48747686-tm-5-3805-293-10-motor-grader-120m.pdf

TM 5-3805-293-10TECHNICAL MANUAL

OPERATOR'S MANUALFOR

MOTORIZED ROAD GRADERMODEL 120M

(NSN 3805-01-560-2384)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

DECEMBER 2010&'()��*+,�"(-'./

This page is blank.

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WARNING SUMMARY -

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

FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS 0000

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

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

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

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

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

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

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

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

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

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

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GENERAL SAFETY WARNING DESCRIPTION 0000

WARNING

120M MOTOR GRADER OPERATION 0000

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

WARNING

COMPRESSED AIR 0000

Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) when using compressedair. Failure to follow this warning may result in injury or death to personnel.

WARNING

HEARING PROTECTION 0000

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

WARNING

HEAVY COMPONENTS 0000

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

WARNING

HOT COMPONENTS 0000

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

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GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

SLAVE STARTING ENGINE 0000

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

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

– DO NOT proceed if suitable cable is not available.

– DO NOT use civilian-type jumper cables.

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

Failure to follow these warnings may result in injury or death to personnel or damage to equip-ment.

EXPLANATION OF HAZARDOUS MATERIALS ICONS 0000

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

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

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

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

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

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

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GENERAL SAFETY WARNING DESCRIPTION 0000

WARNING

BATTERIES 0000

• To avoid injury, eye protection and acid-resistant gloves must be worn when working aroundbatteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources aroundbatteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove alljewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal,a direct short will result in instant heating or electric shock, damage to equipment, and injury topersonnel.

• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makescontact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects.Failure to follow these procedures may result in death or injury to personnel.

– EYES. Flush with cold water for no less than 15 minutes and seek medicalattention immediately.

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

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

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

– CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals, and relatedaccessories contain lead and lead components. These chemicals are known tothe State of California to cause cancer and reproductive harm. Wash hands afterhandling.

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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!! 0000

• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body ofoxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms ofheadache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent braindamage or death can result from severe exposure.

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

– DO NOT operate engine in enclosed areas.

– DO NOT idle engine without adequate ventilation.

– BE ALERT for exhaust poisoning symptoms. They are:

• Headache

• Dizziness

• Sleepiness

• Loss of muscular control

– If you see another person with exhaust poisoning symptoms:

• Remove person from area.

• Expose to fresh air.

• Keep person warm.

• DO NOT permit physical exercise.

• Administer Cardiopulmonary Resuscitation (CPR) if necessary.

• Notify a medic.

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

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

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION!

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WARNING

CARC PAINT 0000

• The following must be done before grinding, cutting, or welding any equipment that has been CARC-coated:

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

– Use high-efficiency air purifying respirators when grinding or sanding CARC-coated equipment.

– Never weld or cut CARC-coated equipment; grind or sand off CARC paintcompletely before welding.

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

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

WARNING

HAZARDOUS WASTE DISPOSAL 0000

• When servicing this equipment, performing maintenance, or disposing of materials such as engine/hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safetyoffice for local regulatory guidance.

• Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills.


WARNING

HYDRAULIC SYSTEM PRESSURE 0000

• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down andhydraulic system pressure has been relieved. Tighten all connections before applying pressure.Escaping hydraulic fluid under pressure can penetrate skin.

• Use a piece of cardboard, newspaper, or wood to check for pressurized leaks, to prevent fluid pene-trating the skin.


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WARNING

CBRN EXPOSURE 0000

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

To order this CBRN decal use:National Stock Number (NSN) - 7690-01-474-3533

Part Number (PN) - 1709220Commercial and Government Entity Code (CAGEC) - 11083

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WARNING

SOLVENT CLEANING COMPOUND 0000

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

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LIST OF EFFECTIVE PAGES/WORK PACKAGES -

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You can help improve this publication. If you find any errors, or if you would like to recommend anyimprovements to the procedures in this publication, please let us know. The preferred method is to submit yourDA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the ArmyElectronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and clickon SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and bettermanage the DA Form 2028 program. You may also mail, E-mail, or fax your comments or DA Form 2028 directlyto the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM LifeCycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL61299-7630. The E-mail address is [email protected]. The fax number is DSN 793-0726 orCommercial (309) 782-0726.

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TABLE OF CONTENTS -

WP Sequence No.-

Page No.-

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Chapter 1 - General Information, Equipment Description, and Theory of OperationGeneral Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003

Chapter 2 - Operator InstructionsDescription and Use of Operator Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007Stowage and Decal/Data Plate Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008

Chapter 3 - Troubleshooting ProceduresTroubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009Operator Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011

Chapter 4 - PMCS InstructionsPreventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013

Chapter 5 - Maintenance InstructionsAir Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014Blade Lift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015Brake Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016Centershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021Fuel/water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025Scarifier Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026Scarifier Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029

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

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HOW TO USE THIS MANUAL -

NOTEIf at any time you are unsure how to use this manual or you cannot locate the information youneed, notify your supervisor.

INTRODUCTION

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

2. This manual is written in work package format:a. Chapters divide the manual into major categories of information: General Information, Equipment

Description, and Theory of Operation; Operator Instructions; Troubleshooting Procedures; PreventiveMaintenance Checks and Services (PMCS) Instructions; Maintenance Instructions; and SupportingInformation.

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

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

CONTENTS OF THIS MANUAL

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

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

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

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

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

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

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

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

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FEATURES OF THIS MANUAL

1. This manual contains information on operating and maintaining the 120M Motorized Road Grader.2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are titled in BOLD print

as a visual aid.

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

CAUTIONA CAUTION is a reminder of safety practices or directs attention to usage practices that may resultin damage to equipment.

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

3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.4. Within a procedural step, reference may be made to another chapter or work package in this manual or to

another manual. These references indicate where you should look for more complete information. If you areinstructed to: “Replace air filter (WP 0014)”, go to WP 0014 in this manual for instructions on air cleanerreplacement.

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

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

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

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

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

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CHAPTER 1

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

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0001-1

0001

OPERATOR MAINTENANCE -

0 0 0 1 GENERAL INFORMATION

SCOPE 0001

1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the 120M Motor Grader.

2. Model Numbers and Equipment Names. Grader, Road, Motorized, Diesel Engine Driven (DED), Heavy, Commercial Construction Equipment (CCE) Model 120M.

3. Purpose of Equipment. The 120M Motor Grader is used for rough and finished grading, low and high bank sloping, flat and V-ditching, scarifying bituminous road mixes, and snow removal. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, site preparation for pipeline, and river crossing.

MAINTENANCE FORMS, RECORDS, AND REPORTS 0001

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001

If your 120M Motor Grader needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. (E-Mail: [email protected]) We will send you a reply. The preferred method for submitting Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. If the above method is not available to you, put it on an SF 368 (Product Quality Deficiency Report), and mail it to us at: Department of the Army, U.S. Army Tank-automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000.

CORROSION PREVENTION AND CONTROL (CPC) 0001

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM750-8, TAMMS Users Manual.

OZONE DEPLETING SUBSTANCES 0000 00

There are no ozone depleting substances contained on the machine or used during machine maintenance.

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.

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0001-2

0001

PREPARATION FOR STORAGE OR SHIPMENT 0001

General 0001

1. This work package contains requirements and procedures for administrative storage of equipment that is issued to and in use by Army activities worldwide.

2. The requirements specified herein are necessary to maintain equipment in administrative storage in such a way as to achieve the maximum readiness condition.

3. Equipment that is placed in administrative storage should be capable of being readied to perform its mission within a 24-hour period, or as otherwise may be prescribed by the approving authority. Before equipment is placed in administrative storage, a current PMCS should be completed and deficiencies corrected.

4. Report equipment in administrative storage as prescribed for all reportable equipment.5. Perform inspections, maintenance services, and lubrication as specified herein.6. Records and reports to be maintained for equipment in administrative storage are those prescribed by DA PAM

750-8 for equipment in use.7. A 10 percent variance is acceptable on time used to determine the required maintenance actions.8. Accomplishment of applicable PMCS, as mentioned throughout this work package, will be on a semiannual

basis.

Definition of Administrative Storage 0001

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

Preparation of Equipment for Administrative Storage 0001

Storage Site 0001

1. Select the best available site for administrative storage. Separate stored equipment from equipment in use. Conspicuously mark the area “ADMINISTRATIVE STORAGE.”

2. Covered space is preferred.3. Open sites should be improved hardstand, if possible. Unimproved sites should be firm, well drained, and free

of excessive vegetation.

Storage Plan 0001

1. Store equipment to provide maximum protection from the elements and to provide access for inspection, maintenance, and exercising. Anticipate removal or deployment problems and take suitable precautions.

2. Take into consideration environmental conditions, such as extreme heat or cold, high humidity, blowing sand, or loose debris, soft ground, mud, heavy snows, or any combination thereof, and take adequate precautions.

3. Establish a fire plan and provide for adequate fire fighting equipment and personnel.

Maintenance Services and Inspection 0001

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

in storage.

0001-3

TM 5-3805-293-10 0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

Correction of Shortcomings and Deficiencies 0001

Correct all shortcomings and deficiencies prior to storage, or obtain a deferment from the approving authority.

Lubrication. Lubricate equipment in accordance with LO 5-3805-293-13. 0001

General Cleaning, Painting, and Preservation 0001

CAUTIONDo not direct water or steam, under pressure, against electrical wires or any exterioropening. Failure to follow this caution may result in damage to equipment.

1. Cleaning. Clean all equipment for dirt, grease, and other contaminants in accordance with applicable provisions of this manual. Do not use vapor degreasing. Remove foreign objects that are wedged in tire treads.

WARNING

Chemical Agent Resistant Coating (CARC) paint debris may be consideredenvironmentally hazardous during removal. Consult local procedures prior to removal ofCARC paint to ensure compliance with local laws. Failure to follow these warnings mayresult in injury or death to personnel.

2. Painting. Remove rust and damaged paint by scraping, wire brushing, sanding, or buffing. Sand to a smooth finish and spot paint as necessary (TB 43-0209).

3. Preservation. After cleaning and drying, immediately coat unpainted wear surfaces with oil or grease, as appropriate.

NOTE• Place a piece of barrier material between desiccant bags and metal surfaces.• Air circulation under draped covers reduces deterioration from moisture and heat.

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

BII Items 0001

1. Process BII items simultaneously with the major item to which they are assigned.2. If possible, store BII items with the major item.3. If stored apart from the major item, mark BII items with tags indicating the major item, its registration or serial

number, and location, and store in protective-type closures. In addition, place a tag or list indicating the location of the removed items in a conspicuous place on the major item.

Maintenance Services 0001

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

0001-4

TM 5-3805-293-10 0001


Inspection 0001

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

Repair During Administrative Storage 0001

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

Exercising 0001

Exercise equipment in accordance with Table 1 and the following instructions:1. Vehicle Major Exercise. Depreserve equipment by removing only that material restricting exercise. Close all

drains, remove blocks, and perform all BEFORE operational checks. Make several right and left 90-degree turns. Make several hard-braking stops without skidding. While exercising, and when it is convenient and safe, operate all functional components such as moldboard, drawbar, scarifier, front wheel tilt, articulation, and all wheel drive. Perform all DURING and AFTER operational checks.

2. Scheduled Services. Scheduled services will include inspection per Inspection in this work package, and will be conducted in accordance with PMCS (WP 0013). Lubricate in accordance with instructions in LO 5-3805-293-13.

3. Corrective Action. Immediately take action to correct shortcomings and deficiencies noted. Record inspection and exercise results on DA Form 2404 or DA Form 5988E. Record and report all maintenance actions on DA Form 2407. After exercising, restore the preservation to the original condition. Replenish lubricants used during exercising and note the amount on DA Form 2408.

Rotation 0001

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

Table 1. Exercise Schedule.

Weeks 01 2 01 4 01 6 01 8 01 10 01 12 01 14 01 16 01 18 01 20 01 22 01 24 01

Scheduled Services01 X

Major Exercise 01 X

0001-5

TM 5-3805-293-10 0001


Procedures for Common Components and Miscellaneous Items 0001

Tires 0001

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

Seals 0001

Seals may develop leaks during storage or shortly thereafter. If leaking persists, notify Field Level Maintenance.

Removal of Equipment from Administrative Storage 0001

Activation 0001

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

Servicing 0001

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

Preparation of Equipment for Shipment 0001

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

TM 5-3805-293-10

0001-6

0001


CAUTIONTurbocharger may spin when engine is off due to air flow past grader exhaust pipe.

Rotation of turbocharger without engine operation may result in damage to turbocharger.

6. Cover exhaust opening. 7. Chock grader tires.8. Secure grader with tiedowns.

Figure 1. Tiedown Locations. 0001

9. Refer to FM 4-01.41 Army Rail Operations for additional instructions on processing, storage, and shipment of materiel.

10. Graders that have been removed from storage for shipment do not have to be reprocessed if they will reach their destination within the administrative storage period. Reprocess only if inspection reveals any corrosion or if anticipated in-transit weather conditions make it necessary.

11. When a grader is received that has already been processed for domestic shipment, as indicated on DD Form 1397, the grader does not have to be reprocessed for storage unless corrosion and deterioration are found during the inspection upon receipt. List on SF Form 364 all discrepancies found because of poor preservation, packaging, packing, marking, handling, loading, storage, or excessive preservation. Repairs that cannot be handled by the receiving unit must be annotated on DA Form 5988E or DA Form 2404 and reported to Field Level Maintenance.

0001-7

TM 5-3805-293-10 0001

WARRANTY INFORMATION 0001

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

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

Table 2. Warranty Information.

WarrantedComponent

Duration of Commercial Warranty

Manufacturer Responsible

ContactInformation

Base Machine (1) 1 Year/Unlimited Hours (1)

Caterpillar Inc.Defense and Federal ProductsPhone 309-578-3295

Ground Engaging Tools (GET)

Not limited by time

Caterpillar Battery (2) 3 Years (2)

Engine Emission Components (3)

5 Year/3,000 Hours (3)

Warranty - See Separate Manufacturer’s Warranty Statements

Tires (4) 5 Years (4) Bridgestone/Firestone Phone 800-572-8905

Tires (4) 5 Years (4) Michelin Phone 877-574-8473

TM 5-3805-293-10

0001-8

0001

LIST OF ABBREVIATIONS/ACRONYMS 0001

NOTERefer to ASME Y14.38-2007, Abbreviations and Acronyms, for standard abbreviations.

ABBREVIATION/ACRONYM DEFINITION

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AmpereAAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American RailroadsABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Braking SystemA/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air ConditioningBII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue ItemB.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BlackoutC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CelsiusCAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity CodeCBRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological, Radiological, NuclearCCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CounterclockwiseCID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacementcm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CentimeterCOEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component of End ItemCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United StatesCPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Corrosion Prevention and ControlCPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cardiopulmonary ResuscitationCSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Structural Framecu ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Footcu m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic MeterCW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockwiseDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct CurrentECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control ModuleECPC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Clutch Pressure ControlECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control UnitEIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement RecommendationEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Monitoring SystemF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FahrenheitFOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Falling Object Protective Structureft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Footgal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GallonGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabarit International de ChargementHVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heating, Ventilation, and Air ConditioningI.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identificationin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inchkg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogramkm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer

0001-9

TM 5-3805-293-10 0001

LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED 0001

ABBREVIATION/ACRONYM DEFINITION

kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascalkm/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per HourkW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KilowattL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LiterLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Shiplb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Poundlb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Footlb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-InchLCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal DisplayLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Emitting Diodem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Metermin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minutemm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MillimeterMOPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mission Oriented Protective PostureMOS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Military Occupational Specialtymph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miles per HourNATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty OrganizationNBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and ChemicalNm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton-meterNSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Stock NumberOCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United StatesPMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and ServicesPQDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Reportpsi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds per Square Inchpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PintROC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated Operating CapacityROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective StructureRO/RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-offrpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions per MinuteSAHR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Applied Hydraulically ReleasedSDDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution CommandSEABEE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naval Construction Engineer, Sea BargeSPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Special Purpose KitTAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management SystemTOE/MTOE . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and EquipmentU/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit of MeasureUV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ultra VioletV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VoltWCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim ActionWP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Package

0001-10

TM 5-3805-293-10 0001

ELECTROMAGNETIC PULSE (EMP) EXPOSURE 0001

Components designated as EMP susceptible may be damaged by EMP exposure. If the machine is exposed to an EMP incident, verify proper operation and repair as necessary.

THREAT OF CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) CONTAMINATION 0001

1. The 120M Motor Grader incorporates a CARC painted exterior. Materials used in the machine are metal, rubber, plastic, fabric, and glass.

2. In the event of CBRN contamination, see FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination.

COMMON TOOLS AND EQUIPMENT 0001

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Dura-ble Items, as applicable to your unit.

END OF WORK PACKAGE

TM 5-3805-293-10

0002-1

0002


0 0 0 2 EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002

1. The 120M Motor Grader provides the Army with the capability of rough and finished grading, low and high bank sloping, flat and V-ditching, scarifying, mixing bituminous road mixes, and snow removal. Mission support role includes construction and maintenance of roads, airfields, hardstands, drainage, and site preparation for pipeline and river crossing.

2. The 120M Motor Grader has excellent maneuverability; fast, precise blade control without drift; superior visibil-ity, convenience, and safety; and an advanced cab design featuring joysticks for control.

8

TM 5-3805-293-10

0002-2

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002

Figure 1. 120M Motor Grader (Left Side). 0002

KEY COMPONENT DESCRIPTION

1 Operator Cab Location of operator controls.

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

3 Exhaust Pipe Directs exhaust fumes away from machine.

4 Air Cleaner Removes debris from air entering engine.

5 Left Front Access Door Provides access to coolant tank, circuit breakers, engine air fil-ters, engine oil level gauge, transmission oil level gauge and transmission oil filler tube.

6 Left Rear Access Door Provides access to NATO slave receptacle, battery disconnect switch, and hydraulic tank sight gauge.

7 Blade Side Shift Cylinder Extends and retracts blade horizontally.

0002-3

TM 5-3805-293-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. 120M Motor Grader (Left Side). 0002


1 Turn Signal Flashes to indicate direction machine intends to turn.

2 Headlights Provide light forward of machine.

3 Work Lights Provide illumination of blade/work area.

4 Side View Mirror Provides view toward rear and side of machine.

5 Grab Handle Provides a hand-hold for cab entry and exit.

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

7 Fuel Tank Fuel storage.

8 Filler Neck and Cap Provide means to fill fuel tank and seal tank.

9 Blackout Driving Light Used when operating in blackout mode.

10 Scarifier Shank Stowage Rack Provide stowage capability for up to five scarifier shanks.

TM 5-3805-293-10

0002-4

0002


Figure 3. 120M Motor Grader (Right Side). 0002


1 Rear Blackout Lights Provide illumination during blackout mode.

2 Rear Work Lights Provide illumination behind machine.

3 Right Rear Access Door Provides access to batteries and refrigerant condenser.

4 Right Front Access Door Provides access to refrigerant compressor

5 Right Front Access Panel Provides access to engine drive belt.

6 Emergency Exit Provides an emergency exit for operator.

7 Work Lights Provide illumination of blade/work area.

0002-5

TM 5-3805-293-10 0002


Figure 4. 120M Motor Grader (Right Side). 0002


1 Radiator Provides cooling for engine coolant.

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

3 Blade Lift Cylinders Raise and lower each side of blade independently.

4 Scarifier Hydraulic Cylinder Raises and lowers scarifier.

5 Scarifier Link Rods Link rods with adjustable height setting.

6 Scarifier Used for breaking up material.

7 Moldboard/Blade Hydraulically controlled with replaceable end bits and cutting edges.

8 End Bit Replaceable outer edges of blade.

9 Tandem Housing Houses drive gears for tandem wheels.

10 Rear Hitch Pin Attachment point for towing.

TM 5-3805-293-10

0002-6

0002

EQUIPMENT DATA 0002

LengthOverall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ft 10 in. (8.49 m)

WidthOverall (blade perpendicular with centerline of machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ft. (3.767 m)Outside front tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 4 in. (2.54 m)Outside rear tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 5 in. (2.56 m)

Wheelbase (centerline of front tire to centerline of rear tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ft. 10 in. (6.7 m)Height

Top of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ft. 0 in. (3.4 m)Top of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft. 9 in. (3.3 m)Top of exhaust stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 7 in. (2.9 m)Top of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 9 in. (3.0 m)

Weight (approximate operating)Without Armor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,080 lb (17,726 kg)With Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000 lb (20,412 kg)

EngineManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CaterpillarModel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6.6Variable Horsepower (VHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 to 153 HPEngine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 RPMCylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 cu. in. (6.6 L)Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct InjectionCooling system (thermostat opening temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 180°F (70 to 82�C)

Cooling system (thermostat completely open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203�F (95�C)Transmission

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CaterpillarType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 speeds forward, 6 reverse CZM1-UPRange selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction trigger and gear selection buttons on left joystick

Front Axles

Wheel lean angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18�Rear Axle

Tandem axle spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ft 11.5 in. (1.5 m)

0002-7

TM 5-3805-293-10 0002

EQUIPMENT DATA – CONTINUED

Service BrakesType. . . . . . . . . . . . . . . . . . . . . Multiple disc, oil bathed, hydraulically activated, located at each tandem wheel

Parking BrakesType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple disc, spring applied, hydraulically released

TiresType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TubelessSize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.00R 24 12PR (G-2)

InflationWithout Armor Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 psi (241 kPa)Rear – All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa)With Armor Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa)Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 psi (379 kPa)

SteeringType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HydraulicTurning Radius (frame fully articulated, front wheels NOT leaning) . . . . . . . . . . . . . . . . . . . . 26 ft. 9 in. (8.2 m)Steering Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.5� Articulation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20�

Service Refill CapacitiesFuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 gal. (341 L)Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 gal. (33 L)Engine crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 gal. (15.5 L)Hydraulic system (tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17.1 gal. (64.6 L)Transmission and differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 gal. (53 L)Tandem housing (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.0 gal. (56.8 L)All-wheel drive gearbox (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 gal. (7 L)Front wheel spindle bearing housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.13 gal. (0.5 L)Circle drive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8 gal. (7.0 L)

Electrical SystemBatteries

Quantity Without Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Quantity With Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Volt DCSystem voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Volt DC

Blade Range Circle centershift

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm)Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm)

Blade Sideshift Hydraulic

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 in. (660 mm)Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 in. (510 mm)

TM 5-3805-293-10

0002-8

0002

EQUIPMENT DATA – CONTINUED

Blade Lift (maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8 in. (427 mm)Blade Shoulder Reach (maximum)

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in. (190.5 cm)Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.6 in. (174.2 cm)

Maximum Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3 in. (72 cm)Hydraulic Blade Tip

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40°Rearward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5°

END OF WORK PACKAGE

TM 5-3805-293-10

0003-1

0003

INTRODUCTORY INFORMATION -

0 0 0 3 THEORY OF OPERATION

INTRODUCTION 0003

1. The 120M Motor Grader consists of the following functional systems: engine, powertrain, brakes, electrical, steering, and hydraulics.

2. This work package explains how the systems and components of the machine work together. A functional description is provided for each major component and system.

3. The 120M Motor Grader is an all-purpose, medium sized, wheeled vehicle used for spreading and evening various types of granular material (dirt, stone, sand, etc.). Power is provided by a Caterpillar in-line, six-cylinder, direct injected, diesel engine. Hydraulically operated implements allow blade positioning for forward or backward grading, ditch or embankment grading, and snow removal. A scarifier allows loosening of compacted material prior to grading. Front leaning wheel and frame articulation provide maximum maneuverability. The grader has a sound-suppressing Rollover Protective Structure (ROPS) cab with insulation, heater, and windows, which allows for all-weather operation.

6

0003-2

TM 5-3805-293-10 0003

ENGINE 0003

1. General. The grader is equipped with a Caterpillar C6.6 Acert VHP turbocharged diesel engine with six in-line cylinders, generating 153 horsepower @ 2,000 RPM.

2. Fuel System. Diesel fuel is drawn from the tank by a fuel transfer pump, filtered by a primary fuel filter, routed to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzles into the engine cylinders. Air is drawn in through dry-type, replaceable filter elements. A check valve removes incoming dust from the air and routes it out through the exhaust system. The air is routed from the filter assembly to the turbocharger which pressurizes the air and sends it to the air-to-air aftercooler. The aftercooler, located near the radiator, reduces the air temperature making it denser. The denser air charge allows for more air and fuel to be combusted per engine cycle, increasing engine output power.

3. Cooling System. Provides coolant to the engine. Coolant is circulated through the engine by a gear-driven water pump. The hydraulic oil cooler is located in front of the radiator. The engine oil cooler is integral to the engine. The transmission oil cooler is located behind an access cover below the left front access door.

4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan. The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head.

5. Exhaust System. The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow into exhaust pipes and a muffler to the atmosphere behind the cab.

Figure 1. Engine Components. 0003

0003-3

TM 5-3805-293-10 0003

ENGINE – CONTINUED

Figure 2. Engine Components. 0003

TM 5-3805-293-10

0003-4

0003

POWERTRAIN 0003

1. Transmission. Eight speeds are provided in forward and six in reverse. A transmission modulator control (inching pedal) disengages the transmission from the drive wheels. Inching allows the operator to vary the machine ground speed while keeping engine speed high for quick implement response.

2. Rear Axle Differential and Lock Differential. A four-wheeled tandem rear axle arrangement houses axle shafts driven by a lock-unlock equipped differential. The axle shafts turn the final drive sprocket chains through planetary reduction gears. The sprocket chains then drive the final drive sprockets.

3. Final Drive Assembly. The sprocket chains drive the final drive sprockets and axle shafts which turn the rear wheel spindles inside the tandem axle housing.

Figure 3. Powertrain Components. 0003

0003-5

TM 5-3805-293-10 0003

BRAKES 0003

1. General. The oil-bathed, multiple-disc service brakes are hydraulically activated. Each tandem wheel end contains a service brake unit. A brake wear indicator is easily accessible for checking brake wear. A compensator maintains consistent brake performance.

2. Service Brakes. A foot pedal is used for engaging multiple disc brake assemblies for each wheel within the tandem and spindle housings.

3. Parking Brakes. Multiple oil-bathed disc-type located in the transmission case. Electrically actuated by an ON/OFF switch on the right side of the instrument panel, the parking brake is spring applied and hydraulically released. The parking brake is integrated into the Operator Presence System to prevent unintended machine movement while the operator is not in the cab seat.

4. Brake Accumulators. Two brake accumulators, located behind the cab, assist in applying the service brakes. The accumulator remains charged even after the engine is shut down and provides limited braking ability.

Figure 4. Brake Components. 0003

0003-6

TM 5-3805-293-10 0003

ELECTRICAL 0003

1. The electrical system, interruptible by a lockable battery disconnect switch, consists of two 12V batteries con-nected in series with negative grounding, providing 24V to operate the electrical systems and components.

2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate the machine, including a NATO slave receptacle.

3. The major systems comprising the electrical system are:a. Starting system.b. Charging systems.c. Messenger display system.d. Service, work, and blackout lights.

HYDRAULICS 0003

1. General. The hydraulic system is comprised of a single fluid tank, an implement and steering pump, a brake and hydraulic fan pump, a secondary steering pump, and a set of bank valves to distribute hydraulic fluid pressure to the various hydraulically activated systems (braking, steering, articulation, wheel lean, and earth moving components). The system also contains various control valves, check valves, sensors, and accumulators to maintain correct pressures. The fluid tank with a sight glass to check fluid level is located behind the left rear access door. A hydraulic fluid cooler is located in front of the radiator.

