by

operating conditions.

WARNING

High pressure air can cause severe injury

or death from hot oil and flying parts.

Always relieve pressure before removing

caps, plugs, covers or other parts from

pressurized air system. Ensure the

following conditions are met:

- Discharge air pressure gauge reads

zero (0).

- No air discharging from an “open”

manual blowdown valve.

An oil change is good insurance against the

accumulation of dirt, sludge, or oxidized oil

products.

TM 5-3805-280-10

18-10
Completely drain the receiver- separator,

piping, and oil cooler. If the oil is drained

immediately after the unit has been run for

some time, most of the sediment will be in

suspension and, therefore, will drain more

readily. However, the fluid will be hot and

care must be taken to avoid contact with the

skin or eyes.

After the unit has been completely drained

of all old oil, close the drain valve. Add oil in

the specified quantity at the filler plug.

Tighten the filler plug and run the machine to

circulate the oil. Check the oil level WHEN

RUNNING AT FULL LOAD. If not near the

middle of the sight tube, stop the unit and

make corrections. DO NOT OVERFILL.

NOTICE

Ingersoll-Rand provides compressor oil

specifically formulated for Portable

Compressors and requires the use of these

fluids in order to obtain extended limited

airend warranty. Refer to Fuels and

Lubricants Chapter.

TM 5-3805-280-10

18-11
TM 5-3805-280-10

BLANK

18-12
TM 5-3805-280-10

CHAPTER 19

MAINTENANCE—ROCK DRILL ATTACHMENT
TM 5-3805-280-10

BLANK
Maintenance intervals

MAINTENANCE - ROCK DRILL ATTACHMENT

These maintenance intervals only cover all

routine operation and scheduled maintenance

tasks by operation and maintenance staff. Major

overhauls are outside the scope of this section

and should be referred to an authorized

INGERSOLL–RAND service department.

			 




	

	








	



	


	




First oil change

Change the drill guide reducer oil after 50 operating hours.

Change the rod changer reducer oil after 150 operating hours.

TM 5-3805-280-10

19-1
Maintenance intervals

50 h

CPA

10 h

1000 h

2000 h

TM 5-3805-280-10

19-2
Maintenance intervals

WHEN REQUIRED









Drifter chain tension

The adjustment is carried out on the chain tightener A (see Figure). Generally speaking, the chains

should not be too tight (the front chain vibrates abnormally during drilling) or too loose (the front chain

lashes out against the feed box or the tightener

strikes against the feed extension cylinder attachment).

Change the chains when the tightener no longer reaches their extension.

Hose reel chain tension

In the same way, the adjustment is carried out on

the chain tightener B (see Figure). The cable should

not sag.

Hose tension

All the hoses should be tightened with the exception of the drifter hoses (P1 and P2) which should sag

slightly when they are not under pressure (the pressure tightens these hoses when in operation).

Chain replacement

The guide should be put in toe hole drilling position, horizontal, to prevent cradles from sliding when

the chains or the reel rope are dismounted.

After chain (rope) replacement, move the drifter

back to its rear end position. Verify the distance between the drifter cradle and the hose reel cradle is 60

 15 mm (2.4  .6 in) (see Figure).

TM 5-3805-280-10

19-3
Adjustment of drilling automatisms

ADJUSTMENT OF DRILLING AUTOMATISMS

LOCATION OF ADJUSTING SCREWS





 





1) V1 Feed pressure

 !* -$- *++!& !* % . !$ *++!& ,( + 

% !& '& *!+ +' *,!+ !+ +0( & !%+)

)*++!& &  % !&  *++! %' ()!') +'

)!$$!& 0 !& +  !+ !&*+ *'% )*!*+&

!&$ *++!& !* % + ,$$ (),**!'& ('.)

. !$ )!$$!& !& +  )*+ %'*+ '%'&',*

'%(+&+ )'# &',&+)

2) MP Maximum percussion pressure

+ *+* +  )!+) %/!%,% (),**!'& ()**,)

. & )!$$!& .!+ '$ '!$ . !$ *+)+!& ,(

 !* +')0 *++!& 
  	 


3) V2 Operating percussion pressure

+ *+* +  )!+) (),**!'& ('.) +'  *,!+$

$-$ ') !+ *!1 & )'# )&**   *++!&

* ',$  (()'/!%+$0 

 	  
 )   (*! ')  

 
   )   	 (*! ')  	

   
 ) 	  		 (*! ')  

(&!& ,('& +  (()'()!+ )!+) ('.) $-$

4) V3 Drifter power regulation


 %*,)* +,$  ') 0 *&*!& '+ 

').) & )+,)&  ()**,)*

  
 ",*+%&+ *+* +   ()**,) $!%!+

$'. . ! +  )!+) ('.) .!$$  ),

 !* '&+)'$ .!$$ '&+!&, +' ), +  )!+)

('.) $-$ +'  
 )  (*! ()*+ %!&!%,% *

)'# )*!*+& )**

5) Feed flow regulator

 !* $'. ),$+') ",*+* +   %/!%,%

$'. +' *$! +$0 '- +  )!$$ )+ !& +  )*+ )'#

&',&+)

 +   $'. . !$ )!$$!& !& *'+) )'# '&!2

+!'&* ) * +  ()*+ %/!%,% +  )*,$+!&

# ()**,) %#* +   ') +' )* &

+ '& 


 !* +* * '+ & &+!'! & '$$)!&

'&+)'$

6) V4 Progressive feed control and

anti–jam

 !* & ",*+$ ),$+') . ! *&** + 

()**,) !)&+!$ )'** +  )'++!'& %'+') &

+* !)+$0 ,('&  $'.*

TM 5-3805-280-10

19-4
Adjustment of drilling automatisms


# " $"!% (# $ "#$$

#  # $ #$ $ "% $  '# #

"#$"$  '# "#%$  '"  " 

 $ #'# ' 
#  # #$  # *

"$ " $  %#$$ #" '"#

"$" "%## "##%"  "# # $ $ 

" "%$

" & $  #$$ $ ' "#$

#$  $ "&"# " $ $ $# #$%

 #$$ #  %#$ & " " *

$# $ & "$  %# "

7) Flushing control valve


 %# $" && ' %) #$ $  # 

%# "&"#  $ ' $ $ # %

"$" )  "$ "# $ $ ' $ $ #

"$"$

# $%" # %)  "$& '$ "&"# "%#*

# "$"#

E.53734 PRESSURE GAUGES

ref. 42501







$







	 

	 

Connect the pressure gauges with hydraulic

dampers (ref. 42501) to the pulsating P1 and P2 circuits.

Connect the two other pressure gauges to the A1 and

A2 feed circuits.

TM 5-3805-280-10

19-5
Adjustment of drilling automatisms

PRESETTING BEFORE DRILLING

"


"

"



"


$&+,0( 1))


 !0.1&- 5$)(6; 076 $0' .115(0 " 5&4(9 706,.

6+( ,06(40$. 524,0* %(&1/(5 )4(( " 5&4(9 4(67405 61

)4(( 416$6,10


 !0.1&- 5$)(6; 076 $0' )7..; 6,*+6(0 " 5&4(9

+1.' " 5&4(9 61 24(8(06 4(6,*+6(0,0*



 (6 6+( )((' ).19 4(*7.$614  10 215,6,10 
	


 (/18( "
 &$2 $0' )7..; 6,*+6(0 "
 5(66,0*

$&+,0( 4700,0*


 4(55 6+( %,6 $*$,056 6+( 41&- %; $&6,0* 10

)((' .(8(4


 4(5(6 '4,..,0* )((' 24(5574( "
 5(66,0* 61

	  
		 %$4 


	  

	 25,

PRESETTING WHILE DRILLING

 +(5( 5(66,0*5 /756 %( &$44,(' 176 9+(0 1,. +$5

4($&+(' ,65 014/$. 12(4$6,10 6(/2(4$674(


 6$46 '4,..,0* ).75+,0* 416$6,10 2(4&755,10

)((' 

 	


   9,6+

'4,)6(4 2(4&755,10 &10641. ,0 =761215,6,10


 (6 6+( 12(4$6,0* 2(4&755,10 24(5574( 61

 

	  
 %$4 			 
 25, )14 & 
	

14 .(55 '(2(0',0* 1) 6+( %,6 5,<( 41' ',$/(6(45

41&- +$4'0(55 %; .115(0,0* " 5&4(9 +(&- 6+(

24(5574( 10 =*$7*(

	 ; $&6,0* 10 "
 5&4(9 4(5(6 )((' 24(5574(

)14 &144(&6 &172.,0* /16,10  $%176 
 /,..,/(6(4 8,%4$?

6,10 $0' &172.,0* 6(/2(4$674( .(55 6+$0 
		> 

10641. 5,/7.6$0(175.; 2(0(64$6,10 4$6( $0' &17?

2.,0* 6(/2(4$674(

) &172.,0* 6(/2(4$674( ,5 $%18( .,/,6 $.6+17*+

&172.,0* 8,%4$6,10 ,5 &144(&6 4('7&( 12(4$6,0* 2(4?

&755,10 24(5574( %; 6,*+6(0,0* " 5&4(9

SETTING WHILE DRILLING

Adjust flow regulator on feed return A2


 #+,.( '4,..,0* 6+( 56$46(4 41' 14 6+( 41' '4,..('

$6 6+( +,*+(56 '4,..,0* 4$6( 241*4(55,8(.; &.15( 6+(

).19 4(*7.$614  706,. 6+( )((' %$&-24(5574(

4($&+(5  %$4 &+(&- 6+( 24(5574( 10 =*$7*(

 +(0 4(12(0 6+( ).19 4(*7.$614  %; 
 ',8,?

5,10

14 (:$/2.(  ,) 215,6,10  &4($6(5  %$4 %$&-

24(5574( 4(12(0 6+( ).19 4(*7.$614 61 215,6,10 

V3 drifter power regulator setting

 +,5 5(66,0* /756 %( &$44,(' 176 9+(0 '4,..,0*

&10',6,105 $..19 /$:,/7/ 2(4&755,10 24(5574( $0'

$&67$. )((' )14&( ,( +$4' 010 )4$&674(' 41&- )(('

%$&- 24(5574( =	 %$4

 #,6+ $ 94(0&+ +1.' " 5&4(9 ,0 215,6,10


 ,*+6(0 " 706,. 2(4&755,10 24(5574( '4125

&+(&- 6+( 24(5574( 10 =*$7*(

 115(0 51 $5 61 4(&18(4 6+( ,0,6,$. 24(5574(

2.75 $0 $'',6,10$. 

 6740

 #+,.( '4,..,0* 9,6+ '4,)6(4 2(4&755,10 &10641.

$.6(40$6,8(.; ,0 =761$0' =$07$.215,6,105 8(4,);

6+$6 6+( 2(4&755,10 24(5574( 4(/$,05 6+( 5$/(

 (&74( $.. .1&-,0* 0765

V4 – Progressive feed control setting.

 #+,.( '4,..,0* 6+( .$56 41' 14 6+( 41' '4,..('

9,6+ 6+( +,*+(56 416$6,10 61437( 

 	



 .115(0 "
 5(66,0* 706,. 6+( )((' %$&- 24(5?

574( 5.,*+6.; ,0&4($5(5 &+(&- 6+( 24(5574( 10 =

*$7*(

 +(0 4(6,*+6(0 "
 5(66,0* )14 
 6740

Air flushing valve

#+,.( '4,..,0* 9,6+ 6+( '4,)6(4 2(4&755,10 &10641. ,0

=$761215,6,10 59,6&+ 1)) $,4 ).75+,0* $0' &+(&- 6+(

'4,)6(4 4(8(45(5

TM 5-3805-280-10

19-6
Adjustment of drilling automatisms

EXCEPTIONAL ADJUSTMENTS

  

  # !.&& +$!- + + / +, * +.,,$)( *+ ,,.+ 

$, )(&2 )-$(  0# ( +$&&$(" $( 3'(.&*),$-$)(

# !-)+2 , - *+ ,,.+ 	 +  	 *,$ (

 ')$!$  2 , --$(" -# ,-)* ,+ 0  

 $"#- ( -) + . -# *+ ,,.+ 

 )), ( -) $(+ , 

# % -# *+ ,,.+ )( 3
"." 

	    
  





  







)+ # %$(" )+ , --$(" !- + *+- + *& ' (-

	 $,)(( - ( *&." -# +$!- + * +.,,$)(

#), 


  ')/ -# *+)- -$)( * ( &)), ( 

'1$'.' * +.,,$)( *+ ,,.+ + &$ ! /&/ 


  - -# '1$'.' * +.,,$)( *+ ,,.+ -)

	 + 


 *,$ 2 -$"#- ($(" -# + &$ ! /&/ 


# % -# *+ ,,.+ )( 3
"." 

	  .+ -# ,! -2 (.- + ').(- -# *+)- 4

-$)( *

TM 5-3805-280-10

19-7
CED,OUOE042,51 –19–19OCT99–1/1

REPLACING ROCK DRILL DUST

COLLECTOR FILTERS

T125111 –UN–28OCT99

A—Dust Bin Hopper

B—Latches

1. Remove dust collector hopper (A) by releasing latches

(B).

2. Release filter separating grid and use strap wrench to

replace filters.

TM 5-3805-280-10

19-8
DAILY MAINTENANCE HYDRAULIC

DUST COLLECTOR

1 Start up the collector.

At low temperatures affecting hydraulic oil

viscosity, let diesel motor warm up before

starting the dust collector.

2. After start-up of the dust collector,

first thing that happens, is that a

free cleaning cycle automatically

runs.When compressor produces

correct working pressure - allow

further one cleaning cycle without

drilling.

3. Check that your dust collector

sucks properly by looking at the

rubber dump valve (or plastic bag)

which shall QUICKLY AND

STRONGLY be sucked up against

dust collector bottom.

4. Check that GASKET in pick up

hood A) and SKIRT B) are not

worn out.

5. Check that suction hose is not

damaged or bent.

6. Every da y before stopping

machine :

 Clean filters as described under point

2 above

TM 5-3805-280-10

19-9
Maintenance intervals

DAILY

The CPA should be lowered in its rest position.

Attachment to carrier

Check the CPA attachment to the carrier boom

end. Check all fixing pins are secured.

Pressurization air oiler

The oiler is located on the side of the CPA cradle,

close to the oscillation cylinder. Remove the oil fill

plug (Pos. 1) to add oil.



Drifter Front head lubrication

Wipe the fitting before lubrication.

Guide chains and ropes inspection

– Examine the front chain in search of any

signs of wear or corrosion. replace if required.

– Examine the whole length of the hose reel

rope. In particular, check the attachment points on the

tightener and the chain. The wire rope should not

show signs of abnormal wear (flats on the outside

strands, crushing, swelling or fraying).

In any case, replace the cable immediately if :

 there are at least 2 broken wires at an interval of less than 36 mm (1.44 in) ( (6 times the nominal diameter of the cable)

 or, there are at least 4 broken wires at an interval of less than 180 mm (7.2 in) (30 times the

nominal diameter of the cable)

 or, if the cable diameter is inferior to 5,4 mm

(.21 in) (nominal diameter of the cable less 10%).

Move the drifter at reduced speed until it reaches

its front end position.

– Examine the chain reel in search of any

signs of wear or corrosion. Replace if required.

EVERY 50 HOURS

Wash the machine.

Check tightening of fixing cap bolts.

Wipe all fittings before lubricating.

Inspect all hoses. Replace if damaged.

TM 5-3805-280-10

19-10
Maintenance intervals

EVERY 1000 HOURS

Guide reducer oil change

Oil changes must be carried out after every 1000

hours or at least once a year.

The CPA should be lowered in its rest position.

Unscrew the top filling plug.

Using a seryng remove old oil.

Fill the reducer with oil (capacity 0.5 liter).

EVERY 2000 HOURS

Rod changer reducer oil change

Oil changes must be carried out after every 2000

hours.

The CPA should be lowered in its rest position.

Open plugs A and B. Allow oil to drain. Mount plug

A. Fill the reducer with oil (capacity 0.3 liter). Mount

plug B.





TM 5-3805-280-10

19-11
Drifter maintenance 

DRIFTER MAINTENANCE


 		 	 
	


		

	

 		

 

Daily

Lubricate the drifter front part (5 or 6 shots of a

hand grease pump).

Weekly

Check tightening of drifter mounting bolts.

Every 1000 drilled meters

Dismount the shank adaptor to check the condition of the splines.

Replace shank if damaged.

Check the wear of the flushing nozzle bronze bush

(or front guide for drifter with reverse percussion).

maximum wear = shank diameter+1 mm (.04 in).

Replace the complete flushing nozzle by a renovated one if damaged (or replace the bronze bush for

drifter with reverse percussion).

TM 5-3805-280-10

19-12
CHAPTER 20

MAINTENANCE

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Maintenance

TX,90,FF3116 –19–18NOV92–1/1

DO NOT SERVICE INJECTION NOZZLES

IMPORTANT: Do not service or remove injection

nozzles. The service life of the injection

nozzles may be shortened by:

• Overheating

• Improper operation

• Poor quality fuel

• Excessive idling

If injection nozzles are not working correctly or are dirty,

the engine will not run normally. (See your authorized

dealer for service.)

04T,90,C83 –19–16AUG93–1/1

DO NOT CHANGE INJECTION PUMP

IMPORTANT: Never steam clean or pour cold

water on an injection pump while the

pump is running, or while it is still

warm. To do so may cause seizure

of pump parts.

Clean trash regularly from under

injection pump.

Changing the injection pump in any way not approved

by the manufacturer will end the warranty. (See your

copy of the John Deere warranty on this machine.)

Do not service an injection pump that is not operating

correctly. (See your authorized injection pump service

center.)

TM 5-3805-280-10

20-1
Maintenance

TX,90,DH5581 –19–26JUL96–1/1

BLEEDING THE FUEL SYSTEM

T108260E –UN–27MAR97 T102673 –UN–02AUG96

1. Open bleed screws (A) on fuel filter and on water

separator.

2. Pump water separator primer (B) until fuel fills

separator bowl and until fuel escapes from water

separator bleed screw.

