Attachment_0025__Backhoe_Loader_-_TM_5-2420-231-10.pdf

*TM 5-2420-231-10

TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

TRACTOR, WHEELED, INDUSTRIAL

BACKHOE LOADER (BHL)

NSN 2420-01-532-3399

*Supersedes TM 5-2420-231-10, 30 March 2007, including all changes.

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

FEBRUARY 2009

TM 5-2420-231-10

a

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous material icons used within the Technical Manual (TM). Most of the icons are non-standard, and are included because they appear on the safety decals on the equipment.

FIRST AID

For first aid, refer to FM 4-25.11.

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.

EXPLANATION OF STANDARD SAFETY WARNING ICONS

ELECTRICAL – Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.

HOT AREA – Hand over object radiating heat shows that part is hot and can burn.

EYE PROTECTION – Person with goggles shows that the material will injure the eyes.

HEAVY PARTS – Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.

HEAVY PARTS – Foot with heavy object on top shows that heavy parts can crush and harm.

b

WARNING SUMMARY - Continued

EXPLANATION OF BACKHOE LOADER (BHL) SPECIFIC SAFETY WARNING ICONS

FAN – Hand cut by fan shows that fan and other moving parts can cause injury.

TOPPLE – Vehicle falling over shows that vehicle can topple.

FEL – Human figure under Front End Loader (FEL) shows that bucket or other moving parts can cause serious injury or death.

CRUSH – Bucket falling on human figure shows that bucket or other heavy components can cause serious injury or death.

LATCHPIN – Falling bucket shows that if latchpin is not installed, bucket can cause serious injury or death.

HEAT STRESS – Heat fumes rising from human figure show that excessive heat can be dangerous.

EXPLOSION – Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition or high pressure.

PINCH – Fingers getting cut off shows that moving parts can cause injury.

c

WARNING SUMMARY - Continued

EXPLANATION OF BACKHOE LOADER (BHL) SPECIFIC SAFETY WARNING ICONS -

Continued

UNCONTROLLED MOVEMENT – Boom striking person shows that uncontrolled movement of boom or other moving components can cause serious injury or death.

PINCH – Fingers getting cut off shows that moving parts can cause injury.

ROLLOVER – Vehicle on top of human figure shows that vehicle rollover on hillside can cause serious injury or death.

RUNOVER – Vehicle on top of human figure shows an uncontrolled vehicle can cause serious injury or death.

SEAT BELT – Person with seat belt shows that operator must wear seat belt.

GENERAL SAFETY WARNINGS DESCRIPTION

Before Operating The BHL

WARNING

Adjust, secure, and latch seat and fasten seat belt before starting engine. Make sure that you can reach all controls, brakes, and necessary functions. Failure to comply may result in serious injury or death to personnel.

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.

d

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION

Before Operating The BHL - Continued

WARNING

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

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.

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.

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

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.

When operating off road it is recommended that speed be reduced to 7 mph (11 kph). Failure to comply may result in serious injury to personnel.

Operation of the vehicle over rough terrain for extended periods will result in excessive vibration. Take periodic rest breaks for ever two to three hours of continuous whole-body vibration exposure; do not lift objects immediately after prolonged whole-body vibration exposure; and leave the vehicle using simple egress motions.

Failure to comply may result in injury to personnel.

e

Operation Of The BHL

WARNING

Operate the BHL in accordance with the instructions in this manual. Failure to comply may result in serious injury or death to personnel. Before using the BHL, make certain that every operator does the following:

Is instructed in safe and proper use of the BHL.

Reads and understands manual(s) pertaining to the BHL.

Reads and understands all safety decals on the BHL.

Clears area of all other personnel.

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

f

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation Of The BHL - Continued

WARNING

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.

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.

Remove all loose objects stored in the BHL. Avoid loose fitting clothing or jewelry. Failure to comply may result in serious injury or death to personnel.

Observe all gages or 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.

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.

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.

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 a slide. 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.

Always know location of all other personnel in area. Warn them before operating the BHL. Always keep all other personnel away from area. Failure to comply may result in serious injury or death to personnel.

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.

Do not jump on or off the BHL. Always face the BHL, use hand rails and steps, and use three points of contact to get on or off the BHL. Failure to comply may result in serious injury or death to personnel.

g

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation Of The BHL - Continued

WARNING

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.

Do not use the BHL for any application or purpose other than those described in this TM. Failure to comply may result in serious injury or death to personnel.

