John Deere 230LCR Operator's Manual

TECHNICAL MANUAL

TM 5-3805-280-10

OPERATOR’S MANU

AL

HYDRAULIC EXCAVATOR

JOHN DEERE

MODEL 230LCR

NSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILL

NSN 3805-01-463-0806

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

Reproduced by permi
All rights reserved.

ssion of Deere & Company, Moline, IL © 2000.

HEADQUARTERS, DEPARTMENT OF THE ARMY

15 FEBRUARY 2000

TM 5-3805-280-10

INSERT LATEST UPDATED PAGES. DESTROY SUPERSEDED DATA.

LIST OF EFFECTIVE PAGES

Note: The portion of text or illustration affected by the updates is indicated by a vertical line in the outer margins of
the page. Updates to wiring diagrams are indicated by shaded areas.

Dates of issue for original and updated pages are:

Original .. 0 .. 15 February 2000

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TM 5-3805-280-10

Technical Manual
No. 5-3805-280-10 HEADQUARTERS,

DEPARTMENT OF THE ARMY

Washington, DC,

OPERATOR’S MANUAL

HYDRAULIC EXCAVATOR

JOHN DEERE

MODEL 230LCR

NSN 3805-01-463-0804

AND

MODEL 230LCRD WITH ROCK DRILL

NSN 3805-01-463-0806

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

15 February 2000

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures,
please let us know. Submit your DA Form 2028-2 (Recommended Changes to Equipment Technical Publications),
through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is

http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST FORM”. The DA

Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on
SUBMIT. Using this form on the AEPS will enab le us to respond quicker to your comments and better manage the
DA Form 2028 program. You may also mail, fax or email your letter, DA Form 2028, or DA Form 2028-2 direct
to: Commander, U.S. Army Tank-aut omotive and Armaments Command, ATTN: AMSTA-LC-CI, Rock Island, IL
61299-7630. The email address is [e-mail]. The fax number is DSN 793-0726 or
Commercial [phone].

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

NOTE

As this operator manual is a commercial product supplemented to include Army specific
procedures, the manual may advise the operator to perform tasks that would normally not be
assigned to the operator level in a DATM. Always follow the limits established in the PMCS.
Also, references are made throughout the manual to see your authorized dealer or John Deere
dealer for repair or information. In those instances, notify your supervisor or next higher
maintenance level.

TABLE OF CONTENTS

Page

Introduction

Chapter 1 Safety and Safety Signs

John Deere Excavator Safety Features.......................................................................................1-1

Recognize Safety Information....................................................................................................1-2

Understand Signal Words...........................................................................................................1-2

Follow Safety Instructions .........................................................................................................1-2

Avoid Injury From: Loading Machine on a Trailer, Fastening Machine to

Trailer, and Unloading Machine From Trailer......................................................................1-3

i

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TABLE OF CONTENTS (Continued)

Page

Avoid Injury From Backover Accidents....................................................................................1-4

Avoid Injury From Rollaway Accidents....................................................................................1-5

Inspect Machine.........................................................................................................................1-5

Use Handholds and Steps ...........................................................................................................1-6

Use Seat Belt..............................................................................................................................1-6

Maintain Seat Belt......................................................................................................................1-7

Move and Operate Machine Safely............................................................................................1-7

Operate Only From Operator’s Seat...........................................................................................1-8

Secondary Exits..........................................................................................................................1-8

Operate Machine Safely.............................................................................................................1-8

Dig With Caution.......................................................................................................................1-9

Operate With Caution.................................................................................................................1-9

Avoid Tipping............................................................................................................................1-9

Avoid Power Lines.....................................................................................................................1-10

Drive Machine Safely.................................................................................................................1-10

Beware of Exhaust Fumes..........................................................................................................1-10

Park Machine Safely..................................................................................................................1-11

Keep Riders Off Machine ..........................................................................................................1-11

Operate Attachment Safely ........................................................................................................1-12

Handle Fluids Safely—Avoid Fires...........................................................................................1-12

Prepare for Emergencies............................................................................................................ 1-13

Handle Starting Fluid Safely......................................................................................................1-13

Clean Trash From Machine........................................................................................................1-14

Protect Against Flying Debris....................................................................................................1-14

Wear Protective Clothing...........................................................................................................1-14

Protect Against Noise.................................................................................................................1-15

Handle Chemical Products Safely..............................................................................................1-15

Warn Others of Service Work....................................................................................................1-16

Stay Clear of Moving Parts........................................................................................................1-16

Support Machine Properly .........................................................................................................1-17

Service Cooling System Safely.................................................................................................. 1-17

Practice Safe Maintenance.........................................................................................................1-18

Remove Paint Before Welding or Heating.................................................................................1-19

Avoid Heating Near Pressurized Fluid Lines.............................................................................1-19

Avoid High-Pressure Fluids.......................................................................................................1-20

Prevent Battery Explosions........................................................................................................1-20

Clean the Machine Regularly.....................................................................................................1-21

Store Attachments Safely...........................................................................................................1-21

Battery Terminals, Lifting Equipment, Dry Cleaning Solvent and Compressed Air.................1-22

Dispose of Waste Properly.........................................................................................................1-23

Drilling.......................................................................................................................................1-24

Rock Drill Maintenance.............................................................................................................1-24

Emergency Stops........................................................................................................................1-25

Safety Signs................................................................................................................................1-27

Chapter 2 Operator’s Station

Pedal, Levers and Panels............................................................................................................2-1

Right Front Panel and Right Console Panel............................................................................... 2-2

Monitor Panel.............................................................................................................................2-3

Engine Coolant Temperature Gauge..........................................................................................2-4

Warm-Up Indicator....................................................................................................................2-4

Fuel Gauge.................................................................................................................................2-4

H/P (High Power) Mode Indicator.............................................................................................2-4

E (Economy) Mode Indicator.....................................................................................................2-5

Auto-Idle Indicator.....................................................................................................................2-5

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TABLE OF CONTENTS (Continued)

Page

Hydraulic Oil Level Indicator....................................................................................................2-5

Hydraulic Oil Filter Restriction Indicator (Model 230LCRD)...................................................2-6

Fuel Level Indicator...................................................................................................................2-6

Air Filter Restriction Indicator...................................................................................................2-6

Engine Coolant Temperature Indicator......................................................................................2-7

Charge Air Temperature Indicator.............................................................................................2-7

Engine Oil Pressure Indicator.....................................................................................................2-8

Alternator Voltage Indicator......................................................................................................2-8

Engine Oil Level Indicator.........................................................................................................2-8

Coolant Level Indicator..............................................................................................................2-9

Switch Panel...............................................................................................................................2-10

Buzzer and Buzzer Stop Switch.................................................................................................2-11

Wiper Switch..............................................................................................................................2-11

Washer Switch............................................................................................................................2-12

Operating Lights Switch.............................................................................................................2-12

Operating Rear Lights Switch....................................................................................................2-13

Cab Light....................................................................................................................................2-13

Overload Alarm and Indicator....................................................................................................2-13

Key Switch.................................................................................................................................2-14

Engine RPM Dial.......................................................................................................................2-14

Power Boost Switch...................................................................................................................2-14

Horn...........................................................................................................................................2-15

Hour Meter.................................................................................................................................2-15

Cab Heater and Air Conditioner.................................................................................................2-16

Control Panel Switches..............................................................................................................2-17

Cab Heater Operation.................................................................................................................2-18

Air Conditioner Operation..........................................................................................................2-18

Defroster Operation....................................................................................................................2-19

Front Console.............................................................................................................................2-19

Operating the AM/FM Radio.....................................................................................................2-20

Setting the Clock........................................................................................................................2-20

Cab Door Release Lever.............................................................................................................2-21

Secondary Exit Tool...................................................................................................................2-21

Opening Upper Front (Secondary Exit) Window.......................................................................2-21

Closing Upper Front Window....................................................................................................2-22

Removing and Storing the Lower Front Window......................................................................2-23

Opening Side Windows..............................................................................................................2-23

Opening and Closing the Roof Exit Cover.................................................................................2-24

Removing and Storing Fire Extinguisher (Model 230LCR)......................................................2-24

Rock Drill Start—Stop Selection Control Box (Model 230LCRD)..........................................2-25

Compressor Remote Instrument Control Panel (Model 230LCRD)..........................................2-26

Removing and Storing Rifle.......................................................................................................2-26

J-Hooks......................................................................................................................................2-27

Toolbox Security Hasp...............................................................................................................2-27

Decontamination Kit Bracket.....................................................................................................2-28

Vandal Protection Panel Storage................................................................................................2-28

Adjusting the Seat......................................................................................................................2-29

Adjusting the Armrest................................................................................................................2-30

Seat Belt.....................................................................................................................................2-30

Operator’s Manual Compartment...............................................................................................2-30

Chapter 3 Break-In

Engine Break-In Oil...................................................................................................................3-1

Every 4 Hours.............................................................................................................................3-1

iii

Every 10 Hours or Daily ............................................................................................................3-2

After the First 50 Hours..............................................................................................................3-2

After the First 100 Hours............................................................................................................3-3

Chapter 4 Pre-Start Inspection

Inspect Machine Daily Before Starting......................................................................................4-1

Chapter 5 Operating the Engine

Check Instruments Before Starting............................................................................................5-1

Level Check................................................................................................................................5-1

Starting the Engine.....................................................................................................................5-2

Using Booster Batteries—24 Volt System................................................................................. 5-3

Slave Receptacle—24 Volt System............................................................................................5-4

Starting Fluid (Cold Weather Starting Aid) ...............................................................................5-5

Using the Arctic Starter ..............................................................................................................5-7

Starting the Arctic Starter...........................................................................................................5-8

Check Instruments After Starting...............................................................................................5-8

Warming the Machine................................................................................................................5-9

Cold Weather Warm-Up ............................................................................................................5-10

Stopping the Engine...................................................................................................................5-11

TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

Chapter 6 Driving the Machine

Steering the Machine Using Pedals....................................................................................6-1

Steering the Machine Using Levers ...........................................................................................6-3

Removing Propel Levers............................................................................................................6-5

Propel Speed Switch...................................................................................................................6-6

Travel Alarm and Travel Alarm Cancel Switch.........................................................................6-6

Parking the Machine...................................................................................................................6-7

Parking Machine During Freezing Weather...............................................................................6-8

Lock All Compartments.............................................................................................................6-8

Chapter 7 Operating the Machine

Control Levers............................................................................................................................7-1

Control Lever Pattern Conversion..............................................................................................7-3

Control Levers John Deere Pattern.............................................................................................7-5

Pilot Control Shut-Off Lever......................................................................................................7-6

Auto-Idle Switch........................................................................................................................7-7

Mode Selection Switch...............................................................................................................7-8

Power Boost Switch...................................................................................................................7-8

E (Economy) Mode....................................................................................................................7-9

H/P (High Power) Mode ............................................................................................................7-10

Standard Mode...........................................................................................................................7-10

Operating Tips............................................................................................................................7-11

Driving Machine ........................................................................................................................7-11

Driving on Slopes.......................................................................................................................7-12

Driving Down a Slope................................................................................................................7-12

Driving Up a Slope.....................................................................................................................7-12

Driving Up a Steep or Slippery Slope—Boom on Uphill End of Machine................................7-13

Driving Up a Steep or Slippery Slope—Boom on Downhill End of Machine...........................7-13

Moving Machine off an Embankment........................................................................................7-14

Leveling Machine.......................................................................................................................7-15

Using Quick-Disconnect Hitch...................................................................................................7-16

Two Way Hydraulic Thumb Foot Pedal (Model 230LCR)........................................................7-20

Using Hydraulic Thumb.............................................................................................................7-21

Using Bucket..............................................................................................................................7-23

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TM 5-3805-280-10

TABLE OF CONTENTS (Continued)

Page

Planning Spoil Piles ................................................................................................................... 7-25

Trenching ...................................................................................................................................7-25

Backfilling..................................................................................................................................7-27

Truck Loading............................................................................................................................7-28

Operating in Water and Mud......................................................................................................7-29

