BackHoe Loader Student Guide

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October 2008

STUDENT GUIDE

FOR

BACKHOE LOADER

CASE 580 SUPER M


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PREFACE

This student guide contains selected course information and material. Most of the informationcontained in this student guide can be found in the BHL Operator Technical Manual TM 5-2420-231-

10. Some additional information pertinent to this course is not contained in the technical manual and

has been added to this student guide. This student guide is not intended as a replacement, but as a

supplement to the technical information contained in the technical manuals. You will not receivefuture updates to your personal copy of the student guide.


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ATSE-DT

MEMORANDUM

SUBJECT: Student Evaluation Plan for the Heavy Construction Equipment Operators Course, 21E10, ClassNo. 1-50 and follow-on classes.

1. ACADEMIC GRADING AND TEST PLAN: Academic subject matter is evaluated on a basis of 700 weightpoints which are distributed according to this document. Weight point achievement is calculated to apercentage computed to the second decimal place (0.00%) and used to determine student's completion oftraining. The written examination (TE) applies to the Active Component only.

a. Module A The Army Maintenance Management System (TAMMS) Weight Points

21E10-A06 TAMMS Written Examination (TE2 AC Only) 100

(1) This is an open book performance-based test that contains multiple choice questions whichrequire the student to determine solutions to questions/situations concerning The ArmysMaintenance Management System, Grade Stakes and Earthwork Principles. The students are

allowed to use any reference material given for the training received with the exception of theirstudent guide. Only those specific items covered in Annex A of which an equipment operatorshould have immediate knowledge will be included in this test.

(2) This test covers POI File 21E10-A05.

(3) The time indicated in this lesson plan includes 30 minutes to critique this test.

b. Module A Earthwork Principles Weight Points

21E10-A11 Earthwork Principles Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning Grade Stakes, Soils,Construction Prints and Surveying. The students are allowed to use any reference materialgiven for the training received with the exception of their student guide. Only those specificitems covered in Annex A of which an equipment operator should have immediate knowledgewill be included in this test.

(2) This test covers POI File 21E10-A07, A08, A09, and A10.


c. Module A Earthwork Principles (TE1) Weight Points

21E10-A10 Surveying (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to shoot elevation shots from multiple points and determine selectedelevations. The student must receive a GO in all above mentioned tasks to pass this module.

(2) The time indicated in these lesson plans includes 5 minutes per task to critique this test.

(3) This test covers POI Files 21E10-A10.


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d. Module B Dump Truck Weight Points

21E10-B01 through B04 Dump Truck (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures, drivingoperations, dumping operations and spreading operations with the Dump Truck. The studentmust receive a GO in all above mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-B01, B02, B03 and B04.

e. Module C Scoop Loader Weight Points

21E10-C01 through C05 Scoop Loader (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,

maneuvering operations, load a haul unit, clamshell operations, and excavation operations withthe Scoop Loader. The student must receive a GO in all above mentioned tasks to pass thismodule.


(3) This test covers POI Files 21E10-C01, C02, C03, C04, and C05.

f. Module C Scoop Loader Weight Points

21E10-C06 Scoop Loader Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning perform operatorsmaintenance, starting/stopping procedures, maneuvering operations, load a haul unit, clamshelloperations, and excavation operations with the Scoop Loader. The students are allowed to useany reference material given for the training received with the exception of their student guide.Only those specific items covered in Annex A of which an equipment operator should haveimmediate knowledge will be included in this test.

(2) This test covers POI File 21E10-C01, C02, C03, C04 and C05.


g. Module D Backhoe Loader Weight Points

21E10-D01 through D04 BHL (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,maneuvering operations and excavation with the BHL. The student must receive a GO in allabove mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-D01, D02, D03 and D04.


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h. Module D Backhoe Loader Weight Points

21E10-D05 Backhoe Loader Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning perform operatorsmaintenance, starting/stopping procedures, maneuvering operations and excavation with theBHL. The students are allowed to use any reference material given for the training received

with the exception of their student guide. Only those specific items covered in Annex A of whichan equipment operator should have immediate knowledge will be included in this test.

(2) This test covers POI File 21E10-D01, D02, D03 and C04.


i. Module D Hydraulic Excavator (HYEX) Weight Points

21E10-D06 through D12 HYEX (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,maneuvering operations, lifting operations, replacing attachments, excavation and loading withthe HYEX. The student must receive a GO in all above mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-D06, D07, D08, D09, D10, D11, and D12.


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j. Module D Hydraulic Excavator Weight Points

21E10-D13 Backhoe Loader Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning perform operatorsmaintenance, starting/stopping procedures, maneuvering operations, lifting operations,replacing attachments, excavation and loading with the HYEX. The students are allowed to use

any reference material given for the training received with the exception of their student guide.Only those specific items covered in Annex A of which an equipment operator should haveimmediate knowledge will be included in this test.

(2) This test covers POI File 21E10-D06, D07, D08, D09, D10, D11 and D12.


k. Module E Crawler Tractor Weight Points

21E10-E06 through E11 Crawler Tractor (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,maneuvering operations, excavation operations, and ditching operations with the CrawlerTractor. The student must receive a GO in all above mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-E06, E07, E08, E09 and E10.

l. Module E Crawler Tractor Weight Points

21E10-E11 Crawler Tractor Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning perform operatorsmaintenance, starting/stopping procedures, maneuvering operations, excavation operations,and ditching operations with the Crawler Tractor. The students are allowed to use anyreference material given for the training received with the exception of their student guide. Onlythose specific items covered in Annex A of which an equipment operator should haveimmediate knowledge will be included in this test.

(2) This test covers POI File 21E10-E06, E07, E08, E09 and E10.



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m. Module E Motorized Grader Weight Points

21E10-E01 through E05 Motorized Grader (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,maneuvering operations, leveling operations, and v-ditching operations with the Motorized

Grader. The student must receive a GO in all above mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-E01, E02, E03, and E04.

n. Module E Motorized Grader Weight Points

21E10-E05 Motorized Grader Written Examination (TE2 AC Only) 100

(1) This is performance-based test that contains multiple choice questions which require thestudent to determine solutions to questions/situations concerning perform operators

maintenance, starting/stopping procedures, leveling operations, and ditching operations withthe Motorized Grader. The students are allowed to use any reference material given for thetraining received with the exception of their student guide. Only those specific items covered inAnnex A of which an equipment operator should have immediate knowledge will be included inthis test.

(2) This test covers POI File 21E10-E01, E02, E03 and E04.


o. Module F Motorized Scraper Weight Points

21E10-F01 through F05 Motorized Scraper (TE1) GO

(1) This test contains performance-based, hands on evaluation performance measures. Thestudent is required to perform operators maintenance, starting/stopping procedures,maneuvering operations, push loading operations and excavation operations with the MotorizedScraper. The student must receive a GO in all above mentioned tasks to pass this module.


(3) This test covers POI Files 21E10-F01, F02, F03, F04 and F05.


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TOTAL POINTS 700

1. COUNSELING: Students will participate in counseling sessions conducted by instructor supervisors and bythe Student Affairs Counseling Division (or equivalent) throughout the course to review academic progressand discuss personal development. Students will be formally counseled whenever their academic standingfalls to borderline failing status or if they fail to comply with the Standards of Academic Integrity and

Conduct (or equivalent). When a student is formally counseled, a counseling form will be completed.Student must attend a mandatory study hall if he/she is failing or is in danger of failing.