Do not engage ride control switch with starter key switch turned to ON or ACC position. FEL lift arms can drop.

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

Always transport the BHL with transport pin in position to lock backhoe boom. Failure to comply may result in serious injury or death to personnel.

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.

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

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

If the BHL rolls over and seat belt is not fastened, you can be crushed by Rollover Protection Structure (ROPS) or the BHL. Failure to comply may result in serious injury or death to personnel.

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.

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.

h

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation Of The BHL - Continued

WARNING

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 ROPS if subjected to rollover or damage.

Do not attempt to repair. Failure to comply may result in serious injury or death to personnel.

WARNING

Operating the BHL in hot weather increases risk of heat stress. Heat stress impairs performance and can result in injury. 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.

Operation on Hill

WARNING

Hillside operations can be dangerous. Rain, mud, snow, ice, loose gravel, soft ground, etc., change ground conditions. Exercise care and use good judgment when operating the BHL on hill or ramp. Failure to comply may result in serious injury or death to personnel.

Before operating the BHL on hill, always shift gear selection control lever to lower gear and test service brakes.

Do not let the BHL move downhill with direction control lever in neutral position. Do not let engine speed increase greater than 2,500 rpm. Failure to comply may result in serious injury or death to personnel.

i

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation on Hill - Continued

WARNING

Exercise care when using clutch cutout switch while operating the BHL on hill. When clutch cutout switch is pushed, transmission is disengaged from drive wheels. Loss of control may result. Use service brakes to stop the BHL. Failure to comply may result in serious injury or death to personnel.

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

Be careful when moving the BHL on hill. The BHL can go out of control and turn over. Always position seat in loader position with seat belt fastened when driving the BHL forward. Always engage parking brake and shift direction control lever to neutral position before operating backhoe. Failure to comply may result in serious injury or death to personnel.

Operating the BHL with full FEL bucket on hill can cause the BHL to roll over. If possible, avoid turning the BHL. Always move forward up hill and always back down hill. Always keep load low for better balance and view of work area. Failure to comply may result in serious injury or death to personnel.

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.

Always check service brakes before working on hill. Failure to comply may result in serious injury or death to personnel.

Make sure seat is in normal operating position and seat belt is fastened when moving BHL forward on hill. Loss of control may result. Failure to comply may result in serious injury or death to personnel.

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

Do not exceed front, aft, or side slopes in excess of 15% on hard firm ground. On ground which is not solid, maximum slopes are less than 15%. Failure to comply may result in serious injury or death to personnel.

j

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation of Backhoe

WARNING

A working backhoe can cause serious injury or death. Before starting, always make sure that all other personnel are away from the backhoe. Failure to comply may result in serious injury or death to personnel.

Before each period of operation, check that each backhoe control functions correctly. Failure to comply may result in serious injury or death to personnel.

Do not dig ground under backhoe stabilizers. The BHL can fall into excavation if bank falls in. Failure to comply may result in serious injury or death to personnel.

Before operating backhoe in area where visibility is reduced, such as next to a building, always install guard rail and warning signs to keep all other personnel away from the BHL. Failure to comply may result in serious injury or death to personnel.

Engage parking brake and shift direction control lever to neutral position before turning seat around to backhoe operating position. Alarm will sound if direction control lever is in forward or reverse position. Failure to comply may result in serious injury or death to personnel.

Lower stabilizers to operating position before lowering backhoe boom and extending dipper. Front of the BHL can raise above ground and cause an accident. Failure to comply may result in serious injury or death to personnel.

When operating backhoe, use hand throttle to control engine speed. DO NOT USE HAND THROTTLE AS CRUISE CONTROL. You can have an accident if you use hand throttle for any other operation. Failure to comply may result in serious injury or death to personnel.

The BHL is equipped with two backhoe control function patterns. Check control functions before operating the BHL. Failure to check pattern before operating may result in unexpected boom movement. Failure to comply may result in serious injury or death to personnel.

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.

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.

k

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Operation of Backhoe - Continued

WARNING

Rear windows can interfere with backhoe control levers. Make sure window adjustments are locked into position before actuating backhoe hydraulics. Accidental actuation could cause unexpected movement of backhoe.

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

De-activate backhoe control system before adjusting windows. Accidental actuation could cause unexpected movement of backhoe. Failure to comply may result in serious injury or death to personnel.

Operation of FEL

WARNING

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.

