TM 5-3805-293-10

TECHNICAL MANUAL

OPERATOR'S MANUAL
FOR

MOTORIZED ROAD GRADER

MODEL 120M
(NSN 3805-01-560-2384)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

DECEMBER 2010
&'()*+,"(-'./
This page is blank.
h

TM 5-3805-293-10

WARNING SUMMARY -

This warning summary contains general safety warnings and hazardous materials warnings that must be under-
stood and applied during operation and maintenance of this equipment. Failure to observe these precautions could
result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials
icons used within the technical manual.
FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS 0000

EAR PROTECTION - headphones over ears show that noise level will harm ears.

ELECTRICAL - electrical wire to arm with electricity symbol running through human
body shows that shock hazard is present.

EYE PROTECTION - person with goggles shows that the material will injure the
eyes.

FLYING PARTICLES - arrows bouncing off face with face shield show that particles
flying through the air will harm face.

HEAVY OBJECT - human figure stooping over heavy object shows physical injury
potential from improper lifting techniques.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush
and harm.

HEAVY PARTS - heavy object on human figure shows that heavy parts present a
danger to life or limb.

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

PINCH POINT - Object crushing human figure shows that areas between vehicles or
parts present a danger to life or limb.

SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a
danger from falling.

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION 0000

WARNING

120M MOTOR GRADER OPERATION 0000

Use of seat belt while operating machine is mandatory. Failure to follow this warning may result in
injury or death to personnel in the event of an accident or machine overturn.

WARNING

COMPRESSED AIR 0000

Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed
30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) when using compressed
air. Failure to follow this warning may result in injury or death to personnel.

WARNING

HEARING PROTECTION 0000

Hearing protection is required when standing within 50 ft (15.2 m) of the 120M Motor Grader while
it is operating. Failure to wear hearing protection may result in hearing loss.

WARNING

HEAVY COMPONENTS 0000

Use extreme caution when handling heavy parts. Lifting device is required when parts weigh 50 lb
(23 kg) for a single person lift, over 100 lb (45 kg) for a two person lift, and over 150 lb (68 kg) for a
three or more person lift. Keep clear of heavy parts supported only by lifting device. Failure to
follow this warning may result in death or injury to personnel or damage to equipment.

WARNING

HOT COMPONENTS 0000

Components with metal parts can cause severe burns at operating temperature. Allow
components to cool before performing maintenance on them. Wear insulated gloves, long sleeves,
and eye protection when working with heated parts. Failure to follow this warning may result in
injury to personnel.

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

SLAVE STARTING ENGINE 0000

When slave starting the engine of the 120M Motor Grader:

– Use NATO slave cable that does NOT have loose or missing insulation.
– DO NOT proceed if suitable cable is not available.
– DO NOT use civilian-type jumper cables.
– DO NOT allow disabled 120M Grader and booster vehicle to come in contact with
each other at any time during slave starting.
Failure to follow these warnings may result in injury or death to personnel or damage to equip-
ment.

EXPLANATION OF HAZARDOUS MATERIALS ICONS 0000

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or
viruses that present a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or irrita-
tion to human skin or tissue.

FIRE - flame shows that a material may ignite and cause burns.

HIGH PRESSURE FUEL - high pressure fuel spraying human hand shows that fuel
escaping under great pressure can cause injury or death.

RADIOACTIVE - identifies a material that emits radioactive energy and can injure
human tissue or organs.

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

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION 0000

WARNING

BATTERIES 0000

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around
batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around
batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all
jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal,
a direct short will result in instant heating or electric shock, damage to equipment, and injury to
personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes
contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects.
Failure to follow these procedures may result in death or injury to personnel.
– EYES. Flush with cold water for no less than 15 minutes and seek medical
attention immediately.
– SKIN. Flush with large amounts of cold water until all acid is removed. Seek
medical attention as required.
– INTERNAL. If corrosion or electrolyte is ingested, drink large amounts of water or
milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical
attention immediately.
– CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize
acid with baking soda or household ammonia.
– CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals, and related
accessories contain lead and lead components. These chemicals are known to
the State of California to cause cancer and reproductive harm. Wash hands after
handling.

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!! 0000

• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of
oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of
headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain
damage or death can result from severe exposure.

• Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide
can become dangerously concentrated under conditions of inadequate ventilation. The following
precautions must be observed to ensure safety of personnel when the engine of the 120M Motor
Grader is operated.

– DO NOT operate engine in enclosed areas.

– DO NOT idle engine without adequate ventilation.

– BE ALERT for exhaust poisoning symptoms. They are:

• Headache

• Dizziness

• Sleepiness

• Loss of muscular control

– If you see another person with exhaust poisoning symptoms:

• Remove person from area.

• Expose to fresh air.

• Keep person warm.

• DO NOT permit physical exercise.

• Administer Cardiopulmonary Resuscitation (CPR) if necessary.

• Notify a medic.

– BE AWARE. The field protective mask for Chemical, Biological, Radiological, and
Nuclear (CBRN) protection will not protect you from carbon monoxide poisoning.

– CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its

constituents are known to the State of California to cause cancer, birth defects,
and other reproductive harm.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION!

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

CARC PAINT 0000

• The following must be done before grinding, cutting, or welding any equipment that has been CARC-
coated:
– Wear protective equipment (e.g., goggles, gloves, apron) when grinding or
sanding CARC-coated equipment. Do not leave any skin exposed.
– Use high-efficiency air purifying respirators when grinding or sanding CARC-
coated equipment.
– Never weld or cut CARC-coated equipment; grind or sand off CARC paint
completely before welding.
– CARC paint contains isocyanate (HDI) which is highly irritating to skin and
respiratory system. High concentrations of HDI can produce symptoms of itching
and reddening of skin, a burning sensation in throat, and nose and watering of the
eyes. In extreme concentrations, HDI can cause coughing, shortness of breath,
pain during respiration, increased sputum production, and chest tightness.
• Failure to follow these warnings may result in injury or death to personnel.

WARNING

HAZARDOUS WASTE DISPOSAL 0000

• When servicing this equipment, performing maintenance, or disposing of materials such as engine/
hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety
office for local regulatory guidance.
• Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills.
• Failure to follow these warnings may result in injury or death to personnel.

WARNING

HYDRAULIC SYSTEM PRESSURE 0000

• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and
hydraulic system pressure has been relieved. Tighten all connections before applying pressure.
Escaping hydraulic fluid under pressure can penetrate skin.
• Use a piece of cardboard, newspaper, or wood to check for pressurized leaks, to prevent fluid pene-
trating the skin.
• Failure to follow these warnings may result in injury or death to personnel.

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

CBRN EXPOSURE 0000

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air
cleaner media. Contaminated filters must be handled using adequate precautions and must be
disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate
handling or disposal procedures. Failure to follow this warning may result in injury or death to
personnel.

To order this CBRN decal use:

National Stock Number (NSN) - 7690-01-474-3533
Part Number (PN) - 1709220
Commercial and Government Entity Code (CAGEC) - 11083

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 TM 5-3805-293-10

GENERAL SAFETY WARNING DESCRIPTION – CONTINUED

WARNING

SOLVENT CLEANING COMPOUND 0000

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxicity
material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles.
Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to
follow this warning may result in injury or death to personnel.

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 TM 5-3805-293-10

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    9  

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

"   - Approved for public release; distribution is unlimited.

0
 TM 5-3805-293-10

TABLE OF CONTENTS -

WP Sequence No. -

Page No. -

How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Chapter 1 - General Information, Equipment Description, and Theory of Operation
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001
Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003
Chapter 2 - Operator Instructions
Description and Use of Operator Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004
Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005
Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006
Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007
Stowage and Decal/Data Plate Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008
Chapter 3 - Troubleshooting Procedures
Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009
Operator Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011
Chapter 4 - PMCS Instructions
Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012
Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013
Chapter 5 - Maintenance Instructions
Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014
Blade Lift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015
Brake Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016
Centershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017
Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018
Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019
Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020
Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021
Fuel/water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0023
Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0024
Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025
Scarifier Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026
Scarifier Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027
Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028
Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0029

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Chapter 6 - Supporting Information

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030
Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0032
Index

