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TM 5-3805-294-10

TECHNICAL MANUAL

OPERATOR'S MANUALFOR

HYDRAULIC EXCAVATOR (HYEX)

(JOHN DEERE 240D LCR)

TYPE 1 WITH HYDRAULIC THUMB AND QUICK LATCH

NSN 3805-01-573-0677 (EIC : ALL)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

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WARNING SUMMARY

This warning summary contains general safety and hazardous materials warnings that must be understood and

applied during operation and maintenance of the machine. Failure to observe these precautions or operating this

machine without training or instruction may result in serious injury or death to personnel.

FIRST AID

First aid is de fined a s "urgent a nd immediate lifes aving a nd othe r mea su res , which ma y be pe rformed for cas ua lties

by nonme dica l pe rsonne l when me dica l pe rsonne l are not immediate ly availab le."

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

EXPLANATION OF SAFETY WARNING ICONS

AIR P RESS URE - Human hand blocking air gun shows the need to reduce air

press ure be fore us e, or de bris may injure us er a nd/or dama ge equipment.

BIOLOGICAL - Abstract bug symbol shows that a mate rial may con tain ba cteria

or viruse s tha t pres en t a da nge r to life or hea lth.

EAR P ROTECTION - Hea dphone s ove r ea rs show tha t noise leve l will ha rm ea rs

ELECTRICAL - Electrica l wire to ha nd with e lectricity s ymbol running throughhuman ha nd shows that shock hazard is pres ent.

EXPLOSION - Human figure in front of explosion symbol shows that the material

may explode if subjec ted to high tempera tures , sources of ignition, or high pres su re

EXTREMELY COLD SURFACE - Hand touching object with ice formed on both

shows that surface is extreme ly cold and can da mage human tiss ue.

EYE P ROTECTION - Pe rson with goggles shows tha t material will injure the eye s

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WARNING SUMMARY - Continued

EXPLANATION OF SAFETY WARNING ICONS - Continued

FIRE - Flame shows that material may ignite and cause burns.

FIRE EXTINGUISHER - Fire extinguisher shows that material may ignite and a fire

extinguishe r should be within e as y rea ch.

HEAVY OBJ ECT - Human figure stooping over he avy object s hows physical injury

potentia l for imprope r lifting te chnique , a nd/or a id of ass is tan t(s) and/or lifting device

(as required).

HEAVY PARTS - Hand with hea vy objec t on top s hows that heavy parts can crush

and harm.

HEAVY PARTS - Foot with hea vy objec t on top shows tha t hea vy pa rts c an crush

and harm.

HEAVY PARTS - Moving heavy object pinning human figure against stationary

objec t shows that he avy, moving pa rts/objects p res en t a da nge r to life or limb.

HEAVY PARTS - Hea vy objec t on human figure s hows tha t heavy pa rts pre se nt a

da nge r to life or limb.

HOT AREA - Hand over object radiating he ats shows that pa rt is hot and ca n burn.

MOVING P ARTS - Hand with finge rs caught betwee n ge ars s hows tha t the m oving

pa rts of the equipme nt pres en t a da nge r to life or limb.

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WARNING SUMMARY - Con tinued

EXPLANATION OF SAFETY WARNING ICONS - Continued

POISON - Skull and cross bones symbol shows that dange rous gas es , sprays,

vapors, liquids , or materials conta in compounds that pres en t a da nge r to life orhealth.

PR OJ ECTILE HAZARD - Human body with objec t pas sing through it shows that a

projec tile hazard exists.

RADIATION - Three circular wedge s show that the ma terial emits radioactive

ene rgy and can injure huma n tiss ue.

SE AT BELT USE - Human figure wearing seat belt indicates a seat belt must be

us ed to prevent injury or dea th in the eve nt of a veh icle cras h or rollover.

SKIN IRRITATION - Hand radiating s hows that ma terial can ca us e skin irritation.

SLICK FLOOR - Wavy line on floor with legs prone shows tha t slick floor pre sents

a danger of falling.

STEAM HAZARD - Human engulfed in s team cloud shows s team ha zard e xists

that could injure/burn huma n tiss ue .

VAPOR - Human figure in a cloud s hows tha t material vapors pres en t a da nge r to

life or health.

WARNING - Triangle with e xclama tion point within s hows tha t a WARNING is

pres en t tha t indicates a potential haza rd, which ma y caus e injury or death to

personnel.

WARNING DESCRIPTIONS

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WARNING

Pe rform a complete wa lk around the machine prior to starting the engine . Ens ure s ufficien t

clea rance from personne l and equipment for sa fe ope ration of machine. P rior to starting

engine , s ound horn to a lert pe rsonne l. Fa ilure to comply may re sult in injury or dea th to

personnel.

WARNING

SAFE CLEARANCE:

Before moving the machine or ope rating the boom, e nsu re that the boom has a t lea st 10

ft. (3 m) of clea rance from overhead wires , power line s, or structures . If line s are near to

your operating area, notify your supervisor prior to operating the boom. Failure to comply

may re su lt in injury or dea th to pe rsonne l.

Kee p pe rsonne l clea r of the machine when trave ling. Fa ilure to comply may res ult in injury

or dea th to pe rsonnel.

WARNING

PREVENTING CAVE IN

Work perpe ndicular to or a t an ang le to exca vation, with trave l motors to the rea r of the

machine . Fa ilure to comply may res ult in injury or dea th to pe rsonne l.