Exercise care when removing FEL bucket. Always position yourself in front of bucket when disconnecting clamshell quick-disconnect hydraulic connectors. Failure to comply may result in serious injury or death to personnel.

Towing The BHL

WARNING

Tow a disabled BHL in accordance with the instructions in this manual. Failure to comply may result in serious injury or death to personnel.

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.

l

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Towing The BHL - Continued

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.

Towing vehicle must have a towing pintle for maximum stability while towing. Failure to comply may result in serious injury or death to personnel.

Tow straps provided in BII are not intended for BHL recovery. Failure to comply may result in serious injury or death to personnel.

Inspect tow straps for broken or missing parts, chafing, or wear before attaching. Check wear identification strips on straps. Failure to comply may result in serious injury or death to personnel.

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.

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.

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.

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.

Tow 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.

m

WARNING SUMMARY - Continued

Lifting With The BHL

WARNING

Make sure person holding handline is away from load. Failure to comply may result in serious injury or death to personnel.

Do not move load over top of personnel. Keep all other personnel away from load. Failure to comply may result in serious injury or death to personnel.

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.

Exercise care when lifting 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 under load. Failure to comply may result in serious injury or death to personnel.

Exercise care when lifting load using the backhoe. Do not exceed lifting capacity limits (WP 0002, Table 5). Make sure rigging equipment has capacity to lift load and that no personnel are under load. Failure to comply may result in serious injury or death to personnel.

Fording

WARNING

Do not enter water at more than walking speed of 5 miles per hour (8 km/h) with an entrance or side slope of more than 15 percent. Failure to comply may result in serious injury or death to personnel.

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.

Do not enter water deeper than 20 inches (51 cm), including wave height. Failure to comply may result in serious injury or death to personnel.

Do not enter water that has ice or large debris on surface. Failure to comply may result in serious injury or death to personnel.

Check stream bottom for firmness and that there are no obstacles. Failure to comply may result in serious injury or death to personnel.

n

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Parking The BHL

WARNING

Park the BHL on level ground whenever possible and engage parking brake. If the BHL must be parked temporarily on hill, put front of the BHL toward bottom of 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.

Before leaving cab, engage parking brake, shift direction control lever to neutral position, lower FEL/backhoe bucket to ground or put in locked position, and shut engine off. Failure to comply may result in serious injury or death to personnel.

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.

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

WARNING

Avoid high voltage power lines, underground cables, etc. Failure to comply may result in serious injury or death to personnel.

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

Warn all other personnel to stay away from the BHL.

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

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

o

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Electrical-Batteries

WARNING

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.

NATO slave receptacle is electrically live at all times and is unfused. NATO slave receptacle is only dead when batteries are fully disconnected. Batteries must be disconnected before performing maintenance on NATO slave receptacle. Failure to comply may result in damage to equipment and serious injury or death to personnel.

Metal jewelry can conduct electricity. Remove metal jewelry when near batteries. Failure to comply may result in serious injury or death to personnel.

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.

Tires

WARNING

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 overinflate. Tires and rim parts can explode. Failure to comply may result in serious injury or death to personnel.

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.

p

WARNING SUMMARY - Continued

GENERAL SAFETY WARNINGS DESCRIPTION - Continued

Servicing

WARNING

Before servicing the BHL, put DO NOT OPERATE tag on starter key switch. Failure to comply may result in serious injury or death to personnel.

When servicing the BHL with FEL raised, always use lift arms safety support strut to lock FEL. Failure to comply may result in serious injury or death to personnel.

When FEL lift arms safety support strut is engaged, 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.

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

WARNING

Keep clear of rotating fan and belts. 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.

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.

q

WARNING SUMMARY - Continued

EXPLANATION OF STANDARD HAZARDOUS MATERIALS ICONS

EYE PROTECTION – Person with goggles shows that the material will injure the eyes.

CHEMICAL – Drops of liquid on hand shows that material will cause burns or irritation to human skin or tissue.

VAPOR – Human figure in a cloud shows that material vapors present a danger to life or health.

FIRE – Flames show that a material may ignite and cause burns.

EXPLANATION OF BHL SPECIFIC HAZARDOUS MATERIALS ICONS

BATTERY – Human figure over exploding battery shows that storage batteries can be dangerous.

HIGH PRESSURE – Hand punctured by liquid shows that high pressure liquids can cause injury.