2. MINIMUM ACHIEVEMENTS:

a. The student will complete all graded requirements and attend 100% of the classroom instructioncourse. The student is allowed to miss up to 20% of the hands on training but must pass allperformance evaluations in order to receive credit for training.

b. To graduate, the student must complete each test to the established standard. Failure to pass any testwill constitute failure of the course.

c. One retest will be administered if the student fails the initial test. Only with the commanders permissionwill a third test be administered.

3. OTHER EVALUATIONS: None

4. CHALLENGING TRAINING: Students may take any or all tests prior to receiving the training. If the studentreceives a 100% on the written examination or a GO" on the performance evaluation, the student will stillbe required to attend all training to be given credit for that training module.

JERRY C. MEYERCOL, ENDirector, DOTLD


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TABLE OF CONTENTS

CHAPTER TITLE PAGE

Chapter 1 Introduction to the Backhoe Loader 1-1

Chapter 2 Hand and Arm signals 2-1

Chapter 3 Safety Requirements 3-1

Chapter 4 Preventive Maintenance Checks and Services 4-1

Chapter 5 Maneuvering 5-1

Chapter 6 Excavation 6-1

AppendixA Performance Evaluation Sheets A-1

AppendixB Fighting Positions B-1

AppendixC Training Schedule C-1

AppendixD Required Study D-1

AppendixE Abbreviations and Acronyms E-1


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Chapter 1

Introduction to the Backhoe Loader

1-1

Introduction to the Backhoe Loader (BHL)

1. The BHL is designed for moving earthen materials around a construction site, opening up an

underground utility site, or the like. It has a backhoe to dig into the earth and loosen material so it canbe moved around. It can dig openings for basements, trenches for drainage tubes, etc. The BHL also

has a Front End Loader (FEL) to move the excess material a short distance away, or load it into a

vehicle for moving to a new location. Together, the backhoe and the FEL can be used to quickly level,and prepare a complete construction site.

2. The BHL is a heavy piece of equipment, which when used correctly and according to the operatortechnical manual, is very safe to operate. However, when used incorrectly, the BHL is capable of

inflicting severe damage to buildings, other equipment, vehicles, or personnel.

Backhoe Uses

1. The BHL is designed for moving earthen materials around a construction site or opening up anunderground utility site.

2. It can dig openings for basements, trenches, foxholes, fighting positions, crew served weapons, etc.

3. The Front End Loader (FEL) is used for moving excess material a short distance away from theimmediate area or loading it into a vehicle for moving to a new location.

4. Together, the backhoe and the FEL can be used to quickly level, and prepare a complete construction

site.

Characteristics

1. Manufactured by Case

2. Model 445T / M2

3. In the transport configuration, the BHL is 22 ft, 8 in long; 10 ft, 10 in high; and 7 ft, 10 in wide

weighing 16,868 pounds (wet weight including fuel).

4. The BHL weights 16,868 pounds (wet weight including fuel).

5. When transporting the BHL, you must tape the exhaust stack to prevent the turbocharger fromspinning.

6. The BHL has 4WD. The 4WD front axle can be engaged to provide additional traction.

7. The rear axle has a selectable differential lock to help prevent rear wheel slippage when using the FEL.


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8. The service brakes are:

a. Hydraulically actuated

b. Self adjusting

c. Inboard mounted

d. Wet disk.

e. Park brake is manual

Backhoe Loader Components

1. The BHL has a four cylinder turbocharged diesel engine with a gross horsepower rating of 95hp. The

engine must be warmed up and cooled down for 2 minutes.

2. There are four types of fuel that can be used in the BHL. (Diesel Fuel DF, Jet Petroleum JP)

a. DF-1

b. DF-2

c. JP-5

d. JP-8

3. Electrical system consists of 12 and 24 volts.

a. The 24V DC is used for the starting and charging system.

b. The 12V DC is used for the controls and indicators system.

c. NATO Slave Receptacle is used to slave start the BHL when needed.

It is located behind the battery box, is used for 24V DC slave starting.

4. Cab Structure

a. Roll Over Protective Structure (ROPS)

b. Falling Object Protective Structure (FOPS)

Protects the operator from roll over, falling objects, debris, dust, and rain and contains all the

operator controls and instruments.


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Front End Loader (FEL) Components

1. FEL bucket

a. A 4-in-1 bucket with four configurations

1) Dozer

In this configuration the BHL can be used to back fill ditches, fighting positions, etc.

2) Scraper

In this configuration the BHL can be used to level working areas and perform light

cutting.

3) Loader (standard bucket)

In this configuration with the bucket flat, the BHL can dig to a depth of 6. 8" belowgrade.

4) Clamshell

In this configuration the BHL can dig to a depth of 4. 1" below grade.

b. Bucket capacity of 1.25 cubic yards

c. Maximum lifting capacity of the FEL is 7800 pounds.

d. Dump clearance at full height with clamshell open is 9 ft, 8 in

Backhoe Components

1. Stabilizers

a. One on each side of the BHL, provide stability to the BHL when the backhoe is in operation.

b. Rubber pads for working on hard finished surfaces

c. Dirt pads for working in most other surfaces such as dirt, sand, rock, etc.

2. Backhoe Boom

a. Raises the backhoe

b. Lowers the backhoe


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3. Backhoe Dipper

a. Extends the backhoe

b. Retracts the backhoe

4. Backhoe Bucket

a. Digs material

b. Dumps material

5. Attachments

a. Paving breaker attachment

b. Auger attachment

6. Auxiliary attachment hydraulic lines

a. One single directional hydraulic line

b. Two dual directional hydraulic lines

7. Backhoe capabilities

a. Digging radius from the swing pivot of 17 ft, 10 in

b. Loading height of 11 ft, 2 in

c. Loading reach of 5 ft, 10 in

d. Maximum height of the backhoe is 19' 2"

e. Digging depth of 14 ft, 1 in

f. Maximum digging depth 14 ft. 4 in.

g. Bucket capacity of 0.28 cubic yards.

Capabilities

1. Maximum fording depth is 20 in.

2. Ground clearance at backhoe frame is 13.7 in.


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3. Travel speeds

a. A maximum speed of 25.5 mph in the manual mode on improved roads.

b. A maximum speed of 25.9 mph in the automatic mode on improved roads.

c. A maximum speed of 7 mph when maneuvering across uneven terrain.

4. Ride Control Switch

WARNING: Do not engage ride control switch with starter key switch turned to ON or ACC position.

Front end loader lift arms can drop. Failure to comply may result in serious injury or death to

personnel.

a. Reduces forward and backward pitching motion

b. Increases productivity

c. Improves operator comfort

Limitations

1. Negotiate a 15% up hill slope on firm ground.

2. Negotiate a 15% down hill slope on firm ground.

3. Negotiate a 15% side slope on firm ground.

CAUTION: On ground which is not solid, maximum slopes are LESS than 15%.

4. Towing

a. Towing speed is 5 mph

b. Towing distance is no more than a mile

5 Operation

a. Keep all parts of the BHL a minimum of 15 ft away from all power sources (overhead or underground power lines, buried cables)

b. Do not move BHL forward using backhoe bucket when operating on a slope.

c. Do not allow the engine to over speed by exceeding 2500 rpm.


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Shoring

1. Stairways, ladders, ramps or other safe means of egress shall be located in trench excavations

that are 4 or more in depth so as to require no more than 25 of lateral travel.

a. Open trench safety

(1) Mark open trenches to prevent accidents using;

a) Safety / warning tape

b) Safety fencing

c) Warning signs

d) Vehicle barriers

b. Means of egress

(1) Provides a means of escape from trenches in case of cave-ins and /or other emergency

situations.

a) Stairways

b) Ladders

c) Ramps

c. Protective systems

(1) Protect personnel from cave-ins whenever employees must work within an openexcavation.

a) Required when depth of excavation is 48 feet deep or more.