Do not drive ne ar the edge of an e xcavation or trench. Fa ilure to com ply may res ult in

injury or dea th to pe rsonne l.

Do not dig under the machine . Fa ilure to comply may res ult in injury or dea th to pers onne l.

To preven t the s poil pile from caving in the e xcavation, s poil piles should be placed at

least 3 ft (1 m) from trench. Failure to comply may result in injury or death to personnel.

WARNING

DIESEL FUEL

Diesel fuel is highly flammable and can be accidentally ignited. Do not smoke or allow

open flame or sparks in the vicinity while working on any part of fuel system. Keep fire

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extinguisher within easy reach when working with fuel. Failure to comply may result in

injury or dea th to pers onne l.

Sp illed fue l is s lippe ry and crea tes a hazardous condition. Clean up a nd prope rly dispos eof spilled fuel as soon as possible. Failure to comply may result in injury or death to

personnel.

Do not work on fuel system when engine is hot. Failure to comply may result in injury or

dea th to pe rsonnel.

Safety glasses must be worn when working on pressurized systems. Failure to comply

may result in injury or death to personnel.

WARNING

LUBRICATING OIL

Prolonged contact with lubrica ting oil may ca us e skin ras h. Re move s aturated clothing

immediately and wash skin thoroughly that comes in contact with lubricating oil. Failure

to comply may result in injury or death to personnel.

Sp illed oil is slippe ry and crea tes a hazardous condition. Clean up a nd prope rly dispos e

of hydraulic oil. Failure to comply may result in injury or death to personnel.

WARNING

Ens ure e lectrica l powe r is off prior to working on a ll e lectrica l connections . Re move a ll jewelry

such a s rings , ID tags , brace lets , e tc., prior to working on or around vehicle. Je welry and tools

can ca tch on equ ipment, contact positive e lec trica l circuits, and ca use a d irect short, se vere

burns, or electrical shock. Failure to comply may result in injury or death to personnel.

WARNING

LEAD-ACID BATTERIES

Avoid ba ttery electrolyte contact with skin, e yes , and c lothing. If ba ttery electrolyte s pills ,

take the following immediate action to stop burning effects:

External - If battery electrolyte contacts skin, immediately flush affected area with cold

running water. Failure to comply may result in injury or death to personnel.

Eyes - If battery electrolyte contacts eyes, immediately flush eyes with cold water for 15

minutes and s ee k immed iate med ical a tten tion. IMPORTANT - If only one eye is affec ted,

ensu re the a ffec ted e ye is always kept lower than the una ffecte d eye, during both flus hing

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and transport. This will help keep the affected eye from draining into and contaminating

the una ffecte d e ye. Fa ilure to comply may re su lt in injury or dea th to pe rsonne l.

Internal - If battery electrolyte is ingested, drink large amounts of water or milk. Followwith milk of magnesia, a beaten egg, or vegetable oil and seek immediate medical

attention. Failure to comply may result in injury or death to personnel.

Clothing or vehicle - Immediately flush area with cold water and neutralize battery

electrolyte with baking s oda or hous ehold a mmonia s olution. Failure to comply may res ult

in injury or death to personnel.

Batteries produce e xplosive gas es . Do not smoke or use open flame nea r batteries . Do

not a llow hot, s pa rking, or g lowing objec ts nea r batteries . If ba tteries are giving o ff gas es ,

the pres ence of heat, flame , or spa rk may caus e fire and/or explosion. Failure to comply

may re su lt in injury or dea th to pe rsonne l.

Wear proper eye protection, gloves, and an apron when working near batteries. Failure

to comply may result in injury or death to personnel.

WARNING

Che mical Age nt Res is tant Coating (CARC) paint conta ins isocyana te which is h ighly irritating

to skin and res piratory sys tem. High conce ntrations of isocyana te can produce s ymptoms of

itching a nd redden ing of skin, a burning s ensa tion in the throat and nos e, a nd wate ring of the

eyes . In e xtreme conce ntrations, isocyana te can caus e cough, shortnes s of brea th, pain

during res piration, increa se d s putum production, a nd che st tightnes s. First aid for inge stion:

do not induce vomiting. Seek immediate medical attention. First aid for skin contact: remove

contaminated clothing. Was h s kin thoroughly with soa p a nd wate r. If symptoms pe rsist, s ee kme dical atten tion. Firs t aid for eye conta ct: flus h with wa ter for 15 minutes or until irritation

subs ide s. If symptoms pe rsist, s ee k med ica l atten tion. First a id for inha lation: move to fres h

a ir. If not brea thing, provide a rtificial respira tion. If symptoms pe rsist, s eek med ica l a ttention.

Failure to comply may result in injury or death to personnel.

WARNING

If Nuclear, Biological, or Chemical (NBC) exposure is suspected, all filter media should be

handled by personnel wearing protective equipment. Consult your unit NBC Officer or NBCNCO for appropriate handling or disposal instructions. Failure to comply may result in injury

or dea th to pe rsonnel.

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WARNING

Pe rsonnel hearing ca n be permane ntly dama ged if expose d to constant high noise levels of

85 dB or greater. Failure to comply may result in injury to personnel.