2. Steering System. The steering system utilizes hydraulic pressure produced by the implement and steering pump to actuate steering cylinders. An electric secondary hydraulic steering pump, located below the cab, provides hydraulic steering pressure in the event of implement and steering pump failure.

3. Steering Cylinders. There are two steering cylinders mounted at the front axle that turn the front wheels. The cylinders are powered by the hydraulic system and controlled by the steering pump and joystick controls.

4. Wheel Lean Cylinder. The wheel lean cylinder is mounted on the right side of the front axle. It is powered by the hydraulic system and controlled by a switch on the left joystick. The function of the wheel lean cylinder is to set the front wheels at an angle. This counteracts blade pressure exerted sideways against the front wheels when grading or moving heavy material. The wheel lean cylinder also sets front wheel angle to prevent the front of the machine from slipping sideways and downward when the machine is moving across a slope.

5. Ground Engagement Tools. The scarifier height, blade height, rotation, tilt, sideshift, centershift, and angle are all hydraulically powered and controlled using joysticks and joystick controls.

6. Brake System. The service brakes are hydraulically activated by pressing down on the foot pedal in the cab. Hydraulic pressure is provided by the engine driven fan and brake pump located behind the left front access door. The parking brake is spring actuated and hydraulically released via a switch located on the right side of the instrument panel activated by the operator.

7. All-Wheel Drive (AWD). All-wheel drive provides machine propulsion to the front tires when commanded by the operator. The AWD control is located on the right-side control panel. All-wheel drive can be operated in either CREEP or MANUAL mode by providing hydraulic fluid pressure to hydraulic motors at the front wheels. When in CREEP mode, the machine is propelled only by the front wheels. Speed in CREEP mode is variable from 0 to 5 mph (0 to 8 km/h). In MANUAL mode, the front wheels can be commanded to run at 99 percent, 100 percent, or 120 percent of rear wheel speed.

END OF WORK PACKAGE

TM 5-3805-293-10

CHAPTER 2

OPERATOR INSTRUCTIONS

TM 5-3805-293-10

0004-1

0004


0 0 0 4 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

GENERAL 0004

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

MAIN ENTRY AND EXIT 0004

Figure 1. Steps and Handhold – Main Entry and Exit. 0004


1 Handhold Provides hand grips for mounting and dismounting machine.

2 Steps Provide stepped platform for mounting and dismounting machine.

26

TM 5-3805-293-10

0004-2

0004

ALTERNATE EXIT 0004

Figure 2. Alternate Exit. 0004


1 Right Door Provides alternate exit from cab.

0004-3

TM 5-3805-293-10 0004

ARTICULATION LOCK PIN 0004

Figure 3. Articulation Lock Pin. 0004


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

2 Spring Rods Pull back on spring rod to release lock pin.

3 Lock Pin Storage Bracket Articulation lock pin stowage location during machine opera-tion.

0004-4

TM 5-3805-293-10 0004

WHEEL LEAN LOCK BOLT 0004

Figure 4. Wheel Lean Lock Bolt. 0004

0004

0004


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

2 Lean Bar (left side) Connects both front wheels to lean cylinder.

0004-5

TM 5-3805-293-10 0004

DOOR HANDLES AND LATCHES 0004

Figure 5. Door Handles. 0004


1 Outer Door Handle Unlatches door from outside cab.

2 Inner Door Handle Unlatches door from inside cab.

TM 5-3805-293-10

0004-6

0004

DOOR HANDLES AND LATCHES – CONTINUED

Figure 6. Door Latch and Release. 0004


1 Latch Assembly Secures open door to cab.

2 Remote Latch Release Unlatches door from inside cab.

0004-7

TM 5-3805-293-10 0004

SEAT 0004

Figure 7. Seat. 0004

KEY COMPONENT DESCRIPTION1 Lumbar Support Knob Rotate knob counterclockwise to increase stiffness of lumbar

support. Rotate knob clockwise to decrease stiffness.2 Fore/Aft Lever Pull up on lever to adjust seat forward or rearward. Release

lever to lock.3 Seat Height Lever Pull up on lever to adjust seat upward or downward. Release

lever to lock.4 Weight Adjustment Knob Rotate knob clockwise to increase height of seat. Rotate knob

counterclockwise to decrease seat height.5 Backrest Adjustment Lever Pull up on lever to adjust seat back lean angle. Release lever

to lock seat back.6 Seat Cushion Tilt Front of seat cushion is pinned in a groove. Grasp seat pan

and rotate “forward-up-and-back” to position seat into a steep angle.Grasp seat pan and rotate forward-down-and-back to position seat at normal angle.

TM 5-3805-293-10

0004-8

0004

SEAT BELT 0004

Figure 8. Retractable Seat Belt. 0004


1 Seat Belt (Retractable) Secures operator in seat.

0004-9

TM 5-3805-293-10 0004

WRIST RESTS, ARM PADS, AND CONTROL PODS 0004

Figure 9. Wrist Rests, Arm Pads, and Control Pods. 0004


1 Wrist Rest Height Adjustment Knob Pull wrist rest height adjustment knob to allow adjustment of wrist rest. Release knob to lock. Right side shown, left side similar.

2 Control Pod Fore/Aft Adjustment Lever

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

3 Arm Pad Adjustment Knob Turn knob counterclockwise to allow adjustment of arm pads. Turn knob clockwise to lock. Left side shown, right side similar.

4 Control Pod Vertical Adjustment Knob Turn knob counterclockwise to allow height adjustment of control pods. Turn knob clockwise to lock. Left side shown, right side similar.

TM 5-3805-293-10

0004-10

0004

JOYSTICK CONTROLS 0004

Figure 10. Left Joystick Controls. 0004


1 Downshift Switch Depress switch to downshift to desired gear in forward or reverse.

2 Wheel Lean Control - LEFT Press button to lean wheels left. Wheels will remain leaning after button is released.

3 Upshift Switch Depress switch to upshift to desired gear in forward or reverse.

4 Wheel Lean Control - RIGHT Press button to lean wheels right. Wheels will remain leaning after button is released.

5 Automatic Articulation Centering Control

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

0004-11

TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED


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

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

8 Blade Lower and Blade Float for Left Side

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

9 Blade Lift for Left Side Pull left joystick rearward to raise left end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position.

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

TM 5-3805-293-10

0004-12

0004

JOYSTICK CONTROLS – CONTINUED 0004

Figure 11. Right Joystick Controls. 0004

0004-13

TM 5-3805-293-10 0004



1 Blade Sideshift Control - LEFT Move right joystick left to sideshift blade to the left. When joystick is released, blade sideshift will remain in selected position. Joystick will return to HOLD position.

2 Blade Sideshift Control - RIGHT Move right joystick right to sideshift blade to the right. When joystick is released, blade sideshift will remain in selected position. Joystick will return to HOLD position.

3 Blade Lower and Blade Float for Right Side

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

4 Blade Lift for Right Side Pull right joystick rearward to raise right end of blade. When joystick is released, blade remains in selected position. Joystick returns to HOLD position.

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

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

7 Blade Pitch Control - FORWARD Push top of thumb button to pitch blade forward. When button is released, blade remains in selected position. Button returns to HOLD position.

8 Blade Pitch Control - BACKWARD Push bottom of thumb button to pitch blade backward. When button is released, blade remains in selected position. Button returns to HOLD position.

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

10 Horn Button Press to activate horn.

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

TM 5-3805-293-10

0004-14

0004


Figure 12. Joystick Controls. 0004


1 Throttle Resume/Decel Switch Pull trigger switch to resume engine speed previously selected.Hold trigger switch to decrease engine speed by approximately 100 RPM/per second held.Bump trigger switch to decrease engine speed in 100 RPM increments.

2 Differential Lock Control Push to engage or disengage differential lock. Locks differential to increase traction in soft or wet ground.

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

0004-15

TM 5-3805-293-10 0004

MID-MOUNT SCARIFIER CONTROL ROLLER AND ARCTIC HEATER SWITCH 0004

Figure 13. Mid-Mount Scarifier Control. 0004


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

2 Arctic Heater Switch Press button to activate and deactivate arctic heater.

TM 5-3805-293-10

0004-16

0004

FORWARD CONTROLS AND INDICATORS 0004

Figure 14. Forward Controls and Indicators. 0004


1 Centershift Lock Indicator Illuminates when centershift lock is DISENGAGED.

2 Secondary Steering Test Switch Allows operator to test secondary steering system.

3 Parking Brake Switch Engages and disengages parking brakes.

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

5 Accelerator Control Depress pedal to increase engine speed. Release pedal to decrease engine speed.

6 Service Brake Control Depress pedal to apply service brakes to slow or stop machine.

7 Transmission Modulator Control (Inching Pedal)

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

469-0018

0004-17

TM 5-3805-293-10 0004

RIGHT-SIDE CONTROL PANEL 0004

Figure 15. Right-Side Control Panel. 0004


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

2 Defroster Fan Switch Push top of switch to operate defroster fan at HIGH speed. Move switch to center position for MEDIUM speed. Push bot-tom of switch for LOW speed.

3 Blade Cushion Switch Machine not equipped with blade cushion option.

4 Power Port (12V) Remove cap to access port to power 12V electrical equipment or accessories.

5 Throttle Set/Accel Switch Allows operator to set speed of throttle.

6 Electrical Coolant Switch Push button to turn arctic heater ON. Push button again to turn OFF.

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

8 Hazard Flasher Switch Push top of switch to activate hazard flashers. Push bottom of switch to deactivate.

9 Front and Rear Worklight Switch Push top of switch to activate front worklights only. Push bot-tom of switch to activate front and rear worklights. Move switch to middle position to deactivate all worklights.

10 Headlight Dimmer Switch Push top of switch to activate high beams. Push bottom of switch to deactivate high beams; low beams remain ON.

TM 5-3805-293-10

0004-18

0004

ALL-WHEEL DRIVE (AWD) CONTROLS 0004

Figure 16. All-Wheel Drive Controls. 0004

.


1 All-Wheel Drive Control Controls speed (aggression) of front wheels when AWD is activated.

2 All-Wheel Drive Mode Switch Three-position switch used to engage all-wheel drive. Turn switch to left of center for CREEP mode. Turn switch to right of center for MANUAL mode. Turn switch to center position to turn off AWD.

3 Manual Mode Indicator Light Indicator illuminates when MANUAL mode is activated.

0004-19

TM 5-3805-293-10 0004

HEATING AND AIR CONDITIONING CONTROLS 0004

Figure 17. Heater and Air Conditioning Controls. 0004


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

2 Temperature Variable Control Adjust temperature from minimum (full left) to maximum (full right).

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

TM 5-3805-293-10

0004-20

0004

WIPER/WASHER CONTROLS 0004

Figure 18. Wiper/Washer Controls. 0004


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

2 Front Windshield Wiper/Washer Control

Operates the same as left door wiper/washer control.

3 Right Door Wiper/Washer Control Operates the same as left door wiper/washer control.

0004-21

TM 5-3805-293-10 0004

MONITORING SYSTEM 0004

Figure 19. Monitoring System. 0004

KEY COMPONENT DESCRIPTION1 Left Turn Signal Indicator Flashes when left turn signal is activated.2 Left Blade Float Indicator Illuminates when left blade float is activated.3 Battery Charge Alert Indicator Illuminates when a problem with machine voltage or alternator

is present.4 Electric Coolant Heater Alert Indicator Illuminates when coolant heater is activated.5 Engine System Alert Indicator Illuminates when an engine problem is present.6 Implement System Alert Indicator Illuminates when an implement system problem is present.7 Throttle Lock Indicator Illuminates when throttle lock is activated.8 Primary Steering Alert Indicator Illuminates when a steering system problem is present.9 Action Light Alert Indicator Illuminates when a problem occurs with machine.

10 Analog Tachometer Displays engine speed in revolutions per minute.11 Parking Brake Indicator Illuminates when parking brakes are engaged.12 Transmission System Alert Indicator Illuminates when a transmission system problem is present.13 Differential Lock Indicator Illuminates when differential lock is activated.14 Secondary Steering System Alert Indi-

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

15 High Beam Indicator Illuminates when high beams are activated.16 Brake System Indicator Illuminates when a general fault occurs in brake system. 17 Operator Not Present Alert Indicator Illuminates when under specific conditions operator is not in

cab.18 Right Blade Float Indicator Illuminates when right blade float is activated.19 Right Turn Signal Indicator Flashes when right turn signal is activated.20 Articulation Angle Gauge Indicates amount of right or left articulation.21 Fuel Level Gauge Indicates amount of fuel in tank.22 LCD Display Provides information on ground speed, actual gear and

direction, operator requested gear, service hour meter.23 Hydraulic Oil Temperature Gauge Indicates hydraulic oil temperature. Red area indicates oil

temperature above 199°F (93ºC).24 Coolant Temperature Gauge Indicates coolant temperature. Red area indicates coolant

temperature above 225ºF (107ºC).

TM 5-3805-293-10

0004-22

0004

MESSENGER DISPLAY AND IMPLEMENT LOCKOUT SWITCH 0004

Figure 20. Messenger Display and Implement Lockout Switch. 0004


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

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

0004-23

TM 5-3805-293-10 0004

MILITARY LIGHT SWITCH 0004

Figure 21. Military Light Switch. 0004


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

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

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

4 Panel Brightness Switch Not applicable to 120M.

0004-24

TM 5-3805-293-10 0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE 0004

Figure 22. Battery Disconnect Switch and Slave Receptacle. 0004


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

2 24V Slave Receptacle Connection for 24V slave start cable.

0004-25/(26 blank)

TM 5-3805-293-10 0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE – CONTINUED

Figure 23. Arctic Heater Fuel Shutoff Valve. 0004

END OF WORK PACKAGE


1 Arctic Heater Fuel Shutoff Valve Lever in horizontal position indicates valve is closed, shutting off fuel supply from tank.Lever in vertical position indicates valve is open, allowing fuel flow from tank to arctic heater.

TM 5-3805-293-10

0005-1

0005


0 0 0 5 OPERATION UNDER USUAL CONDITIONSScope; Initial Adjustment Before Use; Mounting and Dismounting; Seat, Seat Belt, and Control

Adjustments; Engine Starting and Machine Warm-up; Parking; Articulation Lock Pin Installation; Messenger Display; Machine Warning Summaries; Joystick Steering; Differential Lock Control;

Transmission Operation; Throttle Hold Mode Switch; Centershift Lock Switch; All-Wheel Drive (AWD); Slope Operation; Scarifier Operation

SCOPE 0005

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

(WP 0013).

INITIAL ADJUSTMENT BEFORE USE 0005

1. Perform all Before PMCS checks and services (WP 0013). 2. Pull back on spring rod and remove articulation lock pin from frame pocket. Stow in lock pin storage bracket

and engage spring rod to lock pin in place.3. If installed, remove wheel lean lock bolt (WP 0004). Stow in machine-mounted tool box.4. Turn battery disconnect switch to ON position (WP 0004).

END OF TASK

INITIAL SETUP

Tools and Special Tools 0

Strap, Tiedown (WP 0032, Item 18) 0

References 0

WP 0004 0

WP 0006 0

WP 0007 0

WP 0013 0

WP 0027 0

WP 0032 0

34

TM 5-3805-293-10

0005-2

0005

MOUNTING AND DISMOUNTING 0005

WARNING• Mount and dismount the machine only at locations that have steps and handholds.• Clean steps and handholds prior to mounting machine.• Face machine during mounting and dismounting.• Maintain three-point contact (two hands and one foot, or one hand and two feet) at all

times.• Do not mount or dismount a moving machine. • Do not jump off a moving machine. • Do not carry tools or supplies when mounting or dismounting machine. • Do not use any controls as handholds during mounting or dismounting.• Failure to follow these warnings may result in injury or death to personnel.

1. Open left door.2. Enter machine from left side and occupy operator’s seat.3. Close left door.

END OF TASK

SEAT, SEAT BELT, AND CONTROL ADJUSTMENTS 0005

1. Adjust operator’s seat (WP 0004).2. Grasp seat belt and pull out of retractor in one continuous motion, then insert catch into buckle. Seat belt

adjusts tension automatically. Make sure belt is positioned low across lap (WP 0004).3. Adjust wrist rests, control pods, and arm pads (WP 0004).4. With the aid of an assistant, adjust mirrors to obtain a clear view behind machine.

END OF TASK

0005-3

TM 5-3805-293-10 0005

ENGINE STARTING AND MACHINE WARM-UP 0005

WARNING

• CARBON MONOXIDE (EXHAUST GASES) CAN KILL!• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives

the body of oxygen and causes suffocation. Exposure to air containing carbon monoxideproduces symptoms of headache, dizziness, loss of muscular control, apparentdrowsiness, and coma. Permanent brain damage or death can result from severeexposure.

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

• DO NOT operate engine in enclosed areas.• DO NOT idle engine without adequate ventilation.• BE ALERT for exhaust poisoning symptoms. They are:

• Headache• Dizziness• Sleepiness• Loss of muscular control

• If you see another person with exhaust poisoning symptoms:• Remove person from area.• Expose to fresh air.• Keep person warm.• DO NOT permit physical exercise.• Administer Cardiopulmonary Resuscitation (CPR) if necessary.• Notify a medic.

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

• CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituentsare known to the State of California to cause cancer, birth defects, and other reproductiveharm.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

TM 5-3805-293-10

0005-4

0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED

WARNING

Hearing protection is required when standing within 26 ft (8 m) of the 120M Motor Graderwhile it is operating. Failure to wear hearing protection may result in hearing loss.

1. Check to make sure all bystanders are clear of machine before starting engine.2. Place transmission control switch in NEUTRAL (WP 0004).3. Engage parking brake (WP 0004).

WARNINGMonitoring system will perform an automatic self-diagnostic functional test wheneverengine start switch is turned to ON position. If action alarm does not sound or monitoringdisplays are not functioning, do not start or operate machine until cause has beencorrected. Failure to follow this warning may result in injury or death to personnel as anyWarning Category 3 notifications will not be relayed to operator.

NOTE• Automatic self-diagnostic functional test verifies outputs (gauges, alert indicators, and

alarms) are operating correctly. • Gauges must sweep to the far right of their scale and then back.• Alert indicators must come on momentarily. • All segments of the LCD must come on momentarily.• Action alarm must sound.

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

CAUTION• When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30

seconds. Allow starting motor to cool for two minutes before cranking again or damage tostarting motor or batteries may result.

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


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

NOTEIf engine fails to start, you must turn ignition switch to the OFF position, then back to ONand START.

5. Turn and hold engine start switch to START. Release when engine starts.

0005-5

TM 5-3805-293-10 0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED

6. Allow engine to run at low idle speed while observing engine system indicator or action light indicator. If either indicator comes on during warm-up, shut down engine immediately and notify Field Level Maintenance.

7. Continue to idle machine while monitoring hydraulic oil temperature on Messenger dIsplay. Only operate machine after hydraulic oil temperature is equal to or greater than 41°F (5°C). If necessary to raise hydraulic oil temperature, cycle all implement and steering controls to allow warm hydraulic oil to circulate through all hydraulic lines.

END OF TASK

PARKING 0005

Stopping Machine 0005

1. Choose a level surface to stop machine whenever possible.2. Decrease engine speed.3. Apply service brakes to slow machine. Apply transmission modulator pedal and service brakes to stop

machine (WP 0004).4. Place transmission control switch in NEUTRAL position (WP 0004).5. Engage parking brake (WP 0004).6. Lower scarifier to the ground and apply a slight downward pressure (WP 0004).7. Angle blade to either side, lower onto wood blocks and tilt forward.8. Lock out hydraulic controls by placing the hydraulic lockout switch in the LOCK position (WP 0004).

Stopping Engine 0005

CAUTIONStopping the engine immediately after it has been working under load can result inoverheating and accelerated wear of engine components.

1. Operate engine at low idle for five minutes to allow engine and components to cool gradually.2. Turn engine start switch to OFF (WP 0004).

Leaving Machine 0005

WARNINGUse caution and maintain three-point contact at all times when dismounting machine.Failure to follow this warning may result in injury or death to personnel.

1. Exit cab through left door.2. Use steps and hand holds to dismount. Face machine when dismounting (WP 0004).3. Perform all After PMCS (WP 0013).4. Turn battery disconnect switch to OFF (WP 0004).5. Secure machine against vandalism. Lock all covers and compartments.

Operator Presence System 0005

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

END OF TASK

TM 5-3805-293-10

0005-6

0005

ARTICULATION LOCK PIN INSTALLATION 0005

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

(Figure 1, Item 3).

Figure 1. Articulation Lock Pin in Storage Bracket. 005

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

6. Rotate pin until spring rod falls into detent in pin (Figure 2, Item 2).

Figure 2. Articulation Lock Pin Installed. 005

END OF TASK

0005-7

TM 5-3805-293-10 0005

MESSENGER DISPLAY 0005

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

Figure 3. Messenger Display 005

1. The digital display area (Figure 3, Item 1) displays system information.2. The OK button (Figure 3, Item 2) confirms selections after you have made them by scrolling with the Down/

Right button (Figure 3, Item 3) and the Up/Left button (Figure 3, Item 4).3. The Down/Right button (Figure 3, Item 3) is used to scroll down and/or right through information shown on the

digital display area (Figure 3, Item 1).4. The Up/Left button (Figure 3, Item 4) is used to scroll up and/or left through information shown on the digital

display area (Figure 3, Item 1).5. The Back button (Figure 3, Item 5) is used to return to information previously shown on the digital display area

(Figure 3, Item 1).6. The Implement Lockout switch (Figure 3, Item 6) locks and unlocks implement controls.

TM 5-3805-293-10

0005-8

0005

MESSENGER DISPLAY – CONTINUED

Performance Menu 0005

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

Figure 4. Performance Menu. 005

The following options are available through the Performance menu.a. ENGINE SPEED. When scrolling to this option, display shows engine speed in revolutions per minute

(RPM).b. MPH GROUND SPEED. When scrolling to this option, display shows ground speed in miles per hour

(mph) or kilometers per hour (km/h).c. ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant tem-

perature in degrees Fahrenheit (°F) or in degrees Celsius (°C).d. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot

point.e. FUEL LEVEL. When scrolling to this option, display shows amount of fuel remaining as a percentage of

full.f. HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature in degrees Fahren-

heit (°F) or in degrees Celsius (°C). g. REQ GEAR. When scrolling to this option, display shows gear that is selected by operator.h. ACTUAL GEAR. When scrolling to this option, display shows gear that is currently engaged in transmis-

sion.i. TOS. When scrolling to this option, display shows transmission output speed.j. TRANSMISSION OIL TEMPERATURE. When scrolling to this option, display shows transmission oil tem-

perature in degrees Fahrenheit (°F) or in degrees Celsius (°C). k. IMPLEMENT LOCKOUT SWITCH POSITION. When scrolling to this option, display shows position of

implement lockout switch.l. IMPLEMENT PILOT SUPPLY SOLENOID. When scrolling to this option, display shows status of imple-

ment pilot supply solenoid.

0005-9

TM 5-3805-293-10 0005


m. BLADE LEFT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of blade left lift cylinder float.

n. BLADE RIGHT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of blade right lift cylinder float.

o. SECONDARY STEERING SYSTEM TEST. When scrolling to this option, display shows status of second-ary steering system test.

p. SECONDARY STEERING REQUEST SIGNAL. When scrolling to this option, display shows secondary steering request signal.

q. CHARGE FILTER BYPASS STATUS. When scrolling to this option, display shows status of powertrain fil-ter bypass.

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

Totals Menu 0005

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

Figure 5. Totals Menu. 005

TM 5-3805-293-10

0005-10

0005


1. The following options are available through the Lifetime Totals sub-menu:a. FORWARD DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of

distance travelled in forward direction in miles or kilometers.b. REVERSE DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of distance

travelled in reverse direction in miles or kilometers.c. TOTAL FUEL. When scrolling to this option, display shows lifetime total of amount of fuel consumed by

machine.d. SERVICE HOURS. When scrolling to this option, display shows lifetime total of number of hours machine

has run.2. The following options are available through the Trip Totals sub-menu:

NOTETotal Fuel and Service Hours can be reset to zero from each of these screens.

a. TOTAL FUEL. When scrolling to this option, display shows amount of fuel consumed by machine since trip total has been reset.

b. SERVICE HOURS. When scrolling to this option, display shows total of number of hours machine has run since trip total has been reset.

3. The following option is available through the Trip Reset sub-menu:CLEAR TRIP TOTALS. When scrolling to this option, you can reset trip total values.

Settings Menu 0005

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

Figure 6. Settings Menu. 005

0005-11

TM 5-3805-293-10 0005


1. The following options are available through the Monitoring System sub-menu:a. LANGUAGE. Select this option to change display language.b. UNITS. Select this option to set the desired measurement system (English or Metric).c. CONTRAST ADJUST. Select this option to adjust display contrast to improve visibility. A bar graph is dis-

played to show level of contrast.d. BACKLIGHT ADJUST. Select this option to adjust brightness of Messenger display area, switch lights,

and instrument panel lights for better visibility. Headlights and/or taillights must be turned ON to make these adjustments. A bar graph is displayed to show level of brightness.

2. The following options are available through the Machine sub-menu:a. PRODUCT ID. Select this option to view product identification number.b. EQUIPMENT ID. Select this option to view equipment identification number.

3. The following options are available through the Transmission sub-menu:a. GEAR SELECTION. When scrolling to this option, display shows gear of transmission.b. TRANSMISSION INITIAL FORWARD GEAR. When scrolling to this option, display shows initial forward

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

gear.d. MIN FORWARD AUTOSHIFT GEAR. Not applicable.e. MIN REVERSE AUTOSHIFT GEAR. Not applicable.f. MAX FORWARD AUTOSHIFT GEAR. Not applicable.g. MAX REVERSE AUTOSHIFT GEAR. Not applicable.

NOTEThe following list shows Caterpillar approved lubricants. Refer to Expendable and DurableItems List (WP 0032) for lubricant options.

h. TRANSMISSION OIL TYPE.When scrolling to this option, display shows viscosity of oil in transmission.i. TDTO SAE 0W-20. When scrolling to this option, display shows Cat TDTO SAE 0W-20 oil type.j. TDTO SAE 0W-30. When scrolling to this option, display shows Cat TDTO SAE 0W-30 oil type (OEA-30).k. TDTO SAE 5W-30. When scrolling to this option, display shows Cat TDTO SAE 5W-30 oil type.l. TDTO SAE 10W. When scrolling to this option, display shows Cat TDTO SAE 10W oil type (OE/HDO-10).m. ARCTIC TDTO. When scrolling to this option, display shows Cat Arctic TDTO oil type (OEA-30).n. TDTO TMS. When scrolling to this option, display shows Cat TDTO TMS oil type.o. TDTO SAE 30. When scrolling to this option, display shows Cat TDTO SAE 30 oil type (OE/HDO-30).p. TDTO SAE 50. When scrolling to this option, display shows Cat TDTO SAE 50 oil type.

4. The following option is available through the Implement sub-menu:AUXILIARY POD STATUS. When scrolling to this option, display shows status of machine implements (enabled or not enabled).

