BackHoe Loader Student Guide

STUDENT GUIDE
FOR BACKHOE LOADER CASE 580 SUPER M
October 2008
PREFACE
This student guide contains selected course information and material. Most of the information contained in this student guide can be found in the BHL Operator Technical Manual TM 5-2420-23110. 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 receive future updates to your personal copy of the student guide.
ATSE-DT MEMORANDUM SUBJECT: Student Evaluation Plan for the Heavy Construction Equipment Operators Course, 21E10, Class No. 1-50 and follow-on classes.
1. ACADEMIC GRADING AND TEST PLAN: Academic subject matter is evaluated on a basis of 700 weight points which are distributed according to this document. Weight point achievement is calculated to a percentage computed to the second decimal place (0.00%) and used to determine student's completion of training. The written examination (TE) applies to the Active Component only. a. Module A The Army Maintenance Management System (TAMMS) 21E10-A06 TAMMS Written Examination (TE2 AC Only) Weight Points 100
(1) This is an open book performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning The Armys Maintenance 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 their student guide. Only those specific items covered in Annex A of which an equipment operator should 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 21E10-A11 Earthwork Principles Written Examination (TE2 AC Only) Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning Grade Stakes, Soils, Construction Prints and Surveying. 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-A07, A08, A09, and A10. (3) The time indicated in this lesson plan includes 30 minutes to critique this test. c. Module A Earthwork Principles (TE1) 21E10-A10 Surveying (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to shoot elevation shots from multiple points and determine selected elevations. 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.
d. Module B Dump Truck 21E10-B01 through B04 Dump Truck (TE1)
Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, driving operations, dumping operations and spreading operations with the Dump Truck. 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-B01, B02, B03 and B04. e. Module C Scoop Loader 21E10-C01 through C05 Scoop Loader (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, maneuvering operations, load a haul unit, clamshell operations, and excavation operations with the Scoop Loader. 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-C01, C02, C03, C04, and C05. f. Module C Scoop Loader 21E10-C06 Scoop Loader Written Examination (TE2 AC Only) Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning perform operators maintenance, starting/stopping procedures, maneuvering operations, load a haul unit, clamshell operations, and excavation operations with the Scoop Loader. 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-C01, C02, C03, C04 and C05. (3) The time indicated in this lesson plan includes 30 minutes to critique this test. g. Module D Backhoe Loader 21E10-D01 through D04 BHL (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, maneuvering operations and excavation with the BHL. 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-D01, D02, D03 and D04.
h. Module D Backhoe Loader 21E10-D05 Backhoe Loader Written Examination (TE2 AC Only)
Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning perform operators maintenance, starting/stopping procedures, maneuvering operations and excavation with the BHL. 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-D01, D02, D03 and C04. (3) The time indicated in this lesson plan includes 30 minutes to critique this test. i. Module D Hydraulic Excavator (HYEX) 21E10-D06 through D12 HYEX (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, maneuvering operations, lifting operations, replacing attachments, excavation and loading with the HYEX. 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-D06, D07, D08, D09, D10, D11, and D12.
j.
Module D Hydraulic Excavator 21E10-D13 Backhoe Loader Written Examination (TE2 AC Only)
Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning perform operators maintenance, 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-D06, D07, D08, D09, D10, D11 and D12. (3) The time indicated in this lesson plan includes 30 minutes to critique this test. k. Module E Crawler Tractor 21E10-E06 through E11 Crawler Tractor (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, maneuvering operations, excavation operations, and ditching operations with the Crawler Tractor. 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-E06, E07, E08, E09 and E10. l. Module E Crawler Tractor 21E10-E11 Crawler Tractor Written Examination (TE2 AC Only) Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning perform operat ors maintenance, starting/stopping procedures, maneuvering operations, excavation operations, and ditching operations with the Crawler Tractor. 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-E06, E07, E08, E09 and E10. (3) The time indicated in this lesson plan includes 30 minutes to critique this test.
m. Module E Motorized Grader 21E10-E01 through E05 Motorized Grader (TE1)
Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student 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. (2) The time indicated in these lesson plans includes 5 minutes per task to critique this test. (3) This test covers POI Files 21E10-E01, E02, E03, and E04. n. Module E Motorized Grader 21E10-E05 Motorized Grader Written Examination (TE2 AC Only) Weight Points 100
(1) This is performance-based test that contains multiple choice questions which require the student to determine solutions to questions/situations concerning perform operators maintenance, starting/stopping procedures, leveling operations, and ditching operations with the Motorized Grader. 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 have immediate knowledge will be included in this test. (2) This test covers POI File 21E10-E01, E02, E03 and E04. (3) The time indicated in this lesson plan includes 30 minutes to critique this test. o. Module F Motorized Scraper 21E10-F01 through F05 Motorized Scraper (TE1) Weight Points GO
(1) This test contains performance-based, hands on evaluation performance measures. The student is required to perform operators maintenance, starting/stopping procedures, maneuvering operations, push loading operations and excavation operations with the Motorized Scraper. 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-F01, F02, F03, F04 and F05.
TOTAL POINTS
700
1. COUNSELING: Students will participate in counseling sessions conducted by instructor supervisors and by the Student Affairs Counseling Division (or equivalent) throughout the course to review academic progress and discuss personal development. Students will be formally counseled whenever their academic standing falls 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 instruction course. The student is allowed to miss up to 20% of the hands on training but must pass all performance 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 test will constitute failure of the course. c. One retest will be administered if the student fails the initial test. Only with the commanders permission will 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 student receives a 100% on the written examination or a GO" on the performance evaluation, the student will still be required to attend all training to be given credit for that training module.
JERRY C. MEYER COL, EN Director, DOTLD
TABLE OF CONTENTS
CHAPTER Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Appendix A Appendix B Appendix C Appendix D Appendix E
TITLE Introduction to the Backhoe Loader Hand and Arm signals Safety Requirements Preventive Maintenance Checks and Services Maneuvering Excavation Performance Evaluation Sheets Fighting Positions Training Schedule Required Study Abbreviations and Acronyms
PAGE 1-1 2-1 3-1 4-1 5-1 6-1 A-1 B-1 C-1 D-1 E-1
Chapter 1 Introduction to the Backhoe Loader

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 can be 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 operator technical 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 an underground 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 the immediate 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 from spinning. 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. 1-2

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" below grade. 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 1-3

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. 1-4

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 under ground 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 open excavation. 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 to 8.1 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 the bucket. 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 related components 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. 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. 1-7 Figure 1-1

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 airconditioned for operator comfort in various weather conditions. 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 system holds 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 battery box, is used for 24 VDC slaves starting.
BHL ORIENTATION Right-hand, Left-hand, Front, and Rear indicate the right and left sides of the BHL as seen from the operators seat as shown in Figure 1-3.
1-8 Figure 1-3

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 14. 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 top of 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. 1-9

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 supplying hydraulic 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 ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
1-10

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
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
Figure 1-7 NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ 1-11

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
1 2 Figure 1-8
NOTES ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ 1-12
Chapter 2 Hand and Arm Signals

Equipment Specific Hand and Arm Signals 1. Raise Bucket / Stabilizer / Boom Arms extended at shoulder height with closed fist and thumbs extended up.
2. Lower Bucket / Stabilizer / Boom Arms extended at shoulder height with closed fist and thumbs extended downward.
3. Dump Bucket With closed fists, upper arms stationary, and forearms parallel to the ground twisting wrists downward.
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4. Retract Bucket With closed fists, upper arms stationary, and forearms parallel to the ground curling wrists upward.
5. Level Bucket Left 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 leveling motion.
6. Open Clam Arm 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 Clam Arm 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 Right Left arm extended parallel to the ground.
9. Swing Boom Left Right arm extended parallel to the ground.
2-3

10. Dipper Arm In Arm perpendicular to the body with palm facing up, fist closed, thumb pointing toward body.
11. Dipper Arm Out Arm perpendicular to the body with palm facing up, fist closed, thumb pointing away from body.
NOTES ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ 2-4

Common Equipment Hand and Arm Signals 1. Assemble on Signalman Right arm extended above head, fingers extended and joined facing up moving in circular motion.
2. Start Engine Arm extended to the front and side of the body with hand open. Move arm in a circular counter-clockwise motion
3. Stop Engine With palm facing downward and arm at shoulder level move forearm and hand across throat in a cutting motion.
2-5

4. Stop Arm perpendicular to the body with forearm vertical and fist closed; or both fists closed and both forearms crossed at chest level.
5. Lights On With 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 Off 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 across eyes left to right in a cutting motion.
2-6

7. Increase Throttle Right arm extended above head with fist closed, palm facing head moving up and down in a pumping motion.
8. Reduce Throttle Arms extended to side bent at the elbow with forearms in front of body with fingers extended and joined facing down moving in a fanning motion.
9. Break Arms 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 Forward Palms facing towards body, upper arms stationary, forearms motioning back and forth towards body.
11. Move Backward Palms facing away from body, upper arms stationary, and forearms motioning away from body.
12. Turn Right Left arm extended pointing away from body with fingers extended and joined arm extended and right arm bent at the elbow facing up with closed fist.
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13. Turn Left Right 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 Right Left 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 a forward movement.
15. Forward Left Right arm extended to side at shoulder height with fingers extended and joined, left arm 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 Brake Left 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, thumb extended touching open palm of left hand.
17. Release Park Brake Left 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 Position Both arms in front of body at waist height with hands clasped together.
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19. Float Position Left 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 Position Arms extended out to both sides with fingers joined.
NOTES ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ 2-11
Chapter 3 Safety Requirements

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 the WARNING 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 you understand 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 training course. g. WARNING: The safety alert symbol shown on the right indicates important safety messages 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 to personnel. c. Before operating the BHL, make sure the service and parking brakes are operable. Failure to comply may 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 3rd or 4th gear to provide equalized brake action. Failure to comply may result in serious injury or death to personnel. 3-1

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 on job 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 of types 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, shut engine 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 as quickly 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 injury or death to personnel.
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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 site conditions 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 the BHL. Always keep all other personnel away from the work area. Failure to comply may result in serious injury or death to personnel. j. Dust, fog, smoke, etc., can decrease visibility and cause an accident. Stop the BHL or decrease speed until 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 comply may 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. Failure to 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. Failure to comply may result in serious injury or death to personnel. 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, or adding 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 injury or death to personnel.
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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 clutch cutout 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 to comply 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 injury or death to personnel. b. Do not move a load over the top of personnel. Keep all other personnel away from load. Failure to comply may result in serious injury or death to personnel. c. Make sure all other personnel involved are shielded in event lifting apparatus might break. Failure to comply may result in serious injury or death to personnel. d. Exercise care when lifting a load using the FEL. Do not exceed 7,800 lb (3538 kg) load. Make sure rigging equipment has capacity to lift load and that no personnel are the under load. Failure to comply may result in serious injury or death to personnel. e. Exercise care when lifting a load using the backhoe. Do not exceed lifting capacity limits in TM 52420-231-10, 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 be parked 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 may result in serious injury or death to personnel. c. Remove starter key when leaving the BHL parked or unattended. Failure to comply may result in serious injury or death to personnel. ELECTRICAL HIGH 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 the BHL away from danger area. 3. If unable to break contact, stay in the BHL until utility workers de-energize power lines. ELECTRICAL BATTERIES 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 result in serious injury or death to personnel. b. Metal jewelry can conduct electricity. Remove metal jewelry when near the batteries. Failure to comply may result in serious injury or death to personnel. TIRES a. When inflating tires, keep yourself and all other personnel out of danger area. Stand on tread side of tire. 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. Failure to comply may result in serious injury or death to personnel. SERVICING a. Before servicing the BHL, put a DO NOT OPERATE tag on starter key switch. Failure to comply may result in serious injury or death to personnel. 3-5

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 to personnel. d. Prolonged exposure to bright sunlight produces very hot metal surfaces which will burn flesh on contact. 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 flesh on 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 anyone stops 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 after handling. 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 result in serious injury or death to personnel.
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First aid for battery acid exposure: Antidote: EXTERNAL Flush with water. Antidote: INTERNAL Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Do not induce vomiting. SEEK MEDICAL ATTENTION IMMEDIATELY. Antidote: EYES Flush 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. Ventilate when 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 in battery 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 any pressurized 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 and water. 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 sources of 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 result in serious injury or death to personnel. 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 serious injury or death to personnel. 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 to personnel. 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 cause flames 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 when cleaning. 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 for help. 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. 3-8

