Perform Operator's Preventive-Maintenance Checks and Services on a Hydraulic Excavator 21J10B01 / Version ADT 01 Oct 2006

SECTION I. All Courses Including This Lesson Task(s) Taught(*) or Supported

ADMINISTRATIVE DATA
Course Number Version Course Title

052-21J10 (R)

RCLS

General Construction Equipment Operators Course

Task Number

Task Title

INDIVIDUAL 052-255-1165 (*) Perform Operator's Preventive-Maintenance Checks and Services (PMCS) on a Hydraulic Excavator
Task Title

Reinforced Task(s) Academic Hours

Task Number

The academic hours required to teach this lesson are as follows:

ADT Hours/Methods

Test Test Review Total Hours: Test Lesson Number

/ Conference/Demonstration 25 mins / Demonstration 2 hrs 25 mins / Practical Exercise (Hands-on) 4 hrs / Practical Exercise (Performance) 0 hrs 0 hrs 8 hrs
Hours Lesson No.

1 hr

Testing
(to include test review)

N/A
Lesson Title

Prerequisite Lesson(s) Clearance Access Foreign Disclosure Restrictions References

Lesson Number

None

Security Level: Unclassified Requirements: There are no clearance or access requirements for the lesson. FD5. This product/publication has been reviewed by the product developers in coordination with the Fort Leonard Wood, MO / Maneuver Support Center foreign disclosure authority. This product is releasable to students from all requesting foreign countries without restrictions.
Additional Information Number Title Date

TM 5-3805-280-10

Operator's Manual for Hydraulic Excavator John Deere Model 230LCR (NSN 3805-01-463-0804) and Model 230LCRD With Rock Drill (NSN 3805-01463-0806).

15 Feb 2000

Student Study Assignments Instructor Requirements Additional Support Personnel Requirements Equipment Required for Instruction

Read student guide Instructors must be ITC certified, course certified and licensed.
Stu Ratio

Name

Qty

Man Hours

Fuel Handler (Enlisted)

Id Name Stu Ratio Instr Ratio

8 hrs

Spt

Qty

Exp

3805-01-463-0804 Excavator, Multipurpose, Crawler M (HYEX) 4240-00-022-2946 Protector, Hearing 4240-00-052-3776 Goggles, Industrial 4930-00-253-2478 Lubricating Gun, Hand 4930-00-926-3581 Tank and Pump Unit, Fuel Dispensing 5120-00-189-7935 Socket, Socket Wrench, 15/16, 1/2" drive 5120-00-541-8444 Handle, Socket Wrench, 1/2" drive 7000-21-000-0115 Radio System, Trunk, Handheld, MACOM, UHF P170 Model 128 7920-00-205-1711 Rag, Wiping 8415-00-268-7868 Gloves, Work, Men's and Women's 8415-00-857-4915 Helmet, Safety, Construction Workers * Before Id indicates a TADSS

1:3 1:1 1:1 1:2 1:1 1:1

No No No No Yes

1 0 0 0 1 0 0 0

No Yes Yes Yes No Yes No No

1:2 1:2 1:2 1:1

No No No

1:12 1:1 1:1 1:1 1:1

No No No

0 0 0

Yes No Yes

Materials Required

Instructor Materials:
Gloves Goggles Hard hat Safety boots B01 Lesson plan Hearing protection TM 5-3805-280-10

Student Materials:
Gloves Goggles Safety boots Pen or pencil Kevlar/hard hat Hearing protection TM 5-3805-280-10 Equipment records folder

Classroom, Training Area, and Range Requirements Ammunition Requirements Instructional Guidance

AUTO-AID INST, 1400 SF (Classroom XXI) MED/HV EQUIP TR RG SPT FAC SIM BLD NON-MOT, 2400 SF
Id Name Exp Stu Ratio Instr Ratio Spt Qty

None NOTE: Before presenting this lesson, instructors must thoroughly prepare by studying this lesson and identified reference material.