3. Tighten water separator bleed screw.

4. Pump water separator primer (B) until fuel escapes

from final fuel filter bleed screw.

5. Tighten final fuel filter bleed screw.

T82,EXMA,I –19–03AUG92–1/1

PRECAUTIONS FOR ALTERNATOR AND REGULATOR

When batteries are connected, follow these rules:

1. Disconnect negative (-) battery cable when you

work on or near alternator or regulator.

2. DO NOT TRY TO POLARIZE ALTERNATOR OR

REGULATOR.

3. Be sure alternator wires are correctly connected

BEFORE you connect batteries.

4. Do not ground alternator output terminal.

5. Do not disconnect or connect any alternator or

regulator wires while batteries are connected or

while alternator is operating.

6. Connect batteries or a booster battery in the correct

polarity (positive [+] to positive [+] and negative [-]

to negative [-]).

7. Do not disconnect the batteries when engine is

running and alternator is charging.

8. Disconnect battery cables before you connect

battery charger to the batteries.

TM 5-3805-280-10

20-2
Maintenance

TX,90,DH1018 –19–30APR94–1/2

SERVICE BATTERIES CAREFULLY

TS204 –UN–23AUG88 TS203 –UN–23AUG88

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a

flashlight to check battery electrolyte level.

Never check battery charge by placing a metal

object across the posts. Use a voltmeter or

hydrometer.

Always remove grounded (-) battery clamp first

and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in

clothing, and cause blindness if splashed into

eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is

added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize

the acid.

3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do

not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

If electrolyte spills on the floor, use one of the following

mixtures to neutralize the acid: 0.5 kg (1 lb) baking soda

in 4 L (1 gal) water, or 0.47 L (1 pt) household ammonia

in 4 L (1 gal) water.

Continued on next page

TM 5-3805-280-10

20-3
Maintenance

TX,90,DH1018 –19–30APR94–2/2

IMPORTANT: Electrolyte can damage paint and metal

surfaces of your machine. Do not

overfill the battery cells.

TM 5-3805-280-10

20-4
Maintenance

04T,90,FF20 –19–12MAY93–1/2

CHECKING ELECTROLYTE SPECIFIC

GRAVITY

TS204 –UN–23AUG88 TS203 –UN–23AUG88

CAUTION: Battery gas can explode. Keep

sparks and flames away from batteries. Use a

flashlight to check battery electrolyte level.

Never check battery charge by placing a metal

object across the posts. Use a voltmeter or

hydrometer.

Always remove grounded (-) battery clamp first

and replace it last.

Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in

clothing, and cause blindness if splashed into

eyes.

Avoid the hazard by:

1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is

added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize

the acid.

3. Flush your eyes with water for 15—30

minutes. Get medical attention immediately.

If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do

not exceed 1.9 L (2 quarts).

3. Get medical attention immediately.

Check the specific gravity of electrolyte in each battery

cell.

Continued on next page

TM 5-3805-280-10

20-5
Maintenance

04T,90,FF20 –19–12MAY93–2/2T85402 –UN–10NOV88

See your John Deere dealer for JT05460 SERVICEGARD

battery and coolant tester. Follow directions included with

the tester.

A fully charged battery will have a corrected specific

gravity reading of 1.260. If the reading is below 1.200,

charge the battery.

NOTE: In tropical areas, use 1.225 for the full charge

reading. In cold areas, use 1.280 for the

full-charge reading.

T82,EXMA,G –19–03AUG92–1/1

USING BATTERY CHARGER

TS204 –UN–23AUG88

CAUTION: Disconnect battery ground before

you charge batteries in the machine to prevent

damage to electrical components.

A battery may explode if charged when it is

frozen. Warm battery to 16°C (60°F) before

charging.

A battery charger may be used as a booster to start

engine.

IMPORTANT: Do not use battery charger as a booster

if a battery has a 1.150 specific gravity

reading or lower. Turn off charger

before connecting or disconnecting it.

TM 5-3805-280-10

20-6
Maintenance

CED,OUOE020,49 –19–13APR99–1/1

REPLACING BATTERIES

Your machine has two 12 volt batteries with negative (-)

ground. Batteries must meet one of the specifications

below.

Battery—Specification

Cold Cranking Amps .................................................. 1400 at -18°C (0°F)

Minutes Reserve Capacity ................................................ 440 at 25 amps

If one battery in a 24-volt system has failed but the other

is still good, replace the failed battery with one of the

same type. For example, replace a failed

maintenance-free battery with a new maintenance-free

battery. Different types of batteries may have different

rates of charge. This difference could overload one of the

batteries and cause it to fail.

TX,90,DH5154 –19–10AUG96–1/1

REMOVING BATTERIES

1. Remove two wing nuts from battery cover.

2. Disconnect negative (-) battery cables first, then

positive (+) cables.

3. Remove hold down brackets.

4. Lift batteries out of compartment.

TM 5-3805-280-10

20-7
Maintenance

TX,90,DH5140 –19–08AUG96–1/1

WELDING ON MACHINE

IMPORTANT: Disconnect battery ground strap or turn

battery disconnect switch to ’OFF’ to

prevent voltage spikes through

alternator or monitor.

If machine is equipped with a controller

(microprocessor) like Main Controller,

disconnect harness connector from

controller to prevent voltage spikes

through microprocessor.

Connect welder ground clamp close to

each weld area so electrical current

does not arc inside any bearings.

TM 5-3805-280-10

20-8
Maintenance

TX,90,DH3734 –19–18AUG95–1/1

ADDING 12—VOLT ACCESSORIES

IMPORTANT: This machine has a 24-volt electrical

system. Installing 12-volt accessories

without addition of 24-volt to 12-volt

converter may cause battery failure.

When possible, use 24-volt accessories. If 12-volt

accessories are added, use a 24-volt to 12-volt converter.

Converters are available from your authorized dealer.

(See the Industrial Equipment Attachment Guide.)

Converter capacity requirements depend on the load of

the accessories installed. Follow electronic dealer and

manufacturer’s recommendations to determine the

capacity of the converter required and its installation

requirements.

IMPORTANT: DO NOT connect an accessory to one

battery. Connecting a 12-volt accessory

to one battery will cause one battery to

overcharge, and the other battery to

undercharge, causing battery failure.

TX,90,DH5331 –19–26NOV96–1/2

REPLACING FUSES

T105381 –UN–26NOV96

The fuse box is located behind the seat.

Remove cover (A).

Continued on next page

TM 5-3805-280-10

20-9
Maintenance

TX,90,DH5331 –19–26NOV96–2/2T101638 –UN–26JUN96

1—5 Amp—Back up

2—10 Amp—Controller

3—10 Amp—EC Motor

4—5 Amp—Solenoid

5—10 Amp—Pow. on

6—5 Amp—Sw box

7—5 Amp

8—10 Amp

9—5 Amp

10—5 Amp—Travel

11—20 Amp—Lamp

12—10 Amp—Wiper

13—20 Amp—Heater

14—5 Amp—Air con

15—10 Amp—Horn

16—5 Amp—Radio

17—10 Amp—Lighter

18—5 Amp—Room Lamp

19—10 Amp—Auxiliary

20—20 Amp—Lamp

IMPORTANT: Install fuse with correct amperage

rating to prevent electrical system

damage from overload.

TM 5-3805-280-10

20-10
Maintenance

04T,90,J22 –19–28SEP92–1/1

FUSE (BLADE-TYPE) COLOR CODES

Amperage Rating Color

1 Black

3 Violet

4 Pink

5 Tan

7-1/2 Brown

10 Red

15 Light Blue

20 Yellow

25 Natural (White)

30 Light Green

TX,90,DH5141 –19–08AUG96–1/1

CHECKING TRAVEL ALARM SYSTEM

T102893 –UN–07AUG96

1. Propel machine forward.

Travel alarm must sound.

2. Stop machine.

Travel alarm must stop.

3. Propel machine forward.

4. Depress travel alarm cancel switch (A).

After an initial 12 second alarm, alarm must stop.

5. Repeat test with machine traveling in reverse.

6. If the travel alarm does not operate properly, do not

operate machine. See your authorized dealer.

TM 5-3805-280-10

20-11
Maintenance

04T,90,M16 –19–05APR91–1/3

REPLACING BUCKET TEETH

T95784 –UN–10NOV88

CAUTION: Guard against injury from flying

pieces of metal; wear goggles or safety glasses.

IMPORTANT: Angle the drift toward the bucket to

avoid damaging the rubber pin lock.

1. Use a hammer and drift to drive out locking pin.

NOTE: Alternate buckets may use different tooth

assemblies.

2. Remove tooth.

04T,90,M16 –19–05APR91–2/3T95785 –UN–10NOV88

3. Inspect rubber pin lock (A) for damage. Replace if

necessary.

4. If rubber pin lock has moved, reposition in slot in

adapter tooth shank.

04T,90,M16 –19–05APR91–3/3T95786 –UN–10NOV88

5. Position the new tooth over the tooth shank.

6. Drive the locking pin into the hole fully.

NOTE: Check bucket teeth periodically so that wear does

not extend to the bucket tooth shank.

TM 5-3805-280-10

20-12
Maintenance

CED,OUOE020,21 –19–08MAR99–1/1

REMOVING THE BUCKET

T120450 –UN–25MAR99

42 Inch Bucket

T120448 –UN–25MAR99

60 Inch Bucket

Remove bucket. (See Using Quick-Disconnect Hitch in

this manual.)

TM 5-3805-280-10

20-13
Maintenance

04T,90,K273 –19–28JAN92–1/1

REPLACING BUCKET TOOTH TIP—

HEAVY-DUTY BUCKET

T6879EE –UN–06DEC88 T7527DO –UN–27JUN91

A—Tooth

B—Tooth Tip

C—Pin

D—’Front’ Mark

1. Clean tooth (A) and tooth tip (B).

2. Insert lock removal tool under U-shaped pin (C).

CAUTION: Avoid possible injury. Pin may fly

after it is released from tooth tip. Keep a firm

grip on pin to prevent injury.

3. Remove pin.

4. Turn tooth tip counterclockwise and pull it towards you

to remove.

5. Clean tooth shank.

6. Replace U-shaped pin at same time you replace tooth

tip.

7. Insert tooth tip on shank turning tip clockwise.

8. Install U-shaped pin. Side of pin marked ’FRONT’ (D)

must face tooth tip. Make sure pin is firmly engaged

over tooth tip.

TX,90,FF3114 –19–18NOV92–1/1

DO NOT SERVICE CONTROL VALVES,

CYLINDERS, PUMPS OR MOTORS

Special tools and information are needed to service

control valves, cylinders, pumps, or motors.

If these parts need service, see your authorized dealer.

TM 5-3805-280-10

20-14
Maintenance

04T,90,M197 –19–07NOV90–1/1

TRACK SAG GENERAL INFORMATION

To maximize undercarriage life, keep track sag within

specification. Tracks may require adjustment several times

during a working day due to changing soil type and

moisture content.

Adjust tracks in the actual operating conditions.

TIGHT TRACK: Packing causes a tight track. If material

packs in the undercarriage, adjust tracks with the material

packed in the components.

While the track spring will recoil and the machine can

continue to operate with a tight track, continued operation

will result in excessive pin and bushing wear, sprocket

popping, tooth tip wear, and excessive loads on the entire

undercarriage and propel drive system.

Machine productivity and fuel consumption are also

adversely affected because increased horsepower is

needed to move the machine.

LOOSE TRACK: A loose track has more side to side

motion, increasing side wear on the links, rollers and front

idler. An excessively loose track will slap at high ground

speeds, resulting in high impact loads on the sprocket

teeth, bushings, and carrier rollers.

T82,SKMA,AT –19–01AUG94–1/1

HARDWARE TORQUE SPECIFICATIONS

Check cap screws and nuts to be sure they are tight. If

hardware is loose, tighten to torque shown on the

following charts unless a special torque is specified.

TM 5-3805-280-10

20-15
Maintenance

TX,90,FF,294 –19–09APR92–1/1

CHECK TRACK SHOE TORQUE

T82862 –UN–08NOV88 T6794AM –UN–23FEB89

A—Rounded Edge

B—Chamfered Edge

Track shoe cap screw torque should be periodically

checked. If the cap screws do not meet the minimum

torque specifications, remove the shoes and clean the

mating surfaces of the shoes and links before tightening

the cap screws.

If unit is operated with loose track shoes, the cap screw

holes in the shoes and links will wear and it may be

difficult to keep the track shoes tight. Loose shoes can

also cause hardware failure and loss of track shoes.

Install all track shoe nuts with rounded edges (A) against

the link and chamfered edges (B) away from the link. Be

sure nut is properly positioned in the link so there is full

contact area between the nut and the link.

Cap Screw—Specification

Torque 298 N•m (220 lb-ft) Plus 1/2 turn

(180°)

....................................................

TM 5-3805-280-10

20-16
Maintenance

DX,TORQ1 –19–20JUL94–1/1

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES

TS1656 –19–02APR97

TM 5-3805-280-10

20-17
Maintenance

DX,TORQ2 –19–20JUL94–1/1

METRIC BOLT AND CAP SCREW TORQUE VALUES

TS1657 –19–02APR97

TM 5-3805-280-10

20-18
Maintenance

04T,90,M170 –19–01AUG94–1/1

ADDITIONAL METRIC CAP SCREW TORQUE

VALUES

T6873AA –UN–18OCT88 T6873AB –UN–18OCT88 T6873AC –UN–18OCT88

CAUTION: Use only metric tools on metric

hardware. Other tools may not fit properly. They

may slip and cause injury.

Check tightness of cap screws periodically. Torque values

listed are for general use only. Do not use these values if

a different torque value or tightening procedure is listed

for a specific application.

Shear bolts are designed to fail under predetermined

loads. Always replace shear bolts with identical grade.

Fasteners should be replaced with the same or higher

grade. If higher grade fasteners are used, these should

only be tightened to the strength of the original.

Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from

failing when tightening.

Tighten cap screws having lock nuts to approximately 50

percent of amount shown in chart.

METRIC CAP SCREW TORQUE VALUESa

T-Bolt H-Bolt M-Bolt

Nominal

Dia N•m lb-ft N•m lb-ft N•m lb-ft

8 29 21 20 15 10 7

10 63 46 45 33 20 15

12 108 80 88 65 34 25

14 176 130 137 101 54 40

16 265 195 206 152 78 58

18 392 289 294 217 118 87

20 539 398 392 289 167 125

22 735 542 539 398 216 159

24 931 687 686 506 274 202

27 1372 1012 1029 759 392 289

30 1911 1410 1421 1049 539 398

33 2548 1890 1911 1410 735 542

36 3136 2314 2401 1772 931 687

aTorque tolerance is ±10%.

TM 5-3805-280-10

20-19
Maintenance

T82,FLMA,AI –19–14MAR90–1/1

CHECK OIL LINES AND FITTINGS

X9811 –UN–23AUG88 T85401 –UN–24JAN89

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid

the hazard by relieving pressure before

disconnecting hydraulic or other lines. Tighten

all connections before applying pressure.

Search for leaks with a piece of cardboard.

Protect hands and body from high pressure

fluids.

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be

surgically removed within a few hours or

gangrene may result. Doctors unfamiliar with

this type of injury may call the Deere &

Company Medical Department in Moline, Illinois,

or other knowledgeable medical source.

Check all oil lines, hoses and fittings regularly for leaks or

damage. Make sure all clamps are in position and tight.

Make sure hoses are not twisted or touching machine

parts which are moving.

Tubing with dents may cause the oil to overheat. If you

find tubing with dents, install new tubing immediately.

IMPORTANT: Tighten fittings as specified in torque

chart.

When you tighten connections, use two wrenches to

prevent bending or breaking tubing and fittings.

TM 5-3805-280-10

20-20
Maintenance

04T,90,K66 –19–19MAR96–1/2

SERVICE RECOMMENDATIONS FOR O-RING

BOSS FITTINGS

T6243AE –UN–18OCT88

STRAIGHT FITTING

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electrical

tape over threads to protect O-ring. Slide O-ring over

tape and into O-ring groove of fitting. Remove tape.

3. Tighten fitting to torque value shown on chart.

Continued on next page

TM 5-3805-280-10

20-21
Maintenance

04T,90,K66 –19–19MAR96–2/2T6520AB –UN–18OCT88

ANGLE FITTING

1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.

2. Turn fitting into threaded boss until back-up washer

contacts face of boss.

3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).

NOTE: Do not allow hoses to twist when tightening

fittings.

4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8-24 UNF 8 6

7/16-20 UNF 12 9

1/2-20 UNF 16 12

9/16-18 UNF 24 18

3/4-16 UNF 46 34

7/8-14 UNF 62 46

1-1/16-12 UN 102 75

1-3/16-12 UN 122 90

1-5/16-12 UN 142 105

1-5/8-12 UN 190 140

1-7/8-12 UN 217 160

NOTE: Torque tolerance is ± 10%.

TM 5-3805-280-10

20-22
Maintenance

04T,90,K67 –19–01AUG94–1/1

SERVICE RECOMMENDATIONS FOR FLAT

FACE O-RING SEAL FITTINGS

T6243AD –UN–18OCT88

1. Inspect the fitting sealing surfaces. They must be free

of dirt or defects.

2. Inspect the O-ring. It must be free of damage or

defects.

3. Lubricate O-rings and install into groove using

petroleum jelly to hold in place.

4. Push O-ring into the groove with plenty of petroleum

jelly so O-ring is not displaced during assembly.

5. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.

6. Tighten fitting or nut to torque value shown on the

chart per dash size stamped on the fitting. Do not allow

hoses to twist when tightening fittings.

FLAT FACE O-RING SEAL FITTING TORQUE

Nominal Tube O.D. Swivel Nut Bulkhead Nut

Thread Size

mm in. Dash Size in. N•m lb-ft N•m lb-ft

6.35 0.250 -4 9/16-18 16 12 5.0 3.5

9.52 0.375 -6 11/16-16 24 18 9.0 6.5

12.70 0.500 -8 13/16-16 50 37 17.0 12.5

15.88 0.625 -10 1-14 69 51 17.0 12.5

19.05 0.750 -12 1 3/16-12 102 75 17.0 12.5

22.22 0.875 -14 1 3/16-12 102 75 17.0 12.5

25.40 1.000 -16 1 7/16-12 142 105 17.0 12.5

31.75 1.250 -20 1 11/16-12 190 140 17.0 12.5

38.10 1.500 -24 2-12 217 160 17.0 12.5

NOTE: Torque tolerance is +15 -20%.