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 extreme caution. 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 manufacturers recommendations. 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 ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ 3-9
Chapter 4 PMCS
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 the CAUTIONS 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 around diagram 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. 4-1
Chapter 4 PMCS
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 are fully 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. It is 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. 4-2
Chapter 4 PMCS
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 sure the area is clear of other persons.
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Chapter 4 PMCS
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 to service your BHL at the correct time periods.
Figure 4-2 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 injury or death to personnel. NOTES ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ 4-4
Chapter 4 PMCS
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 injury or 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 retaining pin (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 are lowered 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). 4-5
Chapter 4 PMCS
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 during constant 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 Always Use Lubrication Instructions as your guide. Use correct type/grade lubricant Clean area where lubricant is to be applied to prevent buildup of dirt, grit, and contaminants. 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 52420-231-10, 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 or to 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. Never Use wrong type/grade lubricant. Use too much lubricant. Apply lubricant to dirty components.
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Chapter 4 PMCS
Troubleshooting procedures for the following functions are included in TM 5-2420-231-10, WP 0014: a. Engine b. Steering c. Brakes d. Transmission e. 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. Backhoe h. Cooling System i. Electrical System j. Air Conditioner SLAVE STARTING OPERATION
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WARNING: NATO slave receptacle is electrically live at all times and has no fuse. NATO slave receptacle 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 serious injury or death to personnel. 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 serious injury or death to personnel. CAUTION: Do not allow vehicles to touch while slave-starting. Failure to comply may result in damage to equipment.
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Chapter 4 PMCS
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 Check d. Hydraulic Fluid Level Check e. Hydraulic Filter Check f. Transmission Fluid Level Check g. Coolant Fluid Level Check h. Windshield Washer Solvent Level Check i. Engine Oil Check j. Engine Air Filter Service
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Chapter 4 PMCS
TOWING A DISABLED BHL
! ! ! ! ! ! ! ! ! ! !
WARNING: Do not tow disabled BHL incorrectly. Failure to comply may result in serious injury or death to personnel. WARNING: If the BHL is disabled, you must make a judgment if the BHL can be moved safely and without 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 the grade, 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 comply may result in serious injury or death to personnel. 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 been damaged by ultraviolet light, and should not be used. Failure to comply may result in serious injury or death to personnel.
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Chapter 4 PMCS
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 may result 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 each side 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 for no more than one mile (1.6 km).
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Chapter 4 PMCS
INSTRUMENT PANEL CONTROLS AND INDICATORS
Figure 4-4 KEY EXPLANATIONS FOR FIGURES 4-4 AND 4-5 KEY/CONTROL/INDICATOR 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)). FUNCTION
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 or death to personnel. 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 of rocker switch. Green lamp in switch illuminates. Push bottom of rocker switch to disengage. Push top of rocker switch to turn lamp on; green lamp in switch illuminates. Push bottom of rocker switch to turn lamp off.
4. Ride control switch
5. Rear work lamp switch
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Chapter 4 PMCS
Figure 4-5 KEY/CONTROL/INDICATOR 6. Air conditioning system pressure FUNCTION 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 level maintenance. Failure to comply may result in severe damage to engine. 10. Low engine oil pressure warning lamp Illuminates when, with engine operating, there is no engine oil pressure or low engine oil pressure. Audible alarm will also sound when this condition exists. Illuminates when rear axle oil temperature reaches 305F. (152C)
11. Rear axle oil temperature warning lamp 12. Not used.
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Chapter 4 PMCS
Figure 4-6 KEY/CONTROL/INDICATOR 13. Alternator warning lamp FUNCTION Illuminates when, with engine operating, alternator is not charging batteries. Illuminates when, with engine operating and hydraulic fluid at operating temperature, hydraulic filter is restricted and requires service. Illuminates when, with engine operating, air filter element is restricted and requires service.
14. Hydraulic oil filter warning lamp
15. Air filter restriction warning lamp
WARNING: The BHL is equipped with an engine grid heater that will ignite flammable starting fluids. Do not use starting fluid. Fire and explosion may occur. Failure to comply may result in serious injury or death to personnel Illuminates when starter key switch is turned to ON position and incoming air needs to be preheated due to cold temperatures. Wait until lamp extinguishes before starting engine.
16. Engine grid heater indicator lamp
NOTES ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ 4-13
Chapter 4 PMCS
Figure 4-7 KEY/CONTROL/INDICATOR 17. Low fuel level warning lamp 18. Fuel level gage FUNCTION Illuminates when fuel level is low (below 5 gallons (19L)). Indicates amount of fuel in fuel tank.
CAUTION Do not continue to operate engine with voltmeter gage needle in red area (discharge or overcharge). Notify field level maintenance. Failure to comply may result in damage to batteries. NOTE When starter key switch in turned to ON position, voltmeter gage needle will move to bottom of green area. After engine starts, gage needle should move up to upper part of green area. 19. Voltmeter gage Indicates condition of electrical system. System is normal when, with key switch in ON position, gage needle is in green area of gage (11 to 15.3 volts). If gage needle is in red area, battery charge is too low, alternator in not charging enough, or there is an overcharge condition.
NOTES ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________________________________________________________________ 4-14
Chapter 4 PMCS
Figure 4-8 KEY/CONTROL/INDICATOR 20. Tachometer FUNCTION Indicates engine speed in rpm. Each mark on gage equals 100 rpm. Engine should be operated in green area of gage. Indicates number of hours engine has run. Far right number indicates tenths of an hour.
21. Engine hour meter
CAUTION Do not continue to operate engine with torque converter oil temperature gage needle in red area. Failure to comply may result in damage to torque converter. 22. Torque converter oil temperature gage Indicates oil temperature of torque converter. Temperature is normal when gage needle is in green area of gage. If gage needle goes into red area, move direction control lever to neutral position and operate engine for 30 seconds to 2 minutes at full throttle. If this does not reduce torque converter oil temperature, shut down engine and check for obstruction in radiator or oil cooler.
NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 4-15
Chapter 4 PMCS
Figure 4-9 KEY/CONTROL/INDICATOR FUNCTION
WARNING: Hot coolant can spray out if radiator cap is removed rapidly. To remove radiator cap, let system cool; then, slowly remove cap by turning in small increments. Failure to comply may result in serious injury or death to personnel. CAUTION Do not continue to operate engine with engine coolant temperature gage needle in red area. Notify field level maintenance. Failure to comply may result in damage to engine.
23. Engine coolant temperature gage
Indicates temperature of engine coolant. Temperature is normal when gage needle is in green area of gage. If gage needle goes into red area, audible alarm will sound. Stop engine, allow to cooling, and check cooling system. Turn heat control Clockwise (CW) to increase temperature in cab; turn heat control Counterclockwise (CCW) to decrease temperature.
24. Heater temperature control switch
NOTES ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ 4-16
Chapter 4 PMCS
Figure 4-10 KEY/CONTROL/INDICATOR 25. Blower fan switch FUNCTION Turn switch to center detent for low fan speed; fully CW for high fan speed; completely CCW to OFF position to stop fan.
26. Key switch (4-position) Position A Position B Position C ACC - Turn key CCW from OFF position to ACC position to provide power to accessories. OFF - Turn key to OFF position to shut engine off. ON Turn key CW to ON position. Before starting engine, check status of all warning lamps. Use voltmeter gage to check battery condition. START - Turn key completely CW to actuate starter motor. After engine starts, release key, which will automatically return starter key switch to ON position.
Position D
NOTE Air conditioning should produce air approximately 10F cooler than outside air temperature. 27. Air conditioning temperature switch Controls air conditioning output temperature. Turn switch CW to decrease temperature in cab; turn switch completely CCW to turn off. NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 4-17
Chapter 4 PMCS
Figure 4-11 KEY EXPLANATIONS FOR FIGURES 4-11 AND 4-12 KEY/CONTROL/INDICATOR 1. Not used 2. Front wiper switch Low High Off 3. Front windshield washer switch 3 position switch Controls front wiper Push left side of rocker switch to first position to turn front wiper to low. Push left side of rocker switch to second position to turn front wiper to high. Push right side of rocker switch to turn front wiper to off. Push and hold rocker switch to activate front windshield washer; release rocker switch to stop front windshield washer. Push left side of rocker switch to retract FEL tool carrier lock pins; push right side of rocker switch to extend FEL tool carrier lock pins. FUNCTION
4. Front End Loader (FEL) tool carrier switch
5. Not used. 6. Front work lamp switch Push right side of rocker switch to turn on front work lamps; push opposite end of rocker switch to turn off front work lamps. Push right side of rocker switch to turn on flashers; push opposite end of rocker switch to turn off flashers. 4-18
7. Flasher lamp switch
Chapter 4 PMCS
8. Not used 9. Not used 10. Fuel pump solenoid switch Momentary rocker switch. Push and hold right side of switch to disengage fuel pump solenoid switch and prevent engine from starting; release switch to engage fuel pump solenoid switch and allow engine to operate.
Figure 4-12
11. Driving lamp switch (lever)
Push lever forward to turn driving lamps on; pull lever rearward to turn driving lamps off. Push lever up to signal left turn; push lever down to signal right turn; move lever to center to stop turn signal. Push button to sound horn. Provides directional control to the BHL. Flash to show turn signal activation (left or right).
12. Turn signal lever
13. Horn button 14. Steering Wheel 15. Turn signal indicators
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Chapter 4 PMCS
Figure 4-13 KEY/CONTROL/INDICATOR FUNCTION
NOTE All light control switch keys are push-on momentary keys. When key is pushed, blue light in key will flash once. ENTER key must then be pushed within 5 seconds, or switch will revert to previous setting. Active key will remain illuminated in blue. Amber backlight is for keypad illumination only. 1. B.O.DRIVE key Allows blackout drive light, blackout taillights, and blackout stop lights to operate. All other lights, horn, and audible alarms are disabled. Must be pressed within 5 seconds after selecting a function key to allow function to operate. Allows blackout taillights and blackout stop lights to operate. All other lights, horn, and audible alarms are disabled. Turns all lights off. Switch will turn off after 20 seconds. Only instrument panel warning lights operate. Horn and audible alarms do not operate. Allows service stop light and service tail lights to operate. All other lights and audible alarms are disabled.
2. ENTER key
3. B.O. MARKER
4. ALL OFF key
5. STOP LIGHT key
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Chapter 4 PMCS
6. SER. DRIVE key Allows service driving lights, turn signals, service stop lights, front and rear work lights, service taillights, hazard flasher, horn, dome light, and audible alarms to operate. Sets all panel lights to full intensity. Allows service driving lights, turn signals, service stop lights, front and rear work lights, service taillights, hazard flasher, horn, dome light and audible alarms to operate. Sets all panel lights to half intensity. POWERSHIFT TRANSMISSION CONTROLS DIRECTION CONTROL LEVER The direction control lever, reference 1 in Figure 4-14, controls the travel direction of the BHL. The center position N is NEUTRAL. The top position F is FORWARD. The bottom position R is REVERSE. To travel forward in 1st, 2nd, 3rd, or 4th gear, lift the lever and push it all the way forward toward the F position. To travel in reverse in 1st or 2nd gear, lift the lever and pull completely rearward toward R position. Make sure the direction control lever is in N or NEUTRAL before you start the engine or before you operate the backhoe.
7. PANEL BRT. Key 8. PARK key
9. PANEL DIM key
Figure 4-14 GEAR SELECTIONCONTROL LEVER The gear selection control lever is used to select gears (1, 2, 3, 4). Rotate the lever hand grip, reference 2 in Figure 4-14, to align the number corresponding to the desired gear with the indicator mark on the lever. In manual transmission mode, the BHL will stay in the selected gear until selection is changed. Gear change can be made without stopping the BHL. Position 1 1st gear, forward or reverse Position 2 - 2nd gear, forward or reverse Position 3 - 3rd gear, forward only Position 4 - 4th gear, forward only 4-21
Chapter 4 PMCS
In automatic transmission mode the BHL will reach the maximum gear selected by the gear selection lever Position 1 - no automatic shifting, transmission remains in 1st gear Position 2 - no automatic shifting, transmission remains in 2nd gear Position 3 - automatic shifting between 2nd and 3rd gear Position 4 - automatic shifting between 2nd, 3rd and 4th gear When operating in automatic mode, some incline and load conditions may cause the transmission to shift from 4th to 3rd and back to 4th, or from 3rd to 2nd and back to 3rd. If this happens select a lower gear. Downshift as needed until the transmission discontinues shifting between gears. TRANSMISSION KICKDOWN SWITCHES IMPORTANT: On start up the transmission mode will be automatic. There are 2 transmission kick down switches. One is located on the direction control lever. Reference 3 in Figure 4-15 shows the location of this transmission kick down switch. The other transmission kick down switch is located on the FEL control lever. It is shown by reference 1 in figure 4-15. In manual mode, either transmission kick down switch may be used to change automatically from 2nd gear to 1st gear, to increase digging force. Press the button once to downshift from 2nd gear to 1st gear. Press the button again to shift back to 2nd gear. If the button was pressed to downshift to 1st gear, changing direction from forward to reverse shifts the transmission into 2nd gear reverse. Changing direction back to forward shift the transmission into 2nd gear forward. The kick down switches may also be used to move the transmission mode from manual to automatic. Placing the transmission in neutral and engaging a kick down button will take the transmission from manual to automatic or automatic to manual. The speed of the BHL will have no affect on the selection.
1
Figure 4-15
POWERSHIFT TRANSMISSION CONTROL MODULE This module consists of a display screen, mode selection button, M, and two indicator lamps T and F. Changing the displayed information is done by pressing the M Button. Detailed information about the Power shift Transmission Control Module can be found in this student guide in chapter 5.
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Chapter 4 PMCS
FOOT PEDALS
Figure 4-16 FOOT THROTTLE Reference 1 in Figure 4-16 points to the BHL foot throttle. Push down on the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed. RIGHT BRAKE PEDAL Reference 2 in Figure 4-16 points to the BHL right brake pedal. With the brake pedal lock disengaged, push the right brake pedal to help turn the BHL to the right. LEFT BRAKE PEDAL Reference 3 in Figure 4-16 points to the BHL left brake pedal. With the brake pedal lock disengaged, push the left brake pedal to help turn the BHL to the left. BRAKE PEDAL LOCK Reference A in Figure 4-16 points to the brake pedal lock in the engaged position. The two brake pedals are locked together and operate simultaneously. Reference B in Figure 4-16 points to the brake pedal lock in the disengaged position. The brake pedals are NOT locked together and operate independently. Move the lever up and slide the locking pin all the way to the right into the lock ENGAGED position. Move the lever up and slide the locking pin all the way to the left into the lock DISENGAGED position.
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Chapter 4 PMCS
WARNING: Service brake pedals must remain locked together unless using brake pedals to assist steering limited clearance conditions. Once steering assist maneuver is complete, return pedals to locked position. Failure to comply may result in damage to equipment or serious injury or death to personnel. PARKING BRAKE PARKING BRAKE ENGAGED Pull the parking brake control lever back to apply the parking brake as shown in Figure 4-17. NOTE: A warning alarm will sound if you shift the direction control lever into FORWARD or REVERSE while the parking brake is engaged. IMPORTANT: You can damage the parking brake, which is also the service brake, if you move the BHL and the parking brake is applied. Figure 4-17 PARKING BRAKE DISENGAGED Push the parking brake control lever forward to release the parking brake as shown in Figure 4-18. PARKING BRAKE ADJUSTMENT a. Release the parking brake and turn the end of the lever clockwise two or three turns. b. Pull the parking brake lever back to engage the parking brake. c. Perform the Parking Brake Check in accordance with TM 5-2420-231-10 to test the parking brake. If the parking brake does not hold the BHL, turn the BHL over to maintenance
Figure 4-18
WARNING: Uncontrolled BHL movement can injure. Before you turn the operators seat around to the BACKHOE operating position, shift the direction control lever and transmission control to NEUTRAL and apply the parking brake.
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Chapter 4 PMCS
FEL CONTROL LEVER The FEL control lever, shown in Figure 4-19 is used to control the position of the FEL lift arms and the bucket.
Figure 4-19 LIFT ARM AND BUCKET CONTROL
References A through C are shown in Figure 4-20. A. FLOAT. Push lever forward past detent. The bucket can follow the level of the ground without movement of the control lever. B. LOWER. Moves the bucket down.
C. RAISE. Moves the bucket up.
Figure 4-20
4-25
Chapter 4 PMCS
References D through F are shown in Figure 4-21. D. ROLLBACK. Rolls the bucket back. E. DUMP. Dumps the bucket. F. RETURN-To-DIG. After the bucket is dumped, move the control to ROLLBACK and FLOAT. When the bucket is at the height selected, pull the control back to HOLD. G. HOLD-NEUTRAL. The FEL lift arms and bucket stop moving when the control lever is in HOLD. When released, this control will return to HOLD automatically. You must manually move this control from FLOAT to HOLD.
Figure 4-21
CLAM CONTROL AND LOCKOUT See Figures 4-22 and 4-23. The clam stops moving when the control handle is in HOLD. The clam control handle is equipped with a lock latch. The latch should be in the LOCKED position when the clam is not in use.
Figure 4-22, A. CLAM OPEN B. CLAM CLOSED C. HOLD NEUTRAL NOTE: The latch is not automatic; it must be manually engaged. 4-26 Figure 4-23
Chapter 4 PMCS
CLUTCH CUTOUT BUTTON Push the clutch cutout button to disengage transmission from drive wheels and allow the engine to increase speed and supply the FEL with more hydraulic oil for greater FEL power and faster control reaction time. When you push the clutch cutout button, the transmission is disengaged from the drive wheels. Release the clutch cutout button to engage the transmission power. The BHL can move freely when the clutch cutout button is pushed. If required, use the brake to stop the BHL.
Figure 4-24 DIFFERENTIAL LOCK SWITCH To engage the differential locks use the following procedure: a. Before engaging the differential lock make sure neither rear wheel is spinning freely. b. Press and hold the differential lock switch (Figure 4-25, reference 4), located on the FEL control lever. c. To disengage the differential lock, release the differential lock switch. NOTE: The differential lock will release automatically when the load is removed. Figure 4-25 TRANSMISSION KICKDOWN SWITCHES The transmission kick down switches (Figure 4-25, reference 5 and Figure 4-14, reference 3) are momentary switches used to change automatically from 2nd gear to 1st gear, when in manual mode, to increase digging force. AUDIBLE ALARM The audible alarm sounds if, a. The engine oil pressure is low. b. The engine coolant temperature is high. c. The parking brake is applied and you shift the direction control lever to the FORWARD or REVERSE position. d. The seat is turned away from the driving position and the direction control lever is in FORWARD or REVERSE position. NOTE: See Seat Switch Alarm System operation in the next paragraphs
5
4-27
Chapter 4 PMCS
SEAT ALARM OPERATION The Seat Alarm sounds when the operator rotates the seat from the driving position towards the backhoe position and leaves the direction control lever in forward or reverse. A warning decal on the BHL, repeated in the operators manual with additional operating instructions, requires the operator to take certain precautions before operating the backhoe. The seat switch alarm is an additional warning. The alarm will sound if the seat is rotated approximately 15 to 20 degrees from the straight forward position. To make sure the system is working, the operator must know that the same alarm will also sound if the parking brake is set and the direction control lever is in forward or reverse. SEAT ALARM TEST PROCEDURE a. The operator must be in the seat in the driving position with the seat belt on. b. Start the engine. c. Park the BHL on a level surface in a clean area. Make sure all other persons are clear of the area. d. Make sure the parking brake is OFF, and the transmission shift lever is in NEUTRAL with the FEL bucket on the ground. e. Put your foot on the service brake and keep it there. f. Move the direction control lever to the FORWARD position and turn the seat approximately 15 to 20 degrees. The buzzer sounds. The same procedure is repeated for REVERSE. The alarm and also the backup alarm will sound. This will tell if the seat switch alarm system is operating. NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 4-28
Chapter 4 PMCS
LEFT REAR CONSOLE CONTROLS Figure 4-26 shows the left rear console controls. Reference numbers 1, 4, and 7 are not used on the BHL. The functionality of the remaining referenced items is explained in the following paragraphs. REAR WIPER SWITCH The rear wiper switch, reference 2 in Figure 4-26, is a three position switch. Push the top of the rocker switch to the first position to turn the rear wiper to LOW. Push the top of the rocker switch to the second position to turn the rear wiper to HIGH. Push the bottom of the rocker switch to turn the rear wiper OFF. REAR WINDOW WASHER SWITCH Press and hold the top of the rear window washer rocker switch, reference 3 in Figure 4-26, to activate the rear window washer. Release the top of the rocker switch to stop the rear window washer. BACKHOE QUICK COUPLER SWITCHES Reference 5 in Figure 4-26 is the backhoe right hydraulic quick coupler switch. Reference 6 in Figure 4-26 is the backhoe left hydraulic quick coupler switch. It is necessary to push both rocker Figure 4-26 switches at the same time to activate (retract) the backhoe quick coupler lock pins. a. Push the top of the rocker switches to disengage/retract the backhoe quick coupler lock pins. b. Push the bottom of the rocker switches to engage/extend the backhoe quick coupler lock pins. REAR THROTTLE CONTROL Push the rear throttle control, reference 8 in Figure 4-26, away from you to increase the engine speed. Pull the rear throttle control toward you to decrease the engine speed
WARNING: When you operate the backhoe, use the hand throttle to control the engine speed. You can have an accident if you use the hand throttle for any other operation
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Chapter 4 PMCS
LEFT PILOT CONTROL TOWER
Figure 4-25 LEFT PILOT CONTROL TOWER CONTROLS AND INDICATORS KEY/CONTROL/INDICATOR FUNCTION
NOTE: Bi-directional auxiliary hydraulic switches operate only when auxiliary hydraulic equipment is installed. 1. Bi-directional auxiliary hydraulic switches 2. Horn button 3. Left control lever Control operation of optional auxiliary hydraulic equipment connected to backhoe boom. Push button to activate horn; release button to stop horn. Controls backhoe functions for Boom and Swing (pattern 1) or Dipper and Swing (pattern 2). Located on backhoe side of tower. Turn knob CCW and tip upper part of tower into position; turn knob CW to lock position.
4. Tower tip adjustment knob
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Chapter 4 PMCS
KEY/CONTROL/INDICATOR 5. Left wrist rest adjustment knob FUNCTION Turn knob CCW to adjust wrist rest; turn CCW to tighten wrist rest.
NOTE: Auto Up feature allows operator to automatically bring stabilizers (left or right) up to transport position without holding switch in position. For Auto Up feature, pull switch all the way rearward momentarily past detent position. Release switch and stabilizer will automatically raise to full transport position. Push switch in either direction to cancel Auto Up. 6. Right stabilizer switch Pull switch rearward to bring right stabilizer up; push switch forward to lower stabilizer. Pull switch rearward to bring left stabilizer up; push switch forward to lower stabilizer. Supports operator's wrist during backhoe operation to prevent fatigue.
7. Left stabilizer switch
8. Adjustable wrist rest
RIGHT PILOT CONTROL TOWER CONTROLS AND INDICATORS KEY/CONTROL/INDICATOR 1. Right backhoe control lever FUNCTION Controls backhoe functions for dipper and bucket (pattern 1) or boom and bucket (pattern 2). Supports operator's wrist during backhoe operation to prevent fatigue.
2. Adjustable wrist rest
NOTE: Make sure all rear window adjustments have been made prior to setting backhoe towers into position. 3. Tower fore and aft control handles Squeeze handles together to adjust left and right towers fore and aft; release handles to hold position.
NOTE: When turning pilot control switch to on position, there may be a delay of less than 1/2 second before being able to operate stabilizers or bi-directional auxiliary equipment. If operator attempts to operate any of these functions sooner than 1/2 second delay, functions will not operate again until pilot control switch is cycled off and on.
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Chapter 4 PMCS
Figure 4-26 KEY/CONTROL/INDICATOR 4. Pilot control switch (3 positions) FUNCTION Used to activate/de-activate backhoe controls. A (ON) Enable - Momentary position; activates all backhoe functions; illuminates when activated. B (ENABLE) On - Allows only stabilizers to operate. C (OFF) Off - Shuts all backhoe controls off.
NOTE: It is necessary to use two hands to change control patterns. This safety feature prevents accidental switching of patterns. 5. Backhoe control pattern switch (2 positions) Used to select backhoe pattern 1 or 2. E (orange locking tab) To change switch positions, push orange locking tab up toward D (lock release) center of switch to release lock. Turn knob CCW to adjust wrist rest, turn knob CW to tighten wrist rest. Push pedal to release boom latch.
6. Right wrist rest adjustment knob
7. Boom latch release pedal
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Chapter 4 PMCS
8. Tower tip adjustment knob Located on backhoe side of tower. Turn knob CCW and tip upper part of tower into desired position; turn knob CW to lock position.
PILOT CONTROL PATTERNS
WARNING: The BHL is equipped with two backhoe control function patterns. Check control functions before operating the BHL. Failure to check control pattern before operating can cause unexpected BHL movement, death or serious injury. BACKHOE CONTROL PATTERN SWITCH Use this switch to change the control pattern of the backhoe. To change switch positions, push the orange locking tab up towards the center of the switch to release the lock. To change control patterns it is necessary to use two hands. This safety feature helps prevent accidental switching of patterns. The control pattern switch is illuminated when the switch is in Position 2. (Excavator pattern)
Figure 4-27
PILOT CONTROL PATTERN 1