WARNING

Unles s o therwise spec ified , pe rform all maintenance procedu res with all attachme nts lowere d

to the ground, pilot shutoff lever in the up pos ition, a nd e ngine s hut off. Fa ilure to comply may

result in injury or death to personnel.

WARNING

Do not opera te bucke t or any attachme nt if the quick attach wedge is not fully se ate d and the

sa fety lock pin is not in the locked pos ition . The bucket or a ttachme nt may fall. One exce ption

to this rule is when s pe cifica lly ins tructed to do so during the re moving and insta lling of bucke t

or attachment to and from machine. Failure to comply may result in injury or death to

personnel.

WARNING

CARBON MONOXIDE

Carbon monoxide is a colorles s, odo rles s, de ad ly poison which, when breathe d, dep rives

the body of oxygen a nd ca us es su ffoca tion. Expos ure to a ir containing ca rbon monoxide

produces symptoms of heada che, dizzines s, loss of muscular control, appa rent

drowsiness , and coma . Pe rmanent brain dama ge or de ath to personnel can res ult from

se vere exposure.

Carbon monoxide occurs in e xhaus t fumes from internal combus tion e ngine s. It also

occurs in exhaus t fumes from e ngine coolant hea ter (arctic ma chine only). Carbon

monoxide can become dangerously concentrated under conditions of inadequate

ventilation. The following precau tions mus t be obs erved to e ns ure s afety of pe rsonne l

when engine of HYEX is ope rated:

1. DO NOT operate engine in enclosed areas without adequate ventilation.

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WARNING SUMMARY

2. DO NOT idle engine without adequate ventilation.

3. DO NOT drive ma chine with ins pection plates or cover plate s removed .

4. BE ALERT for exha us t poisoning s ymptoms . They a re: Headache

Dizziness

Sleepiness

Los s of muscular control

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

Remove pe rson from area

Expose to fresh air

Kee p person warm

DO NOT permit physical exercise

Administe r ca rdiopulmonary res usc itation (CPR) if nece ss ary

Notify a Medic

6. BE AWARE. The fie ld prote ctive m ask for nuclea r-biologica l-chemical (NBC) protec tionwill NOT protect you from carbon monoxide poisoning.

THE BEST DEFENS E AGAINST CARBON MONOXIDE P OISONING IS G OOD

VENTILATION. Fa ilure to comply may re sult in injury or de a th to pe rsonne l.

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LIST OF EFFECTIVE P AGES/WORK P ACKAGES

NOTE: Zero in the "Change No." column indica tes an origina l page or work packa ge .

Date of iss ue for the origina l manua l is:

Original 07 March 2011TOTAL NUMBER OF P AGES FOR FRONT AND REAR MATTER IS 54 AND TOTAL NUMBER OF

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HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 07 MARCH 2011

TECHNICAL MANUAL

OPERATORS MANUAL

FOR HYDRAULIC EXCAVATOR TYPE 1 (HYEX)

NSN 3805-01-573-0677 (EIC ALL)

REP ORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any

improvements to the proce dures in this publica tion, pleas e let us know. The preferred method is to

submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the

Internet, on the Army Elec tronic P roduct Support (AEPS) website. The Internet addres s is

https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the

AEP S P ublic Home Page . Fill out the form and click on SUBMIT. Using this form on the AEPS we bs ite

will enab le u s to res pond more quickly to your comments and be tter ma nage the DA Form 2028

program.

You ma y also ma il, e -mail, or fax your comme nts o r DA Form 2028 d irectly to the U.S. Army TACOM

Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle

Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI

48397-5000. The e-ma il addres s is: tacomlcmc.daform2028@ us .army.mil. The fax numbe r is DSN

793-0726 or Commercial (309) 782-0726. A reply will be furnished to you.

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

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TABLE OF CONTENTS

Page No

WP Se quence No

How to Use this Manua l

Chapter 1 - OPERATOR GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

Figure 4. HYEX Spe cifications............................................................................................................ 0002-7

Table 5. HYEX S pecification.............................................................................................................. 0002-7

Figure 5. HYEX Working Range s........................................................................................................ 0002-8

Table 6. HYEX Working Range s........................................................................................................ 0002-9

Table 7. Front Lift Capa cities ........................................................................................................... 0002-10

Table 8. Side Lift Ca pacities ............................................................................................................. 0002-11

Table 9. HYEX Weights With Attachme nts...................................................................................... 0002-12

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

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

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

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

Figure 2. Hydraulic System Compone nts............................................................................................ 0003-3

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

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

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

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TABLE OF CONTENTS - Con tinued

Page No.

WP Se quence No.