STEAM – Steam escaping shows that steam or other hot liquids can scald.

r

WARNING SUMMARY - Continued

EXPLANATION OF BHL SPECIFIC HAZARDOUS MATERIALS ICONS - Continued

PRESSURE – Hand next to pressure vessel shows that high pressure can cause injury.

EXPLOSION – Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition or high pressure.

HAZARDOUS MATERIALS DESCRIPTION

Exhaust

WARNING

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

DO NOT operate engine indoors unless you have SUFFICIENT FRESH AIR VENTILATION.

DO NOT idle engine for a long time unless there is SUFFICIENT FRESH AIR VENTILATION.

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

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

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.

s

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

Exhaust - Continued

WARNING

Engine exhaust fumes contain deadly poisonous gases. Severe exposure may result in permanent brain damage or death to personnel.

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.

WARNING

The BHL is equipped with 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.

Coolant

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.

t

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

Batteries

WARNING

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.

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.

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.

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.

When battery electrolyte is frozen, battery can explode if you try to charge battery or if you try to slave start and operate engine. To prevent battery electrolyte from freezing, try to keep battery at full charge. Failure to comply may result in serious injury or death to personnel.

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.

u

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

Hydraulic Fluid

WARNING

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.

WARNING

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

WARNING

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 con-tact. 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.

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.

v

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

Fuel - Continued

WARNING

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.

Do not fill fuel tank completely to top. Allow room for expansion. Failure to comply may result in serious injury or death to personnel.

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.

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.

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

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.

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

Compressed Air

WARNING

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.

w/x blank

WARNING SUMMARY - Continued

HAZARDOUS MATERIALS DESCRIPTION - Continued

Filters

WARNING

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.

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.

Noise

When operating, the BHL engine produces a high noise level. Hearing protection is required when working near the operating engine. Failure to comply may result in injury to personnel.

x

A/B blank

LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes TM 5-2420-231-10 dated 30 March 2007, including all changes.

Zero in the “Change No.” column indicates an original page or work package.

Date of issue for original manual is:

Original ………. 27 February 2009

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 46 AND TOTAL

NUMBER OF WORK PACKAGES IS 29, CONSISTING OF THE FOLLOWING:

Page/WP Change No. No.

Page/WP Change No. No.

Front Cover a to x i to vi

Chapter 1 Title Page

WP 0001 ( 4 pgs)

WP 0002 (16 pgs)

WP 0003 ( 2 pgs)

Chapter 2 Title Page

WP 0004 ( 8 pgs)

WP 0005 ( 6 pgs)

WP 0006 ( 8 pgs)

WP 0007 ( 8 pgs)

WP 0008 ( 8 pgs)

WP 0009 (18 pgs)

WP 0010 (10 pgs)

WP 0011 (10 pgs)

WP 0012 (18 pgs)

WP 0013 (20 pgs)

WP 0014 ( 2 pgs)

WP 0015 (12 pgs)

WP 0016 ( 2 pgs)

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Back Cover i

HEADQUARTERS,

DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 27 FEBRUARY 2009

TECHNICAL MANUAL

OPERATOR’S MANUAL

FOR

TRACTOR, WHEELED, INDUSTRIAL

BACKHOE LOADER (BHL)

NSN 2420-01-532-3399

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP / TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

*Supersedes TM 5-2420-231-10, 30 March 2007, including all changes.

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

ii

TABLE OF CONTENTS

WP Sequence No.

Page No.

WARNING SUMMARY.............................................................................................................. a

HOW TO USE THIS MANUAL ................................................................................................. vi

CHAPTER 1 – GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY

OF OPERATION FOR BACKHOE LOADER (BHL)

General Information Equipment Description and Data

Table 1. Major Components ..............................................................................0002-2 Figure 1. Location of Major Components ...........................................................0002-3 Table 2. BHL Equipment Data...........................................................................0002-6 Figure 2. BHL Physical Dimensions .................................................................0002-10 Table 3. BHL Physical Dimensions .................................................................0002-11 Figure 3. Backhoe Physical Dimensions ..........................................................0002-12 Table 4. Backhoe Physical Dimensions ..........................................................0002-13 Figure 4. Backhoe Lifting Capacities................................................................0002-14 Table 5. Backhoe Lifting Capacities................................................................0002-15

Theory of Operation

CHAPTER 2 – OPERATOR INSTRUCTIONS FOR BACKHOE LOADER (BHL)