TM 5-3805-280-10

20-23
Maintenance

T82,BHMA,EL –19–19MAR96–1/1

SERVICE RECOMMENDATIONS FOR 37°

FLARE AND 30° CONE SEAT CONNECTORS

T6234AC –UN–18OCT88

1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.

2. Defects in tube flare cannot be repaired.

Overtightening a defective flared fitting will not stop

leaks.

3. Align tube with fitting before attempting to start nut.

4. Lubricate male threads with hydraulic fluid or petroleum

jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening

fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft

3/8 - 24 UNF 8 6

7/16 - 20 UNF 12 9

1/2 - 20 UNF 16 12

9/16 - 18 UNF 24 18

3/4 - 16 UNF 46 34

7/8 - 14 UNF 62 46

1-1/16 - 12 UN 102 75

1-3/16 - 12 UN 122 90

1-5/16 - 12 UN 142 105

1-5/8 - 12 190 140

1-7/8 - 12 UN 217 160

NOTE: Torque tolerance is ± 10%.

TM 5-3805-280-10

20-24
Maintenance

04T,90,M171 –19–28JAN92–1/1

SERVICE RECOMMENDATIONS FOR

FLARED CONNECTIONS—STRAIGHT OR

TAPERED THREADS

T6873AE –UN–18OCT88

Straight Thread

T6873AD –UN–18OCT88

Tapered Thread

1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.

2. Defects in the tube flare cannot be repaired.

Overtightening a defective flared fitting will not stop

leaks.

3. Align the tube with the fitting before attempting to start

the nut.

4. Lubricate the male threads with hydraulic fluid or

petroleum jelly.

5. Index angle fittings and tighten by hand.

6. Tighten fitting or nut to torque value shown on the

chart. Do not allow hoses to twist when tightening

fittings.

TORQUE CHART a

Straight Thread b Tapered Thread

Thread lb-ft

Size N•m lb-ft N•m

1/8 15 11

1/4 20 15 45 33

3/8 29 21 69 51

1/2 49 36 93 69

3/4 69 51 176 130

1 157 116 343 253

1-1/2 196 145 539 398

2 255 188 588 434

aTorque tolerance is ±10%.

bWith seat face.

NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced

approximately 10%.

TM 5-3805-280-10

20-25
Maintenance

04T,90,K174 –19–01AUG94–1/2

SERVICE RECOMMENDATIONS FOR INCH SERIES FOUR BOLT FLANGE FITTINGS

T6890BB –UN–01MAR90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.

Out-of-flat causes seal extrusion. If defects cannot

be polished out, replace component.

2. Install O-ring (and backup washer if required) into

groove using petroleum jelly to hold it in place.

3. Split flange: Loosely assemble split flange (B)

halves. Make sure split is centrally located and

perpendicular to port. Hand tighten cap screws to

hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in

center of flange and install cap screws. Flange

must be centrally located on port. Hand tighten cap

screws to hold flange in place. Do not pinch O-ring.

5. Tighten one cap screw, then tighten the diagonally

opposite cap screw. Tighten two remaining cap

screws. Tighten all cap screws as specified in the

chart below.

DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO

NOT over tighten.

Continued on next page

TM 5-3805-280-10

20-26
Maintenance

04T,90,K174 –19–01AUG94–2/2

TORQUE CHART a

N•m lb-ft

Nominal Flange Size Cap Screw Size Min Max Min Max

1/2 5/16-18 UNC 20 31 15 23

3/4 3/8-16 UNC 28 54 21 40

1 3/8-16 UNC 37 54 27 40

1-1/4 7/16-14 UNC 47 85 35 63

1-1/2 1/2-13 UNC 62 131 46 97

2 1/2-13 UNC 73 131 54 97

2-1/2 1/2-13 UNC 107 131 79 97

3 5/8-11 UNC 158 264 117 195

3-1/2 5/8-11 UNC 158 264 117 195

4 5/8-11 UNC 158 264 117 195

5 5/8-11 UNC 158 264 117 195

a

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Torques can be

increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond this maximum will result in flange

and cap screw bending and connection failures.

TM 5-3805-280-10

20-27
Maintenance

04T,90,K175 –19–05JAN96–1/1

SERVICE RECOMMENDATIONS FOR METRIC SERIES FOUR BOLT FLANGE FITTING

T6890BB –UN–01MAR90

A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches

cause leaks. Roughness causes seal wear.

Out-of-flat causes seal extrusion. If defects cannot

be polished out, replace component.

2. Install the correct O-ring (and backup washer if

required) into groove using petroleum jelly to hold it

in place.

3. Split flange: Loosely assemble split flange (B)

halves. Make sure split is centrally located and

perpendicular to the port. Hand tighten cap screws

to hold parts in place. Do not pinch O-ring (C).

4. Single piece flange (D): Place hydraulic line in

center of flange and install four cap screws. Flange

must be centrally located on port. Hand tighten cap

screws to hold flange in place. Do not pinch O-ring.

5. After components are properly positioned and cap

screws are hand tightened, tighten one cap screw,

then tighten the diagonally opposite cap screw.

Tighten two remaining cap screws. Tighten all cap

screws as specified in the chart below.

DO NOT use air wrenches. DO NOT tighten one

cap screw fully before tightening the others. DO

NOT over tighten.

TORQUE CHART a

Thread b N•m lb-ft

M6 12 9

M8 30 22

M10 57 42

M12 95 70

M14 157 116

M16 217 160

M18 334 246

M20 421 318

a

Tolerance ± 10%. The torques given are enough for the given

size connection with the recommended working pressure.

Increasing cap screw torque beyond these amounts will result in

flange and cap screw bending and connection failures.

bMetric standard thread.

TM 5-3805-280-10

20-28
CHAPTER 21

OPERATIONAL CHECKOUT

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Operational Checkout

TX,95,DH5871 –19–10DEC99–1/1

OPERATIONAL CHECKOUT

Use this procedure to check all systems and functions on

the machine. It is designed so you can make a quick

check of machine operation while doing a walk around

inspection and performing specific checks from the

operator's seat.

Should you experience a problem with your machine, you

will find helpful diagnostic information in this checkout that

will pinpoint the cause. This information may allow you to

perform a simple adjustment yourself which will reduce

the down time of your machine. Use the table of contents

to help find adjustment procedures.

The information you provide after completing the

operational checkout will allow you or your authorized

dealer to pinpoint a specific test or repair needed to

restore the machine to design specifications.

A location will be required which is level and has

adequate space to complete the checks. No tools or

equipment are needed to perform the checkout.

Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, linkage, wiring,

etc.) prior to doing the checkout. The machine must be at

operating temperature for many of the checks.

Start at the top of the left column and read completely

down column before performing check. Follow this

sequence from left to right. In the far right column, if no

problem is found, you will be instructed to go to next

check. If a problem is indicated, you will be referred to

either a section in this manual or to your authorized dealer

for repair.

TM 5-3805-280-10

21-1
Operational Checkout

– – –1/1

1 OPERATOR STATION CHECKS—KEY SWITCH ON, ENGINE OFF

– – –1/1

GAUGES, MONITOR,

AND BATTERY

DISCONNECT RELAY

CHECKS

T125196 –UN–29OCT99

NOTE: Monitor buzzer is not checked during this procedure.

NOTE: If engine coolant temperature is below 30°C (86°F) engine temperature gauge

needle may not move to the right. Run engine a few minutes to warm coolant before

check.

Engine OFF.

Key switch ON.

Does battery relay click?

Do engine temperature gauge (A) and fuel gauge (B) needles move to the right?

Do all (10) monitor lights come on and after 2—3 seconds only the alternator indicator

and engine oil pressure indicator remain on?

YES: Go to next check.

NO: Check monitor fuse.

NO: Check and replace

bulb if any bulb fails to

come on. Go to your

authorized dealer.

TM 5-3805-280-10

21-2
Operational Checkout

– – –1/1

FLUID LEVEL

(COOLANT, HYDRAULIC

OIL, AND ENGINE OIL)

INDICATOR CIRCUIT

CHECKS

T107699 –UN–27FEB97

Engine OFF.

Key switch ON.

Push and hold level check switch (A).

Are the hydraulic oil level (B), coolant level (C), and

engine oil level (D) indicator lights ON?

YES: Go to next check.

NO: Check fluid levels in

radiator, recovery tank,

hydraulic reservoir, or

engine. If OK, check fluid

level sensing switch for

wiring. Check monitor

fuse. If fuse is OK, go to

your authorized dealer.

– – –1/1

PROPEL LEVER AND

PEDAL CUSHION

CYLINDER CHECKS

T7531AO –UN–07JUN91

Engine OFF.

Push each propel lever and pedal forward (A), then

release.

Pull each propel lever and pedal rearward (B), then

release.

Does each lever and pedal have equal effort to operate

forward and reverse?

Does each lever and pedal return to neutral at the same

time when released?

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-3
Operational Checkout

– – –1/1

2 OPERATOR STATION CHECKS—ENGINE ON

– – –1/1

MONITOR CIRCUIT,

GAUGE CHECKS

T107698 –UN–27FEB97

Start engine.

Are all monitor indicator lights OFF after engine starts?

Is coolant temperature gauge needle (A) in normal

operating zone after a few minutes?

Does fuel gauge (B) indicate fuel level?

Stop engine.

YES: Go to next check.

NO: Check alternator belt

if battery light is on after

engine starts. Go to your

authorized dealer.

– – –1/1

POWER MODE CIRCUIT

CHECKS

T102098 –UN–26JUL96

Start engine.

Auto-idle switch OFF.

Propel speed switch in fast position.

Pilot shut-off lever in LOCKED position.

Push power mode select switches (A) and (B) one at a

time.

Do corresponding indicator lights come on as each

switch is pushed?

YES: Go to next check.

NO: Check controller

fuse. Go to your

authorized dealer.

TM 5-3805-280-10

21-4
Operational Checkout

– – –1/1

WORK MODE CIRCUIT

CHECKS

T102099 –UN–26JUL96

Start engine.

Auto-idle switch OFF.

Pilot shut-off lever in LOCKED position.

Push work mode select switch (A) to select desired work

mode.

Do corresponding indicator lights come on as switch is

pushed?

YES: Go to next check.

NO: Check fuse. Go to

your authorized dealer.

– – –1/1

ENGINE RPM DIAL

CHECKS

T102100 –UN–26JUL96

Start engine.

Auto-idle switch OFF.

Pilot shut-off lever in LOCKED position.

Move engine RPM dial (A) clockwise.

Does engine speed increase?

Move engine RPM dial counterclockwise.

Does engine speed decrease?

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-5
Operational Checkout

– – –1/1

AUTO-IDLE CIRCUIT

CHECK

T107700 –UN–27FEB97

Run engine at fast idle.

Mode select switch in H/P mode.

Auto-idle switch OFF.

Pilot shut-off lever in UNLOCKED position.

Push auto-idle switch (A) to ON.

Does auto-idle indicator (B) come on?

Does engine speed decrease after 4 to 6 seconds?

Slowly actuate any dig function control lever.

Does engine speed return to fast idle?

YES: Go to next check.

NO: Check fuse. Go to

your authorized dealer.

– – –1/1

PILOT SHUT-OFF VALVE

CHECKS

T7351CC –UN–22AUG90

CAUTION: Machine may move during this

check. Make sure area is clear, and large

enough to operate all controls.

Run engine at slow idle.

Pilot shut-off lever in LOCKED (rearward) position.

Actuate all dig and propel function controls.

Do any dig or propel functions operate?

YES: Go to your

authorized dealer.

NO: Continue check,

– – –1/1

PILOT SHUT-OFF VALVE

CHECKS—(CONTINUED)

T7351CB –UN–22AUG90

Move pilot shut-off lever to UNLOCKED position

(forward).

Operate all dig and propel functions.

Do all functions operate?

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-6
Operational Checkout

– – –1/1

TRAVEL ALARM CHECK

T7850AF –UN–22OCT92

CAUTION: Machine will move during this

check. Make sure area is clear, and large

enough to operate all controls.

Engine running.

Pilot shut-off lever (A) in UNLOCKED position (forward).

Push propel pedals or levers forward (B).

Does travel alarm sound?

Pull propel pedals or levers rearward (C).

Does travel alarm sound?

YES: Go to next check.

NO: Check motion alarm

fuse. Go to your

authorized dealer.

– – –1/1

TRAVEL ALARM STOP

CIRCUIT

T102919 –UN–08AUG96

CAUTION: Machine will move during this

check. Make sure area is clear, and large

enough to operate all controls.

NOTE: Travel alarm must operate for this check.

Push propel pedals or levers and allow travel alarm to

operate for a minimum of 12 seconds.

While continuing travel, push travel alarm cancel switch

(A).

Does travel alarm stop sounding?

YES: Go to next check

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-7
Operational Checkout

– – –1/1

3 HYDRAULIC SYSTEM CHECKS

– – –1/1

PRESSURIZED

RESERVOIR CHECK

T7884AG –UN–12NOV92

Raise boom to full height, then lower boom to ground.

NOTE: Ensure that engine is properly shut down.

Slowly loosen vent plug on hydraulic reservoir.

Is air heard escaping from vent plug?

NOTE: The pressurized reservoir creates pressure at the

inlet to the hydraulic pumps. If filler cap does not seal,

hydraulic pumps could cavitate and be damaged.

YES: Go to next check.

NO: Replace cap. Go to

your authorized dealer.

– – –1/1

PUMP GEARBOX OIL

LEVEL CHECK

T8187BB –UN–08MAR94

NOTE: Ensure that engine is properly shut down.

Pull dipstick from tube, check oil level.

Is oil level below “H” (level) mark?

YES: Go to next check.

NO: Add oil if low.

– – –1/1

SWING GEARBOX OIL

LEVEL CHECK

T8187BF –UN–08MAR94

NOTE: Ensure that engine is properly shut down.

Pull dipstick from tube, check oil level.

Is oil between marks?

YES: Go to next check.

NO: Add oil if low.

TM 5-3805-280-10

21-8
Operational Checkout

– – –1/1

PILOT CONTROLLER

PATTERN CHECK (SAE

PATTERN)

T102070 –UN–16JUL96

Left Control Lever

T102071 –UN–16JUL96

Right Control Lever

Engine at slow idle.

Operate machine in clear area.

Move pilot shut-off lever to UNLOCKED position. Slowly move hydraulic levers to all

positions on decals.

Do bucket, boom, arm, and swing move as decals show?

NOTE: See John Deere control lever pattern in Operating the Machine chapter.

YES: Go to next test.

NO: Install decals for

pattern (operator

preference). Go to your

authorized dealer.

TM 5-3805-280-10

21-9
Operational Checkout

– – –1/1

PILOT CONTROLLER

PATTERN CHECK (JOHN

DEERE PATTERN)

T102197 –UN–19JUL96

Left Control Lever

T102198 –UN–19JUL96

Right Control Lever

Engine at slow idle.

Operate machine in clear area.

Move pilot shut-off lever to UNLOCKED position. Slowly move hydraulic levers to all

positions on decals.

Do bucket, boom, arm, and swing move as decals show?

NOTE: See John Deere control lever pattern in Operating the Machine chapter.

YES: Go to next test.

NO: Install decals for

pattern (operator

preference). Go to your

authorized dealer.

– – –1/1

(DYNAMIC) SWING

BRAKE CHECK

T6479AY –UN–19OCT88

CAUTION: Make sure area is clear and large

enough to swing extended bucket. Machine

must be on level ground.

Position upperstructure with boom in front.

Put boom, arm and bucket in fully extended position with

bucket 900 mm (3 ft) above ground level.

Operate engine at fast idle.

Actuate swing control valve to full stroke. Swing around

90 degrees and release lever.

Does upperstructure stop within 45 degrees (1/8 turn)

after releasing lever?

Repeat procedure in opposite direction.

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-10
Operational Checkout

– – –1/1

SWING CIRCUIT

LEAKAGE CHECK

T6479AZ –UN–19OCT88

Engine at slow idle.

Position machine on a side hill or raise one side of

machine 300 mm (1 ft) with the boom and ease block

under track.

Position bucket 300 mm (1 ft) off the ground at

maximum reach.

Bottom bucket cylinder and hold lever in the actuated

position.

NOTE: Actuating the bucket function releases the

mechanical swing brake.

Does upperstructure move only slightly?

YES: Go to next check.

NO: Go to your

authorized dealer.

– – –1/1

DIG FUNCTION DRIFT

CHECK

T6290AF –UN–19OCT88

Engine at slow idle.

Fill bucket with dirt and position bucket at maximum

reach with bucket 2 in. (50 mm) above ground.

Observe bucket for 1 minute.

Does bucket drift down to ground within 1 minute?

YES: Go to your

authorized dealer.

NO: Go to next check.

– – –1/1

CONTROL VALVE LIFT

CHECK TEST

T6292AZ –UN–19OCT88

Engine at slow idle.

Position machine as illustrated.

Slowly actuate pilot controller to lower boom, extend arm

(retract cylinder), and dump bucket (retract cylinder).

Do functions move in opposite direction as control levers

are moved, then change direction as levers are moved

further?

YES: If functions move in

opposite direction first, a

leak within the cylinder or

lift check valve is

indicated. Go to your

authorized dealer.

NO: Go to next check.

TM 5-3805-280-10

21-11
Operational Checkout

– – –1/1

PROPEL SYSTEM

TRACKING CHECKS

(PROPEL ONLY)

Engine at fast idle.

Propel speed switch in fast position.

Propel machine at full speed forward on a flat and level area.

Repeat procedure in reverse.

Do both tracks move and machine does not mistrack excessively in forward or

reverse?

YES: Go to next check.

NO: Note which track

does not move or if

machine mistracks note

the mistrack pattern. Go

to your authorized dealer.

– – –1/1

PROPEL SYSTEM

TRACKING CHECKS

(WHILE OPERATING A

DIGGING FUNCTION)

Engine at fast idle.