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

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

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

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

Figure 6. High-Press ure Pump and Injectors...................................................................................... 0003-7

Table 6. High-Press ure Pump and Injectors...................................................................................... 0003-7

Figure 7. Cooling Pa ckage.................................................................................................................. 0003-8

Table 7. Cooling Pa ckage.................................................................................................................. 0003-8

Figure 8. Cooling System Compone nts............................................................................................... 0003-9

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

Chapter 2 - OPERATOR INSTRUCTIONS

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

Table 1. Front Switch Pa nel............................................................................................................... 0004-1

Figure 1. Front Switch P ane l............................................................................................................... 0004-1

Figure 2. Front Switch Pa nel Continued.............................................................................................. 0004-2

Table 2. Heater/Air Conditioner (A/C) Controller and Ra dio.............................................................. 0004-3

Figure 3. Heater/Air Conditioner (A/C) Controller a nd Ra dio.............................................................. 0004-3

Figure 4. Heater/Air Conditioner (A/C) Controller a nd Ra dio Continued............................................. 0004-4

Table 3. Control Pe dals and Levers................................................................................................... 0004-5

Figure 5. Control Pe dals and Levers................................................................................................... 0004-5

Figure 6. Control Pe dals and Levers Continued.................................................................................. 0004-6

Table 4. Left Console and P ilot Shutoff Lever.................................................................................... 0004-7

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

Table 5. Right and Left Pilot Control Levers....................................................................................... 0004-8

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

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

Table 6. Se at Controls...................................................................................................................... 0004-10

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Page No

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Figure 10. Se at Controls...................................................................................................................... 0004-10

Table 7. Cab Door Relea se Lever and Coolant Heater Display....................................................... 0004-12

Figure 11. Cab Door Relea se Lever and Coolant Heater Display....................................................... 0004-12

Table 8. Quick Latch Control............................................................................................................ 0004-13

Figure 12. Quick Latch Control............................................................................................................ 0004-13

Table 9. Cab Light S witch................................................................................................................ 0004-14

Figure 13. Cab Light Switch................................................................................................................ 0004-14

Table 10. Hydraulic Hose Ree l........................................................................................................... 0004-15

Figure 14. Hydraulic Hose Reel........................................................................................................... 0004-15

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

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

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

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

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

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

Table 2. Warning Indicators and Alarms............................................................................................ 0005-6

Figure 5. Warning Indicators a nd Alarms............................................................................................ 0005-6

Figure 6. Overload Alarm.................................................................................................................... 0005-7

ADJUSTING THE OP ERATOR'S SE AT...................................................................................................... WP 0006

Figure 1. Operator's Se at Adjustments................................................................................................ 0006-1

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

Figure 1. Se at Belt............................................................................................................................... 0007-1

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

Figure 3. Engine Spe ed Dial Slow Idle................................................................................................ 0007-2

Figure 4. Key Switch ON..................................................................................................................... 0007-3

Figure 5. System Starting and Default Scree n.................................................................................... 0007-3

Figure 6. Prehe at Indicator.................................................................................................................. 0007-4

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Page No.

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Figure 7. Key Switch to START........................................................................................................... 0007-4

Figure 8. Alarm indicator..................................................................................................................... 0007-5

Figure 9. Engine S pee d Dial Turned to 1/3 Pos ition........................................................................... 0007-5

Figure 10. Return Engine Spe ed Dial to S low Idle................................................................................ 0007-6

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

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

Figure 2. Boom and Arm Raise d......................................................................................................... 0008-2

Figure 3. Travel Mode Switch.............................................................................................................. 0008-2

Figure 4. Moving Forward a nd Backwards.......................................................................................... 0008-3

Figure 5. Right Turn............................................................................................................................. 0008-4

Figure 6. Left Turn............................................................................................................................... 0008-4

Figure 7. Counter-Rotate..................................................................................................................... 0008-5

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

Figure 1. Machine In Pa rked Pos ition.................................................................................................. 0009-1

Figure 2. Auto-Idle Switch and Engine Spe ed Dial.............................................................................. 0009-2

Figure 3. Engine Spe ed Dial................................................................................................................ 0009-3


Figure 5. Key S witch Turned OFF....................................................................................................... 0009-4

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

Figure 1. Machine In Pa rked Pos ition.................................................................................................. 0010-1

Figure 2. Auto-Idle Switch and Engine Spe ed Dial.............................................................................. 0010-2



Figure 5. Key Switch Turned OFF....................................................................................................... 0010-4

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

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

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

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Figure 3. Lock Windshield Open......................................................................................................... 0011-2

Figure 4. Releas e Windshield Latch.................................................................................................... 0011-3

Figure 5. Close Windshield.................................................................................................................. 0011-3

Figure 6. Latch Windshield.................................................................................................................. 0011-4

Figure 7. Open a nd Close Ca b Door Window..................................................................................... 0011-4

Figure 8. Open Access Cover............................................................................................................. 0011-5

Figure 9. Open and Close Skylight Window........................................................................................ 0011-5

Figure 10. Close Acces s Cover............................................................................................................. 0011-6

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

Figure 1. Stow Wea pon In Rea r Bracket............................................................................................. 0012-1

Figure 2. Stow Wea pon In Front Bracket............................................................................................ 0012-2

Figure 3. Remove Wea pon From Front Bracket.................................................................................. 0012-2

Figure 4. Remove Wea pon From Rea r Bracket.................................................................................. 0012-3

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

Figure 1. Se lect Time Se t Menu.......................................................................................................... 0013-1

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

Figure 3. Se lect Ope rating Conditions Menu....................................................................................... 0013-2

Figure 4. Res et Ope rating Conditions................................................................................................. 0013-3

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

Figure 1. Unlock S afety Lock P in........................................................................................................ 0014-1

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

Figure 3. Move Quick Latch S witch to Unlatch P osition...................................................................... 0014-2

Figure 4. Extend Bucket Cylinder........................................................................................................ 0014-3

Figure 5. Retract Bucket Cylinder........................................................................................................ 0014-3

Figure 6. Lower Boom......................................................................................................................... 0014-4