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 TM 5-3805-293-10

HOW TO USE THIS MANUAL -

NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you
need, notify your supervisor.
INTRODUCTION
1. This manual contains operating instructions, and operator-level maintenance procedures, for the Motorized
Road Grader Model 120M.
2. This manual is written in work package format:
a. Chapters divide the manual into major categories of information: General Information, Equipment
Description, and Theory of Operation; Operator Instructions; Troubleshooting Procedures; Preventive
Maintenance Checks and Services (PMCS) Instructions; Maintenance Instructions; and Supporting
Information.
b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002)
located on the upper right-hand corner of each page. The work package page number (e.g., 0001-1,
0001-2) is located centered at the bottom of each page.
3. Read through this manual to become familiar with its organization and contents before attempting to operate
or maintain the equipment.
CONTENTS OF THIS MANUAL
1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before
operating or maintaining the grader.
2. The Table of Contents, located in the front of the manual, lists all chapters and work packages in the publica-
tion. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the
back of the manual.
3. Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general informa-
tion about the grader, identifies the major components and systems, and describes how the components and
systems work.
4. Chapter 2, Operator Instructions, identifies operating controls and indicators and explains how to use them.
This chapter covers grader operating procedures under usual and unusual conditions. It also contains the
Stowage and Decal/Data Plate Guide.
5. Chapter 3, Troubleshooting Procedures, describes procedures for locating and correcting malfunctions of the
grader. Included in this chapter is the Troubleshooting Index. If the loader malfunctions, this index should
always be consulted to locate the appropriate troubleshooting procedure.
6. Chapter 4, Preventive Maintenance Checks and Services (PMCS) Instructions, contains operator-level pre-
ventive maintenance and lubrication procedures for the grader.
7. Chapter 5, Maintenance Instructions, contains work packages with information on operator-level mainte-
nance of the grader.
8. Chapter 6, Supporting Information, contains the following: References; Components of End Item (COEI) and
Basic Issue Items (BII) Lists; Additional Authorization List, and Expendable and Durable Items List.

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 TM 5-3805-293-10

FEATURES OF THIS MANUAL

1. This manual contains information on operating and maintaining the 120M Motorized Road Grader.
2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are titled in BOLD print
as a visual aid.

WARNING
A WARNING indicates a hazard which may result in injury or death to personnel.

CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result
in damage to equipment.

NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.
4. Within a procedural step, reference may be made to another chapter or work package in this manual or to
another manual. These references indicate where you should look for more complete information. If you are
instructed to: “Replace air filter (WP 0014)”, go to WP 0014 in this manual for instructions on air cleaner
replacement.
5. Illustrations are placed after, and as close as possible to, the procedural steps to which they apply. Callouts
placed on the art are text or numbers.
6. Numbers located at the lower right corner of art (e.g., 469-0033; 469-0850) are art control numbers and are
used for tracking purposes only. Disregard these numbers.
7. Technical instructions include standard units as well as metric units. For your reference, a Metric Conversion
Chart is located on the inside back cover of the manual.
8. Location Terms. The terms left, right, front, or rear are used to describe areas of the equipment. These terms
indicate location as seen when seated in the driver’s seat and facing forward.
9. Unless another MOS is specified in the initial setup of a work package, all tasks are to be performed by a
Construction Equipment Operator, Military Occupational Speciality (MOS) 21E.

v/(vi blank)
 TM 5-3805-293-10

CHAPTER 1
GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND
THEORY OF OPERATION
10

TM 5-3805-293-10 0001

OPERATOR MAINTENANCE -

0 0 0 1 GENERAL INFORMATION

SCOPE 0001

1. Type of Manual. This manual is for use in operating and performing operator troubleshooting and
maintenance on the 120M Motor Grader.
2. Model Numbers and Equipment Names. Grader, Road, Motorized, Diesel Engine Driven (DED), Heavy,
Commercial Construction Equipment (CCE) Model 120M.
3. Purpose of Equipment. The 120M Motor Grader is used for rough and finished grading, low and high bank
sloping, flat and V-ditching, scarifying bituminous road mixes, and snow removal. Mission support role includes
construction and maintenance of roads, airfields, hardstands, drainage, site preparation for pipeline, and river
crossing.
MAINTENANCE FORMS, RECORDS, AND REPORTS 0001

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as
applicable) DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual or AR 700-138,
Army Logistics Readiness and Sustainability.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) 0001