Clean Track Frame Area............................................................................................................ 7-29

Lifting.........................................................................................................................................7-30

Air Compressor - Operating Instructions...................................................................................7-32

Using Quick-Coupler Type Attachments...................................................................................7-37

Rock Drill Attachment (Model 230LCRD)................................................................................ 7-38

Install Rock Drill........................................................................................................................ 7-38

Remove Rock Drill.....................................................................................................................7-41

Operating the Rock Drill Attachment.........................................................................................7-43

Remote Control Operator’s Panel ..............................................................................................7-43

Rod Changer...............................................................................................................................7-45

Start Up ......................................................................................................................................7-49

Travelling...................................................................................................................................7-50

Drilling.......................................................................................................................................7-51

Shut Down..................................................................................................................................7-53

Lower Boom With Engine Stopped...........................................................................................7-54

Using Hydraulic Hand Tools Hose Reel....................................................................................7-55

Using Hydraulic Hand Tools Flow Rate Valve and Switch.......................................................7-55

Using Hand Held Air Tools........................................................................................................7-55

Chapter 8 Transporting

Loading Machine on a Trailer....................................................................................................8-1

Tiedowns....................................................................................................................................8-2

Fasten Machine to Trailer ..........................................................................................................8-3

Loading and Fastening Rock Drill on a Trailer..........................................................................8-6

Fasten Machine to Rail Car (Model 230LCR) ...........................................................................8-8

Fasten Machine and Rock Drill to Rail Car (Model 230LCRD)................................................8-10

Unloading Machine From Trailer...............................................................................................8-12

Towing Machine ........................................................................................................................8-13

Lifting the Machine....................................................................................................................8-14

Chapter 9 Fuels and Lubricants

Diesel Fuel .................................................................................................................................9-1

Lubricity of Diesel Fuels............................................................................................................9-1

Low Sulfur Diesel Fuel Conditioner..........................................................................................9-2

Diesel Fuel Storage ....................................................................................................................9-2

Fuel Tank ...................................................................................................................................9-3

Do Not Use Galvanized Containers ...........................................................................................9-3

Diesel Engine and Pump Gearbox Oils......................................................................................9-4

Hydraulic Oil..............................................................................................................................9-5

Swing Gearbox and Propel Gearbox Oils...................................................................................9-6

Track Roller, Front Idler, and Carrier Roller Oil .......................................................................9-6

Track Adjuster, Working Tool Pivot, Swing Bearing, and Swing Bearing Gear Grease...........9-7

Oil Filters ...................................................................................................................................9-7

Rock Drill Lubricants Specifications.........................................................................................9-8

Air Compressor Lubricants........................................................................................................9-10

Lubricant Storage.......................................................................................................................9-11

Alternative and Synthetic Lubricants.........................................................................................9-11

Mixing of Lubricants..................................................................................................................9-12

Factory/Initial Fill Lubricants ....................................................................................................9-12

v

TABLE OF CONTENTS (Continued)

Chapter 10 Periodic Maintenance—Excavator

Service Your Machine at Specified Intervals...........................................................................10-1

Check the Hour Meter Regularly .............................................................................................10-1

Use Correct Fuels and Lubricants............................................................................................10-1

Prepare Machine for Maintenance............................................................................................10-2

Open Access Doors for Service................................................................................................10-3

Open Hood for Service.............................................................................................................10-4

Chapter 11 Maintenance—As Required

Sampling Engine Oil (GRP NO. 0400)....................................................................................11-1

Sampling Hydraulic Oil (GRP NO. 3360) ...............................................................................11-2

Clean Fuel Tank Inlet Screen (GRP NO. 0560).......................................................................11-3

Drain Fuel Tank Sump (GRP NO. 0560).................................................................................11-3

Clean Radiator Air Inlet Screens (GRP NO. 0511) ..................................................................11-4

Drain Water Separator (GRP NO. 0560)..................................................................................11-4

Clean Air Cleaner Dust Unloader Valve (GRP NO. 0521)......................................................11-5

Check Track Sag (GRP NO. 0132)..........................................................................................11-5

Adjusting Track Sag (GRP NO. 0132).....................................................................................11-6

Windshield Washer Fluid Level...............................................................................................11-7

TM 5-3805-280-10

Page

Chapter 12 Maintenance—Every 10 Hours or Daily

Check Engine Oil Level (GRP NO. 0400)...............................................................................12-1

Check Recovery Tank Coolant Level (GRP NO. 0510)...........................................................12-2

Check Hydraulic Oil Level (GRP NO. 3360) ..........................................................................12-3

Chapter 13 Maintenance—Every 50 Hours

Grease Working Tool Pivots (GRP NO. 3302)........................................................................13-1

Chapter 14 Maintenance—Every 250 Hours

Check Swing Gearbox Oil Level (GRP NO. 4351)..................................................................14-1

Drain Hydraulic Tank Sump (GRP NO. 3364)........................................................................14-1

Check Pump Drive Gearbox Oil Level (GRP NO. 3361)........................................................14-2

Change Engine Oil and Replace Filter (GRP NO. 0407).........................................................14-3

Check Radiator Coolant Level.................................................................................................14-5

Check Battery Electrolyte Level and Terminals (GRP NO. 1671)...........................................14-6

Check Propel Gearbox Oil Level (GRP NO. 0250).................................................................14-8

Clean Dusty Primary Element (GRP NO. 0521)......................................................................14-9

Inspect Element (GRP NO. 0521)............................................................................................14-10

Chapter 15 Maintenance—Every 500 Hours

Grease Swing Bearing (GRP NO. 4353)..................................................................................15-1

Grease Swing Bearing Gear (GRP NO. 4353).........................................................................15-2

Replace Final Fuel Filter (GRP NO. 0420)..............................................................................15-3

Replace Primary Fuel Filter (Water Separator) (GRP NO. 0560)............................................15-4

Check Air Intake Hoses (GRP NO. 0521)................................................................................15-5

Replace Hydraulic Oil Filter (GRP NO. 3360) ........................................................................15-6

Add Coolant Conditioner to Radiator (GRP NO. 0510) ..........................................................15-8

Chapter 16 Maintenance—Every 1000 Hours

Change Swing Gearbox Oil (GRP NO. 4351)..........................................................................16-1

Change Pilot Control Oil Filter (GRP NO. 3362)....................................................................16-1

Change Pump Drive Gearbox Oil (GRP NO. 3360) ................................................................16-2

Clean the Engine Crankcase Ventilation Tube.........................................................................16-3

Check and Adjust Engine Valve Lash (Clearance)..................................................................16-3

Firing Order 6-Cylinder Engine...............................................................................................16-5

vi

TABLE OF CONTENTS (Continued)

Check Engine Speeds...............................................................................................................16-6

Engine Speed Learning Procedure...........................................................................................16-7

Change Air Cleaner Elements (GRP NO. 0521)......................................................................16-7

Inspect Fan Belt (GRP NO. 0429)............................................................................................16-8

Replace Air Cleaner Dust Valve (GRP NO. 0521)..................................................................16-8

Chapter 17 Maintenance—Every 2000 Hours

Drain Cooling System (GRP NO. 0510)..................................................................................17-1

Diesel Engine Coolant (GRP NO. 0510)..................................................................................17-2

Cooling System Fill and Deaeration Procedure (GRP NO. 0510) ...........................................17-3

Change Propel Gearbox Oil .....................................................................................................17-4

Change Hydraulic Oil...............................................................................................................17-5

Chapter 18 Maintenance—Air Compressor

General.....................................................................................................................................18-1

Scheduled Maintenance............................................................................................................18-1

Compressor Oil Maintenance...................................................................................................18-1

Air Cleaner...............................................................................................................................18-2

Gauges......................................................................................................................................18-3

Fuel Tank .................................................................................................................................18-3

Battery......................................................................................................................................18-3

Automatic Shutdown System...................................................................................................18-3

Compressor Oil Cooler.............................................................................................................18-4

Radiator....................................................................................................................................18-4

Hoses........................................................................................................................................18-4

Compressor Oil Filters.............................................................................................................18-5

Fasteners...................................................................................................................................18-6

Compressor Oil ........................................................................................................................18-6

Receiver-Separator Systems.....................................................................................................18-6

Scavenge Line..........................................................................................................................18-6

Cooling Fan Drive ....................................................................................................................18-6

Oil Separator Element..............................................................................................................18-7

Exterior Finish Care.................................................................................................................18-8

Lubrication...............................................................................................................................18-10

TM 5-3805-280-10

Page

Chapter 19 Maintenance—Rock Drill Attachment

First Oil Change.......................................................................................................................19-1

When Required.........................................................................................................................19-3

Adjustment of Drilling Automatisms.......................................................................................19-4

Replacing Rock Drill Dust Collector Filters ............................................................................19-8

Daily Maintenance Hydraulic Dust Collector..........................................................................19-9

Daily.........................................................................................................................................19-10

Every 50 Hours.........................................................................................................................19-10

Every 1000 Hours.....................................................................................................................19-11

Every 2000 Hours.....................................................................................................................19-11

Drifter Maintenance .................................................................................................................19-12

Chapter 20 Maintenance

Do Not Service Injection Nozzles............................................................................................20-1

Do Not Change Injection Pump ...............................................................................................20-1

Bleeding the Fuel System.........................................................................................................20-2

Precautions for Alternator and Regulator.................................................................................20-2

Service Batteries Carefully.......................................................................................................20-3

Checking Electrolyte Specific Gravity.....................................................................................20-5

Using Battery Charger..............................................................................................................20-6

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TABLE OF CONTENTS (Continued)

Page

Replacing Batteries (GRP NO. 1671)......................................................................................20-7

Removing Batteries (GRP NO. 1671)......................................................................................20-7

Welding on Machine................................................................................................................20-8

Adding 12-Volt Accessories ....................................................................................................20-9

Replacing Fuses........................................................................................................................20-9

Fuse (Blade-Type) Color Codes...............................................................................................20-11

Checking Travel Alarm System (GRP NO. 1671)...................................................................20-11

Replacing Bucket Teeth (GRP NO. 3302)...............................................................................20-12

Removing the Bucket (GRP NO. 3302)...................................................................................20-13

Replacing Bucket Tooth Tip—Heavy-Duty Bucket (GRP NO. 3302) ....................................20-14

Do Not Service Control Valves, Cylinders, Pumps or Motors.................................................20-14

Track Sag General Information................................................................................................20-15

Hardware Torque Specifications..............................................................................................20-15

Check Track Shoe Torque........................................................................................................20-16

Unified Inch Bolt and Cap Screw Torque Values....................................................................20-17

Metric Bolt and Cap Screw Torque Values..............................................................................20-18

Additional Metric Cap Screw Torque Values..........................................................................20-19

Check Oil Lines and Fittings....................................................................................................20-20

Service Recommendations for O-Ring Boss Fittings...............................................................20-21

Service Recommendations for Flat Face O-Ring Seal Fittings................................................20-23

Service Recommendations for 37° Flare and 30° Cone Seat Connectors................................20-24

Service Recommendations for Flared Connections—Straight or Tapered Threads.................20-25

Service Recommendations for Inch Series Four Bolt Flange Fittings......................................20-26

Service Recommendations for Metric Series Four Bolt Flange Fitting....................................20-28

Chapter 21 Operational Checkout

Operational Checkout...............................................................................................................21-1

Operator Station Checks—Key Switch On, Engine Off ..........................................................21-2

Operator Station Checks—Engine On......................................................................................21-4

Hydraulic System Checks ........................................................................................................21-8

Undercarriage Checks..............................................................................................................21-15

Hydraulic Thumb Check..........................................................................................................21-17

Quick-Disconnect Hitch Checks..............................................................................................21-17

Accessories Checks..................................................................................................................21-18

Air Conditioning Checks..........................................................................................................21-20

Seat, Doors, Windows, Latches, and Locks Checks.................................................................21-23

Coolant Checks ........................................................................................................................21-29

Chapter 22 Troubleshooting

Using Troubleshooting Charts..................................................................................................22-1

Engine ......................................................................................................................................22-2