BOOM AND SWING DIPPER AND BUCKET
LEFT CONTROL LEVER
RIGHT CONTROL LEVER
Figure 4-28
4-33
Chapter 4 PMCS
PILOT CONTROL PATTERN 2
DIPPER AND SWING BOOM AND BUCKET
LEFT CONTROL LEVER
RIGHT CONTROL LEVER
SEATBELTS
Figure 4-29
! !
WARNING: You are protected by the ROPS system on the BHL (Roll-Over Protective Structure). The seat belt is an important part of the ROPS system. Before you operate this BHL, always fasten the seat belt. If the BHL rolls over and you DO NOT have the seat belt fastened, you could be crushed by the ROPS or the BHL. MECHANICAL SUSPENSION SEAT WARNING: An accident or sudden BHL movement can cause injury or death. Always fasten the seat belt and adjust the seat before you start the engine. The operators seat can be raised, lowered, moved forward and rearward, and can be turned around to operate the backhoe or the FEL. You can also adjust the armrests, seat cushion and backrest. For added operator comfort there is lumbar support adjustment and a weight adjustment for ride firmness.
SWIVEL CONTROL Lift lever (Figure 4-30, reference 1) to rotate (swivel) from the normal driving position to the backhoe operation position or from the backhoe operation position to the normal driving position.
Figure 4-30
4-34
Chapter 4 PMCS
FORWARD / REARWARD CONTROL Lift lever (Figure 4-30, reference 2) and move the seat forward or rearward. Release the control lever and make sure the seat is locked in position. BACKREST TILT ADJUSTMENT CONTROL Sitting in the seat, the backrest tilt adjustment control is located on the left side of the seat as shown with the arrow in Figure 2-30. Raise the lever and tilt the seat backrest until it is comfortable for you. Releasing the tilt adjustment control will lock it in place. Figure 4-31 WEIGHT ADJUSTMENT CONTROL Use the hand crank on the control wheel to turn the weight adjustment control knob shown in Figure 4-32 clockwise to increase seat firmness or counterclockwise to decrease seat firmness. Figure 4-32 LUMBAR ADJUSTMENT CONTROL The lumbar adjustment control is located on the left rear of the seat as shown in Figure 4-33. Turn the control wheel down or clockwise to increase the lumbar support. Turn the knob up or counterclockwise to decrease the lumbar support. Figure 4-33 ARMREST ADJUSTMENT CONTROL The armrest adjustment controls shown in Figure 4-34 adjusts the low or bottom armrest position for operator comfort. Turn the control knob clockwise to raise the arm rest. Turn the knob counterclockwise to lower the arm rest. The armrests may be folded completely up for operator comfort. Figure 4-34 4-35
Chapter 4 PMCS
CAB AIR LOUVERS AND VENTS The air louvers in the cab are adjustable and can be completely closed. Move the two bars in each louver to the center to stop air flow. Move each bar outward to start air flow. NOTE: During some conditions, it is possible to have ice on the air conditioning core. Ice can be caused by operating at LOW blower speed and MAXIMUM cold setting of the temperature control. It is best to operate the MEDIUM or HIGH speed setting of the blower and center range of the temperature control. If ice does block the core, you will feel a reduction of air flow in the cab. Close the recirculation louver, turn the temperature control to OFF and run the blower at HIGH speed. Another cause of ice can be a restricted air filter in the cab. DEFROST LOUVERS There are two louvers in the front of the cab and two in the rear of the cab, reference 1 in Figure 4-35. To get maximum air flow, close the recirculation grill, reference 2 in Figure 4-35, in the center of the cab and the two main louvers by the center posts.
Figure 4-35 4-36
Chapter 4 PMCS
MAIN LOUVERS The four main louvers (two by the center posts and two in the front), reference 3 in Figure 4-35, are used to direct the flow of air for heating and cooling. RECIRCULATION GRILL The grill between the main louvers, reference 2 in Figure 4-35, is used for recirculation of the cab air. To get maximum pressure in the cab, close the recirculation grill. To get maximum heat in the winter and maximum cooling in the summer, open the recirculation grill. CAB LOWER VENTS These vents, reference 4 in Figure 4-35, in the center front of the cab are used to direct the flow of air for heating and cooling. To get maximum air flow from the lower vents, close the overhead louvers and grill. DOME LAMP SWITCH The dome lamps switch, Figure 4-36, has three positions. 1. AUTO ON When the switch is in the AUTO ON (forward) position, the dome lamp comes ON when the door is opened. When the door is closed the dome lamp is OFF. 2. OFF When the switch is in the OFF (center) position the dome light is always OFF. 3. ON When the switch is in the ON (rear) position the dome light is always ON.
Figure 4-36
DOORS AND WINDOWS DOOR LATCH Pull door latch, Figure 4-37, up to open door.
Figure 4-37
4-37
Chapter 4 PMCS
WINDOW RETAINER RELEASE Pull window retainer release, Figure 4-38 up to release window. Push the window completely back to hold the window in the OPEN position.
Figure 4-38 WINDOW LATCH Push the window latch tab, Figure 4-39, to release and open the window. 1. Latch and Handle 2. Partial Window Hold Open (Shown in storage position in Figure 2-38) 3. Partial Window Hold Open (Shown in use in Figure 4-40) Figure 4-39 NOTE: Always return the hold open rod to the STORED position when not in use. IMPORTANT: DO NOT transport BHL on trailer at highway speeds with the windows in the partial open position. Damage to cab windows could occur.
Figure 4-40 REAR WINDOW OPERATION The rear windows in the cab have four positions. 1. All Closed top window up and bottom window up. 2. Top window up and bottom window full down. 3. Top window down and bottom window full down. 4. Both windows full down. To raise a window, uses both handles and raise the window. To lower a window raise the window with both handles (Figure 4-41), push down on the latch bars, and lower the window. Use the handles to raise or lower the windows.
Figure 4-41
4-38
Chapter 4 PMCS
! !
WARNING: UNEXPECTED MOVEMENT HAZARD: Before adjusting windows Turn Off Backhoe Control System.
WARNING: The window can interfere with pilot control levers Make sure window adjustment is locked into position before actuating the hydraulics. To raise a window, use both handles and raises the window. To lower a window raise the window with both handles, push down on the latch bars, and lower the window. Use the handles to raise or lower the windows COAT HOOK AND TETHER STRAP There is a coat hook and tether strap located inside the cab on the right side. After hanging coat on hook use the tether strap to secure coat in place against cab post. Failure to use tether strap could result in reduced visibility. REAR VIEW MIRROR A rear view mirror is mounted at the top of the front window. The driver can use the rear view mirror to see behind the BHL when the seat is in the normal driving position.
NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ 4-39
Chapter 5 Maneuvering the Backhoe Loader