1. Ensure classroom is set-up for training. a. One student guide per student. b. Ensure the computer interface is operational. c. Maintain a clean classroom. 2. Have inclement weather lesson plans on hand and ready for implementation.
Proponent Lesson Plan Approvals
Name Rank Position Date

Blake, Timothy King, Ronnie Goff, Daniel

GS-11 GS-12 GS-14

Training Specialist Chief CE Branch Chief DOTLD

02 Oct 2006 02 Oct 2006 02 Oct 2006

SECTION II.

INTRODUCTION

Method of Instruction: Conference/Demonstration Instructor to Student Ratio is: 1:6 Time of Instruction: 5 mins Media: Hands-on Instruction
Motivator

NOTE: Allow one to two minutes for the lesson introduction. Explain the Contemporary Operational Environment (COE) to include lessons learned. Ensure the students are aware of how it will affect them during their future assignments. The purpose of this lesson is to provide you with the skills and knowledge required to effectively perform operators PMCS on a hydraulic excavator in a combat and peacetime environment.

Terminal Learning Objective

NOTE: Inform the students of the following Terminal Learning Objective requirements. At the completion of this lesson, you [the student] will: Action: Conditions:

Perform Operator's Preventive-Maintenance Checks and Services on a Hydraulic Excavator At a training site, given a HYEX, TM 5-3805-280-10, a student guide, an equipment records folder, a grease gun, petroleum, oil, and lubricants (POL), rags, and all personal protective equipment. Performs operator's PMCS on the hydraulic excavator utilizing the PMCS table in TM 5-3805-280-10. Annotates all deficiencies on DA Form 5988-E, corrects all operator deficiencies, and gives the DA Form 5988-E to the maintenance supervisor. Performs all levels of PMCS without error and without damage to equipment or injury to personnel.

Standards:

Safety Requirements

Review local training area SOP. Kevlars/Hard hats must be worn at all times. Hearing protection must be worn while equipment is running. Eye protection, gloves, and must be worn when required. Use three points of contact when mounting or dismounting equipment. Remove all jewelry. Use caution around moving parts. Low - Instructors should complete a risk assessment before conducting training operations, or logistical operations.
NOTE: It is the responsibility of all Soldiers and DA civilians to protect the

Risk Assessment Level Environmental Considerations

environment from damage. Avoid unnecessary stripping of vegetation and waterways. Control dust conditions and limit water erosion by dressing area at the end of each day. Explain the purpose of drip pans and their location under the equipment. Avoid unnecessary equipment usage and follow established procedures for cleanup of fluid leaks. Restore site and surrounding areas as close as possible to the original ecological condition. Performance evaluation, refer to the student evaluation plan in the student guide.

Evaluation

Instructional Lead-In

As with all equipment, if it is not properly cared for it will not remain operational. Checking the oil, water and tracks etc. is the operators responsibility. If your assigned equipment is not kept operational, you will not be able to accomplish your mission. Pay close attention and learn how to perform these simple checks to ensure you and your machine can successfully complete your units missions.

SECTION III.

PRESENTATION

1.

Learning Step / Activity 1. Conduct an Equipment Familiarization Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Demonstration 1:6 25 mins Hands-on Instruction

NOTE: The first 30 minutes of this block of training is intended to be refresher to the prerequisite dL phase. A. Conduct an Equipment walk around Inspection 1) Engine a) Location b) 6-cylinder diesel c) Engine oil - 15W-40

d) Engine Oil capacity - 5 gallons 2) Coolant System a) Radiator capacity - 6 gallons b) Coolant mixture - 50/50 water antifreeze mix c) Coolant recovery tank

d) Normal operating range is between 120 - 130 3) Fuel System a) Tank located on right side b) Fuel tank capacity - 82 gallons 4) Hydraulic System a) Tank located right side behind fuel tank b) System oil 10W

c)