Figure 7. Pos ition Quick Latch S witch to Latch pos ition...................................................................... 0014-4

Figure 8. Remove Quick Latch............................................................................................................ 0014-5

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Figure 9. Pos ition Quick Latch S witch to Unlatch pos ition.................................................................. 0014-6

Figure 10. Raise Boom for Clea rance................................................................................................... 0014-6

Figure 11. Retract Wedges .................................................................................................................... 0014-7

Figure 12. Ins tall Quick Latch................................................................................................................ 0014-7

Figure 13. Position Quick Latch Switch toLatch position....................................................................... 0014-8

Figure 14. Ra ise Boom.......................................................................................................................... 0014-8

Figure 15. Sa fety Pin Locked................................................................................................................ 0014-9

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

Figure 1. Lifting with Quick Latch Loop............................................................................................... 0015-2

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

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

Figure 2. Add or R emove Material....................................................................................................... 0016-1

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

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

Figure 5. Planning Spoil P iles .............................................................................................................. 0016-5

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

Figure 7. Clea ning Cave In.................................................................................................................. 0016-6

Figure 8. Trenching on a Slope........................................................................................................... 0016-7

Figure 9. Straight Line Trenching........................................................................................................ 0016-8

Figure 10. Back Filling........................................................................................................................... 0016-9

Figure 11. Truck Loading..................................................................................................................... 0016-10

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

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

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

Figure 3. Releas ing Objects................................................................................................................ 0017-3

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

Figure 1. Se lect Attachme nt................................................................................................................ 0018-1

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Table 1. Attachme nt Se lection........................................................................................................... 0018-1

Figure 2. Attachme nt Spe cification S creen......................................................................................... 0018-2

INSTALLING AND OPERATING THE CRUS H-ALL............ ........... ............ ........... ........... ............ ............ ... WP 0019

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

Figure 2. Move Quick Latch S witch to Unlatch P osition...................................................................... 0019-2


Figure 4. Install Quick Latch................................................................................................................ 0019-3

Figure 5. Quick Latch S witch to Latch P osition................................................................................... 0019-4

Figure 6. Pos ition Crush-All................................................................................................................. 0019-4

Figure 7. Connect Auxiliary Supply Line.............................................................................................. 0019-5

Figure 8. Connect Auxiliary Return Line.............................................................................................. 0019-5

Figure 9. Crush-All Operation.............................................................................................................. 0019-7

Figure 10. Ope n Lid............................................................................................................................... 0019-9

Figure 11. Clea ring Ja m from Crush-All................................................................................................ 0019-9

Figure 12. Pus h Crush-All Rotor Backwards....................................................................................... 0019-10

Figure 13. Position Crush-All............................................................................................................... 0019-10

Figure 14. Disconne ct Auxiliary Re turn Line ....................................................................................... 0019-11

Figure 15. Disconne ct Auxiliary Supply Line ....................................................................................... 0019-12

Figure 16. Move Quick Latch Switch................................................................................................... 0019-12

Figure 17. Ra ise Boom........................................................................................................................ 0019-13

Figure 18. Remove Quick Latch.......................................................................................................... 0019-14

Figure 19. Move Quick Latch Switch................................................................................................... 0019-14

Figure 20. Ope n Hydraulic Thumb Circuit........................................................................................... 0019-15

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


Figure 2. Move Quick Latch S witch..................................................................................................... 0020-2


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Figure 4. Quick Latch Wedges Retracted............................................................................................ 0020-3



Figure 7. Move Quick Latch S witch to Latch P osition......................................................................... 0020-5

Figure 8. Quick Latch Wedge s Enga ged............................................................................................. 0020-5

Figure 9. Sa fety P in to Lock Pos ition................................................................................................... 0020-6

Figure 10. Conne ct Auxiliary Supply Line .............................................................................................. 0020-6

Figure 11. Conne ct Auxiliary Re turn Line .............................................................................................. 0020-7

Figure 12. Brea ker Tool Lock Bolt......................................................................................................... 0020-8

Figure 13. Ins ert Brea ker Tool............................................................................................................... 0020-9

Figure 14. Lock Brea ker Tool................................................................................................................ 0020-9

Figure 15. Brea ker Operation.............................................................................................................. 0020-10

Figure 16. Tool Removal..................................................................................................................... 0020-10

Figure 17. Remove Brea ker Tool........................................................................................................ 0020-11

Figure 18. Lock Brea ker Tool.............................................................................................................. 0020-11

Figure 19. Disconne ct Auxiliary Re turn Line ....................................................................................... 0020-12

Figure 20. Disconne ct Auxiliary Supply Line ....................................................................................... 0020-12

Figure 21. Sa fety Pin to Unlock Position............................................................................................. 0020-13

Figure 22. Raise Boom for Clea rance................................................................................................. 0020-13

Figure 23. Move Quick Latch Switch to Unlatch Pos ition.................................................................... 0020-14

Figure 24. Quick Latch Wedges Retracted.......................................................................................... 0020-14

Figure 25. Impact Brea ker Removal.................................................................................................... 0020-15

Figure 26. Quick Latch Switch to Latch Pos ition................................................................................. 0020-15

Figure 27. Ope n Hydraulic Thumb Circuit........................................................................................... 0020-16

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


Figure 2. Move Quick Latch Switch..................................................................................................... 0021-3