If your 120M Motor Grader needs improvement, let us know. Send us an EIR. You, the user, are the only one who
can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. (E-
Mail: TACOM-TECH-PUBS@conus.army.mil) We will send you a reply. The preferred method for submitting
Quality Deficiency Reports (QDRs) is through the Army Electronic Product Support (AEPS) website under the
Electronic Deficiency Reporting System (EDRS). The web address is: https://aeps.ria.army.mil. If the above
method is not available to you, put it on an SF 368 (Product Quality Deficiency Report), and mail it to us at:
Department of the Army, U.S. Army Tank-automotive and Armaments Command, AMSRD-TAR-E, PDQR MS 268,
6501 E. 11 Mile Road, Warren, MI 48397-5000.
CORROSION PREVENTION AND CONTROL (CPC) 0001

1. CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be
reported so that the problem can be corrected and improvements can be made to prevent the problem in future
items.
2. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of
metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of
iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface
residue, and/or cracking.
3. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation
(oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are
excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or
breaking.
4. SF Form 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM
750-8, TAMMS Users Manual.
OZONE DEPLETING SUBSTANCES 0000 00

There are no ozone depleting substances contained on the machine or used during machine maintenance.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE 0001

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.

0001-1
 TM 5-3805-293-10 0001

PREPARATION FOR STORAGE OR SHIPMENT 0001

General 0001

1. This work package contains requirements and procedures for administrative storage of equipment that is
issued to and in use by Army activities worldwide.
2. The requirements specified herein are necessary to maintain equipment in administrative storage in such a
way as to achieve the maximum readiness condition.
3. Equipment that is placed in administrative storage should be capable of being readied to perform its mission
within a 24-hour period, or as otherwise may be prescribed by the approving authority. Before equipment is
placed in administrative storage, a current PMCS should be completed and deficiencies corrected.
4. Report equipment in administrative storage as prescribed for all reportable equipment.
5. Perform inspections, maintenance services, and lubrication as specified herein.
6. Records and reports to be maintained for equipment in administrative storage are those prescribed by DA PAM
750-8 for equipment in use.
7. A 10 percent variance is acceptable on time used to determine the required maintenance actions.
8. Accomplishment of applicable PMCS, as mentioned throughout this work package, will be on a semiannual
basis.
Definition of Administrative Storage 0001

The placement of equipment in administrative storage can be for short periods of time when a shortage of
maintenance effort exists. Items should be ready for use within the time factors as determined by the directing
authority. During the storage period, appropriate maintenance records must be kept.
Preparation of Equipment for Administrative Storage 0001

Storage Site 0001

1. Select the best available site for administrative storage. Separate stored equipment from equipment in use.
Conspicuously mark the area “ADMINISTRATIVE STORAGE.”
2. Covered space is preferred.
3. Open sites should be improved hardstand, if possible. Unimproved sites should be firm, well drained, and free
of excessive vegetation.
Storage Plan 0001

1. Store equipment to provide maximum protection from the elements and to provide access for inspection,
maintenance, and exercising. Anticipate removal or deployment problems and take suitable precautions.
2. Take into consideration environmental conditions, such as extreme heat or cold, high humidity, blowing sand,
or loose debris, soft ground, mud, heavy snows, or any combination thereof, and take adequate precautions.
3. Establish a fire plan and provide for adequate fire fighting equipment and personnel.
Maintenance Services and Inspection 0001

1. Maintenance Services. Prior to storage, perform the next scheduled PMCS.

2. Inspection. Inspect and approve the equipment prior to storage. Do not place non-mission-capable equipment
in storage.

0001-2
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PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

Correction of Shortcomings and Deficiencies 0001

Correct all shortcomings and deficiencies prior to storage, or obtain a deferment from the approving authority.
Lubrication. Lubricate equipment in accordance with LO 5-3805-293-13. 0001

General Cleaning, Painting, and Preservation 0001

CAUTION
Do not direct water or steam, under pressure, against electrical wires or any exterior
opening. Failure to follow this caution may result in damage to equipment.
1. Cleaning. Clean all equipment for dirt, grease, and other contaminants in accordance with applicable
provisions of this manual. Do not use vapor degreasing. Remove foreign objects that are wedged in tire treads.