MANEUVERING THE BHL Driving the BHL includes all tasks associated with driving the BHL to and from the excavation site. You may have to maneuver the BHL around obstacles over several types of terrain. You must observe BHL operation during driving as well as using the FEL and backhoe to ensure the BHL is operating properly. When you are finished using the BHL for the day, you should find an appropriate parking area and shut the BHL down. ENGINE STARTING PROCEDURES Engine starting and turbocharger priming procedures are located in TM 5-2420-231-10, WP0010. a. Make sure the seat is in the normal driving position. b. Adjust the seat and fasten the seat belt. c. Make sure the parking brake is applied. d. Position the direction control lever in the NEUTRAL position. e. Position engine hand throttle in the IDLE position. CAUTION: If the BHL has not been run for several weeks, or if the engine oil filter has been replaced, prime the turbocharger with oil. Failure to comply may result in damage to turbocharger. Prime turbocharger with oil as follows: a. Refer to Figure 5-1 and push and hold right side of fuel pump solenoid switch (item 1) to disengage fuel pump to prevent the engine from starting. b. Turn starter key switch to START and actuate the starter for 10 seconds. Then, turn key switch to OFF position. c. Release right side of fuel pump solenoid switch to engage injection pump solenoid. f. Turn the starter key switch to ON Figure 5-1 NOTE: If operating in blackout conditions, do not set light control switch to SER.DRIVE position. Start engine, and then set switch to appropriate setting. g. Set light control switch to SER.DRIVE position. Audible alarm will sound. NOTE: If the BHL engine grid heater lamp illuminates, wait until the lamp extinguishes before engaging starter motor. h. Check that the low engine oil pressure and alternator warning lamps are both illuminated. i. Make sure air filter restriction warning lamp and hydraulic oil filter warning lamp momentarily illuminate.
5-1

CAUTION: If the engine starts and stops, do not actuate the starter motor again until the starter motor stops turning. Failure to comply may result in damage to engine. CAUTION: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for 2 minutes before you actuate the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply. Failure to comply may result in damage to engine. CAUTION: If audible alarm continues after several seconds, shut down engine and notify maintenance. Failure to comply may result in damage to engine. j. Push the foot throttle 1/4 down and turn the key switch to the START position to actuate the starter motor. k. After the engine starts, low engine oil pressure audible alarm should cease. Alternator and oil pressure warning lamps should extinguish. Check the instrument panel to make sure instrument readings are normal. l. Run the engine at 1000 rpm until the coolant temperature is warm (engine coolant temperature gage in green range) before moving the BHL. SLAVE STARTING BHL FROM ANOTHER VEHICLE
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WARNING: NATO slave receptacle is electrically live at all times and is not fused. NATO slave receptacle 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 serious injury or death to personnel. WARNING: Do not attempt to jump start or charge a battery when electrolyte is frozen. Battery could explode
WARNING: Batteries produce explosive gasses.
ENGINE SPEED CAUTION: Do not run the engine at idle speed for long periods. This can cause a low operating temperature. Low operating temperature can cause acids and deposits in the engine oil. It is recommended that you run the engine at full throttle when operating conditions permit and when safe.
5-2

TRANSMISSION OPERATION POWERSHIFT TRANSMISSION CONTROL MODULE
Figure 5-2 NOTE: The Power shift Transmission Control Module (TCM) displays operational mode and test information for the operator. Reference 1 Display Screen Reference 2 Mode Button Reference 3 T Test Mode and Fault Indicator Lamp Reference 4 F Reset Mode Indicator Lamp between 2nd and 3rd gear NOTE: Under normal conditions the T lamp remains OFF. A blinking T lamp indicates a test failure and Sd is displayed on the display indicating to the operator to move the BHL to a safe location, Shut down, and call maintenance.
Figure 5-3, Power shift TCM Startup Display NOTE: At start up the F indicator and GA will illuminate momentarily as the power shift module goes through a brief self check. 5-3

NOTE: At power up the power shift transmission will always be in automatic mode. The operator may change to manual mode by pressing a kick down button while in neutral. AUTOMATIC MODE After the module has gone through the self test, the left side of the display will indicate the position of the Direction Control Lever. Figure 5-4 shows the N position of the Direction Control Lever. After moving the Direction Control Lever to forward the display shows the letter F, as shown in Figure 5-5, indicating the position is confirmed. The operator may now choose the transmission range to operate in by placing the Gear Selection Control Lever in position 1 through 4. In automatic transmission mode the BHL will reach the maximum gear selected by the Gear Selection Lever. Position 1 - no automatic shifting, transmission will remain in 1st gear Position 2 - no automatic shifting, transmission will remain in 2nd gear Position 3 - automatic shift Position 4 - automatic shifting between 2nd, 3rd and 4th gear CHANGE TO MANUAL SHIFT MODE To change to manual shift mode, press and release the mode button until the SL appears on the display screen, or Place the transmission in neutral and press the kick down button. After releasing the button the display shows the Neutral character and the position of the shift selector. In manual shift mode the left side of the display will indicate the position of the Direction Control Lever and the right side of the display will indicate Gear Selection Control Lever position 1 through 4. Figure 5-6 shows a typical manual shift mode display.
Figure 5-4
Figure 5-5
Figure 5-6
5-4

DISPLAY MODES To change the display mode, press the Mode button. While the button is held down, the display mode is indicated. After the button is released, the data is displayed. Four display modes are available.
Figure 5-7 This mode shows actually engaged direction and range. If either or both differ from the shift lever, the corresponding dot blinks. This example shows NEUTRAL 1st. (Figure 5-7)
Figure 5-8 This mode shows vehicle speed in km/h. For speeds below 10 km/h, speed is shown with 0.1 km/h resolution. The example shows 2.2 km/h. (Figure 5-8)
Figure 5-9 This mode shows vehicle speed in miles per hour. For speeds below 10 m.p.h. speed is shown with 0.1 m.p.h resolution. The example shows 2.2 m.p.h. (Figure 5-9) 5-5
Figure 5-10 This mode shows the current shift lever position. Only positions actually available on the transmission are shown. If different from the transmission, the corresponding dot blinks. IN CASE OF FAILURE When a failure in the Power shift electrical circuit is detected, the T indicator lamp flashes. Press and hold the M key until failure code is displayed which identifies the most serious problem which has been detected. Failure codes will be provided to field level maintenance personnel. If the transmission control module has an internal problem it will automatically switch itself to the safety mode and all gear changes are manual shift. Only first and second gears will be available. Move the BHL to a place of safety, lower the attachment to the ground and stop the engine. Find the cause of the problem or report it to the responsible maintenance personnel. Take measures required to prevent the use of the BHL. SYSTEM TEST MODES The transmission control module has seven different test modes: Turbine speed monitoring. Battery voltage monitoring. Input test. Output test. Transmission temperature monitoring. Analog output 0 monitoring. Analog output 1 monitoring. Consult TM 5-2420-231-10 NOTES _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ 5-6

DRIVING TIPS a. Get familiar with the BHL driving control functions before attempting to drive the BHL. Seat, seatbelt, window operation Brakes Foot and hand throttles Automatic and Manual transmission operation Transmission kick down switches Horn, driving lights, work lights, turn signals Oil pressure, engine temperature, etc indicators FEL controls Correct engine starting procedures Correct engine shutdown procedures b. Maneuvering the BHL Get a feel for the following: Visibility Constant observation situational awareness Keep bystanders away from driving area BHL physical characteristics length, width, height Steering capabilities turning radius use both hands for steering Moving forward from a dead stop stopping from forward motion Moving in reverse from a dead stop stopping from reverse motion Emergency stop from forward and reverse motion BHL speed in both forward and reverse motion. Forward and reverse gear selection Correct speed for smooth terrain and rough terrain BHL PARKING AND ENGINE SHUT DOWN PROCEDURES Before you leave the BHL, make sure the BHL is parked on a level surface. The BHL must be on level ground before you do scheduled maintenance. IMPORTANT: If you must temporarily park the BHL on a hillside, put the front of the BHL toward the bottom of the hill. Make sure the BHL is behind an object that will not move. a. Lower the FEL bucket to the ground. b. Apply the parking brake. c. Shift the direction control lever to NEUTRAL. d. Run the engine at idle speed for two minutes or more if the engine has been working at full load. This procedure will cool the engine parts evenly. NOTE: Turning the engine OFF at higher than idle RPM will damage the turbocharger.
5-7

e. Move the backhoe into the transport position or lower the backhoe bucket to the ground. f. Move the hand throttle to the IDLE position and stop the engine. g. Turn the key switch to OFF to stop the engine and remove the key.
WARNING: Jumping on or off the BHL can cause an injury. Always face the BHL, use the hand rails and steps, and get on or off the BHL slowly.
NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ 5-8
Chapter 6 Excavating with the Backhoe Loader