Hydraulic tank capacity - 39 gallons

d) Hydraulic system capacity 71 gallons 5) Electrical System a) Battery located inside left rear engine compartment b) Slave receptacle 24 volt 6) Undercarriage a) Propel motors b) Tracks c) Track tension

d) Track shoes and bolts e) Track bearings f) Drive sprocket

g) Lower rollers 7) Hydraulic Attachments a) Boom assembly b) Boom cylinder c) Dipper arm

d) Dipper cylinders e) Bucket assembly f) Hydraulic quick latch

g) Lift Point h) Remote lube 8) Operator Compartment Controls and Instruments a) Right front panel and right console panel (1) Monitor panel (2) Switch panel (3) Air conditioner panel (4) Engine RPM dial

(5) Economy mode switch (6) High power mode switch (7) Key switch (8) Rear light switch (9) Overload alarm/indicator b) Monitor panel (1) Engine coolant temperature gauge (2) Warm up indicator (3) Fuel gauge (4) High power mode indicator (5) Economy mode indicator (6) Auto idle indicator (7) Hydraulic oil level indicator (8) Fuel lever indicator (9) Air filter restriction indicator (10) (11) (12) (13) (14) (15) (16) (17) Charge air temperature indicator Engine coolant temperature indicator Engine oil pressure indicator Alternator voltage indicator Engine oil level indicator Engine coolant level indicator Cab door release Hour meter

c) Switch panel (1) Level check switch (2) Work mode indicator (3) Attachment mode indicator (4) Precision mode indicator

(5) Grading mode indicator (6) Dig mode indicator (7) Buzzer stop switch (8) Propel speed switch (9) Auto idle switch (10) (11) (12) Wiper switch Washer switch Operating light switch

d) Pilot control shut-off lever e) Power boost switch f) Auto-idle switch

g) Mode selection switch (1) Economy mode (2) High Power (H/P) mode (3) Standard mode B. Safety (1) Hard hats will be worn when on or around the equipment. (2) Use three points of contact when climbing in, on or out of the equipment. (3) Remain aware of your surroundings. (4) Wear your seat belt. (5) Sound "FIRE IN THE HOLE" prior to starting the equipment. (6) Sound the horn prior to moving the machine or any attachment. (7) Never back up, swing 180 and move in desired direction. (8) When acting as the ground guide, always maintain eye to eye contact with the operator. (9) If you have a ground guide, remember they are in control. "PAY ATTENTION" (10) At the first sign of lighting, dismount the equipment and find shelter.

CAUTION: Read all warning labels before operating machine. NOTE: Safety depends on our ability to communicate.

C. Travel position. (1) Curl the bucket completely (2) Retract the arm completely (3) Lower the boom and arm assembly until the lowest part of the assembly is 23 from the ground. D. Park line position. (1) Position the dipper arm at a 90 angle. (2) Position the bucket flat on the ground. (3) Close thumb. NOTE: 2. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 2. Perform Before Operations PMCS Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Hands-on) 1:6 25 mins Hands-on Instruction

NOTE: The students may be tested on this task at any time during this practical exercise. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Conduct a Practical Exercise on Before Operations PMCS Refer to appendix C for practical exercise instructions. NOTE: 3. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 3. Demonstrate Starting Procedures Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference/Demonstration 1:6 10 mins Hands-on Instruction

A. Start the Hydraulic Excavator NOTE: NOTE: Refer students to TM 5-3805-308-10 for normal and cold weather starting procedures. 1) Pre-start procedures a) Perform a 360-degree walk around inspection.

NOTE: Always pull pilot control shutoff lever to the locked position whenever you stop the engine or leave the operator's station. b) Perform before operations PMCS IAW TM 5-3805-280-10. c) Adjust the seat.

d) Adjust the mirrors. e) Fasten and adjust the seat belt. f) Ensure pilot control shutoff lever is in the locked position.

NOTE: Refer students to TM 5-3805-280-10. 2) Starting procedures a) Turn engine RPM knob to 1/3 throttle. b) Turn key to on position c) Check the indicator lights (3 seconds).