Electrical System......................................................................................................................22-8

Hydraulic System.....................................................................................................................22-14

Chapter 23 Storage

Prepare Machine for Storage ....................................................................................................23-1

Quick-Disconnect Hitch Storage Procedure.............................................................................23-2

Monthly Storage Procedure......................................................................................................23-3

Chapter 24 Specifications

230LCR/LCRD........................................................................................................................24-1

230LCR/LCRD Working Ranges.............................................................................................24-3

230LCR/LCRD........................................................................................................................24-4

230LCR/LCRD Drain and Refill Capacities............................................................................24-5

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TABLE OF CONTENTS (Continued)

Page

230LCR/LCRD Lift Capacity—KG (LB)................................................................................24-6

Rock Drill Attachment - Technical Specifications...................................................................24-7

Air Compressor General Data..................................................................................................24-8

Appendix A Operator Preventive Maintenance Checks and Services (PMCS) .......................................A-1

Appendix B Components of End Item and Basic Issue Items List............................................................ B-1

Appendix C References.................................................................................................................................C-1

ix

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WARRANTY

1. General. This sectio n explains the contractor’s warranty for the Hydraulic Excavator (HYEX),

including all of its components and subassemblies. It also contains information, instructions, methods
and forms required to obtain services and/or supplies and for processing claims for items covered
under warranty for the HYEX. If additional warranty i nformation is required for the HYEX, contact
your local Warranty Control Office/Officer (WARCO) or TACOM-WRN Logistics Assistance
Representative (LAR). If your WARCO or TACOM LAR is not available, contact TACOM-WRN.
The numbers at TACOM to call are DSN 786-7215/[phone], DSN 786-7420/[phone],
or DSN 786-8297/[phone]. The caller should be prepared to provide: (1) name, (2) telephone
number and/or electronic address, (3) complete unit designation, (4) identification of the vehicle to
include serial number(s) and (5) a brief description of the problem.

2. Coverage Specific. The information and data contained in this Technical Manual applies to the U.S.

Army’s Hydraulic Excavator (HYEX), model number 230LCR, NSN 3805-01-463-0804 and model
number 230LCRD, NSN 3805-01-463-0806. The HYEX is manufactured by Deere & Company,
Moline, IL under contract number DAAE07-98-D-S009.

3. Claim Procedures. DA Form 2407, along with information and instructions provided by the

contractor at time of delivery of the HYEX, shall be used to process warranty claims.

4. Clai m Denial/Disputes. All denials or disputes will be handled by TACOM. The contact point for

warranty claim denials or disputes is:

Commander
U.S. Army T ank-Automo t i ve and Armaments Command
ATTN: AMSTA-LC-CJBB
Warren, MI 48397-5000

Telephone: DSN 786-5314

Commercial: [phone]

5. Local WARCO. Upo n completion of warranty actions by the contractor, the WARCO shall complete

and provide a copy of DA Form 2407 to TACOM for information and warranty tracking purposes
only. NOTE: The DA Form 2407 shall be stamped or otherwise clearly marked "FOR
INFORMATION ONLY". Send the completed DA Form 2407 to:

Commander
U.S. Army T ank-Automo tive and Armaments Command
ATTN: AMSTA-LC-CJCB
Warren, MI 48397-5000

Telephone: DSN 786-7215

Commercial: [phone]

Forms may also be faxed to TACOM. Fax the forms to: DSN 786-5605, Commercial - (810) 574-

5605. Include ATTN: AMSTA-LC-CJCB on all related materials being faxed to TACOM.

x

INTRODUCTION

TM 5-3805-280-10

READ THIS MANUAL carefully to learn how
to operate and service your machine
correctly. Failure to do so could result in
personal injury or equipment damage. This
manual and safety signs on your machine
may also be available in other languages.
(See your John Deere dealer to order.)

THIS MANUAL SHOULD BE CONSIDERED
a permanent part of your machine and
should remain with the machine when you
sell it.

MEASUREMENTS in this manual are given
in both metric and customary U.S. unit
equivalents. Use only correct replacement
parts and fasteners. Metric and inch
fasteners may require a specific metric or
inch wrench.

RIGHT-HAND AND LEFT-HAND sides are
determined by facing in the direction of
forward travel.

GROUP NUMBERS (e.g., GRP NO. XXXX)
following maintenance task titles in the

Table of Contents refer to the John Deere
Functional Group Coding system.

WARRANTY is provided as part of John

Deere’s support program for customers who
operate and maintain their equipment as
described in this manual. The warranty is
explained on the warranty certificate, which
you should have received from your dealer .

This warranty provides you the assurance
that John Deere will back its products where
defects appear within the warranty period. In
some circumstances, John Deere also
provides field improvements, often without
charge to the customer, even if the product
is out of warranty. Should the equipment be
abused, or modified to change its
performance beyond the original factory
specifications, the warranty will become void
and field improvements may be denied.
Setting fuel delivery above specifications or
otherwise overpowering machines will result
in such action.

CALIFORNIA PROPOSITION 65 WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and

other reproductive harm.

xi

TM 5-3805-280-10

BLANK

xii

TM 5-3805-280-10

CHAPTER 1

SAFETY AND SAFETY SIGNS

TM 5-3805-280-10

BLANK

1-1

JOHNDEEREEXCAVATORSAFETYFEATURES

Safety

TM 5-3805-280-10

TX,05,DH5854 –19–15AUG97–1/1

T111123 –19–14AUG97

TM 5-3805-280-10

Safety

RECOGNIZESAFETYINFORMATION

Thisisthesafety-alertsymbol.Whenyouseethissymbol
onyourmachineorinthismanual,bealerttothe
potentialforpersonalinjury.

Followrecommendedprecautionsandsafeoperating
practices.

UNDERSTANDSIGNALWORDS

Asignalword—DANGER,WARNING,orCAUTION—is
usedwiththesafety-alertsymbol.DANGERidentifiesthe
mostserioushazards.

DANGERorWARNINGsafetysignsarelocatednear
specifichazards.Generalprecautionsarelistedon
CAUTIONsafetysigns.CAUTIONalsocallsattentionto
safetymessagesinthismanual.

DX,ALERT –19–03MAR93–1/1

T81389 –UN–07DEC88

TS187 –19–30SEP88

DX,SIGNAL–19–03MAR93–1/1

FOLLOWSAFETYINSTRUCTIONS

Carefullyreadallsafetymessagesinthismanualandon
yourmachinesafetysigns.Keepsafetysignsingood
condition.Replacemissingordamagedsafetysigns.Be
surenewequipmentcomponentsandrepairpartsinclude
thecurrentsafetysigns.

Learnhowtooperatethemachineandhowtouse
controlsproperly.Donotletanyoneoperatewithout
instruction.

Keepyourmachineinproperworkingcondition.
Unauthorizedmodificationstothemachinemayimpairthe
functionand/orsafetyandaffectmachinelife.

TS201 –UN–23AUG88

TX,05,DY336–19–15MAY96–1/1

1-2

TM 5-3805-280-10

Safety

AVOIDINJURYFROM:
LOADINGMACHINEONATRAILER,
FASTENINGMACHINETOTRAILER,
UNLOADINGMACHINEFROMTRAILER

---------------------------------­ALWAYSUSECAUTIONWHENLOADING
ANDUNLOADINGMACHINESONATRAILER

---------------------------------­ALWAYSKNOWANDFOLLOWTHE
RECOMMENDEDPROCEDURESFORTHE
MACHINE,BECAUSEALLMACHINESARE
NOTLOADED,FASTENED,ANDUNLOADED
THESAMEWAY

---------------------------------­ALWAYSKEEPBYSTANDERSCLEAROF
THEAREA

T8513AB –UN–28JUN95T7405BJ –UN–29NOV90

Toavoidinjury:
Keepthetrailerbedclean.
Parkthetraileronafirm,hard,levelsurfacethatwillnot

givewaywhentheweightofthemachineisonthetrailer.
Putchockblocksagainsttruckwheels.
Usearamporloadingdock.Rampsmustbestrong

enoughtoadequatelyhandletheloadandhavealow
angleandcorrectheight.

Ifmachineisequippedwithaseatbelt,fastenitbefore
startingtheengine.

Drivemachineonorofftherampslowly.
fastenchainsorcablestomachinetracksortrackchain

links.Donotplacechainsorcableoveroragainst
hydrauliclinesorhoses.

1-3

TX,05,FF1808 –19–28JUN90–1/1

TM 5-3805-280-10

Safety

AVOIDINJURYFROMBACKOVER
ACCIDENTS

---------------------------------­BEFOREMOVINGMACHINE,BESUREALL
PERSONSARECLEAROFAREA

---------------------------------­ALWAYSBEALERTFORBYSTANDERS
MOVINGINTOTHEWORKAREA.USEHORN
OROTHERSIGNALTOWARNBYSTANDERS
BEFOREMOVINGMACHINE

---------------------------------­WHENUSINGASIGNALPERSON,KEEP
PERSONINVIEWATALLTIMES,BESURE
SIGNALPERSONISCLEARBEFORE
BACKINGUP

Toavoidbackoveraccidents:

T7241AY –UN–21FEB90

Alwayslookaroundbeforeyoubackup.Besurethat
everyoneisintheclear.

Keeptravelalarminworkingcondition.
Useasignalpersonwhenbackingupifviewis

obstructed.Alwayskeepsignalpersoninview.
Learnthemeaningofallflags,signs,andmarkingsused

onthejobandwhohastheresponsibilityforsignaling.
Keepwindows,mirrors,andlightscleanandingood

condition.
Dust,heavyrain,fog,etc.,canreducevisibility.As

visibilitydecreases,reducespeedanduseproperlighting.
Readandunderstandtheoperatinginstructionsinthis

operator’smanual.

1-4

TX,05,DY337–19–15MAY96–1/1

TM 5-3805-280-10

AVOIDINJURYFROMROLLAWAY
ACCIDENTS

-------------------------------­TOPREVENTROLLAWAY,ALWAYSMAKE
SUREMACHINEISPROPERLYSECURED
BEFORELEAVINGOPERATOR’SSEAT

-------------------------------­DEATHORSERIOUSINJURYMAYRESULT
IFYOUATTEMPTTOMOUNTORSTOPA
MOVINGMACHINE

Toavoidrollaways:
Selectlevelgroundwhenpossibletoparkmachine.
Pullpilotcontrolshut-offlevertolockedposition.
Lowerallequipmenttoground.

Safety

T7241AZ –UN–21FEB90

Stoptheengine.
Blockalltracksifyoumustparkonagrade.Position

machinetopreventrolling.
Parkareasonabledistancefromothermachines.
Readandunderstandtheoperatinginstructionsinthis

operator’smanual.

INSPECTMACHINE

TX,05,FF2433–19–22MAY91–1/1

Inspectyourmachinecarefullyeachdaybywalking
arounditbeforeyoustartit.(SeePre-StartInspection
Chapter.)

T82,BHSA,CL–19–14MAR90–1/1

T6607AQ –UN–18OCT88

1-5

TM 5-3805-280-10

Safety

USEHANDHOLDSANDSTEPS

Fallingisoneofthemajorcausesofpersonalinjury.
Whenyougetonandoffthemachine,alwaysmaintaina

threepointcontactwiththestepsandhandrailsandface
themachine.Donotuseanycontrolsashandholds.

Neverjumponoroffthemachine.Nevermountor
dismountamovingmachine.

Becarefulofslipperyconditionsonplatforms,steps,and
handrailswhenleavingthemachine.

USESEATBELT

Alwaysusetheseatbeltwhenoperatingyourmachine.

T6981AN –UN–15JUN89

TX,05,DH832–19–16MAR92–1/1

TS175 –UN–23AUG88

TX,05,DH3732 –19–18AUG95–1/1

1-6

TM 5-3805-280-10

Safety

MAINTAINSEATBELT

Keeptheseatbeltingoodcondition.

Thecompleteseatbeltassemblyshouldbereplaced
afterthreeyearsofusage,regardlessofappearance.