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l. The engine is the Case 445T/M2 turbocharged diesel engine. Engine speed is controlled by a foot

throttle and by a hand throttle for backhoe use. Fuel is delivered by direct injection. Precise injection

timing optimizes the engines performance for starting, emissions, noise, and fuel consumption.

2. The BHL has a power-shift 4-speed synchromesh transmission. The transmission operates in either of

two selectable modes, automatic mode or manual mode. Forward travel speeds range from 0 to 25.9

mph in automatic mode and from 0 to 25.5 mph in manual mode. Reverse travel speeds range from 0 to8.1 mph in both automatic and manual modes.

Major Components Left Side

1. FEL bucket- A 4-in-1 bucket with four configurations:

dozer, scraper, loader (standard bucket), and clamshell.

2. FEL bucket cylinders- Provide movement for the

bucket.

3. FEL lift arms- Provide support and control for thebucket.

4. FEL lift arm cylinders- Raise and lowers the lift arms.

5. FEL lift arms safety support strut- Holds the lift arms

up in a safe servicing/inspection position to prevent

accidental lowering of the lift arms.

6. Engine Hood- Protects the engine and relatedcomponents from dust, rain, and other contaminants.The hood can be raised for access to engine

components.

7. Engine- Provides power for all BHL functions.

8. Exhaust Pipe- Directs exhaust away from the cab. Figure 1-1

9. Front Lights- Two hazard/turn lights.

10. Two marker lights

11. Two 55 Watt halogen driving lights.

12. Two 55 Watt halogen work lights.

13. One blackout light.

14. Backhoe boom- Allows up and down and side-to-side movement for the backhoe.


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Figure 1-3

15. Backhoe Dipper- Allows the backhoe to move up and down.

16. Backhoe Bucket- Allows digging and scooping of material.

17. Stabilizers- One on each side of the BHL provides stability to the BHL when the backhoe is in

operation.

18. Fuel Tank- Located on the left side of BHL, holds 31.4 gallons (119L) of fuel.

BHL Major Components, Right Side

19. Four 55 Watt adjustable halogen work lights.

20. Two hazard/turn lights.

21. Two blackout lights.

22. ROPS/FOPS Cab- Protects the operator from rollover,falling objects, debris, dust, and rain and contains all the

operator controls and instruments. The cab is heated and air-

conditioned for operator comfort in various weatherconditions.

23. Decontamination Kit Mount- Located above the battery

box, is used to mount the decontamination kit.

Figure 1-2

24. Hydraulic Tank- Holds reserve hydraulic fluid for the hydraulic system. The entire hydraulic systemholds 31.5 gallons (119L) of fluid.

25. Battery Box- Protects the two 12 volt batteries from the elements.

26. Tool Box- Provides a place for storage of required operator tools.

27. NATO Slave Receptacle- Located behind the batterybox, is used for 24 VDC slaves starting.

BHL ORIENTATION

Right-hand, Left-hand, Front, and Rear indicate the right andleft sides of the BHL as seen from the operators

seat as shown in Figure 1-3.


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Chapter 1


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BHL LIFT POINTS AND TIE-DOWN POINTS

BHL lift points provide points to attach a crane or other suitable lifting device to lift the BHL onto a truck,

railcar, trailer, or other suitable transport system for transporting the BHL long distances. Refer to Figure 1-4. The rear lift points are on the backhoe near the rear corners of the cab. The front lift points are near the

front corners of the cab.

Once the BHL is lifted onto the transport vehicle it must be tied down or secured to the transport vehicle.

Refer to Figure 3-4. The rear tie-down points are located on the lower backhoe frame just to the left and right

of the backhoe pivot point. The front tie-downs are located on the BHL frame just in front of and at the topof front wheels.

Figure 1-4

FEL AND BACKHOE QUICK COUPLER PINS

a. A quick coupler system is provided on the BHL, FEL and backhoe to facilitate rapid FEL bucket and

backhoe bucket removal and installation.


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FEL BUCKET

a. Refer to Figure 1-5. On the FEL bucket, the bucket upper mounting hooks must be engaged over the

upper mounting pins and the hydraulically actuated tool carrier lock pins holding the bucket in place

must be fully extended. There are two hydraulic quick disconnect couplers on the FEL for supplyinghydraulic fluid to the clamshell cylinders. The quick disconnect couplers should be inspected for proper

connection and the respective hydraulic hoses should be checked for proper routing to prevent rubbing

and pinching during normal FEL bucket operation.

1. Upper mounting pin.

2. Upper mounting hook

3. Part of hydraulic quick disconnects.

4. Part of hydraulic quick disconnects.

5. Hydraulically actuated tool carrier lock pin.

Figure 1-5

NOTES

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


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BACKHOE BUCKET

a. Refer to Figure 1-6. On the backhoe bucket, the upper hook must engage the upper mounting pin and the

hydraulically actuated lock pins holding the bucket in place must be fully extended

1. Upper mounting hook

2. Hydraulically actuated quick coupler lock pin

Figure 1-6

BACKHOE SWING LOCK PIN AND TRANSPORT LOCK

a. Refer to Figure 1-7. The backhoe swing lock pin and transport lock are located on the backhoe swing

pivot. The swing lock pin (Figure 1-7 item 1) keeps the backhoe straight behind the BHL, locking the

backhoe to keep it from swinging freely from side to side during BHL transport. The transport lock(Figure 1-7, item 2) keeps the boom locked in the transport

position during BHL transport.

1. Swing Lock Pin

2. Transport Lock

NOTES

______________________________________________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________

______________________________________________________________________________________________________________________________________________________________________________

2

1

Figure 1-7


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Chapter 1


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FEL REMOVABLE BUCKET TEETH AND CUTTING EDGES

a. Refer to Figure 1-8. The removable teeth and cutting edges must be inspected for loose or missing parts,

bent or broken teeth, and damaged cutting edges.

1. Removable Teeth

2. Removable Bucket Cutting Edge

3. Removable Dozer Cutting Edge

Figure 1-8

NOTES

______________________________________________________________________________________

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______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

1

2

3


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Chapter 2

Hand and Arm Signals

2-1

Equipment Specific Hand and Arm Signals

1. Raise Bucket / Stabilizer / BoomArms extended at shoulder height with closed fist and thumbs

extended up.

2. Lower Bucket / Stabilizer / BoomArms extended at shoulder height with closed fist and thumbs

extended downward.

3. Dump BucketWith closed fists, upper arms stationary, and forearms parallel to the ground twistingwrists downward.


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4. Retract BucketWith closed fists, upper arms stationary, and forearms parallel to the ground

curling wrists upward.

5. Level BucketLeft and right arms bent at the elbows, forearms extended in front of the body with

fingers extended and joined, palms facing the ground arms moving left to right making a levelingmotion.

6. Open ClamArm perpendicular to the body with forearm vertical, fingers extended and joined

forming an arch with thumb several inches below the index finger making an open motion.


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7. Close ClamArm perpendicular to the body with forearm vertical, fingers extended and joined

forming an arch with thumb touching the index finger making a closed motion.

8. Swing Boom RightLeft arm extended parallel to the ground.

9. Swing Boom LeftRight arm extended parallel to the ground.


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10. Dipper Arm InArm perpendicular to the body with palm facing up, fist closed, thumb pointing

toward body.

