SOW_-_Enclosure_1_-_LUBRICATION_ORDER_HYEX_250G.PDF

Card 1 of 31

LO 5-3805-302-13

HYDRAULIC EXCAVATOR (HYEX)

(250G LCR)

TYPE 1 WITH HYDRAULIC THUMB AND QUICK

LATCH NSN 3805-01-649-4676

References: TM 5-3805-302-10, TM 5-3805-302-23

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

GENERAL NOTICE: - Copy of this lubrication order will remain with the equipment at all times; instructions contained herin are mandatory.

HEADQUARTERS, DEPARTMENT OF THE ARMY

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 TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the US Army Tank-automotive and Armaments Command. The postal mail address is US Army Tank-automotive and Armaments Command, ATTN: AMSTA-LCL-IMP/TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000.48 The e-mail address is usarmy.detroit.tacom.mbx.ilsc-tech-pubs@mail.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

LUBRICATION ORDER

15 MARCH 2018

Card 2 of 31

Maintenance Levels. This Lubrication Order (LO) is for Field Maintenance. Within Field Maintenance, the lowest level of maintenance authorized to lubricate a point is indicated by either Operator/Crew (C) or Maintainer (F). Operator/Crew may lubricate points authorized for Intermediate Maintenance when authorized by the Field Maintenance Activity.

Cleaning. Clean grease fitting and grease gun tip before lubricating. Clean parts with degreasing solvent (MIL-PRF-680, Type III or equivalent). Dry before lubricating. After high-pressure washing, lubricate all fittings and oil can points outside and underneath the machine. Drain if water is found. For corrosion control, refer to

TM 5-3805-302-23.

Locators. Points indicated with dotted lines are lubricated on both sides of the machine. Reference to the appropriate localized view is given after most lubrication entries. Localized views begin on Card 12.

Hard-time Hours. Letter “H” is used to indicate hard-time hours and is the only abbreviation used to indicate time.

Oil Filters. Oil filters shall be serviced/cleaned/changed as applicable, when:

•They are known to be contaminated or clogged, or

•At prescribed hard-time intervals.

Oil Analysis Program. This Hydraulic Excavator (HYEX) (John Deere 250G LCR) Type 1 with Hydraulic Thumb and Quick Latch is not enrolled in the Army Oil Analysis Program. HARD-TIME INTERVALS APPLY.

Warranty. For equipment under manufacturer’s warranty, hard-time oil service intervals shall be followed. Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions, such as longer than usual operating hours, extended idling periods, or extreme dust.

Initial Break-in. For initial break-in, the following items must be changed after the first 250 hours of operation:

Engine oil and engine oil filter element (refer to Engine Assembly Service, TM 5-3805-302-23).

Lube Intervals. Lube intervals (on-condition or hard-time) and the related man-hour times are based on normal operation. The man-hour time specified is the time needed to do all the services prescribed for a particular interval.

Change the hard-time interval if lubricants are contaminated or if operating the equipment under adverse operating conditions, including longer-than-usual operation hours. Hard-time intervals must be applied during the warranty period. Intervals shown in this lubrication section are hourly. Notes are located in Cards 29 through 31. Lubricate swing bearing after fording operations.

Interval Hours Man-Hour

100 0.5

250 1.7

500 2.4

1000 4.9

2000 8.1

5000 9.9

Card 3 of 31

WARNING

• Degreasing solvent MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition.

• Solvent cleaning compound MIL-PRF-680 Type II and III may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Use respirator as needed.

• Accidental ingestion can cause irritation to the digestive tract and respiratory tract, and may cause lung and central nervous system damage. Can be fatal if swallowed. First aid for ingestion: Do not induce vomiting. Seek immediate medical attention.

• First aid for skin contact: Remove contaminated clothing. Wash skin thoroughly with soap and water. If symptoms persist, seek medical attention.

• First aid for eye contact: Flush with water for 15 minutes or until irritation subsides. If symptoms persist, seek medical attention.

• Inhalation of high/massive concentrations can cause coma or be fatal. First aid for inhalation: Move to fresh air. If not breathing, provide artificial respiration. If symptoms persist, seek medical attention.

• Keep away from open flames and other sources of ignition. Failure to comply may result in injury or death to personnel. The flash point for Type II solvent cleaning compound is 141 to 198°F (61 to 92°C) and Type III is 200 to 241°F (93 to 116°C). Fire extinguishers should be placed nearby when using solvent cleaning compound.