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Service Menu 0005

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

Figure 7. Service Menu. 005

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

System Parameters Sub-Menu 0005

a. The following options are available through the Monitoring system sub-sub-menu:(1) BATTERY VOLTAGE. When scrolling to this option, display shows available battery voltage.(2) FUEL LEVEL. When scrolling to this option, display shows fuel tank fill level.(3) ALTERNATOR STATUS. When scrolling to this option, display shows status of alternator.

b. The following options are available through the Engine sub-sub-menu:(1) ENGINE RPM. When scrolling to this option, display shows engine speed in revolutions per minute.(2) DESIRED ENGINE RPM. When scrolling to this option, display shows desired engine speed in revolu-

tions per minute. (3) ENGINE OIL PRESSURE. When scrolling to this option, display shows engine oil pressure.(4) ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant

temperature.(5) FUEL PRS. When scrolling to this option, display shows fuel pressure.(6) AIR PRS. When scrolling to this option, display shows intake manifold air pressure.(7) AIR TEMP. When scrolling to this option, display shows intake manifold air temperature.(8) ATMOSPHERIC PRS. When scrolling to this option, display shows atmospheric pressure.

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

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

mission.(6) TRANSMISSION MODULATOR CONTROL (INCHING PEDAL) POS. When scrolling to this option,

display shows position of inching pedal.d. The following options are available through the Steering sub-sub-menu:

(1) STEERING CONTROL POS. When scrolling to this option, display shows position of steering control.(2) STEERING DUTY CYCLE. When scrolling to this option, display shows status of steering signal for

duty cycle.(3) LEFT CYL EXT. When scrolling to this option, display shows position of left steering cylinder.(4) RIGHT CYL EXT. When scrolling to this option, display shows position of right steering cylinder.(5) SECONDARY STEERING POS. When scrolling to this option, display shows position of secondary

steering test switch.(6) SECONDARY STEERING TEST. When scrolling to this option, display shows status of secondary

steering test.(7) SECONDARY STEERING SIGNAL. When scrolling to this option, display shows status of command

signal for the secondary steering.(8) SECONDARY STEERING RELAY. When scrolling to this option, display shows status of secondary

steering relay.e. The following options are available through the Implement sub-sub-menu:

(1) HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature.(2) HYD OIL PRS. When scrolling to this option, display shows main hydraulic oil pressure.(3) LOCKOUT POS. When scrolling to this option, display shows position of implement lockout switch.(4) PILOT SUPPLY. When scrolling to this option, display shows status of implement pilot supply solenoid.(5) BLADE LEFT LIFT POS. When scrolling to this option, display shows lift position for left side of blade.(6) BLADE LEFT LIFT CYL. When scrolling to this option, display shows status of blade float function for

left lift cylinder.(7) BLADE RIGHT LIFT POS. When scrolling to this option, display shows lift position for right side of

blade.(8) BLADE RIGHT LIFT CYL. When scrolling to this option, display shows status of blade float function

for right lift cylinder.(9) WHEEL LEFT LEAN POS. When scrolling to this option, display shows wheel lean (left) position.(10)WHEEL RIGHT LEAN POS. When scrolling to this option, display shows wheel lean (right) position.(11)PITCH FORWARD POS. When scrolling to this option, display shows blade pitch forward position.

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(12)PITCH BACKWARD POS. When scrolling to this option, display shows blade pitch backward position.(13)SIDESHIFT POS. When scrolling to this option, display shows position of blade sideshift.(14)CIRCLE LEFT SIDESHIFT POS. When scrolling to this option, display shows left position of circle

drawbar.(15)CIRCLE RIGHT SIDESHIFT POS. When scrolling to this option, display shows right position of circle

drawbar.(16)CIRCLE DRIVE POS. When scrolling to this option, display shows position of circle drive.(17)ARTICULATION POS. When scrolling to this option, display shows position of articulation joint.(18)AUTO ARTICULATION POS. When scrolling to this option, display shows status of automatic articula-

tion centering control.f. The following options are available through the Brake sub-sub-menu:

(1) PARK BRAKE SWITCH. When scrolling to this option, display shows status of parking brake switch.(2) BRAKE SOLENOID. When scrolling to this option, display shows status of parking brake solenoid.(3) PARK BRAKE PRS. When scrolling to this option, display shows status of parking brake pressure.(4) PARK BRAKE. When scrolling to this option, display shows park brake status (engaged or

disengaged).(5) SERVICE BRAKE. When scrolling to this option, display shows status of service brake pedal.

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

degrees Fahrenheit (ºF) or in degrees Celsius (ºC).

System Test Sub-Menu 0005

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

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System Information Sub-Menu 0005

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

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

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

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

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

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

Service Test Sub-Menu 0005

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

2. STEERING DEAD ENGINE.

NOTEPress OK when messenger displays NEXT.

a. NEXT. When scrolling to this option, display shows option to begin Steering Dead Engine test.b. Before test can be performed, the machine must meet the following conditions:

(1) No warnings for primary steering system.(2) No warnings for secondary steering system.(3) No warnings for implement systems.(4) Start switch in ON position.(5) Engine must be off.(6) Transmission must be in NEUTRAL.(7) Parking brake must be engaged.(8) Operator must be present.(9) Implements must be locked.

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

has started.d. When test begins, use left joystick to move front wheels. Secondary steering pump will be activated for a

maximum of ten seconds. To cancel test, press ABORT button on Messenger or turn start switch to the OFF position.

Calibration 0005

NOTEThe transmission fill calibration is to be performed by Field Level Maintenance only.Calibration could take up to 45 minutes to complete. If calibration is interrupted or aborted,old calibration numbers will remain.

TRANSMISSION FILL CALIBRATION. When scrolling to this option, display shows option to begin transmission fill calibration.

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Tattletale 0005

The following information is available through the Tattletale sub-sub-menu:a. TATTLETALE MODE ACTIVE. When scrolling to this option, display shows tattletale mode is active.b. OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature.c. ENGINE COOLANT TEMP. When scrolling to this option, display shows engine coolant temperature.d. ENGINE SPEED. When scrolling to this option, display shows engine speed.e. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot

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

END OF TASK

MACHINE WARNING SUMMARIES 0005

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

Warning Category 1 0005

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


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

Warning Category 2S 0005

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


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

END OF TASK

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JOYSTICK STEERING 0005

NOTEFailure to properly align left (steering) joystick causes inability to steer machine, inability todisengage parking brake, and inability to shift transmission out of NEUTRAL position.

Before operating machine, align left joystick in relation to steering angle of front wheels.1. Start engine.2. Move left joystick slowly and smoothly left or right to closely match steering angle of front wheels to synchro-

nize joystick to front wheels.3. During alignment, note the following conditions:

a. Joystick alignment event disappears from Messenger display.b. Steering system alert indicators not illuminated on monitoring system.c. Front wheels move with movement of left joystick.

END OF TASK

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DIFFERENTIAL LOCK CONTROL 0005

CAUTION• Do not engage the differential lock control at high speeds.• Do not turn machine with differential lock engaged.• Do not engage the differential lock control while one wheel is spinning. Decrease engine

RPM until the wheel stops spinning. Anticipate using the differential lock before wheelslippage occurs.

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

NOTE• In areas of high resistance, it may be necessary to turn the machine slightly in order to aid

in unlocking the differential lock. Decreasing the engine RPM may also be helpful.• Differential lock can be engaged while machine is in motion.• Anticipate need for use of differential lock before wheel slippage occurs.

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

2. Continue grading.3. Disengage differential lock by pushing switch on right joystick again.

Figure 8. Differential Lock Control and Indicator. 005

END OF TASK

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0005

TRANSMISSION OPERATION 0005

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

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

NOTEParking brake will automatically engage if the operator leaves the seat while the machineis stopped and parking brake is not already engaged.

6. To re-establish operational control after parking brake has been automatically set, operator must return to seat and reset parking brake by pushing top of parking brake switch, then pushing bottom of switch (Figure 9). Park-ing brake will disengage and allow operator to regain operational control.

7. If steering joystick was disturbed during step 6, repeat steps 1 though 5.

Figure 9. Parking Brake Switch. 005

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TRANSMISSION OPERATION – CONTINUED

Moving Machine from NEUTRAL Using Automodulation 0005

CAUTION• Avoid automodulation while machine is under load.• Selecting forward gears six through eight or reverse gears five or six is

NOT recommended.• Failure to follow these cautions may result in damage to equipment.

NOTE• Forward gears one through five and reverse gears one through four are recommended for

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

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

Figure 10. Transmission Control Switch. 005

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Moving Machine from NEUTRAL Using Transmission Modulation Control (Inching Pedal) 0005

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

Figure 11. Transmission Modulation Control (Inching Pedal). 005

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Sequential Speed Shifting 0005

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

Figure 12. Transmission Upshift and Downshift Buttons. 005

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0005-24

0005


Shuttle Shifting 0005

CAUTIONDo not perform shuttle shifting while using scarifier or while towing heavy load. Damage toequipment may result.

Shuttle shifting, also known as directional shifting, allows operator to change machine direction quickly. Shuttle shifting is performed by moving the transmission control switch from FORWARD to REVERSE position or from REVERSE to FORWARD position WITHOUT stopping in the NEUTRAL position (Figure 13). If switch remains in NEUTRAL position for more than 0.2 seconds, transmission will shift into NEUTRAL. The shifts shown in Table 1 are allowed.

Figure 13. Transmission Control Switch. 005

Table 1. Shuttle Shifting.

SHUTTLE SHIFT ENGINE SPEED CONDITIONS FOR SHIFT OPERATOR INPUT

1 Forward to 1 Reverse1 Reverse to 1 Forward

Entire engine speed range Transmission Control Switch






Less than 1,500 RPM Transmission Control Switch

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Programmable Transmission Initial Gear Setting 0005

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

Programmable Transmission Maximum Gear Setting 0005

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

Transmission Modulator Control (inching pedal) 0005

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

CAUTION• Avoid prolonged use of the inching pedal when moving heavy loads. Shift into lower gear

to match load condition. Failure to follow this caution may result in equipment damage.• Do not use inching pedal as a clutch for directional changes. Machine is designed to

“shuttle shift”. Failure to follow this caution may result in equipment damage.If the inching function is used in high load conditions, the operator should shift into a gear matched for that load condition. If constant stalling occurs, downshifting is advisable.

Figure 14. Transmission Modulation Control (Inching Pedal). 005

END OF TASK

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0005

THROTTLE HOLD MODE SWITCH 0005

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

NOTEThe indicator light for the throttle lock will be illuminated when the throttle is locked duringAUTOMATIC or MANUAL mode.

To Select AUTOMATIC Mode 0005

1. Push top of Throttle Hold Mode switch (Figure 15). 2. Use accelerator control to increase engine speed to desired RPM. Push in top of Throttle Set/Accel switch to

set the throttle at the current engine speed. 3. Use Throttle Set/Accel Switch and/or Throttle Resume/Decel switch to change throttle setting. 4. The throttle setting of AUTOMATIC mode will be suspended and engine speed will adjust to setting of acceler-

ator control if either of the following conditions occur: a. Accelerator control is moved more than 20 percent.b. Service brakes are applied.

5. Push top of Throttle Set/Accel Switch to resume preset engine speed. 6. Resume feature will be disabled if any of the following conditions occur:

a. Switch is moved to OFF mode.b. Switch is moved to MANUAL mode.c. Engine start switch is moved to OFF position.d. Engine is stalled.

Figure 15. Throttle Hold Mode Switch and Throttle Resume/Decel Switch. 005

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TM 5-3805-293-10 0005

THROTTLE HOLD MODE SWITCH – CONTINUED

To Select MANUAL Mode 0005

WARNINGApplying service brakes or pressing accelerator control will not disengage throttle lock.Failure to follow this warning may result in injury or death to personnel.

1. Push bottom of Throttle Hold Mode switch. 2. Use accelerator control to increase engine speed to desired RPM. Push in top of throttle Set/Accel switch to

set throttle at current engine speed. 3. Use Throttle Set/Accel switch and/or Throttle Resume/Decel switch to change throttle setting. 4. Engine speed will increase if accelerator control is pressed past throttle setting. When accelerator control is

released, engine will return to preset engine speed.

NOTEThe resume feature will not be available after the throttle lock is disengaged.

5. To disengage throttle lock:a. Move throttle Hold/Mode switch to OFF position.b. Move engine start switch to OFF position.

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0005

THROTTLE HOLD MODE SWITCH – CONTINUED

To Select OFF Mode 0005

Move switch to middle position. Throttle will only be operated by accelerator control.

END OF TASK

CENTERSHIFT LOCK SWITCH 0005

WARNING

Personal injury could result from the sudden movement of the blade when centershift lockpin is released. Before releasing centershift lockpin, be sure all personnel are clear ofblade area, circle and blade are centered under machine, and blade is lowered to ground.

1. Use right joystick centershift control to shift drawbar left or right as required. Move drawbar to desired direction and position. Place both left and right sides of blade in FLOAT position to ground moldboard.

2. Press red tab to unlock then move centershift lock switch to DISENGAGED position (push top of switch) (Fig-ure 16). When switch is in DISENGAGED position, an indicator light will illuminate on monitoring system.

Figure 16. Centershift Controls and Indicator. 005

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CENTERSHIFT LOCK SWITCH – CONTINUED

3. To move link bar to first hole or second hole on either side of center, proceed to Step a. To move link bar to third hole or farthest hole on either side of center, proceed to Step c.a. Make sure that left side of blade and right side of blade are in FLOAT position. Move right joystick

centershift control in the opposite direction from what was used to position the drawbar in Step 1. As centershift cylinder moves, linkage will roll freely. Also, link bar will move sideways.

b. Proceed to step 4.c. Move left side and right side of blade out of FLOAT position. d. Simultaneously move right joystick centershift control left, and lower right side of blade by moving right joy-

stick forward. Simultaneously, raise left side of blade by moving left joystick backward. 4. Line up centershift lock pin with desired hole in link bar. Use centershift indicator on right lift arm to check align-

ment.

NOTEIf centershift lock indicator light does not turn off, move link bar slightly to align hole withcentershift lock pin.

5. Move centershift lock switch to ENGAGED position (push bottom of switch). Monitoring system centershift lock indicator light should go off when centershift lock pin is engaged.

6. Sideshift link bar toward desired direction. Use blade lift cylinders to adjust blade angle.

Figure 17. Centershift Indicator. 005

END OF TASK

TM 5-3805-293-10

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0005

ALL-WHEEL DRIVE (AWD) 0005

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

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

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

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

Figure 18. All-Wheel Drive Controls. 005

Operating Machine in Creep Mode 0005

1. Before turning AWD Mode switch to CREEP position, the machine must meet the following conditions:a. Machine stopped (zero ground speed).b. Engine running.c. Parking brake switch set to ENGAGED position.d. Transmission control switch set to NEUTRAL position.

2. Turn AWD Mode switch to CREEP position.a. Rear transmission will be neutralized.b. AWD indicator will illuminate.

3. Disengage parking brake (WP 0004).4. Move Transmission Control switch to desired direction (FORWARD or REVERSE). When in CREEP mode,

power is supplied only to the front wheels.

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ALL-WHEEL DRIVE (AWD) – CONTINUED

5. Turn AWD Control Dial to desired speed.a. Turn control dial counterclockwise to decrease front wheel speed. Placing the dial in the full

counterclockwise position will bring the machine to a stop. b. Turn the control dial to the center (detent) position to set front wheel speed at 2.5 mph (4 km/h).c. Turn the control dial clockwise to increase front wheel speed. Placing the dial to the full clockwise position

will set front wheel speed to a maximum of 5 mph (8 km/h).6. Depressing transmission modulator control (inching pedal) proportionally reduces front wheel speed.

a. With pedal fully depressed, machine comes to a stop. b. With pedal partially released, machine is propelled at speed in proportion to amount pedal is released, up

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

Operating Machine in MANUAL Mode 0005

1. Before turning AWD Mode switch to MANUAL position, the machine must meet the following conditions:a. Actual gear is anything but NEUTRAL, eighth gear FORWARD, or sixth gear REVERSE.b. Engine running.c. Parking brake switch set to DISENGAGED position.d. Inching pedal not fully depressed.

2. Turn AWD Mode switch to MANUAL position. AWD indicator will illuminate.

NOTE• While in MANUAL mode, amount of speed commanded to front wheels is affected by

available traction.• Transmission gear is also used to limit aggression. Aggression will be limited to

100 percent in gears above fifth FORWARD and above fourth REVERSE. 3. Turn AWD Control Dial to desired speed.

a. Turning the dial to the full counterclockwise position (negative aggression) front wheels will turn at 99 percent of rear wheel speed.

b. Turn the control dial to the center (detent) position to set front wheel speed at 100 percent of rear wheel speed.

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

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

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

END OF TASK

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0005

SLOPE OPERATION 0005

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

• Speed of travel – At higher speeds, forces of inertia tend to make machine less stable.• Roughness of terrain or surface – The machine may be less stable on uneven terrain.• Direction of travel – Avoid operating machine across the slope. When possible, operate the machine up

and down rather than across slopes. Place heaviest end of machine uphill when you are working on an incline.

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

• Nature of surface – Ground that has been newly filled with earth may collapse from weight of machine.• Surface material – Rocks and moisture of surface material may drastically affect machine’s traction and

stability. Rocky surfaces may promote side slipping of machine.• Slippage due to excessive loads – This may cause downhill tracks or downhill tires to dig into the ground,

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

stable.• Implements attached to drawbar – This may decrease weight on uphill tires. The decreased weight will

cause machine to be less stable.• Height of working load of machine – When working loads are in higher positions, stability of machine is

reduced.• Operating equipment – Be aware of performance features of equipment in operation and effects on

machine stability.• Operating techniques – Keep all attachments or pulled loads low to ground for optimum stability.• Machine systems have limitations on slopes – Slopes can affect the proper function and operation of the

various machine systems. These machine systems are needed for machine control on slopes.

END OF TASK

0005-33/(34 blank)

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SCARIFIER OPERATION 0005

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

Figure 19. Scarifier Shank Stowage Rack. 005

END OF TASK

END OF WORK PACKAGE

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0 0 0 6 ADVANCED OPERATION AND OPERATOR TIPSScope, Traveling and Earth Moving Operations

SCOPE 0006

1. This work package provides advanced operation instructions and operator tips for operating the 120M Motor Grader.

2. Refer to WP 0005 for operating instructions under usual conditions.3. Refer to WP 0007 for operating instructions under unusual conditions.4. Before, during, and after operation, perform applicable PMCS (WP 0013).

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

INITIAL SETUP

References 0

WP 0005 0

WP 0007 0

WP 0013 0

0

0

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TRAVELING AND EARTH MOVING OPERATIONS 0006

Turning Around Using Articulation 0006

CAUTION• Make sure differential lock is unlocked before turning or maneuvering through tight

corners.• Do not allow the blade to contact the tires when articulating the machine. • Failure to follow these cautions may result in damage to the machine.

NOTEAWD set to 120% will reduce turning radius in soft surfaces.

1. Turn left and articulate frame left.

Figure 1. Left Turn - Frame Articulated Left. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

2. Turn right and articulate frame right.

Figure 2. Right Turn - Frame Articulated Right. 0006

END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 0006

Turning Around in Tight Areas 0006

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

(WP 0004).• Do not allow the blade to contact the tires when articulating the machine. • Failure to follow this caution may result in damage to the machine.

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

Figure 3. Turning in a Tight Area. 0006

2. Travel as far forward as possible.


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3. Turn front wheels in the opposite direction. Back machine as far as possible to line it up with new direction of travel.


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


END OF TASK

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Backing Out of a Drop-off or Ditch 0006

NOTEThis procedure is for backing out of a drop-off or ditch on the left side. Reverse articulationand turning direction if drop-off or ditch is on right side.

1. Stop machine. Raise blade and implements.

Figure 7. Backing Out of Drop-Off or Ditch. 0006

2. Articulate right while moving back slowly.

Figure 8. Articulating Right While Backing Slowly. 0006

3. Turn left while moving back slowly.

Figure 9. Steering Left While Backing Slowly. 0006

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4. Continue to back out until machine is completely out of drop-off or ditch.

Figure 10. Backing Out of Drop-Off or Ditch. 0006

END OF TASK

Grading Around an Object 0006

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

Figure 11. Approaching Object. 0006

NOTEGrade as close to the object as possible to minimize hand cleanup.

2. Grade close to object.

Figure 12. Grading Close to Object. 0006

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3. While traveling in a straight line, adjust blade sideshift and/or drawbar centershift to grade around object.

Figure 13. Sideshifting Blade to Avoid Object. 0006

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

Figure 14. Grading Past Object. 0006

END OF TASK

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Grading on an “S” Curve 0006

CAUTIONDo not allow the blade to contact the tires when articulating the machine. Failure to followthis caution may result in damage to the machine.

1. Articulate left, turn left, and sideshift right.

Figure 15. Entering “S” Curve. 0006

2. Turn straight and move sideshift as necessary.

Figure 16. Center of “S” Curve. 0006

3. Articulate right, turn right and sideshift left.

Figure 17. Reversing Direction on “S” Curve. 0006

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4. Continue to grade.

Figure 18. Exiting “S” Curve. 0006

END OF TASK

Scarifying Operations 0006

CAUTION• When using the scarifier, the frame must be straight.• When carrying the scarifier in the fully raised position, do not allow the scarifier beam or

shanks to contact the drawbar.• Raise the scarifier when turning. Failure to follow these cautions may cause damage to

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

NOTE• If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce

number of shanks being used.• Use all shanks in light material, fewer shanks in heavier material.• Break up paving by digging under surface and lifting scarifier.

1. Position the grader outside the working area of the project to configure the grader for scarifying.2. Raise the scarifier log all the way up.3. Raise the moldboard 4-6 in. (100-150 mm) off the surface and pitch the blade halfway.4. Circle the blade to a 25-30 degree angle.5. Centershift until the heel cylinder is straight up and down.6. Fully raise the moldboard 4-6 in. (100-150 mm) above the surface.7. Lower the scarifier log to the surface.8. Place the grader in forward motion.9. Lower the scarifier log as it crosses the project starting point and penetrate the surface10. Scarify the entire length of the area to a minimum depth of 6 in. (150 mm).11. Raise the scarifier log at the finish point.12. Exit the project area, pull off at a 45 degree angle, and stop the grader.13. Return to the starting point, ensuring you are not backing over the scarified area, and reposition the grader for

a second scarifying pass.14. Overlap teeth on subsequent passes.15. Repeat until completed.

END OF TASK

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Right-Hand Grading 0006

NOTEDuring right-hand grading, left lift (heel) cylinder will be vertical, and right lift (toe) cylinderwill be slightly angled.

1. Position the grader outside the working area of the project approximately 12-18 in. (30-45 cm) from the right boundary of the project area.

2. Raise the scarifier log all the way up.3. Lower the moldboard to within 4-6 in. (100-150 mm) from the surface. This will provide unrestricted movement

and prevent metal-to-metal contact.4. Pitch the blade half way.

Figure 19. Pitch Blade Half Way. 0006

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

Figure 20. Adjusting Centershift. 0006

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7. Lean the front wheels toward the heel.

Figure 21. Leaning Wheels Toward Heel. 0006

8. Lower the moldboard to the ground.

Figure 22. Lower Moldboard to Ground. 0006

9. Place the grader in motion.

Figure 23. Place Grader in Motion. 0006

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

Figure 24. Adjust Moldboard to Penetrate Surface. 0006

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

NOTEFeathering is a process accomplished by raising the moldboard in 1/2 to 1 inchincrements, while in a forward motion. Two or three seconds are recommended betweeneach upward adjustment until all the material in front of the moldboard passes under it.

12. Be sure to feather the material out at the end of the pass.

Figure 25. Feathering Material. 0006

13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side.14. Stop the grader and straighten the front wheels.15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles.16. Position the grader to straddle the windrow just made and back up straight to the start point. Ensure the

windrow is between the wheels, and do not drive on top of it.17. Stop the grader just outside the boundary line.

END OF TASK

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Left-Hand Grading 0006

NOTEDuring left-hand grading, right lift (heel) cylinder will be vertical and left lift (toe) cylinderwill be slightly angled.

1. Position the grader outside the working area of the project centered on the previous windrow of the project area.

2. Raise the scarifier log all the way up.3. Lower the moldboard to within 4-6 in. (100-150 mm) of the surface. 4. Pitch the blade half way.

Figure 26. Pitch Blade Halfway. 0006

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

Figure 27. Adjusting Centershift. 0006

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7. Lean the front wheels toward the heel.

Figure 28. Leaning Wheels Toward Heel. 0006


Figure 29. Lower Moldboard to Ground. 0006

9. Place the grader in motion.


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

Figure 31. Adjust Moldboard to Penetrate Surface. 0006

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

NOTEFeathering is a process accomplished by raising the moldboard in 1/2 to 1 inchincrements, while in a forward motion. Two or three seconds are recommended betweeneach upward adjustment until all the material in front of the moldboard passes under it.

12. Be sure to feather the material out at the end of the pass.

Figure 32. Feathering Material. 0006

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13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side.14. Stop the grader and straighten the front wheels.

WARNINGNever back the grader with the front tires leaned. Steering accuracy is compromised. Aftercompleting each general position, always return the front wheels to straight up and downposition prior to executing the next position. Failure to follow this warning may result inpersonal injury or death.

15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles.16. Execute a three-point turn toward the toe and position the grader to straddle the windrow just made. Ensure

the windrow is between the wheels, and do not drive on top of it.17. Stop the grader just outside the boundary line.

END OF TASK

Center Windrow 0006

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

NOTEDo not lean the front wheels. The wheels will remain straight during this grading method.

7. Place the grader in forward motion, making only minor adjustments to the moldboard.8. Continue to the end of the project or until material in front of the moldboard passes under it.

END OF TASK

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Road Building - “V” Ditch Method 0006

NOTEThe steps in this procedure are for one side of the road. Repeat these steps for theopposite side.

1. Position the grader outside the working area of the project to configure the grader for “V” ditching.2. Place the grader into ditching position as follows;

a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.b. Pitch the blade halfway.c. Center the blade on the circle by side shifting if needed.d. Center shift until the heel cylinder is straight up and down.e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire.f. Raise the heel cylinder all the way up.g. Lean the front wheels toward the heel.

3. Perform a marking cut followed by a ditching (heavy) cut.

Figure 33. Marking and Ditching Cuts. 0006

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

Figure 34. Ditch Cuts. 0006

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5. Spread to center.

Figure 35. Center Windrow Position. 0006

6. Clean shoulder and spread to center.

Figure 36. Leveling the Area. 0006

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

Figure 37. Cutting Back Side of Ditch. 0006

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8. Make a ditching pass to clean and shape inside slope.

Figure 38. Cleaning and Shaping Inside Slope. 0006

9. Finish shoulder pass.

Figure 39. Finishing Shoulder Pass. 0006

10. Level and finish.

Figure 40. Leveling and Finishing. 0006

END OF TASK

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Right-Hand “V” Ditching 0006

CAUTION• Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow

this caution may result in damage to machine.• Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls

may be forced against the back slope, causing tire sidewall damage and also forcing dirtbetween the tire and rim, causing air loss and flat tires.

NOTE• Steps 1 through 7 pertain to making a “Marking Cut.”• Ditching is normally done on the right side of the grader as it has greater reach to this side.

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

Figure 41. Positioning Grader. 0006

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2. Place the grader into ditching position as follows;a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.b. Pitch the blade halfway.c. Center the blade on the circle by side shifting if needed.d. Center shift until the heel cylinder is straight up and down.e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire.f. Raise the heel cylinder all the way up.g. Lean the front wheels toward the heel.

Figure 42. Leaning Wheels Toward the Heel. 0006

NOTEThe grader is now in the ditching position. Align the right front tire on top of the proposedditch line. Make a visual check to finish point of the ditch. Maintain control of the graderand do not permit it to deviate from the proposed ditch line.