Propel speed switch in fast position.

Propel machine at full speed forward on a flat and level area.

After machine is moving, slowly move the arm control lever from neutral to full

actuation to extend the arm.

Does machine mistrack excessively when the arm is extended?

NOTE: Machine will slow down during this test.

YES: Go to your

authorized dealer.

NO: Go to next check.

– – –1/1

PROPEL SYSTEM

MANEUVERABILITY

CHECK

Engine at fast idle.

Propel speed switch in fast position.

Propel machine at full speed forward down a slope.

Turn in each direction.

Repeat the procedure in reverse.

Does each track slow down in response to pedal/lever movement in order to turn?

YES: Go to next check.

NO: Counterbalance

valve malfunction. Go to

your authorized dealer.

TM 5-3805-280-10

21-12
Operational Checkout

– – –1/1

PROPEL SPEED

SELECTION CHECK

T102104 –UN–26JUL96

Engine at fast idle.

Turn propel speed switch (A) to slow speed (turtle).

Actuate propel function to full speed.

Turn propel speed switch to fast position (rabbit).

Does machine travel speed increase?

Actuate a dig function and then return to neutral.

Does machine travel speed decrease and then increase?

Turn propel speed switch to slow speed (turtle).

Does machine travel speed decrease?

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-13
Operational Checkout

– – –1/1

CYCLE TIMES CHECK

CAUTION: Make sure area is clear and large enough to operate all

functions of machine.

IMPORTANT: Warm hydraulic oil to operating temperature for this check.

Engine at fast idle.

Auto-idle switch OFF.

T6477AQ –UN–19OCT88

BOOM

T7884AE –UN–10NOV92

ARM, BUCKET, SWING, PROPEL

Move machine to position shown for each test.

Record cycle time for each function.

Function Typical New (Seconds)

Boom Raise (cylinder 3.1 ± 0.3 with 2.96 m (9 ft

extend) 9 in.) arm

Boom Lower (cylinder 2.5 ± 0.3 with 2.96 m (9 ft

retract) 9 in.) arm

Arm In (cylinder extend) 3.9 ± 0.3

Arm Out (cylinder retract) 2.6 ± 0.3

Bucket Load (cylinder 4.1 ± 0.3

extend)

Bucket Dump (cylinder 2.5 ± 0.3

retract)

Swing Left or Right 3 14.4 ± 1.0

Revolutions From a

Running Start

Propel:

20 m (65 ft) From a

Running Start (check in

forward and reverse)

propel speed switch in 13.4 ± 0.6

FAST position

propel speed switch in 20.6 ± 2.0

SLOW position

Does machine perform within specifications?

YES: Go to next check.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-14
Operational Checkout

– – –1/1

4 UNDERCARRIAGE CHECKS

– – –1/1

TRACK SAG ROLLER

AND IDLER LEAKAGE

CHECKS

T6915AN –UN–07APR89

T7850AI –UN–22OCT92

Swing upperstructure to side and raise track off ground.

Operate track in reverse.

Stop engine.

Measure distance between top of track shoe to center of lower surface of track frame.

Track sag specifications:

Track Sag—Specification

Distance................................................................ 300—335 mm (11-13/16—13-3/16 in.)

Check rollers and idlers for oil leaks.

Is oil leaking from rollers or idlers?

Raise other side of machine and repeat checks.

NOTE: If track sag is less than specified, track chain wear will be accelerated. If it is

less than specified on one side only, the machine may mistrack.

YES: Go to your

authorized dealer for

repair if oil leakage is

noted from idlers or

rollers.

NO: Go to next check.

TM 5-3805-280-10

21-15
Operational Checkout

– – –1/1

SPROCKET WEAR

CHECK

T6981AC –UN–13MAR89

Inspect drive sprocket.

Is tooth wear excessive?

NOTE: Do not evaluate sprocket by condition of tooth

tip. Tooth tip wear does not affect sprocket operation if it

does not extend into the bushing contact area.

NOTE: Reverse drive side wear is generally more than

forward drive side wear.

YES: Go to your

authorized dealer.

NO: Go to next check.

– – –1/1

GROUSER WEAR, BENT

TRACK SHOE, AND

LOOSE HARDWARE

CHECKS

T7322AF –UN–21JUN90

Inspect for worn grousers, bent track shoes, and loose

shoe hardware.

Are grouser bars worn excessively?

Are track shoes bent?

Is track shoe width appropriate for ground condition?

Is track shoe hardware tight?

NOTE: Excessive grouser wear weakens track shoes

and may result in track shoes bending.

YES: If shoe hardware is

loose, remove shoe and

clean joint before

tightening. Go to Check

Track Shoe Torque in

Maintenance chapter.

NO: Go to next check.

– – –1/1

TRACK LINK ROLLER

AND FRONT IDLER

WEAR CHECKS

T6484AZ –UN–19OCT88

Inspect track links for pin boss wear.

Do link pin boss areas indicate contact with roller flanges

or track guides?

NOTE: Some contact or wear is normal. Excessive

contact or wear indicates excessive rail wear.

Inspect front idler flanges.

Do idler flanges contact bushings?

NOTE: Idler contact with bushings indicates excessive

chain rail wear and idler tread surface wear.

YES: Go to your

authorized dealer for

additional track

component information.

NO: Go to next check.

TM 5-3805-280-10

21-16
Operational Checkout

– – –1/1

5 HYDRAULIC THUMB CHECK

– – –1/1

5a INSPECT THE

HYDRAULIC THUMB

Is the hydraulic thumb hardware loose?

Is there damage and weld cracks?

Do pin joints have excess wear and play?

YES: Contact

maintenance shop.

NO: Go to the next

check.

– – –1/1

6 QUICK-DISCONNECT HITCH CHECKS

– – –1/1

6a HITCH CHECK

T120322 –UN–29MAR99

Inspect hitch.

Are there damage or weld cracks?

YES: Contact

maintenance shop.

NO: Go to next check.

– – –1/1

6b LATCH CYLINDER,

HOSES, AND

CONNECTIONS

CHECKS

T120455 –UN–25MAR99

Check latch cylinder, hoses, and connections for leaks.

Is oil leaking from latch cylinder, hoses, or connections?

YES: Go to your

authorized dealer for

repair if oil leakage is

noticed.

NO: Go to next check.

TM 5-3805-280-10

21-17
Operational Checkout

– – –1/1

7 ACCESSORIES CHECKS

– – –1/1

LIGHT CIRCUIT CHECKS

T102105 –UN–26JUL96

IMPORTANT: All accessories are powered from the

fuse block. If any accessories do not function, check

fuses in fuse block.

Turn key switch ON.

Turn light switch (A) to 1st on position.

Are monitor panel back lights and cab lights on?

Turn light switch to 2nd position.

Do work lights on boom come on also?

YES: Go to next check.

NO: Check fuse and/or

monitor panel back light

bulbs. Go to your

authorized dealer.

– – –1/1

REAR LIGHT CIRCUIT

CHECKS

T121043 –UN–14APR99

IMPORTANT: All accessories are powered from the fuse block. If any

accessories do not function, check fuses in fuse block.

Turn key switch ON.

Turn light switch (A) to the on position.

Are the rear lights on?

YES: Go to next check.

NO: Check fuse and/or

monitor panel back light

bulbs. Contact

maintenance shop.

TM 5-3805-280-10

21-18
Operational Checkout

– – –1/1

WINDSHIELD WIPER

CIRCUIT CHECK

T102106 –UN–26JUL96

Key switch ON.

Turn wiper switch (A) to INT position.

Does wiper operate intermittently?

Turn wiper switch to ON position.

Does wiper operate continuously?

Move wiper switch to OFF position.

Does wiper arm stop in park position?

YES: Go to next check.

NO: Check if wiper

harness and/or fuse is

connected. Go to your

authorized dealer.

– – –1/1

WINDSHIELD WASHER

CIRCUIT CHECK

T102107 –UN–26JUL96

IMPORTANT: Washer motor may be damaged if

washer switch is held for more than 20 seconds, or

continually operated with no fluid in the windshield

washer tank.

Key switch ON

Push washer switch (A)

Does washer fluid squirt on windshield?

YES: Go to next check.

NO: Check washer fluid

level and check wiper

fuse. Go to your

authorized dealer.

– – –1/1

CAB DOME LIGHT

CIRCUIT CHECK

T102183 –UN–26JUL96

Key switch ON.

Move switch (A) to on position.

Does cab dome light come on?

YES: Go to next check.

NO: Check fuse. Go to

your authorized dealer.

TM 5-3805-280-10

21-19
Operational Checkout

– – –1/1

LEFT CONTROL LEVER

HORN CIRCUIT CHECK

T102195 –UN–26JUL96

Key switch ON.

Press horn button (A) on top of left control lever.

Does horn sound?

YES: Go to next check.

NO: Check fuse. Go to

your authorized dealer.

– – –1/1

8 AIR CONDITIONING CHECKS

– – –1/1

AIR CONDITIONER

T103130 –19–29AUG96

Start engine and run at fast idle.

Turn air conditioner switch to ON position.

Turn blower switch to high speed.

Wait for any warm air in duct system to dissipate.

Is air from ducts cool?

YES: Check complete.

NO: Go to your

authorized dealer.

TM 5-3805-280-10

21-20
Operational Checkout

– – –1/1

ALL LINES AND HOSES Engine OFF.

Inspect all lines and hoses.

Are lines and hoses straight, NOT kinked or worn from rubbing on other machine parts

or "weather checked"?

Are hose and line connections clean NOT showing signs of leakage, such as oil or

dust accumulation at fittings?

All hose and line clamps must be in place and tight. Clamps must have rubber inserts

or cushions in place to prevent clamps from crushing or wearing into hoses or lines?

YES: Check complete.

NO: Reposition hoses or

lines and tighten or

replace clamps. Tighten

fittings or replace O-rings

in fittings. Replace hoses

or lines as required.

– – –1/1

EVAPORATOR CORE

CHECK

Engine ON.

Blower switch on high.

Is air from ducts cool and air flow good?

Is water dripping from evaporator drain hose?

YES: Check complete.

NO: Repair, replace or

clean evaporator.

– – –1/1

CONDENSER CHECK Engine OFF.

Inspect condenser cores.

Is condenser core free of dirt or debris?

Does condenser show signs of leakage, dust accumulation or oily areas?

Are condenser fins straight, not bent or damaged?

Inspect engine fan.

Are fan blades in good condition, not worn, bent, broken or missing?

YES: Check complete.

NO: Clean, repair or

replace condenser core.

Replace engine fan.

TM 5-3805-280-10

21-21
Operational Checkout

– – –1/1

COMPRESSOR CLUTCH

CHECK

Engine OFF. Key switch ON. Blower switch on LOW. Air conditioner switch ON.

Does compressor clutch "click" as switch is pushed?

YES: Check complete.

NO: Replace compressor

clutch.

– – –1/1

RECEIVER DRYER

CHECK

Engine OFF.

Check hoses for damage and fittings for looseness.

Are hoses not showing signs of leakage and fittings tight?

YES: Check complete.

NO: Tighten fittings.

Replace hoses, as

required.

TM 5-3805-280-10

21-22
Operational Checkout

– – –1/1

8 SEAT, DOORS, WINDOWS, LATCHES, AND LOCKS CHECKS

– – –1/1

SEAT CONTROL

CHECKS

T102507 –UN–29JUL96

Push down lever (B) and raise and lower seat.

Does seat raise and lower easily?

Push down lever (B) and adjust angle of seat.

Does seat angle change easily?

Push down lever (C). Move seat and both side consoles forward and rearward.

Release lever to lock seat and side consoles in position.

Does lever unlock easily and then lock to hold seat and consoles in position?

Pull up lever (D). Move seat forward and rearward. Release lever to lock seat in any

position.

Does lever move easily to unlock seat support?

Does seat move forward and rearward easily?

Does lever lock seat support in position when released?

Pull up lever (E). Tilt seat back forward and rearward. Release lever to lock seat back

in any position.

Does seat back tilt forward and rearward easily?

Does lever unlock and lock easily to hold seat back in position?

YES: Go to next check.

NO: Inspect linkage and

repair. Go to your

authorized dealer.

TM 5-3805-280-10

21-23
Operational Checkout

– – –1/1

UPPER FRONT WINDOW

CHECK

T102109 –UN–26JUL96 T102110 –UN–26JUL96

Move lock pins (A) toward center of window.

Pull window up and back until it catches in latch (B) for convenient storage overhead.

Slide the two lock pins (C) into the cab frame boss holes and turn to lock.

Do pins move smoothly to lock and unlock window?

Does rear latch operate freely?

Do pins engage rear holes and lock window securely in full open position?

YES: Go to next check.

NO: Inspect. Repair.

TM 5-3805-280-10

21-24
Operational Checkout

– – –1/1

WINDOW PROTECTION

KIT CHECK (MODEL

230LCRD)

T121078 –UN–14APR99

A—Lynch Pin

B—Cap Screw, 10 mm x 25 mm

C—Washer

Upper screen:

Remove center cap screw (B) and washer (C).

Remove two lynch pins (A).

Raise upper screen.

Does screen move freely?

YES: Go to next check.

NO: Inspect. Repair.

TM 5-3805-280-10

21-25
Operational Checkout

– – –1/1

LOWER FRONT WINDOW

STORAGE CHECK

T102111 –UN–26JUL96 T106163 –UN–07JAN97

NOTE: Upper front window must be raised before lower window can be removed from

window frame.

Pull in on lock pins (A) to unlock window.

Lift the lower front window from the frame.

Insert tabs on bottom of window into brackets (B) and lock the pins into holes (C).

Does window lock securely into holding bracket?

YES: Go to next check.

NO: Inspect. Repair.

– – –1/1

RIGHT SIDE AND LEFT

SIDE WINDOW CHECKS

T102113 –UN–26JUL96

Right rear side window: Unlatch lock (A). Push joint part

of lock to open window.

Does latch operate smoothly?

Does window remain opened when latched open?

Left side cab window: Slide both window panes open

and closed?

Do both window panes slide freely to left and right?

YES: Go to next check.

NO: Inspect. Repair. Go

to your authorized dealer.

– – –1/1

ROOF EXIT CHECK

T102205 –UN–26JUL96

Move lock pins (A) toward center of roof exit cover.

Push on handle (B) until roof cover is in a secured

position.

Hold handle and pull cover down until pins lock in

position.

Does cover open and close freely?

Does cylinder hold roof cover in the open position?

YES: Go to next check.

NO: Inspect. Repair.

TM 5-3805-280-10

21-26
Operational Checkout

– – –1/1

CAB DOOR LATCH

CHECK

T102114 –UN–26JUL96

Open cab door.

Lock cab door in open position.

Push down on lever (A) to release door from locked

open position.

Close door.

Does door unlatch easily, lock in open position securely,

unlock from open position easily, and latch closed

securely?

YES: YES Go to next

check.

NO: Go to your

authorized dealer.

– – –1/1

CAB DOOR LOCK

CHECK

T7425AH –UN–10DEC90

From outside cab, close cab door.

Insert ignition key into door lock, turn clockwise 1/4 turn

to lock.

Allow key to return to vertical.

Try to open door.

Turn key 1/4 turn counterclockwise to unlock.

Allow key to return to vertical.

Remove key from lock.

Does lock turn easily?

Does lock prevent door from opening when locked?

YES: Go to next check.

NO: Inspect. Repair.

– – –1/1

LEFT AND RIGHT

ACCESS DOORS LOCK

CHECK

T7425AG –UN–28NOV90

Insert ignition key into lock and turn 180° clockwise to

lock.

Turn key 180° counterclockwise to unlock.

Does lock turn easily and lock door and cap in position?

Are all parts free of any visible damage?

YES: Go to next check.

NO: Inspect. Repair.

TM 5-3805-280-10

21-27
Operational Checkout

– – –1/1

FUEL CAP LOCK CHECK

T7351AH –UN–22AUG90 T7425AF –UN–04DEC90

Turn lock cover to expose lock.

Insert ignition key into fuel cap lock.

Turn key 45° counterclockwise to lock fuel cap.

Does lock prevent cap from being removed?

Turn key 45° clockwise to unlock fuel cap.

Does lock turn easily to lock and unlock?

YES: Go to next check.

NO: Replace fuel cap.

– – –1/1

HOOD CHECK

T108577 –UN–26MAR97

Unlock hood latch with ignition key.

Release latches.

Open hood.

Engage hold-open rod (A).

Does rod hold hood open?

Close hood and engage latches.

Do latches operate easily?

Do latches hold hood closed?

YES: Go to next check.

NO: Inspect. Repair.

TM 5-3805-280-10

21-28
Operational Checkout

– – –1/1

9 COOLANT CHECKS

– – –1/1

RADIATOR CAP

T6488FY –UN–19OCT88

CAUTION: Prevent possible injury. DO NOT

remove radiator cap unless engine is cool.

When engine is hot and cap is removed, hot

coolant or steam will spray out causing

serious burns.

Engine OFF and cool.

Remove radiator cap.

If coolant is warmer than surrounding air temperature is,

a ’whoosh’ sound heard when cap is loosened?

Does cap have a stop position that requires it to be

pushed down to remove?

Does cap have a good seal (C) and gasket (A)?

T7690AB –UN–23JAN92

Is spring (B) in good condition?

YES: Go to next check.

NO: Replace radiator

cap.

– – –1/1

COOLANT LEVEL AND

COOLANT CONDITION IN

RECOVERY TANK

CHECKS

T6488FX –19–21MAR89

Engine OFF and cool.

Open radiator access door.

Inspect coolant level and coolant condition in recovery

tank.

Is coolant level between FULL and LOW marks on

recovery tank?

Is coolant clear, not oily, foamy, or rust colored?

YES: Go to next check.

NO: Add or replace

coolant. (See ’Check

Coolant Level’ in

Maintenance-Every 10

Hours or Daily chapter.)

TM 5-3805-280-10

21-29
Operational Checkout

– – –1/1

COOLANT LEVEL AND

COOLANT CONDITION IN

RADIATOR CHECKS

CAUTION: Prevent possible injury. DO NOT remove cap unless engine is

cool.