• Improper cleaning methods and use of unauthorized cleaning solvents may injure personnel and damage equipment.

• Cloths or rags saturated with solvent cleaning compound must be disposed of using authorized facilities procedures.

• Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury.

• Personnel hearing can be PERMANENTLY DAMAGED if exposed to constant high noise levels of 85 dB or greater. Wear approved hearing protection devices when working within 46 ft (14 m) of machine. Personnel exposed to high noise levels shall participate in a hearing conservation program in accordance with TB MED 501. Hearing loss occurs gradually, but becomes permanent over time.

• Position bucket on ground prior to performing lubrication procedures.

Card 4 of 31

KEY

LUBRICANTS CAPACITIES

EXPECTED TEMPERATURES

INTERVALS

(Hours of Normal

Operation)

Above +5°F

(Above -15°C)

Below +5°F

(Below -15°C)

OE/HDO

(MIL-PRF-2104)

LUBRICATING OIL,

Engine

26 qt (24.6 L)

OE/HDO-

15W/40

OEA

Fo r A rc tic o pe ra tio n re fe r t o

FM

-2

Engine Crankcase

OEA

(MIL-PRF-46167)

Oil, Engine, Arctic

See Note 6.

OE/HDO -10

or 15W40

(MIL-PRF-2104)

Hydraulic System 64.2 gal (243 L)

Grade 5 Grade 1 5000 See Note 5.

GO

(MIL-PRF-2105)

LUBRICATING OIL,

Gear, Multipurpose

GO-

80W/90

GO-75

Swing Motor Gearbox

9.6 qt (9.1 L) 1000

Travel Motor Gearbox

8.2 qt (7.8 L) each

See Note 2.

Pump Drive Gearbox

1.2 qt (1.1 L) 1000 See Note 7.

GAA

(MIL-PRF-10924)

GREASE,

Automotive and Artillery

GAA

ALL TEMPERATURES

Working Tool Pivot As Reqd 100

See Note 1.

Boom, Arm, Quick Latch, and Hydraulic Thumb

As Reqd 500 See Notes 1 and 4.

Swing Bearing As Reqd 500

See Note 3.

Swing Bearing Gear As Reqd 500

NOTES

1. LUBRICATION. During adverse weather or abnormal dusty conditions, lubrication may require daily servicing.

2. Check the travel gearboxes’ oil level while machine is on a level surface. Oil should be at the bottom of the check hole (GO).

3. Lubricate after fording operations (GAA).

4. Boom pivot, upper boom cylinders, and rear arm cylinder lube points are remotely located at base of boom mount to frame (GAA).

5. Drain hydraulic reservoir every 5000 hours. Change hydraulic oil filter and add oil (OE/HDO) to reservoir until oil level is between the ADD and FULL marks on the sight gauge. Operate hydraulic system and check oil level again.

6. Drain Interval is reduced to 1/2 of normal.

7. 15W40 engine oil may be used in pump drive gearbox.

Card 5 of 31

CHART A. ENGINE

EXPECTED TEMPERATURE

°F -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

°C -46 -40 -34 -29 -23 -18 -12 -7 -1 5 10 16 21 27 32 38 43 49

OE/HDO - 15W/40

OEA

LUBRICANTS: LUBRICATING OIL, ENGINE CE/HDO 15W/40 (MIL-PRF-2104)

OEA LUBRICATING OIL, ICE, ARCTIC (MIL-PRF-46167) *See Note 2

CHART B. HYDRAULIC RESERVOIR/HYDRAULIC PUMP GEARBOX/SWING GEARBOX

EXPECTED TEMPERATURE

°F -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

°C -46 -40 -34 -29 -23 -18 -12 -7 -1 5 10 16 21 27 32 38 43 49

OE/HDO - 15W/40

OEA

LUBRICANTS: LUBRICATING OIL, ENGINE OE/HDO 15W/40 (MIL-PRF-2104)

OEA LUBRICATING OIL, ICE, ARCTIC (MIL-PRF 46167) *See Notes 3, 4, and 9d

CHART C. TRAVEL MOTOR

EXPECTED TEMPERATURE

°F -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

°C -46 -40 -34 -29 -23 -18 -12 -7 -1 5 10 16 21 27 32 38 43 49

GO - 80W/90

GO - 75

LUBRICANTS: LUBRICATING OIL, GEAR, MULTIPURPOSE (MIL-PRF-2105)

*See Notes 5a and 5b

Card 6 of 31

LUBRICANT • INTERVAL

ARM LINKS

Lubricate. (C) (See Notes 1a and 1b and Views 1 and 2.)