3. Place the grader in motion and as the right front tire passes over the starting point of the ditch, lower the toe.

Figure 43. Adjusting Blade to Deliver Material. 0006

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4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTEAt this point, the primary concern is to follow the proposed ditch line. Example: If stakesare utilized, ensure the right front tire is directly in line with the next stake.

5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward movement until the rear tires pass over and off the marking cut.

6. Straighten the front wheels and steer the grader to the right approximately 45 degrees to the ditch. 7. Back the grader along the outside edge of the windrow to the start point.

NOTE• After the initial marking cut, ensure quality control on all remaining cuts. The marking cut

provides and excellent track for the grader to follow. The grader is set up already for theditching cut to follow.

• Steps 8 through 13 pertain to making “Ditching Cuts.”8. Pull forward and stop the grader just as the right front tire enters the marking cut.

Figure 44. Positioning Right Front Tire and Right End of Blade. 0006

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9. Lean the front tires toward the heel.

Figure 45. Leaning Wheels. 0006

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

CAUTIONAttempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pullingto one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TOSTEER OUT OF THE PULL.

11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching cuts until the desired depth is achieved.

Figure 46. Reposition Grader. 0006

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12. Repeat ditch cut as necessary.

Figure 47. Repeat Ditch Cut as Necessary. 0006

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

NOTE• Steps 14 through 26 pertain to cleaning the shoulder of the ditch.• This task is accomplished by placing the grader in the wide side reach position.

14. Position the grader so the right front tire is approximately 12-15 in. (30-38 cm) to the left of the ditch center line and stop the grader.

15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the moldboard to 0 degrees.

16. Center shift all the way to the right.17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface.18. Blade side shift all the way right.

CAUTIONDo not adjust the moldboard height, especially the heel (left lift) cylinder. The view isobscured because the heel is under the main frame of the grader.

19. Circle the moldboard counterclockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside edge of the right front tire (approximately a 45 degree angle).

Figure 48. Setting Blade to Deliver Material. 0006

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20. Place the grader in forward motion and maintain a position and course so the tow of the moldboard passes directly over the center of the ditch.

21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 49. Lower the Blade to the Ground. 0006

22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the moldboard passes under it or is windrowed off the heel.

23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTIONDo not back the grader in the wide reach position. A safety factor is apparent; themoldboard would be extended out past the tires. By placing the moldboard in the righthand general grading position, the safety factor is minimized and the moldboard ispositioned to execute the next maneuver.

24. Stop the grader and place the moldboard in the right hand general grading position.25. Ensure the front wheels are straight up and down prior to backing the grader. 26. Back the grader to the starting point by straddling the windrow.

NOTESteps 27 through 33 pertain to skimming the surface to spread material towards centerestablishing a crown in the road.

27. Stop the grader outside the starting point of the project and lean the wheels toward the heel.28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the

surface.


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

NOTEWith the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditchshould pass under and off the heel of the moldboard, thereby establishing the crown of theroad.

30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road.31. At the end of the pass, ensure the material is feathered prior to stopping the grader.32. Straighten the front wheels and raise both lift cylinders all the way up. 33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch

on the other side of the project area going the opposite direction.

NOTESteps 34 through 39 pertain to “Center Windrow Positioning.”

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

NOTE• Steps 40 through 42 pertain to “Leveling the Area.”• Determine which of the following procedures is applicable to the current task. Proceed to

the step indicated.Right to Left - go to Step 40

Left to Right - go to Step 41

Center to Right/Center to Left - go to Step 42

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40. Right to Lefta. Beginning at the right side of the area boundary, blade the material from the right side to the left side.b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material

along the left boundary.41. Left to Right

a. Beginning at the left side of the area boundary, blade the material from the left side to the right side.b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material

along the right boundary.42. Center to Right / Center to Left

a. Beginning at approximately the center line of the area, blade (level) the material from the center starting point to the left boundary line.

b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the right boundary line.

END OF TASK

Left-Hand “V” Ditching 0006

CAUTION• Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow

this caution may result in damage to machine.• Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls

may be forced against the back slope, causing tire sidewall damage and also forcing dirtbetween the tire and rim, causing air loss and flat tires.

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

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

Figure 51. Positioning Grader. 0006

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

2. Place the grader into ditching position as follows;a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.b. Pitch the blade halfway.c. Center the blade on the circle by side shifting if needed.d. Centershift until the heel cylinder is straight up and down.e. Rotate the moldboard so the toe is just behind the outside edge of the left front tire.f. Raise the heel cylinder all the way up.g. Lean the front wheels toward the heel.

Figure 52. Leaning Wheels Toward the Heel. 0006

NOTEThe grader is now in the ditching position. Align the right front tire on top of the proposedditch line. Make a visual check to finish point of the ditch. Maintain control of the graderand do not permit it to deviate from the proposed ditch line.

3. Place the grader in motion and as the left front tire passes over the starting point of the ditch, lower the toe.


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4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTEAt this point, the primary concern is to follow the proposed ditch line. Example: If stakesare utilized, ensure the left front tire is directly in line with the next stake.

5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward movement until the rear tires pass over and off the marking cut.

6. Straighten the front wheels and steer the grader to the left approximately 45 degrees to the ditch. 7. Back the grader along the outside edge of the windrow to the start point.

NOTE• After the initial marking cut, ensure quality control on all remaining cuts. The marking cut

provides and excellent track for the grader to follow. The grader is set up already to theditching cut to follow.

• Steps 8 through 13 pertain to making “Ditching Cuts.”8. Pull forward and stop the grader just as the left front tire enters the marking cut.

Figure 54. Tire Position. 0006

9. Lean the front tires toward the heel.

Figure 55. Wheels Placed for Continued Ditching. 0006

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

CAUTIONAttempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pullingto one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TOSTEER OUT OF THE PULL.

11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching cuts until the desired depth is achieved.

Figure 56. Reposition Grader. 0006

12. Repeat ditch cut as necessary.

Figure 57. Repeat Ditch Cut as Necessary. 0006

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

NOTE• Steps 14 through 26 pertain to cleaning the shoulder of the ditch.• This task is accomplished by placing the grader in the wide side reach position.

14. Position the grader so the left front tire is approximately 12-15 in. (30-38 cm) to the right of the ditch center line and stop the grader.

15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the moldboard to 0 degrees.

16. Centershift all the way to the left.17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface.18. Blade side shift all the way left.

CAUTIONDo not adjust the moldboard height, especially the heel (right) lift cylinder. The view isobscured because the heel is under the main frame of the grader.

19. Circle the moldboard clockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside edge of the left front tire (approximately a 45 degree angle).


20. Place the grader in forward motion and maintain a position and course so the toe of the moldboard passes directly over the center of the ditch.

21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 59. Lowering Blade to the Ground. 0006

0006-33

TM 5-3805-293-10 0006


22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the moldboard passes under it or is windrowed off the heel.

23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTIONDo not back the grader in the wide reach position. A safety factor is apparent; themoldboard would be extended out past the tires. By placing the moldboard in the left handgeneral grading position, the safety factor is minimized and the moldboard is positioned toexecute the next maneuver.

24. Stop the grader and place only the moldboard in the left hand general grading position.25. Ensure the front wheels are straight up and down prior to backing the grader. 26. Back the grader to the starting point by straddling the windrow.

NOTESteps 27 through 33 pertain to skimming the surface to spread material towards centerestablishing a crown in the road.

27. Stop the grader outside the starting point of the project and lean the wheels toward the heel.28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the

surface.


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

NOTEWith the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditchshould pass under and off the heel of the moldboard, thereby establishing the crown of theroad.

30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road.31. At the end of the pass, ensure the material is feathered prior to stopping the grader.32. Straighten the front wheels and raise both lift cylinders all the way up. 33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch

on the other side of the project area going the opposite direction.

TM 5-3805-293-10

0006-34

0006


NOTESteps 34 through 39 pertain to “Center Windrow Positioning.”

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

NOTE• Steps 40 through 42 pertain to “Leveling the Area.”• Determine which of the following procedures is applicable to the current task then proceed

to the step indicated.Right to Left - go to Step 40

Left to Right - go to Step 41

Center to Right/Center to Left - go to Step 42

40. Right to Lefta. Beginning at the right side of the area boundary, blade the material from the right side to the left side.b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material

along the left boundary.41. Left to Right

a. Beginning at the left side of the area boundary, blade the material from the left side to the right side.b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material

along the right boundary.42. Center to Right / Center to Left

a. Beginning at approximately the center line of the area, blade (level) the material from the center starting point to the left boundary line.

b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the right boundary line.

END OF TASK

0006-35

TM 5-3805-293-10 0006


Ditch Back Sloping 0006

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

1. Position grader outside of the ditch.2. Circle moldboard to 0 degrees to the grader frame and lower moldboard to approximately 2 in. (50 mm) above

the ground. 3. Side shift the moldboard all the way to the right.4. Centershift circle assembly all the way to the right.

CAUTIONLower moldboard as needed to prevent metal-to-metal contact between lift arm andframe.

5. Lower moldboard to the ground.

NOTEActivating blade float will relieve all pressure from the moldboard.

6. Retract centershift lock pin.7. Using right and left blade control levers, position the centershift saddle to the far left centershift position.8. Place the centershift lockpin into the far left centershift position.

NOTEYou may have to move the blade controls to completely seat the centershift lockpin.

9. Move the centershift lock lever to the LOCKED position, and then back to the INDEX and RUN position.10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the

grader.

Figure 61. Adjusting Blade. 0006

TM 5-3805-293-10

0006-36

0006


11. Circle the moldboard assembly to the right to the desired position.12. Position the heel of the moldboard in front of the right rear tire.

Figure 62. Heel Position. 0006

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

Figure 63. Positioning Blade. 0006

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

Figure 64. Leaning Wheels IN for Heavier Cut. 0006

0006-37

TM 5-3805-293-10 0006


15. Reverse procedures to return the moldboard to general grading position.

Figure 65. Leaning Wheels AWAY for Lighter Cut. 0006

END OF TASK

Grading in a Wet Ditch 0006

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

NOTEThis method may be used to avoid obstructions whenever cleaning old ditches, which mayhave tree overhangs, rock ledges, etc.

2. Keep rear wheels on shoulder to prevent wheel slippage in wet or soft material in ditch.

Figure 66. Positioning Wheels to Prevent Slippage. 0006

END OF TASK

TM 5-3805-293-10

0006-38

0006


Flat Bottom Ditching 0006

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

NOTEThe shoulder slope should be flatter than normal, ending at the finished shoulder line.

2. Tip blade forward.

Figure 67. Pitching Blade. 0006

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

3. Move centershift lock pin to right-center position.4. Have right front tire in bottom of “V” ditch.

Figure 68. Positioning Tire in Bottom of Ditch. 0006

0006-39

TM 5-3805-293-10 0006


5. Set blade so toe is inside right front tire at desired width of flat bottom ditch.

Figure 69. Setting Blade. 0006

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

Figure 70. Lowering Right Lift Cylinder. 0006

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

Figure 71. Raising Left Lift Cylinder and Leaning Wheels. 0006

TM 5-3805-293-10

0006-40

0006


9. Cut a flat bottom. Set right lift cylinder to required depth.

Figure 72. Setting Right Lift Cylinder and Cutting Bottom. 0006

10. Set left lift cylinder as required.

Figure 73. Setting Left Lift Cylinder. 0006

0006-41

TM 5-3805-293-10 0006



11. Move centershift lock pin to far-right position.12. Start right front tire in bottom of first “V” ditch.13. Set right end of blade at bottom of backslope.

Figure 74. Positioning Right Front Tire and Right End of Blade. 0006

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


0006-42

TM 5-3805-293-10 0006


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

Figure 76. Finishing Final Grade. 0006

END OF TASK

Grading on a 3-to-1 Slope 0006

WARNING• Only an experienced operator should operate the machine on a steep side slope.• Never fully articulate the machine uphill on steep slopes. • Failure to follow these warnings may cause injury to personnel or damage to equipment.

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

speed.• When working on slopes, use the accelerator to control the speed of the machine.• When operating on extreme slopes, use crab steering to keep the back of the grader on

the downhill side of cut.1. Articulate frame to place frame in an offset position for maximum stability.

Figure 77. Articulating Frame for Stability. 0006

0006-43

TM 5-3805-293-10 0006


2. Use crab steering when front of machine tends to slip due to heavy side load on blade.

Figure 78. Crab Steering to Overcome Heavy Load. 0006

END OF TASK

High Bank Cuts - Right Side 0006

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

Figure 79. Cleaning Roadbed. 0006

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

Figure 80. Pitching Blade Forward. 0006

TM 5-3805-293-10

0006-44

0006



4. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm) above the ground.

5. Side shift the moldboard all the way to the right.6. Centershift the circle assembly all the way to the right.

CAUTIONLower the moldboard as needed to prevent metal-to-metal contact between the lift armand frame.



8. Retract centershift lock pin.9. Using right and left joysticks, position the centershift saddle to the far left centershift position.10. Place the centershift lockpin into the far left centershift position.

NOTEYou may need to move the blade controls to completely seat the centershift lockpin.

11. Press the centershift lock switch to engage and lock centershift lockpin. 12. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the

grader. 13. Circle the moldboard assembly to the right to the desired position.

Figure 81. Setting Blade Position. 0006

0006-45

TM 5-3805-293-10 0006


14. Lower left lift cylinder to set heel of blade at bottom of slope and in line with outer edge of rear tire.


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

Figure 83. Positioning Right Rear Tire. 0006

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

Figure 84. Beginning Cut. 0006

TM 5-3805-293-10

0006-46

0006


NOTEThe wheels should be near the vertical position.

18. Lean wheels toward slope for a heavier cut.

Figure 85. Leaning Wheels In for Heavier Cut. 0006

NOTEThe procedure shown is for right side. Position blade opposite to that shown for left side.

19. Lean wheels away from slope for a lighter cut. Keep material from slope moved to outside of rear wheels.

Figure 86. Leaning Wheels Away for Lighter Cut. 0006

END OF TASK

0006-47

TM 5-3805-293-10 0006


Extreme Side Reach 0006


NOTEThe following steps are for extreme side reach to the right. For extreme left side reach,position the centershift lock pin and blade to the far left.

1. Position the grader outside the working area of the project.2. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm)

above the ground.3. Side shift the moldboard all the way to the right.4. Centershift the circle assembly all the way to the right.

CAUTIONLower the moldboard as needed to prevent metal-to-metal contact between the lift armand frame.



6. Retract centershift lock pin.7. Using right and left joysticks, position the centershift saddle to the far left centershift position.8. Place the centershift lockpin into the far left centershift position.

NOTEYou may need to move the blade controls to completely seat the centershift lockpin.

9. Press the centershift lock switch to engage lockpin. 10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the

grader. Circle the moldboard assembly to the right to the desired position.

11. Move centershift lock pin to far right position.12. Sideshift blade to far right position.13. Centershift circle assembly to far right position.14. Circle the blade to the desired angle.15. Lower blade to desired depth to deliver material to side.

TM 5-3805-293-10

0006-48

0006


Mid-Mounted Scarifier Operation 0006

CAUTION• When using the scarifier, the frame must be straight.• When carrying the scarifier in the fully raised position, do not allow the scarifier beam or

shanks to contact the drawbar.• Raise the scarifier when turning. • Do not reverse the scarifier teeth. They may impact frame.• Failure to follow these cautions may cause damage to machine.

NOTE• If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce

number of shanks being used.• Use all shanks in light material, fewer shanks in heavier material.• Break up paving by digging under surface and lifting scarifier.

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

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10

0007-1

0007


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

Machine Out of Danger.

GENERAL 0007

WARNINGThis machine has been designed to operate safely and efficiently within the limitsspecified in this TM. Operation beyond these limits is prohibited in accordance withFM 21-305 without written approval from: Commander, U.S. Army Tank-Automotive andArmaments Command, ATTN: AMSTA-DSA-CS, Warren, MI 48397-5000.

This section contains instructions for safely operating the 120M Motor Grader under unusual conditions. In addition to normal preventive maintenance, special care must be taken to keep the machine operational in extreme temperatures and other environmental conditions.

INITIAL SETUP

References 0

FM 9-207 0

FM 21-305 0

FM 31-70 0

FM 31-71 0

FM 90-3 0

LO 5-3805-293-13 0

WP 0004 0

WP 0005 0

WP 0013 0

WP 0021 0

WP 0025 0

WP 0025 0

WP 0027 0

14

TM 5-3805-293-10

0007-2

0007

SLAVE STARTING 0007

WARNING

• When slave starting, use NATO slave cable that does NOT have loose or missinginsulation.

• DO NOT proceed if suitable cable is not available.• DO NOT use civilian-type jumper cables.• DO NOT allow disabled and booster machines to come in contact with each other at any

time during slave starting. Failure to follow these warnings may cause injury or death topersonnel.

NOTEEnsure that both disabled machine and booster machine are equipped with serviceableNATO slave receptacles.

1. Remove cover from slave receptacle (Figure 1, Item 1) on disabled machine and booster machine.2. Connect slave cable to booster machine slave receptacle.3. Connect other end of slave cable to slave receptacle of disabled machine, located on left side of engine

compartment.4. Turn battery disconnect switch of disabled machine to ON position.5. Start booster machine and run at a speed just above idle.6. Wait approximately five minutes, then crank disabled machine. If engine fails to crank, notify Field Level

Maintenance.7. After starting disabled machine, return booster machine to idle.8. Remove slave cable from disabled machine, then from booster machine.9. Replace cover on slave receptacle (Figure 1, Item 1).

Figure 1. Slave Receptacle. 0007

0007-3

TM 5-3805-293-10 0007

END OF TASK

EXTREME COLD 0007

General 0007

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

Checks 0007

1. Perform all Before PMCS checks and services (WP 0013).2. Lubricate in accordance with LO 5-3805-293-13.3. Check to ensure tires and ground engaging tools are not frozen to ground.4. Drain a small amount of fuel from the fuel/water separator to ensure fuel is not gelled (WP 0013).

CAUTIONIf oil is too cold to drip off oil level gauge, do not attempt to start engine. Notify Field LevelMaintenance.

5. Check engine and transmission/differential oils to ensure they are thin enough to flow. Oil must be thin enough to drip from oil level gauge (dipstick).

6. Ensure ether starting aid cylinder is in place and not empty (WP 0021).

Starting Procedures – Machine NOT Equipped with Arctic Kit 0007

CAUTION• When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30

seconds. Allow starting motor to cool for two minutes before cranking again or damage tostarting motor or batteries may result.



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

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

TM 5-3805-293-10

0007-4

0007

EXTREME COLD – CONTINUED

Starting Procedures – Machine Equipped with Arctic Kit 0007

CAUTION• At temperatures nearing -40°F (-40°C), it is necessary to shut off the arctic heater at least

30 seconds before attempting to start the machine’s engine. Failure to follow this cautionmay result in internal damage to the heater or localized boiling of the coolant in the heaterbody which may cause a heater hose to come off.

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



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

NOTE• If engine coolant heater has not been started for several months, or if heater is being

started for the first time, it may take several attempts to start.• If engine coolant heater fails to start at first attempt, it will automatically attempt to start a

second time. If heater still does not start, it will shut down.• During operation, engine coolant heater continually senses supply voltage. If voltage is too

low or too high, heater will automatically shut down. If this occurs, notify Field LevelMaintenance.

1. Activate engine coolant heater as follows:a. Turn battery disconnect switch to ON position (WP 0004).b. Activate engine coolant heater switch (WP 0004).

2. Allow heater to run up to 40 minutes.3. Push engine coolant heater button to turn heater off, then wait at least 30 seconds.

CAUTIONAt temperatures of less than -25°F (-32°C), be sure to keep starter engaged until enginespeed approaches 500 rpm. Multiple short (15-second) start attempts at coldtemperatures can result in engine bearing damage due to inadequate lubrication.

4. Start engine (WP 0005).5. Check that engine oil pressure light on monitor system registers pressure within 10 seconds of engine starting.6. Allow engine to idle for at least five minutes before moving machine.

0007-5

TM 5-3805-293-10 0007

EXTREME COLD – CONTINUED

Machine Operation 0007

1. Move machine approximately 100 yards (91 m) in both forward and reverse directions to exercise transmission and powertrain.

2. Test brakes and vehicle controls carefully.3. Slowly exercise ground engaging tools to warm hydraulic oil. Cycle each control several times. Monitor

Messenger until transmission oil temperature reaches 41°F (5°C) (WP 0005).4. Operate machine under light loads until machine is sufficiently warmed up (warm air blows from heater vents).5. Frequently monitor Messenger system, alert indicators, and gauges. Take appropriate action if a problem is

noted, and if necessary, notify Field Level Maintenance.

Parking Machine 0007

1. Clean snow, ice, and mud from machine as soon as possible after shutdown.2. When possible, park in sheltered area, or if shelter is not available, park machine so radiator is not facing the

wind.3. If shelter is not available, park machine on dry, high ground, and place planks or dunnage under tires and

ground engaging tools to make a raised and relatively dry platform.4. Perform all After PMCS checks and services (WP 0013).

END OF TASK

SNOW PLOWING 0007

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

Operating Speed 0007

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

Use of Tire Chains 0007

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

TM 5-3805-293-10

0007-6

0007

SNOW PLOWING – CONTINUED

Use of Moldboard 0007

CAUTIONTip moldboard forward to prevent cutting into road surface and causing damage toequipment.

1. Tip moldboard forward to prevent damage to road surface and machine. This allows the cutting edge to ride over road surface, instead of cutting into it, which could cause damage to machine and the road surface.

2. When plowing over asphalt or frozen ground, use blade float to allow moldboard to move freely over uneven surfaces, and prevent road damage.

Use of All Wheel Drive (AWD) 0007

All wheel drive provides additional steering and traction control, and reduces the need for tire chains.

END OF TASK

EXTREME HEAT 0007

General 0007

Extreme heat causes problems that an operator must be aware of, such as: 0007

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

SYSTEM indicator illuminates on the monitor system.

Checks 0007

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


1. During very hot weather operation, avoiding continuous high engine RPM will help prevent machine from overheating. Alter operating procedures accordingly.

2. Check coolant level in coolant tank at frequent intervals throughout any single work shift (WP 0013).3. Keep radiator and grille free of bugs, dust, dirt, mud, and other foreign matter. Clean frequently if necessary

(WP 0025).4. Monitor engine coolant temperature gauge. Red range on gauge indicates coolant temperature is above 225°F

(107°C). If coolant temperature indicator comes on, machine may be operated at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field Level Maintenance.

5. Monitor hydraulic oil temperature gauge. Red range on gauge indicates coolant temperature is above 199°F (93°C). If hydraulic oil temperature indicator comes on, machine may be operated at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field Level Maintenance.

6. Refer to FM 90-3 for additional extreme heat operation information.

0007-7

TM 5-3805-293-10 0007

EXTREME HEAT – CONTINUED

Parking 0007

1. When possible, park machine under cover. Refer to WP 0005.2. Perform all After PMCS checks and services (WP 0013).

END OF TASK

MUD OR SOFT SURFACES 0007

1. Before entering mud or other soft surfaces, check conditions and engage all-wheel drive and differential lock (WP 0005). Select appropriate transmission gear range. Enter soft area at a medium speed for gear range selected.

2. Maintain steady pressure on accelerator pedal to keep machine rolling until solid ground is reached. Do not accelerate to point where wheels spin, if possible.

3. If machine gets stuck, try to pull out slowly in a low gear. Boards, dunnage, or similar materials may be placed under tires to provide traction.

4. Clean and inspect for proper lubrication.

END OF TASK

SANDY OR DUSTY AREAS 0007

Checks 0007

1. Perform all Before PMCS checks and services (WP 0013).2. Lubricate in accordance with LO 5-3805-293-13.3. Check radiator for build-up of sand/dirt/debris often. Clean when necessary (WP 0025).


1. Maintain steady speeds with transmission in lower gears.2. Engage differential lock and AWD when required (WP 0005).3. Keep machine rolling through sand without straining engine or powertrain. If machine gets stuck, refer to

Recovery and Towing in this work package.4. Monitor engine coolant and hydraulic oil temperature gauges on monitor system more frequently during

operation.5. If ENGINE SYSTEM indicator illuminates on the monitor system, check and clean or replace engine air filter

elements.6. Check hydraulic cylinders, circle top, centershift linkage, and articulation cylinders frequently. Do not allow

dust, dirt, or sand to collect on these components as their smooth working surfaces can be damaged by such abrasive materials.

TM 5-3805-293-10

0007-8

0007

SANDY OR DUSTY AREAS – CONTINUED

Parking 0007

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

END OF TASK

SALTWATER AREAS 0007

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

END OF TASK

HIGH ALTITUDES 0007

NOTEEngine operates at less than peak performance at high altitudes.

1. Coolant level and engine indicators must be watched closely. 2. Add coolant if necessary.

END OF TASK

SNOW AND ICE 0007

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

Driving 0007

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

Stopping 0007

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

0007-9

TM 5-3805-293-10 0007

Parking 0007

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

END OF TASK

FORDING 0007

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

CAUTIONDo not ford even the narrowest stream more than 30 in. (76 cm) deep. Failure to followthis caution may result in damage to machine.

1. Check depth of water at its deepest point.2. Ensure the bottom is stable enough for fording.3. Remove center five scarifier shanks and stow in scarifier shank stowage rack. Flip remaining shanks upside

down in scarifier frame (WP 0027).4. Start engine and allow it to fully warm up (WP 0005).5. Ensure engine system indicator and action light indicator are not illuminated, and all gauges are indicating

proper machine operation (WP 0005).6. Raise scarifier and blade to their maximum height (WP 0005).

WARNINGDuring fording operation, if blade is not set perpendicular to centerline of machine, force ofthe water could cause operator to lose control of machine. Failure to follow this warningmay result in injury or death to personnel.

7. Set blade perpendicular to centerline of machine.

NOTEFording speed should not exceed 3-4 mph (5-6 km/h). Once in the water, do not stop untilthe opposite bank is reached.

8. Engage transmission in low gear (WP 0005).9. Release parking brake (WP 0005).10. Enter water slowly to minimize waves and backsplash and continue across body of water WITHOUT

STOPPING until the opposite bank is reached.11. If machine stalls, refer to Recovery and Towing Techniques in this work package.12. Once machine is out of water, lubricate machine completely IAW LO 5-3805-293-13.

END OF TASK

TM 5-3805-293-10

0007-10

0007

RECOVERY AND TOWING TECHNIQUES 0007

WARNING• Ensure recovery line is strong enough (rated capacity of 150% of gross weight of the

towed machine) and is in good condition.• Attach recovery line only to towing connection points provided on frame.• DO NOT have tension on the recovery line when inspecting it.• DO NOT jerk on recovery line; it may break.• DO NOT allow riders on machine being recovered.• Failure to follow these warnings may result in injury or death to personnel.

CAUTION• Recovery of a disabled machine with engine stopped may cause transmission damage.

Transmission will not have lubrication.• If further evacuation is necessary, notify Field Level Maintenance to tow or haul machine

to convenient location for repairs.

NOTETowing must be performed by Field Level Maintenance.

Towing With a Running Engine 0007

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

Figure 2. Front Towing Connection Points. 0007

0007-11

TM 5-3805-293-10 0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED

Figure 3. Rear Towing Connection Points. 0007

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

Towing With a Dead Engine 0007

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

NOTEIf the brakes are in good operating condition, the machine has limited wheel brake ability.The pedal effort is high due to the lack of hydraulic boost.

1. Turn on secondary steering pump on stopped machine. You can steer machine while secondary steering pump is on. Secondary steering pump will be activated for a maximum of ten seconds. While secondary steering pump is activated you can use left joystick to align front wheels of machine.