Betweenreplacementintervals:
Carefullyexaminebuckle,webbing,andattaching

hardware.
Besurethattheretractor,ifequipped,lockstoprevent

beltextensionafterlatchingbuckle.
Besurethatattachinghardwareisinplace.Tighten,if

necessary.
Replacetheseatbeltifitdoesnotoperateproperly,orifit

isdamaged,worn,ordeteriorated.

MOVEANDOPERATEMACHINESAFELY

Bystanderscanberunover.Knowthelocationof
bystandersbeforemoving,swinging,oroperatingthe
machine.

Alwayskeepthetravelalarminworkingcondition.It
warnspeoplewhenthemachinestartstomove.

Useasignalpersonwhenmoving,swinging,oroperating
themachineincongestedareas.Coordinatehandsignals
beforestartingthemachine.

TX,05,DH3729 –19–09AUG95–1/1

T7273AL –UN–08JUN90

TX,05,FF1806 –19–05OCT90–1/1

1-7

TM 5-3805-280-10

Safety

OPERATEONLYFROMOPERATOR’SSEAT

Avoidpossibleinjuryormachinedamage.Donotstart
enginebyshortingacrossstarterterminals.

NEVERstartenginewhilestandingonground.Start
engineonlyfromoperator’sseat.

SECONDARYEXITS

Machinesequippedwithcabsareequippedwith
secondaryexits.Foradditionalsecondaryexitinformation,
seethetopics”SecondaryExitTool”and’OpeningUpper
Front(SecondaryExit)Window’inchapter10ofthis
manual.

OPERATEMACHINESAFELY

Clearallpersonsfromareaofoperationandmachine
movement.

Useyourseatbelt.

TX,05,FF1615 –19–14JUN90–1/1

T6607AO –UN–18OCT88

TX,05,DH5848 –19–13AUG97–1/1

Makesuretheworksitefootinghassufficientstrengthto
firmlysupportthemachine.Whenworkingclosetoan
excavation,positionmachinewithpropelmotorsatthe
rear.

Becautiousoftippingwhenworkingonfrozenground.
Temperatureincreaseswillcausegroundtobecomesoft,
makinggroundunstable.

Whendiggingdeep,avoidhittingbottomofboomor
bucketcylinderhosesagainsttheground.

Usethebucketonlyfordigging.Donotuseitasajack
hammerorwreckingball.

T7252AL –UN–08JUN90

TX,05,DH3730 –19–09AUG95–1/1

1-8

DIGWITHCAUTION

Beforedigging,checkthelocationofcables,gaslines,
andwaterlines.

TM 5-3805-280-10

Safety

OPERATEWITHCAUTION

Avoidcontactofboomorarmandoverheadobstacles
whenyouoperatethemachine.

AVOIDTIPPING

Useyourseatbelt.
Whenoperatingonaslope,keepbucketlowtoground

andclosetomachine.Pointtracksuphill.

05,RR,592–19–12JUN90–1/1

T7252AJ –UN–08JUN90

T7286AJ –UN–08JUN90

TX,05,RR,602 –19–26FEB91–1/1

Avoidtippingthemachinewhenswingingheavyloads.
Reduceswingspeedasnecessary.

Becautiousoftippingwhenworkingonfrozenground.
Temperatureincreaseswillcausegroundtobecomesoft
andmakegroundtravelunstable.

T7273AE –UN–08JUN90

TX,05,DH3731 –19–09AUG95–1/1

1-9

TM 5-3805-280-10

AVOIDPOWERLINES

Seriousinjuryordeathcanresultfromcontactwith
electriclines.

Nevermoveanypartofthemachineorloadcloserto
electriclinethan3m(10ft)plustwicethelineinsulator
length.

Safety

DRIVEMACHINESAFELY

Useyourseatbelt.
Beforemovingmachine,findoutwhichwaytomove

propelpedals/leversforthedirectionyouwanttogo.
Pushingdownonthefrontofthepropelpedalsorpushing
theleversmovesthemachinetowardstheidlers.

Keepthebucketontheuphillside,approximately30cm
(12in.)(A)aboveground,whengoingupordownhill.If
machinestartstosliporbecomeunstable,lowerthe
bucketimmediately.

TX,05,RR,594 –19–12JUN90–1/1

T7273AD –UN–08JUN90

T7273AG –UN–08JUN90

TX,05,DH3733 –19–09AUG95–1/1

BEWAREOFEXHAUSTFUMES

Preventasphyxiation.Engineexhaustfumescancause
sicknessordeath.

Ifyoumustoperateinabuilding,bepositivethereis
adequateventilation.Eitheruseanexhaustpipeextension
toremovetheexhaustfumesoropendoorsandwindows
tobringenoughoutsideairintothearea.

02T,05,J9 –19–07JAN91–1/1

T6458AO –UN–18OCT88

1-10

PARKMACHINESAFELY

Beforeworkingonthemachine:

•Parkmachineonalevelsurface.

•Lowerbuckettotheground.

•Turnauto-idleswitchoff.

•Runenginewithenginerpmdialat1/3positionfor2

minutes.

•Moveenginerpmdialtoslowidleposition.

•TurnkeyswitchtoOFF.Removekeyfromswitch.

•Pullpilotcontrolshut-offlevertolockedposition.

•Allowenginetocool.

TM 5-3805-280-10

Safety

TX,05,DH5002 –19–28MAY96–1/1

KEEPRIDERSOFFMACHINE

Onlyallowtheoperatoronthemachine.Keepridersoff.
Ridersonmachinearesubjecttoinjurysuchasbeing

struckbyforeignobjectsandbeingthrownoffthe
machine.Ridersalsoobstructtheoperator’sviewresulting
inthemachinebeingoperatedinanunsafemanner.

TX,05,RR,560–19–05OCT90–1/1

T7273AH –UN–08JUN90

1-11

TM 5-3805-280-10

Safety

OPERATEATTACHMENTSAFELY

Anattachmentmaychangethecapabilitiesofyour
machineinanyoralloftheseways:

•Saferangeofmotion

•Machinestability

•Hydraulicperformance

•Engineperformance

Readtheattachmentmanualtolearnhowtheattachment
works.

Inanareafreeofbystandersandobstructions,carefully
operatetheattachmenttolearntheavailablerangeof
motion.Anticipatehowobjectsmanipulatedbythe
attachment,ortheattachmentitself,maycontactthe
machine,especiallytheoperator’sstation.Consider
addingguardstothemachinetoprotecttheoperator,and
ifnecessary,topreventdamagetomachine.

Seeyourdealertomatchattachmentdemandsto
machineperformance.

HANDLEFLUIDSSAFELY—AVOIDFIRES

Handlefuelwithcare;itishighlyflammable.Donotrefuel
themachinewhilesmokingorwhennearopenflameor
sparks.Alwaysstopenginebeforerefuelingmachine.Fill
fueltankoutdoors.

TX,05,FF2883 –19–29OCT92–1/1

Continuedonnextpage

1-12

TX,05,FF1622 –19–14JUN90–1/2

TS202 –UN–23AUG88

TM 5-3805-280-10

Safety

Storeflammablefluidsawayfromfirehazards.Donot
incinerateorpuncturepressurizedcontainers.

Makesuremachineiscleanoftrash,grease,anddebris.
Donotstoreoilyrags;theycanigniteandburn

spontaneously.

PREPAREFOREMERGENCIES

Bepreparedifafirestarts.
Keepafirstaidkitandfireextinguisherhandy.
Keepemergencynumbersfordoctors,ambulanceservice,

hospital,andfiredepartmentnearyourtelephone.

HANDLESTARTINGFLUIDSAFELY

Startingfluidishighlyflammable.
Keepallsparksandflameawaywhenusingit.Keep

startingfluidawayfrombatteriesandcables.

TX,05,FF1622 –19–14JUN90–2/2

TS227 –UN–23AUG88

TS291 –UN–23AUG88

DX,FIRE2–19–03MAR93–1/1

Topreventaccidentaldischargewhenstoringthe
pressurizedcan,keepthecaponthecontainer,andstore
inacool,protectedlocation.

Donotincinerateorpunctureastartingfluidcontainer.

TS1356 –UN–18MAR92

DX,FIRE3 –19–16APR92–1/1

1-13

TM 5-3805-280-10

Safety

CLEANTRASHFROMMACHINE

Keepenginecompartment,radiator,batteries,hydraulic
lines,fueltank,andoperator’sstationclean.

Temperatureinenginecompartmentmaygoup
immediatelyafterengineisstopped.BEONGUARDFOR
FIRESDURINGTHISPERIOD.

Openaccessdoor(s)tocooltheenginefaster,andclean
enginecompartment.

T6669AG –UN–18OCT88

02T,05,J33–19–14MAR90–1/1

PROTECTAGAINSTFLYINGDEBRIS

Guardagainstinjuryfromflyingpiecesofmetalordebris;
weargogglesorsafetyglasses.

WEARPROTECTIVECLOTHING

Wearclosefittingclothingandsafetyequipment
appropriatetothejob.

Operatingequipmentsafelyrequiresthefullattentionof
theoperator.Donotwearradioormusicheadphones
whileoperatingmachine.

TX,05,FF1613 –19–14JUN90–1/1

T6642DK –UN–18OCT88

1-14

DX,WEAR2 –19–03MAR93–1/1

TS206 –UN–23AUG88

TM 5-3805-280-10

PROTECTAGAINSTNOISE

Prolongedexposuretoloudnoisecancauseimpairment
orlossofhearing.

Wearasuitablehearingprotectivedevicesuchas
earmuffsorearplugstoprotectagainstobjectionableor
uncomfortableloudnoises.

Safety

HANDLECHEMICALPRODUCTSSAFELY

Directexposuretohazardouschemicalscancause
seriousinjury.Potentiallyhazardouschemicalsusedwith
yourmachineincludesuchitemsaslubricants,coolants,
paints,andadhesives.

AMaterialSafetyDataSheet(MSDS)providesspecific
detailsonchemicalproducts:physicalandhealthhazards,
safetyprocedures,andemergencyresponsetechniques.

ChecktheMSDSbeforeyoustartanyjobusinga
hazardouschemical.Thatwayyouwillknowexactlywhat
therisksareandhowtodothejobsafely.Thenfollow
proceduresandrecommendedequipment.

SeeyourauthorizeddealerforMSDS’sonchemical
productsusedwithyourmachine.

DX,NOISE–19–03MAR93–1/1

TS207 –UN–23AUG88

TS1132 –UN–26NOV90

1-15

TX,05,DH2500 –19–02OCT92–1/1

TM 5-3805-280-10

Safety

WARNOTHERSOFSERVICEWORK

Unexpectedmachinemovementcancauseseriousinjury.
Beforeperforminganyworkonthemachine,attacha’Do

NotOperate’tagontherightcontrollever.

STAYCLEAROFMOVINGPARTS

Entanglementsinmovingpartscancauseseriousinjury.
Topreventaccidents,usecarewhenworkingaround

rotatingparts.

TX,05,RR,566 –19–23JUL91–1/1

T7273AP –UN–08JUN90

T7273AS –UN–08JUN90

TX,05,RR,572 –19–12JUN90–1/1

1-16

TM 5-3805-280-10

Safety

SUPPORTMACHINEPROPERLY

Alwayslowertheattachmentorimplementtotheground
beforeyouworkonthemachine.Ifyoumustworkona
liftedmachineorattachment,securelysupportthe
machineorattachment.

Donotsupportthemachineoncinderblocks,hollowtiles,
orpropsthatmaycrumbleundercontinuousload.Donot
workunderamachinethatissupportedsolelybyajack.
Followrecommendedproceduresinthismanual.

TS229 –UN–23AUG88

DX,LOWER–19–04JUN90–1/1

SERVICECOOLINGSYSTEMSAFELY

Explosivereleaseoffluidsfrompressurizedcooling
systemcancauseseriousburns.

Shutoffengine.Onlyremovefillercapwhencoolenough
totouchwithbarehands.Slowlyloosencaptofirststop
torelievepressurebeforeremovingcompletely.