(2 Points)

GAA 100 HRS

THUMB and THUMB CYLINDER PIVOT Lubricate. (C) (See Notes 1a and 1b and Views 3, 4, and 5.)

(3 Points)

GAA 100 HRS

BUCKET LINK and BUCKET CYLINDER Lubricate. (C) (See Notes 1a and 1b and Views 6, 7, and 8.)

(5 Points)

GAA 100 HRS

RADIATOR COOLANT

Check. (C) (See View 9.)

Drain and Flush. (F) (See View 9 and

TM 5-3805-302-23.)

Antifreeze

Antifreeze

250 HRS

2000 HRS

DOOR HINGES

Lubricate. (C) (See Note 1c and View 33.)

GAA 100 HRS

QUICK LATCH

Lubricate. (C) (See Note 1a and 1b and View 37.) (1 Point)

GAA 100 HRS

ARM PIVOT PIN

Lubricate. (C) (See Notes 1a and 1b and Views 11 and 12.)

GAA 500 HRS

THUMB CYLINDER PIVOT

Lubricate. (C) (See Notes 1a and 1b and View 13.)

GAA 500 HRS

ENGINE OIL and FILTER Change. (F) (See Note 2 and View 10.)

OE/HDO 500 HRS

SWING BEARING

Lubricate. (C) (See Notes 7c and 7d and Views 14 and 15.)

(2 Points)

GAA 500 HRS

Card 7 of 31

ARM CYLINDER PIVOT PIN

Lubricate. (C) (See Notes 1a and 1b and View 16.)

GAA 500 HRS

REMOTE LUBE POINTS

(Lower Boom, Upper Boom Cylinders, and Arm Cylinder) Lubricate. (C) (See Notes 1a and 1b and View 17.) (5 Points)

GAA 500 HRS

BUCKET CYLINDER PIVOT PIN

Lubricate. (C) (See Notes 1a and 1b and View 18.)

GAA 500 HRS

LOWER BOOM CYLINDERS PIVOT

Lubricate. (C) (See Notes 1a and 1b and View 19.)

(2 Points)

GAA 500 HRS

SWING GEARBOX

Check. (C) (See Notes 3a and 3b and View 20.)

Drain and Fill (F) (See View 20.)

OE/HDO

OE/HDO

250 HRS

1000 HRS

PUMP 1 AND 2 DRIVE

Check. (C) (See Note 4 and View 21.)

Drain and Fill (F) (See View 21.)

OE/HDO

OE/HDO

250 HRS

1000 HRS

SWING BEARING GEAR

Lubricate. (F) (See Notes 7a and 7b and View 22 and

TM 5-3805-302-23.)

GAA 500 HRS

TRAVEL MOTOR

Check. (C) (See Note 5 and

TM 5-3805-302-23

Travel Motor Gearbox Service.)

Drain and Fill. (F) (See Note 5 and

TM 5-3805-302-23

Travel Motor Gearbox Service.)

GO

GO

250 HRS

1000 HRS

Card 8 of 31

HYDRAULIC OIL FILTER

Change. (F) (See TM 5-3805-302-23 Hydraulic Oil Filter Replacement.)

Hydraulic Fluid

1000 HRS

PILOT OIL FILTER

Change. (F) (See TM 5-3805-302-23 Pilot Oil Filter Replacement.)

OE/HDO 1000 HRS

HYDRAULIC OIL RESERVOIR

Check. (C) (See Notes 8a and 8b.)

Drain and Fill (F) (See Note 8 and

TM 5-3805-302-23

Hydraulic Oil Reservoir Service.)

Hydraulic Fluid Hydraulic Fluid

250 HRS

5000 HRS

PRIMARY FUEL FILTER/

WATER SEPERATOR

Change. (F) (See Notes 6b and 6c and TM 5-3805-302-23 Primary Fuel Filter Replacement.)

FILTER 500 HRS

FINAL FUEL FILTER

Change. (F) (See Note 6b and

TM 5-3805-302-23

Final Fuel Filter Replacement.)