BHL FEL OPERATION The information presented here for FEL operation does not include all possible conditions. This is basic information that you need to operate the BHL. SAFETY If you are a new operator, always operate in a clear area at decreased engine speed. Fasten your seat belt before you start the engine. Be a careful operator. You can prevent accidents.
WARNING: When you lower a loaded bucket, material can spill out if you do not manually roll back the bucket. The self-leveling feature does not roll back the bucket automatically when the FEL is lowered. Other persons in the area can be injured if material spills from the bucket when the FEL is lowered. CLUTCH CUTOUT SWITCH Push the clutch cutout switch to allow the engine to increase speed and supply the FEL with more hydraulic oil for greater FEL power and faster control function. When you push the clutch cutout switch, the transmission is disengaged from the drive wheels. Release the clutch cutout switch to engage the transmission. The BHL can roll free when the clutch cutout switch is pushed. If required, use the brake to stop the BHL.
NOTES _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ 6-1

4-IN-1 BUCKET INDICATORS Refer to TM 5-2420-231-10, WP 0011, for more information about the bucket position and clam depth indicators.
Figure 6-1 BUCKET POSITION INDICATOR Reference 1 in Figure 6-1 indicates the bucket links location of the Bucket Position Indicator. It shows the correct bucket angle to use the bucket as a scraper, loader, dozer, or clam. Put the FEL bucket one foot above the ground and tilt the bucket to the desired position. CLAM DEPTH INDICATOR Reference 2 in Figure 6-1 indicates the location of the Clam Depth Indicator on the right side of the bucket. It is most often used when the bucket is in the scraper position. The bucket opening or depth of cut is shown on the clam depth indicator. The 4-In-1 bucket can make a cut up to four inches in depth. 4-IN-1 BUCKET OPERATION Figure 6-2 illustrates the 4-in-one buckets four modes of operation. Refer to TM 5-2420-231-10, WP0011 for complete FEL operation instructions. NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 6-2
DOZER SCRAPER
STANDARD BUCKET CLAMSHELL
Figure 6-2 SCRAPER Tilt the bucket to the scraper position on the indicator and open the clam to the desired depth of cut. STANDARD BUCKET Close the clam and the bucket is a standard bucket. DOZER Put the bucket in the position shown and open the clam completely. CLAMSHELL Put the bucket over the material to be moved. Close the clam on the material to be moved. RETURN TO DIG After you dump the load, use the return-to-dig function to put the bucket in position for another dig cycle. 6-3
Figure 6-3

The return-to-dig uses the FEL Control Lever FLOAT and ROLLBACK positions shown in Figure 6-3. To operate, put the lift arm control in the ROLLBACK position and the FLOAT position. The bucket will roll backward until the bottom of the bucket is level. The bucket stops automatically when it is correctly positioned. The FEL arms continue to lower, Figure 6-4, until (1) the bucket reaches the ground or (2) you manually pull the lift arm control back to HOLD (NEUTRAL).
BUCKET IN FLOAT POSITION
BUCKET IN ROLLBACK POSITION
Figure 6-4 JOB LAYOUT Set up the work cycle as short as possible. Truck positioning is very important for fast cycles. See Figure 6-5. Spend a few minutes leveling off the work area, if necessary. Smooth runways for the BHL and a level parking area for trucks will speed up the job.
WARNING: Operating a FEL with a full bucket on a hillside can cause the BHL to roll over. If possible, avoid turning the BHL and always move forward up the hill and back down. Always keep the load low. If you do not follow these instructions, you can be injured or killed.
Figure 6-5 6-4
WARNING: When you operate the BHL, keep the FEL bucket as low as possible. This low position gives better balance and permits you to see more clearly. If the bucket is full and you move the BHL over ground that is rough or surfaces that can cause the BHL to slide, always operate at slow speed. If you do not use this procedure the BHL can go out of control and roll-over. LIFTING WITH THE FEL If you lift a load with the FEL, be very careful. The BHL is NOT a crane.
IMPORTANT: Make sure that you use rigging equipment that has the capacity to lift the loads that you will be moving. Always attach the rigging equipment to the buckets lifting points shown in Figure 6-6, reference 1. Always check the rigging equipment each day for damaged or missing parts. Be sure no other persons are under the load as you move it.
Figure 6-6 FEL HYDRAULIC COUPLER The FEL hydraulic coupler, shown in Figure 6-7 allows the operator to change FEL attachments without the use of special tools or additional manpower.
REMOVING THE FEL BUCKET
Figure 6-7
WARNING: Exercise care when removing FEL bucket. Be sure FEL bucket is flat on ground and hydraulic pressure is released. Failure to comply may result in serious injury or death to personnel. a. Dump material from FEL bucket. b. Park the BHL on level ground. Lower FEL bucket flat on ground, and move backhoe into transport position. 6-5

c. Engage parking brake. d. Shift direction control lever to NEUTRAL position. e. Shut engine off. f. Toggle clamshell control pistol grip handle to release hydraulic pressure. g. Disconnect removable quick-disconnect hydraulic connector (Figure 6-8, Item 1) by rotating knurled barrel either direction 90 until notch (Figure 6-8, Item 3) in knurled barrel is aligned with pin (Figure 6-8, Item 4) on installed connector. Slide knurled barrel and pull off removable quick-disconnect hydraulic connector (Figure 6-8, Item 1) off. Repeat for second removable quick-disconnect hydraulic connector. h. Connect both removable quick-disconnect hydraulic connectors (Figure 6-8, Item 1) together. i. Place both removable quick-disconnect hydraulic connectors (Figure 6-8, Item 1) on top and forward of FEL bucket. j. Start engine k. Push and hold left side of FEL tool carrier switch (Figure 6-8, Item 5) to retract both tool carrier lock pins (Figure 6-8, Item 8).
Figure 6-8 6-6

l. Raise FEL bucket maximum 1 to 2 inches (25.4 to 50.8 mm) off ground and slowly rotate top of bucket outward until both tool carrier lock pins (Figure 6-8,Item 8) are clear of bucket mounting bores. m. Carefully lower FEL bucket to ground while rotating top of tool carrier outward. n. Back the BHL away from FEL bucket when both upper mounting pins (Figure 6-8 Item 7) are free from bucket upper mounting hooks (Figure 6-8 Item 6). INSTALLING THE FEL BUCKET
WARNING: Exercise care when installing FEL bucket. Always position yourself in front of bucket when connecting clamshell quick-disconnect hydraulic connectors. Failure to comply may result in serious injury or death to personnel. CAUTION: Both removable clamshells quick-disconnect hydraulic connectors must be placed on top and forward of FEL bucket. Failure to comply may result in damage to connectors. a. Place both removable quick-disconnect hydraulic connectors (Figure 6-8, Item 1) on top and forward of FEL bucket. b. From operator seat, start engine. c. Tilt FEL hydraulic quick coupler forward and engage both upper mounting pins (Figure 6-8, Item 7) in bucket upper mounting hooks (Figure 6-8, Item 6). d. Move the BHL forward several inches to make sure FEL bucket is fully engaged. e. Push and hold left side of FEL tool carrier switch (Figure 6-8, Item 5) to retract both tool carrier lock pins (Figure 6-8, Item 8). f. Raise FEL lift arms and rotate tool carrier rearward until both tool carrier lock pins (Figure 6-8, Item 8) are aligned with bucket lower mounting bores. g. Push and hold right side of FEL tool carrier switch (Figure 6-8, Item 5) to extend both tool carrier lock pins (Figure 6-8, Item 8) in bucket mounting bores. h. Visually confirm that FEL bucket is secured by both tool carrier pins (Figure 6-8, Item 8) and both mounting pins (Figure 6-8, Item 7). i. Lower FEL to ground. j. Shut engine off. k. Toggle clamshell control pistol grip handle to release hydraulic pressure. l. Remove caps from installed quick-disconnect hydraulic connectors (Figure 6-8, Items 1 and 2). m. Separate removable quick-disconnect hydraulic connectors (Figure 6-8, Items 1 and 2). BHL BACKHOE OPERATION The backhoe will dig more material in less time when a smooth, short dig cycle is used. Keep each dig cycle smooth.
6-7

When you force the bucket to dig a load that is too large, you will cause a hydraulic stall (dipper control lever pulled back and the bucket is not moving). The main relief valve of the hydraulic system will make a noise when hydraulic stall occurs. Hydraulic stall will cause: a. Longer cycle times. b. Increased hydraulic oil temperature c. Increased fuel consumption. Refer to TM 5-2420-231-10, WP0012 for complete BHL backhoe operation. PREPARATION FOR DIGGING WITH THE BACKHOE SAFETY
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WARNING: Always know the location of all workers in your area. Warn them before you start working the BHL. Always keep al other persons away from your area. Serious injury or death can result if you do not follow these instructions. WARNING: Uncontrolled BHL movement can injure. Before you turn the operators seat around to the BACKHOE operating position, shift the direction control lever and transmission control to NEUTRAL and apply the parking brake. GENERAL PREPARATIONS IMPORTANT: To avoid damage to the hood parts, always close the hood before moving the FEL. NOTE: Use hand rails and steps when getting onto BHL. Always use the three point contact rule when mounting or dismounting the BHL. a. Maneuver BHL to excavation site. b. Dump any material in FEL bucket and position BHL for digging. c. Engage the parking brake. d. Position the direction control lever to the NEUTRAL position. e. Stop engine. NOTE: Make sure the ride control switch is in the OFF position. CONFIGURE BACKHOE FOR DIGGING
! !
WARNING: Before each period of operation, check that each backhoe control functions correctly. A backhoe that operates correctly can prevent accidents. Failure to comply may result in serious injury or death to personnel. WARNING: Engage parking brake and shift direction control lever to neutral position before turning operator seat to backhoe position. Failure to comply may result in serious injury or death to personnel. 6-8
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WARNING: Do not dig ground under backhoe stabilizers. The Backhoe Loader (BHL) can fall into excavation if bank falls in. Failure to comply may result in serious injury or death to personnel. WARNING: When operating backhoe on hill, use stabilizers to level the BHL and put earth from trench on highest side of trench. Failure to comply may result in serious injury or death to personnel. WARNING: Avoid contact with high voltage overhead power lines, buried power lines, or buried cables. Keep all parts of the BHL at least 15 feet (4.6m) away from power sources. Failure to comply may result in serious injury or death to personnel. CAUTION: Exercise care when swinging backhoe completely to the side. In some positions, backhoe can contact stabilizers. Failure to comply may result in damage to stabilizers. POSITION THE FEL a. Ensure parking brake is engaged. b. Ensure shift direction control lever is in NEUTRAL position. c. Start engine and adjust engine speed. d. Using FEL controls, lower bucket to raise front wheels approximately 2 inches (5 cm) off ground. ADJUST SEAT, WINDOWS, AND PILOT CONTROLS a. Push bottom of ride control switch to off position (disengages ride control). b. Rotate seat to backhoe position. c. Adjust the windows before actuating the backhoe hydraulics. d. Adjust the pilot control towers forward or rearward for easy reach and comfort. e. Adjust the upper pilot control towers left or right for easy reach and comfort. POSITION STABILIZER PADS IMPORTANT: Always position the stabilizer pads for maximum stability when you are not operating the backhoe next to a wall, building, etc. IMPORTANT: Be careful when you swing the backhoe completely to the side. In some positions, the backhoe can contact the stabilizers and can cause damage. Position the rubber pads down when the BHL is positioned on hard finished surfaces such as concrete or asphalt. Position the dirt pads down when the BHL is positioned on most other surfaces such as dirt, sand, or rock. (Figure 6-9) a. Push top of pilot control switch to enable position. (enables pilot controls) b. Lower stabilizers to waist high. c. Push bottom of pilot control switch to off position. (disables pilot controls)
6-9

d. Shut engine off. e. If necessary, set flip over stabilizer pads as follows (Figure 6-9): 1. Remove safety pin (Figure 6-9, Item 1) and retaining pin (Figure 6-9, Item 2) on each stabilizer pad (Figure 6-9, Item 3). 2. Flip stabilizer pads (Figure 6-9, Item 3) and install retaining pins (Figure 6-9, Item 2) and safety pins (Figure 6-9, Item 1).
Figure 6-9 MOVE BOOM OUT OF TRANSPORT POSITION
WARNING: Rear windows can interfere with left and right backhoe control levers. Make sure window adjustments are locked into position before actuating backhoe hydraulics. Failure to comply may result in serious injury or death to personnel. a. Remove swing lock pin (Figure 6-10, Item 1) from transport position and place in storage position. b. Make sure the seat is locked into backhoe position and your seat belt is secure. c. Ensure parking brake is engaged. d. Ensure shift direction control lever is in NEUTRAL position. e. Start engine and adjust engine speed. NOTE: Make sure the ride control switch is in the OFF position. f. Push top of pilot control switch to enable position. (enables pilot controls) g. Lower stabilizers to ground; then, use stabilizers to raise rear wheels several inches above ground. h. Disengage parking brake.
6-10
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Figure 6-10 WARNING: Lower stabilizers to operating position before lowering backhoe boom and extending dipper. Front of the BHL can rise above ground and cause an accident. Failure to comply may result in serious injury or death to personnel. WARNING: Position stabilizer pads for maximum stability when not operating backhoe next to a wall, building, etc. Failure to comply may result in serious injury or death to personnel. WARNING: The BHL can become unstable and cause an accident if stabilizers are raised and tires and backhoe bucket are not touching ground. Before raising stabilizers from operating position, move backhoe into transport position and completely retract dipper and raise boom or make sure tires are touching ground and put backhoe bucket on ground. Failure to comply may result in serious injury or death to personnel. NOTE: Two backhoe control patterns are available. Pattern 1 allows boom and swing control with left backhoe control lever and dipper and bucket control with right backhoe control lever. Pattern 2 allows dipper and swing control with left backhoe control lever and boom and bucket control with right backhoe control lever. i. Elect desired control pattern (Figure 4-28 and 4-29) j. Push down on backhoe boom latch release and at same time push backhoe control lever (pattern 1 or pattern 2) forward to move boom forward to over center position. k. When backhoe boom reaches over center position, pull backhoe control lever rearward to continue boom movement forward. Return backhoe control to center position. l. Backhoe is now in operating position. ESTABLISH DANGER AREA Before you begin to dig you should extend the boom as far as possible and mark the outer extremity of the backhoe by swing the backhoe from one side to the other as shown in Figure 6-11. Mark the area with guard rails, construction cones or barrels, warning signs, or yellow danger tape. 6-11
WARNING: Before you operate the backhoe in an area where your visibility is reduced, such as next to a building, etc., always install a guard rail and warning signs to keep other persons away from your BHL.
Figure 6-11 DIGGING WITH THE BHL BACKHOE Fill the bucket by moving the dipper in. See Figure 6-12. Keep the bottom of the bucket parallel with the cut. Let the bucket teeth and cutting edge cut through the ground like a knife blade. The type of material that you dig determines the depth of the cut.
WARNING: A working backhoe can injure or kill. Before you start, always make sure that all persons are away from the DANGER AREA.
CORRECT
WRONG
WRONG
CORRECT TRENCHING METHOD
Figure 6-12
6-12