DX,RCAP –19–04JUN90–1/1

TS281 –UN–23AUG88

1-17

TM 5-3805-280-10

PRACTICESAFEMAINTENANCE

Understandserviceprocedurebeforedoingwork.Keep
areacleananddry.

Neverlubricateorservicemachinewhileitismoving.
Keephands,feetandclothingfrompower-drivenparts.

Beforeservicingmachine.

•Parkmachineonalevelsurface.

•Lowerbuckettotheground.

•Turnauto-idleswitchoff.

•Runenginewithenginerpmdialat1/3speedfor2

minutes.

•Moveenginerpmdialtoslowidleposition.

•TurnkeyswitchtoOFF.Removekeyfromswitch.

•Attacha’DoNotOperate’tagontherightside

controllerlever.

•Pullpilotcontrolshut-offlevertolockedposition.

•Allowenginetocool.

Safety

Ifmaintenanceproceduremustbeperformedwithengine
running,donotleavemachineunattended.

Securelysupportanymachineelementsthatmustbe
raisedforservicework.Neverworkunderamachine
raisedbytheboom.Ifthemachinemustberaised,keep
a90-110°anglebetweenboomandarm.

Keepallpartsingoodconditionandproperlyinstalled.Fix
damageimmediately.Replacewornorbrokenparts.
Removeanybuildupofgrease,oil,ordebris.

Disconnectbatterygroundcable(-)beforemaking
adjustmentsonelectricalsystemsorweldingonmachine.

TS218 –UN–23AUG88

1-18

TX,05,DH5001 –19–28MAY96–1/1

TM 5-3805-280-10

Safety

REMOVEPAINTBEFOREWELDINGOR
HEATING

Avoidpotentiallytoxicfumesanddust.
Hazardousfumescanbegeneratedwhenpaintisheated

bywelding,soldering,orusingatorch.
Doallworkoutsideorinawellventilatedarea.Disposeof

paintandsolventproperly.
Removepaintbeforeweldingorheating:

•Ifyousandorgrindpaint,avoidbreathingthedust.
Wearanapprovedrespirator.

•Ifyouusesolventorpaintstripper,removestripperwith
soapandwaterbeforewelding.Removesolventor
paintstrippercontainersandotherflammablematerial
fromarea.Allowfumestodisperseatleast15minutes
beforeweldingorheating.

AVOIDHEATINGNEARPRESSURIZEDFLUID
LINES

Flammablespraycanbegeneratedbyheatingnear
pressurizedfluidlines,resultinginsevereburnsto
yourselfandbystanders.Donotheatbywelding,
soldering,orusingatorchnearpressurizedfluidlinesor
otherflammablematerials.Pressurizedlinescanbe
accidentallycutwhenheatgoesbeyondtheimmediate
flamearea.

TS220 –UN–23AUG88

DX,PAINT–19–03MAR93–1/1

1-19

TS953 –UN–15MAY90

DX,TORCH –19–03MAR93–1/1

TM 5-3805-280-10

Safety

AVOIDHIGH-PRESSUREFLUIDS

Escapingfluidunderpressurecanpenetratetheskin
causingseriousinjury.

Avoidthehazardbyrelievingpressurebefore
disconnectinghydraulicorotherlines.Tightenall
connectionsbeforeapplyingpressure.

Searchforleakswithapieceofcardboard.Protecthands
andbodyfromhighpressurefluids.

Ifanaccidentoccurs,seeadoctorimmediately.Anyfluid
injectedintotheskinmustbesurgicallyremovedwithina
fewhoursorgangrenemayresult.Doctorsunfamiliarwith
thistypeofinjuryshouldreferenceaknowledgeable
medicalsource.SuchinformationisavailablefromDeere
&CompanyMedicalDepartmentinMoline,Illinois,U.S.A.

X9811 –UN–23AUG88

PREVENTBATTERYEXPLOSIONS

Keepsparks,lightedmatches,andopenflameawayfrom
thetopofbattery.Batterygascanexplode.

Nevercheckbatterychargebyplacingametalobject
acrosstheposts.Useavolt-meterorhydrometer.

Donotchargeafrozenbattery;itmayexplode.Warm
batteryto16°C(60°F).

DX,FLUID –19–03MAR93–1/1

TS204 –UN–23AUG88

DX,SPARKS –19–03MAR93–1/1

1-20

TM 5-3805-280-10

Safety

CLEANTHEMACHINEREGULARLY

Removeanygrease,oil,fuel,ordebrisbuild-uptoavoid
possibleinjuryormachinedamage.

Highpressurewashing[greaterthan1379kpa(13.8bar)
(200psi)]candamagefreshlypaintedfinishes.Paint
shouldbeallowedtoairdryfor30daysminimumafter
receiptofmachinebeforecleaningwithhighpressure.
Uselowpressurewashoperationsuntil30dayshave
elapsed.

Donotsprayoilcoolerfinsatanangle.Finsmaybend.

T6642EJ –UN–18OCT88

TX,05,FF2787–19–27JUL94–1/1

STOREATTACHMENTSSAFELY

Storedattachmentssuchasbuckets,hydraulichammers,
andbladescanfallandcauseseriousinjuryordeath.

Securelystoreattachmentsandimplementstoprevent
falling.Keepplayingchildrenandbystandersawayfrom
storagearea.

TX,05,RR,576 –19–26APR90–1/1

TS219 –UN–23AUG88

1-21

TM 5-3805-280-10

Safety

BATTERYTERMINALS,LIFTING
EQUIPMENT,DRYCLEANINGSOLVENTAND
COMPRESSEDAIR

WARNING:Avoidpossibleinjury.Disconnectthe
negativeterminalfirstandreconnectthenegative
terminallastwhendisconnecting/reconnectingbattery
terminals.

WARNING:Whenliftingequipment,ensurethatthe
liftingdeviceiscapableofsupportingthedesired
weightsandtheinspectiondatestampedonthelifting
devicehasnotexpired.

WARNING:DrycleaningsolventPD-680TypeIIIis
toxicandflammable.Wearprotectivegogglesand
glovesanduseonlyinawellventilatedarea.Avoid
contactwithskin,eyes,andclothesanddon’tbreathe
vapors.Donotusenearopenflamesorexcessive
heat.Theflashpointis200°F(93°C).Ifyoubecome
dizzywhileusingsolvent,getfreshairimmediately
andgetmedicalaid.Ifcontactwitheyesismade,
washyoureyeswithwaterandgetmedicalaid
immediately.

WARNING:Compressedairusedforcleaning
purposesshallnotexceed30psi.Useonlywith
effectivechipguardingandpersonnelprotective
equipment(goggles/shield/gloves,etc.).

CED,OUOE042,44–19–19OCT99–1/1

1-22

TM 5-3805-280-10

Safety

DISPOSEOFWASTEPROPERLY

Improperlydisposingofwastecanthreatenthe
environmentandecology.Potentiallyharmfulwasteused
withyourmachineincludesuchitemsasoil,fuel,coolant,
brakefluid,filters,andbatteries.

Useleakproofcontainerswhendrainingfluids.Donotuse
foodorbeveragecontainersthatmaymisleadsomeone
intodrinkingfromthem.

Donotpourwasteontotheground,downadrain,orinto
anywatersource.

Airconditioningrefrigerantsescapingintotheaircan
damagetheEarth’satmosphere.Governmentregulations
mayrequireacertifiedairconditioningservicecenterto
recoverandrecycleusedairconditioningrefrigerants.

Inquireontheproperwaytorecycleordisposeofwaste
fromyourlocalenvironmentalorrecyclingcenter,orfrom
yourauthorizeddealer.

TS1133 –UN–26NOV90

TX,05,DH2502 –19–26AUG92–1/1

1-23

TM 5-3805-280-10

DRILLING

Before starting work, the operator will make sure
there are no buried electrical, gas, water or other
pipes or lines.

Always be aware of previously drilled holes, and
where they are located : any open hole can cause se­vere injury to the operator or someone else. The loss
of tools, drill rods, drill bits or any other item can occur.

Safety

be ready to activate the cabin emergency stop if need
be.

 communication must be established in a reli-

able manner.

Make sure any hand signal will be perfectly

understood.

 the operator must make sure the following
safety decal is affixed on the drill guide to warn the
service man of risks incurred.



! !
 #

"#!

#

 the service man must be informed about the
use of the emergency stop mounted on the guide.



$" ! #


#
"#
"

When rising the guide, take care of any overhead

lines.

Always maintain a minimum distance of 25 Ft.
(7.6 m) distance between the machine and any
overhead lines during any operation.

The operator will make sure that everybody
stands clear from the machine in operation and stays
at a distance of 7 meters (25 ft.).

Nevertheless, some operations may need people
to enter the restricted area (checking of coupling tem­perature during feed thrust adjustment for instance).

On such an occasion :

 the operator must supervise, from the cabin,
the safety of the service man doing the work. He must

Always have the cabin door closed and the dust
collector running when drilling to prevent respiratory
damage.

Keep all work areas clean and orderly.

ROCK DRILL MAINTENANCE

Keep hands, arms, legs and clothing away from
moving or rotating parts.

Only use genuine replacement parts.

Stopping the drill for mainte-

nance or bit change etc...

Prior to leaving the operators compartment, the
excavators hydraulic safety arm must be raised to
lock in the machines safety switch. This renders all
controls inoperable thus preventing any unwanted
movement.

Hydraulic cylinder

The hydraulic cylinder is equipped with 2 load–
sustaining valves.

The load–sustaining valves allow the disconnect­ing of the hydraulic hoses from the cylinder if they
need to be changed. But :

1-24

TM 5-3805-280-10

Safety

Respiratory damage prevention



Never disconnect a valve from the cylinder
without supporting the controlled element (drill
guide ...).

Burn prevention

At operating temperature, the hydraulic tank, cir­cuit and components are hot and can be under pres­sure. Any contact can cause severe burns.

Always release the pressure and wait for cool­ing before intervening on the hydraulic circuit.

W RNING

Dust coming out from the dust collector fan indi­cates that one or several filter elements are dam­aged.

Change the damaged elements immediately.

Always dismount all the filters elements to check
the functioning of the automatic filter cleaning se­quence.

Compressed air

Compressed air can be dangerous.

Never point an air hose at yourself or co–workers.

Be sure all hoses and fittings are tightly se­cured.

A loose hose not only leaks but can come com­pletely off and while whipping under pressure, can
injure the operator and others in the area.

Never disconnect a pressurized air hose.

W RNING








Fire prevention

Fuel or hydraulic oil leaked or spilled onto hot sur-

faces or electrical components can cause a fire.

Repair immediately any leaks.

Regularly clean the machine to remove all flam-

mable materials such as fuel, oil and other debris.

Always use approved safety solvent when clean-

ing parts or the machine.

Have all loose electrical wires connected and tight

before operating the machine.

Prior to any welding operation, make sure that the
surfaces and their environment are free of flammable
debris.

   








EMERGENCY STOPS

The CPA remote control assembly incorporates
an emergency stops selector with allows to connect
the CPA emergency stops to the machine circuit.

B

– When the CPA is installed, place the selec­tor on position A to have the CPA emergency stops
active.

– Place the selector on position B to refind the
normal excavator safety circuit when the CPA is not
used.

1-25

The CPA safety circuit incorporates 2 emergency

stops.

One mushroom type push–button is located in the

cabin on the remote control panel.

Pressing on this button shuts down the engine.
Unlock the knob by pulling it up to be in position to

restart the engine.

TM 5-3805-280-10

Safety

wire

The second emergency stop is located on the
guide rail, and stops the engine when pulling on the
wire attached along the guide.

To unlock the safety device and be in position to
restart the engine, press on the button.

WARNING: Take all necessary steps to safely
start the engine after emergency stop.