WARNINGWhen the driveshaft is removed, the machine has NO parking brake. The machine can rolland cause personal injury or death. Block the wheels securely so that the machine cannotmove.

2. If you suspect internal transmission failure or driveline failure, remove driveshaft located between the differential and transmission.

0007-12

TM 5-3805-293-10 0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED

3. Fasten tow line or tow bar to front or rear towing connection points on frame (Figure 2 or Figure 3).4. Remove wheel blocks. Tow machine slowly. Do not tow machine faster than 1.2 mph (2 km/h).

END OF TASK

OPERATING PORTABLE FIRE EXTINGUISHER 0007

1. Remove fire extinguisher from storage.2. Hold fire extinguisher upright. Stand back 8 ft (2.4 m) from base of fire, point nozzle toward fire, and pull safety

pin.3. Squeeze lever, discharging chemical at base of fire. Use a side-to-side motion to spread chemical.4. After using fire extinguisher, order new fire extinguisher.

END OF TASK

SECONDARY STEERING 0007

WARNING• Personal injury or death can occur if steering is lost completely during operation.• Do not continue to operate the machine using secondary steering. If the secondary

steering activates during operation, immediately park machine in a safe location. NotifyField Level Maintenance.

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

CAUTIONOnce secondary steering system has been activated, it should remain on no longer thanone minute. This should be sufficient time to safely steer machine to a stop. When themachine is stopped, turn engine start switch to OFF position to turn off secondarysteering. Prolonged use of secondary steering system (longer than one minute) will causeelectric motor to overheat and cause damage to its components. If secondary steeringsystem is activated for longer than one minute, replace the pump, motor, and relay. Also,wiring must be inspected for damage due to overheating. Notify Field Level Maintenance.

1. The secondary steering pump will activate automatically when the main steering power source fails, such as a primary steering pump failure or engine failure. The secondary steering control will activate automatically when the primary steering control system fails. Engine start switch must be in ON position for this system to operate.

2. The primary steering system pressure indicator will illuminate when there is a problem with the primary steering system.

3. The secondary steering system indicator will be amber in color when secondary steering system is active or secondary steering system is being tested. Alert indicator will be red in color when a problem with secondary steering system exists.

4. If a problem exists with the primary steering system or the secondary steering system, an alert indicator and an action light come on and an action alarm sounds at a pulse rate. Notify Field Level Maintenance.

END OF TASK

0007-13

TM 5-3805-293-10 0007

STOPPING ENGINE IF AN ELECTRICAL MALFUNCTION OCCURS 0007

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

Figure 4. Battery Disconnect Switch. 0007

END OF TASK

MOVING MACHINE OUT OF DANGER 0007

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

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

CAUTIONDo not use wheel lean lock bolt and bracket to center the wheel lean of machine. Damageto equipment may result.

NOTE• “1F” and “1R” are the only gears available to drive through the parking brake. Upshifting

will not change selected gear.• A warning category 3 will activate during machine movement. The event will be logged in

Messenger but the alarm should deactivate once the transmission control switch isreturned to NEUTRAL position.

TM 5-3805-293-10

0007-14

0007

MOVING MACHINE OUT OF DANGER – CONTINUED

To drive through the parking brake:a. Start engine. Transmission control switch must be in NEUTRAL position and parking brake must be

engaged to allow engine to start.b. Fully depress inching pedal. With parking brake engaged, “1F/1R” will flash on LCD display on monitoring

system.c. Select direction of travel on transmission control switch.d. Raise engine speed to full throttle, then release inching pedal. Machine movement will be jerky since

powertrain is trying to propel machine against engaged parking brake.e. When desired location is reached, depress inching pedal and move transmission control switch to

NEUTRAL position to stop machine.

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10

0008-1

0008


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

SCOPE 0008

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

STOWAGE 0008

Basic Issue Items (BII) 0008

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

Figure 1. Tool Box. 0008

14

TM 5-3805-293-10

0008-2

0008

WARNING MESSAGE LABELS 0008

WARNINGFailure to follow the warning safety messages listed here may result in injury or death topersonnel.

Figure 2. Warning Message Labels. 0008

0008-3

TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

KEY LABEL IDENTIFICATION 08 WARNING DEFINITION 08

1 Lift Here Identifies proper location to attach lift device to machine.

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

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

4 Tie Down Identifies proper location to attach tie-down to machine.

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

6 Improper Connections for JumpStart Cables

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

0008-4

TM 5-3805-293-10 0008



0008-5

TM 5-3805-293-10 0008


KEY LABEL IDENTIFICATION 08 WARNING DEFINITION 08

1 Seat Belt A seat belt should be worn at all times during machine opera-tion to prevent serious injury or death in the event of an acci-dent or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

2 Do Not Weld On the ROPS/FOPS Structure

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

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

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

5 No Clearance Connect the steering frame lock between the front and the rear frames before lifting, transporting, or servicing the machine in the articulation area. Disconnect the steering frame lock and secure the steering frame lock before resuming operation. Severe injury or death could occur.

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

TM 5-3805-293-10

0008-6

0008



KEY LABEL INDENTIFICATION 08 WARNING DEFINITION 08

1 Recoil Spring Housing contains a highly compressed spring that can cause injury or death. Only trained Field Level Maintenance person-nel may disassemble parking brake housing.

0008-7

TM 5-3805-293-10 0008


Figure 5. Warning Message Label. 0008

KEY LABEL INDENTIFICATION 08 WARNING DEFINITION 08

1 CBRN (Chemical, Biological, Radio-logical and Nuclear).

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

TM 5-3805-293-10

0008-8

0008

CAUTION AND NOTICE MESSAGE LABELS 0008

CAUTIONFailure to follow cautions listed may result in damage to equipment.

Figure 6. Additional Message Labels. 0008

KEY LABEL IDENTIFICATION 08 LABEL DEFINITION 08

1 Air Conditioning System (Caution Label)

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

0008-9

TM 5-3805-293-10 0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED


KEY LABEL IDENTIFICATION 08 LABEL DEFINITION 08

1 Do Not Weld or Drill (Caution Label) Do not weld or drill on frame. (Not applicable to operator.)

2 Fuel Type Diesel or JP-8 Fuel only

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

4 24V Slave Grader equipped with a 24V slave receptacle.

5 Articulation Bearing Identifies location of grease points for articulation bearings.

0008-10

TM 5-3805-293-10 0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED



1 Cooling System Drain Identifies location of engine coolant drain valve. (Not applicable to operator.)

2 Hydraulic Tank Drain Identifies location of hydraulic fluid tank drain valve. (Not applicable to operator.)

3 Engine Oil Drain Identifies location of engine oil drain valve. (Not applicable to operator.)

0008-11

TM 5-3805-293-10 0008

DATA PLATE 0008

Figure 9. Data Plate. 0008


1 Shipping Data Plate Provides tiedown, lift, and shipping weight information.

2 Lubrication Data Plate Provides lubrication information for machine systems.

TM 5-3805-293-10

0008-12

0008

UNIQUE IDENTIFICATION (UID) LABELS 0008

Figure 10. UID Labels. 0008

Figure 11. UID Labels – Continued. 0008

0008-13/(14 blank)

TM 5-3805-293-10 0008

UNIQUE IDENTIFICATION (UID) LABELS – CONTINUED



END OF WORK PACKAGE

TM 5-3805-293-10

CHAPTER 3

TROUBLESHOOTING PROCEDURES

TM 5-3805-293-10

0009-1

0009


0 0 0 9 TROUBLESHOOTING INTRODUCTION

GENERAL 0009

1. This chapter provides information for identifying and correcting malfunctions that you may find while operating the 120M Motor Grader.

2. WP 0010, Troubleshooting Symptom Index lists common malfunctions which may occur and refers you to the proper page in WP 0011 for a troubleshooting procedure.

3. If you are unaware of the location of an item mentioned in troubleshooting, refer to WP 0002, Equipment Description and Data or WP 0004, Description and Use of Operator Controls and Indicators.

4. Before performing troubleshooting, read and follow all safety instructions found in the warning summary at the front of this manual.

5. This chapter cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify Field Maintenance.

6. When troubleshooting a malfunction:a. Locate the symptom or symptoms in WP 0010, Troubleshooting Index that best describes the malfunction.

If the appropriate symptom is not listed, notify Field Maintenance.b. Turn to the page in WP 0011, Troubleshooting Procedures where the troubleshooting procedures for the

malfunction in question are described. Headings at the top of each page show how each troubleshooting procedure is organized: Malfunction, Test or Inspection (in step number order), and Corrective Action.

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

EXPLANATION OF HEADINGS 0009

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

4

0009-2

TM 5-3805-293-10 0009

MONITORING SYSTEM WARNINGS 0009

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

0009

Table 1.

WARNING ALERT TO OPERATOR ACTION REQUIRED

Category 1 AlertMachine system needs attention.

• Alert indicator activated. 1. Check Messenger system for alert message.

2. Follow instructions on Messenger system.

Category 2 AlertA change in machine operation is required.

• Alert indicator activated. • Action light activated.

1. Check Messenger system for alert message.


Category 2S AlertImmediate change in machine operation is required.

• Alert indicator activated. • Action light activated.• Action alarm sounds at a

steady rate.

1. Check Messenger system for alert message.


Category 3 AlertImmediate need to shut down machine.

• Alert indicator activated. • Action light activated.• Action alarm sounds at a

pulse rate.

WARNINGFailure to follow this warning may result in injury or death to personnel or damage to equipment.1. Shut down machine immediately.2. Check Messenger system for alert

message.3. Follow instructions on Messenger

system.

0009-3/(4 Blank)

TM 5-3805-293-10 0009

MONITORING SYSTEM WARNINGS – CONTINUED

Figure 14. Alert Indicators. 09

KEY COMPONENT DESCRIPTION1 Battery Charge Alert Indicator Illuminates when a problem with machine voltage or alternator

is present.2 Electric Coolant Heater Alert Indicator Illuminates when coolant heater is activated.3 Engine System Alert Indicator Illuminates when an engine problem is present.4 Implement System Alert Indicator Illuminates when an implement system problem is present.5 Primary Steering Alert Indicator Illuminates when a steering system problem is present.6 Action Light Alert Indicator Illuminates when a problem occurs with machine. 7 Parking Brake Indicator Illuminates when parking brakes are engaged.8 Transmission System Alert Indicator Illuminates when a transmission system problem is present.9 Secondary Steering System Alert Indi-

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

10 Brake System Indicator Illuminates when a general fault occurs in brake system. 11 Operator Not Present Alert Indicator Illuminates when under specific conditions operator is not in

cab.

TM 5-3805-293-10

0010-1

0010


0 0 1 0 OPERATOR TROUBLESHOOTING SYMPTOM INDEX

Malfunction/Symptom Troubleshooting Procedure Page

ELECTRICAL SYSTEM 00010

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

HYDRAULIC SYSTEM 00010

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

2

0010-2

TM 5-3805-293-10 0010

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

END OF WORK PACKAGE

TM 5-3805-293-10

0011-1

0011


0 0 1 1 TROUBLESHOOTING PROCEDURESElectrical System, Engine, Hydraulic System, Steering, Transmission, All-Wheel Drive

INITIAL SETUP

Materials/Parts 0

Goggles, Industrial (WP 0032, Item 10) 0

Gloves, Chemical and Oil Protective (WP0032, Item 9) 0

References 0

LO-5-3805-293-13 0

WP 0004 0

WP 0005 0

WP 0013 0

WP 0014 0

WP 0018 0

WP 0019 0

References - Continued 0

WP 0020 0

WP 0022 0

WP 0023 0

WP 0025 0

Equipment Conditions 0

Machine parked on level ground(WP 0005) 0

Blade and scarifier lowered to ground(WP 0005) 0

MALFUNCTIONTEST OR INSPECTION

CORRECTIVE ACTION0.

ELECTRICAL SYSTEM

1. BACKUP ALARM INOPERATIVE.

Step 1. Ensure STOP LIGHT or SER DRIVE has been selected on military light switch (WP 0004).

a. Select STOP LIGHT or SER DRIVE. b. If problem persists, go to Step 2.

Step 2. Check for blown fuse at fuse panel.

a. Replace fuse (WP 0023).b. If problem persists, notify Field Level Maintenance.

2. ALL GROUND ENGAGING TOOLS INOPERATIVE.

Step 1. Check that implement lockout switch is in UNLOCK position (WP 0004).

a. Push bottom of implement lockout switch.b. If problem persists, go to Step 2.



14

0011-2

TM 5-3805-293-10 0011

ELECTRICAL SYSTEM – CONTINUED3. CERTAIN GROUND ENGAGING TOOLS INOPERATIVE – OTHERS OPERATE PROPERLY.

Step 1. Check that implement lockout switch is in UNLOCK position (WP 0004).

a. Push bottom of implement lockout switch.b. If problem persists, go to Step 2.

Step 2. Check for blown fuse(s) at fuse panel.


4. DEFROSTER FAN INOPERATIVE.

Check for blown fuse at fuse panel. a. Replace fuse (WP 0023).b. If problem persists, notify Field Level Maintenance.

5. DIFFERENTIAL LOCK INOPERATIVE.


6. DIRECTIONAL TURN SIGNALS INOPERATIVE.

Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP 0004).


Step 2. Check electrical connector at lamp assembly.

a. Reconnect connectors, if required.b. If connectors are okay, go to Step 3.


a. Replace fuse (WP 0023). If problem persists, notify Field Level Maintenance.


CORRECTIVE ACTION0.

0011-3

TM 5-3805-293-10 0011

ELECTRICAL SYSTEM – CONTINUED7. DOME LAMP INOPERATIVE.



Step 2. Check for burned out or defective bulb.

a. Replace bulb (WP 0020). b. If problem persists, go to Step 3.



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

Step 1. Ensure SER DRIVE or STOP LIGHT function has been selected on military light switch (WP 0004).

a. Select SER DRIVE or STOP LIGHT.b. If problem persists, go to Step 2.

Step 2. Check lights for disconnected or damaged connectors.

a. Reconnect connectors, if required.b. If connectors are secure or if damage is found, notify Field Level Maintenance.

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

Step 1. Ensure STOP LIGHT function has been selected on military light switch (WP 0004).

a. Select STOP LIGHT. b. If problem persists, go to Step 2.

Step 2. Check lights for disconnected or damaged connectors.


10. HEATER AND AIR CONDITIONING INOPERATIVE.


11. HIGH BEAMS INOPERATIVE.

a. Ensure SER DRIVE function has been selected on military light switch (WP 0004).b. If problem persists, notify Field Level Maintenance.


CORRECTIVE ACTION0.

TM 5-3805-293-10

0011-4

0011

ELECTRICAL SYSTEM – CONTINUED12. HORN INOPERATIVE.




a. Replace fuse (WP 0023). b. If problem persists, go to Step 3.

Step 3. Check wiring harness connector is properly connected to horn.

a. Reconnect connector, if required.b. If connector is okay or if harness damage is found, notify Field Level Maintenance.

13. MONITOR SYSTEM BACKLIGHT INOPERATIVE.

Check for blown fuse at fuse panel.a. Replace fuse (WP 0023).b. If problem persists, notify Field Level Maintenance.

14. MONITOR SYSTEM INOPERATIVE.


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




a. Replace fuse (WP 0023). b. If problem persists, go to Step 3.

Step 3. Check wiring harness connector is properly connected to worklight.

If fault is found, notify Field Level Maintenance.


CORRECTIVE ACTION0.

0011-5

TM 5-3805-293-10 0011

ELECTRICAL SYSTEM – CONTINUED16. STOPLIGHTS INOPERATIVE.

Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch(WP 0004).

a. Select SER DRIVE or PARK.b. If problem persists, go to Step 2.

Step 2. Check lights for disconnected connections or damage.


17. TAILLIGHTS INOPERATIVE.

Ensure SER DRIVE function has been selected on military light switch (WP 0004).a. Select SER DRIVE. b. If problem persists, notify Field Level Maintenance.

18. WINDSHIELD WIPER, LEFT DOOR WIPER, OR RIGHT DOOR WIPER INOPERATIVE.

Check for blown fuse at fuse panel.a. Replace fuse (WP 0023).b. If problem persists, notify Field Level Maintenance.


CORRECTIVE ACTION0.

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0011-6

0011

ENGINE

WARNING

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

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

CAUTIONDo not crank engine for longer than 30 seconds. Allow starter motor to cool for two minutes beforecranking again or damage to equipment may result.

1. COOLANT TEMPERATURE TOO HIGH.

WARNING

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

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

• Wear protective eye, hand, and skin protection when handling coolant.• Failure to follow these warnings may result in injury or death to personnel.

Step 1. Check coolant level in coolant tank (WP 0013).

a. Fill coolant tank to specifications (WP 0013). b. If problem persists, go to Step 2.

Step 2. Check radiator for dirt, debris, or damaged fins.

a. Clean dirt and debris from radiator (WP 0025).b. If problem persists or if fins are damaged, notify Field Level Maintenance.


CORRECTIVE ACTION0.

0011-7

TM 5-3805-293-10 0011

ENGINE – CONTINUED2. ENGINE CANNOT REACH TOP ENGINE RPM.

Step 1. Check for diagnostic codes (WP 0005).

a. If diagnostic codes are present, notify Field Level Maintenance. b. If no diagnostic codes are present, go to Step 2.

Step 2. Check air filters (WP 0014).

a. Clean or replace air filters (WP 0014).b. If problem persists, go to Step 3.

Step 3. Check fuel supply.

a. Verify fuel is not solidified (temperatures below 32°F (0°C)).b. Add fuel (WP 0013).c. If problem persists, notify Field Level Maintenance.

3. ENGINE CRANKS BUT WILL NOT START.


a. If diagnostic codes are present, notify Field Level Maintenance. b. If there are no diagnostic codes, go to Step 2.


a. Clean or replace air filters (WP 0014). b. If problem persists, go to Step 3.

Step 3. Verify fuel level.

a. Add fuel as necessary (WP 0013). b. If problem persists, go to Step 4.

Step 4. Check circuit breakers.

a. Reset circuit breakers (WP 0018).b. If problem persists, notify Field Level Maintenance.


CORRECTIVE ACTION0.

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0011-8

0011

ENGINE – CONTINUED4. ENGINE DOES NOT CRANK WHEN START SWITCH IS ENGAGED.

Step 1. Verify parking brake is engaged and transmission control switch is in NEUTRAL position.

a. Engage parking brake and move transmission control switch to NEUTRAL. b. If problem persists, go to Step 2.

Step 2. Verify battery disconnect switch is turned to ON position.

a. Turn battery disconnect switch to ON position. b. If problem persists, go to Step 2.

Step 3. Check circuit breakers (WP 0019).

a. Reset circuit breakers (WP 0019). b. If problem persists, notify Field Level Maintenance.

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


a. If diagnostic codes are present, notify Field Level Maintenance. b. If there are no diagnostic codes, go to Step 2.



Step 3. Check for water in fuel (WP 0013).

a. Drain fuel/water separator (WP 0022).b. If problem persists, notify Field Level Maintenance.

6. ENGINE STARTS BUT DIES.


a. If diagnostic codes are present, notify Field Level Maintenance.b. If there are no diagnostic codes, go to Step 2.

Step 2. Check for water in fuel (WP 0013).

a. Drain fuel/water separator (WP 0022).b. If problem persists, notify Field Level Maintenance.

7. EXCESSIVE EXHAUST SMOKE AT NORMAL OPERATING TEMPERATURE.

Check air filters (WP 0014).a. Clean or replace air filters (WP 0014).b. If problem persists, notify Field Level Maintenance.


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0011-9

TM 5-3805-293-10 0011

ENGINE – CONTINUED8. EXCESSIVE OIL CONSUMPTION.

Step 1. Check for misreading of oil level.

a. Accurately measure oil level. b. If problem persists, go to Step 2.



Step 3. Check for loose or leaking oil lines and oil leaks.

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

9. ENGINE QUITS WHILE RUNNING.

Step 1. Check fuel level on gauge and in Messenger (WP 0005).

a. Add fuel if low. b. If problem persists, go to Step 2.


a. If diagnostic codes are present, notify Field Level Maintenance.b. If there are no diagnostic codes, go to Step 3.

Step 3. Check fuel/water separator bowl for presence of fuel and that fuel is not gelled.

a. If fuel is not present or is gelled, notify Field Level Maintenance.b. If fuel is present and not gelled, go to Step 4.


a. Clean or replace air filters (WP 0014).b. If problem persists, notify Field Level Maintenance.

10. LOW ENGINE OIL PRESSURE.

Check engine oil level.a. Fill oil to specification (LO 5-3805-293-13).b. If problem persists, notify Field Level Maintenance.


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TM 5-3805-293-10

0011-10

0011

HYDRAULIC SYSTEM

WARNING

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

NOTEIt is normal for hydraulic functions to operate slowly when hydraulic oil is very cold (less than 32°F(0°C). Allow machine additional time to warm up if required.

1. TRAVEL TIME FOR BLADE LIFT CYLINDERS IS SLOW, HYDRAULIC OIL TEMPERATURE EQUAL TO OR GREATER THAN 32°F (0°C).

Step 1. Check blade hydraulic cylinder for buildup of debris.

a. Remove debris.b. If problem persists, go to Step 2.

Step 2. Check hydraulic fluid level (LO 5-3805-293-13).

a. Add hydraulic fluid as necessary (LO 5-3805-293-13).b. If problem persists, notify Field Level Maintenance.

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

Step 1. Check scarifier area for buildup of debris.

a. Remove debris.b. If problem persists, go to Step 2.




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0011-11

TM 5-3805-293-10 0011

STEERING

WARNING• Hitch and steering movement can reduce clearances suddenly. Stop engine before servicing.

Failure to follow this warning may result in injury or death to personnel.• Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to fol-

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

Maintenance. Failure to follow this warning may result in serious injury or death to personnel,or damage to equipment.

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

Step 1. Check tire pressures (WP 0013).

a. If tire inflation pressure is from 1 to 4 psi low, inflate to specifications (WP 0013).b. If tire inflation pressure is more than 4 psi low, notify Field Level Maintenance.c. If problem persists, notify Field Level Maintenance.

Step 2. Check steering linkage and hydraulic cylinders for damage.

If damage is found, notify Field Level Maintenance.

2. MACHINE STEERING IS SLOW OR RESPONDS INTERMITTENTLY.

Check hydraulic fluid level (LO 5-3805-293-13).a. Add hydraulic fluid as necessary (LO 5-3805-293-13).b. If problem persists, notify Field Level Maintenance.

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

Step 1. Check for oil leaks at steering cylinders.

a. If leaks are found, notify Field Level Maintenance.b. If no leaks are found and problem persists, go to Step 2.

Step 2. Check hydraulic oil level (LO 5-3805-293-13).


4. MACHINE TURNS SLOWLY IN BOTH DIRECTIONS AFTER REACHING OPERATING TEMPERATURE.

Check hydraulic oil level (LO 5-3805-293-13).a. Add hydraulic fluid as necessary (LO 5-3805-293-13).b. If problem persists, notify Field Level Maintenance.


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0011-12

0011

STEERING – CONTINUED5. MACHINE TURNS SLOWLY IN ONE DIRECTION.

Step 1. Check for oil leaks at steering cylinders.

a. If leaks are found, notify Field Level Maintenance.b. If no leaks are found and problem persists, go to Step 2.

Step 2. Check hydraulic oil level (LO 5-3805-293-13).


6. STEERING IS ERRATIC.


a. Add hydraulic fluid as necessary (LO 5-3805-293-13). b. If problem persists, go to Step 2.

Step 2. Check for air bubbles in hydraulic reservoir.

If bubbles are found, notify Field Level Maintenance.

TRANSMISSION

NOTEBefore checking oil level, ensure machine is parked on level ground, parking brake is engaged,transmission control switch is in the NEUTRAL position, and the engine is warmed up and at lowidle.

1. SLOW OR ERRATIC TRANSMISSION ENGAGEMENT.

Step 1. Check transmission fluid level (LO 5-3805-293-13).

a. Add fluid as necessary (LO 5-3805-293-13).b. If problem persists, notify Field Level Maintenance.

2. TRANSMISSION DOES NOT OPERATE IN ANY GEAR.

Step 1. Check transmission fluid level (LO 5-3805-293-13).

a. Add fluid as necessary (LO 5-3805-293-13).b. If problem persists, go to Step 2.

Step 2. Check circuit breakers (WP 0018).

a. Reset circuit breakers (WP 0018).b. If problem persists, notify Field Level Maintenance.


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0011-13/(14 blank)

TM 5-3805-293-10 0011

ALL-WHEEL DRIVE

WHEEL SPEED OR ENGINE SPEED SURGES AT HIGH AGGRESSION SETTINGS.

Machine being operated in sand or similar loose, dry conditions.Reduce aggression to a maximum of 100 percent.

END OF WORK PACKAGE


CORRECTIVE ACTION0.

TM 5-3805-293-10

CHAPTER 4

PMCS INSTRUCTIONS

TM 5-3805-293-10

0012-1

0012


0 0 1 2 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL 00012

1. To ensure that the 120M Motor Grader is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in injury, damage, or equipment failure.

2. The PMCS Table in WP 0013 contains systematic instructions on inspections, lubrications, services, tests, and corrections to be performed by the operator to keep the equipment in good operating condition and ready for its primary mission.

EXPLANATION OF TABLE ENTRIES 00012

1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E, Equipment Inspection and Maintenance Worksheet, include the item number for the check/service indicating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed.

2. Interval Column. This column tells you when you must perform the procedure in the Procedure column:a. Before procedures must be done immediately before you operate the grader. b. During procedures must be done while you are operating the grader.c. After procedures must be done immediately after you have operated the grader.d. Biweekly or Every 100 Service Hours procedures must be done once every two weeks or after every

100 hours of machine operation. e. Initial 500 Service Hours (or at first oil change) procedures must be done after the first 500 hours of

machine operation or at the first engine oil change.f. Every 500 Service Hours or 3 Months procedures must be done every 500 hours of machine operation or

every three months.g. Every 1,000 Service Hours or 6 Months procedures must be done every 1,000 hours of machine operation

or every six months.h. Every 2,000 Service Hours or 2 Years procedures must be done every 2,000 hours of machine operation

or every two years.i. Yearly procedures must be done once each year.

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

NOTEThe WARNINGs and CAUTIONs appearing in your PMCS table should always beobserved. WARNINGs and CAUTIONs appear before applicable procedures. You mustobserve these WARNINGs to prevent injury or death to yourself and others, andCAUTIONs to prevent your equipment from being damaged.

4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item to Check/Service column, to know if the equipment is ready and available for its intended mission. You must perform the procedure at the time stated in the Interval column.

5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equip-ment from being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or reporting equipment failure.

4

TM 5-3805-293-10

0012-2

0012

GENERAL PMCS PROCEDURES 00012

1. Intervals (on-condition or hardtime) and the related manhour times are based on normal operation. The manhour time specified is the time you need to do all the services prescribed for a particular interval. Change the hardtime interval if your lubricants are contaminated or if you are operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The hardtime interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken.

2. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will spot anything wrong in a hurry. If the equipment does not perform as required, refer to the appropriate trouble-shooting procedure in Chapter 3.

3. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find something seriously wrong, IMMEDIATELY report it to your supervisor.

4. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all that is needed to make all the checks. You will always need a rag (Item 17, WP 0032) or two.