WARNING

Chemical Agent Resistant Coating (CARC) paint debris may be considered

environmentally hazardous during removal. Consult local procedures prior to removal of
CARC paint to ensure compliance with local laws. Failure to follow these warnings may
result in injury or death to personnel.
2. Painting. Remove rust and damaged paint by scraping, wire brushing, sanding, or buffing. Sand to a smooth
finish and spot paint as necessary (TB 43-0209).
3. Preservation. After cleaning and drying, immediately coat unpainted wear surfaces with oil or grease, as
appropriate.

NOTE
• Place a piece of barrier material between desiccant bags and metal surfaces.
• Air circulation under draped covers reduces deterioration from moisture and heat.
4. Weatherproofing. Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install all
covers authorized for the equipment. Close and secure all openings except those required for venting and
draining. Seal openings to prevent the entry of rain, snow, or dust. Insert desiccant when complete seal is
required. Place equipment, and provide blocking or framing, to allow for ventilation and water drainage.
Support cover away from item surfaces, which may rust, rot, or mildew.
BII Items 0001

1. Process BII items simultaneously with the major item to which they are assigned.
2. If possible, store BII items with the major item.
3. If stored apart from the major item, mark BII items with tags indicating the major item, its registration or serial
number, and location, and store in protective-type closures. In addition, place a tag or list indicating the
location of the removed items in a conspicuous place on the major item.
Maintenance Services 0001

After equipment has been placed in administrative storage, inspect, service, and exercise as specified in this
manual.

0001-3
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PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

Inspection 0001

Inspection will usually be visual and must consist of at least a walk-around examination of all equipment to detect
any deficiencies. Inspect equipment in open storage WEEKLY and equipment in covered storage MONTHLY.
Inspect all equipment immediately after any severe storm or environmental change. The following are examples of
things to look for during a visual inspection:
1. Low or flat tires.
2. Oil leaks.
3. Condition of preservatives, seals, and wraps.
4. Corrosion or other deterioration.
5. Missing or damaged parts.
6. Water in components.
7. Any other readily recognizable shortcomings or deficiencies.
Repair During Administrative Storage 0001

Keep equipment in an optimum state of readiness. Accomplish the required services and repairs as expeditiously
as possible. Whenever possible, perform all maintenance on-site.
Exercising 0001

Exercise equipment in accordance with Table 1 and the following instructions:

1. Vehicle Major Exercise. Depreserve equipment by removing only that material restricting exercise. Close all
drains, remove blocks, and perform all BEFORE operational checks. Make several right and left 90-degree
turns. Make several hard-braking stops without skidding. While exercising, and when it is convenient and safe,
operate all functional components such as moldboard, drawbar, scarifier, front wheel tilt, articulation, and all
wheel drive. Perform all DURING and AFTER operational checks.
2. Scheduled Services. Scheduled services will include inspection per Inspection in this work package, and will
be conducted in accordance with PMCS (WP 0013). Lubricate in accordance with instructions in LO 5-3805-
293-13.
3. Corrective Action. Immediately take action to correct shortcomings and deficiencies noted. Record inspection
and exercise results on DA Form 2404 or DA Form 5988E. Record and report all maintenance actions on DA
Form 2407. After exercising, restore the preservation to the original condition. Replenish lubricants used
during exercising and note the amount on DA Form 2408.

Table 1. Exercise Schedule.

Weeks 01 2 01 4 01 6 01 8 01 10 01 12 01 14 01 16 01 18 01 20 01 22 01 24 01

Scheduled Services 01 X
Major Exercise 01 X

Rotation 0001

Rotate items in accordance with any rotational plan that will keep the equipment in an operational condition and
reduce the maintenance effort.

0001-4
 TM 5-3805-293-10 0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

Procedures for Common Components and Miscellaneous Items 0001

Tires 0001

If tires are found to be low by 5 psi (34 kPa) or more, damaged, or excessively worn, notify Field Level
Maintenance.
Seals 0001

Seals may develop leaks during storage or shortly thereafter. If leaking persists, notify Field Level Maintenance.
Removal of Equipment from Administrative Storage 0001

Activation 0001

Notify Field Level Maintenance to restore the equipment to normal operating condition.
Servicing 0001

Resume the maintenance service schedule in effect at the commencement of storage or service the equipment
before the scheduled dates in order to produce a staggered maintenance workload.
Preparation of Equipment for Shipment 0001

1. Remove ether starting aid cylinder, if equipped (WP 0021).

2. After grader is positioned on transporter, park machine (WP 0005).
3. Secure grader frame by installing articulation lock pin (WP 0004).
4. Turn battery disconnect to OFF position (WP 0004).
5. Make sure cab doors, access doors, and access covers are secured.