1-26

SAFETYSIGNS

TM 5-3805-280-10

SafetySigns

Caution Decal (Model 230LCR)

T125071 –UN–28OCT99

T125070 –UN–28OCT99

Caution Decal (Model 230LCRD)

Continuedonnextpage

1-27

Caution Decal Location

T125069 –UN–28OCT99

TX,06,DH5564 –19–22MAR99–1/11

TM 5-3805-280-10

Safety Signs

A—DangerDecalLocation

Continuedonnextpage

T7748CZ –19–14OCT92

T101484 –UN–27JUN96

TX,06,DH5564 –19–22MAR99–2/11

1-28

TM 5-3805-280-10

Safety Signs

T7748DA –19–14OCT92

A—WarningDecalLocation

Continuedonnextpage

T101485 –UN–27JUN96

TX,06,DH5564 –19–22MAR99–3/11

1-29

TM 5-3805-280-10

Safety Signs

A-Caution Decal

Continuedonnextpage

T102888 –19–23AUG96

T101483 –UN–27JUN96

A—CautionDecalLocation

TX,06,DH5564 –19–22MAR99–4/11

1-30

TM 5-3805-280-10

Safety Signs

T108112B –UN–27MAR97

T7972AP –19–22MAR93

Continuedonnextpage

TX,06,DH5564 –19–22MAR99–5/11

1-31

TM 5-3805-280-10

Safety Signs

T7748DC –19–14OCT92

T7748CX –19–14OCT92

Continuedonnextpage

T8167AL –UN–06FEB94

A—WarningDecalLocation

TX,06,DH5564 –19–22MAR99–6/11

T7748DH –UN–15OCT92

TX,06,DH5564 –19–22MAR99–7/11

1-32

TM 5-3805-280-10

Safety Signs

T7748DK –UN–22OCT92

A—CautionDecalLocation

T101279 –19–14MAY96

T7900AB –19–03DEC92

Continuedonnextpage

TX,06,DH5564 –19–22MAR99–8/11

T7869BZ –UN–05NOV92

TX,06,DH5564 –19–22MAR99–9/11

1-33

TM 5-3805-280-10

Safety Signs

Decal is located on top of each battery.

Continuedonnextpage

T6888AC –19–06JAN89

TX,06,DH5564 –19–22MAR99–10/11

1-34

TM 5-3805-280-10

Safety Signs

1-35

T120457 –19–25MAR99

TX,06,DH5564 –19–22MAR99–11/11

TM 5-3805-280-10

Safety Signs

Look for these signs on machine, which points out potential hazards to the safety of you and others. Read and
understand thoroughly. Heed warnings and follow instructions. If you do not understand, inform your
supervisor.

Indicates the presence of a hazard which WILL cause serious
injury, death or property damage, if ignored.

Indicates the presence of a hazard which CAN cause serious
injury, death or property damage, if ignored.

Indicates the presence of a hazard which WILL or can cause
injury or property damage, if ignored.

Indicates important set-up, operating or maintenance
information.

1-36

TM 5-3805-280-10

1-37

TM 5-3805-280-10

BLANK

1-38

TM 5-3805-280-10

CHAPTER 2

OPERATOR’S STATION

TM 5-3805-280-10

BLANK

Operator’sStation

PEDALS,LEVERSANDPANELS

TM 5-3805-280-10

T121034 –UN–29OCT99

A—LeftControlLever/HornSwitch(OnTopof

Lever)
B—LeftTravelPedal
C—LeftTravelLever
D—RightTravelLever
E—RightTravelPedal
F—RightControlLever/PowerBoostSwitch(On

TopofLever)
G—FrontRightPanel
H—RightConsolePanel
I—AirConditionerPanel—IfEquipped
J—CabDoorReleaseLever
K—Radio
L—LeftConsolePanel
M—PilotControlShut-OffLever
N—HydraulicThumbPedal(Model230LCR)
O—RockDrillControlPanel(Model230LCRD)

CED,OUOE042,5058 –19–14APR99–1/1

2-1

TM 5-3805-280-10

Operator’s Station

RIGHTFRONTPANELANDRIGHTCONSOLE
PANEL

A—MonitorPanel
B—SwitchPanel
C—AshTray
D—CigarLighter
E—AirConditionerPanel-IfEquipped
F—EngineRPMDial
G—E(Economy)ModeSwitch
H—H/P(HighPower)ModeSwitch
I—KeySwitch
J—RearLightSwitch
K—OverloadAlarm/Indicator
L—ArcticHeaterSwitch
M—ArcticHeaterIndicator

2-2

T121035 –UN–14APR99

TX,10,DH5708–19–21APR97–1/1

MONITORPANEL

TM 5-3805-280-10

Operator’s Station

A—EngineCoolantTemperatureGauge
B—Warm-upIndicator
C—FuelGauge
D—H/P(HighPower)ModeIndicator
E—E(Economy)ModeIndicator
F—Auto-IdleIndicator
G—HydraulicOilFilterRestrictionIndicator

(Model230LCRD)
H—HydraulicOilLevelIndicator
I—FuelLevelIndicator
J—AirFilterRestrictionIndicator
K—ChargeAirTemperatureIndicator
L—EngineCoolantTemperatureIndicator
M—EngineOilPressureIndicator
N—AlternatorVoltageIndicator
O—EngineOilLevelIndicator
P—EngineCoolantLevelIndicator

CED,OUOE020,15–19–03MAR99–1/1

T120386 –UN–25MAR99

2-3

TM 5-3805-280-10

Operator’s Station

ENGINECOOLANTTEMPERATUREGAUGE

IMPORTANT:Ifneedlepointsto’RED’zone,idle

enginetobringbackneedleto’GREEN’
zonebeforestoppingengine.Ifneedle
continuestorise,shutengineOFF.

WARM-UPINDICATOR

Yellowindicatorwillturnoffwhentheenginecoolant
temperaturereachesapproximately30°C(86°F).

T101569 –UN–11JUL96

TX,10,DH5451–19–25JUN96–1/1

FUELGAUGE

Fuelmachinebeforeneedlereaches“E”.

H/P(HIGHPOWER)MODEINDICATOR

GreenindicatorwilllightwhentheH/Pmodeswitchis
turnedon.

T101574 –UN–11JUL96

TX,10,DH5453 –19–04MAR97–1/1

T101570 –UN–11JUL96

TX,10,DH5454–19–04JUN96–1/1

2-4

T101571 –UN–11JUL96

TX,10,DH5455 –19–11JUL96–1/1

Operator’s Station

E(ECONOMY)MODEINDICATOR

GreenindicatorwilllightwhentheEmodeswitchis
turnedon.

AUTO-IDLEINDICATOR

Greenindicatorwilllightwhentheauto-idleswitchis
turnedon.

TM 5-3805-280-10

T101572 –UN–11JUL96

TX,10,DH5456–19–17JUN96–1/1

HYDRAULICOILLEVELINDICATOR

Parkmachineonlevelground.
Positionmachinewitharmcylinderfullyretractedand

bucketcylinderfullyextended.
Pressingthelevelcheckswitchbeforestartingthe

machinewillturntheindicatoronifoillevelisadequate
foroperation.

NOTE: This check does NOT take the place of daily

inspection.

T101573 –UN–11JUL96

TX,10,DH5457–19–17JUN96–1/1

T101577 –UN–27JUN96

TX,10,DH5458–19–04JUN96–1/1

2-5

TM 5-3805-280-10

Operator’s Station

HYDRAULICOILFILTERRESTRICTION
INDICATOR(MODEL230LCRD)

IMPORTANT:Preventpossiblehydraulicpump

damage.Changehydraulicoilfilteras
soonaspossiblewhenaproblem
occurs.

Indicatorlightwilllightandservicerequiredindicatorlight
willlightwhenfilterelementsarerestricted.Changefilter
elements.

NOTE: Cold oil may cause hydraulic oil filter restriction

indicator light to light temporarily.

T8381AG –UN–03JAN95

CED,OUOE020,16–19–03MAR99–1/1

FUELLEVELINDICATOR

Whenredfuelindicatorlights,approximately30liters(8
gal.)offuelremain.

AIRFILTERRESTRICTIONINDICATOR

Redindicatorwilllightwhentheairfilterelementsare
clogged.Cleanorreplaceelements.

T101578 –UN–27JUN96

TX,10,DH5459–19–25JUN96–1/1

2-6

T101580 –UN–27JUN96

TX,10,DH5460–19–04JUN96–1/1

Operator’s Station

ENGINECOOLANTTEMPERATURE
INDICATOR

IMPORTANT:Donotstopenginewhencoolant

temperaturelightcomesonor
temperaturewillrisefurther.Reduce
loadandrunengineatslowidle.If
temperaturelightcontinuestostayON,
shutengineOFF.

TM 5-3805-280-10

Redindicatorwilllightandbuzzerwillsoundwhenthe
enginecoolantoverheats.Reduceloadimmediatelyand
runengineatslowidle.Inspectfordebrisaroundradiator.
Checkforlowcoolantlevelintheradiatorrecoverytank.

CHARGEAIRTEMPERATUREINDICATOR

IMPORTANT:Preventpossibleenginedamage.If

chargeairindicatorlightcomeson
whileoperating,stopengine.

Redindicatorwilllightwhenairintaketemperatureis
excessivelyhigh.Stopengine.Checkfordebrisoncharge
aircoolerinletscreens.Checkfanforproperoperation.A
cloggedchargeairsystemwillreduceengine
performance.

T101581 –UN–11JUL96

TX,10,DH5461–19–04JUN96–1/1

T107672 –UN–27FEB97

2-7

TX,10,DH5712–19–21APR97–1/1

TM 5-3805-280-10

Operator’s Station

ENGINEOILPRESSUREINDICATOR

IMPORTANT:Ifengineoilpressurelightcomeson

whileoperating,stopengine
immediately.

Redindicatorwilllightandbuzzerwillsoundwhenengine
oilpressureislow.Stopengineimmediately.

NOTE: Cold oil, low oil level, or extreme off level

operation may cause indicator to light.

T101579 –UN–27JUN96

TX,10,DH5462–19–04JUN96–1/1

ALTERNATORVOLTAGEINDICATOR

Indicatorwilllightwithnoalternatoroutput.Check
electricalsystem.

ENGINEOILLEVELINDICATOR

Pressingthelevelcheckswitchbeforestartingthe
machinewillturntheindicatoronifoillevelisadequate
foroperation.

NOTE: This check does NOT take the place of daily

inspection.

T101582 –UN–27JUN96

TX,10,DH5463–19–09APR92–1/1

2-8

T101575 –UN–27JUN96

TX,10,DH5464–19–18JUN96–1/1

Operator’s Station

COOLANTLEVELINDICATOR

Pressingthelevelcheckswitchbeforestartingthe
machinewillturntheindicatoronifcoolantlevelis
adequateforoperation.

NOTE: This check does NOT take the place of daily

inspection.

TM 5-3805-280-10

T101576 –UN–27JUN96

TX,10,DH5465–19–04JUN96–1/1

2-9

SWITCHPANEL

TM 5-3805-280-10

Operator’s Station

A—LevelCheckSwitch
B—AttachmentModeIndicator
C—PrecisionModeIndicator
D—GradingModeIndicator
E—DigModeIndicator
F—WorkModeSwitch
G—BuzzerStopSwitch
H—PropelSpeedSwitch
I—Auto-idleSwitch
J—WiperSwitch
K—WasherSwitch
L—OperatingLightsSwitch

T107673 –UN–27FEB97

TX,10,DH5466–19–27FEB97–1/1

2-10

TM 5-3805-280-10

Operator’s Station

BUZZERANDBUZZERSTOPSWITCH

THEBUZZERSOUNDSWHEN:

•Engineoilpressureislow(indicatorlight(C)willalso
light).Ifengineoilpressureislow,stoptheengine
immediately.

NOTE: The buzzer cannot be turned off when engine oil

pressure is low.

•Enginecoolantoverheats(indicatorlight(B)willalso
light).Ifcoolanttemperatureishigh,pushbuzzerstop
switch(A),reduceloadimmediately,andrunengineat
decreasedenginespeed.Ifhightemperaturecontinues,
stoptheengine.Checkfluidlevels.

Whenthebuzzerstopswitchispushedandreleasedthe
buzzerstopssoundingandthebuzzerfunctionis
automaticallyresetfortheenginecoolantoverheat
function.