WARNING

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

CAUTIONBe especially careful when cleaning electrical system components including lighting.Damage or impaired operation could result if this caution is not observed.

a. Keep Equipment Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use solvent cleaning compound (Item 2, WP 0032) on all metal surfaces. Use detergent (Item 4, WP 0032) and water when you clean rubber, plastic, and painted surfaces. Spot paint as required to prevent corrosion.

b. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing, or damaged bolts, nuts, and screws to your supervisor.

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

d. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Report loose connections and faulty wiring to your supervisor.

e. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any worn, damaged, or loose hoses, lines, and fittings to your supervisor.

0012-3/(4 blank)

TM 5-3805-293-10 0012

FLUID LEAKAGE 00012

NOTENotify Field Level Maintenance of any leaks the operator cannot fix.

It is necessary for you to know how fluid leakage affects the status of the 120M Motor Grader. Following are types/classes of leakage you need to know to be able to determine the status of the 120M Motor Grader. Learn these leakage definitions and remember - when in doubt, notify your supervisor. Equipment operation is allowed with minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify your supervisor.When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS.Class III leaks should be reported immediately to your supervisor.

GENERAL LUBRICATION PROCEDURES 00012

NOTERefer to Lubrication Order (LO 5-3805-293-13).

1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under extreme conditions, lubricants should always be changed more frequently. When in doubt, notify your supervisor.

2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep container covers clean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep all lubrication equipment clean and ready for use.

3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to DA PAM 750-8 for maintenance forms and procedures to record and report any findings.

4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fittings with a clean Rag, Wiping (WP 0032, Item 17). After lubrication, wipe off excess oil or grease to prevent accumulation of foreign matter.

5. Refer to FM 9-207 for lubrication instructions in cold weather.6. Refer to AR 70-12 for use of standardized lubricants.

END OF WORK PACKAGE

Leakage Definitions for PMCS

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

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

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

TM 5-3805-293-10

0013-1

0013


0 0 1 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP


Basic Issue Items (WP 0031) 0

Materials/Parts 0

Antifreeze (WP 0032, Item 1) 0

Cleaning Compound, Solvent, Type III (WP0032, Item 2) 0

Cleaning Compound, Windshield (WP 0032,Item 3) 0

Detergent, General Purpose, Liquid (WP0032, Item 4) 0

Diesel Fuel, DF-1 Grade, Arctic (WP 0032,Item 5) 0

Diesel Fuel, DF-2 Grade (WP 0032, Item 6) 0

Fuel, Turbine, Aviation (WP 0032, Item 8) 0

Grease, Automotive and Artillery (GAA) (WP0032, Item 11) 0

Lubricant, Dry Film (WP 0032, Item 12) 0

Oil, Lubricating, OE/HDO-30 (WP 0032, Item13) 0

Oil, Lubricating, OE/HDO-15W/40 (WP 0032,Item 15) 0

Oil, Lubricating, OEA Arctic (WP 0032, Item16) 0

Rag, Wiping (WP 0032, Item 17) 0

0

References 0

WP 0004 0

WP 0005 0

WP 0010 0

WP 0014 0

WP 0015 0

WP 0017 0

WP 0019 0

WP 0021 0

WP 0022 0

WP 0024 0

WP 0026 0

WP 0027 0

WP 0032 0

LO 5-3805-293-13 0

Equipment Conditions 0

Machine parked on level ground (WP 0005) 0

Blade and scarifier lowered to ground (WP 0005) 0

Parking brake engaged (WP 0004) 0

56

TM 5-3805-293-10

0013-2

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) with Lubrication Information.

ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURENOT FULLY MISSION

CAPABLE IF:

NOTE• Review all WARNINGs, CAUTIONs, and NOTEs before

performing PMCS and operating the machine.• Perform all PMCS checks if:

– You are the assigned operator but havenot operated the machine since the lastweekly checks.

– You are operating the machine for thefirst time.

• Unless otherwise indicated, perform PMCS with machineparked on level ground, parking brake applied,transmission in N (Neutral), blade lowered to the ground,wheels blocked, and engine shut down.

• If leakage is detected during performance of PMCS,further investigation is required to determine location andcause of leak.

• Walk around machine and look for any obvious leaks ordamage.

• During walk around, also visually check tires for lowinflation, damage, and debris.

LEFT SIDE

1 Before Overall View Check left side of machine for evidence of leakage or damage.

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

2 Before All-Wheel Drive Hoses

Check all-wheel drive (AWD) hoses and fittings for damage or leaks.


0013-3

TM 5-3805-293-10 0013

3 Before Left Front Tire WARNING• Improperly inflated tires can cause excessive heat buildup

resulting in blowouts. Failure to follow this warning mayresult in serious injury or death, or damage to equipment.

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

Visually check tire for underinflation.

Tire pressure appears low.

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

Missing or damaged components if required for mission.

5 Before Fuel Tank Filler Cap

Ensure fuel tank filler cap is present and secure.

Missing fuel tank filler cap.

Figure 1. Fuel Tank Filler Cap. 0013

6 Before Below Operator Compartment

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

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

Table 1. Preventive Maintenance Checks and Services (PMCS) with Lubrication Information - Continued.

ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-4

0013

7 Before Arctic Heater (if equipped)

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

Class III leaks or damaged or missing components if required for mission.

Figure 2. Arctic Heater. 0013

8 Before 0.2 Engine Oil Level Check

a. Open left front access door.

b. Clean area around engine oil level gauge (dipstick) (Figure 3, Item 2) and fill cap (Figure 3, Item 1).

c. Remove oil level gauge, wipe clean and reinstall. Remove oil level gauge and check level of oil. Maintain oil level between the marks on oil level gauge (Figure 3, Item 3).

Oil level is below or above crosshatch area on gauge, or fill cap missing.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-5

TM 5-3805-293-10 0013

8 (Cont.)

Before 0.2 Engine Oil Level Check

d. Add oil as required through filler opening. Refer to LO 5-3805-293-13 for proper grade of oil based on ambient temperature. Clean oil filler cap, then reinstall.

Figure 3. Oil Level Gauge (Dipstick) and Fill Cap. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-6

0013

9 Coolant Level Checks WARNING

• DO NOT service cooling system unless engine has beenallowed to cool down. This is a pressurized coolingsystem and escaping steam or hot coolant will causeserious burns.

• DO NOT remove cooling system radiator cap whenengine is hot. Allow engine to cool down. Loosen cap tofirst stop and let any pressure out of cooling system, thenremove cap. Failure to follow this warning may causeserious burns.

• Wear effective eye, hand, and skin protection whenhandling coolants. Failure to do so may cause injury topersonnel.

CAUTION• Do not add water to pre-mixed antifreeze. If water is

added to pre-mixed antifreeze, it will be diluted and will notprovide proper engine protection and engine and/or cool-ing system damage may occur.

• Be sure to identify the type of antifreeze being added, orengine and/or cooling system damage may occur.

NOTE• Some antifreeze is pre-mixed with water and does not

require mixing with water.• Traditional antifreeze requires mixing with an equal

amount of water. Mix antifreeze and water before addingto machine cooling system to ensure proper 1:1 ratio isused.

• It is allowable to mix traditional and pre-mix antifreezetypes in the same cooling system.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-7

TM 5-3805-293-10 0013

9 (Cont.)

Before Coolant Level Checks

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

Coolant level is below ADD mark.

Figure 4. Coolant Tank Level. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-8

0013

10 Before Transmission/Differential Oil Level Check

a. Clean area around transmission oil level gauge/fill cap (dipstick).

b. Start engine and run engine at low idle (WP 0005).

c. Remove oil level gauge/fill cap, wipe, clean, and reinstall.

d. Remove oil level gauge/fill cap, and check level of oil.

Oil level does not register on gauge, or fill cap missing.

NOTEProceed to next step only if oil does not register on gauge.

e. Add oil (WP 0032, Items 18 or 21) as required through oil filler tube. Refer to LO 5-3805-293-13 for proper grade of oil based on ambient temperature.

f. Stop engine (WP 0005).

g. Close left front access door.

Figure 5. Transmission/Differential Oil Level Check. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-9

TM 5-3805-293-10 0013

11 Before Hydraulic Tank Sight Gauge

a. Open left rear access door.

b. Clean area around hydraulic tank sight gauge.

c. Check oil level is visible in sight gauge.

NOTEProceed to the following steps only if oil level is not visiblein sight gauge.

d. Operate machine until oil is warm (WP 0005).

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

e. Clean area around hydraulic oil filler cap.

f. Maintain oil level above the MIN mark on sight gauge.

g. Add oil (WP 0032, Items 18 or 21) as required through hydraulic oil filler cap. Refer to LO 5-3805-293-13 for proper grade of oil based on ambient temperature.

Figure 6. Hydraulic Oil Level Check. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-10

0013

12 Before NATO Receptacle

a. Ensure NATO slave receptacle cover is installed.

b. Close left rear access door.

13 Before Left Rear Tires WARNING• Improperly inflated tires can cause excessive heat buildup

resulting in blowouts. Failure to follow this warning mayresult in serious injury or death to personnel, or damage toequipment.




REAR

14 Before Rear of Machine

a. Check for damage to rear blackout light, taillights, turn signal lights, backup lights and rear worklight.


b. Check radiator grille, backup alarm, and towing pin for debris and damage.


c. Check under engine compartment for evidence of fluid leakages such as oil, coolant, fuel, and hydraulic fluid.

Class III oil or hydraulic fluid leaks are present. Any fuel leakage is evident.

d. Check rear of machine for obvious damage that would impair operation.



ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-11

TM 5-3805-293-10 0013

RIGHT SIDE

15 Before Right Rear Tires

WARNING• Improperly inflated tires can cause excessive heat buildup


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

Visually check tires for underinflation.


16 Before Overall View Check right side of machine for evidence of leakage or damage.

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

17 Before Right Rear Access Door

a. Open right rear access door.b. Visually check for loose, damage, cracked components, or evidence of leaks.c. Close right rear access door.



ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-12

0013

18 Before Ether Cylinder a. Open right front access door.

b. Remove ether cylinder and shake to check if cylinder is empty (WP 0021). Install new cylinder if required (WP 0021).


c. If no ether cylinder is present, ensure cap is installed on ether valve.

Figure 7. Ether Cylinder. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-13

TM 5-3805-293-10 0013

19 Before Engine Compartment

a. Visually check for loose, damage, cracked components, or evidence of leaks.b. Close right front access door.


20 Before BelowOperator Compartment

a. Check hoses and connections below right side of operator compartment for damage or leaks.b. Check cables for fraying or damage.


21 Before Right Front Tire






22 Before Lights Check right front work light, headlight, blackout drive light, blade work light, and front turn signal light for missing or damaged components.

Missing or damaged components if necessary for mission.

CABINTERIOR

23 Before Battery Disconnect Switch

Turn battery disconnect switch to ON position.

24 Before Fire Extinguisher

a. Visually check for missing or damaged fire extinguisher. Ensure it is securely stowed in mounting bracket.

Fire extinguisher is missing or damaged.

b. Check gauge for pressure reading in green area on gauge.

Pressure gauge needle is in red area.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-14

0013

24 (Cont.)

Before Fire Extinguisher

c. Check for damaged or missing seal.

Seal is broken or missing.

d. Inspect fire extinguisher inspection tag.

Inspection date is not current and/or tag is missing.

25 Before Operator Seat Check seat and seat belt mounting hardware (Figure 8, Item 1), seat belt buckle (Figure 8, Item 2), and seat belt (Figure 8, Item 3) for damage or wear (WP 0004).

Seat belt is damaged.

Figure 8. Seat Belt Inspection. 0013

26 Before Rearview Mirror and Side View Mirrors

Check and adjust inside rearview mirror. With an assistant, check and adjust side view mirrors.

27 Before Lights With an assistant, check operation of lights (service and blackout light, brake lights, turn signals and work lights) (WP 0005).

Any lights do not function, if required for mission.

28 Before Wipers and Washers (if equipped)

Operate all wipers and washers to verify correct operation (WP 0004).

Wipers and washers not operating if required for mission.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-15

TM 5-3805-293-10 0013

29 Before Backup Alarm and Horn

a. Verify that backup alarm functions when transmission is placed in R (Reverse) (WP 0005).

Backup alarm does not function.

b. Check operation of horn (WP 0005).

Horn does not function.

NOTEMonitor system self-diagnostic test takes approximately10 seconds to complete.

30 Before Monitor System Indicators and Gauges

a. Turn engine start switch from OFF position to ON position (do not start engine) to initialize self-diagnostic test.

Fails to enter diagnostic test.

b. Monitor the following:

1. All gauges must sweep to far right position, then return.

Any gauge does not move.

Figure 9. Monitor System Display - Gauges. 0013

2. All alert indicators must come on momentarily.

Any alert light does not come on.

3. All segments in LCD display must come on momentarily.

LCD display segment(s) inoperative

4. The action alarm must sound.

Action alarm does not sound.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-16

0013

31 Before Left and Right Blade Float Indicators

WARNINGBlade must be lowered before activating blade float.Failure to follow this warning may result in injury topersonnel.

NOTEIf engine fails to start, turn ignition switch to the OFFposition, and retry.

a. Start engine and run engine at low idle (WP 0005).

b. Move right and left joysticks to most forward detent (WP 0005). Blade float indicators should be ON in display.

Blade float indicators do not come ON.

32 Before Action Light Indicator

a. Run engine at low idle (WP 0005).

b. Monitor action light indicator in display.

c. If action light indicator is ON, machine needs service.

Action light indicator is ON.

Figure 10. Monitor System Display - Action Light and Blade Float Indicators.

0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-17

TM 5-3805-293-10 0013

33 Before Messenger Display

With engine running, observe the Messenger display.

Messenger displays error message or Messenger is not operating.

Figure 11. Messenger Display. 0013

34 Before Differential Lock

Push control button on right joystick. Indicator light should go ON (WP 0004).

Differential lock indicator inoperative.

35 Before Hydraulic Controls

Perform a functional check of all hydraulic systems: blade lift, centershift, circle drive, blade tilt, steering, wheel lean, and scarifier (WP 0005).

Class III oil leak is evident. Any hydraulic system or function does not operate properly.

36 Before Brake Accumulator

a. Start engine and run for no less than one minute to increase accumulator pressure.

b. Stop engine.

c. Turn ignition switch to ON position. DO NOT start engine.

d. Fully depress service brake slowly a minimum of five applications.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-18

0013

36 (Cont.)

Before Brake Accumulator

e. If brake system indicator light illuminates with less than five applications, notify Field Level Maintenance.

Brake system indicator light illuminates with less than five applications.

37 Before Pedals Check accelerator pedal, service brake pedal, and transmission modulator control pedal for binding and obstructions.

Pedal binds or does not operate properly.

Figure 12. Accelerator, Brake, and Transmission Pedals. 0013

38 During Brakes Check service brakes for pulling, grabbing, or reduced braking capacity.

Brakes pull, grab, or do not operate properly.

39 During Steering Check for smooth, controlled steering without pulling or drifting.

Steering is erratic.

40 During Drive Train Monitor grader operation for unusual noise or vibrations from engine, transmission, drive shafts, axles, and wheels.

Unusual noises or vibrations are present.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-19

TM 5-3805-293-10 0013

41 During Blade andScarifier

Monitor blade and scarifier operations for unusual noise or vibrations.

Unusual noises or vibrations present.

42 During Overall Leakage

Watch for evidence of fluid leakage.


43 During Instrument Panel

a. With machine fully warmed up, monitor indicators and gauges and Messenger Display.

Gauges and warnings indicate an abnormal reading.

b. If action light indicator is flashing, troubleshoot system (WP 0010).

Any flashing of action light indicator.

44 During Air Conditioner, Heater and Defroster Fan

Check air conditioner, heater and defroster fan for correct operation.

Damaged or does not operate if required for mission.

45 After Overall View NOTEEnsure machine is clean in order to facilitateperformance of PMCS inspections.

a. Check under machine for evidence of fluid leakages such as oil, coolant, fuel, or hydraulic fluid.


b. Check machine for obvious damage that would impair operation.

Damage that would impair operation is evident.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-20

0013

LEFT SIDE

46 After Left Front Wheel and Tire




a. Check tires for cuts or bulges in tread or sidewall area. Check for uneven wear and foreign material embedded in tread or sidewall area.

Tire has cuts, bulges, or foreign material in tread or sidewall area or other damage that would impair operation.

b. Clean area around valve stem, then remove valve stem cap.

Valve stem damaged.

c. Check tire inflation pressure with tire pressure gauge. Refer to WP 0002 for proper tire inflation pressures.

Tire inflation pressure more than 4 psi low.

d. Check for loose or missing lug bolts.

Loose, or two or more missing lug bolts.

e. Check wheel for damage. Wheel damaged.

47 After Steering a. Check steering linkage for cracks, distortion, or damage.

Cracks or distortion in steering linkage that would impair operation.

b. Check left front steering cylinder and hoses for damage or leaks.

Class III leaks or damage that would impair operation.

48 After Drawbar a. Check drawbar and drawbar pivot point for damage.


b. Check all hoses and fittings for leaks.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-21

TM 5-3805-293-10 0013

49 After Scarifier Check scarifier frame, link sockets, and teeth for excessive wear (WP 0026 and WP 0027), damage, or missing components.

Damage that would impair operation, or missing six scarifier teeth if required for mission.

50 After Hydraulic Cylinders

a. Check scarifier hydraulic cylinder and hoses for damage or leaks.


b. Check left blade lift cylinder and hoses for damage or leaks.


c. Check centershift cylinder and hoses for damage or leaks.


51 After Circle Drive Check all circle drive and circle drive components for leaks, damage or debris. Remove debris.


52 After Blade, Cutting Edges, and End Bits

a. Check entire blade for damage or distortion.

Damage or distortion.

b. Check all cutting edges and end bits for damage or loose bolts.

Damage or loose bolts.

c. Check all cutting edges and end bits for excessive wear (WP 0019).

Cutting edge or end bits are worn to within 3/4 in. (19 mm) of blade.

d. Check sideshift cylinder for debris, damage, or leaks. Remove debris.


53 After Blade Work Lights

Ensure blade work lights are present and securely mounted.


54 After Left Door Check left door for damage or missing components.


55 After Left Mirror and Step

Check left side mirror and step for damage or missing components.


56 After Rollover Protective Structure (ROPS)

Check ROPS for damage and loose or missing mounting bolts.

Loose or missing ROPS bolts or damage to structure.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-22

0013

57 After Refueling WARNING

• DO NOT smoke or permit any open flame in area ofmachine while you are servicing fuel system. Be surehose nozzle is grounded against filler tube during refuelingto prevent static electricity. Failure to follow this warningmay cause injury to personnel or damage to equipment.

• Operating personnel must wear fuel-resistant gloves whenhandling fuels. If exposed to fuel, promptly wash exposedskin and change fuel-soaked clothing.

NOTE• Place portable fire extinguisher within reach prior to

refueling.• DO NOT overfill fuel tank. If fuel starts foaming from fuel

tank, stop IMMEDIATELY to avoid fuel spillage.• Observe sight glass while adding fuel to ensure fuel spill-

age due to overfilling does not occur.

a. Check fuel tank, filler tube, and filler cap for damage or leaks.

Any fuel leaks or damage are noted.

Figure 13. Fuel Tank, Filler Tube, Sight Glass, and Cap. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-23

TM 5-3805-293-10 0013

57 (Cont.)

After Refueling b. Remove filler cap. Inspect filler cap, gasket, and screen for damage.

Filler cap, gasket or screen is missing or damaged.

c. Reinstall screen.

d. Add fuel (WP 0032, Items 11, 12, or 15) to tank. DO NOT overfill. Reinstall filler cap and secure.

Figure 14. Filler Cap, Gasket, and Screen. 0013

58 After Articulation Lock Pin

Check articulation lock pin is present in lock pin storage bracket.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-24

0013

WARNING

If CBRN exposure is suspected, personnel wearing pro-tective equipment must handle all air cleaner media. Con-taminated filters must be handled using adequateprecaution and must be disposed of by trained personnel.Consult your CBRN Officer or CBRN NCO for appropriatehandling or disposal procedures. Failure to follow thiswarning may result in injury or death to personnel.

59 After Primary and Secondary Air Filters

a. Remove air filter cover.

b. Ensure primary air filter is present.

c. Remove primary and secondary air filters.

Missing or damaged air filter components.

d. Inspect and clean or replace filters (WP 0014).

e. Install secondary and primary air filters.

f. Install air filter cover.

Figure 15. Air Filters and Cover. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-25

TM 5-3805-293-10 0013

60 After Fuel/ Water Separator WARNING

Fuel leaked or spilled onto hot surfaces or electricalcomponents can cause a fire. Failure to follow thiswarning may cause injury to personnel or equipmentdamage.

Drain fuel/water separator (WP 0022).

Excessive amounts of water in fuel.

Figure 16. Fuel/Water Separator. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-26

0013

61 After 0.2 Transmission/Differential Oil Level Check

a. Clean area around transmission oil level gauge/fill cap.

b. Start engine and run engine at low idle (WP 0005). Remove oil level gauge/fill cap, clean, and reinstall.

c. Remove oil level gauge/fill cap and check level of oil. Maintain oil level between marks on oil level gauge/fill cap.

d. Add oil (WP 0032, Item 18 or 21) as required through oil filler tube.

e. Stop engine (WP 0005).

Figure 17. Transmission/Differential Oil Level Check. 0013

62 After 0.2 Engine Oil Level Check

a. Open left front access door.

b. Clean area around engine oil level gauge (dipstick) (Figure 18, Item 2) and fill cap (Figure 18, Item 1).

Class III oil leak or damage is evident.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-27

TM 5-3805-293-10 0013

62 (Cont.)

After 0.2 Engine Oil Level Check

c. Add oil (WP 0032, Items 18 or 21) as required through oil filler cap opening. Refer to LO 5-3805-293-13 for proper grade of oil based on ambient temperature. Clean oil filler cap, then reinstall.

Fill cap missing.

Figure 18. Engine Oil Level Check. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-28

0013

63 After Arctic Heater (if equipped)

Check arctic heater fuel line (Figure 19, Item 1), coolant hoses (Figure 19, Item 2), grommets (Figure 19, Item 3), electrical harness and connector (Figure 19, Item 4), and exhaust tube (Figure 19, Item 5) for leaks, damaged or missing components.

Class III leaks or damaged or missing components if required for mission.

Figure 19. Arctic Heater. 0013

64 After Left Rear Wheels and Tires






b. Clean area around valve stems, then remove valve stem caps.

Valve stem damaged.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-29

TM 5-3805-293-10 0013

64 (Cont.)

After Left Rear Wheels and Tires




Loose or two or more missing lug bolts.

e. Check wheels for damage. Wheel damaged.

65 After Left Tandem Housing

Check for damage and leaks from tandem housing.


66 After Coolant Level Checks WARNING

• DO NOT service cooling system unless engine has beenallowed to cool down. This is a pressurized coolingsystem and escaping steam or hot coolant will causeserious burns.

• DO NOT remove cooling system radiator cap whenengine is hot. Allow engine to cool down. Loosen cap tofirst stop and let any pressure out of cooling system, thenremove cap. Failure to follow this warning may causeserious burns.

• Wear effective eye, hand, and skin protection whenhandling coolants. Failure to do so may cause injury topersonnel.

CAUTION• Do not add water to pre-mixed antifreeze. If water is

added to pre-mixed antifreeze, it will be diluted and will notprovide proper engine protection and engine and/or cool-ing system damage may occur.

• Be sure to identify the type of antifreeze being added, orengine and/or cooling system damage may occur.

NOTE• Some antifreeze is pre-mixed with water and does not

require mixing with water.• Traditional antifreeze requires mixing with an equal

amount of water. Mix antifreeze and water before addingto machine cooling system to ensure proper 1:1 ratio isused.

• It is allowable to mix traditional and pre-mix antifreezetypes in the same cooling system.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-30

0013

66 (Cont.)

After Coolant Level Checks

a. Check coolant level in coolant tank (Figure 20, Item 1). Maintain level between FULL mark and ADD mark on the coolant tank (Figure 20, Item 1).

b. Close left front access door.

Figure 20. Coolant Tank. 0013

67 After 0.2 Hydraulic Tank Sight Gauge

a. Open left rear access door.

b. Clean area around hydraulic tank sight gauge and hydraulic oil filler cap.

c. Maintain oil level above MIN mark on sight gauge.

d. Add oil (WP 0032, Items 18 or 21) as required through filler tube. Refer to LO 5-3805-293-13 for proper oil based on ambient temperature.

Fill cap missing.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-31

TM 5-3805-293-10 0013

67 (Cont.)

After 0.2 Hydraulic Tank Sight Gauge

Figure 21. Hydraulic Oil Tank. 0013

68 After NATO Receptacle

a. Ensure NATO slave receptacle cover is installed.

b. Close left rear access door.

REAR

69 After Rear of Machine WARNING

Wear suitable eye protection and keep face and eyesaway from exhausting air tank drain valves. Failure to doso may cause injury to personnel.

a. Check for damage to rear blackout light, taillights, turn signal lights, and rear work light.


b. Check radiator grille and backup alarm for debris and damage.



ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-32

0013

69 (Cont.)

After Rear of Machine

c. Check under engine compartment for evidence of fluid leakages such as oil, coolant, fuel, and hydraulic fluid.


d. Check machine for obvious damage that would impair operation.


e. Check rear support brackets mounted on rear bumper for damaged or missing components.

Missing or damaged component if required for mission.

f. Check for presence of hitch pin. Missing or damaged component if required for mission.

RIGHT SIDE AND FRONT

70 After Refrigerant Condenser and Hydraulic Oil Cooler

a. Open right rear access door.b. Check condenser and cooler for debris and damage.

Refrigerant condenser and/or hydraulic oil cooler damage.

c. Close right rear access door.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-33

TM 5-3805-293-10 0013

70 (Cont.)

After Refrigerant Condenser and Hydraulic Oil Cooler

Figure 22. Refrigerant Condenser and Hydraulic Oil Cooler. 0013

71 After Right Rear Wheels and Tires







Valve stem damaged.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-34

0013

71 (Cont.)

After Right Rear Wheels and Tires




Loose or two or more missing lug bolts.

e. Check wheels for damage. Wheel damaged.

72 After RightTandem Housing

Check for damage and leaks from right side tandem housing.


73 After Right Front Access Door

Visually check exhaust system, air intake system components, and turbocharger air tubes for looseness, damage, or missing components.

Missing, damaged, or loose components.

74 After Frame Articulation Point Area

WARNINGHitch and steering movement can reduce clearancessuddenly and cause injury to personnel. Always stopengine BEFORE working in area of hitch link.

Visually check for any obstructions between moving components of frame articulation point. Remove obstructions and check for damage.


75 After Rollover Protective Structure (ROPS)

Check ROPS for damage and loose or missing mounting bolts.

One loose or missing ROPS bolt or damage to structure.

76 After Right Door Check right door for damage or missing components.


77 After Right Mirror Check right side mirror for damage or missing components.

Missing or damaged component.

78 After Blade Work Lights

Ensure blade work lights are present and securely mounted and not damaged.

Work lights damaged or missing if required for mission.

79 After Hydraulic Cylinders

a. Check right lift cylinder and hoses for damage or leaks.



ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-35

TM 5-3805-293-10 0013

79 (Cont.)

After Hydraulic Cylinders

b. Check centershift cylinder and hoses for damage or leaks.


c. Check sideshift cylinder and hoses for damage or leaks.


80 After Circle Drive a. Check all circle drive components for damage or debris. Remove debris.

Damage to circle drive that would impair operation.

b. Check circle drive for damage or leaks.


81 After Scarifier Check scarifier frame, link rod, and teeth for excessive wear, damage, or missing components (WP 0026, WP 0027).

