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
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LIST OF EFFECTIVE PAGES
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the page. Updates to wiring diagrams are indicated by shaded areas.
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Original .. 0 .. 15 February 2000
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TM 5-3805-280-10
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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 AMSTA-LC-CI@ria.army.mil. The fax number is DSN 793-0726 or
Commercial (309) 782-0726.
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
TM 5-3805-280-10
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
ii
TM 5-3805-280-10
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
vii
TM 5-3805-280-10
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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TM 5-3805-280-10
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
TM 5-3805-280-10
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/(810) 574-7215, DSN 786-7420/(810) 574-7420,
or DSN 786-8297/(810) 574-8297. 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: (810) 574-5314
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: (810) 574-7215
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
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