Description and Use of Controls and Indicators for Right Hand Instrument Panel Figure 1. Right Hand Instrument Panel Controls/Indicators...............................0004-2 Table 1. Right Hand Instrument Panel Controls/Indicators...............................0004-2 Description and Use of Controls and Indicators for Front and Left Rear Consoles Figure 1. Front Console Controls/Indicators.......................................................0005-2 Table 1. Front Console Controls/Indicators.......................................................0005-3 Figure 2. Left Rear Console Controls/Indicators ................................................0005-4 Table 2. Left Rear Console Controls/Indicators ................................................0005-5 Description and Use of Controls and Indicators for Front End Loader (FEL) Control Lever Figure 1. FEL Control Lever Controls/Indicators ................................................0006-2 Table 1. FEL Control Lever Controls/Indicators ................................................0006-3 Description and Use of Controls and Indicators for Left and Right Backhoe Control Towers Figure 1. Left Backhoe Control Tower Controls/Indicators ................................0007-2 Table 1. Left Backhoe Control Tower Controls/Indicators ................................0007-3 Figure 2. Right Backhoe Control Tower Controls/Indicators ..............................0007-4 Table 2. Right Backhoe Control Tower Controls/Indicators ..............................0007-5 Figure 3. Backhoe Control Levers Pattern 1 ......................................................0007-6 Table 3. Backhoe Control Levers Pattern 1 Controls/Indicators .......................0007-6 Figure 4. Backhoe Control Levers Pattern 2 ......................................................0007-7 Table 4. Backhoe Control Levers Pattern 2 Controls/Indicators .......................0007-7 Description and Use of Controls and Indicators for Transmission and Display Screen Figure 1. Transmission Controls/Indicators........................................................0008-2 Table 1. Transmission Controls/Indicators........................................................0008-2 Figure 2. Display Screen Controls/Indicators .....................................................0008-4 Table 2. Display Screen Controls/Indicators .....................................................0008-4 iii

TABLE OF CONTENTS - Continued WP Sequence No.

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CHAPTER 2 – OPERATOR INSTRUCTIONS FOR BACKHOE LOADER (BHL) - Continued Description and Use of Controls and Indicators for Miscellaneous Cab Items Figure 1. Foot Pedals Controls/Indicators ..........................................................0009-2 Table 1. Foot Pedals Controls/Indicators ..........................................................0009-3 Figure 2. Parking Brake Controls/Indicators.......................................................0009-4 Table 2. Parking Brake Controls/Indicators.......................................................0009-5 Figure 3. Seat Controls/Indicators ......................................................................0009-6 Table 3. Seat Controls/Indicators ......................................................................0009-7 Figure 4. Seat Belt Controls/Indicators...............................................................0009-8 Table 4. Seat Belt Controls/Indicators...............................................................0009-9 Figure 5. Cab Air Louvers Controls/Indicators .................................................0009-10 Table 5. Cab Air Louvers Controls/Indicators .................................................0009-11 Figure 6. Dome Lamp Controls/Indicators........................................................0009-12 Table 6. Dome Lamp Controls/Indicators........................................................0009-12 Figure 7. Cab Latches Controls/Indicators .......................................................0009-13 Table 7. Cab Latches Controls/Indicators .......................................................0009-13 Figure 8. Miscellaneous Cab Items Controls/Indicators...................................0009-14 Table 8. Miscellaneous Cab Items Controls/Indicators...................................0009-15 Figure 9. Light Control Switch Controls/Indicators ...........................................0009-16 Table 9. Light Control Switch Controls/Indicators ...........................................0009-17 Operation of Backhoe Loader (BHL) Under Usual Conditions Figure 1. Fuel Pump Solenoid Switch ................................................................0010-4 Figure 2. Operating on a Hill...............................................................................0010-8 Operation of Front End Loader (FEL) Under Usual Conditions Figure 1. Clutch Cutout Switch ...........................................................................0011-3 Figure 2. 4-in-1 FEL Bucket Indicators...............................................................0011-3 Figure 3. 4-in-1 FEL Bucket Operation...............................................................0011-4 Figure 4. FEL Lifting Points ................................................................................0011-5 Figure 5. FEL Bucket Removal/Installation ........................................................0011-7 Operation of Backhoe Under Usual Conditions Figure 1. Flipover Stabilizer Pads.......................................................................0012-4 Figure 2. Swing Lock Pin....................................................................................0012-5 Figure 3. Danger Area ........................................................................................0012-8 Figure 4. Backhoe Digging .................................................................................0012-9 Figure 5. Moving the BHL Using Backhoe .......................................................0012-10 Figure 6. Backhoe Boom Latch ........................................................................0012-11 Figure 7. Backhoe Lifting Eye...........................................................................0012-13 Figure 8. Backhoe Bucket, Boom, and Dipper .................................................0012-15 Figure 9. Backhoe Bucket Removal .................................................................0012-16 Figure 10. Backhoe Bucket Installation ..............................................................0012-18 Decals and Operation Instruction Plates Figure 1. Decals and Operation Instruction Plates.............................................0013-2 Operation of Auxiliary Equipment Figure 1. Backhoe Auxiliary Hydraulic Lines ......................................................0014-2 iv