Damage that would impair operation or missing six scarifier teeth, if required for mission.

82 After Drawbar a. Check drawbar and drawbar pivot point for damage.

Damage that would impair operation.

b. Check all hoses and fittings for damage or leaks.


83 After Steering a. Check steering linkage for cracks, distortion, or damage.

Cracks or distortion to steering linkage that would impair operation.

b. Check right front steering cylinder and hoses for damage or leaks.


84 After Right Front Wheel and Tire







ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-36

0013

84 (Cont.)

After Right Front Wheel and Tire


Valve stem damaged.




Loose, or two or more missing lug bolts.

e. Check for damage. Wheel damaged.

85 After 0.2 Circle Drive Pinion Teeth

a. Clean dirt and old lubricant from circle drive pinion teeth and from blade circle.

b. Check pinion teeth and blade circle for missing or damaged gear teeth.

Teeth missing or damaged if required for mission.

c. Using GAA (WP 0032, Item 16), lubricate IAW LO 5-3805-293-13.

Figure 23. Circle Drive Lubrication. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-37

TM 5-3805-293-10 0013

86 After 0.2 Circle Top Apply dry film lubricant (WP 0032, Item 17) IAW LO 5-3805-293-13.

Figure 24. Circle Top Lubrication. 0013

CAB INTERIOR

87 Biweekly or Every 100 Engine Hours

Inside Cab Air Filter WARNING

If CBRN exposure is suspected, personnel wearing pro-tective equipment must handle all air cleaner media. Con-taminated filters must be handled using adequateprecautions and must be disposed of by trained person-nel. Consult your CBRN Officer or CBRN NCO for appro-priate handling or disposal procedures. Failure to followthis warning may result in injury or death to personnel.

CAUTIONDo not use compressed air at pressure greater than 30 psi(207 kPa) to clean or dry filter element. Failure to followthis caution may result in damage to equipment.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-38

0013

87 (Cont.)

Biweekly or Every 100 Engine Hours

Inside Cab Air Filter

a. Loosen two thumb screws (Figure 25, Item 1) on filter cover (Figure 25, Item 2).

Filter missing if required for mission.

b. Remove filter cover (Figure 25, Item 2).

c. Remove filter element and clean with either pressurized air or nonsudsing detergent.

d. Rinse the filter and allow to dry.

e. Inspect filter for damaged pleats or a damaged seal. If filter is damaged, replace filter.

f. Install the filter element.

g. Install filter cover (Figure 25, Item 2).

h. Tighten two thumb screws (Figure 25, Item 1).

Figure 25. Inside Cab Air Filter. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-39

TM 5-3805-293-10 0013


Secondary Steering

WARNINGEnsure immediate area around machine, specifically infront of machine, is free of all personnel. Failure to followthis warning may result in injury or death to personnel.

NOTETo protect secondary steering pump, secondary steeringtest will automatically shut off if switch is held in TESTposition for more than 10 seconds.

a. Ensure parking is engaged, transmission is in NEUTRAL, and then start engine (WP 0005).

b. Push top of secondary steering switch (Figure 26, Item 1) and hold (TEST position).

c. With secondary steering switch in TEST position, use left joystick to steer left, steer right, and steer center. Verify front wheels turn with each steering position.

d. Release secondary steering switch.

e. If alert indicator (Figure 26, Item 2) is illuminated after secondary steering switch is released, test has failed. Notify Field Level Maintenance.

Secondary steering fails test.

Figure 26. Secondary Steering Test. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-40

0013

LEFT SIDE


Outside Cab Air Filter WARNING

If CBRN exposure is suspected, personnel wearing pro-tective equipment must handle all air cleaner media. Con-taminated filters must be handled using adequateprecautions and must be disposed of by trained person-nel. Consult your CBRN Officer or CBRN NCO for appro-priate handling or disposal procedures. Failure to followthis warning may result in injury or death to personnel.

CAUTION• Do not use compressed air at pressure greater than 30 psi

(207 kPa) to clean or dry filter element. Failure to followthis caution may result in damage to filter element.

• Filter element must be completely dry before installation.Failure to follow this caution may result in damage toequipment.


Outside Cab Air Filter

a. Loosen thumb screw (Figure 27, Item 3) and open outside cab air filter access cover (Figure 27, Item 2).

Filter missing if required for mission.

b. Remove filter element (Figure 27, Item 1) and clean with either pressurized air or nonsudsing detergent.

c. Rinse filter and allow to dry.

d. Inspect filter for damaged pleats or a damaged seal. If filter is damaged, replace filter.

e. Install filter element.

f. Close outside cab air filter access cover (Figure 27, Item 2).


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-41

TM 5-3805-293-10 0013

89 (Cont.)


Outside Cab Air Filter

g. Tighten thumb screw (Figure 27, Item 3).

Figure 27. Outside Cab Air Filter. 0013

WARNING

Fuel leaked or spilled onto hot surfaces or electrical com-ponents can cause a fire. Failure to follow this warningmay cause injury to personnel or damage to equipment.


Fuel Tank Water and Sediment

a. Articulate machine RIGHT, then shut off engine (WP 0005).


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-42

0013

90 (Cont.)


Fuel Tank Water and Sediment

b. Place a suitable container under fuel tank.

c. Open the drain valve and allow water and sediment to drain.

Drain valve damaged or tank contains excessive water or sediment. Notify Field Level Maintenance.

d. Close drain valve.

e. Start engine. Center machine articulation, then shut off engine (WP 0005).

Figure 28. Fuel Tank Drain. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-43

TM 5-3805-293-10 0013

RIGHT SIDE AND REAR

91 Monthly Batteries WARNING

• To avoid injury, eye protection and acid-resistant glovesmust be worn when working around batteries. DO NOTsmoke, use open flame, make sparks, or create other igni-tion sources around batteries. If a battery is giving offgases, it can explode and cause injury. Remove all jewelrysuch as rings, ID tags, watches, and bracelets. If jewelryor a tool contacts a battery terminal, a direct short willresult in instant heating, damage to equipment, and injuryto personnel.

• Sulfuric acid contained in batteries can cause seriousburns. If battery corrosion or electrolyte makes contactwith skin, eyes, or clothing, take immediate action to stopthe corrosive burning effects. Failure to follow these pro-cedures may cause death or serious injury to personnel.

• DO NOT use compressed air to clean batteries. Use aclean, dry rag.

a. Open right rear access door.

b. Check battery holddown for looseness or damage.

Holddown is loose or damaged.

c. Inspect battery for a cracked case and evidence of leaking.

Battery case is cracked or leaks are evident.

d. Check for missing, broken, split, or frayed battery cables.

Damage is noted.

e. Check for damaged battery posts.

Damage is noted.

f. Check electrolyte level in each cell unless equipped with maintenance-free batteries. If level is low, fill with distilled or clean drinking water to bottom of filler opening.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-44

0013

91 (Cont.)

Monthly Batteries g. Close right rear access door.

92 Monthly Arctic Batteries (if equipped)

WARNING




a. Disengage two arctic battery cover latches, and with the aid of an assistant, remove cover.

b. Check battery holddowns for looseness or damage.

Holddown is loose or missing.

c. Inspect batteries for cracked cases and evidence of leaking.

Battery case(s) cracked or leaks are evident.

d. Check for missing, broken, split, or frayed battery cables or connectors.

Damage is noted.


Damage is noted.

f. Check electrolyte level in each cell unless equipped with maintenance-free batteries. If level is low, fill with distilled or clean drinking water to bottom of filler opening.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-45

TM 5-3805-293-10 0013

92 (Cont.)

Monthly Arctic Batteries (if equipped)

g. With the aid of an assistant, install cover, then engage two latches.

93 Monthly All Systems - Machine Exercise

WARNING

If machine is parked indoors, DO NOT run engine unlessexhaust fumes are vented to the outside. Failure to followthis warning may cause injury or death due to carbonmonoxide poisoning.

NOTE• DO NOT exercise machine if it has been operated

within the past month.• Ensure Before operation PMCS has been performed.

a. Start engine and run at idle for five minutes (WP 0005).

NOTEIf temperature is below 32°F (0°C), operate controls priorto moving machine.

b. After machine has idled for five minutes, begin to operate all controls slowly (WP 0004):

1. transmission in all ranges including reverse;

2. differential lock and center shift lock engaged and disengaged;

3. parking and service brakes applied and released;

4. steering and wheel lean from full left to full right; and

5. all grader hydraulic controls (blade lift, blade side shifts, blade centershift, blade tilt, and scarifier).

c. Operate controls for another five minutes.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-46

0013

93 (Cont.)

Monthly All Systems - Machine Exercise

d. Move machine and operate all controls through full motion, to bring all systems to operating temperature.

e. Move machine and continue to operate all controls through full motion for 30 minutes remove bolt after machine systems have reached operating temperature.

f. Stop machine and allow to idle for five minutes.

g. Shut down engine.

h. Perform After operation PMCS.

6. Check blade lift cylinder sockets for wear (WP 0015).

Cylinder sockets in need of adjustment if required for mission.

7. Check centershift cylinder sockets for wear (WP 0017).

Cylinder sockets in need of adjustment if required for mission.

8. Check scarifier link sockets for wear (WP 0026).

Link sockets in need of adjustment if required for mission.

9. Check moldboard wear strips (WP 0024).

Moldboard wear strips worn if required for mission.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-47

TM 5-3805-293-10 0013

RIGHT SIDE AND REAR

94 Initial 500 Engine Hours (or at first oil change)

Batteries and Battery Cables WARNING




CAUTIONTo reduce battery damage, check battery compartment forcorrosion (greenish/white powder) and DO NOT jerk orpull on battery cables during visual inspection. Failure tofollow this caution may result in damage to equipment.

a. Open right rear access door.

b. Check battery holddown for looseness or damage.

Holddown is loose or damaged.

c. Inspect battery for a cracked case and evidence of leaking.

Battery case is cracked or leaks are evident.

NOTEOriginal equipment batteries are maintenance-free, anddo not have removable caps.

d. Check for missing, broken, split, or frayed battery cables.

Damage is noted.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-48

0013

94 (Cont.)

Initial 500 Engine Hours (or at first oil change)

Batteries and Battery Cables


Damage is noted.

f. If equipped with non-maintenance-free batteries, check electrolyte level in each cell. If level is low, fill with distilled or clean drinking water to bottom of filler opening. Close right rear access door.

95 Initial 500 Engine Hours (or at first oil change)

Arctic Batteries (if equipped)

WARNING




CAUTIONTo reduce battery damage, check battery compartment forcorrosion (greenish/white powder) and DO NOT jerk orpull on battery cables during visual inspection. Failure tofollow this caution may result in damage to equipment.

a. Disengage two arctic battery cover latches, and with the aid of an assistant, remove cover.

b. Check battery holddowns for looseness or damage.

Holddown is loose or missing.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-49

TM 5-3805-293-10 0013

95 (Cont.)

Initial 500 Engine Hours (or at first oil change)

Arctic Batteries (if equipped)

c. Inspect batteries for cracked cases and evidence of leaking.

Battery case(s) cracked or leaks are evident.

d. Check for missing, broken, split, or frayed battery cables or connectors.

Damage is noted.

e. Check for damaged battery posts.f. If equipped with non-maintenance-free batteries, inspect electrolyte level in each cell. If level is low, fill with distilled or clean drinking water to bottom of filler opening.

Damage is noted.

g. With the aid of an assistant, install cover, then engage two latches.

BOTH SIDES

96 Every 500 Engine Hours or 3 Months

0.2 Tandem Drive Oil Level

a. Clean surface area around the oil check plug.b. Remove oil check plug.

c. When tandem drive oil is full, oil should trickle from check plug opening. Notify Field Level Maintenance if oil level is low.

Tandem drive oil level is low.

d. Replace oil check plug.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-50

0013

96 (Cont.)

Every 500 Engine Hours or 3 Months

0.2 Tandem Drive Oil Level

Figure 29. Tandem Drive Oil Level Check. 0013


Service Brake Holding Ability WARNING

Be ALERT for personnel in the area while operatingmachine. Always check to ensure area is clear of person-nel and obstructions before starting engine, movingmachine, or lowering or raising blade. Failure to follow thiswarning may cause injury or death to personnel or dam-age to equipment.

CAUTIONAllow machine to fully warm up (warm air blows fromheater vents) before performing this test. Failure to followthis caution may result in damage to equipment.

a. Fasten seat belt before testing brakes (WP 0005).

b. Start engine (WP 0004).


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-51

TM 5-3805-293-10 0013

97 (Cont.)

Every 500 Engine Hours or 3 Months

Service Brake Holding Ability

c. Raise blade slightly (WP 0004).

d. Depress transmission modulator control (WP 0004).

e. Fully apply service brake (WP 0004).

f. Select FIFTH SPEED FORWARD (WP 0004).

g. Set throttle Hold Mode switch to MANUAL (WP 0004).

h. Push and hold top of throttle SET/ACCEL switch to set engine at high idle speed.

i. Gradually release transmission modulator control. Machine should not move and engine should stall.

Service brakes do not hold.


Parking Brake Holding Ability WARNING

Be ALERT for personnel in the area while operatingmachine. Always check to ensure area is clear of person-nel and obstructions before starting engine, movingmachine, or lowering or raising blade. Failure to follow thiswarning may cause injury or death to personnel or dam-age to equipment.

a. Test brakes on hard, packed dirt.

b. Fasten seat belt before testing brakes.

c. Position the machine on a slope of 20 percent.

d. Engage parking brake control. Release the service brake control.

e. If machine moves, notify Field Level Maintenance.

Parking brake does not hold.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-52

0013


Fuel System Prime

a. Open left front access door.b. Turn engine start switch to ON position for 2 minutes.

c. Verify water separator is full of fuel.

d. If water separator is not full of fuel, turn engine start switch OFF, then turn engine start switch ON.

e. If water separator is still not full of fuel after 2 minutes, notify Field Level Maintenance.

Fuel system does not prime.

f. Close left front access door.


ExhaustSystem

Engine and exhaust system components may beextremely hot after engine is shut down. Do not touch anypart of the exhaust system until engine has cooled downsufficiently. Failure to follow this warning may result ininjury to personnel.

a. Open right front access door.b. Check exhaust system pipes, clamps, and muffler for looseness, leakage, or damage.c. Close right rear access door.

Looseness, damage or leaks are noted.


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-53

TM 5-3805-293-10 0013

CAB

101 Every 1,000 Engine Hours or 6 Months

Rollover Protective Structure (ROPS)

a. Check ROPS for drilled holes, corrosion, loose, damaged, or missing mounting hardware. Notify Field Level Maintenance to retorque/replace mounting hardware.

Loose, damaged, or missing mounting hardware is noted.

b. Check ROPS for any signs of cracking in base metal or welded areas.

Any signs of damage or cracked welds are noted.

Figure 30. ROPS Hardware. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

0013-54

0013

LEFT SIDE

102 Every 2,000 Engine Hours or 2 Years

Cooling System Pressure Cap

WARNING

• Personal injury can result from hot coolant, steam, andalkali.

• At operating temperature, engine coolant is hot and underpressure. The radiator and all lines to heaters or theengine contain hot coolant or steam. Any contact cancause severe burns.

• Remove filler cap slowly to relieve pressure only whenengine is stopped and radiator cap is cool enough to touchwith your bare hand.

• Do not attempt to tighten hose connections when thecoolant is hot as the hose can come off causing burns.

• Cooling system conditioner contains alkali. Avoid contactwith skin and eyes.

a. Open cooling system pressure cap access door (Figure 31, Item 1).


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-55

TM 5-3805-293-10 0013

102 (Cont.)

Every 2,000 Engine Hours or 2 Years


Figure 31. Cooling System Pressure Cap Access Door. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

0013-56

TM 5-3805-293-10 0013

END OF WORK PACKAGE

102 (Cont.)

Every 2,000 Engine Hours or 2 Years


b. Clean area around cooling system pressure cap.c. Remove cooling system pressure cap.

d. Clean cooling system pressure cap and inspect cap and cap seals for damage. Replace cooling system pressure cap if damaged.

Cooling system pressure cap is damaged.

e. Install cooling system pressure cap.

f. Close cooling system pressure cap access door.

Figure 32. Cooling System Pressure Cap Seals. 0013


ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/


CAPABLE IF:

TM 5-3805-293-10

CHAPTER 5

MAINTENANCE INSTRUCTIONS

TM 5-3805-293-10

0014-1

0014


0 0 1 4 AIR FILTER ELEMENTS MAINTENANCERemoval, Cleaning and Inspection, Installation

INITIAL SETUP


Work Light 0

Materials/Parts 0


Equipment Condition 0

Machine parked (WP 0005) 0

Left front access door opened (WP 0004) 0

Estimated Time to Complete 0

0.2 Hr 0

4

0014-2

TM 5-3805-293-10 0014

REMOVAL 00014

NOTE• Replace the secondary air filter element if: (A) primary air filter element has been replaced

three times since the secondary element has been replaced, (B) exhaust smoke is blackeven after primary element has been replaced, or (C) the secondary element has been inservice for one year.

• If hose comes off dust ejector, be sure to connect it during installation.1. Disengage three latches (Figure 1, Item 1) and remove engine air filter cover (Figure 1, Item 2).

CAUTIONDo not remove secondary air filter element (Figure 1, Item 4) until after the air filterhousing is cleaned, and then only if it is being replaced. This will reduce the possibility ofdirt entering the engine. Failure to follow this caution may result in damage to equipment.

2. Remove primary air filter element (Figure 1, Item 3).

Figure 1. Air Filter Housing and Elements. 0014

END OF TASK

0014-3

TM 5-3805-293-10 0014

CLEANING AND INSPECTION 00014

1. Clean inside of air filter housing.

CAUTION• Do not tap or strike air filter element to remove dust. Damage to air filter element may

result.• Do not wash the air filter element.• Do not use air filter elements with damaged pleats, gaskets, or seals. Dirt entering engine

will cause damage to engine components.• Do not attempt to clean a secondary air filter element.• Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean primary

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

NOTEUse either low pressure compressed air or a vacuum to clean primary air filter element.Direct airflow from inside element and up and down pleats rather than across pleats.

2. With assistance from Field Level Maintenance personnel, clean primary element.3. Inspect primary element for tears, holes, damaged pleats, gaskets, or seals. Discard if damaged.4. Inspect element using a work light. Light should be visible through the element when light is placed inside ele-

ment. If necessary, compare to a new element to confirm results.

CAUTIONDo not remove secondary air filter element until you have the new element ready to install.This will reduce the possibility of dirt entering the engine. Failure to follow this caution mayresult in damage to equipment.

5. Remove secondary air filter element (Figure 1, Item 4). Discard element.

END OF TASK

INSTALLATION 00014

1. Install secondary air filter element (Figure 1, Item 4).2. Install primary air filter element (Figure 1, Item 3).

0014-4

TM 5-3805-293-10 0014

INSTALLATION – CONTINUED

3. Position engine air filter cover (Figure 2, Item 1) ensuring proper orientation, and engage three latches (Figure 2, Item 2).

4. Check, and if necessary, connect hose to dust ejector (Figure 2, Item 3).5. Close left front access door (WP 0004).

Figure 2. Air Filter Housing Cover. 0014

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0015

0015-1/(2 blank)


0 0 1 5 BLADE LIFT CYLINDER SOCKET INSPECTIONInspection

INSPECTION 00015

NOTEPerform this inspection on both left- and right-side blade lift cylinders.

1. Operate blade lift cylinders slowly while having an assistant observe socket connections (Figure 1, Item 1) at top of circle (drawbar/blade) (Figure 1, Item 2).

2. Observe sockets for movement without circle movement, indicating adjustment required.3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Blade Lift Cylinder Socket. 00015

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP

Personnel 0

Two 0


Engine running (WP 0005) 0

0

Equipment Condition - Continued 0


Blade rotated 90 degrees to frame andlowered to ground (WP 0005) 0


0.1 Hr 0

2

TM 5-3805-293-10

0016-1

0016


0 0 1 6 BRAKE ACCUMULATOR TESTTesting

TESTING 00016

WARNING• Cold ambient temperatures could result in loss of secondary braking capability due to

inadequate hydraulic accumulator nitrogen pre-charge. Loss of the secondary brakingsystem as well as main hydraulic pressure will result in little or no braking capability and apotential for injury or death.

• Perform a brake accumulator check anytime machine has been idle for longer than twohours below -13°F (-25°C). Failure to follow these warnings may result in injury or death topersonnel.

NOTEAlert indicator will illuminate when brake accumulator pressure is below operationalstandard.

1. Move engine start switch to ON position. Alert indicator (Figure 1, Item 1) will come on if accumulator pressure is below operational standard.

Figure 1. Brake Accumulator Indicator. 00016

INITIAL SETUP




0.1 Hr 0

2

TM 5-3805-293-10

0016-2

0016

TESTING – CONTINUED 00016

2. Start engine and run for at least one minute to increase accumulator pressure. Alert indicator should go off when pressure increases.

3. Shut down engine after one minute or when indicator goes off, whichever is longer.4. With ignition in ON position, apply and release service brake pedal a minimum of five times, to decrease

accumulator pressure, until alert indicator illuminates. 5. Notify Field Level Maintenance if alert indicator illuminates before the minimum five applications of the service

brake pedal.

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0017

0017-1/(2 blank)


0 0 1 7 CENTERSHIFT CYLINDER SOCKET INSPECTIONInspection

INSPECTION 00017

1. Operate centershift cylinder (Figure 1, Item 1) slowly while having an assistant observe lower socket connec-tion (Figure 1, Item 3) at top of circle (Figure 1, Item 4) and then upper socket connection (Figure 1, Item 2) at centershift bar (Figure 1, Item 5).

2. Observe socket for movement without circle movement. 3. If socket moves without circle moving, notify Field Level Maintenance adjustment is required.

Figure 1. Centershift Cylinder Socket. 00017

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP

Personnel 0

Two 0



0



Moldboard rotated 90 degrees to frame andlowered to ground (WP 0005) 0


0.1 Hr 0

2

TM 5-3805-293-10

0018-1

0018


0 0 1 8 CIRCUIT BREAKER RESETReset

RESET 00018

1. Identify correct circuit breaker for inoperative system/circuit.

Figure 1. Circuit Breakers. 00018

INITIAL SETUP


Ignition ON (WP 0004) 0

Left front access door open (WP 0002) 0


0.1 Hr 0


1 20 Amp Circuit Breaker Not used.

2 15 Amp Circuit Breaker Transmission and chassis control systems.

3 15 Amp Circuit Breaker Ignition circuit.

4 20 Amp Circuit Breaker Engine control system.

5 150 Amp Circuit Breaker Alternator circuit.

6 80 Amp Circuit Breaker Main - Feeds power to fuses in cab that are turned on when ignition is in ON position.

7 80 Amp Circuit Breaker Load Circuit - Feeds power to fuses in cab that are continuously on.

2

TM 5-3805-293-10

0018-2

0018

RESET – CONTINUED

2. Push button to reset circuit breaker. Button should remain pushed in. This indicates circuit breaker was reset successfully.

Figure 2. Fast Speed Blower Circuit Breaker. 00018

3. If button does not remain in, notify Field Level Maintenance.

END OF TASK

FOLLOW-ON TASKS 00018

1. Close left front access door (WP 0002).2. Turn ignition OFF (WP 0005).

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0019

0019-1/(2 blank)


0 0 1 9 CUTTING EDGES AND END BITS INSPECTIONInspection

INSPECTION 00019

1. Visually inspect cutting edges (Figure 1, Item 2), and end bits (Figure 1, Item 1) for damage or excessive wear.2. Notify Field Level Maintenance if cutting edges or end bits are damaged or worn to within approximately 3/4 in.

(19 mm) (approximately the width of your thumb) of the blade.

Figure 1. Cutting Edges and End Bits. 00019

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP



Blade tilted forward (WP 0004) 0

Blade lowered onto wooden blocks 0


0.1 Hr 0

2

TM 5-3805-293-10 0020

0020-1/(2 blank)


0 0 2 0 DOMELAMP BULB REPLACEMENTRemoval, Installation

REMOVAL 00020

1. Remove domelamp cover (Figure 1, Item 1) from domelamp.2. Remove domelamp bulb (Figure 1, Item 2) by pushing in slightly and turning bulb left to disengage bulb locking

lugs. Pull bulb out of socket.

END OF TASK

INSTALLATION 00020

1. Install bulb (Figure 1, Item 2) in socket, push in slightly, and turn bulb right to engage bulb locking lugs.2. Install cover (Figure 1, Item 1).

Figure 1. Domelamp Bulb Replacement. 00020

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP




0.2 Hr 0

2

TM 5-3805-293-10

0021-1

0021


0 0 2 1 ETHER STARTING AID CYLINDER REPLACEMENTRemoval, Cleaning and Inspection, Installation

INITIAL SETUP

Materials/Parts 0


Cylinder, Engine Starting (Ether) (WP 0032,Item 7) 0


0



Right front access door open 0

4

0021-2

TM 5-3805-293-10 0021

REMOVAL 00021

1. Loosen clamp (Figure 1, Item 2).

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in awell-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoidcontact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritatethe eyes, wash immediately with large quantities of clean water for 15 minutes. Seekmedical attention immediately if ether is inhaled or causes eye irritation. Failure to followthis warning may cause serious injury or death to personnel.

2. Unscrew and remove ether starting aid cylinder (Figure 1, Item 1) from valve (Figure 1, Item 3). Discard empty cylinder IAW local regulations and Unit SOP.

3. Remove gasket from valve (Figure 1, Item 3). Discard gasket.

Figure 1. Ether Starting Aid Cylinder. 0021

END OF TASK

CLEANING AND INSPECTION 00021

Clean valve (Figure 1, Item 3) of any dirt or debris. Inspect valve for any damage. If damage is present, notify Field Level Maintenance.

END OF TASK

0021-3/(4 blank)

TM 5-3805-293-10 0021

INSTALLATION 00021

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in awell-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoidcontact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritatethe eyes, wash immediately with large quantities of clean water for 15 minutes. Seekmedical attention immediately if ether is inhaled or causes eye irritation. Failure to followthis warning may cause serious injury or death to personnel.

Ensure gasket is properly seated in valve prior to installing cylinder. If gasket is notproperly seated, ether will escape from valve. Seek medical attention immediately if etheris inhaled or causes eye irritation. Failure to follow this warning may cause serious injuryor death to personnel.

CAUTIONMake sure gasket is positioned correctly on ether starting aid cylinder before installing.Failure to follow this caution may result in damage to gasket and ether leakage.

1. Install new gasket on valve (Figure 1, Item 3).2. Install ether starting aid cylinder (Figure 1, Item 1) on valve.3. Tighten clamp (Figure 1, Item 2).

END OF TASK

FOLLOW-ON TASK 00021

Close right front access door.

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10

0022-1

0022


0 0 2 2 FUEL/WATER SEPARATOR DRAINDrain Fuel/Water Separator

DRAIN FUEL/WATER SEPARATOR 00022

WARNING

Fuel leaking or spilled onto hot surfaces or electrical components can cause a fire. Failureto follow this warning may cause injury or death to personnel and damage to equipment.

1. Place a suitable container beneath fuel/water separator bowl (Figure 1, Item 1).2. If hose is not already connected to bowl, connect suitable hose (Figure 1, Item 2) to nipple on bowl and place

open end into container.3. Open fuel/water separator drain valve (Figure 1, Item 3) and allow water and sediment to drain into container. 4. Close valve once all water and sediment have drained from bowl.5. Remove container and hose.6. Dispose of fuel IAW local regulations and Unit SOP.