Engine OFF and cool.

Remove radiator cap.

Inspect coolant level.

Inspect coolant condition.

Is coolant level at bottom of fill neck on radiator?

Is coolant clear, not oily, foamy or rust colored?

YES: Go to next check.

NO: Add or replace

coolant. (See ’Check

Coolant Level’ in

Maintenance-Every 250

Hours chapter.)

– – –1/1

COOLANT HOSES AND

CLAMPS CHECKS

Are radiator and heater hoses free of twists, kinks, cracks, leaks, or wear from rubbing

on adjacent parts?

Are hose clamps tight and installed correctly?

YES: Go to next check.

NO: Replace hoses as

required. Tighten or

reinstall hose clamps.

– – –1/1

FAN SHROUD AND FAN

GUARD CHECKS

T6488GN –UN–19OCT88

Check fan to fan shroud clearance.

Is fan centered in shroud?

Is guard free of damage?

Are all mounting brackets and hardware tight?

YES: Go to next check.

NO: Adjust fan shroud to

center fan. Repair or

replace guard. Tighten

loose hardware. Replace

fan shroud if needed.

TM 5-3805-280-10

21-30
Operational Checkout

– – –1/1

FAN DIRECTION CHECK

T6171CB –UN–25MAY89

Is fan installed correctly with concave (cupped) side

(Arrow) of fan blade towards engine?

NOTE: If fan is installed backwards, about 50% of its

capacity is lost.

YES: Check complete.

NO: Install fan correctly.

– – –1/1

RADIATOR OUTSIDE AIR

FLOW CHECK

Inspect radiator screen for mud and debris.

Inspect radiator fins for mud and debris.

Inspect radiator for bent or damaged fins.

Are radiator fins free of mud, leaves, grass, and other debris?

Are fins straight, not broken or cracked?

YES: Go to next check.

NO: Clean screen. Clean

outside of radiator.

Straighten fins. Replace

radiator if severely

damaged.

– – –1/1

FAN BELT CHECK Is fan belt free of oil or grease?

Is inside surface of belt free of cracks or frayed edges?

Is belt aligned with pulleys?

YES: Check complete.

NO: Replace belt if oily,

greasy, cracked, or

otherwise damaged.

TM 5-3805-280-10

21-31
TM 5-3805-280-10

BLANK

21-32
CHAPTER 22

TROUBLESHOOTING

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Troubleshooting

TX,100,DH5621 –19–26MAR97–1/1

USING TROUBLESHOOTING CHARTS

NOTE: Troubleshooting charts are arranged from the

simplest to verify, to least likely, more difficult to

verify. When diagnosing a problem, use all

possible means to isolate the problem to a single

component or system. Use the following steps to

diagnose problems:

• Step 1. Operational Checkout Procedure.

• Step 2. Troubleshooting charts.

• Step 3. Adjustments.

• Step 4. See your authorized dealer.

TM 5-3805-280-10

22-1
Troubleshooting

TX,100,DH5155 –19–10AUG96–1/6

ENGINE

Symptom Problem Solution

Engine Cranks But Will Not Start No fuel Add fuel. Bleed air.

Or Hard To Start

Wrong fuel Use correct fuel.

Fuel filter clogged Replace filter. Bleed air. Clean fuel

tank strainer.

Leaks in fuel system Check fuel system connections.

Contaminated fuel Drain tank. Clean tank strainer. Add

clean fuel.

Air in fuel system Bleed air.

Low battery power Charge or install new batteries.

Slow cranking speed (poor electrical Clean and tighten battery and starter

connection) connections.

Wrong engine oil Use correct oil.

Air filter clogged Clean or replace elements.

Injection pump linkage Go to your authorized dealer.

Injection nozzles Go to your authorized dealer.

Injection pump Go to your authorized dealer.

Starter Replace starter.

Engine compression low Go to your authorized dealer.

Engine Knocks, Runs Irregularly, Air filter clogged Clean or replace elements. Clean

Or Stops system.

Fuel filter clogged Replace filter. Bleed air. Clean fuel

tank strainer.

Engine oil level low Add oil.

Continued on next page

TM 5-3805-280-10

22-2
Troubleshooting

TX,100,DH5155 –19–10AUG96–2/6

Symptom Problem Solution

Contaminated fuel Drain tank. Clean tank strainer. Add

clean fuel.

Injection pump out of time Go to your authorized dealer.

Wrong valve clearance Check and adjust valves.

Injection nozzles Go to your authorized dealer.

Coolant temperature low Thermostat not operating within

correct temperature range. Replace

thermostat or go to your authorized

dealer.

Injection pump Go to your authorized dealer.

Engine Not Developing Full Air filters clogged Clean or replace filter elements.

Power

Fuel filter clogged Change filter. Bleed air.

Contaminated fuel Drain fuel tank. Clean tank strainer.

Add clean fuel.

Wrong fuel Use correct fuel.

Fuel line restricted Repair or replace fuel line.

Clogged vent in fuel tank cap Clean or install new cap.

Injection pump linkage adjustment Adjust or go to your authorized

dealer.

Intake system leakage Go to your authorized dealer.

Exhaust restriction Remove muffler and run engine.

Wrong valve clearance Check and adjust valves.

Engine too hot or cold See below.

Wrong oil Use correct oil.

Injection nozzles Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-3
Troubleshooting

TX,100,DH5155 –19–10AUG96–3/6

Symptom Problem Solution

Turbocharger Go to your authorized dealer.

Injection pump Go to your authorized dealer.

Engine malfunction Go to your authorized dealer.

Engine Overheats Coolant level low Add coolant.

Thermostat Go to your authorized dealer.

Radiator screen clogged Remove and clean screen.

Radiator core or oil cooler core Clean radiator and oil cooler.

clogged

Air filter clogged Clean or replace elements.

Radiator cap Install new cap.

Fan belt malfunction Go to your authorized dealer.

Fan Replace fan.

Alternator/fan belt loose Go to your authorized dealer.

Engine overloaded Check hydraulic relief valves.

Cooling system passages dirty Flush cooling system.

Temperature gauge or sending unit Go to your authorized dealer.

Injection pump Go to your authorized dealer.

Pulley grooves worn Replace pulleys.

Coolant Temperature Too Low Thermostat Go to your authorized dealer.

Temperature gauge or sending unit Go to your authorized dealer.

Low Engine Oil Pressure Oil level low Add oil.

Oil filter clogged Install new oil filter.

Oil pump intake screen clogged Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-4
Troubleshooting

TX,100,DH5155 –19–10AUG96–4/6

Symptom Problem Solution

Wrong oil Use correct oil.

Oil leaks Check for leaks.

Engine oil pump or pump drive Go to your authorized dealer.

Engine oil pressure regulating valve Go to your authorized dealer.

Oil diluted with fuel or coolant Go to your authorized dealer.

Engine temperature too high Check cooling system.

Engine Uses Too Much Oil Wrong oil Use correct oil.

Oil leaks Check engine oil drain plug.

Engine temperature too high Check cooling system.

Air cleaner clogged Clean element or install new

element.

Internal engine component wear Go to your authorized dealer.

Engine Uses Too Much Fuel Clogged or dirty air intake system Clean air intake system.

Wrong fuel Use correct fuel.

Hydraulic pump regulators set Go to your authorized dealer.

incorrectly

Fuel injection nozzles Go to your authorized dealer.

Injection pump Go to your authorized dealer.

Excessive Black Or Gray Exhaust Wrong fuel Use correct fuel.

Smoke

Hydraulic pump regulators set Go to your authorized dealer.

incorrectly

Clogged or dirty air intake or exhaust Clean air intake and exhaust system.

system

Injection pump Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-5
Troubleshooting

TX,100,DH5155 –19–10AUG96–5/6

Symptom Problem Solution

Injection nozzles Go to your authorized dealer.

Engine Go to your authorized dealer.

Exhaust Gas Is White Wrong fuel Use correct fuel.

Cold engine Run engine until warm.

Thermostat faulty or too ’cool’ Go to your authorized dealer.

Injection pump Go to your authorized dealer.

Coolant leakage into engine cylinder Go to your authorized dealer.

Turbocharger Excessively Noisy Bearings not lubricated Insufficient oil pressure. Check for

Or Vibrates restricted turbocharger oil line.

Worn bearings Go to your authorized dealer.

Air leak in engine, intake, or exhaust Inspect, repair.

manifold

Improper clearance between turbine Go to your authorized dealer.

wheel and turbine housing

Broken blades on turbine Remove exhaust elbow and air inlet

hose and inspect.

Oil Dripping From Turbocharger Damaged or worn bearings and/or Go to your authorized dealer.

Adapter worn seals

Excessive crankcase pressure Check vent tube to ensure tube is

not clogged. Clean.

Turbocharger oil return line carbon Remove line. Inspect, clean.

buildup where line passes exhaust

manifold

Excessive Drag In Turbocharger Carbon buildup behind turbine wheel Inspect, clean.

Rotating Members caused by combustion deposits

Dirt buildup behind compressor Inspect, clean.

wheel caused by air intake leaks

Continued on next page

TM 5-3805-280-10

22-6
Troubleshooting

TX,100,DH5155 –19–10AUG96–6/6

Symptom Problem Solution

Bearing seizure or dirty or worn Go to your authorized dealer.

bearings, caused by excessive

temperature, unbalanced wheel, dirty

oil, oil starvation, or insufficient

lubrication

TM 5-3805-280-10

22-7
Troubleshooting

TX,100,DH5361 –19–19DEC96–1/6

ELECTRICAL SYSTEM

Symptom Problem Solution

Nothing Works Battery Recharge or replace.

Fusible link Replace fusible link.

Battery cables making poor Clean connections.

connections

Batteries Undercharged Loose or corroded connections Clean and tighten or replace

batteries.

Alternator/fan belt tension adjuster Go to your authorized dealer.

Alternator not charging Go to your authorized dealer.

Fuse Replace fuse.

Key switch Replace key switch.

Batteries Will Not Take A Charge Loose or corroded connections Clean and tighten.

Low battery power Install new batteries.

Alternator not charging Go to your authorized dealer.

Battery Uses Too Much Water Cracked battery case Replace battery.

High ambient temperature Refill with water.

Shorted cell Check if one or more cells take more

water than the others. Check specific

gravity.

Battery being overcharged Go to your authorized dealer.

Cracked Battery Case No battery hold down clamp Replace battery and install hold

down clamp.

Loose battery hold down clamp Replace battery and install hold

down clamp.

Battery hold down clamp too tight Replace battery and install battery

hold down clamp correctly.

Continued on next page

TM 5-3805-280-10

22-8
Troubleshooting

TX,100,DH5361 –19–19DEC96–2/6

Symptom Problem Solution

Frozen battery Replace battery. Keep battery fully

charged in cold weather.

Low Battery Output Low water level Add water.

Dirty or wet battery top, causing Clean and wipe battery top dry.

discharge

Corroded or loose battery cables Clean and tighten battery cables.

Broken battery post Wiggle battery post by hand. If post

wiggles or turns, replace battery.

Low battery voltage Measure ’stabilized’ battery voltage.

Stabilize voltage by actuating horn

for 30 seconds. If stabilized voltage

is below 24 volts, charge battery.

Battery cell Measure specific gravity of each cell.

If more than 50 points between cells,

replace battery.

Starter Will Not Turn Battery undercharged or dead Recharge or replace battery.

Battery cables making poor Clean connections.

connections

Fusible link Replace fusible link.

Key switch Go to your authorized dealer.

Starter relay Go to your authorized dealer.

Starter solenoid Go to your authorized dealer.

Starter Repair or replace starter motor.

Starter pinion jammed in flywheel Repair or replace starter.

gear

Engine Go to your authorized dealer.

Starter Solenoid Chatters Poor connections at batteries or Clean connections.

starter

Continued on next page

TM 5-3805-280-10

22-9
Troubleshooting

TX,100,DH5361 –19–19DEC96–3/6

Symptom Problem Solution

Low battery charge Recharge or replace batteries.

Starter solenoid ’hold-in’ windings Go to your authorized dealer.

open

Starter Turns But Will Not Crank Starter pinion gear not engaging Go to your authorized dealer.

Engine flywheel ring gear

Pinion shift mechanism jammed or Go to your authorized dealer.

malfunctioning

Pinion gear teeth broken Go to your authorized dealer.

Flywheel gear teeth broken Go to your authorized dealer.

Engine Cranks Slowly Battery cables damaged or broken Inspect and replace cables.

internally

Battery or starter cable connections Clean and tighten connections.

loose or corroded

Battery discharged or will not hold a Recharge or replace battery.

charge

Starter ’dragging’ Go to your authorized dealer.

Low battery voltage Recharge or replace battery.

Starter Continues To Run After Starter relay stuck Go to your authorized dealer.

Engine Starts

Starter solenoid stuck Go to your authorized dealer.

Starter not disengaging Go to your authorized dealer.

Key switch Go to your authorized dealer.

Charging Indicator Light On, Loose or glazed alternator belt Check belt. Replace if glazed.

Engine Running

Engine rpm low Adjust rpm to specifications.

Excessive electrical load from added Remove accessories or install higher

accessories output alternator.

Continued on next page

TM 5-3805-280-10

22-10
Troubleshooting

TX,100,DH5361 –19–19DEC96–4/6

Symptom Problem Solution

Loose or corroded electrical Inspect, clean, or tighten electrical

connections on battery, ground connections.

strap, starter, or alternator

Battery voltage low Charge or replace battery.

Alternator or regulator Go to your authorized dealer.

Indicator circuit Go to your authorized dealer.

Noisy Alternator Worn drive belt Replace belt.

Worn pulleys Replace pulleys and belt.

Pulley misaligned Adjuster alternator mount.

Alternator bearing Loosen alternator belts. Turn pulley

by hand. If any roughness is felt,

repair alternator.

No Monitor Panel Indicators Fuse Replace fuse.

Work

Monitor panel logic module Go to your authorized dealer.

Wiring harness Go to your authorized dealer.

Individual Light In Monitor Panel Bulb Replace bulb.

Is Not Working

Fuse Replace fuse.

Wiring harness Go to your authorized dealer.

No Indicators In Gauge Panel Circuit board Go to your authorized dealer.

Operate

Wiring harness Go to your authorized dealer.

Fuse Replace fuse.

Indicator Light In Gauge Panel Is Bulb Replace bulb.

Inoperative

Fuse Replace fuse.

Continued on next page

TM 5-3805-280-10

22-11
Troubleshooting

TX,100,DH5361 –19–19DEC96–5/6

Symptom Problem Solution

Wiring harness Go to your authorized dealer.

Engine Water Temperature Fuse Replace fuse.

Gauge Does Not Work

Gauge Go to your authorized dealer.

Gauge sender Go to your authorized dealer.

Wiring harness Go to your authorized dealer.

Indicator Lights Do Not Operate Fuse Replace fuse.

Bulb Replace bulb.

Auto-idle switch Go to your authorized dealer.

Propel switch Go to your authorized dealer.

Fuel Gauge Does Not Work Fuse Replace fuse.

Gauge Go to your authorized dealer.

Wiring harness Go to your authorized dealer.

Work Mode Selector Switch Does Mode switches Replace switches.

Not Work

Electrical connector Repair or replace.

Pilot pressure switch Go to your authorized dealer.

Wiring harness Go to your authorized dealer.

Propel Speed Does Not Function Speed switches Go to your authorized dealer.

Two speed travel solenoid valve Go to your authorized dealer.

Propel pilot pressure switch Go to your authorized dealer.

Propel motor Go to your authorized dealer.

Rotary manifold Go to your authorized dealer.

Auto-Idle Does Not Work Fuse Replace fuse.

Continued on next page

TM 5-3805-280-10

22-12
Troubleshooting

TX,100,DH5361 –19–19DEC96–6/6

Symptom Problem Solution

Engine speed too low Increase speed to higher than

auto-idle. Press auto-idle switch.

Switch panel Go to your authorized dealer.

Electrical connector Go to your authorized dealer.

Wiring harness Go to your authorized dealer.

Windshield Wiper Does Not Work Fuse Replace fuse.

Upper front right window latch not Lock upper front right window latch.

locked

TM 5-3805-280-10

22-13
Troubleshooting

TX,100,DH3697 –19–18AUG95–1/5

HYDRAULIC SYSTEM

Symptom Problem Solution

Control Lever Moves Hard Corroded joint, worn out pusher Go to your authorized dealer.

Control Lever Does Nothing Worn out pusher Go to your authorized dealer.

Pilot valve Go to your authorized dealer.

Control Lever Does Not Return Pilot valve Go to your authorized dealer.

To Neutral

Too Much Play In Control Lever Worn out pivot joint Go to your authorized dealer.

Control Lever Is Not Vertical In Pilot valve Go to your authorized dealer.

Neutral

No Hydraulic Functions Lack of hydraulic oil Add oil.

Pilot shut-off valve Go to your authorized dealer.

Pilot pump Go to your authorized dealer.

Pilot pressure regulating valve Go to your authorized dealer.

System relief valve Go to your authorized dealer.

Pressure switches Go to your authorized dealer.

Clogged suction filter Clean.

Damaged suction line or hose Go to your authorized dealer.

Hydraulic pump Go to your authorized dealer.

Some Functions Do Not Work Pilot controller Go to your authorized dealer.

Pilot shut-off valve not released Go to your authorized dealer.

Pilot controller hoses pinched Inspect and correct

Control valve Go to your authorized dealer.

Circuit relief valves Go to your authorized dealer.

Cylinders Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-14
Troubleshooting

TX,100,DH3697 –19–18AUG95–2/5

Symptom Problem Solution

Hydraulic Functions Are Slow Low oil level Fill reservoir to full mark.

Wrong oil Use correct oil.

Engine speed too slow Increase speed or see your

authorized dealer.

Pilot circuit Go to your authorized dealer.

Worn pump Go to your authorized dealer.

Suction screen clogged Inspect and clean.

Restricted pump suction line Go to your authorized dealer.

Improperly adjusted relief valves Go to your authorized dealer.

One Function Does Not Work Pilot controller Go to your authorized dealer.

Relief valve pressure low Go to your authorized dealer.