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CHAPTER 2 – OPERATOR INSTRUCTIONS FOR BACKHOE LOADER (BHL) - Continued Operation Under Unusual Conditions Figure 1. Differential Lock Switch.......................................................................0015-5 Figure 2. Fording ................................................................................................0015-6 Figure 3. 4WD Switch.........................................................................................0015-7 Figure 4. NATO Slave Receptacle .....................................................................0015-9 Figure 5. Towing the BHL.................................................................................0015-12 Stowage and Decal/Data Plate Guide Figure 1. Data Plate Locations ...........................................................................0016-1 On-Vehicle Equipment Loading Plan Figure 1. Loading Plan Locations .......................................................................0017-2 Table 1. Loading Plan List.................................................................................0017-3

CHAPTER 3 – TROUBLESHOOTING PROCEDURES FOR BACKHOE LOADER (BHL)

Troubleshooting Index Troubleshooting Procedures Table 1. Troubleshooting Procedures ...............................................................0019-2

CHAPTER 4 – MAINTENANCE INSTRUCTIONS FOR BACKHOE LOADER (BHL)

Service Upon Receipt Preventive Maintenance Checks and Services (PMCS) Introduction Preventive Maintenance Checks and Services (PMCS), Including Lubrication Instructions Figure 1. PMCS Walkaround Diagram ...............................................................0022-1 Table 1. PMCS ..................................................................................................0022-2 Table 2. FEL Grease Fittings ..........................................................................0022-12 Figure 2. FEL Grease Fittings ..........................................................................0022-13 Table 3. Backhoe Grease Fittings...................................................................0022-14 Figure 3. Backhoe Grease Fittings...................................................................0022-15 Table 4. BHL Grease Fittings ..........................................................................0022-16 Figure 4. BHL Grease Fittings ..........................................................................0022-16 Servicing Figure 1. FEL Lift Arms Safety Support Strut Engagement/

Disengagement ...................................................................................0023-3 Figure 2. Engine Hood Raising/Closing .............................................................0023-4 Figure 3. Fuel Tank ............................................................................................0023-7 Table 1. Fuel Grade Selection Chart.................................................................0023-7 Figure 4. Sediment Check ..................................................................................0023-9 Figure 5. Hydraulic Tank ..................................................................................0023-10 Figure 6. Transmission Dipstick .......................................................................0023-11 Figure 7. Coolant Reservoir..............................................................................0023-13 Figure 8. Windshield Washer Reservoir ...........................................................0023-14 Figure 9. Parking Brake....................................................................................0023-15 Figure 10. Engine Oil Dipstick and Fill Cap........................................................0023-17 Table 2. Engine Oil Grade Selection Chart .....................................................0023-17 Figure 11. Cab Air Filter .....................................................................................0023-19 Figure 12. Fire Extinguisher ...............................................................................0023-20 Figure 13. Tire Pressure.....................................................................................0023-22 Figure 14. Fuse Replacement ............................................................................0023-23 Figure 15. FEL Bucket Teeth and Cutting Edges Measurement........................0023-27 v

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Page No.

Cleaning Preparation for Shipment and Storage

CHAPTER 5 – SUPPORTING INFORMATION FOR BACKHOE LOADER (BHL)

References Components of End Item (COEI) and Basic Issue Items (BII) Lists Table 1. Components of End Item List ..............................................................0027-2 Figure 1. Basic Issue Items ................................................................................0027-3 Table 2. Basic Issue Items List..........................................................................0027-4 Additional Authorization List (AAL) Table 1. Additional Authorization List ................................................................0028-2 Expendable and Durable Items List Table 1. Expendable and Durable Items List ....................................................0029-2

INDEX.............................................................................................................................. Index-1 vi

HOW TO USE THIS MANUAL

This manual contains operator instructions for the Industrial Wheeled…