IMPORTANT: Do not back fill a trench with the backhoe by swinging the bucket against the soil. MOVING THE BHL FORWARD ON LEVEL GROUND You can use the backhoe to move the BHL forward as you trench. a. Make sure the front wheels of the BHL are STRAIGHT forward. b. Decrease the engine speed to 1200 rpm. c. Make sure the transmission controls are in NEUTRAL and release the parking brake. d. Raise the boom and retract the dipper. Move the boom as required positioning the bucket teeth on firm ground. Lower the backhoe bucket to the ground. e. Raise the stabilizers and FEL bucket about one foot above the ground. f. Use the boom and dipper to move the BHL. Slowly move the dipper out. At the same time, lower the boom. g. At the new position, lower the stabilizers and FEL bucket to the ground and level the BHL. h. Apply the parking brake. i. Increase the engine speed and continue digging. BHL OPERATION ON A HILL Before you work the BHL on a hill, always put the transmission in a lower gear and test your brakes. DO NOT let the BHL move down the hill with the transmission in NEUTRAL. DO NOT let the engine speed increase greater than 2500 rpm. Use caution if you must use the clutch cutout when you are digging with the FEL on a hill.
! ! ! ! ! !
WARNING: Hillside operations can be dangerous. Rain, mud, snow, ice, loose gravel, soft ground, etc., change the ground conditions. Exercise care and good judgment when operating on a hill or ramp. Failure to comply may result in serious injury or death to personnel. WARNING: Do not exceed published side slope or fore and aft slope conditions. Failure to comply may result in serious injury or death to personnel. WARNING: Make sure seat is in normal operating position and seat belt is fastened when moving BHL forward on a hill. Loss of control may result. Failure to comply may result in serious injury or death to personnel. WARNING: Before operating backhoe, always engage parking brake and shift direction control lever to neutral position. Failure to comply may result in serious injury or death to personnel. WARNING: Excessive speed can cause loss of BHL control. Do not coast in NEUTRAL. Failure to comply may result in serious injury or death to personnel.
WARNING: Do not move the BHL downhill when direction control lever is in neutral position Loss of control may result. Failure to comply may result in serious injury or death to personnel.
6-13
WARNING: Always check service brakes before work on a hill. Failure to comply may result in serious injury or death to personnel.
MOVING THE BHL FORWARD ON A HILL
WARNING: Be careful when you dig on the side of a hill. When you move the BHL forward, the BHL can go out of control and topple. You must be in the seat (seat in the FEL position) when you drive the BHL forward. Always engage the parking brake and shift the transmission and direction control to NEUTRAL before you operate the backhoe. a. Make sure the front wheels of the BHL are STRAIGHT forward. b. Decrease the engine speed to 1200 rpm. c. Make sure the transmission controls are in NEUTRAL and release the parking brake. d. Raise the boom and retract the dipper. e. Raise the stabilizers and FEL bucket about one foot above the ground. f. Position the seat to the FEL position. g. Carefully drive the BHL forward to the new position. h. Position the seat back to the backhoe position. i. Lower the stabilizers and FEL bucket to the ground and level the BHL raising the rear and front wheels off the ground. j. Apply the parking brake. k. Increase the engine speed and continue digging. CONFIGURING BACKHOE TO TRANSPORT POSITION CAUTION: Configure backhoe to transport position before using FEL or before moving the BHL on road or highway. Failure to comply may cause damage to backhoe. a. Use swing controls and position backhoe bucket straight behind the BHL. Make sure swing lock holes are aligned. b. Use hand throttle and set engine speed at approximately 1,200 rpm. c. Retract backhoe dipper and curl in bucket. NOTE: Two backhoe control patterns are available. Pattern 1 allows boom and swing control with left backhoe control lever and dipper and bucket control with right backhoe control lever. Pattern 2 allows dipper and swing control with left backhoe control lever and boom and bucket control with right backhoe control lever. d. Pull backhoe control lever (pattern 1 or pattern 2) rearward to move backhoe boom to rearward (toward operator). NOTE: Backhoe boom latch (Figure 6-13, Item 2) will automatically engage. e. When backhoe boom reaches over center position, push backhoe control lever forward so boom continues rearward to boom stop. Return backhoe control lever to center position. 6-14

f. Decrease engine speed to idle. g. Engage parking brake. h. Raise stabilizers. i. Push bottom of pilot control switch to off position. (Disables pilot controls)
WARNING: Rear windows can interfere with backhoe control levers. Make sure window adjustments are locked into position before actuating backhoe hydraulics. Failure to comply may result in serious injury or death to personnel j. Adjust rear windows. k. Install swing lock pin (Figure 6-13, Item 1). l. Backhoe is now in transport position. m. Rotate seat to driving position. n. Raise FEL about a foot above ground level. o. Maneuver BHL away from excavation site. p. Park BHL and shut down engine.
Figure 6-13 LIFTING WITH THE BHL BACKHOE IMPORTANT: Make sure that you use rigging equipment that has the capacity to lift the loads that you will be moving. Always check the rigging equipment each day for damaged or missing parts. Be sure no other persons are under the load as you move it. The backhoe is NOT a crane. For this reason, always be very careful when you lift a load with the backhoe. Refer to the backhoe lifting capacities in TM 5-2420-231-10, WP 0002, Table 5 and read the instructions below before you lift any load with the backhoe.
a. Know and understand each signal from the signalman before you start. b. Always know the location of all persons in your working area. c. Install a clevis hook, Figure 6-14 reference 1, in the lift eye, Figure 6-14 reference 2. d. Attach safety approved sling, cable or chain to the clevis hook. Figure 6-14,
WARNING: Do not use the hook end of the coupler shown in Figure 6-15 when lifting loads. The sling can come out of the coupler and the load can fall, injuring others in the area.
6-15

e. Lower both stabilizers and raise the BHL so that both rear tires are about 25 to 50 mm (one to two inches) above the ground. Make sure the BHL is level. NOTE: If the ground is soft, put a wide pad (wood boards) under each stabilizer pad. f. Dump and lower the FEL bucket to the ground. Figure 6-15 g. Connect a hand line to the load before you start. Make sure the person holding the hand line is away from the load. h. Test the lift capacity before you start your job: 1. Put the BHL close to the load. 2. Use a cable or sling to fasten the load to the end of the dipper at the lift eye. 3. Lift the load with the backhoe so the load is 25 to 50 mm (one or two inches) above the ground. 4. Swing the load all the way to one side. 5. Move the load away from the BHL. Make sure you keep the load 25 to 50 mm (one to two inches) above the ground. 6. Lower the load to the ground immediately if: (a) One of the stabilizers is raised above the ground. (b) There is any indication that the stability of the BHL is reduced. i. Always move the load slowly. Do not move the load over the top of persons. Keep all persons away from the load. Do not exceed the lift capacity for the BHL shown in the specifications section of the TM. j. When the load is raised, keep all persons away until the load is placed on blocks or is placed on the ground. BACKHOE BUCKET REMOVAL a. Park the BHL on a level surface, lower the stabilizers to the ground and level the BHL. Make sure all persons are away from the BHL.
b. Rotate the bucket out as shown in Figure 6-16 and put the bucket on the ground.
c. Push the top of the backhoe quick coupler rocker switches, Figure 6-17, to disengage/retract the backhoe quick coupler pins shown in Figure 6-18.
Figure 6-16,
6-16
Figure 6-17,
Figure 6-18,
NOTE: It is necessary to push both rocker switches at the same time to activate the Backhoe Quick Coupler. d. Hold down the top of the backhoe quick coupler rocker switches and extend the bucket cylinder to rotate the backhoe bucket quick coupler out of the bucket as shown in Figure 619.
WARNING: Do not use the boom to move the BHL unless a bucket is attached. Damage to the coupler may occur. BACKHOE BUCKET INSTALLATION a. Move the backhoe into position to pick up the bucket as shown in Figure 6-20.
Figure 6-19,
Figure 6-20,
b. Retract the bucket cylinder to engage the bucket into the quick coupler as shown Figure 6-21.
Figure 6-21
6-17

c. Push the top of the backhoe quick coupler rocker switches, Figure 6-22 to disengage/retract the backhoe quick coupler pins.
Figure 6-22, d. Hold down the top of the quick coupler rocker switches and lift the bucket to allow the bucket to rotate into the locking position as shown on the left half of Figure 6-23.
Figure 6-23 e. Push the bottom rocker switches to engage/extend the backhoe quick coupler pins as shown on the right half of Figure 6-23. NOTE: Visually check to make sure the quick coupler pins are fully extended into the bucket ears before operating the backhoe. NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 6-18

BHL BACKHOE AUXILIARY HYDRAULICS For attachments, read manufacturers instructions before attaching hydraulic lines. Reverse connection could cause damage to attachment or injury to personnel.
Figure 6-24 Three hydraulic lines are provided on backhoe dipper to attach auxiliary equipment. Two dual directional fittings (Figure 6-24, Items 2 and 3) are used with dual directional attachments. One single directional fitting (Figure 6-24, Item 1) is used with single directional attachment. BHL PREPARATION FOR COLD WEATHER OPERATION Cold weather conditions cause special problems. During these conditions, the BHL requires special attention to prevent serious damage. Cold weather maintenance will extend the service life of the BHL. BATTERY AND ELECTRICAL SYSTEM Clean the batteries and make sure the batteries are fully charged. NOTE: A fully charged battery at 0 F (-18 C) has only 40 percent of the normal starting power. Then, when the temperature decreases to -20 F (-29 C), the battery has only 18 percent of the power remaining. If you add water to the batteries and the temperature is below 32 F (0 C), make sure you charge the batteries or run the engine for approximately two hours. This procedure will prevent battery freezing. Inspect the battery cables and terminals. Clean the terminals and put a coat of grease on each terminal to prevent corrosion.
6-19

LUBRICANTS Use the correct viscosity oil in each component. As an example: SAE 30 engine oil at 32 F (0 C) increases the starting load by about 250 percent. Make sure you follow the recommended oil and filter service according to TM 5-2420-231-10. FUEL SYSTEM Make sure you are using the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters. Make sure to check for water in the fuel system. Cold temperatures can cause water to collect in the fuel tank. Check the main fuel filter for water every 50 hours of operation. If no water is found, extend the interval. If water is found, check the fuel tank. COOLING SYSTEM Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in the BHL. This mixture is used if the lowest ambient temperature is above 34 F (37 C). If the ambient temperature is lower, adjust the mixture to 60% ethylene glycol and 40% water. It is recommended that ethylene glycol and water be used in the BHL all year. BHL COLD WEATHER OPERATION
WARNING: The BHL is equipped with engine grid heater that will ignite flammable starting fluids. Do not use starting fluids. Fire and explosion may occur. Failure to comply may result in serious injury or death to personnel. CAUTION: If the BHL has not been operated for several weeks or engine oil filter has been replaced, prime turbocharger with oil (WP 0010). Failure to comply may result in damage to turbocharger. NOTE: Open throttle fully when starting cold engine at temperatures below 29F (1C). NOTE: If the operator does not crank engine within 30 seconds after engine grid heater indicator lamp extinguishes, the operator must perform the starting procedure again from the beginning. a. Engage parking brake. b. Make sure seat is in normal driving position. c. Adjust seat and fasten seat belt. d. Shift direction control lever to neutral position. e. Make sure engine hand throttle is in idle position. f. Set light control switch to STOP LIGHT position. g. Turn starter key switch to ON position and make sure the following instrument panel indicator and warning lamps illuminate: engine grid heater low engine oil pressure alternator air filter restriction hydraulic oil filter h. Wait for engine grid heater indicator lamp to extinguish. 6-20