11. Dipper Arm OutArm perpendicular to the body with palm facing up, fist closed, thumb pointing

away from body.

NOTES______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________

______________________________________________________________________________________


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Chapter 2


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Common Equipment Hand and Arm Signals

1. Assemble on SignalmanRight arm extended above head, fingers extended and joined facing upmoving in circular motion.

2. Start EngineArm extended to the front and side of the body with hand open. Move arm in a

circular counter-clockwise motion

3. Stop EngineWith palm facing downward and arm at shoulder level move forearm and hand across

throat in a cutting motion.


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4. StopArm perpendicular to the body with forearm vertical and fist closed; or both fists closed and

both forearms crossed at chest level.

5. Lights OnWith right palm facing downward, arm at shoulder level, extended in front of body and

bent at the elbow, two fingers spread pointing at eyes moving forward and backward.

6. Lights OffRight palm facing downward, arm at shoulder level, extended in front of body and bentat the elbow, two fingers spread pointing at eyes moving across eyes left to right in a cutting motion.


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7. Increase ThrottleRight arm extended above head with fist closed, palm facing head moving up

and down in a pumping motion.

8. Reduce ThrottleArms extended to side bent at the elbow with forearms in front of body withfingers extended and joined facing down moving in a fanning motion.

9. BreakArms extended in front of body fists closed and facing down wrists flexing right and left in a

breaking motion.


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10. Move ForwardPalms facing towards body, upper arms stationary, forearms motioning back and

forth towards body.

11. Move BackwardPalms facing away from body, upper arms stationary, and forearms motioning

away from body.

12. Turn RightLeft arm extended pointing away from body with fingers extended and joined armextended and right arm bent at the elbow facing up with closed fist.


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13. Turn LeftRight arm extended pointing away from body with fingers extended and joined arm

extended and left arm bent at the elbow facing up with closed fist.

14. Forward RightLeft arm extended to side at shoulder height with fingers extended and joined, right

arm bent at the elbow facing up hand opened, palm facing body, motions towards ground guide in aforward movement.

15. Forward LeftRight arm extended to side at shoulder height with fingers extended and joined, leftarm bent at the elbow facing up hand opened, palm facing body, motions towards ground guide in a

forward movement.


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16. Engage Park BrakeLeft arm perpendicular to the body with forearm vertical, fingers extended and

joined and palm facing to the right, right arm perpendicular to the body with closed fist, thumbextended touching open palm of left hand.

17. Release Park BrakeLeft arm perpendicular to the body with forearm vertical, fingers extended and

joined and palm facing to the right, right arm perpendicular to the body with closed fist, fist touching

palm of left hand and thumb facing to the right.

18. Travel PositionBoth arms in front of body at waist height with hands clasped together.


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19. Float PositionLeft and right arms bent at the elbows, forearms extended to the front of the body

with fingers extended and joined, palms facing up, both arms dropping to side in a float motion.

20. Park line PositionArms extended out to both sides with fingers joined.

NOTES

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BHL SAFETY AND GENERAL SAFETY WARNINGS

SAFETY RULES

a. Most accidents involving BHL operation and maintenance can be avoided by following basic rules and

precautions while observing all CAUTIONS and WARNINGS. Read and understand all theWARNING and safety messages in the front of TM 5-2420-231-10 before you operate or service the

BHL.

b. READ THE OPERATOR TECHNICAL MANUAL COMPLETELY and make sure youunderstand the characteristics of speed, stability, steering, and operation of the BHL.

c. Do not remove TM 5-2420-231-10 from the BHL

d. Safety messages in this section point out situations which can be encountered during BHL operation

and maintenance of the BHL under usual conditions. These safety messages also give possible ways of

dealing with these conditions.

e. Additional safety messages appear in the manual to indicate specific safety hazards.

f. There are many icons associated with the BHL safety warnings outlined in TM 5-2420-231-10. Refer to

the warning summary section in the front of TM 5-2420-231-10, pages a through v for visual pictures of

all the icons and their meanings. The wording of the WARNINGS is included in this student guide so

each student can quickly read them during the BHL Operator and Operator Maintenance trainingcourse.

g. WARNING: The safety alert symbol shown on the right indicates important safetymessages in this student guide. When you see this symbol, carefully read the message

that follows and be alert to the possibility of personal injury or death.

BEFORE OPERATING THE BHL

a. Adjust, secure, and latch the seat and fasten the seat belt before starting the engine. Make sure that you

can reach all controls, brakes, and necessary functions before operating the BHL. Failure to comply

may result in serious injury or death to personnel.

b. Before starting engine, engage parking brake and shift direction control lever to neutral position. Start

and operate the BHL only from operator seat. Failure to comply may result in serious injury or death topersonnel.

c. Before operating the BHL, make sure the service and parking brakes are operable. Failure to complymay result in serious injury or death to personnel.

d. Lock service brake pedals together when operating on road or with gear selection control lever in 3rdor 4th gear to provide equalized brake action. Failure to comply may result in serious injury or death to

personnel.

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e. Do not bypass the BHL neutral-start system. Neutral-start system must be repaired if it malfunctions.

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

f. Before operating at night, check that all lamps illuminate. Failure to comply may result in serious injury

or death to personnel.

g. Do not start engine until all other personnel are away from the BHL. Failure to comply may result in

serious injury or death to personnel.

OPERATION OF THE BHL

a. Operate the BHL in accordance with the instructions in TM 5-2430-231-10. Failure to comply may

result in serious injury or death to personnel. Before using the BHL, make certain that every operator

does the following:

1. Is instructed in safe and proper use of the BHL.

2. Reads and understands manuals pertaining to the BHL.3. Reads and understands all safety decals on the BHL.

4. Clears area of all other personnel.

5. Learns and practices safe use of the BHL controls in safe, clear area before operating the BHL onjob site.

b. Know and use protective equipment that is to be worn when operating the BHL. Hard hats, protective

glasses, protective shoes, gloves, reflector-type vests, respirators, and ear protection are examples oftypes of equipment that may be required. Failure to comply may result in serious injury or death to

personnel.

c. Always wear seat belt when operating the BHL. Do not permit riders on the BHL. Make sure all

protective guards, canopies, doors, etc., are in place and secure. Failure to comply may result in serious

injury or death to personnel.

d. Remove all loose objects stored in the BHL. Avoid loose fitting clothing, loose or uncovered long hair,

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

e. Observe all gages and warning instruments for proper operation. If any malfunctions are found, shutengine off and remove starter key. Failure to comply may result in serious injury or death to personnel.

f. If failure that causes loss of control such as steering, service brakes, or engine occurs, shut engine off asquickly as possible. Keep the BHL securely parked until malfunction is corrected or the BHL can be

safely towed. Failure to comply may result in serious injury or death to personnel.

g. Operate and drive the BHL with care and at speed compatible with conditions. Use extra care when

operating over rough ground, on slopes, and when turning. Failure to comply may result in serious



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h. Be aware of and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs,

overhead electrical wires, or areas where there is danger of the BHL sliding. Never lift loads in excess

of capacity. Carry loads in recommended positions for maximum stability. Be aware that job siteconditions may change hourly. Failure to comply may result in serious injury or death to personnel.

i. Always know the location of all other personnel in the area. Warn all personal before operating theBHL. Always keep all other personnel away from the work area. Failure to comply may result in


j. Dust, fog, smoke, etc., can decrease visibility and cause an accident. Stop the BHL or decrease speeduntil you can see. Failure to comply may result in serious injury or death to personnel.