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


Figure 6. Pos ition Quick Latch............................................................................................................. 0021-5

Figure 7. Quick Latch S witch to Latch P osition................................................................................... 0021-5

Figure 8. Raise Boom for Clea rance................................................................................................... 0021-6

Figure 9. Engage Quick Latch Wedge s............................................................................................... 0021-6

Figure 10. Lock Sa fety Lock.................................................................................................................. 0021-7

Figure 11. Conne ct Auxiliary Supply Line .............................................................................................. 0021-7

Figure 12. Conne ct Auxiliary Re turn Line .............................................................................................. 0021-8

Figure 13. Attachme nt P eda l Lock Re lea se .......................................................................................... 0021-8

Figure 14. Disconne ct Auxiliary Re turn Line ......................................................................................... 0021-9

Figure 15. Conne ct Auxiliary Supply Line ............................................................................................ 0021-10

Figure 16. Unlock Sa fety Lock............................................................................................................. 0021-10

Figure 17. Quick Latch Switch to Unlatch Pos ition.............................................................................. 0021-11

Figure 18. Ra ise Boom........................................................................................................................ 0021-11

Figure 19. Dise ngage Quick Latch Wedges ........................................................................................ 0021-12

Figure 20. Re trac t Bucket Cylinde r...................................................................................................... 0021-12

Figure 21. Remove Quick Latch.......................................................................................................... 0021-13

Figure 22. Quick Latch Switch to Latch Pos ition................................................................................. 0021-13

Figure 23. Clos e Hydraulic Thumb Circuit........................................................................................... 0021-14

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

Figure 1. Lifting Barrier Grapple.......................................................................................................... 0022-2

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

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

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


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

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

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

Figure 1. Pos ition Bucket..................................................................................................................... 0024-1

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

Figure 3. Pos ition Bucket on Lower Level........................................................................................... 0024-3

Figure 4. Rotate Upperstructure to Upper Level.................................................................................. 0024-3

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

Figure 1. Right Side Re ar Cover Installation....................................................................................... 0025-1

Figure 2. Right Side Ce nter Cover Installation.................................................................................... 0025-1

Figure 3. Right S ide Front Cover Installation....................................................................................... 0025-2

Figure 4. Lock Bar Installation............................................................................................................. 0025-2

Figure 5. Front Door Cover Installation............................................................................................... 0025-3

Figure 6. Center Door Cover Installation............................................................................................. 0025-3

Figure 7. Lower Door Cover Installation.............................................................................................. 0025-4

Figure 8. Side Upper Glas s Cover Installation.................................................................................... 0025-4

Figure 9. Side Lower Glas s Cover Installation.................................................................................... 0025-5

Figure 10. Right Rea r Cab Cover Installation........................................................................................ 0025-5

Figure 11. Left Re ar Cab Cover Installation.......................................................................................... 0025-6

Figure 12. Left Rea r Ca b Cover Re moval............................................................................................. 0025-6

Figure 13. Right Re ar Cab Cover Re moval........................................................................................... 0025-7

Figure 14. Side Lower Glass Cover Removal....................................................................................... 0025-7

Figure 15. Side Upper Glas s Cover Removal....................................................................................... 0025-8

Figure 16. Lower Door Cover Removal................................................................................................. 0025-8

Figure 17. Center Door Cover Removal................................................................................................ 0025-9

Figure 18. Front Door Cover Removal.................................................................................................. 0025-9

Figure 19. Lock Bar Removal.............................................................................................................. 0025-10

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Figure 20. Right Side Front Cover Removal........................................................................................ 0025-10

Figure 21. Right S ide Center Cover Removal..................................................................................... 0025-10

Figure 22. Right S ide Rea r Cover Re moval........................................................................................ 0025-11

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

Figure 1. Hydraulic Tool Attachme nt................................................................................................... 0026-1

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

Figure 3. Turn Off Hydraulic Tool........................................................................................................ 0026-2

Figure 4. Hydraulic Tool Removal....................................................................................................... 0026-3

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

Figure 1. Left Side, Rear Cab Window, and Top Deca ls..................................................................... 0027-1

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

Figure 3. Top Under Engine Cover...................................................................................................... 0027-2

Figure 4. Right Side on Hydraulic Re se rvoir....................................................................................... 0027-3

Figure 5. Right Side............................................................................................................................. 0027-3

Figure 6. Boom, Right Side, and Rear Cab Window........................................................................... 0027-4

Figure 7. Counterweight...................................................................................................................... 0027-4

Figure 8. Front and Re ar Frame.......................................................................................................... 0027-5

Figure 9. Cab on Se at......................................................................................................................... 0027-5

Figure 10. Key Switch............................................................................................................................ 0027-5

Figure 11. Winds hield............................................................................................................................ 0027-6

Figure 12. Side Window........................................................................................................................ 0027-6

Figure 13. Upper a nd Lower Right S ide Window.................................................................................. 0027-7

Figure 14. Lower Right Side Window.................................................................................................... 0027-8

Figure 15. Vanda l Protection Kit............................................................................................................ 0027-9

Figure 16. Upper S ection Pe riodic Maintena nce................................................................................. 0027-10

Figure 17. Lower Se ction Pe riodic Maintena nce................................................................................. 0027-11

Figure 18. Ditch Clea ning Bucket........................................................................................................ 0027-12