Tube or hose damaged Repair or replace.

Hydraulic fittings loose Tighten.

Damaged O-rings in fittings Install new O-ring.

Pilot controller hose pinched Inspect and correct.

Cylinder Go to your authorized dealer.

Hydraulic pump Go to your authorized dealer.

Control valve Go to your authorized dealer.

One Function Has Little Power Pilot controller Go to your authorized dealer.

Pilot lines Repair or replace.

Control valve Go to your authorized dealer.

Circuit relief valve Go to your authorized dealer.

Cylinder seals leaking Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-15
Troubleshooting

TX,100,DH3697 –19–18AUG95–3/5

Symptom Problem Solution

Cylinder rod Go to your authorized dealer.

Hydraulic Cylinders Operate But Hydraulic oil level low Add oil.

Cannot Lift Load

Suction screen clogged Clean strainer and system.

System or circuit relief valves Go to your authorized dealer.

Pump suction line leaking Inspect suction line.

Hydraulic pump worn Go to your authorized dealer.

Go to your authorized dealer.

System relief valve Go to your authorized dealer.

Low Or No Oil Pressure No oil in system Fill with correct oil.

Wrong oil Use correct oil.

Improperly adjusted relief valves Go to your authorized dealer.

Worn cylinder packings Go to your authorized dealer.

Tank cap Replace cap.

Hydraulic Oil Overheats Wrong oil Use correct oil.

Clogged radiator or oil cooler Clean and straighten fins.

Radiator screen clogged Remove and clean.

Clogged filters Install new filters.

Low oil level Fill tank to full mark.

Oil line restricted Go to your authorized dealer.

Contaminated oil Drain oil and refill.

Oil cooler bypass Go to your authorized dealer.

Relief valve Go to your authorized dealer.

Continued on next page

TM 5-3805-280-10

22-16
Troubleshooting

TX,100,DH3697 –19–18AUG95–4/5

Symptom Problem Solution

Air leak in pump suction line Go to your authorized dealer.

Worn pump Go to your authorized dealer.

Propel motors Go to your authorized dealer.

Oil Foams High or low oil level Correct level.

Wrong oil Use correct oil.

Water in oil Change oil.

Kinks or dents in oil lines Check lines.

Air leak in line from reservoir to Repair leak.

pump

No Swing Function Pilot controller Go to your authorized dealer.

Swing control valve spool Go to your authorized dealer.

Pilot control hoses pinched or kinked Inspect and correct.

Swing brake Go to your authorized dealer.

Swing motor Go to your authorized dealer.

Swing Function Is ’Jerky’ Lack of grease Fill with grease

Swing gear Go to your authorized dealer.

Swing brake Go to your authorized dealer.

Swing bearing Go to your authorized dealer.

Slow Propel System, Does Not Propel brake Go to your authorized dealer.

Propel

Rotary manifold Go to your authorized dealer.

Individual Propel Function Is Rock under pedal Remove

Slow

Pilot controller hoses pinched or Inspect and correct.

kinked

Continued on next page

TM 5-3805-280-10

22-17
Troubleshooting

TX,100,DH3697 –19–18AUG95–5/5

Symptom Problem Solution

Pilot controller Go to your authorized dealer.

Propel brake Go to your authorized dealer.

Rotary manifold Go to your authorized dealer.

Propel motor Go to your authorized dealer.

Propel Is ’Jerky’ Track sag Adjust tension.

Track idler or rollers Go to your authorized dealer.

Track frame bent Go to your authorized dealer.

Rocks or mud jammed in track frame Remove and repair.

Propel gearbox Go to your authorized dealer.

Propel brake not releasing Go to your authorized dealer.

Engine Stops When Propel Or Engine Go to your authorized dealer.

Control Lever Is Moved

Wiring harness Repair.

Fuel filter Replace.

Engine speed sensor Go to your authorized dealer.

TM 5-3805-280-10

22-18
CHAPTER 23

STORAGE

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Storage

TX,105,FF2313 –19–03APR91–1/3

PREPARE MACHINE FOR STORAGE

T47764 –UN–09NOV88

1. Repair worn or damaged parts. Install new parts, if

necessary, to avoid needless delays later.

2. Clean primary air cleaner.

TX,105,FF2313 –19–03APR91–2/3T5813AM –UN–09FEB89

IMPORTANT: High pressure washing [greater than

1379 kPa (13.8 bar) (200 psi)] can

damage freshly painted finishes. Paint

should be allowed to air dry for 30 days

minimum after receipt of machine

before cleaning parts or machines with

high pressure. Use low pressure wash

operations until 30 days have elapsed.

3. Wash the machine. [Use low pressure wash operations

(less than 1379 kPa (13.8 bar) (200 psi) until 30 days

after receipt of machine have elapsed.] Paint areas to

prevent rust. Replace decals, where needed.

4. Apply waste oil to track chains. Run machine back and

forth several times. Park machine on a hard surface to

prevent tracks from freezing to ground.

5. Store machine in a dry, protected place. If stored

outside, cover with a waterproof material.

Continued on next page

TM 5-3805-280-10

23-1
Storage

TX,105,FF2313 –19–03APR91–3/3T7034AA –UN–18APR89

A—Cylinder Rod Areas

IMPORTANT: LPS 3 Rust Inhibitor can destroy

painted finish. Do not spray LPS 3

Rust Inhibitor on painted areas.

6. Park machine as shown. Inspect cylinder rods for

evidence of damage or rust. Report deficiencies to

your supervisor. Coat exposed cylinder rods (A) with

LPS 3 Rust Inhibitor.

IMPORTANT: Prevent possible machine damage from

unauthorized persons operating

machine. Attach a ’DO NOT OPERATE’

tag to right control lever.

7. Place a ’DO NOT OPERATE’ tag on the right control

lever.

8. Lubricate all grease points.

9. Remove batteries.

10. Remove seat cushion and other perishable items.

11. Remove keys and lock all covers and doors.

LPS is a trademark of the Holt Lloyd Corporation.

CED,OUOE020,8 –19–19FEB99–1/1

QUICK-DISCONNECT HITCH STORAGE

PROCEDURE

1. Plug cylinder ports.

2. Lubricate wedge bar.

3. Apply light coating of oil to all exposed metal parts.

TM 5-3805-280-10

23-2
Storage

TX,105,FF,400 –19–06SEP94–1/4

MONTHLY STORAGE PROCEDURE

T6191AA –UN–18OCT88

CAUTION: Engine exhaust fumes can cause

sickness or death. Start engine ONLY in a

well-ventilated area.

1. Drain water and sediment from fuel tank when air

temperature is above freezing.

2. Remove LPS 3 Rust Inhibitor from cylinder rods with a

cleaning solvent.

Continued on next page

TM 5-3805-280-10

23-3
Storage

TX,105,FF,400 –19–06SEP94–2/4T6181AU –UN–18OCT88

IMPORTANT: Prevent possible engine damage.

During cold temperatures, check

viscosity of engine oil on dipstick. If the

oil appears waxy and/or jelly-like rather

than liquid, DO NOT attempt to start

engine. Use external heat source to

warm the crankcase until oil appears

fluid.

3. Check all fluid levels. If low, check for leaks and add

oil as required.

4. Check belt.

5. Check condition of all hoses and connections.

6. Check electrolyte level. Charge and install battery.

7. Fill fuel tank. (See Fuels and Lubricants chapter.)

8. Start engine. Run engine at 1/2 speed for 5 minutes.

Do not run at fast or slow idle.

9. Bleed fuel system. If engine fails to start or runs poorly

after starting, change fuel filter(s). Bleed fuel system

again.

CAUTION: Prevent possible injury from

unexpected machine movement. Clear the area

of all persons before running machine through

the operation procedure.

10. Make sure that area is clear to allow for movement.

Operate (cycle) boom, arm, and bucket functions for

three complete cycles.

11. Operate the swing function for three complete

revolutions in each direction.

12. Check condition of tracks. Check track sag.

Continued on next page

TM 5-3805-280-10

23-4
Storage

TX,105,FF,400 –19–06SEP94–3/4T6879AT –UN–06DEC88

13. Operate the propel functions in forward and reverse

directions. This can be performed by one of two

methods.

a. Propelling the machine in forward and reverse for

a distance of 30 m (100 ft).

CAUTION: Prevent possible injury from machine

sliding backwards. Keep the angle between

boom and arm 90-110°.

b. If machine is equipped with bucket, raise each

track (keeping angle between boom and arm

90-110°) and propel in each direction for three

revolutions.

14. Park the machine with cylinder rods retracted.

TX,105,FF,400 –19–06SEP94–4/4T7034AA –UN–18APR89

15. Apply LPS 3 Rust Inhibitor to the exposed cylinder

rod areas (A).

TM 5-3805-280-10

23-5
TM 5-3805-280-10

BLANK

23-6
CHAPTER 24

SPECIFICATIONS

TM 5-3805-280-10
TM 5-3805-280-10

BLANK
Specifications

TX,115,JC3513 –19–05FEB98–1/2

230LCR/LCRD

T113215 –UN–03FEB98

230LCR

T125074 –UN–01NOV99

230LCRD

Continued on next page

TM 5-3805-280-10

24-1
Specifications

TX,115,JC3513 –19–05FEB98–2/2

NOTE: Specifications and design subject to change

without notice. Wherever applicable,

specifications are in accordance with PCSA

and SAE standards. Except where otherwise

noted these specifications are based on a

machine equipped with 800 mm (32 in.) shoes,

counterweight, 3.61 m (11 ft 10 in.) arm, 809

kg (1785 lb) 1.0 m3 (1.38 yd3) bucket, full fuel

tank, 79 kg (175 lb) operator and standard

equipment.

A 3840 mm (12 ft 7 in.)

B 4640 mm (15 ft 3 in.)

C 1090 mm (3 ft 7 in.)

D

(230LCR) 2940 mm (9 ft 8 in.)

(230LCRD) 3683 mm (12 ft 1 in.)

E 2870 mm (9 ft 5 in.)

F 2940 mm (9 ft 8 in.)

G 460 mm (1 ft 6 in.)

H 2590 mm (8 ft 6 in.)

I 600 mm (24 in.) or 700 mm (28 in.) or 800 mm (32 in.)

J—With 2390 mm (7 ft 10 in.) undercarriage and

With 600 mm (24 in.) shoes 3190 mm (10 ft 6 in.)

With 700 mm (28 in. shoes) 3290 mm (10 ft 10 in.)

With 800 mm (32 in.) shoes 3390 mm (11 ft 1 in.)

K—With 2960 mm (9 ft 9 in.) arm (230LCR) 10140 mm (33 ft 3 in.)

With 2960 mm (9 ft 9 in.) arm (230LCRD) 10261 mm (35 ft 8 in)

L— With 2320 mm (7 ft 7 in.) arm 3290 mm (10 ft 10 in.)

With 2960 mm (9 ft 9 in.) arm 3100 mm (10 ft 2 in.)

With 3610 mm (11 ft 10 in.) arm 3320 mm (10 ft 11 in.)

TM 5-3805-280-10

24-2
Specifications

TX,115,DH5418 –19–01MAR97–1/2

230LCR/LCRD WORKING RANGES

T102389 –UN–24MAR97

Continued on next page

TM 5-3805-280-10

24-3
Specifications

TX,115,DH5418 –19–01MAR97–2/2

2.32 m (7 ft 7 in.) Arm 2.96 m (9 ft 9 in.) Arm 3.61 m (11 ft 10 in.) Arm

A 9710 mm (31 ft 10 in.) 10270 mm (33 ft 8 in.) 10900 mm (35 ft 9 in.)

A1 9530 mm (31 ft 3 in.) 10100 mm (33 ft 2 in.) 10730 mm (35 ft 2 in.)

B 6300 mm (20 ft 8 in.) 6950 mm (22 ft 10 in.) 7590 mm (24 ft 11 in.)

C 6070 mm (19 ft 11 in.) 6740 mm (22 ft 1 in.) 7430 mm (24 ft 5 in.)

D 5400 mm (17 ft 9 in.) 6020 mm (19 ft 9 in.) 6740 mm (22 ft 2 in.)

E 9410 mm (30 ft 10 in.) 9630 mm (31 ft 7 in.) 9990 mm (32 ft 9 in.)

F 6540 mm (21 ft 5 in.) 6760 mm (22 ft 2 in.) 7100 mm (23 ft 4 in.)

G 3960 mm (13 ft 0 in.) 3870 mm (12 ft 8 in.) 3890 mm (12 ft 9 in.)

TX,115,DH5419 –19–01MAR97–1/1

230LCR/LCRD

Engine: John Deere POWERTECH 6.8

Type 4-stroke cycle, turbocharged, charge air cooled diesel

Bore and stroke 106 x 127 mm (4.17 x 5.0 in.)

Number of cylinders 6

Displacement 6.8 L (414 cu in.)

Maximum net torque @ 1400 rpm 716 N•m (528 lb-ft)

Cooling fan Suction

Compression ratio 17:1

Lubrication Pressure system with full-flow filter

Electrical system 24 volt

Batteries (2) 12 volt Reserve capacity: 180 minutes

Power at 2100 rpm:

Net SAE 127 kW (170 hp)

Operating Weight 23 773 kg (52, 410 lb)

POWERTECH is a trademark of Deere & Company.

TM 5-3805-280-10

24-4
Specifications

TX,115,DH5420 –19–01MAR97–1/1

230LCR/LCRD DRAIN AND REFILL

CAPACITIES

Metric U.S.

Fuel tank 310 L 82 gal

Cooling system 22 L 6 gal

Engine oil, including filter change 19 L 5 gal

Hydraulic tank 148 L 39 gal

Hydraulic system 270 L 71 gal

Swing gearbox 13 L 14 qt

Propel gearbox (each) 6.0 L 6.5 qt

Pump drive gearbox 1.0 L 1.1 qt

TM 5-3805-280-10

24-5
Specifications

TX,115,DH5738 –19–19APR97–1/1

230LCR/LCRD LIFT CAPACITY—KG (LB)

Ratings are at bucket lift hook, using standard

counterweight, situated on firm, level, uniform

supporting surface.

Power Boost: On

Figures do not exceed 87 percent of hydraulic capacity

or 75 percent of weight needed to tip machine. Figures

marked with an (*) are hydraulically-limited capacities.

Remaining figures are stability-limited capacities.

Arm: 2.96 m (9 ft 9 in.) Bucket: 809 kg (1785 lb) 1.0 m3 (1.38 yd3) Shoe: 800 mm (32 in.)

LIFTING OVER FRONT

Load Point Horizontal Distance from Centerline of Rotation

Height

m (ft) 1.52 (5) 3.05 (10) 4.57 (15) 6.10 (20) 7.62 (25) 9.14 (30)

6.10 (20) 3567 (7863)a

4.57 (15) 4644 (10238)a 4421 (9746)a

3.05 (10) 7574 (16697)a 5744 (12664)a 4935 (10880)a

1.52 (5) 10198 (22483)a 6986 (15402)a 5577 (12296)a 3987 (8789)a

Ground (Line) 11563 (25492)a 7950 (17526)a 5576 (12292) 4002 (8824)a

-1.52 (-5) 5450 (12015)a 11761 (25928)a 7844 (17293) 5480 (12082)

-3.05 (-10) 12512 (27586)a 11222 (24741)a 8264 (18218)a 5480 (12081)

-4.57 (-15) 13417 (29580)a 9858 (21733)a 7316 (16128)a

LIFTING OVER SIDE

m (ft) 1.52 (5) 3.05 (10) 4.57 (15) 6.10 (20) 7.62 (25) 9.14 (30)

(6.10 20) 3567 (7863) a

4.57 (15) 4644 (10238)a 3921 (8645)

3.05 (10) 7574 (16697)a 5744 (12664)a 3766 (8303)

1.52 (5) 7972 (17575) 5147 (11348) 3586 (7905) 2590 (5711)

Ground (Line) 7573 (16696) 4881 (10761) 3435 (7572) 2521 (5559)

-1.52 (-5) 5450 (12015)a 7476 (16482) 4749 (10470) 3348 (7380)

-3.05 (-10) 12513 (27586)a 7523 (16586) 4737 (10443) 3347 (7379)

-4.57 (-15) 13417 (29580)a 7691 (16956) 4847 (10685)

aHydraulically-limited capacity

TM 5-3805-280-10

24-6
ROCK DRILL ATTACHMENT - TECHNICAL SPECIFICATIONS

IR–MONTABERT reference :

CPN :

79700–V1

86372943

76500–V1

86361185

83948–V1

86389624

95220–V1

86489564

Model CPA 200 CPA 220 CPA 225 CPA X–TEND

CARRIER REQUIREMENT

Excavator weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . metric tons 13 to 20 13 to 25 13 to 25 22 to 35

Min. power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KW 55 55 55 74 / 80

Hydraulic flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min 140 140 140 180 / 200

GENERAL SPECIFICATIONS

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 1100 1250 1300 2500 2900

Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 5800 5900 6000 7200 10200

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1300 950 900 1100

Heigthmm 1400 1170 1300 1600

Rotation from vertical axis . . . . . . . . . . . . . . . . . . . . . . . . . . degrees  27  27  180  27

DRIFTER HC 40 HC 40 HC 40 HC 105 / HC 150

Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KW 23 23 23 35 / 42

Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BPM 2900 2900 2900 2900 / 2530

Reverse percussion Optional

FEED ACH CPA ACH CPA ACH CPA GCX

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14’ / 12’ 14’ / 12’ 14’ / 12’ 14’ / 12’ 24’ / 20’

Rod type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R32 / T38 R32 / T38 R32 / T38 T45 / T51

Rod length

Starter rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

ft

4305

(14’)

4305

(14’)

4305

(14’)

4305

(14’)

 7135

(24’)

Extension rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

ft

3050 / 3600

(10’ / 12’)

3050 / 3600

(10’ / 12’)

3050 / 3600

(10’ / 12’)

3660

(12’)

6100

(20’)

Drill depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m

ft

18.3

(60’)

18.3

19.5 (ACH 18/12)

(64’)

18.3

(60’)

25

(82’)

11.3

(37’)

Bit diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

in

38 to 76

(1.5’ to 3’)

38 to 76

(1.5’ to 3’)

38 to 76

(1.5’ to 3’)

76 to 115

3’ to 4.5’

ROD HANDLING

Rod rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Standard Standard –

Single rod loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – – option Standard

Rod changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – – – 6+1 

or 4+1 (T51 x 20’)

CONTROLS Manual on guide Electric remote Electric remote Electric in cabin

DUST COLLECTION

pre–equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . yes yes yes yes

AIR REQUIREMENT An air compressor must be provided for flushing the drilled hole

Compressor recommandation l/min @ 8 bar

cfm @ 120 psi

5000

180

5000

180

5000

180

7400

260

 9350

 330

TM 5-3805-280-10

24-7
AIR COMPRESSOR

GENERAL DATA

COMPRESSOR ............................................................................. MODEL XP330SJD

Rated Delivery - cfm (litres/sec)..................................................... 330 (155)

Rated Pressure - psi (kPa)............................................................. 125 (862)

Safety Valve Setting - psi (kPa) ..................................................... 175 (1207)

Engine - (Diesel) ............................................................................ John Deere Power Tech 4045T

Speed No Load (Full Load) - rpm .................................................. 1400 (2500)

Electrical/Starting System - volts ................................................... 24

Eng. Lube includes: filter, capacity - U.S. gal. (litres) .................... 3.5 (13.2)

Eng. Coolant Capacity - U.S. gal (litres) nominal .......................... 5.8 (22.0)

Compressor Lube Capacity (refill) - U.S. gal. (litres) ..................... 9.5 (36.0)

UNITS MEASUREMENTS/WEIGHT

Overall Length - inches (mm)......................................................... 88 (2235)

Overall Height - inches (mm) ......................................................... 51 (1296)

Overall Width - inches (mm) .......................................................... 44 (1118)

Unit weight (all fluids) - pounds ..................................................... 2860 (1298)

TM 5-3805-280-10

24-8
TM 5-3805-280-10

A-1

APPENDIX A

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

A-1. GENERAL

Preventive Maintenance Checks and Services (PMCS) are performed to keep the Hydraulic Excavator in

operating condition. The checks are used to find, correct, or report problems. Crewmembers are to do the

PMCS jobs as shown in the PMCS table. PMCS are done every day the vehicle is operated, using the

PMCS table. Pay attention to WARNING and CAUTION statements. A WARNING means someone could

be hurt. A CAUTION means equipment could be damaged.