Figure 1. Fuel/Water Separator. 0022

END OF TASK

INITIAL SETUP 0



Left front access door open (WP 0002) 0


0.2 Hr 0

2

TM 5-3805-293-10

0022-2

0022

FOLLOW-ON TASK 00022

Close left front access door.

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10

0023-1

0023


0 0 2 3 FUSE REPLACEMENTReplacement

INITIAL SETUP




0.2 Hr 0

4

TM 5-3805-293-10

0023-2

0023

REPLACEMENT 00023

NOTE• Replace fuses with same type and amperage rating.• Fuse panel is located on cab floor left of operator’s seat.

1. Identify fuse requiring replacement.

Figure 1. Fuse Identification. 00023

0023-3

TM 5-3805-293-10 0023

REPLACEMENT – CONTINUED

Fuse Number Amperage Rating CircuitF1 15 LH Door WiperF2 15 Rear FloodF3 10 Differential LockF4 20 Blade Flood #2F5 15 Powered Seat - not usedF6 10 Defroster FanF7 10 AccugradeF8 -- NOT USEDF9 10 Pin Puller / Cushion

F10 15 HVACF11 -- NOT USEDF12 10 WAVES - not usedF13 -- NOT USEDF14 20 Blade FloodsF15 15 RH Door WiperF16 10 Turn RelaysF17 10 Quicklube - not usedF18 -- NOT USEDF19 -- NOT USEDF20 15 Front WiperF21 15 Condenser Fan Relay #1F22 -- NOT USEDF23 -- NOT USEDF24 -- NOT USEDF25 15 Condenser Fan Relay #2F26 -- NOT USEDF27 -- NOT USEDF28 15 AWD ControllerF29 15 Implement Controller #1F30 10 Dash ClusterF31 10 Dome LampF32 10 BacklightingF33 -- NOT USEDF34 10 HornF35 -- NOT USEDF36 15 Implement Controller #2F37 15 12V ConverterF38 15 BlackoutF39 -- NOT USEDF40 15 Heater Unit

TM 5-3805-293-10

0023-4

0023


2. Remove fuse panel cover (Figure 2, Item 1).

Figure 2. Fuse Panel Cover. 00023

3. Remove blown fuse.4. Install new fuse.

NOTENotify Field Level Maintenance if new fuse blows when component is turned on or if samefuse blows frequently.

5. Install fuse panel cover.

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0024

0024-1/(2 blank)


0 0 2 4 MOLDBOARD WEAR STRIPS INSPECTIONInspection

INSPECTION 00024

1. Operate moldboard lift cylinders slowly while an assistant observes moldboard (Figure 1, Item 1) and circle assembly (Figure 1, Item 2).

2. Observe circle assembly for movement without moldboard movement. 3. If circle assembly moves without moldboard moving, notify Field Level Maintenance that further inspection is

required.

Figure 1. Moldboard Wear Strip Inspection. 00024

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP

Personnel Required 0

Three 0


Moldboard rotated 90 degrees to frame andlowered to ground (WP 0005) 0





0.1 Hr 0

2

TM 5-3805-293-10

0025-1

0025


0 0 2 5 RADIATOR CLEANINGRemoval, Cleaning, Installation

WARNING

Allow engine to cool before cleaning radiator. Failure to follow this warning may result ininjury to personnel.

REMOVAL 00025

1. Open left rear access door (Figure 1, Item 1).2. Remove two bolts (Figure 1, Item 3) from left rear access panel (Figure 1, Item 2) and open panel.

Figure 1. Left Rear Access Door and Panel. 0025

INITIAL SETUP

Materials/Parts 0





0.4 Hr 0

4

TM 5-3805-293-10

0025-2

0025

REMOVAL – CONTINUED

3. Remove two bolts (Figure 2, Item 1) from right rear access panel (Figure 2, Item 2) and open panel.4. Open right rear access door (Figure 2, Item 3).

Figure 2. Right Rear Access Door and Panel. 0025

END OF TASK

CLEANING 00025

WARNING

Cooling fins on radiator and other cooler assemblies can be very sharp. Be sure to wearprotective gloves while working near these components. Failure to follow this warningcould result in injury to personnel.

CAUTIONCooling fins on radiator and other cooler assemblies are easily bent and damaged, whichcan result-in reduced air flow and cooling capacity. Use caution when working near thesecomponents to avoid bending cooling fins. Failure to follow this caution may result indamage to equipment.

Remove dirt and debris from around radiator.

END OF TASK

0025-3/(4 blank)

TM 5-3805-293-10 0025

INSTALLATION 00025

1. Close right rear access door (Figure 2, Item 3).2. Close right rear access panel (Figure 2, Item 2) and install two bolts (Figure 2, Item 1).3. Close left rear access panel (Figure 3, Item 2) and install two bolts (Figure 3, Item 3).4. Close left rear access door (Figure 3, Item 1).

Figure 3. Left Rear Access Door and Panel. 0025

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0026

0026-1/(2 blank)


0 0 2 6 SCARIFIER LINK SOCKET INSPECTIONInspection

INSPECTION 00026

1. Slowly operate scarifier up and down, making very light contact with ground, while having an assistant observe both scarifier link sockets (Figure 1, Item 1) on each side of machine.

2. Observe sockets (Figure 1, Item 1) for movement without scarifier movement, indicating adjustment is required.

3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Scarifier Link Sockets. 00026

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP


0.1 Hr 0

Personnel Required 0

Two 0




0

2

TM 5-3805-293-10

0027-1

0027


0 0 2 7 SCARIFIER TOOTH AND SHANK MAINTENANCEInspection, Replacement

INSPECTION 00027

1. Visually inspect scarifier teeth (Figure 1, Item 2) for excessive wear. Replace tooth when worn to dashed line (Figure 1, Item 3) shown in illustration.

2. Visually inspect shanks (Figure 1, Item 1) for cracks or breakage. 3. Proceed to Replacement in this work package if teeth or shanks require replacement.

Figure 1. Scarifier Tooth and Shank Inspection. 0027

END OF TASK

INITIAL SETUP


Hammer (WP 0031, Item 6) 0

Tooth Removing Tool, Scarifier (WP 0031,Item 16) 0

Material/Parts 0



Scarifier lowered onto 4-6 in. (100-150 mm)wood blocks (WP 0005) 0



0.4 Hr 0

4

TM 5-3805-293-10

0027-2

0027

REPLACEMENT 00027

WARNING

Eye protection is required when replacing scarifier teeth to protect against flying particles.Failure to follow this warning may result in injury to personnel.

1. Using tooth removing tool (Figure 2, Item 2) and a hammer, drive tooth (Figure 2, Item 1) off shank.

Figure 2. Scarifier Tooth Removal. 0027

0027-3

TM 5-3805-293-10 0027

REPLACEMENT – CONTINUED 00027

2. Clean dirt and debris from shank.

WARNINGDO NOT allow shank to fall from scarifier frame. Failure to follow this warning may resultin injury to personnel.

NOTEBe sure rubber grommet (Figure 3, Item 5) remains with lock pin.

3. Using tooth removing tool (Figure 3, Item 3) pry up lock pin (Figure 3, Item 2) and remove.

Figure 3. Scarifier Shank Lock Pin Removal. 0027

4. Remove shank (Figure 3, Item 1) from scarifier (Figure 3, Item 4).5. Install shank (Figure 3, Item 1) on scarifier (Figure 3, Item 4).6. Install lock pin with grommet (Figure 3, Item 2) on scarifier (Figure 3, Item 4).

0027-4

TM 5-3805-293-10 0027


WARNING

DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may resultin injury to personnel.

7. Position and drive tooth (Figure 4, Item 2) onto shank (Figure 4, Item 1) to secure.

Figure 4. Scarifier Tooth and Shank Installation. 0027

END OF TASK

END OF WORK PACKAGE

TM 5-3805-293-10 0028

0028-1/(2 blank)


0 0 2 8 WINDOW WASHER TANK CHECK AND FILLCheck and Fill

CHECK AND FILL 00028

NOTE• Windshield washer tank is located inside the cab and left of operator’s seat. • Fluid level can be viewed through transparent tank. • Fill opening is outside machine at rear of left door.

1. Check fluid level in tank (Figure 1, Item 1).2. Clean tank fill cap (Figure 1, Item 2) and surrounding area.3. Remove tank fill cap (Figure 1, Item 2).4. Fill tank with windshield cleaning compound.5. Install tank fill cap (Figure 1, Item 2).

Figure 1. Windshield Washer Tank. 0028

END OF TASK

END OF WORK PACKAGE

INITIAL SETUP

Materials/Parts 0

Cleaning Compound, Windshield (WP 0032,Item 3) 0





0.1 Hr 0

2

TM 5-3805-293-10

0029-1

0029


0 0 2 9 WINDOW WIPER BLADE REPLACEMENTReplacement

CAUTIONThe wiper arm is spring-loaded. Do not let go of arm after blade has been removed.Carefully lower arm to glass or glass may break.

NOTEExcept for positioning front windshield wiper blade in center of glass for access,replacement is identical for all wiper blades.

INITIAL SETUP


Machine parked, battery disconnect switch inON position (WP 0005) 0

Front windshield wiper stopped in center ofglass (WP 0004) 0


0.3 Hr 0

2

0029-2

TM 5-3805-293-10 0029

REPLACEMENT 00029

NOTEIf front wiper is not being replaced, skip step 1 and go directly to step 2.

1. Position windshield wiper in center of windshield as follows:a. Turn ignition switch to ON position (WP 0004). Do not start engine.b. Activate front wiper (WP 0004).c. When wiper is positioned in center of windshield, turn ignition switch to OFF position.

2. Raise wiper arm (Figure 1, Item 1) and blade (Figure 1, Item 4) up away from glass.3. Squeeze release tab (Figure 1, Item 2) and remove blade (Figure 1, Item 4) from arm (Figure 1, Item 1).4. Position new blade (Figure 1, Item 4) on arm (Figure 1, Item 1) and secure pivot insert (Figure 1, Item 3) to

blade.

Figure 1. Windshield Wiper Replacement. 00029

END OF TASK

END OF WORK PACKAGE

469-0311

TM 5-3805-293-10

CHAPTER 6

SUPPORTING INFORMATION

TM 5-3805-293-10

0030-1

0030


0 0 3 0 REFERENCES

SCOPE 00030

This work package lists all publication indexes, forms, field manuals, technical manuals, and other publications ref-erenced in this manual and which apply to operation and operator maintenance of the 120M Motor Grader.

PUBLICATION INDEXES 00030

The following indexes should be consulted frequently for the latest changes or revisions and for new publications relating to material covered in this technical manual.Consolidated Army Publications and Forms Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30The Army Maintenance Management System (TAMMS) Users Manual . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8

FORMS 00030

NOTERefer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual,for instructions on the use of maintenance forms.

Accident-Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518Equipment Control Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404Equipment Inspection Maintenance Worksheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 5988-EMaintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 91Processing and Deprocessing Record for Shipment, Storage, and

Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 368Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 364Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2258

FIELD MANUALS 00030

Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 55-30Basic Cold Weather Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-3Earthmoving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-434First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 21-305-20Multiservice Helicopter Sling Load: Basic Operations and Equipment . . . . . . . . . . . . . . . . . . . . . . . . FM 4-20.197Multiservice Helicopter Sling Load: Single-Point Load Rigging Procedures . . . . . . . . . . . . . . . . . . . . FM 4-20.198Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and

Nuclear Contamination Avoidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and

Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5

2

TM 5-3805-293-10

0030-2

0030

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71Operations and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 9-207Railway Operating and Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-21Recovery and Battle Damage Assessment and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-30.31Rigging Techniques, Procedures, and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-125

TECHNICAL BULLETINS 00030

Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment,and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209

TECHNICAL MANUALS 00030

Operator’s, Unit, Direct Support, and General Support MaintenanceManual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14

Operator’s, Unit Maintenance Manual for Laser Leveling Equipment . . . . . . . . . . . . . . . . . . TM 5-6675-348-13&PProcedures for Destruction of Equipment to Prevent Enemy Use (Mobility

Equipment Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-3

OTHER PUBLICATIONS 00030

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-2007Army Logistics Readiness and Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 700-138Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CTA 8-100Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items). . . . . . . . . . .CTA 50-970Field and Garrison Furnishings and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CTA 50-909Lubrication Order for Motorized Road Grader Model 120M . . . . . . . . . . . . . . . . . . . . . . . . . . . .LO 5-3805-293-13Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and Logistic Support . . .AR 70-12

END OF WORK PACKAGE

TM 5-3805-293-10

0031-1

0031


0 0 3 1 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

INTRODUCTION 0031

Scope 00031

This work package lists COEI and BII for the 120M Motor Grader to help you inventory items for safe and efficient operation of the equipment.

General 00031

The COEI and BII information is divided into the following lists:a. Components of End Item (COEI). This list is for information purposes only and is not authority to

requisition replacements. These items are part of the 120M Motor Grader. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items.

b. Basic Issue Items (BII). These essential items are required to place the 120M Motor Grader in operation, operate it, and perform emergency repairs. Although shipped separately packaged, BII must be with the 120M Motor Grader during operation and when it is transferred between property accounts. Listing these items is your authority to request/requisition them for replacement based on authorization of the end item by the TOE/MTOE. Illustrations are furnished to help you find and identify the items.

Explanation of Columns in the COEI List and BII List 00031

Column (1) Illus Number. Gives you the number of the item illustrated.Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes.Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses).Column (4) Usable On Code (UOC). When applicable, gives you a code if the item you need is not the same for different models of equipment. Column (5) U/I Unit of Issue. Indicates the physical measurement or count of the item as issued per the National Stock Number shown in Column (2).Column (6) Qty Rqr. Indicates the quantity required.

4

0031-2

TM 5-3805-293-10 0031

COEI LIST 0031

NOTEThere are no COEI for the 120M Motor Grader.

BII LIST 0031

Table 1. Basic Issue Items (BII). 031

(1)

ILLUSNUMBER

(2)

NSN

(3)

DESCRIPTION, PART NUMBER/(CAGEC)

(4)

UOC

(5)

U/I

(6)

QTYRQR

1 5140-01-524-7563 Bag, Tool 1

211-0136/(11083)EA 1

2 5306-01-438-9715 Bolt, Machine 2

8T0670/(11083)EA 1

3 4210-01-493-8162 Extinguisher, Fire 3

B500T/(54905)EA 1

4 4910-01-545-3635 Gauge, Tire Pressure 4

1P-545/(11083)EA 1

5 – Glass Hammer 5

8Y-6379 (11083)EA 1

6 5120-00-061-8546 Hammer 6

11677028-3/(19207)EA 1

0031-3

TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

(1)

ILLUSNUMBER

(2)

NSN

(3)


(4)

UOC

(5)

U/I

(6)

QTYRQR

7 4930-00-253-2478 Lubricating Gun, Hand 7

1142/(1PL57)EA 1

8 Lubrication Order 8

LO 5-3805-293-13 (19207)EA 1

9 Manual, Operator’s 9

TM 5-3805-293-10 (19207)EA 1

10 5310-01-565-6246 Nut, Self-Locking, Hexagon 10

7X0851/(11083)EA 1

11 5340-01-181-2579 Padlock and Keys 11

5P8502/(11083)EA 3

12 5315-01-579-3794 Pin, Grooved, Head (Articulation Lock Pin) 12

2520977/(11083)EA 1

0031-4

TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

END OF WORK PACKAGE

(1)

ILLUSNUMBER

(2)

NSN

(3)


(4)

UOC

(5)

U/I

(6)

QTYRQR

13 5120-01-335-1562 Pliers, Slip Joint, 9.25 in. 13

91ACP/(55719)EA 1

14 5120-01-528-9361 Screwdriver, Flat Tip 14

6V-7935/(11083)EA 1

15 – Strap 15

XXXXX (11083)EA 1

16 3805-00-423-9746 Tooth Removing Tool, Scarifier 16

6B-3260/(11083)EA 1

17 9905-00-148-9546 Warning Device Kit, Highway 17

11669000 (19207)EA 1

18 5120-01-518-2402 Wrench, Adjustable, 12-inch long 18

214-7330/(11083)EA 1

TM 5-3805-293-10

0032-1

0032


0 0 3 2 EXPENDABLE AND DURABLE ITEMS LIST

INTRODUCTION

Scope 00032

This work package lists expendable and durable items you will need to operate and maintain the 120M Motor Grader. This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Durable Items.

Explanation of Columns 00032

1. Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the narrativeinstructions to identify the item (e.g., Use antifreeze (WP 0032, Item 1)).

2. Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item.C - CrewF - Field

3. Column (3) National Stock Number (NSN). This is the National Stock Number assigned to the item, whichyou can use to requisition it.

4. Column (4) Item Name Description, Part Number (CAGEC). This column provides the other informationyou need to identify the item. The last line below the description is the part number and the Commercial andGovernment Entity Code (CAGEC) (in parentheses).

5. Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gal-lon, dozen, gross, etc.

4

TM 5-3805-293-10

0032-2

0032

Table 1. Expendable and Durable Items for the 120M Motor Grader.

(1)

ITEMNUMBER

(2)

LEVEL

(3)

NATIONALSTOCK NUMBER

(4)

ITEM NAME, DESCRIPTION,PART NUMBER/(CAGEC)

(5)

U/I

1 C Antifreeze 1

6850-01-383-4068 1 Gallon Bottle672 4354 (1QK63)

GL 1

6850-01-441-3257 5 Gallon CanA-A-52624 (58536)

CN 1

6850-01-383-3918 55 Gallon DrumA-A-52624 (58536)

DR 1

2 C Cleaning Compound, Solvent, Type III 2

MIL-PRF-680/(81349)

6850-01-474-23186850-01-474-23206850-01-474-2321

1 Gallon Can5 Gallon Can55 Gallon Drum

CN 2

CN 2

DR 2

3 C Cleaning Compound, Windshield 3

0854-000/(0FTT5)

6850-00-926-2275 16 Ounce Bottle BT 3

4 C 4 Detergent, General Purpose, Liquid 4

7930-00-282-9699/(83421)

7930-00-282-9699 4 1 Gallon Can CN 4

5 C 5 Diesel Fuel, DF-1 Grade, Arctic 5

ASTM D 975/(81346)

9140-00-286-5286 5

9140-00-286-5287 5

9140-00-286-5288 5

Bulk5 Gallon Can55 Gallon Drum

GL 5

CN 5

DR 5

6 C 6 Diesel Fuel, DF-2 Grade 6

ASTM D 975/(81346)

9140-00-286-5294 6

9140-00-286-5295 6

9140-00-286-5296 6

Bulk5 Gallon Can55 Gallon Drum

GL 6

CN 6

DR 6

7 C 7 2910-00-646-9727 7 Cylinder, Engine Starting (Ether) 7

MS39254-1/(19207) DZ 7

8 C 8 9130-01-031-5816 8 Fuel, Turbine, Aviation 8

MIL-T-83133 GR JP-8/(81349) GL 8

0032-3

TM 5-3805-293-10 0032

9 C 9 8415-01-297-6876 9 Gloves, Chemical and Oil Protective 9

326Y/LARDC/(88009)

10 C 10 4240-00-190-6432 10 Goggles, Industrial 10

ANSIZ-1989/(80204)

11 C 11 Grease, Automotive and Artillery (GAA) 11

9150-01-197-7688 11 M-10924-A/(81349) 2-1/4 Ounce Tube TU 11

9150-01-197-7693 11 M-10924-B/(81349)14 Ounce Cartridge CA 11

9150-01-197-7690 11 M-10924-C/(81349)1-3/4 Pound Can CN 11

9150-01-197-7692 11 M-10924-E/(81349) 35 Pound Can CN 11

12 C 12 9150-01-089-1697 12 Lubricant, Dry Film 12

MIL-PRF-46147C GL-420 (72657)GAL 12

13 C 13 Oil, Lubricating, OE/HDO-30 13

MIL-PRF-2104/(81349)

9150-00-186-6681 13

9150-00-188-9858 13

9150-00-189-6729 13

1 Quart Can5 Gallon Can55 Gallon Drum

CN 13

CN 13

DR 13

14 C 14 Oil, Lubricating, OE/HDO-40 14 14

9150-00-188-9862 14 55 Gallon Drum DR 14

15 C 15 Oil, Lubricating, OE/HDO-15W/40 15

MIL-PRF-2104/(81349)

9150-01-152-4117 15

9150-01-152-4118 15

9150-01-152-4119 15

1 Quart Can5 Gallon Can55 Gallon Drum

CN 15

CN 15

DR 15

16 C 16 Oil, Lubricating, OEA Arctic 16

9150-00-402-4478 16

9150-00-402-2372

9150-00-491-7197 16

MIL-L-46167/(81349) 1 Quart CanMIL-PRF-46167/(81349) 5 Gallon CanMIL-PRF-46167/(81349) 55 Gallon Drum

16

QT 16

16

GL 16

16

DR 16

16 16

16 16

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1)

ITEMNUMBER

(2)

LEVEL

(3)


(4)


(5)

U/I

0032-4

TM 5-3805-293-10 0032

END OF WORK PACKAGE

17 C 17 Rag, Wiping 17

7920-00-205-1711/(64067)

7920-00-205-1711 17 50 Pound Bale BL 17

18 C 18 Strap, Tiedown 18

5975-00-903-2284 18

5975-00-984-6582

5975-00-935-5946 18

4 Inch Length, Black, Package of 100MS3367-4-0/(96906) 6 Inch Length, Black, Package of 100MS3367-1-0/(96906) 13.35 Inch Minimum Length, BrownMS3367-2-1/(96906)

18

HD 18

18

HD 18

18

EA 18

19 C 19 Tag, Marker 19

9905-00-537-8954/(64067)

19 9905-00-537-8954 Bundle of 20 BD

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1)

ITEMNUMBER

(2)

LEVEL

(3)


(4)


(5)

U/I

INDEX-1

TM 5-3805-293-10

INDEXSubject WP Sequence No.-Page No.

AAbbreviations/Acronyms, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-8Advanced Operation and Operator Tips

Traveling and Earth Moving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-1Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014-1All-Wheel Drive, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1

BBlade Lift

Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015-1Brake

Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016-1

CCentershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017-1Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination, Threat of . . . . . . . . . . . . . . . WP 0001-10Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018-1Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031-1Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-1

DDescription and Use of Operator Controls and Indicators

Mounting and Dismounting - Main Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-1Description and Use of Operator’s Controls and Indicators

All-Wheel Drive (AWD) Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-18Alternate Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-2Battery Disconnect Switch and Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-24Door Handles and Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-5Forward Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-16Frame Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-3Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-19Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-10Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-22Mid-Mount Scarifier Control Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-15Military Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-23Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-21Right-Side Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-17Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-7Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-8Wheel Lean Lock Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-4Wiper/Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-20Wrist Rests, Arm Pads, and Control Pods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-9

Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020-1

EElectrical, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6

INDEX-2

TM 5-3805-293-10

INDEX - CONTINUEDSubject WP Sequence No.-Page No.Electromagnetic Pulse (EMP) Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-10Engine

Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3Engine, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0003-2Equipment

Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-6Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1Improvement Recommendations (EIR), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1

Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0021-1Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1

FFire Extinguisher, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-9Fuel/Water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0022-1Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0023-1

GGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1

HHow To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

LList of

Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-8Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1

MMaintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0024-1

OOperation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-1

Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-3High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8Moving Machine Out of Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7Portable Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7Secondary Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-2Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8Stopping Engine if Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13

Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-1All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-30Centershift Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-28Differential Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-19Engine Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3

INDEX-3

TM 5-3805-293-10

INDEX - CONTINUEDSubject WP Sequence No.-Page No.

Initial Adjustment Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-18Machine Warning Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-17Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-7Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-5

Articulation Lock Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-6Scarifier Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-33Seat, Seat Belt, and Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2Slope Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-32Throttle Hold Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-26Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-20

PPowertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4Preventive Maintenance Checks and Services (PMCS)

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012-1Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013-1

RRadiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025-1References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030-1Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

SScarifier

Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026-1Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027-1

Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-2Stowage and Decal/Data Plate Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008-1

TTheory of Operation

All-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-5Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2Engine Starting and Machine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4

Threat of Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination . . . . . . . . . . . . . . . WP 0001-10Traveling and Earth Moving Operations, Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . WP 0006-1Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009-1Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011-1Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010-1

INDEX-4

TM 5-3805-293-10

INDEX - CONTINUEDSubject WP Sequence No.-Page No.

WWindow Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028-1Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022-1

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

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DATE

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USAPPC V3.00

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*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE


TO: (Forward direct to addressee listed in publication)U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS1 Rock Island Arsenal, Rock Island, IL 61299-7630


PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE ��Z��[� �� [��\��]�� TM /-3)"5-21!-1"�� !" ��#�$"%" G��_�[��%$"[

PAGENO.

COLMNO.

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REFERENCENO.

FIGURENO.

ITEMNO.

TOTAL NO.OF MAJOR

ITEMSSUPPORTED

RECOMMENDED ACTION



USAPPC V3.00




DATE




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PARA-GRAPH

LINE NO. *

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SIGNATURE





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ITEMSSUPPORTED

RECOMMENDED ACTION



USAPPC V3.00




DATE




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RECOMMENDED ACTION



USAPPC V3.00

By Order of the Secretary of the Army:

GEORGE W. CASEY JR.��

��Official:

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: $/0).0, requirements for TM 5-3805-293-10.

��

THE METRIC SYSTEM AND EQUIVALENTS

APPROXIMATE CONVERSION FACTORS

Linear Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches1 Kilometer = 1000 Meters = 0.621 Miles

Weights

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces1 Kilogram = 1000 Grams = 2.2 Pounds1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

Liquid Measure

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

Square Measure

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Cubic Measure

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet

Temperature

5/9 (°F - 32) = °C212° Fahrenheit is equivalent to 100° Celsius90° Fahrenheit is equivalent to 32.2° Celsius32° Fahrenheit is equivalent to 0° Celsius9/5 C° +32 = F°

To Change To Multiply By

Inches Centimeters 2.540

Feet Meters 0.305

Yards Meters 0.914

Miles Kilometers 1.609

Sq Inches Sq Centimeters 6.451

Sq Feet Sq Meters 0.093

Sq Yards Sq Meters 0.836

Sq Miles Sq Kilometers 2.590

Acres Sq Hectometers 0.405

Cubic Feet Cubic Meters 0.028

Cubic Yards Cubic Meters 0.765

Fluid Ounces Milliliters 29.573

Pints Liters 0.473

Quarts Liters 0.946

Gallons Liters 3.785

Ounces Grams 28.349

Pounds Kilograms 0.454

Short Tons Metric Tons 0.907

Pound-Feet Newton-Meters 1.356

Pounds per Sq Inch

Kilopascals 6.895

Miles per Gallon Kilometers per Liter 0.425

Miles per Hour Kilometers per Hour 1.609

To Change To Multiply By

Centimeters Inches 0.394

Meters Feet 3.280

Meters Yards 1.094

Kilometers Miles 0.621

Sq Centimeters Sq Inches 0.155

Sq Meters Sq Feet 10.764

Sq Meters Sq Yards 1.196

Sq Kilometers Sq Miles 0.386

Sq Hectometers Acres 2.471

Cubic Meters Cubic Feet 35.315

Cubic Meters Cubic Yards 1.308

Milliliters Fluid Ounces 0.034

Liters Pints 2.113

Liters Quarts 1.057

Liters Gallons 0.264

Grams Ounces 0.035

Kilograms Pounds 2.205

Metric Tons Short Tons 1.102

Newton-Meters Pound-Feet 0.738

Kilopascals Pounds per Sq Inch

0.145

Kilometers per Liter Miles per Gallon 2.354

Kilometers per Hour Miles per Hour 0.621

��\��

48747686-tm-5-3805-293-10-motor-grader-120m.pdf

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