NOTE: If indicator lights do not go out after starting engine (3 seconds), immediately stop the engine and correct the problem. d) Check the gauges. e) Push the pre-operations level check switch to check: i. ii iii Hydraulic oil level Coolant oil level Engine oil level

NOTE: The electric check does not take the place of the daily check. B. Review Determine if students have learned the material presented by: 1) Soliciting student questions and explanations. 2) Asking questions and receiving answers from the students. 3) Correcting student misunderstandings. NOTE: Conduct a check on learning and summarize the learning activity.

10

4.

Learning Step / Activity 4. Perform During Operations PMCS Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Hands-on) 1:6 25 mins Hands-on Instruction

NOTE: The students may be tested on this task at any time during this block of instruction. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Conduct a Practical Exercise on During Operations PMCS Refer to appendix C for practical exercise instructions. NOTE: 5. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 5. Demonstrate Stopping Procedures Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference/Demonstration 1:6 10 mins Hands-on Instruction

A. Stop the Hydraulic Excavator 1) Leave the machine parked on a level surface. 2) Set the dipper arm at a 90 degree angle with the bucket flat on the ground and the thumb closed (park line position). 3) Set pilot shut off lever to the locked position. 4) Turn off the automatic idle. 5) Bring the engine down to 1/3 throttle. NOTE: Turbo charger can be damaged if the engine is not properly shut down. Allow the machine to idle for 2 minutes prior to turning the key to the off position. 6) Turn the key to the OFF position and remove. 7) Close all windows. 8) Clean tracks. NOTE: Always clean tracks and frames before leaving for the day.

11

B. Review Determine if students have learned the material presented by: 1) Soliciting student questions and explanations. 2) Asking questions and receiving answers from the students. 3) Correcting student misunderstandings. NOTE: 6. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 6. Perform After Operations PMCS Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Hands-on) 1:6 25 mins Hands-on Instruction

NOTE: The students may be tested on this task at any time during this block of instruction. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Conduct a Practical Exercise on After Operations PMCS Refer to appendix C for practical exercise instructions. NOTE: 7. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 7. Demonstrate Manipulation of Controls Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Conference/Demonstration 1:6 20 mins Hands-on Instruction

NOTE: The demonstration will be conducted at the training site. The instructor will explain the control operations while using the appropriate hand and arm signals to communicate with the operator. Manipulate the controls slowly. Assistant operators will be positioned in front of and outside the reach of each excavator. From this position, they will give the operator all hand and arm signals while the operator practices them. A. Perform Manipulation of Controls Using Hand and Arm Signals. 1) Unlock the pilot shut-off lever by pushing it forward. 2) Boom Control a) Pull the boom control lever back to raise the boom. b) Push the boom control lever forward to lower the boom.

12

3) Arm Control a) Push the arm control lever forward to extend the arm. b) Pull the arm control lever back to retract the arm. 4) Bucket Control a) Move the bucket control lever to the left to load the bucket. b) Move the bucket control lever to the right to dump the bucket. 5) Thumb Control a) Push down on the bottom of the pedal to open the thumb. b) Push down on the top of the pedal to close the thumb. 6) Swing Control a) Move the swing control lever to the left to swing left. b) Move the swing control lever to the right to swing right. NOTE: The turning instructions below apply when the propel motors are to the rear of the machine. If the propel motors are to the front of the machine, the machine moves to the opposite direction. 7) Move forward using the foot pedals. a) Push down on the top of the pedal to move forward. b) Push down on the bottom of the pedal to move backward. 8) Configure the HYEX to the travel position. a) Curl the bucket completely b) Retract the arm completely c) Lower the boom and arm assembly until the lowest part of the assembly is 2-3 from the ground. 9) Configure the HYEX to the park line position. a) Position the dipper arm at a 90 angle. b) Position the bucket flat on the ground. c) Close thumb.