NOTE: As this operator manual is a commercial product supplemented to include Army specific

procedures, the manual may advise the operator to perform tasks that would normally not be

assigned to the operator level in a DATM. Always follow the limits established in the PMCS.

See also Chapter 3, Break-In, and Chapters 10 through 17, Scheduled Maintenance, for additional

information.

Before you begin operating the Hydraulic Excavator, do Before PMCS.

During operation, do During PMCS.

After operation, do After PMCS.

Once a week do Weekly PMCS. If Hydraulic Excavator has not been operated in a week, also do Before

PMCS at the same time.

Do Monthly PMCS once a month. If Hydraulic Excavator has not been operated in a month, also do After

PMCS at the same time.

If you are operating the Hydraulic Excavator for the first time, do your Weekly and Monthly PMCS the

first time you do your Before PMCS.

If you find something wrong when performing PMCS, fix it if you can using troubleshooting procedures

and/or maintenance procedures in this manual or notify your supervisor.

The right-hand column of the PMCS table lists conditions that make the Hydraulic Excavator not fully

mission capable. Write up items not fixed on DA Form 2404 for unit maintenance. For further information

on how to use this form, see DA PAM 738-750.

A-2. LEAKAGE DEFINITION

CAUTION: Equipment operation is allowable with minor leakages (Class I or II) except for fuel

leaks. Of course, consideration must be given to the fluid capacity of the item or system being

checked. When in doubt, ask your supervisor.

When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS.

Class III leaks should be reported immediately to your supervisor.
TM 5-3805-280-10

A-2

It is necessary to know how fluid leakage affects the status of the Hydraulic Excavator. The following are

definitions of the classes of leakage an operator or crewmember needs to know to be able to determine the

condition of the leak. Learn and then be familiar with them, and REMEMBER-WHEN IN DOUBT, ASK

YOUR SUPERVISOR.

Leakage Definitions for Crew/Operator PMCS:

CLASS I-Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.

CLASS II-Leakage of fluid great enough to form drops but not enough to cause drops to drip from item

being checked.

CLASS III-Leakage of fluid great enough to form drops that fall from the item being checked.

A-3. INSPECTION

Look for signs of a problem or trouble. Senses help here. You can feel, smell, hear, or see many problems.

Be alert when on the Hydraulic Excavator.

Inspect to see if items are in good condition. Are they correctly assembled, stowed, secured, excessively

worn, leaking, corroded, or properly lubricated? Correct any problems found or notify unit maintenance.

There are some common items to check all over the Hydraulic Excavator. These include the following:

1. Bolts, clamps, nuts, and screws: Continuously check for looseness. Look for chipped paint, bare metal,

rust, or corrosion around bolt and screw heads and nuts. Tighten them when you find them loose. If tools

are not available, notify unit maintenance.

2. Welds: Many items on the Hydraulic Excavator are welded. To check these welds, look for chipped

paint, rust, corrosion, or gaps. When these conditions exist, notify unit maintenance on DA Form 2404.

3. Electrical wires, connectors, and harnesses: Tighten loose connectors. Look for cracked or broken

insulation, bare wires, and broken connectors. If any are found, notify unit maintenance.

4. Hoses and fluid lines: Look for wear, damage, and leaks, and make sure clamps and fittings are tight.

Wet spots mean a leak. A stain by a fitting or connector can also mean a leak. When you find a leak, notify

unit maintenance.

A-4. LUBRICATION SERVICE INTERVALS-NORMAL CONDITIONS

For safer, more trouble-free operations, make sure that the Hydraulic Excavator is serviced in accordance

with the proper lubrication and service intervals specified in the PMCS.

A-5. LUBRICATION SERVICE INTERVALS-UNUSUAL CONDITIONS

The Hydraulic Excavator will require extra service and care when you operate under unusual conditions.

High or low temperatures, long periods of hard use, or continued use, in sand, water, mud, or snow will

break down the lubricant requiring you to add or change lubricant more often.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-3

WARNING: Always remember the

CAUTIONS, WARNINGS, and NOTES

before operating this machine and prior to

PMCS.

PREPARE MACHINE FOR MAINTENANCE

Before performing PMCS and before leaving the

operator’s seat, park the machine as described

below unless another position is specified in the

procedure.

(1) Park machine on a level surface.

(2) Lower bucket to the ground.

(3) Turn auto-idle switch off.

CAUTION: Turbocharger may be damaged if

engine is not properly shut down.

(4) Run engine with engine rpm dial at 1/3 position

without load for 2 minutes.

(5) Move engine rpm dial to slow idle position.

(6) Turn key switch to OFF. Remove key from

switch.

(7) Pull pilot control shut-off lever to locked

position.

Perform all weekly and before operations PMCS if:

(1) You are the assigned operator and have not

operated the machine since the last weekly.

(2) You are operating the machine for the first

time.

WALK-AROUND CHECKS/INSPECTION

Inspect machine daily before starting and after

operation.

NOTE: If leakage is detected, further

investigation is needed to determine the

location and cause of the leak.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-4

1 Before Check Fuel Tank (Fill at End of Day)

NOTE: Items 2 through 4 are applicable to

Model 230LCR only.

2 Before Grease All Material Clamp Joints

(1) Pump grease into the four indicated grease Fittings damaged or

points (see Fuels and Lubricants, Chapter 9). missing

3 Before Check for Loose or Missing Material Clamp Bolts and Nuts Any damage that will

prevent operation

4 Before Inspect Material Clamp for Damage or Weld Cracks Damage or weld

cracks are present

5 Before Clean Dirt and Debris from Quick-Disconnect Hitch

Attachment Front Hooks and Rear Saddles

6 Before Inspect for Damage and Clean Dirt and Debris from Damaged sensor

Overload Alarm Proximity Sensor

NOTE: Items 7 through 16 are applicable to

Model 230LCRD only.

7 Before Check CPA Attachment of Rock Drill to Hitch Adapter Fixing pins are loose

or missing

(1) Ensure that all fixing pins are secure.

8 Before Inspect Guide Chains and Ropes of the Rock Drill 2 broken wires within 36 mm

(1.44 in.) (6 times nominal

(1) Inspect the front chain for wear. diameter of cable)

(2) Inspect hose reel rope. Specifically inspect OR

attachment points on tightener and chain.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-5

Check rope for flats on outside strands, 4 broken wires within 180 mm

crushing, swelling, or fraying. If rope requires (7.2 in.) (30 times nominal

replacement, notify your supervisor. diameter of cable)

(3) Move drifter at slow speed to front end OR

position.

Cable diameter is less than

(4) Check chain reel for wear or corrosion. 5.4 mm (0.21 in.) (nominal

If reel requires replacement, notify your diameter)

supervisor.

9 Before Check Oil Level of Pressurization Air Oiler of Rock Drill

(1) Remove oil fill plug (1).

(2) Check oil level. Add oil if necessary (see Fuels No oil visible or low

and Lubricants, Chapter 9). level

10 Before Lubricate Hydraulic Drifter Front End Head of Rock Drill

(1) Lubricate the hydraulic drifter front part with 5

or 6 shots of hand pump grease (see Fuels and

Lubricants, Chapter 9).

11 Before Check Compressor Oil Level

(1) Open compressor left side access door.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-6

(2) Start unit (refer to air compressor operating

instructions). Allow unit to warm up.

(3) With compressor running at full load, check Oil level not within

sight tube located on the side of the receiver “OK” range

tank. The optimum operating level is midway

of the sight tube. Oil level should be within the

“OK” range.

(4) If oil level is not within the “OK” range, add oil

to receiver tank (see Fuels and Lubricants,

Chapter 9).

NOTE: Ensure that access door is closed

securely after inspection is complete.

12 Before Check Compressor Engine Oil Level

(1) Open compressor rear right access door.

(2) Make sure dipstick is fully seated.

(3) Remove dipstick and check oil level. Oil level is below ADD

mark on dipstick

(4) Add oil if level is below ADD mark (see Fuels

and Lubricants, Chapter 9).

NOTE: Ensure that access door is closed

securely after inspection is complete.

13 Before Check Compressor Gauges/Lamps

(1) Open compressor rear left access door.

(2) On control panel, set switches SW1 and SW2 to Any light fails to

OFF, then to ON. Panel lights PL1 and PL2 function

should go on. All diagnostics lamps will light

(glow) for approximately 2 seconds. Then all

lamps should go off except for LOW ENGINE

OIL PRESSURE.

(3) Check and replace any lamp that fails to light.

(4) Set switches SW1 and SW2 to OFF.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-7

14 Before Check Compressor Air Cleaner Service Indicators

(1) Check ENGINE AIR FILTER AND Flag does not show

COMPRESSOR AIR FILTER service green

indicators located on compressor

instrument/control panel. The flag in a service

indicator should show green.

(2) If flag shows red, service or replace filter

element(s).

NOTE: Ensure that access door is closed

securely after inspection is complete.

15 Before Check Compressor Fuel/Water Separator

16 Before Check Rock Drill Dust Collector Filters Damaged or clogged

During filters

17 Before Inspect Boom, Bucket, Arm, Cylinders, and Hoses for Bent, Any damage that will

After Broken, Loose, Leaking, or Missing Parts prevent operation

18 Before Check Track and Ground Under Machine and Propel Any Class III leak evident

After Motors for Evidence of Leaks

(1) Inspect track for missing or damaged parts. Any damage that will

prevent operation

(2) Look for evidence of leakage. Any Class III leak evident

19 Before Inspect Hydraulic Oil Pump

WARNING: Prevent possible injury from

door closing. Secure door in the OPEN

position.

To hold door open, remove rod from stored

position (A) and insert in tab (B) on door.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-8

(1) Open right-side access door.

(2) Look for evidence of hydraulic leaks. Any Class III leak evident

NOTE: Note the Arm, Boom, and Bucket

position on the placard located to the left of

the hydraulic sight gauge. This information

will be used with the hydraulic oil level check

to be performed later.

(3) Check oil level window (A) on hydraulic tank. No hydraulic oil visible

Oil must be visible in sight gauge within safe or not within safe

operating range as indicated on sight gauge. operating range

(4) If empty or low, add oil (see Check Hydraulic

Oil Level under During - Start and After-Start

Checks).

20 Before Check Pump Drive Gearbox Oil Level

(1) Pull dipstick (A) from tube and check oil level. No oil in pump gearbox

or below the ADD or

SAFE mark on the dipstick

(2) Add oil if below “H” mark (see Monthly -

Check Pump Drive Gearbox Oil Level).

NOTE: Ensure that access door is closed

securely after inspection is complete.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-9

21 Before Check Recovery Tank Coolant Level

NOTE: On Model 230LCRD, the overflow

lines for the main engine and compressor

engine radiators are connected to a common

recovery tank.

(1) Open left rear access door.

(2) With engine cold, coolant level must be at the

FULL mark on the recovery tank (A).

(3) If coolant is below the FULL mark, add coolant

to the recovery tank.

WARNING: Prevent possible injury from hot

spraying water. DO NOT remove radiator

filler cap unless engine is cool. Then turn cap

slowly to the stop. Release all pressure before

you remove cap.

NOTE: If recovery tank is empty, check for

leaks. Repair as required. Add coolant to the

radiator(s) and the recovery tank.

NOTE: Coolant level in radiator(s) must be at Coolant does not cover

bottom of the filler neck. cooling tubes in top of

radiator

NOTE: If recovery tank is full and radiator(s)

is low, check for leaks in radiator cap and the

connections between radiator and recovery

tank.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-10

22 Before Clean Radiator Air Inlet Screens

(1) Remove wing nut (A) and pull handles (B) to

slide screens up for cleaning.

WARNING: Compressed air used for cleaning purposes will not exceed 30 psi. Use only

with effective chip guarding and personal

protective equipment (goggles/shield/gloves,

etc.).

(2) Use pressurized air (30 psi maximum) or lowpressure water to clean screens.

23 Before Check Radiator and Oil Cooler Fins

(1) Check radiator for damage and clean and Any damage to radiator

remove any debris from radiator screens: or oil cooler fins that

may prevent cooling

a. Inner cooler (top center)

b. Oil cooler (lower left)

24 Before Check Batteries

(1) Check battery for damage and connections for Any damage that would

corrosion and secure connections. prevent operation or

battery will not hold charge
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-11

25 Before Check Windshield Washer Fluid Level

(1) Check windshield washer fluid level in tank (A)

and, if necessary, fill to full mark with all

season windshield washer fluid.

NOTE: Ensure that access door is closed

securely after inspection is complete.

26 Before Check Cab, All Glass, Windshield, and Wipers

(1) Check cab and windshield for cracks and/or Broken windows impair

damage that may impair vision. vision or missing glass

(2) Check wiper arm and blade for damage.

NOTE: Mount machine using the right side

track footstep.

27 Before Check that Fire Extinguisher and Window Breaking Fire extinguisher or window

Tool are Installed breaking tool missing

(1) Fire extinguisher and window breaking tool in

cab (230LCR).

(2) Fire extinguisher in engine compartment and

window breaking tool in cab (230LCRD).

28 Before Inspect Seat Belt and Mounting Hardware for Wear Any damage or wear

or Damage that would prevent

safe operation
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-12

29 Before Inspect Swing Gearbox Lines and Oil Level

(1) Remove access panel.

(2) Check swing gearbox hydraulic lines for Any Class III leak evident

evidence of leaks.

(3) Check oil level.

a. Pull dipstick (A) from tube and check oil level. Oil is below the ADD or

SAFE mark on the dipstick

b. Add oil (tube B) if level is below the ADD

or SAFE mark on the dipstick (see Monthly

- Check Swing Gearbox Oil Level).

NOTE: Ensure that access panel is closed

securely after inspection is complete.

30 Before Check Engine Oil

After

Use the handle on the hood to raise hood until the

end of the rod is securely locked into catch (A).

(1) Inspect oil cooling lines and hoses for cracks.

(2) Look for evidence of leakage. Any Class III leak evident
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-13

(3) Make sure dipstick (A) is fully seated.

(4) Remove dipstick and check oil level.

(5) Add oil (filler cap [B]) if level is below ADD Oil level is below ADD

or cross-hatched area mark on the dipstick (see level on the dipstick

Fuels and Lubricants, Chapter 9).

NOTE: BEFORE THE ENGINE IS

STARTED: The engine is full when oil level is

in the cross-hatched area.

AFTER THE ENGINE HAS BEEN RUN:

Allow the oil to drain into the oil pan for 10

minutes after engine stops before checking the oil

level. The oil level must be above the ADD mark.

If necessary, remove oil filler cap (B) and add oil.

(6) Inspect engine compartment for loose or Any damage that would

damaged components. prevent operation

NOTE: Ensure that engine access door is

closed securely after inspection is complete.

31 Before Check Instruments

During

(1) Turn key switch to ON position. All instrument

lights should stay on for approximately 3

seconds.

(2) Check and replace any bulb that fails to light.

(3) Check that gauge indicates fuel level and the Coolant gauge in red zone

coolant gauge does NOT go to the red zone.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-14

32 Before Level Check

During

NOTE: The level check does NOT take the

place of before operation check at hydraulic

oil level window, engine coolant recovery

tank, or engine oil level dipstick.

(1) With key switch in the ON position, press level

CHECK switch (A).

(2) Check that hydraulic oil level (B) engine Any WARNING light

coolant (C) and engine oil level light (D) fails to function

illuminate to indicate levels are adequate for

operation.

33 During Start and After-Start Checks

(1) Move engine rpm dial to slow idle position.

CAUTION: Prevent starter damage. Never

operate starter for more than 20 seconds at a

time. If engine fails to start, return key switch

to OFF. Wait 2 minutes, then try again. After

a false start, do not turn key switch until

engine stops.

(2) Sound horn to alert nearby personnel.