TORESETTHEBUZZER:
TurnthekeyswitchtoOFF.Thebuzzerwillnotsound

morethanonceforthesameproblemunlesstheswitchis
reset.

WIPERSWITCH

Wiperswitch(A)hasthreepositions.

•INTposition.......Wiperstartsoperatingintermittently.

•ONposition........Wiperoperatescontinuously

•OFFposition.......Wiperautomaticallystopsoperating.

NOTE: The wiper and washer do not operate unless the

upper front window is closed and the right-side
lock pin is installed.

T107674 –UN–27FEB97

TX,10,DH5832 –19–24JUL97–1/1

T101626 –UN–20JUN96

2-11

TX,10,DH5468–19–18JUN96–1/1

Operator’s Station

WASHERSWITCH

IMPORTANT:Washermotormaybedamagedif

washerswitchishelddownformore
than20seconds,orcontinually
operatedwithnofluidincontainer.

Pushswitch(A)tosquirtwindshieldwasherfluidon
windshield.Donotholddownswitchformorethan20
seconds.

TM 5-3805-280-10

T101627 –UN–20JUN96

TX,10,DH5469–19–04JUN96–1/1

OPERATINGLIGHTSSWITCH

Turnlightswitch(A)tofirstpositiontoturnonlight(C).
Turnlightswitchtosecondpositiontoturnonlights(B

andC).

T101591 –UN–27JUN96

T120793 –UN–25MAR99

2-12

CED,OUOE042,23–19–05MAR99–1/1

TM 5-3805-280-10

Operator’s Station

OPERATINGREARLIGHTSSWITCH

Moveswitch(A)toturntherearoutsideworklightsonor
off.

CABLIGHT

Moveswitch(A)toturntheinsidecablightonoroff.

T120402 –UN–25MAR99

CED,OUOE042,19–19–03MAR99–1/1

OVERLOADALARMANDINDICATOR

Theoverloadalarmandindicator(A)willactivatewhen
thediggingcapacityisexceeded,whilethemachineis
diggingfromtheside.

T101592 –UN–27JUN96

TX,10,DH5471–19–18JUN96–1/1

T120413 –UN–25MAR99

CED,OUOE020,18–19–03MAR99–1/1

2-13

TM 5-3805-280-10

Operator’s Station

KEYSWITCH

EnginewillstopwhenkeyswitchisturnedfromONto
ACC.AlwaysturnkeytoOFFpositiontopreventbatteries
fromdraining.

T7396DS –UN–27JUN91

A—EngineOff
B—Accessory
C—EngineOn
D—Start

TX,10,DH5472 –19–29MAY96–1/1

ENGINERPMDIAL

Useenginerpmdial(A)toadjustenginespeed.Turndial
clockwisetoincreaseenginespeedorcounterclockwiseto
decreaseenginespeed.

POWERBOOSTSWITCH

Powerboostswitch(A)islocatedontopofrightcontrol
lever.

T101628 –UN–20JUN96

TX,10,DH5473–19–19JUN96–1/1

2-14

T101633 –UN–20JUN96

TX,10,DH5591 –19–22MAR97–1/1

Operator’s Station

HORN

Hornswitch(A)islocatedontopofleftcontrollever.

HOURMETER

Therighthandnumberonthehourmeter(A)indicates
tenthsofanhour(sixminutes).

TM 5-3805-280-10

T101634 –UN–20JUN96

TX,10,DH5475–19–04JUN96–1/1

TX,10,DH5476–19–24JUN96–1/1

T101639 –UN–26JUN96

2-15

CABHEATERANDAIRCONDITIONER

TM 5-3805-280-10

Operator’s Station

A—ControlPanel
B—FrontVent
C—DefrosterVent
D—FootVent
E—RearVents

T101645 –UN–20JUN96

TX,10,DH5480–19–19JUN96–1/1

2-16

Operator’s Station

CONTROLPANELSWITCHES

ModeSwitches

(A)Airflowsoutoffrontventanddefrostervent.
(B)Airflowsoutoffrontandrearvents,anddefroster

vent.
(C)Airflowsoutoffootventonly.

TM 5-3805-280-10

TemperatureControlSwitches

Eightindicatorsaresituatedjustabovethetemperature
controlswitches(I).Theindicatorswillturnredwhenthe
rightarrowswitchispressed,andgreenwhentheleft
arrowswitchispressed.Airtemperatureishighestifall
indicatorsarered,andcoolestifallindicatorsaregreen.
Eitherwarmorcoolairwillflowoutofvent(s)selectedby
themodeswitches.

BlowerSwitches

Pressblowerswitches(G)toselectdesiredblowerspeed.
AirconditionerwillturnonwhenA/Cswitch(D)ispressed
andanyoftheblowerindicatorsison.WhenblowerOFF
switch(H)ispressed,theblowerandtheairconditioner
willturnoff.Theblowerwillturnonifoneoftheblower
switchesispressedwhethertheairconditionerswitchis
turnedonoroff.

FreshAirVentSwitch

Pressfreshairventswitch(F)torouteoutsideairintothe
cab.Pressairventswitch(E)toclosefreshairventand
circulateairalreadyincab.

T102753 –UN–05AUG96

A—ModeSwitch
B—ModeSwitch
C—ModeSwitch
D—AirConditionerSwitch
E—AirVentSwitch
F—FreshAirVentSwitch
G—BlowerSwitches
H—BlowerOFFSwitch
I—TemperatureControlSwitches

2-17

TX,10,DH5481–19–19JUN96–1/1

TM 5-3805-280-10

Operator’s Station

CABHEATEROPERATION

1.Pressdesiredmodeswitch(A,B,orC).

2.Pressrighttemperaturecontrolswitch(I)untilall

indicatorsarered.

3.Pressblowerswitch(Gtoselectdesiredblowerspeed.

4.Pressairconditionerswitch(D)toturnindicatoroffif

notalreadyoff.

5.Presstemperaturecontrolswitchesandblower

switchestoadjustcabtemperature

T102753 –UN–05AUG96

TX,10,DH5633 –19–26MAR97–1/1

AIRCONDITIONEROPERATION

1.Pressdesiredmodeswitch(A,B,orC).

2.Presslefttemperaturecontrolswitch(I)untilall

indicatorsaregreen.

3.Pressblowerswitch(G)toselectdesiredblower

speed.

4.Pressairconditionerswitch(D)toturnindicatorgreen

ifnotalreadygreen.

5.Presstemperaturecontrolswitchesandblower

switchestoadjustcabtemperature

T102753 –UN–05AUG96

TX,10,DH5483–19–20JUN96–1/1

2-18

TM 5-3805-280-10

Operator’s Station

DEFROSTEROPERATION

1.Pressfrontventmodeswitch(A)orrearventmode

switch(B).

2.Presstemperaturecontrolswitches(I)toselectdesired

airtemperature.

3.Pressfreshairventswitch(F).

4.Pressblowerswitches(G)toselectdesiredblower

speed.

5.Adjustthelouversonfrontventanddefrosterventas

required.

6.Presstemperaturecontrolswitchesandblower

switchestoadjustcabtemperature.

7.Pressairconditionerswitch(F)onifwindowsbecome

cloudedorifdehumidifyingisrequired.

FRONTCONSOLE

T102753 –UN–05AUG96

TX,10,DH5484–19–20JUN96–1/1

2-19

T101647 –UN–07AUG96

A—Radio/Clock

TX,10,DH5485–19–20JUN96–1/1

TM 5-3805-280-10

Operator’s Station

OPERATINGTHEAM/FMRADIO

Presspowerswitch(A)toturnradioon,andrepeatedly
pressoneoftuningswitches(D)untildesiredstationis
reached.Topresetastation,selectthedesiredstation
usingtuningswitches.Pressandholdstationpreset(F)
formorethan2secondsuntilanelectronictoneisheard.
Thefrequencyofthepresetstationwillbeindicatedon
digitaldisplay(G).

T101691 –UN–24JUN96

A—PowerSwitch/VolumeControlKnob
B—ToneAdjustmentRing
C—AM/FMSwitch
D—TuningSwitches
E—DisplayModeChangeSwitch
F—StationPresets
G—DigitalDisplay
H—SetSwitch
I—TimeSetSwitches

SETTINGTHECLOCK

NOTE: In order to set the clock, digital display (B) must

be in the time display mode.

Whilepressingdisplaymodechangeswitch(A)usetime
setswitches(C)andsetswitch(D)tosettheclock.

Presssetswitchtoresettheminutedisplayto“00”.
Presstimesetswitch(H)tosetcorrecthour.
Presstimesetswitch(M)tosetcorrectminute.

TX,10,DH5486–19–06JUN96–1/1

T101692 –UN–24JUN96

A—DisplayModeChangeSwitch
B—DigitalDisplay
C—TimeSetSwitches
D—SetSwitch

TX,10,DH5487–19–06JUN96–1/1

2-20

TM 5-3805-280-10

Operator’s Station

CABDOORRELEASELEVER

Thecabdoorcanbelockedintheopenposition.Open
thedoorallthewayuntilitlocksinthelatchonthesideof
thecab.

Toreleasethedoorfromthislockedposition,pushdown
onlever(A).

SECONDARYEXITTOOL

IMPORTANT:FORSECONDARYEXIT.Usetool(A)to

breakwindow.Alwayskeeptoolin
machine.

T101648 –UN–07AUG96

TX,10,DH5488–19–04JUN96–1/1

OPENINGUPPERFRONT(SECONDARY
EXIT)WINDOW

NOTE: The washer and wiper cannot operate with the

upper front window opened.

1.Movelockpins(A)towardcenterofwindow.

Continuedonnextpage

T105379 –UN–26NOV96

TX,10,DH5967 –19–26NOV96–1/1

T101649 –UN–26JUN96

TX,10,DH5489–19–04JUN96–1/2

2-21

TM 5-3805-280-10

Operator’s Station

2.Pullwindowupandbackuntilitcatchesinlatch(B)for

convenientstorageoverhead.

CAUTION:Preventpossibleinjuryfromwindow
closing.DONOTrelyonlatch(B)alonetohold
thewindowintheupposition.Alwayslockthe
pinsinthecabframebossholes.

3.Slidethetwopins(C)intothecabframebossholes

andturntolock.

T101650 –UN–24JUN96

TX,10,DH5489–19–04JUN96–2/2

CLOSINGUPPERFRONTWINDOW

CAUTION:Preventpossibleinjuryfromwindow
closing.Upperfrontwindowcomesdownvery
forcefully.Closewindowonlywhensittingon
operator’sseat.Guidewindowdownslowly.

1.Pulloutlockpins(A)tounlockwindow.

2.Pushlever(B)toreleaselatch.

3.Pullwindowdownslowly.

4.Slidethetwopins(C)intothecabframebossholes

andturntolock.

T101649 –UN–26JUN96

TX,10,DH5490–19–21JUN96–1/2

2-22

T101650 –UN–24JUN96

TX,10,DH5490–19–21JUN96–2/2

TM 5-3805-280-10

Operator’s Station

REMOVINGANDSTORINGTHELOWER
FRONTWINDOW

NOTE: Upper front window must be raised before lower

front window can be removed.

1.Pullinonlockpins(A)tounlockandremovewindow.

2.Thewindowcanbestoredbyinsertingtabsonbottom

ofwindowintobrackets(B)andlockingthepinsinto
holes(C)locatedbelowrearwindowincab.

NOTE: In cold weather some operators may choose to

work with the top glass open and the bottom glass
in place. This provides excellent visibility and
tends to hold the heat being circulated around the
operator’s feet.

T101651 –UN–24JUN96

TX,10,DH5491–19–27FEB97–1/2

OPENINGSIDEWINDOWS

CAUTION:Avoidseriouscrushinginjuryfrom
boom.Neverplaceanypartofbodybeyond
windowbarorframe.Itcouldbecrushedbythe
boomifboomcontrolleverisaccidentally
bumpedorotherwiseengaged.

Donotremovewindowbars.Ifwindoworbars
aremissingorbroken,replaceimmediately.

Bothrightsidewindowandcabdoorwindowcanbe
opened.