k. If extreme conditions, such as fire, force you to leave the BHL, do not step off the BHL. Jump as far

from the BHL as possible with feet together and do not touch ground with hands. Failure to complymay result in serious injury or death to personnel.

l. Do not use the BHL for any application or purpose other than those described in TM 5-2420-231-10.Failure to comply may result in serious injury or death to personnel.

m. Always transport the BHL with the transport pin for the backhoe boom in the locked position. Failureto comply may result in serious injury or death to personnel.

n. If the BHL must travel on public roads, all lights must be in working order and adjusted correctly.


o. Excessive speed can cause loss of control. Failure to comply may result in serious injury or death to

personnel.

p. If the BHL rolls over and seat belt is not fastened, you can be crushed by Rollover Protective Structure

(ROPS) or the BHL. Failure to comply may result in serious injury or death to personnel.

q. Do not attempt to exit the BHL if rollover is imminent. Stay inside the ROPS with seat belt fastened for

maximum safety. Failure to comply may result in serious injury or death to personnel.

r. Do not leave the BHL when engine is operating. If external procedures require engine to be operating,have another person help. Failure to comply may result in serious injury or death to personnel.

s. Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting, oradding attachments can weaken structure and reduce your protection. Replace the ROPS if it is

subjected to a rollover or damage. Do not attempt to repair. Failure to comply may result in serious



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OPERATION ON A HILL

a. Exercise care when using clutch cutout switch while operating the BHL on a hill. When the clutchcutout switch is pushed, the transmission is disengaged from the drive wheels. Loss of control may

result. Use the service brakes to stop the BHL. Failure to comply may result in serious injury or death to

personnel.

b. Do not coast in neutral on a hill. Failure to comply may result in serious injury or death to personnel.

c. Do not use the backhoe bucket to move the BHL on a side slope. The BHL may roll over. Failure tocomply may result in serious injury or death to personnel.

OPERATION OF BACKHOE

a. Deactivate the backhoe control system before adjusting windows. Accidental actuation could cause

unexpected movement of the backhoe. Failure to comply may result in serious injury or death to

personnel.

OPERATION OF FEL

a. Manually roll back FEL bucket before lowering. Material can spill out onto personnel. Failure to

comply may result in serious injury or death to personnel.

LIFTING WITH BHL

a. Make sure the person holding the lead line is away from load. Failure to comply may result in serious


b. Do not move a load over the top of personnel. Keep all other personnel away from load. Failure to


c. Make sure all other personnel involved are shielded in event lifting apparatus might break. Failure to


d. Exercise care when lifting a load using the FEL. Do not exceed 7,800 lb (3538 kg) load. Make surerigging equipment has capacity to lift load and that no personnel are the under load. Failure to comply


e. Exercise care when lifting a load using the backhoe. Do not exceed lifting capacity limits in TM 5-

2420-231-10, WP 0002, Table 5. Make sure rigging equipment has capacity to lift load and that no

personnel are under the load. Failure to comply may result in serious injury or death to personnel.


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PARKING THE BHL

a. Park the BHL on level ground whenever possible and engage the parking brake. If the BHL must beparked temporarily on a hill, put the front of the BHL toward the bottom of the hill. Make sure the BHL

is behind an object that will not move. Failure to comply may result in serious injury or death to

personnel.

b. Before leaving the cab, engage parking brake, shift direction control lever to neutral position, lower

FEL and backhoe bucket to the ground or put in locked position, and shut engine off. Failure to comply


c. Remove starter key when leaving the BHL parked or unattended. Failure to comply may result in


ELECTRICALHIGH VOLTAGE

a. If part of the BHL touches high voltage power, do the following:

1. Warn all other personnel to stay away from the BHL.

2. If able to break contact, reverse operation that caused contact with high voltage power and move theBHL away from danger area.

3. If unable to break contact, stay in the BHL until utility workers de-energize power lines.

ELECTRICALBATTERIES

a. When disconnecting battery cables, always disconnect negative () battery cable first. When

connecting battery cables, always connect negative () battery cable last. Failure to comply may resultin serious injury or death to personnel.

b. Metal jewelry can conduct electricity. Remove metal jewelry when near the batteries. Failure to comply


TIRES

a. When inflating tires, keep yourself and all other personnel out of danger area. Stand on tread side oftire. Wear face protection. For maximum safety, use correct air pressure and use self-attaching inflation

chuck with remote shutoff. Do not over inflate. Tires and rim parts can explode. Failure to comply may

result in serious injury or death to personnel.

b. Check air pressure or add air only when tire is mounted on wheel on the BHL or in tire inflation cage.


SERVICING

a. Before servicing the BHL, put a DO NOT OPERATE tag on starter key switch. Failure to comply may



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b. Close hood carefully. Failure to comply may result in serious injury to personnel.

c. Keep clear of rotating fan and belts. Failure to comply may result in serious injury or death topersonnel.

d. Prolonged exposure to bright sunlight produces very hot metal surfaces which will burn flesh oncontact. Wear gloves when contacting hot metal surfaces. Wear additional protective clothing as

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

e. Make sure engine is shut off before raising engine hood. Hot metal surfaces are hot and will burn fleshon contact. Exercise care when raising hood and servicing engine. Failure to comply may result in

serious injury to personnel.

BHL HAZARDOUS MATERIALS

EXHAUST

a. To protect yourself and other personnel, always obey the following rules:

1. DO NOT operate engine indoors unless you have SUFFICIENT FRESH AIR VENTILATION.2. DO NOT idle engine for a long time unless there is SUFFICIENT FRESH AIR VENTILATION.

3. Be alert at all times. Check for odor of exhaust fumes.

4. REMEMBER: Best defense against exhaust gas poisoning is SUFFICIENT FRESH AIR

VENTILATION.5. Exhaust gas poisoning causes dizziness, headache, loss of muscle control, sleepiness, coma, and

death. If anyone shows signs of exhaust gas poisoning, get ALL PERSONNEL clear of the BHL.

Make sure they have lots of fresh air. KEEP THEM WARM, CALM, AND INACTIVE. If anyonestops breathing, give artificial respiration. SEEK MEDICAL ATTENTION IMMEDIATELY.

b. Engine exhaust fumes contain deadly poisonous gases. Severe exposure may result in permanent brain

damage or death to personnel.

c. Exhaust gases are most dangerous in places with poor airflow. Ventilate with positive airflow. Failure

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

BATTERIES

a. Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands afterhandling. Failure to comply may result in serious injury or death to personnel.

b. Batteries contain sulfuric acid which causes severe burns. Avoid contact with eyes, skin, or clothing.Always wear eye protection and protective gloves when working near batteries. Failure to comply may



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First aid for battery acid exposure:

Antidote: EXTERNALFlush with water.

Antidote: INTERNALDrink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Do not induce vomiting. SEEK MEDICALATTENTION IMMEDIATELY.

Antidote: EYESFlush with water for 15 minutes. SEEK MEDICAL ATTENTION

IMMEDIATELY.

c. Batteries produce explosive gases. Keep sparks, flame, cigars, and cigarettes away. Always wear eye

protection and protective gloves when working near batteries. Wash hands after handling. Ventilatewhen charging or using batteries in enclosed area. Failure to comply may result in serious injury or

death to personnel.

d. Do not use jumper cables. Use only NATO slave cable and receptacle. Improper use may result inbattery explosion or unexpected BHL motion. Failure to comply may result in serious injury or death to

personnel.