FILTER 500 HRS

FUEL LUBRICITY FILTER

Change. (F) (See Note 6b and

TM 5-3805-302-23

Fuel Lubricity Filter Replacement.)

FILTER 500 HRS

FUEL TANK DRAIN VALVE

Drain Sediment. (C) (See Note 6 and

TM 5-3805-302-10

Draining Water and Sediment From Fuel Tank.)

FUEL 250 HRS

Card 9 of 31

DEEP DIG

BUCKET CYLINDER

Lubricate. (F) (See Notes 1a and 1b and View 30.)

GAA 500 HRS

DEEP DIG

BUCKET CYLINDER PIVOT

Lubricate. (F) (See Notes 1a and 1b and View 31.)

GAA 100 HRS

DEEP DIG

BUCKET LINK

Lubricate. (F) (See Notes 1a and 1b and View 32.)

GAA 100 HRS

CRUSH-ALL

UPPER BEARINGS

Lubricate. (F) (See Notes 9a, 9b, and 9c and View 23.)

(2 Points)

GAA BEFORE

and

250 HRS

CRUSH-ALL

LOWER BEARINGS

Lubricate. (F) (See Notes 9a, 9b, and 9c and Views 24 and 25.) (2 Points)

GAA BEFORE

and

250 HRS

CRUSH-ALL

DOOR HINGE

Lubricate. (F) (See Notes 9a, 9b, and 9c and Views 26 and 27.) (2 Points)

GAA BEFORE

and

250 HRS

Card 10 of 31

IMPACT BREAKER

Lubricate. (F) (See Notes 9a, 9b, and 9c and View 28.)

GAA BEFORE

TOOL OPENING

Lubricate. (F) (See Note 9d and View 29.)

GAA A/R

BARRIER GRAPPLE

Service. (F) (See

TM 5-3805-302-23

Barrier Grapple Service.) (16 Points)

GAA ANNUAL

Card 11 of 31

Vegetation Removal Tool (VRT) Lubricate. (C) (See Note 9d, 9e 9f, and View 34.)

GAA DAILY

VRT

Lubricate. (F) (See Note 9e and View 35.)

GAA DAILY

VRT

Lubricate. (C) (See Note 9e and View 36.)

GAA DAILY

Card 12 of 31

LEFT ARM LINK

RIGHT ARM LINK

Card 13 of 31

LEFT THUMB PIVOT

RIGHT THUMB PIVOT

Card 14 of 31

LOWER THUMB CYLINDER

UPPER BUCKET LINK

Card 15 of 31

LOWER BUCKET LINK

BUCKET CYLINDER

Card 16 of 31

RADIATOR COOLANT SURGE TANK

ENGINE OIL AND FILTER

Card 17 of 31

LEFT ARM PIVOT

RIGHT ARM PIVOT

Card 18 of 31

UPPER THUMB CYLINDER

FRONT SWING BEARING

Card 19 of 31

REAR SWING BEARING

ARM CYLINDER PIVOT

Card 20 of 31

REMOTE LUBE POINTS

BUCKET CYLINDER PIVOT PIN

Card 21 of 31

LOWER BOOM CYLINDERS PIVOT

SWING GEARBOX

Card 22 of 31

PUMP 1 AND 2 DRIVE

SWING BEARING GEAR

Card 23 of 31

CRUSH-ALL UPPER BEARINGS

CRUSH-ALL LEFT LOWER BEARING

CRUSH-ALL RIGHT LOWER BEARING

Card 24 of 31

CRUSH-ALL LEFT DOOR HINGE

CRUSH-ALL RIGHT DOOR HINGE

Card 25 of 31

IMPACT BREAKER

TOOL OPENING

Card 26 of 31

DEEP DIG BUCKET CYLINDER

DEEP DIG BUCKET CYLINDER PIVOT

DEEP DIG BUCKET LINK

Card 27 of 31

CAB DOOR HINGE

VRT DRIVE BEARING

Card 28 of 31

VRT ROTOR BEARING (BELT SIDE)

VRT ROTOR BEARING (NON-BELT SIDE)

QUICK LATCH

Card 29 of 31

NOTES

1. THUMB, QUICK LATCH, BUCKET LINKS, REMOTE LUBE, BOOM, ARM, AND DOOR

HINGES.

a. Grease points until grease escapes from joints. Grease every 4 hours for the first 20 hours.

b. Grease points until grease escapes from joints. Grease every 10 hours for the first 30-100 hours.

c. Grease points until grease escapes from joints. Grease every 100 hours.