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Figure 19. Hea vy Duty Bucket............................................................................................................. 0027-12

Figure 20. Right S ide Crush-All........................................................................................................... 0027-13

Figure 21. Left Side Crush-All............................................................................................................. 0027-13

Figure 22. Output Side Crush-All......................................................................................................... 0027-14

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

LOWERING BOOM WITHOUT HYDRAULIC PRESSURE......................................................................... WP 0029

OPERATING IN COLD WEATHER 32TO 5F (0TO -15C)..................................................................... WP 0030

Figure 1. Pres s a nd Hold Back Button................................................................................................ 0030-1

Figure 2. Key S witch to ON P osition................................................................................................... 0030-2

Figure 3. Releas e Back Button............................................................................................................ 0030-2

Figure 4. Highlight Se rvice Menu........................................................................................................ 0030-3

Figure 5. Se lect Monitoring.................................................................................................................. 0030-3

Figure 6. Temperatures Displayed...................................................................................................... 0030-4

Figure 7. Start Engine.......................................................................................................................... 0030-4


Figure 9. Check Engine and Hydraulic Oil Temperatures ................................................................... 0030-5

Table 1. Machine Switch Se lections................................................................................................... 0030-6

Figure 10. Ra ise Machine ...................................................................................................................... 0030-6

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

Figure 1. Pres s a nd Hold Back Button................................................................................................ 0031-1

Figure 2. Key S witch to ON P osition................................................................................................... 0031-2

Figure 3. Releas e Back Button............................................................................................................ 0031-2

Figure 4. Highlight Se rvice Menu........................................................................................................ 0031-3

Figure 5. Se lect Monitoring.................................................................................................................. 0031-3

Figure 6. Temperatures Displayed...................................................................................................... 0031-4

Figure 7. Start Engine.......................................................................................................................... 0031-4

Figure 8. Engine Idle Spe ed................................................................................................................ 0031-5

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Figure 9. Monitor Tempe ratures Displayed......................................................................................... 0031-5

Table 1. Machine Switch Se lection.................................................................................................... 0031-6

Figure 10. Ra ise Machine ...................................................................................................................... 0031-7

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

Figure 1. Slave Rece ptacle................................................................................................................. 0032-2

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

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

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

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

Figure 1. Coolant Heater Control Pa nel.............................................................................................. 0034-2

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

Figure 3. Se tting Program................................................................................................................... 0034-3

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

Figure 5. Manua lly Start Coolant Hea ter............................................................................................. 0034-4

Figure 6. Manua lly Start Coolant Hea ter Continued............................................................................ 0034-5

MOVING UP/DOWN STEEP OR SLIPP ERY S LOP ES............................................................................... WP 0035

Figure 1. Buckle Se at Belt................................................................................................................... 0035-1

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

Figure 3. Buckle Se at Belt................................................................................................................... 0035-3

Figure 4. Pus hing Machine.................................................................................................................. 0035-3

Figure 5. Traveling Down.................................................................................................................... 0035-4

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

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


Figure 3. Check Monitor...................................................................................................................... 0036-2

Chapter 3 - OPERATOR TROUBLESHOOTING PROCEDURES

TROUBLES HOOTING S YMPTOM INDEX - OPERATOR MAINTENANCE.... ....... ....... ....... ....... ............ ... WP 0037

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TRAVEL ALARM DOES NOT OPERATE.................................................................................................... WP 0038

WINDSHIELD WIPER AND WASHER DO NOT OPERATE....................................................................... WP 0039

CAB DOME LIGHT DOES NOT OPERATE.............................................................................................. .. WP 0040

BOOM, CAB, AND DRIVE LIGHTS DO NOT OPERATE............................................................................ WP 0041

CAB FRONT WORK LIGHTS DO NOT OPERATE................................................................................... .. WP 0042

CAB REAR WORK LIGHTS DO NOT OPERATE....................................................................................... WP 0043

LOW NOTE AND HIGH NOTE HORNS DO NOT OPERATE.................................................................... . WP 0044

AIR CONDITIONER DOES NOT OPERATE............................................................................................... WP 0045

ENGINE CRANKS BUT DOES NOT START OR HARD TO START......................................................... . WP 0046

ENGINE WILL NOT CRANK........................................................................................................................ WP 0047

ENGINE RUNS PO ORLY............................................................................................................................ WP 0048

EXCES SIVE FUEL CONSUMPTION.......................................................................................................... WP 0049

EXCESSIVE OIL CONSUMPTION.............................................................................................................. WP 0050

ENGINE IDLES POORLY............................................................................................................................ WP 0051

AUTO-IDLE DOES NOT WORK.................................................................................................................. WP 0052

ENGINE NOT DEVELOPING FULL POWER............................................................................................ .. WP 0053

ENGINE OIL PRES SURE LOW.................................................................................................................. WP 0054

ENGINE COOLANT TEMPERATURE ABOVE NORMAL........................................................................... WP 0055

ENGINE EMITS EXCESSIVE BLACK OR GRAY EXHAUST SMOKE....................................................... WP 0056

ENGINE EMITS EXCESSIVE WHITE EXHAUST SMOKE......................................................................... WP 0057

NO HYDRAULIC FUNCTIONS.................................................................................................................... WP 0058