HYDRAULIC FLUID

a. Make sure hydraulic fluid or grease is not injected into skin. Keep hands and body away from anypressurized leak. Use cardboard or paper to check for leaks. If fluid is injected into skin, SEEK

MEDICAL ATTENTION IMMEDIATELY. Failure to comply may result in serious injury or death

to personnel.

b. Hydraulic fluid may be absorbed through the skin. Wear long sleeves, gloves, and goggles or face

shield when handling hydraulic fluid. If hydraulic fluid gets into the eyes, flush eyes immediately with

water and seek medical attention. If hydraulic fluid gets on the skin, wash thoroughly with soap andwater. Wash hands thoroughly prior to eating or smoking. Failure to comply may result in serious injury

to personnel.

FUEL

a. Fuel is flammable and toxic to eyes, skin, and respiratory tract. Avoid contact with eyes, skin, and

clothing. Always wear eye protection and protective gloves when working with fuel. Avoid

repeated/prolonged contact. Use only in ventilated areas. Keep away from open flames or other sourcesof ignition. Post FUEL FLAMMABLE/NO SMOKING signs around area. Make sure fire extinguisher

is available. Failure to comply may result in serious injury or death to personnel.

b. Do not smoke or permit open flames while fueling or near fueling operations. Failure to comply may


c. Hot engine surfaces are sources of ignition. Keep hood closed. Avoid fuel splashes and fuel spills. Do

not smoke or use open flame when refueling. Failure to comply can cause flames and possible

explosion and may result in damage to equipment and serious injury or death to personnel.


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d. Do not fill fuel tank completely too top Allow room for expansion. Failure to comply may result in


e. Never remove fuel cap or refuel the BHL with engine operating. Shut off engine. Never allow fuel to

spill on hot BHL components. Failure to comply may result in serious injury or death to personnel.

f. Clean up spilled fuel immediately and dispose of contaminated material per Standing Operating

Procedures (SOP). Failure to comply may result in serious injury or death to personnel.

g. Never use fuel for cleaning purposes. Failure to comply may result in serious injury or death topersonnel.

h. Fuel used in the BHL is flammable. When filling fuel tank, maintain metal-to-metal contact between

filler nozzle and fuel tank opening to eliminate static electrical discharge. Failure to comply can causeflames and possible explosion and may result in damage to equipment and serious injury or death to

personnel.

i. Do not fill fuel tank while engine is operating. Failure to comply may result in serious injury or death to

personnel.

COMPRESSED AIR

a. Eye protection is required when cleaning with compressed air. Compressed air can propel particles at

high velocity and injure eyes. Do not exceed 15 psi (103 kPa) when using compressed air whencleaning. Failure to comply may result in serious injury or death to personnel.

FILTERS

a. If Nuclear, Biological, and Chemical (NBC) exposure is suspected, all air filter media shall be handled

by personnel wearing full NBC protective equipment. Failure to comply may result in serious injury or

death to personnel.

b. Removal or installation of cab air filter can cause dirt particles to injure eyes. Eye protection is

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

MAINTENANCE PRECAUTIONS

a. Do not attempt repairs unless trained. Refer to technical manuals and experienced repair personnel forhelp.

b. Before you service the BHL, put a Do Not Operate tag on the key switch.

c. Wear protective glasses and other required safety equipment when servicing or repairing the BHL.

d. Wear gloves to protect hands when handling cable.


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e. Disconnect the battery before working on the electrical system. Know the consequences of

disconnecting any electronic or computer devices.

f. Avoid lubrication or mechanical adjustments with the BHL in motion or the engine operating. If the

engine must be in operation to make certain adjustments, place the transmission in neutral, apply the

parking device, place the equipment in a safe position, securely block the wheels and use extremecaution.

g. Securely block the BHL or any component that may fall before working on the BHL or component. If

possible, use a back up or secondary blocking device, also.

h. To prevent unexpected movement, securely block working elements when repairing or changing

working tool parts such as cutting edges.

i. Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been

relieved according to the manufacturers instructions.

j. Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps. Park the

BHL and let it cool down before opening a pressurized tank.

k. Release all pressure before working on systems which have an accumulator.

l. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid

penetrating the skin. Pressurize accumulators with the proper gas according to manufacturersrecommendations.

m. When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire.Position yourself beside the tire and not beside the rim.

n. When absolutely necessary to tow the BHL, do not exceed the recommended towing speed. Be sure the

towing vehicle has sufficient braking capacity to stop the towed load. Avoid towing over long distances.

o. Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

NOTES___________________________________________________________________________________

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______________________________________________________________________________________________________________________________________________________________________

___________________________________________________________________________________

______________________________________________________________________________________________________________________________________________________________________

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PMCS PROCEDURES

PMCS

a. Always use PMCS procedures as defined in applicable Technical Manuals and their current changes.

b. Do your BEFORE PREVENTIVE MAINTENANCE check before you operate the BHL. Pay attention

to CAUTIONS and WARNINGS associated with operation.

c. Do your AFTER PREVENTIVE MAINTENANCE right after operating the BHL. Pay attention to theCAUTIONS and WARNINGS.

d. If a BHL component does not function properly troubleshoot it with the instructions in the applicable

TM.

e. Always do your PREVENTIVE MAINTENANCE in the same order so that it will become a habit.

Once youve had some practice, you will quickly identify anything wrong. The PMCS walk arounddiagram shown in Figure 4-1 shows the starting point and direction to work your way around the BHL

to complete the PMCS procedure in the same order as shown in TM 5-2420-231-10. This sequence has

been developed to help the operator quickly perform the PMCS procedures in a consistent manner.

Figure 4-1

f. As each check is made, all operator level maintenance should be completed. All items that cannot be

corrected by the operator must be recorded on DA Form 2404 or 5988-E.

g. Ensure that all forms are completed correctly before turning them in.

WALK-AROUND INSPECTION

Perform TM 5-2420-231-10 Before operation PMCS procedures.

Do the following each day before you start the engine.


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a. Check for leaks under the BHL.

b. Check the tires for damage.

c. Check the BHL for broken, missing, or loose parts.

d. Check the FEL removable tooth bar and cutting edges for loose or missing parts, bent or broken teeth,

and damage to cutting edges.

e. Check that the FEL and backhoe buckets are mounted correctly, the hydraulically actuated lock pins arefully engaged, and the clamshell hydraulic supply hoses and connectors are properly connected and

routed.

f. Check that the backhoe swing lock pin and transport boom locks are engaged.

g. Clean any debris from the BHL. Make sure the radiator area is clean.

h. Clean or replace any safety or instructional decals that cannot be read.

i. Clean the steps, hand rails, and operators compartment.

j. Check the engine oil level.

ENGINE OPERATION

WARNING:Before starting engine, study operators manual safety messages. Read all safety signs

on BHL. Clear the area of other persons. Learn and practice safe use of controls before operation. Itis your responsibility to understand and follow instructions on BHL operation and service.

During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following:

a. Operate the BHL with normal loads for the first 8 hours. Do not work the engine hard at stall speeds

(wheels slowly turning or stopped and the engine running at full throttle).

b. Keep the engine at normal operating temperature.

c. Do not run the engine at idle speeds for long periods of time.

FOOT BRAKE CHECK

a. Check the operation of the foot brakes on a hard level surface after the first 100 hours of operation.

b. Make sure the area is clear of other persons.

c. Lock both pedals together with the brake pedal lock and shift the transmission to second gear.

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d. Drive the BHL forward at full throttle.

e. When the BHL is moving at full speed, remove your foot from the throttle and stop the BHL.

f. The BHL must stop smoothly in a straight line and the brake pedal effort must feel firm.