2. ENGINE.

a. Initial Service. Change engine oil and filter after the first 250 hours of operation. Then follow scheduled service intervals of 500 hours.

b. Crankcase. Check oil level with machine parked on level ground and the engine off and cool. Do not over fill crankcase (TM 5-3805-302-10).

c. Engine Oil Filter. After installing new filter, fill crankcase, operate engine for 5 minutes, and check filter for leaks. Shut off engine, check crankcase level, and fill to FULL mark (TM 5-3805-302-10).

3. SWING GEARBOX.

a. Check oil after machine has been shut down.

b. After changing oil, swing upper structure 360 degrees and shut machine off. Check and fill to top mark on dipstick (TM 5-3805-302-10).

4. HYDRAULIC PUMP 1 AND 2 DRIVE.

a. Check oil after machine has been shut down.

b. After changing oil, run engine and check for leaks. Shut engine off, check pump 1 and 2 drive, and fill to top mark on dipstick (TM 5-3805-302-10).

5. TRAVEL MOTOR GEARBOX.

a. Park machine so the LEVEL plug is at the 3-o'clock position.

b. Change gear oil every 1000 hours (TM 5-3805-302-23).

Card 30 of 31

6. FUEL SYSTEM.

a. Fuel Tank Sediment. Drain fuel tank sediment. Open valve and drain until clean fuel flows from valve

(TM 5-3805-302-10).

b. Fuel Filter/Water Separators (Primary and Final) and Lubricity Canister. Do not fill replacement filter or canister with fuel to prevent contamination from unfiltered fuel.

c. Primary Fuel/Water Separator. Clean sediment bowl during each filter change.

7. SWING BEARING GEAR AND SWING BEARING.

a. To check swing bearing gear, remove two screws, washers, cover, and gasket from upper structure.

b. Measure for a grease depth of 1/2-1 in. (13-25 mm) measured from the bottom of the ring gear. Grease must be free of contamination. Remove excess grease from top of ring gear.

c. Put eight pumps of grease in each swing bearing grease point. Start engine, swing upper structure 45 degrees, and shut machine off (TM 5-3805-302-10).

d. Repeat procedure c. three more times.

8. HYDRAULIC RESERVOIR.

a. Hydraulic Oil Check. Check oil level with machine parked on level ground. Position machine with arm cylinder fully retracted and bucket cylinder fully extended. Oil level must be between oil level gauge marks on window.

b. Hydraulic System Oil. If hydraulic system oil becomes contaminated, immediately change oil and filter.

c. Hydraulic Reservoir. Change hydraulic oil filter every 1000 hours and hydraulic system oil every 5000 hours. Remove plug and drain hydraulic reservoir (TM 5-3805-302-23).

d. Hydraulic Tank Strainer. Remove cover with suction strainer. Check to ensure that no holes, tears or damage to the suction strainer exist before refilling. Clean or replace as required (TM 5-3805-302-23).

Card 31 of 31

9. CRUSH-ALL, IMPACT BREAKER, AND VRT.

a. Lubricate impact breaker lube points daily prior to each use.

b. Lubricate impact breaker lube points monthly when not in use.

c. In extreme dusty conditions, lubricate impact breaker every hour when in operation.

d. Use table below and change intervals on the return filter and hydraulic fluid according to the amount of time the Crush-All, impact breaker, and compactor has been used.

10. VRT.

a. Lubricate with one pump of grease gun for every hour of operation.

b. To lube drive bearing, remove top cover (TM 5-3805-302-23).

Percentage of Hydraulic Attachment Operating Time

Hydraulic Return Filter Change Interval in Hours

Hydraulic Oil Change Interval in Hours

100 100 600

60 150 800

40 200 1000

20 300 1300

15 March 2018

By Order of the Secretary of the Army:

MARK A. MILLEY

General, United States Army

Chief of Staff

Official:

GERALD B. O’KEEFE

Administrative Assistant to the

Secretary of the Army

1803751

DISTRIBUTION:

Initially published in electronic media only. If at a later date this publication is printed, it will be distributed in accordance with the initial distribution number (IDN) 258145 requirements for

PIN 106967-000