1.Right-rearsidewindow:Unlatchthelock(A).Pushjoint

partoflocktoopenwindow.

2.Cabdoorwindow:Slidefrontpanetotherearandrear

panetothefront.

T105380 –UN–26NOV96

TX,10,DH5491–19–27FEB97–2/2

T101653 –UN–24JUN96

2-23

TX,10,DH5492–19–04JUN96–1/1

Operator’s Station

OPENINGANDCLOSINGTHEROOFEXIT
COVER

Opening:

1.Movelockpins(A)towardcenterofroofexitcover.

2.Pushonhandle(B)toopenroofexitcover.

Closing:

TM 5-3805-280-10

Holdhandleandpullcoverdownuntilpinslockin
position.

REMOVINGANDSTORINGFIRE
EXTINGUISHER(MODEL230LCR)

NOTE: On model 230LCRD the fire extinguisher is

mounted in the battery compartment.

REMOVING

1.Pullthelatch(A)outward.

2.Removeextinguisher.

STORING

T101654 –UN–24JUN96

TX,10,DH5944 –19–01DEC97–1/1

T120368 –UN–25MAR99

A—LatchAssembly

1.Insertextinguisherintotheseat.

2.Closelatchassembly(A).

TX,OUOE042,10 –19–19FEB99–1/1

2-24

TM 5-3805-280-10

Operator’s Station

ROCKDRILLSTART—STOPSELECTION
CONTROLBOX(MODEL230LCRD)

Settheselectorswitch(B)totheBpositionfornormal
excavatoroperation.

Settheselectorswitch(B)totheApositiontoactivatethe
electricalandhydrauliccircuitsfortherockdrill.Whenset
totheAposition,allpilothydraulicsfortheexcavatorare
neutralized.

A—RockDrillStart—StopSelectionControlBox
B—SelectorSwitch

CED,OUOEBAS,1–19–19JAN00–1/1

T125072 –UN–28OCT99

2-25

COMPRESSORREMOTEINSTRUMENT
CONTROLPANEL(MODEL230LCRD)

TM 5-3805-280-10

Operator’s Station

T125073 –UN–28OCT99

A—CompressorRemoteInstrumentControlPanel

REMOVINGANDSTORINGRIFLE

REMOVING

1.Openlatch(A)andremovebarrel.

2.Liftriflefromsaddle.

STORING

1.Insertriflebuttintosaddle.

2.Snapbarrelintolatch(A).

CED,OUOE042,47–19–19OCT99–1/1

T120371 –UN–25MAR99

A—Latch

2-26

TX,OUOE042,11 –19–19FEB99–1/1

Operator’s Station

J-HOOKS

TheJ-Hooks(A)areusedtohangtheoperator’sLoad
BearingEquipment(LBE)andindividualchemical
equipmentbag.

TM 5-3805-280-10

T120374 –UN–25MAR99

A—J-Hooks

TOOLBOXSECURITYHASP

Thetoolboxsecurityhasp(A)islocatedontheinside
cornerofthetoolbox.Thehaspisusedtosecurethe
toolbox.

TX,OUOE042,12 –19–19FEB99–1/1

T120370 –UN–25MAR99

A—ToolboxSecurityHasp

TX,OUOE042,16 –19–01MAR99–1/1

2-27

TM 5-3805-280-10

Operator’s Station

DECONTAMINATIONKITBRACKET

Thedecontaminationkitbracket(A)islocatedbetween
thetoolboxandtheboom.Thedecontaminationkitis
securedwithastrap(B).

T120373 –UN–28OCT99

A—DecontaminationKitBracket
B—Strap

TX,OUOE042,17 –19–01MAR99–1/1

VANDALPROTECTIONPANELSTORAGE

Theuppersectionofthewindshieldpanelstoresonthe
leftfrontaccessdoorofthemachine.Useknob(A)to
securethepaneltothedoor.Theremainingpanelsstore
inthebox(B)atopthemachine.

T120414 –UN–25MAR99T120415 –UN–25MAR99

2-28

A—Knob
B—StorageBox

TX,OUOE042,20 –19–04MAR99–1/1

TM 5-3805-280-10

Operator’s Station

ADJUSTINGTHESEAT

Turnknob(A)toadjustseattoweightofoperator.Weight
isdisplayedonknob.

Pushdownlever(B)whilesittingonseatorwhile
standingandpullinguponseattoobtaindesiredheight.
Releaselever.Pushdownleverwhilesittingonseatto
adjustseattodesiredangle.Releaselever.

Pushdownlever(C)toadjustseatandbothrightandleft
consolestodesireddistancefromtravelpedalsand
levers.Releaselevertolockseatandconsolesinto
position.

Pulluplever(D)tounlockseatfrombothconsoles.Slide
theseattodesireddistancefromcontrollevers.Release
lever.

Pulluplever(E)toreleasebackrestlock.Movebackrest
todesiredpositionandreleaselever.

A—WeightAdjustmentKnob
B—SeatHeightAndAngleAdjustment
C—ConsoleAndSeatFore-AftAdjustmentLever
D—SeatFore-AftAdjustment
E—BackrestAdjustment

TX,10,DH5494 –19–29JUL96–1/1

T102204 –UN–26JUL96

2-29

TM 5-3805-280-10

Operator’s Station

ADJUSTINGTHEARMREST

Pulluponarmrest(A)tomovearmrestoutofwaywhen
exiting.

Turndial(B)toadjustangleofarmrest.

T107760 –UN–27FEB97

A—Armrest
B—Dial

TX,10,DH5412–19–27FEB97–1/1

SEATBELT

Seatbeltandmountinghardwaremustbeinspected
forwearordamagebeforeoperatingthemachine.
Replacethebeltormountinghardwareifwornor
damaged.

T8415AA –UN–09FEB95

Replacethecompleteseatbeltassemblyeverythree
yearsregardlessofappearance.Adatelabel,to
determinetheageofthebelt,isattachedtoeachbelt.

OPERATOR’SMANUALCOMPARTMENT

Storeoperator’smanualbehindtheseat.

TX,10,DH3548 –19–22MAR99–1/1

TX,10,DH5064–19–24JUN96–1/1

2-30

TM 5-3805-280-10

CHAPTER 3

BREAK-IN

TM 5-3805-280-10

BLANK

ENGINEBREAK-INOIL

TM 5-3805-280-10

Break-In

NewenginesarefilledatthefactorywithJohnDeere
ENGINEBREAK-INOIL.ThisisanSAE5W-30
viscosityoil.Duringthebreak-inperiod(first100
hours),addoilasneededtomaintainthespecifiedoil
level.(SeeFuelsandLubricantschapter.)

Ifatanytimeduringthebreak-inperiod,theengineis
exposedtoairtemperaturesbelow-25°C(-13°F),
changetheoilandfilterusingspecifiedoil.(SeeFuels
andLubricantschapter.)

Changetheoilandfilterafterthefirst100hoursof
operation.Refillwithspecifiedoil.(SeeFuelsand
Lubricantschapter.)

•APIServiceClassificationCE

PLUS-50 is a trademark of Deere & Company.

•CCMCSpecificationD4
Afterthebreak-inperiod,useJohnDeerePLUS-50

otherdieselengineoilasrecommendedinthis
manual.

IMPORTANT:DonotuseJohnDeerePLUS-50

orengineoilsmeetingAPICG4,API
CF4,orCCMCD5performancelevels
duringthefirst100hoursof
operationofaneworrebuiltengine.
Theseoilswillnotallowtheengine
tobreak-inproperly.

CED,OUOE020,50–19–13APR99–1/1



or



oil

EVERY4HOURS

Lubricateboom,arm,andbucketlinkageevery4hours
forthefirst20hoursofoperation.(SeeMaintenance—
Every50Hourschapter.)

TX,15,DH5496 –19–12JUL96–1/1

3-1

TM 5-3805-280-10

Break-In

EVERY10HOURSORDAILY

1.Perform10hoursordailyservice.(SeeMaintenance—

Every10HoursorDailychapter.)

2.Watchforfluidleaks.

3.Lubricateworkingtoolpivotsevery10hoursduringthe

first30—100hoursofoperationandwhenworkingin
mudorwater.(SeeMaintenance—Every50Hours
chapter.)

TX,15,DH5497 –19–12JUL96–1/1

AFTERTHEFIRST50HOURS

1.Perform10hoursordailyand50hourservice.(See

Maintenance—Every10HoursorDailyand
Maintenance—Every50Hourschapters.)

2.Changehydraulicoilfilter(SeeMaintenance—Every

500Hourschapter)andpilotfilter(SeeMaintenance—
Every1000Hourschapter).

3.Checkaccessiblehardwaretorque.(SeeHardware

TorqueSpecificationsinMaintenancechapter.)

TX,15,DH5498 –19–06JUL94–1/1

3-2

TM 5-3805-280-10

Break-In

AFTERTHEFIRST100HOURS

1.Perform10hourordailyand50hourservice.(See

Maintenance—Every10HoursorDailyand
Maintenance—Every50Hourschapters.)

2.Changeengineoilandfilter.(SeeMaintenance—Every

250Hourschapter.)

3.Changefuelfilter.(SeeMaintenance—Every500

Hourschapter.)

TX,15,DH5499 –19–06JUL94–1/1

3-3

TM 5-3805-280-10

BLANK

3-4

TM 5-3805-280-10

CHAPTER 4

PRE-START INSPECTION

TM 5-3805-280-10

BLANK

TM 5-3805-280-10

Pre-StartInspection

INSPECTMACHINEDAILYBEFORE
STARTING

DoperiodicservicechecksintheMaintenance—Every10
HoursorDailychapter.

A—Checkpedalsandleversforfreedomofmovement.
Cleanoperator’sstation.

B—Checkhydraulicreservoiroillevel.
C—Checkengineoillevel.
D—Checkcoolantlevelatrecoverytank.
E—Cleanradiatorandoilcoolerfins.
ELECTRICALSYSTEM:Checkforwornorfrayedwires

andlooseorcorrodedconnections.
BOOM,BUCKET,SHEETMETAL,TRACKS:Checkfor

bent,broken,loose,ormissingparts.
HARDWARE:Checkforlooseormissingparts.
FUELSYSTEM:Drainfuelfilterandfueltanksump.
HYDRAULICSYSTEM:Checkforleaks,missingorloose

clamps,kinkedhoses,andlinesorhosesthatrubagainst
eachotherorotherparts.

LUBRICATION:ChecklubricationpointsonPeriodic
Maintenancechart.

PROTECTIVEDEVICES:Checkguards,shields,covers.
SAFETY:Walkaroundmachinetoclearallpersonsfrom

machinearea.

T105341 –UN–25NOV96

4-1

TX,20,DH5500 –19–25NOV96–1/1

TM 5-3805-280-10

BLANK

4-2

TM 5-3805-280-10

CHAPTER 5

OPERATING THE ENGINE

TM 5-3805-280-10

BLANK

TM 5-3805-280-10

OperatingtheEngine

CHECKINSTRUMENTSBEFORESTARTING

TurnkeyswitchtoONposition.Allindicatorlightswillstay
onforapproximately3seconds.

Theindicatorlightswillalsostayonforapproximately3
secondswhenthekeyswitchisturnedtoSTARTposition.

Ifanylampfailstolight,thebulbmaybeburnedout.
Thefuelgaugewillshowthefuellevel.
ThecoolantgaugeshouldNOTgototheredzone.

T7396DS –UN–27JUN91

TX,25,DH5501 –19–29MAY96–1/1

LEVELCHECK

1.TurnkeyswitchtoONposition.

2.Presslevelcheckswitch(A).

3.Hydraulicoillevel(B)enginecoolantlevel(C)and

engineoillevel(D)indicatorswilllightiflevelsare
adequateforoperation.

IMPORTANT:ThelevelcheckdoesNOTtakethe

placeofdailychecksathydraulicoil
levelwindow,enginecoolantrecovery
tank,andengineoilleveldipstick.

5-1

T107675 –UN–27FEB97

TX,25,DH5405–19–27FEB97–1/1