CAUTION: If engine starts and stops, do not actuate starter motor again until starter motor stops turning. Failure to comply may result in damage to starter motor. CAUTION: Do not actuate starter motor more than 30 seconds at one time. Let starter motor cool for 2 minutes before actuating again. While starter motor is actuated, white or black smoke must be seen at exhaust pipe. If no smoke is seen, check fuel supply. Failure to comply may result in damage to starter motor. NOTE: If engine fails to start after two attempts, allow battery to recover for 4 to 5 minutes before repeating starting procedure (steps 7 thru 10 above). i. Turn starter key switch to START position for a maximum of 30 seconds and hold until engine starts. j. Release starter key switch. k. If engine does not start after maximum of 30 seconds of cranking, wait 2 minutes and repeat starting procedure (steps 7 thru 10 above). l. After engine starts, check instrument panel to make sure instrument readings are normal. m. Operate engine at 1,000 rpm until coolant temperature is warm (engine coolant temperature gage in green range) before moving the BHL. n. Actuate Front End Loader (FEL) or backhoe controls for approximately 10 minutes or until all cylinders work smoothly and hydraulic oil is at operating temperature. o. Before operation, move the BHL slowly in low gear. BHL HOT WEATHER OPERATION
! !
WARNING: Operating vehicle in hot weather increases risk of heat stress. Heat stress impairs performance. Drink lots of water. Work and rest in shade when possible. Use air conditioning. Failure to comply may result in serious injury or death to personnel.
WARNING: Prolonged exposure to bright sunlight produces very hot metal surfaces which will burn flesh on contact. 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. CAUTION: Mold, mildew, and fungus grow very quickly on glass, rubber, and leather surfaces in hot, humid weather. Keep all glass, rubber, and leather surfaces clean and dry in hot humid weather. Failure to comply may result in damage to these materials. CAUTION: Hot, dry weather usually creates a great deal of dust. Pay extra attention to filters and radiator. Make sure they do not become clogged. Lubrication may have to be performed more often. Failure to comply may result in damage to equipment. a. Keep coolant at correct level in coolant reservoir and radiator. b. Use correct solution of antifreeze and water in cooling system. c. Request field level maintenance test radiator cap before seasonal hot weather begins and replace as required. d. Clean dirt and debris from radiator and engine area 6-21

e. Check condition of alternator and air conditioning belts f. Use lubricants of correct viscosity. BHL SOFT AND MUDDY AREAS OPERATION CAUTION: Do not engage differential lock when the BHL is turning or when one rear wheel is rotating faster than the other rear wheel. Engage differential lock only when the BHL is moving in straight direction. Failure to comply may result in damage to rear axle. NOTE: You can engage the differential lock when the BHL is moving straight. a. Make sure that the BHL is moving straight ahead direction and that rear wheels are rotating at the same speed. b. Push down the differential lock switch. Keep this switch pushed down while the BHL moves through soft or muddy areas. c. Release the differential lock switch after the BHL has moved through the area, and keep engine speed below 2500 rpm. FORDING
! ! ! ! !
WARNING: Do not enter water at more than walking speed of 5 miles per hour (8 km/h) with an entrance or exit slope of more than 15 percent. Failure to comply may result in serious injury or death to personnel. WARNING: Do not enter water with current velocity of more than 5 miles per hour (8km/h). This is equivalent to 7 feet (2m) per second. Failure to comply may result in serious injury or death to personnel. WARNING: Do not enter water deeper than 20 inches (51 cm), including wave height (Figure 2). Failure to comply may result in serious injury or death to personnel. WARNING: Do not enter water that has ice or large debris on surface. Failure to comply may result in serious injury or death to personnel. WARNING: Check stream bottom for firmness and that there are no obstacles. Failure to comply may result in serious injury or death to personnel. a. Check both entry and exit slopes for maximum angles of 15 percent. b. Check that water velocity is no more than 5 miles per hour (8 km/h). This is equivalent to 7 feet (2m) per second. c. Check bottom of stream to make sure that it is firm enough to support the BHL and that it is free of underwater obstacles. d. Set 4WD switch to four-wheel drive (4WD) position. (Press the top of the 4WD switch to engage 4WD) e. Enter water at no more than 5 miles per hour (8 km/h) and maintain an even speed. 6-22

f. As soon as possible, open tool box, make sure it has drained properly, and dry off the tools with wiping rag. g. After fording, lubricate front and rear drive shaft slip splines. CAUTION: As soon as the BHL is on dry ground press the bottom of the 4WD switch to disengage 4WD. Failure to comply may cause extensive damage to 4WD function. NOTES _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ _____________________________________________________________________________________ 6-23
Appendix A Student Evaluation Sheets

PERFORMANCE EVALUATION Action: Preventive Maintenance Checks and Services (PMCS) Service Members Name: __________________________________ Class Number: ___________ Date: ____________ GO/NO GO: ______
Branch of Service: _________________
Evaluation Guidance: This test evaluates the service members ability to safely and effectively perform basic preventive maintenance checks and services in accordance with chapter 4 of the student guide. The evaluator will observe the service members performance of pre-operational checks, before PMCS, during PMCS, after PMCS starting procedures, stopping procedures and post-operational checks. The service member shall not ask for or be given any assistance from the evaluator or other service members. The service members performance shall be measured as a GO/NO GO score. If a NO GO is received on any portion of this test, the service member shall receive a written counseling and remediate for a minimum of one hour before being re-evaluated. The evaluator shall also observe the service member for any safety violations which could potentially cause death/injury to personnel and /or damage to equipment. Any safety violation observed shall constitute an automatic performance failure. CONDITIONS: At a training site, given a Backhoe Loader, TM 5-2420-231-10, a student guide, a grease gun, petroleum, oil, and lubricants (POL), rags, an equipment records folder, all personal protective equipment and the requirement to perform PMCS. STANDARDS: Performs operators PMCS on a Backhoe Loader utilizing TM 5-2420-231-10, annotates all deficiencies on a DA Form 5988-E or 2404, corrects all operator level deficiencies, turns in the completed maintenance form to the maintenance supervisor, performs all levels of PMCS without error and with no damage to equipment or injury to personnel. 1st NO GO 2nd NO GO
PERFORMANCE MEASURES
GO
GO
PRE-OPERATION PROCEDURES Did the student: 1. Perform a 360 walk around of equipment. 2. Perform before operations PMCS. 3. Perform pre-start procedures. 4. Perform starting procedures. 5. Configure loader to travel position. ____ ____ ____ ____ ____ ________ ________ ________ ________ ________ ____ ____ ____ ____ ____ ________ ________ ________ ________ ________
A-1

PERFORMANCE MEASURES GO 1st NO GO GO 2nd NO GO
6. Perform all operations within safety guidelines.
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________
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________
POST-OPERATION PROCEDURES Did the student: 1. Configure the bucket to parkline position. 2. Perform stopping procedures. 3. Perform after operations PMCS. 4. Perform all operations within safety guidelines.
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________ ________ ________
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________ ________ ________
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SAFETY Did the student: 1. Perform a 360 walk around before/after. 2. Use 3 points of contact mounting/dismounting. 3. Use hearing protection. 4. Use seat belt.
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________ ________ ________
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________ ________ ________
5. Perform all operations with no damage to equipment or injury to personnel. ____
________
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________
A-2

Evaluators Comments: ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Evaluator's Signature: ______________________________________________________________ Evaluator's Signature: ______________________________________________________________
A-3

PERFORMANCE EVALUATION Action: Maneuvering Operations Service Members Name: __________________________________ Class Number: ___________ Date: ____________ GO/NO GO: ______
Evaluation Guidance: This test evaluates the service members ability to safely and effectively perform basic clamshell operations in accordance with chapter 5 of the student guide. The evaluator will observe the service members performance of placement of a load and post-operational checks. The service member shall not ask for or be given any assistance from the evaluator or other service member. The service members performance shall be measured as a GO/NO GO score. If a NO GO is received on any portion of this test, the service member shall receive a written counseling and remediate for a minimum of one hour before being re-evaluated. The evaluator shall also observe the service member for any safety violations which could potentially cause death/injury to personnel and /or damage to equipment. Any safety violation observed shall constitute an automatic performance failure. CONDITIONS: At a training site, given a Backhoe Loader, all Personal Protective Equipment, a student guide, TM 5-2420-231-10, an equipment records folder and the requirement maneuver the Backhoe Loader. STANDARDS: Maneuver the Backhoe safely across various types of terrain, negotiate hills and low areas without getting stuck. Complete all procedures without error and with no damage to equipment or injury to personnel. 1st NO GO 2nd NO GO
GO
GO
MANEUVERING OPERATIONS Did the student: 1. Perform pre-operation procedures. 2. Maneuver through a pre-designated course. a. In wooded areas. b. On side slopes. c. In rocky areas. d. Through ditches. ____ ________ ____ ________
____ ____ ____ ____ ____
________ ________ ________ ________ ________ A-4
____ ____ ____ ____ ____
________ ________ ________ ________ ________

PERFORMANCE MEASURES e. Through gullies and ravines. e. Through streams. 3. Perform after operations procedures. GO ____ ____ ____ 1st NO GO ________ ________ ________ GO ____ ____ ____ 2nd NO GO ________ ________ ________
CONFIGURE BACKHOE TO TRAVEL POSITION Did the student: 1. Use swing controls and position backhoe bucket straight behind the BHL.
____
________ ____
________
2. Use hand throttle and set engine speed at approximately 1,200 rpm. ____ 3. Retract backhoe dipper and curl in bucket.
________ ____
________
____
________ ____
________
4. Pull backhoe control lever (pattern 1 or pattern 2)rearward to move backhoe boom to rearward. ____ 5. Move backhoe boom over center position, push backhoe control lever forward so boom continues rearward to boom stop. ____ 6. Decrease engine speed to idle. 7. Engage parking brake. 8. Raise stabilizers. 9. Push bottom of pilot control switch to off position. 10. Install swing lock pin. ____ ____ ____
________ ____
________
________ ____ ________ ____ ________ ____ ________ ____
________ ________ ________ ________
____ ____
________ ____ ________ ____
________ ________
A-5

SAFETY 1. Performed 360 walk around before/after. 2. Used 3 points of contact mounting/dismounting. 3. Utilized hearing protection. 4. Utilized seat belt. 5. Performed all operations with no damage to equipment or injury to personnel.
____
________ ____
________
____ ____ ____
________ ____ ________ ____ ________ ____
________ ________ ________
____
________ ____
________
Evaluators Comments: ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Evaluator's Signature: ______________________________________________________________ Evaluator's Signature: ______________________________________________________________
A-6

PERFORMANCE EVALUATION Action: Excavation Operations Service Members Name: __________________________________ Class Number: ___________ Date: ____________ GO/NO GO: ______
Evaluation Guidance: This test evaluates the service members ability to safely and effectively perform basic excavation operations in accordance with chapter 6 of the student guide. The evaluator will observe the service members performance of pre-operational checks, traveling with the scoop loader, excavation, stockpiling, backfilling and post-operational checks. The service members shall not ask for or be given an y assistance from the evaluator or other service members. The service members performance shall be measured as a GO/NO GO score. If a NO GO is received on any portion of this test, the service member shall receive a written counseling and remediate for a minimum of one hour before being re-evaluated. The evaluator shall also observe the service member for any safety violations which could potentially cause death/injury to personnel and /or damage to equipment. Any safety violation observed shall constitute an automatic performance failure. CONDITIONS: At a training site, given a Backhoe Loader, TM 5-2420-231-10, a student guide, an equipment records folder, all personal protective equipment, an excavation location and the requirement to excavate, stockpile and backfill. STANDARDS: Excavates one of the following excavations to the listed specifications; a trench approximately 15' long +/- 1', approximately 2 foot wide +/- 1' and approximately 2 foot deep +/- 1' using the extend and crowd method, a two Soldier fighting position approximately 6' long +/- 1', approximately 2 foot wide +/- 6", approximately arm pit deep to the tallest Soldier, places spoil in front and sides to form a parapet, a "L" and "T" fighting position approximately 6' long +/- 1', 2' wide+/- 6" and approximately arm pit deep to the tallest Soldier, places spoil on rear and sides to form a parapet. All excavations must maintain a straight line. Performs during operation PMCS, avoids contact with known underground hazards without error and without damage to equipment or injury to personnel within 40 minutes. 1st NO GO 2nd NO GO
GO
GO
PREPARE BHL FOR BACKHOE OPERATIONS Did the student: 1. Perform pre-operation procedures. 2. Park vehicle on level ground. 3. Engage parking brake and position direction control lever to NEUTRAL. 4. Adjust windows. ____ ____ ________ ________ ____ ____ ________ ________
____ ____
________ ________ A-7
____ ____
________ ________