IMPORTANT: Refer to TM 5-2420-231-10 if the BHL does not stop in a straight line or if brake pedal

effort feels soft.

PARKING BRAKE CHECK

a. Check the operation of the parking brake after the first 100 hours of operation.

b. Make sure the area is clear of other persons.

c. Apply the parking brake and shift the transmission to third gear.

d. Shift the transmission direction control to FORWARD and increase the engine speed to 1500 rpm.

e. The BHL must not move.

IMPORTANT: If the BHL moves, refer to TM 5-2420-231-10 to adjust the parking brake.

OPERATIONAL CHECKS BEFORE BHL OPERATION

When the engine is warm, decrease the engine speed to idle and do the following:

a. Check the instrument panel.

b. Make sure the backhoe is in the TRANSPORT position and the stabilizers are raised.

c. Raise the FEL about two feet above the ground and roll the bucket back against the stops.

d. Test the parking brake in an open level area. Make sure the area is clear of other persons.

NOTE: If the BHL moves, adjust the parking brake in accordance with TM 5-2420-231-10.

e. Release the parking brake and test the foot brakes in an open area on a hard level surface. Make surethe area is clear of other persons.


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SERVICING PROCEDURES

ENGINE HOURMETER

a. The engine hour meter, reference 1 in Figure 4-2, shows the amount of actual hours the engine has run.

Use the engine hour meter along with the PMCS and Lubrication Charts in TM 5-2420-231-10 toservice your BHL at the correct time periods.

b. BHL Service. Procedures consist of checking and replenishing fluid levels and checking and adjusting

tire pressures. If your BHL requires servicing as a result of PMCS findings, refer to TM 5-2420-231-10,

WP 0023 for servicing procedures.

WARNING: When servicing the Backhoe Loader (BHL) with Front End Loader (FEL) bucket raised,

always use FEL lift arm safety support strut to lock bucket. Failure to comply may result in serious


NOTES

________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________________________________________________________________________________________

Figure 4-2

!


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FEL LIFT ARMS SAFETY SUPPORT STRUT ENGAGEMENT

a. Dump material from FEL bucket.

b. Raise FEL lift arms to maximum height.

c. Engage parking brake and shut engine off.

WARNING:When FEL lift arm safety support strut is raised,

always remove or install retaining pin while standing to rear of

safety support strut. Failure to comply may result in serious injuryor death to personnel.

d. Remove safety pin (Figure 4-3, Item 1)from retaining pin (Figure 4-3, Item 2)

and then, remove retaining pin.

e. Lower FEL lift arms safety

support strut (Figure 4-3, Item 3)

onto cylinder rod(Figure 4-3, Item 4).

f. Stand to rear of FEL lift arms

safety support strut, insert retainingpin (Figure 4-3, Item 2) into safety

support strut (Figure 4-3, Item 3), and

install safety pin (Figure 4-3, Item 1).

Figure 4-3

g. From operator seat, start engine and slowly lower FEL bucket onto FEL lift arms safety support strut

(Figure 4-3, Item 3).

h. Shut engine off.

NOTE: If you do not follow this procedure, you can cause serious injury or death if the FEL lift arms arelowered by accident.

FEL LIFT ARMS SAFETY SUPPORT STRUT DISENGAGEMENT

a. From operator seat, the start engine, raise the FEL lift arms slightly, and shut engine off.

b. Remove safety pin (Figure 4-3, Item 1) and retaining pin (Figure 4-3, Item 2) from FEL lift arms safety

support strut (Figure 4-3, Item 3).

c. Hold FEL lift arms safety support strut (Figure 4-3, Item 3) in stow position and install retaining pin

(Figure 4-3, Item 2) and safety pin (Figure 4-3, Item 1).

!


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d. From operator seat, start engine and lower FEL lift arms to ground.

e. Shut engine off.

LUBRICATION

Lubrication Instructions.

a. In TM 5-2420-231-10, WP 0022 is the instructions for the operator (C) maintenance. Lubrication

intervals (on-condition or hard time) are based on normal operation. Lubricate more frequently duringconstant use, and less often during inactive periods. The task-hour specified is the time needed to do all

the services prescribed for a particular interval. Use correct grade of lubricant for seasonal temperature

expected. The lubrication interval for daily (D) lubrication is daily or every 10 hours of operation. The

lubrication interval for monthly (M) lubrication is monthly.

Before Starting Your Lubrication

AlwaysUse Lubrication Instructions as your guide.

Use correct type/grade lubricantClean area where lubricant is to be applied to

prevent buildup of dirt, grit, and

contaminants.

NeverUse wrong type/grade lubricant.

Use too much lubricant.Apply lubricant to dirty components.

Lubrication steps:

a. Clean grease fittings before lubricating with grease gun.

b. Add grease through grease fitting until clean grease comes out of component; then, wipe off excess.

c. Authorized grease is automotive and artillery grease. Authorized fuel, engine lubricating oil, antifreeze,windshield washer solvent, transmission fluid, and hydraulic fluid are cited in the Servicing work

package (WP 0023).

TROUBLESHOOTING

This section contains operator level troubleshooting information with a list of symptoms, malfunctions,

tests/inspections, and corrective actions required to return the BHL to normal operation. Refer to TM 5-2420-231-10, WP 0018 and WP0019 for operator level troubleshooting procedures. The tests/inspections

and corrective actions should be performed in the order listed. If the first corrective action step is normal,

proceed to the next step. The corrective actions will refer to either a work package TM 5-2420-231-10 orto field level maintenance. Troubleshooting procedures in TM 5-2420-231-10 may not list all possible

malfunctions or tests/inspections required for corrective action. If a symptom/ malfunction are not listed

or are not corrected by the listed corrective action, notify field level maintenance.


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Troubleshooting procedures for the following functions are included in TM 5-2420-231-10, WP 0014:

a. Engineb. Steering

c. Brakes

d. Transmissione. Hydraulics

NOTE: Damaged, crushed, or kinked hydraulic tubes, hoses, and connections can cause erratic or slow

FEL or backhoe operation. Check all hydraulic tubes, hoses, and connections for damage.

NOTE: The backhoe will NOT operate if the pilot controls have NOT been enabled. Make sure that the

pilot control switch on the right-hand pilot control tower is positioned to the backhoe control function

enable position. (Switch is illuminated in the enable position)

f. Front End Loader (FEL)

g. Backhoeh. Cooling System

i. Electrical System

j. Air Conditioner

SLAVE STARTING OPERATION

WARNING:NATO slave receptacle is electrically live at all times and has no fuse. NATO slavereceptacle is only dead when batteries are fully disconnected. Disconnect batteries before performing

maintenance on NATO slave receptacle. Failure to comply may result in damage to equipment and


WARNING:Do not attempt to jump start or charge battery when electrolyte is frozen. Battery could

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

WARNING:Batteries produce explosive gasses. Keep sparks, flame, cigars, and cigarettes away.

Ventilate when charging or using in enclosed area. Always wear eye protection and protective gloves

when working near batteries. Failure to comply may result in serious injury or death to personnel.

WARNING:Remove all jewelry such as rings, identification tags, or bracelets when using slave

cable. If jewelry contacts slave cable or receptacle, arcing can occur. Failure to comply may result in


CAUTION:Do not allow vehicles to touch while slave-starting. Failure to comply may result in damage to

equipment.

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a. Position slave vehicle and disabled BHL close enough for cable hookup.

b. Shut slave vehicle engine off.

CAUTION:Make sure all electrical switches in both vehicles are turned to OFF position. Failure to

comply may result in damage to equipment.

c. Turn all electrical switches on both vehicles to OFF position.

d. Remove NATO slave receptacle covers from disabled BHL and slaving vehicle.