13

B. Review Determine if students have learned the material presented by: 1) Soliciting student questions and explanations. 2) Asking questions and receiving answers from the students. 3) Correcting student misunderstandings. NOTE: 8. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 8. Perform Manipulation of Controls Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Hands-on) 1:6 1 hr Hands-on Instruction

NOTE: Assistant operators will be positioned in front of and outside the reach of each excavator. From this position, they will give the operator all hand and arm signals while the operator practices them. The students may be tested on this task at any time during this block of instruction. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Conduct a Practical Exercise on Manipulation of controls Using Hand and Arm Signals Refer to appendix C for practical exercise instructions. NOTE: 9. Conduct a check on learning and summarize the learning activity. Learning Step / Activity 9. Perform Operator's PMCS Method of Instruction: Instructor to Student Ratio: Time of Instruction: Media: Practical Exercise (Performance) 1:6 4 hrs Hands-on Instruction

NOTE: The students may be tested on this task at any time during this block of instruction. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Conduct a Practical Exercise on Operators PMCS Refer to appendix C for practical exercise instructions. NOTE: Conduct a check on learning and summarize the learning activity.

14

SECTION IV.

SUMMARY Method of Instruction: Conference/Demonstration Instructor to Student Ratio is: 1:6 Time of Instruction: 5 mins Media: Hands-on Instruction

Check on Learning

Determine if the students have learned the material presented by soliciting student questions and explanations. Ask the students questions and correct misunderstandings. Restate the learning objectives and then check on learning.

Review / Summarize Lesson

15

SECTION V. Testing Requirements

STUDENT EVALUATION
NOTE: Describe how the student must demonstrate accomplishment of the TLO. Refer student to the Student Evaluation Plan.

Feedback Requirements

NOTE: Feedback is essential to effective learning. Schedule and provide feedback on the evaluation and any information to help answer students' questions about the test. Provide remedial training as needed.

16

Appendix A - Viewgraph Masters (N/A)

A-1

Appendix B - Test(s) and Test Solution(s) (N/A)

B-1

Appendix C - Practical Exercises and Solutions PRACTICAL EXERCISE(S)/SOLUTION(S) FOR LESSON 1: 21J10B01 version ADT PRACTICAL EXERCISE SHEET PE1
Title Lesson Number / Title Introduction Motivator

Perform Preventive Maintenance Checks and Services 21J10B01 version ADT / Perform Operator's Preventive-Maintenance Checks and Services on a Hydraulic Excavator

NOTE: Allow one to two minutes for the lesson introduction. Explain the Contemporary Operational Environment (COE) to include lessons learned. Ensure the students are aware of how it will affect them during their future assignments. The purpose of this lesson is to provide you with the skills and knowledge required to effectively perform operators PMCS on a hydraulic excavator in a combat and peacetime environment.

Terminal Learning Objective

NOTE: The instructor should inform the students of the following Terminal Learning Objective covered by this practical exercise. At the completion of this lesson, you [the student] will: Action: Perform Operator's Preventive-Maintenance Checks and Services on Conditions:

Standards:

a Hydraulic Excavator At a training site, given a HYEX, TM 5-3805-280-10, a student guide, an equipment records folder, a grease gun, petroleum, oil, and lubricants (POL), rags, and all personal protective equipment. Performs operator's PMCS on the hydraulic excavator utilizing the PMCS table in TM 5-3805-280-10. Annotates all deficiencies on DA Form 5988-E, corrects all operator deficiencies, and gives the DA Form 5988-E to the maintenance supervisor. Performs all levels of PMCS without error and without damage to equipment or injury to personnel.

Safety Requirements

Review local training area SOP. Kevlars/Hard hats must be worn at all times. Hearing protection must be worn while equipment is running. Eye protection, gloves, and must be worn when required. Use three points of contact when mounting or dismounting equipment. Remove all jewelry. Use caution around moving parts. Low - Instructors should complete a risk assessment before conducting training operations, or logistical operations. It is the responsibility of all Soldiers and DA civilians to protect the environment from damage. Avoid unnecessary stripping of vegetation and waterways. Control dust conditions and limit water erosion by dressing area at the end of each day. Explain the purpose of drip pans and their location under the equipment. Avoid unnecessary equipment usage and follow established procedures for cleanup of fluid leaks. Restore site and surrounding areas as close as possible to the original ecological condition.