5. Adjust position of left and right pilot control towers. 6. Dump any material in FEL bucket, lower to ground. 7. Lower FEL bucket until BHLs front wheels are approximately 2 inches above the ground. 8. Disengage ride control. 9. Enable pilot controls. 10. Use correct stabilizer pads for ground surface.
____
________
____
________
____
________
____
________
____ ____ ____
________ ________ ________
____ ____ ____
________ ________ ________
____
________
____
________
11. Lower BHL stabilizers to raise BHLs rear wheels off the ground and level the BHL. ____ 12. Move backhoe from transport position to digging position. ____ 13. Establish backhoe danger area. ____
________
____
________
________ ________
____ ____
________ ________
EXCAVATE USING THE BUCKET DIGGING TECHNIQUE Did the student: 1. Extend the boom and dipper to the starting point. 2. Adjust the bucket so that it is aligned with the dipper arm. 3. Put pressure on the boom to force the bucket teeth into the ground.
____
________
____
________
____
________
____
________
____
________
____
________
A-8

4. Roll the bucket toward the BHL until it is full raising the boom slightly if the bucket stalls. ____ 5. Raise the bucket high enough to clear the spoil pile, and dump the excavated material using a smooth operation.
________
____
________
____
________
____
________
6. Continue the bucket-digging technique until the required length and depth of the area is reached. ____ 7. Configure Backhoe to Transport Position. 8. Position the bucket to Dozer configuration. 9. Position the BHL at a 90 degree angle to the spoil.
________
____
________
____
________
____
________
____
________
____
________
____
________
____
________
10. Lower the bucket to about inch above the ground surface. ____ 11. Position the gear selection control to 1st gear.
________
____
________
____
________
____
________
12. Position the direction control lever to FORWARD and drive forward into the material and continue until material falls into trench/hole approximately half way across the trench. ____ 13. Raise the bucket approximately 18 inches from the ground. 14. Position the direction control lever to REVERSE and back the BHL to position it at approximately 1/2 the width of the bucket for next pass.
________
____
________
____
________
____
________
____
________
____
________
15. Repeat steps 5 through 7 as required to fill the trench/hole. ____
________ A-9
____
________

16. Using the 4-in-one bucket as a scraper or a dozer, level the work area by lowering the bucket to approximately 1/2 inch off the ground.
____
________
____
________
17. Feather the spoil out at the end of each pass. ____ 18. Use the 4-in-one bucket as a scraper to back drag the work area, while keeping pressure on the bucket and lifting slightly to feather. ____
________
____
________
________
____
________
MOVE BHL FORWARD DURING DIGGING OPERATIONS Did the student: 1. Ensure that BHL front wheels are facing in straight forward direction ____ 2. Decrease engine speed to 1200 rpm ____
________ ________
____ ____
________ ________
3. Ensure direction control lever is positioned to NEUTRAL and parking brake is disengaged. 4.
____
________
____
________
Raise boom, retract dipper, and move boom to position the backhoe bucket teeth on firm ground. Lower the backhoe bucket to the ground. ____ Raise the stabilizers and FEL bucket. Use pilot controls to slowly move the dipper out and lower the boom at the same time being careful not to raise the rear wheels off the ground. Move BHL forward to new position. ____
________ ________
____ ____
________ ________
5. 6.
____ ____
________ ________ A-10
____ ____
________ ________
7.

PERFORMANCE MEASURES 8. Lower the FEL bucket to raise front wheels off the ground. Lower stabilizers to raise rear wheels off the ground. GO 1st NO GO GO 2nd NO GO
____
________
____
________
9.
____
________
____
________
10. Disengaged parking brake and continue to excavate. ____
________ ____
________
EXCAVATE USING THE CROWD DIGGING TECHNIQUE Did the student: 1. Extend the boom and dipper to the starting point. 2. Roll the bucket until the cutting edge teeth are flat on the ground. 3. Use the pilot controls to move the bucket toward the BHL until it is half full.
____
________
____
________
____
________
____
________
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________
4. Use the pilot controls to roll the bucket and move the boom towards the BHL to completely fill the bucket. ____ 5. Raise the bucket high enough to clear the spoil pile and dump the excavated material in a smooth operation.
________
____
________
____
________
____
________
6. Continue the crowd-digging technique until the required length and depth of area is reached. ____ 7. Configure Backhoe to Transport Position. 8. Position the bucket to Dozer configuration.
________
____
________
____
________
____
________
____
________
____
________
A-11

PERFORMANCE MEASURES 9. Position the BHL at a 90 degree angle to the spoil. GO 1st NO GO GO 2nd NO GO
____
________
____
________
10. Lower the bucket to about inch above the ground surface. ____ 11. Position the gear selection control to 1st gear. ____ 12. Position the direction control lever to FORWARD and drive forward into the material and continue until material falls into trench/hole approximately half way across the trench. ____ 13. Raise the bucket approximately 18 inches from the ground. 14. Position the direction control lever to REVERSE and back the BHL to position it at approximately 1/2 the width of the bucket for next pass.
________
____
________
________
____
________
________
____
________
____
________
____
________
____
________
____
________
15. Repeat steps 5 through 7 as required to fill the trench/hole. ____ 16. Using the 4-in-one bucket as a scraper or a dozer, level the work area by lowering the bucket to approximately 1/2 inch off the ground.
________
____
________
____
________
____
________
17. Feather the spoil out at the end of each pass. ____ 18. Use the 4-in-one bucket as a scraper to back drag the work area, while keeping pressure on the bucket and lifting slightly to feather material. ____
________
____
________
________
____
________
A-12

INDIVIDUAL FIGHTING POSITIONS Note: Excavation procedures are the same for all fighting positions. The steps listed below are unique for the individual fighting positions. Did the student: 1. Perform pre-operations procedures. 2. Place material in front and on sides to form a parapet around the fighting position. 3. Repeat the digging cycle until ditch is 6 X 2 and armpit deep the tallest Soldier. 4. Perform after operations procedures. ____ ________ ____ ________
____
________
____
________
____ ____
________ ________
____ ____
________ ________
L STYLE MACHINE GUN FIGHTING POSITION Note: Excavation procedures are the same for all fighting positions. The steps listed below are unique for the individual fighting positions. Did the student: 1. Perform pre-operations procedures. ____ ________ ____ ________
2. Reposition the BHL at a 90 to the end of the individual fighting position. ____ 3. Construct a marking cut. 4. Dig a 4 X 2 extension. ____ ____
________ ________ ________
____ ____ ____
________ ________ ________
5. Place material on rear and sides to form a parapet around the fighting position. ____ 6. Perform after operations procedures. ____
________ ________
____ ____
________ ________
A-13

T STYLE MACHINE GUN FIGHTING POSITION Note: Excavation procedures are the same for all fighting positions. The steps listed below are unique for the individual fighting positions. Did the student: 1. Perform pre-operations procedures. 2. Reposition the BHL at a 90 to the center of individual fighting position. 3. Construct a marking cut. 4. Dig a 4 X 2 extension. ____ ________ ____ ________
____ ____ ____
________ ________ ________
____ ____ ____
________ ________ ________
5. Place material on rear and sides to form a parapet around the fighting position. ____ 6. Perform after operations procedures. ____
________ ____ ________ SAFETY ____
________ ________
Did the student: 1. Perform 360 walk around before/after. ____ 2. Use 3 points of contact mounting/dismounting. 3. Use hearing protection. 4. Use seat belt. ________ ____ ________
____ ____ ____
________ ________ ________
____ ____ ____
________ ________ ________
5. Perform all operations with no damage to equipment or injury to personnel. ____
________
____
________
Evaluators Comments: ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ Evaluator's Signature: ______________________________________________________________ Evaluator's Signature: ______________________________________________________________ A-14
Appendix B Fighting Positions (T) Style Machine Gun Position
2FT
4FT FIRING PLATFORM FIRING PLATFORM
2FT
6 FT
Note: Fighting position depth is armpit deep to the tallest Soldier plus or minus 6 inches.
B-1
Appendix B Fighting Positions (L) Style Machine Gun Position
2FT
4FT
FIRING PLATFORM
2FT
6FT
NOTE: Fighting position depth is armpit deep to the tallest Soldier plus or minus 6 inches.
B-2
Appendix B Fighting Positions Individual Fighting Position (Foxhole)
2 FT 6 FT
Note: Fighting position depth is armpit deep to the tallest Soldier plus or minus 6 inches.
NOTES ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________ ________________________________________________________________________________________
B-3
Appendix C Backhoe Loader Phase Training Schedule

Day 1 0800-0850 0850-0915 0915-0945 0945-1030 1030-1100 1100-1200 1200-1215 1215-1415 1415-1445 1445-1630 1630-1700 Introduction to the Backhoe Loader Equipment Walk Around Student Break PMCS/Starting/Stopping Procedures Manipulation of Controls Lunch Manipulation of Controls Maneuvering Operations Student Break Maneuvering Operations After Operations PMCS Day 2 0800-0830 0830-0930 0930-1000 1000-1100 1100-1200 1200-1400 1400-1430 1430-1630 1630-1700 Before Operators PMCS Excavation Operations Student Break Excavation Operations Lunch Excavation Operations Student Break Excavation Operations After Operations PMCS Day 3 0800-0830 0830-0930 0930-1000 1000-1100 1100-1200 1200-1400 1400-1430 1430-1630 1630-1700 Before Operators PMCS Excavation Operations Student Break Excavation Operations Lunch Excavation Operations Student Break Excavation Operations After Operations PMCS
C-1
Appendix B Fighting Positions

Day 4 0800-0830 0830-0930 0930-1000 1000-1100 1100-1200 1200-1400 1400-1430 1430-1630 1630-1700 Before Operators PMCS Excavation Operations Student Break Excavation Operations Lunch Excavation Operations Student Break Excavation Operations After Operations PMCS Day 5 0800-0830 0830-0930 0930-1000 1000-1100 1100-1200 1200-1215 1215-1330 1330-1400 1400-1700 Before Operators PMCS Excavation Operations Student Break Excavation Operations Evaluation Lunch Excavation Operations Evaluation Written Examination Student Break Equipment Maintenance
B-2
Appendix D Required Study

Day 1 Day 2 Day 3 Day 4 Day 5 Review chapters 1 through 3 and read chapter 4. Review chapter 4 and read chapter 5. Review chapter 5 and read chapter 6 Review chapter 6. Review chapters 1 through 6.
D-1
Appendix E Abbreviations and Acronyms

Abbreviation/Acronym Definition/Description @ - At # - Number 1st - First 2nd - Second 2WD - Two-wheel Drive 3rd - Third 4th - Fourth 4WD - Four-wheel Drive AAL - Additional Authorization List ACC - Accessory AEPS - Army Electronic Support AR - Army Regulation BHL - Backhoe Loader BII - Basic Issue Items BT - Bottle BX - Box CAGEC - Commercial and Government Entity Code CBR - Chemical, Biological, and Radiological CCW - Counterclockwise CN - Carton COEI - Components of End Item E-1
CPC - Corrosion Prevention and Control CTA - Common Table of Allowances CW - Clockwise D - During DR - Drum EA - Each EIC - End Item Code EIR - Equipment Improvement Recommendations F - Follows FEL - Front End Loader FOPS - Falling Object Protective Structure GAA - Grease, Automotive and Artillery GL - Gallon IDN - Initial Distribution Number ILLUS - Illustration JTA - Joint Table of Allowances MAC - Maintenance Allocation Chart MTOE - Modified Table of Organization and Equipment NATO - North Atlantic Treaty Organization NO. - Number NSN - National Stock Number PMCS - Preventive Maintenance Checks and Services E-2

PAM - Pamphlet PQDR - Product Quality Deficiency Report QTY - Quantity RECM - Recommended ROPS - Rollover Protection Structure RPSTL - Repair Parts and Special Tools Lists RQR - Required SAE - Society of Automotive Engineers SF - Standard Form TAMMS - The Army Maintenance Management System TAMMS A - The Army Maintenance Management System A TDA - Table of Distribution and Allowances TM - Technical Manual TOE - Table of Organization and Equipment U/I - Unit of Issue USEPA - U.S. Environmental Protection Agency W - Weekly WCA - Warranty Claim Action WP - Work Package
E-3

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STUDENT GUIDE

FOR BACKHOE LOADER CASE 580 SUPER M

d. Module B Dump Truck 21E10-B01 through B04 Dump Truck (TE1)

Weight Points 100

Weight Points 100

m. Module E Motorized Grader 21E10-E01 through E05 Motorized Grader (TE1)

JERRY C. MEYER COL, EN Director, DOTLD

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

1-8 Figure 1-3

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

Chapter 1 Introduction to the Backhoe Loader

1. Swing Lock Pin 2. Transport Lock

Chapter 1 Introduction to the Backhoe Loader

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

8. Swing Boom Right Left arm extended parallel to the ground.

9. Swing Boom Left Right arm extended parallel to the ground.

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 2 Hand and Arm Signals

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

Chapter 3 Safety Requirements

4. Ride control switch

5. Rear work lamp switch

14. Hydraulic oil filter warning lamp

15. Air filter restriction warning lamp

16. Engine grid heater indicator lamp

21. Engine hour meter

Figure 4-9 KEY/CONTROL/INDICATOR FUNCTION

23. Engine coolant temperature gage

24. Heater temperature control switch

4. Front End Loader (FEL) tool carrier switch

7. Flasher lamp switch

11. Driving lamp switch (lever)

12. Turn signal lever

Figure 4-13 KEY/CONTROL/INDICATOR FUNCTION

4. ALL OFF key

5. STOP LIGHT key

7. PANEL BRT. Key 8. PARK key

9. PANEL DIM key

Figure 4-19 LIFT ARM AND BUCKET CONTROL

C. RAISE. Moves the bucket up.