CAUTION:Use twisting motion when installing NATO slave cable to receptacle. Do not forcefully push

cable onto receptacle. Failure to comply may result in damage to receptacle mount.

e. Connect NATO slave cable to slave receptacle of both vehicles.

f. Start slave vehicle engine.g. Start disabled BHL engine.

h. After disabled BHL engine starts, disconnect NATO slave cable from both vehicles.

CAUTION:Use twisting motion when disconnecting NATO slave cable from receptacle. Do not forcefully

pull cable from receptacle. Failure to comply may result in damage to receptacle mount.

NOTE: Apply detergent to inside of NATO slave receptacle covers before installing to aid in future

maintenance.

i. Install NATO slave receptacle covers onto both vehicles.

SERVICE MAINTENANCE

Operator servicing procedures are tasks performed as a result of problems found during PMCS

procedures, TM 5-2420-231-10, WP 0023, or during troubleshooting procedures, TM 5-2420-231-10, WP

0018. The servicing procedures comprise the operator level of maintenance. Operator level service

maintenance procedures for the following functions are included in TM 5-2420-231-10:

a. Engine Hood Raising/Closing

b. Fuel Tank Level Check

c. Water and Sediment in Fuel System Checkd. Hydraulic Fluid Level Check

e. Hydraulic Filter Check

f. Transmission Fluid Level Checkg. Coolant Fluid Level Check

h. Windshield Washer Solvent Level Check

i. Engine Oil Checkj. Engine Air Filter Service


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TOWING A DISABLED BHL

WARNING:Do not tow disabled BHL incorrectly. Failure to comply may result in serious injury ordeath to personnel.

WARNING:If the BHL is disabled, you must make a judgment if the BHL can be moved safely andwithout causing damage. If possible, contact Field Maintenance to repair the disabled BHL at the job

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

WARNING:Towing vehicle must be at least as large as the disabled BHL and have sufficient power,

weight, and braking capability. The towing vehicle must be able to control both machines for thegrade, ground conditions, and distance required. Failure to comply may result in serious injury or

death to personnel.

WARNING:Towing vehicle must have a towing pintle for maximum stability while towing. Failure

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

WARNING:Make sure towing straps have proper capacity to move the BHL safely. Failure to


WARNING:Inspect towing straps for broken or missing parts, chafing, or wear before attaching.

Check wear identification strips on towing straps. Failure to comply may result in serious injury or

death to personnel.

WARNING:Do not exceed towing speed of 5 miles per hour (8 km/h) under ideal ground conditions.

Adverse ground condition requires slower speed. Failure to comply may result in serious injury or

death to personnel.

WARNING:When BHL is being towed, operator must be in operator's seat, with seat belt fastened,

to maintain steering and braking control of the BHL. Failure to comply may result in serious injury or

death to personnel.

WARNING:Do not allow operator on disabled BHL unless it has steering and braking capability.

The BHL may break away from tow. Failure to comply may result in serious injury or death to

personnel.

WARNING:Make sure all necessary personnel nearby are shielded in event towing apparatus might

break. Make sure all other personnel are completely out of area. The BHL may break away from tow.Failure to comply may result in serious injury or death to personnel.

WARNING:Towing straps which have not been properly stowed in a canvas bag may have beendamaged by ultraviolet light, and should not be used. Failure to comply may result in serious injury


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CAUTION:If the FEL, backhoe, or stabilizers cannot be raised, contact Field Maintenance for BHL

recovery. Failure to comply may result in damage to equipment.

CAUTION:Do not attempt to start engine by towing the BHL. Failure to comply may result in damage to

equipment.

CAUTION:Only tow the BHL far enough to reach safe repair location or onto trailer. Do not tow more

than one mile (1.2 km). Failure to comply may result in damage to equipment.

CAUTION:Towing straps should be attached only to the front tie down brackets, or if necessary, to each

side of the front axle. Do not allow the towing straps to contact the steering linkage. Failure to comply mayresult in damage to equipment.

NOTE: For description and use of operator controls and indicators, refer to WP 0004 thru WP 0009.

a. Inspect both towing straps as follows:

1. Check straps for holes, cuts, snags, or embedded particles.2. Check for broken or worn stitching.

3. Check for excessive wear, knots, or damage to the loop eyes.

4. Check that red thread is not visible in the strap webbing.5. Check for evidence of excessive ultraviolet light exposure, including bleaching of the strap color,

increased brittleness of the material, or surface abrasions in areas not normally in contact with the

BHL or towing vehicle.

6. Do not use towing straps if any of the above conditions are found.b. Engage parking brake.

c. Shift direction control lever to neutral position.

d. Set 4WD switch to neutral position.e. On uneven ground, block front and rear wheels with wheel chocks.

f. Start engine. Raise the FEL, backhoe, and stabilizers off ground, into transport position. Shut engine

off.

g. Attach towing straps to the disabled BHL only at the front tie down brackets, or if necessary, to eachside of the front axle. Do not allow the towing attachments to contact the steering linkages. Attach to

towing pintle on towing vehicle.

h. Start engine. Remove wheel chocks and disengage parking brake. Use towing vehicle to slowly take

out slack in towing attachments.i. Confirm disabled BHL has braking and steering capability. Leave disabled BHL engine running, if

possible. The BHL is now ready to be towed.

j. Tow disabled BHL at maximum speed of 5 miles per hour (8 km/h) under ideal ground conditions forno more than one mile (1.6 km).


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INSTRUMENT PANEL CONTROLS AND INDICATORS

KEY EXPLANATIONS FOR FIGURES 4-4 AND 4-5

KEY/CONTROL/INDICATOR FUNCTION

1. Not used.

2. 4WD front axle switch Push top of rocker switch to engage front drive axle (four-wheel

drive (4WD)); green lamp in switch illuminates. Push bottom of

rocker switch to disengage front drive axle (two-wheel drive(2WD)).

3. Not used.

WARNING:Do not engage ride control switch with starter key switch turned to ON or ACC

position. Front End Loader (FEL) lift arms can drop. Failure to comply may result in serious injury


4. Ride control switch Reduces fore and aft pitching motion, reduces shock loads to the

BHL, increases productivity, and improves operator comfort. To

engage, lower FEL bucket to or near ground and push top ofrocker switch. Green lamp in switch illuminates. Push bottom of

rocker switch to disengage.

5. Rear work lamp switch Push top of rocker switch to turn lamp on; green lamp in switch

illuminates. Push bottom of rocker switch to turn lamp off.

Figure 4-4

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6. Air conditioning system pressure Illuminates when air conditioner has stopped because of

indicator lamp too low or too high refrigerant pressures.

7. Not used.

8. Not used.

9. Parking brake indicator lamp Illuminates when parking brake is engaged.

CAUTION:If any warning lamps illuminate (KEYS 13 thru 18 below), shut engine off and notify field levelmaintenance. Failure to comply may result in severe damage to engine.

10. Low engine oil pressure warning Illuminates when, with engine operating, there is no engine oil

lamp pressure or low engine oil pressure. Audible alarm will alsosound when this condition exists.

11. Rear axle oil temperature warning Illuminates when rear axle oil temperature reaches 305F.

lamp (152C)

12. Not used.

Figure 4-5


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13. Alternator warning lamp Illuminates when, with engine operating, alternator is not

charging batteries.

14. Hydraulic oil filter warning lamp Illuminates when, with engine operating and hydraulic fluid at

operating temperature, hydraulic filter is restricted an

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