Risk Assessment Environmental Considerations

D-1

Evaluation Instructional Lead-In

Performance evaluation, refer to the student evaluation plan in the student guide. As with all equipment, if it is not properly cared for it will not remain operational. Checking the oil, water and tracks etc. is the operators responsibility. If your assigned equipment is not kept operational, you will not be able to accomplish your mission. Pay close attention and learn how to perform these simple checks to ensure you and your machine can successfully complete your units missions.
Instructor Materials:

Resource Requirements

Gloves Goggles B01 TSP Hard hat Safety boots Hearing protection TM 5-3805-280-10
Student Materials:

Special Instructions

Gloves Goggles Safety boots Kevlar/hard hats Hearing protection TM 5-3805-280-10 Equipment records folder 1) If the weather does not permit out door training due to thunder storms, lighting, excessive heat or excessive cold etc., the phase will implement their inclement weather training plans and continue training indoors. 2) Inform the students where to go in case of a sever storm or tornado. 3) When the ground is saturated with water, it may be necessary to shut training down early to allow removal of mud from tracks which could cause equipment damage.

Procedures

NOTE: The students may be tested on this task at any time during this block of instruction. If the student tests out on this task early THEY ARE STILL REQUIRED TO COMPLETE THE ENTIRE BLOCK OF TRAINING. Refer students to the lubrication chart for the appropriate checks and intervals. A. Practical Exercise Instructions. 1) Ensure students have required materials and references. 2) The practical exercise for PMCS training will be conducted each day utilizing 25 minutes for before operation PMCS, 10 minutes for during operation PMCS and 25 minutes for after operation PMCS. 3) After performing PMCS, the next 2 hours of practical exercise will be for control manipulation. 4) The last 4 hours of PMCS will be conducted at the end of HYEX phase reinforcing Before, During and After operations PMCS and conducting the Weekly and Monthly PMCS. During this 4 hour

D-2

maintenance block, the equipment will be washed, lubricated, worn out cutting edges and teeth replaced and any other operator maintenance needed to maintain the equipment. 5) Review (with students not operating equipment). a) Solicit student questions. b) Ask questions. c) Correct student misunderstandings.

6) Actively observe students progress and provide assistance as necessary throughout the exercise. 7) At the end of training the day, park and secure equipment. 8) Ensure students complete the practical exercise within the allotted time.

Feedback Requirements

D-3

SOLUTION FOR PRACTICAL EXERCISE SHEET PE1

Evaluation Guidance: Score the Soldier GO if all steps are passed (P). Score the Soldier NO-GO if any step is failed (F). If the Soldier fails any step, retrain and retest them. Retraining will be conducted outside of the training day. 1st NO GO 2nd NO GO

PERFORMANCE MEASURES Did the student: 1. Perform a 360 degree walk around of equipment. 2. Perform before operations PMCS. 3. Perform pre-start procedures. 4. Perform starting procedures. 5. Configure HYEX to travel position.

DATE

GO

PRE-OPERATION PROCEDURES

_______ _______ _______ _______ _______

____ ____ ____ ____ ____

________ ________ ________ ________ ________

________ ________ ________ ________ ________

AFTER OPERATION PROCEDURES Did the student: 1. Configure HYEX to park line position. 2. Perform stopping procedures. 3. Perform after operations PMCS. _______ _______ _______ ____ ____ ____ ________ ________ ________ ________ ________ ________

Evaluators Comments: ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Evaluator's Signature: ______________________________________________________________ Evaluator's Signature: ______________________________________________________________

D-4

Appendix D - Student Handouts (N/A)

D-5