HYDRAULIC FUNCTIONS ARE SLOW OR HAVE LITTLE OR NO P OWER.. ........ ........ ........ ........... ........ WP 0059

POWER DIG DOES NOT WORK................................................................................................................ WP 0060

HYDRAULIC OIL OVERHEATS.................................................................................................................. WP 0061

HYDRAULIC OIL FOAMS............................................................................................................................ WP 0062

NO SWING FUNCTION............................................................................................................................... WP 0063

SWING FUNCTION IS JERKY.................................................................................................................... WP 0064

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SLOW TRAVEL SPEED ONLY................................................................................................................... WP 0065

TRAVEL IS JERKY...................................................................................................................................... WP 0066

ENGINE STOPS WHEN TRAVEL OR CONTROL LEVER ACTUATED..................................................... WP 0067

QUICK LATCH DOES NOT OPERATE....................................................................................................... WP 0068

COMPACTOR DOES NOT OPERATE........................................................................................................ WP 0069

BREAKER DOES NOT OP ERATE.............................................................................................................. WP 0070

BREAKER OPERATES SLOWLY............................................................................................................... WP 0071

CRUSH-ALL DOES NOT OPERATE........................................................................................................... WP 0072

BARRIER GRAPPLE DOES NOT HOLD LOAD....................................................................................... .. WP 0073

DEEP DIG DOES NOT OP ERATE.............................................................................................................. WP 0074

HYDRAULIC HOSE REEL DOES NOT OPERATE................................................................................... .. WP 0075

Chapter 4 - OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INTRODUCTION - P REVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS).......... ............ ..... WP 0076

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)........................................................ . WP 0077

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

Figure 1. Exterior of Machine.............................................................................................................. 0077-3

Figure 2. Exterior of Machine Continued............................................................................................. 0077-4

Figure 3. Coolant Level....................................................................................................................... 0077-5

Figure 4. Engine Oil............................................................................................................................. 0077-6

Figure 5. Exhaust Components........................................................................................................... 0077-7

Figure 6. Hydraulic Res ervoir Ca p...................................................................................................... 0077-7

Figure 7. Fuel Tank and Fuel Level..................................................................................................... 0077-8

Figure 8. Fuel Filters............................................................................................................................ 0077-9

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

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

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

Figure 12. Air Clea ner Housing and Hose Ree l.................................................................................. 0077-12

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

Figure 14. Batteries Continue d............................................................................................................ 0077-14

Figure 15. Cab Glas s........................................................................................................................... 0077-15

Figure 16. Mirrors and Wipe r Arm....................................................................................................... 0077-15

Figure 17. Cab Door, Hinges , a nd Latches......................................................................................... 0077-16

Figure 18. Fire Extinguishe r................................................................................................................ 0077-17

Figure 19. Pe dals and Levers.............................................................................................................. 0077-18

Figure 20. Pilot Control Leve rs............................................................................................................ 0077-19

Figure 21. Se at Belt............................................................................................................................. 0077-20

Figure 22. Ignition Switch.................................................................................................................... 0077-20

Figure 23. Monitor............................................................................................................................... 0077-21

Figure 24. Position Boom and Arm...................................................................................................... 0077-22

Figure 25. Hydraulic Oil Leve l Che ck.................................................................................................. 0077-22

Figure 26. Brea ker............................................................................................................................... 0077-23

Figure 27. Compa ctor.......................................................................................................................... 0077-24

Figure 28. Crush-All............................................................................................................................. 0077-25

Figure 29. Barrier Grapple................................................................................................................... 0077-26

Figure 30. Dee p Dig Arm and Bucket.................................................................................................. 0077-27

Figure 31. Deep Dig Bucket................................................................................................................ 0077-28

Figure 32. Ditch Clea ning Bucket........................................................................................................ 0077-29

Figure 33. Position Boom and Arm...................................................................................................... 0077-31

Figure 34. Hydraulic Oil Leve l Che ck.................................................................................................. 0077-31

Figure 35. Fuel Tank and Fuel Level Check........................................................................................ 0077-32

Figure 36. Engine Oil Che ck................................................................................................................ 0077-33

Figure 37. Engine Compartment......................................................................................................... 0077-33

Figure 38. Exterior of Mach ine Che ck................................................................................................. 0077-34

Figure 39. Swing Gearbox Oil Leve l Che ck......................................................................................... 0077-35

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Figure 40. Hydraulic Pump Oil Leve l Che ck........................................................................................ 0077-36

Figure 41. Se rpentine Belt Che ck........................................................................................................ 0077-37

Figure 42. Air Conditione r Belt Che ck................................................................................................. 0077-38

Figure 43. Fan Check.......................................................................................................................... 0077-39

Chapter 5 - OPERATOR MAINTENANCE INSTRUCTIONS

GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0078

TAKING ENGINE OIL SAMPLE.................................................................................................................. WP 0079

Figure 1. Engine Oil S ampling Valve................................................................................................... 0079-1

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

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

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

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

Figure 4. Mea sure Track Sa g.............................................................................................................. 0080-4

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

Figure 6. Lower Machine..................................................................................................................... 0080-5

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

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

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

Figure 1. Loose n Track........................................................................................................................ 0082-1

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

Figure 1. Hydraulic Oil S ampling Valve............................................................................................... 0083-1

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

Figure 1. Fuse Box Acces s Cover Removal...........................

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