(3) Turn key switch to START. Release key when

engine starts (key should return to ON

position).
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-15

CAUTION: Prevent possible damage to

engine. If indicator lights do not go out after

starting engine, IMMEDIATELY STOP THE

ENGINE. Find and correct the problem.

(4) Check that all indicator lights go out. One or more indicator lights

do not go out after starting

engine

(5) Check hydraulic oil level.

a. Park machine on level surface.

b. Position machine with arm cylinder fully

retracted, bucket cylinder fully extended,

and bucket lowered to the ground.

(Reference placard located to the left of the

hydraulic sight gauge.)

c. Turn auto-idle switch off.

d. Run engine with engine rpm dial at 1/3

position without load for 2 minutes.

e. Move engine rpm dial to slow idle position.

f. Turn key switch OFF and remove key.

g. Attach a “Do Not Operate” tag on the right

control lever.

h. Pull pilot control shut-off lever to locked

position.

i. Open right side access door.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-16

j. Check oil level window (A) on hydraulic No hydraulic oil visible or not

tank. (Oil must be visible in sight gauge within safe operating range

within safe operating range as indicated on

sight gauge.)

k. If necessary, add oil.

To add oil:

WARNING: High-pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove vent plug (A).

Release pressure by loosening vent plug.

(1) Loosen vent plug (A) to release hydraulic

pressure.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-17

(2) Insert 4 mm (0.15 in.) Allen wrench (D) into

hole (E) and turn counterclockwise.

(3) Slowly turn cap (A) counterclockwise. Remove

cap. Add oil (see Fuels and Lubricants,

Chapter 9).

(4) Install cap to case assembly (C) by aligning

marks (B) and turning clockwise to lock

position.

(5) Tighten vent plug.

NOTE: Ensure that access door is closed

securely after inspection is complete.

34 Before Perform Operational Checks

During (See Operational Checkout, Chapter 21.)

35 Before Check Decontamination Kit Holder and Holder Strap

(1) Check decontamination kit holder strap for

fraying, cutting, or wear. Replace if necessary.

(2) Ensure that decontamination kit holder bolts are

tight.

NOTE: The following checks and services are

to be performed weekly or sooner as required

by adverse environmental conditions.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-18

36 After Clean Rock Drill Dust Collector Filters (230LCRD)

(1) Every day after drilling operations are

completed and before stopping the machine,

clean filters by allowing one cleaning cycle

without drilling.

37 Weekly Inspect Material Clamp Pin Joint Movement (230LCR) Clamp action is sloppy

(1) Operate material clamp and check for unusual

slop. Make sure pin joints are snug.

38 Weekly Inspect Quick-Disconnect Hitch Attachment Points

(1) Ensure that attachment is secure in front hooks

and rear saddle.

(2) Inspect quick-disconnect hitch and wedge for Any damage that would

excessive wear, damage, or failure. prevent operation

39 Weekly Inspect Quick-Disconnect Hitch Lifting Hook

(1) Visually inspect lifting hook for wear or Any damage that would

damage. prevent operation

NOTE: Items 40 through 42 are applicable to

Model 230LCRD only.

40 Weekly Wash the Rock Drill

41 Weekly Inspect All Hoses of Rock Drill

(1) Inspect hoses for cracking, wear, or damage. Hoses are damaged

If hoses require replacement, notify your and leaking

supervisor.

42 Weekly Check the Rock Drill Cap Bolts and the Mounting Bolts Bolts are loose or

of the Hydraulic Drifter for Tightness missing
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-19

43 Weekly Grease Working Tool Pivots

*As Required

(1) Pump grease (see Fuels and Lubricants, Fittings damaged or

Chapter 9) into the 20 indicated grease points. missing

Grease until grease escapes from joints.

(2) *As required:

a. Grease every 4 hours during the first 20 hrs.

b. Grease daily during the first 30—100 hrs and

when working in mud and water or sand.

Three Points Three Points Two Points

One Point Three Points, A—Left Side Shown Five Points

Two Points One Point
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-20

44 Weekly Drain Fuel Tank Sump

*As Required

(1) Park machine on level surface. Rotate upperstructure 90° for easier access.

(2) Remove fuel tank fill cap.

NOTE: Plug is installed in drain cock to

prevent vandalism.

(3) Remove plug (A) and open drain cock (B) for

several seconds to drain water and sediment

into a container. Dispose of waste properly.

Close drain cock.

(4) Install and tighten plug.

(5) Install fill cap.

45 Weekly Check Arctic Starter Fuel Lines Any Class III leak evident

(1) Visually check all fuel lines for leaks. Replace

damaged, worn, or corroded fuel lines.

NOTE: Items 46 through 49 are applicable to

Model 230LCRD only.

46 Weekly Check Compressor Air Precleaner Dirt Dumps

(1) Squeeze the rubber valve (precleaner dirt

dump) on each air cleaner housing to ensure

that valves are not clogged.

47 Weekly Check Compressor Fan Belts Damaged or loose belts

48 Quarterly Check All Compressor Hoses Damaged hoses
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-21

49 Quarterly Check Compressor Air Cleaner System

(1) Inspect housing and piping for any leakage Any damage that would

paths, inlet obstructions, dents and loose prevent operation

fasteners.

50 *As Required Clean Fuel Tank Inlet Screen

WARNING: Dry cleaning solvent PD-680

Type III is toxic and flammable. Wear

protective goggles and gloves and use only in

well-ventilated area. Avoid contact with skin,

eyes, and clothes and don’t breathe vapors.

Do not use near open flames or excessive heat.

The flash point is 200°F (94°C). If you become

dizzy while using solvent, get fresh air

immediately and get medical aid. If contact

with eyes is made, wash your eyes with water

and get medical aid immediately.

Use solvent or diesel fuel to clean screen (A). Screen damaged

or missing

51 *As Required Drain Water Separator

(1) Open right access door to access water

separator.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-22

(2) Open drain valve (A) and press pump (B) to

extract water. Collect waste in a container and

dispose of properly.

(3) Close drain valve (A).

NOTE: Ensure that access door is closed

securely after inspection is complete.

52 *As Required Clean Air Cleaner Unloader Valve

NOTE: A missing, damaged, or hardened

dust unloader valve will make the dust cup

precleaner ineffective, causing very short air

filter life. Valve should suck closed above 1/3

engine speed.

(1) Squeeze dust valve (A) to remove dust from the

air cleaner.

(2) When operating in high dust/sand conditions,

squeeze dust valve every couple of hours of

operation to release dust/sand.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-23

53 Monthly Check Swing Gearbox Oil Level

(1) Park machine on level surface.

(2) Remove dipstick (A). Oil must be in the Oil is below the ADD or

operating range. SAFE mark on the dipstick

(3) If oil is needed, remove filler cap (B) and add

oil (see Fuels and Lubricants, Chapter 9).

(4) Recheck oil level.

54 Monthly Drain Hydraulic Tank Sump

WARNING: High-pressure release of oil from

pressurized system can cause serious burns or

penetrating injury. The hydraulic tank is

pressurized. Do not remove plug (A). Release

pressure by loosening vent plug.

(1) Loosen vent plug (A) to release hydraulic

pressure.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-24

(2) Loosen plug (F) for several seconds to drain

water and sediment into a container. Do not

remove plug completely. Dispose of waste

properly.

(3) Tighten sump plug and vent.

55 Monthly Check Pump Drive Gearbox Oil Level

To check oil:

(1) Remove dipstick (A).

(2) Wipe dipstick clean and insert completely into

tube.

(3) Remove dipstick. Oil must be approximately Oil level is below the ADD or

halfway below the “H” (level) mark. SAFE mark on the dipstick

To add oil:

(1) Remove filler cap (B).

(2) Add oil (see Fuels and Lubricants, Chapter 9).

(3) Install filler cap.
TM 5-3805-280-10

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES

FOR HYDRAULIC EXCAVATOR 230LCR/230LCRD

ITEM INTERVAL ITEM TO BE INSPECTED EQUIPMENT IS NOT

NO. PROCEDURE: DO THE PMCS AND HAVE ITEM READY/AVAILABLE

REPAIRED, FILLED, OR ADJUSTED AS NEEDED IF:

A-25

56 Monthly Run Arctic Starter Heater

(1) Switch heater on (for 2 minutes with a

“continuous green” LED light) once a month

during periods when heater is not used. This

will prevent the water pump and combustion

engine from seizing.

57 Monthly Check Arctic Starter Glow Pin

(1) Check glow plug cable and connection. Make

sure that connection is not corroded or dirty.

58 Monthly Inspect Fire Extinguisher Pressure is not within

specification

(1) Check gauge on fire extinguisher. Make sure

the dial is within the green area on the gauge.

(a) Fire extinguisher located in cab (230LCR).

(b) Fire extinguisher located in battery

compartment (230LCRD).

(2) Check tightness of fire extinguisher bracket

bolts.

(3) Check the fire extinguisher hose for cracks,

wear, or damage. Replace if necessary.

(4) Check that tamper seal is intact.

59 Monthly Inspect Primary Air Cleaner Element

(1) Open front service door.

(2) Loosen wing nut to remove cover.

(3) Remove wing nut and primary element (A). Primary element is

Clean the primary element. damaged or dirty

NOTE: Ensure that front service door is

closed securely after inspection is complete.
TM 5-3805-280-10

BLANK

A-26
TM 5-3805-280-10

B-1

APPENDIX B

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST

Section I. INTRODUCTION

B-1. SCOPE

This appendix lists integral components of the end item and basic issue items for the Hydraulic Excavator to

help you inventory items required for safe and efficient operation.

B-2. GENERAL

The Components of End Item and Basic Issue Items Lists are divided into the following sections:

a. Section II. COMPONENTS OF END ITEM. This listing is for informational purposes only and

is not authority to requisition replacements. These items are part of the end item but 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 assist

in identifying the items.

b. Section III. BASIC ISSUE ITEMS. These are the minimum essential items required to place the

Hydraulic Excavator in operation, to operate it, and to perform emergency repairs. Although shipped

separately packaged, BII must be with the Hydraulic Excavator during operation and whenever it is issued

or transferred between property accounts. The illustrations will assist you with hard-to-identify items. This

manual is your authority to requisition/request replacement BII, based on TOE/MTOE authorization of the

end item.

B-3. EXPLANATION OF COLUMNS

The following provides an explanation of columns found in the tabular listings:

a. Column (1) – Illustration Item Number (ILLUST NUMBER). This column indicates the

number of the illustration in which the item is shown.

b. Column (2) – NATIONAL STOCK NUMBER. Indicates the National stock number assigned to

the item and will be used for requisitioning purposes.

c. Column (3) – DESCRIPTION. Indicates the Federal item name and, if required, a minimum

description to identify and locate the item. The last line for each item indicates the Contractor And

Government Entity (CAGE) code in parentheses, followed by the part number. If the item needed differs for

different models of this equipment, the model is shown under the “USABLE ON CODE” heading in this

column. These codes are identified as:

Code Used On

A Model 230LCR

B Model 230LCRD

d. Column (4) – Unit of Measure (U/M). Indicates how the item is issued for the National Stock

Number shown in Column 2.

e. Column (5) – Quantity Required (QTY RQR). Indicates the quantity required.
TM 5-3805-280-10

B-2

Section II. COMPONENTS OF END ITEM

Table 1. Components of End Item

(1)

ILLUST

NUMBER

(2)

NATIONAL

STOCK NUMBER

(3)

DESCRIPTION

CAGE & PART NUMBER

USABLE

ON CODE

(4)

U/M

(5)

QTY

RQR

1 Rock Drill

(75755) AT188374

B EA 1

2 Ditch Bucket, 60 in.

(75755) AT188608

A EA 1

3 Heavy Duty Bucket, 42 in.

(75755) AT188607

EA 1

4 Vandal Protection Kit

(75755) AP33356

EA 1
TM 5-3805-280-10

B-3

Section III. BASIC ISSUE ITEMS LIST

Table 2. Basic Issue Items List

(1)

ILLUST

NUMBER

(2)

NATIONAL

STOCK NUMBER

(3)

DESCRIPTION

CAGE & PART NUMBER

USABLE

ON CODE

(4)

U/M

(5)

QTY

RQR

1 5120-00-240-5328 Wrench, Open End, Adjustable

.95 in. jaw opening, 8-in. long

(19207) 11655778-3

 EA 1

2 5120-01-045-4889 Wrench, Allen

4mm (0.15-in.)

(74445) 57124

 EA 1

3 Wrench, 3 in.

(75755) T183966

B EA 1
TM 5-3805-280-10

Table 2. Basic Issue Items List (Continued)

B-4

(1)

ILLUST

NUMBER

(2)

NATIONAL

STOCK NUMBER

(3)

DESCRIPTION

CAGE & PART NUMBER

USABLE

ON CODE

(4)

U/M

(5)

QTY

RQR

4 Wrench, Filter, Nylon Strap

(75755) TY24252

B EA 1

5 Gauges, Pressure

(75755) 86310943

B EA 1

6 Brackets, Track, Transport

(75755) AT189507

 EA 2

7 Pliers, Vise Grip, 8-inch

PROTO 293R/Fed Spec GGG-W-00649

B EA 1

8 Hammer, Wood Handle,

4 3/16 lb, 1 3/4 in. face dia.,

9 7/8 in. overall length

(75755) 5902A3

 EA 1

9 Pin Removal Tool,

5 lb, 18 in. long

(75755) PRT290

 EA 1

10 Gun, Grease, Lever Action,

23 strokes per oz, 12 in. flexible hose

(75755) 1055K14

 EA 1

11 Operator’s Manual

TM 5-3805-280-10

 EA 1
TM 5-3805-280-10

C-1

APPENDIX C

REFERENCES

C-1. SCOPE

This appendix lists forms, field manuals, technical manuals, and other publications either referenced in this

manual or which apply to the operation and maintenance of the Hydraulic Excavator. Web sites which may

be useful are also included in this appendix.

C-2. DEPARTMENT OF THE ARMY PAMPHLETS

Consolidated Index of Army Publications and Blank Forms DA Pam 25-30

Using Unit Supply System (Manual Procedures) DA Pam 710-2-1

Functional Users Manual for The Army Maintenance Management DA Pam 738-750

System (TAMMS)

C-3. FORMS

Recommended Changes to Publications and Blank Forms DA Form 2028

Recommended Changes to Equipment Technical Publications DA Form 2028-2

Organizational Control Record for Equipment DA Form 2401

Equipment Inspection and Maintenance Worksheet DA Form 2404

Equipment Inspection and Maintenance Worksheet (Electronic) DA Form 5988E

Maintenance Request DA Form 2407

Preventive Maintenance Schedule and Record DD Form 314

Product Quality Deficiency Report (NSN 7540-00-105-0078) SF 368

C-4. FIELD MANUALS

NBC Contamination Avoidance FM 3-3

NBC Protection FM 3-4

NBC Decontamination FM 3-5

NBC Handbook FM 3-7

Camouflage FM 20-3

Operation and Maintenance of Ordnance Materiel in Extreme FM 9-207

Cold Weather (0° to -65°F)
C-2

Recovery and Battlefield Damage Assessment and Repair FM 9-43-2

Soldier’s Manual for First Aid FM 21-11

Basic Cold Weather Manual FM 31-70

Northern Operations FM 31-71

Army Motor Transport Units and Operators FM 55-30

Desert Operations (How to Fight) FM 90-3

Operational Symbols FM 101-5-1

C-5. SUPPLY BULLETIN

Storage Serviceability Standard – Tracked Vehicles, Wheeled SB 740-98-1

Vehicles, and Component Parts

C-6. TECHNICAL BULLETINS

Equipment Improvement Report and Maintenance Digest (US Army TB 43-001-39-Series

Tank-Automotive Command) Tank-Automotive Equipment

Color, Marking, and Camouflage Painting of Military Vehicles, TB 43-0209

Construction Equipment, and Materiels Handling Equipment

Maintenance in the Desert TB 43-0239

Use of Antifreeze and Cleaning Compounds in Engine Cooling Systems TB 750-651

Inspection, Use and Tightening of Metal Fasteners Used on TB 43-0218

Tank-Automotive Equipment

C-7. TECHNICAL MANUALS

Unit Maintenance, Direct Support and General Support Maintenance, TM 5-3805-280-24-1

Hydraulic Excavator, John Deere Model 230LCR/230LCRD TM 5-3805-280-24-2

Chemical, Biological, and Radiological (CBR) Decontamination TM 3-220

Inspection, Care, and Maintenance of Antifriction Bearings TM 9-214

Care and Use of Hand Tools and Measuring Tools TM 9-243

Materials Used for Cleaning, Preserving, Abrading, and Cementing TM 9-247

Ordnance Materiel and Related Items Including Chemicals

Tool Outfit Hydraulic System Test and Repair Unit (HYSTRU) TM 9-4940-468-13

Operator, Unit, Direct Support, and General Support Maintenance TM 9-6140-200-14

Manual for Lead Storage Batteries

Preparing Hazardous Materials for Military Air Shipments TM 38-250

TM 5-3805-280-10
C-3

Principals of Automotive Vehicles TM 9-8000

Painting Instructions for Field Use TM 43-0139

Procedures for Destruction of Tank-Automotive Equipment to TM 750-244-6

Prevent Enemy Use

C-8. OTHER PUBLICATIONS

Army Logistics Readiness and Sustainability AR 700-138

Expendable/Durable Items (Except Medical, Class V, Repair Parts, CTA 50-970

and Heraldic Items)

Abbreviations and Acronyms ASME Y14.38M

C-9. WEB SITES

Military Traffic Management Command (MTMC) http://www.tea.army.mil

Logistical Support Activity (LOGSA) http://www.logsa.army.mil

US Army Tank-Automotive and Armaments Command (TACOM) http://www.tacom.army.mil

TM 5-3805-280-10
TM 5-3805-280-10

BLANK

C-4
By order of the Secretary of the Army:

ERIC K. SHINSEKI

General United States Army

Chief of Staff

Official:

JOEL B. HUDSON

Administrative Assistant to the

Secretary of the Army

9930501

Distribution: To be distributed in accordance with Initial Distribution Number (IDN)

256560, requirements for TM 5-3805-280-10.




THE METRIC SYSTEM AND EQUIVALENTS
PIN: 077618-000