0001-5
 TM 5-3805-293-10 0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED

CAUTION
Turbocharger may spin when engine is off due to air flow past grader exhaust pipe.
Rotation of turbocharger without engine operation may result in damage to turbocharger.

6. Cover exhaust opening.

7. Chock grader tires.
8. Secure grader with tiedowns.

Figure 1. Tiedown Locations. 0001

9. Refer to FM 4-01.41 Army Rail Operations for additional instructions on processing, storage, and shipment of
materiel.
10. Graders that have been removed from storage for shipment do not have to be reprocessed if they will reach
their destination within the administrative storage period. Reprocess only if inspection reveals any corrosion or
if anticipated in-transit weather conditions make it necessary.
11. When a grader is received that has already been processed for domestic shipment, as indicated on DD Form
1397, the grader does not have to be reprocessed for storage unless corrosion and deterioration are found
during the inspection upon receipt. List on SF Form 364 all discrepancies found because of poor preservation,
packaging, packing, marking, handling, loading, storage, or excessive preservation. Repairs that cannot be
handled by the receiving unit must be annotated on DA Form 5988E or DA Form 2404 and reported to Field
Level Maintenance.

0001-6
 TM 5-3805-293-10 0001

WARRANTY INFORMATION 0001

The 120M Motor Grader has separate warranties for various components. See Table 2. The warranty starts on the
date found in block 23 of DA Form 2408-9, Equipment Control Record. Report all defects to your supervisor, who
will take appropriate action.

Table 2. Warranty Information.

Warranted Duration of Manufacturer Contact

Component Commercial Warranty Responsible Information

Base Machine (1) 1 Year/Unlimited Hours

(1)

Ground Engaging Tools Not limited by time Defense and Federal

(GET) Caterpillar Inc. Products
Caterpillar Battery (2) 3 Years (2) Phone 309-578-3295

Engine Emission 5 Year/3,000 Hours (3)

Components (3)

Warranty - See Separate Manufacturer’s Warranty Statements

Tires (4) 5 Years (4) Bridgestone/Firestone Phone 800-572-8905

Tires (4) 5 Years (4) Michelin Phone 877-574-8473

(1) Excluding batteries, GET, and tires that have separate warranties, as shown in the table.
(2) Battery warranty is prorated after 12 months.
(3) Army 120M Engine is EPA Certified. The Emissions Warranty applies to certain engine components.
(4) Tire warranty is prorated based on tire age and tread wear.

0001-7
 TM 5-3805-293-10 0001

LIST OF ABBREVIATIONS/ACRONYMS 0001

NOTE
Refer to ASME Y14.38-2007, Abbreviations and Acronyms, for standard abbreviations.
ABBREVIATION/ACRONYM DEFINITION
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ampere
AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Antilock Braking System
A/C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning
BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Item
B.O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Celsius
CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code
CBRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological, Radiological, Nuclear
CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise
CID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cubic Inch Displacement
cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Centimeter
COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component of End Item
CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States
CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control
CPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cardiopulmonary Resuscitation
CSF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Structural Frame
cu ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Foot
cu m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Meter
CW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Current
ECM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module
ECPC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Clutch Pressure Control
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electronic Control Unit
EIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendation
EMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Monitoring System
F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit
FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Falling Object Protective Structure
ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot
gal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallon
GIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabarit International de Chargement
HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating, Ventilation, and Air Conditioning
I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification
in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch
kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram
km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometer

0001-8
 TM 5-3805-293-10 0001

LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED 0001

ABBREVIATION/ACRONYM DEFINITION
kPa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal
km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilowatt
L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter
LASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighter Aboard Ship
lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound
lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Foot
lb-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Inch
LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display
LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Emitting Diode
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter
min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minute
mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Millimeter
MOPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mission Oriented Protective Posture
MOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Military Occupational Specialty
mph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Miles per Hour
NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization
NBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical
Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton-meter
NSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Stock Number
OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United States
PMCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive Maintenance Checks and Services
PQDR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Quality Deficiency Report
psi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds per Square Inch
pt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pint
ROC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated Operating Capacity
ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure
RO/RO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roll-on/Roll-off
rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions per Minute
SAHR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Applied Hydraulically Released
SDDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Surface Deployment and Distribution Command
SEABEE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naval Construction Engineer, Sea Barge
SPK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Purpose Kit
TAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System
TOE/MTOE . . . . . . . . . . . . . Table of Organization and Equipment/Modified Table of Organization and Equipment
U/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit of Measure
UV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ultra Violet
V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt
WCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim Action
WP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Package

0001-9
 TM 5-3805-293-10 0001

ELECTROMAGNETIC PULSE (EMP) EXPOSURE 0001

Components designated as EMP susceptible may be damaged by EMP exposure. If the machine is exposed to an
EMP incident, verify proper operation and repair as necessary.
THREAT OF CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) CONTAMINATION 0001

1. The 120M Motor Grader incorporates a CARC painted exterior. Materials used in the machine are metal,
rubber, plastic, fabric, and glass.
2. In the event of CBRN contamination, see FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for
Chemical, Biological, Radiological, and Nuclear Decontamination.
COMMON TOOLS AND EQUIPMENT 0001

For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE),
CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), CTA 50-
909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Dura-
ble Items, as applicable to your unit.

END OF WORK PACKAGE

0001-10
8

TM 5-3805-293-10 0002

OPERATOR MAINTENANCE -

0 0 0 2 EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 0002

1. The 120M Motor Grader provides the Army with the capability of rough and finished grading, low and high
bank sloping, flat and V-ditching, scarifying, mixing bituminous road mixes, and snow removal. Mission support
role includes construction and maintenance of roads, airfields, hardstands, drainage, and site preparation for
pipeline and river crossing.
2. The 120M Motor Grader has excellent maneuverability; fast, precise blade control without drift; superior visibil-
ity, convenience, and safety; and an advanced cab design featuring joysticks for control.

0002-1
 TM 5-3805-293-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002

Figure 1. 120M Motor Grader (Left Side). 0002

KEY COMPONENT DESCRIPTION

1 Operator Cab Location of operator controls.
2 Primary Exit Door on left side of machine provides primary entry/exit point
for operator.
3 Exhaust Pipe Directs exhaust fumes away from machine.
4 Air Cleaner Removes debris from air entering engine.
5 Left Front Access Door Provides access to coolant tank, circuit breakers, engine air fil-
ters, engine oil level gauge, transmission oil level gauge and
transmission oil filler tube.
6 Left Rear Access Door Provides access to NATO slave receptacle, battery disconnect
switch, and hydraulic tank sight gauge.
7 Blade Side Shift Cylinder Extends and retracts blade horizontally.

0002-2
 TM 5-3805-293-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. 120M Motor Grader (Left Side). 0002

KEY COMPONENT DESCRIPTION

1 Turn Signal Flashes to indicate direction machine intends to turn.
2 Headlights Provide light forward of machine.
3 Work Lights Provide illumination of blade/work area.
4 Side View Mirror Provides view toward rear and side of machine.
5 Grab Handle Provides a hand-hold for cab entry and exit.
6 Steps Provide safe means of climbing up to and down from cab.
7 Fuel Tank Fuel storage.
8 Filler Neck and Cap Provide means to fill fuel tank and seal tank.
9 Blackout Driving Light Used when operating in blackout mode.
10 Scarifier Shank Stowage Rack Provide stowage capability for up to five scarifier shanks.

0002-3
 TM 5-3805-293-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 3. 120M Motor Grader (Right Side). 0002

KEY COMPONENT DESCRIPTION

1 Rear Blackout Lights
2 Rear Work Lights
3 Right Rear Access Door
4 Right Front Access Door
5 Right Front Access Panel
6 Emergency Exit
7 Work Lights
Provide illumination during blackout mode.
Provide illumination behind machine.
Provides access to batteries and refrigerant condenser.
Provides access to refrigerant compressor
Provides access to engine drive belt.
Provides an emergency exit for operator.
Provide illumination of blade/work area.

0002-4
 TM 5-3805-293-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 4. 120M Motor Grader (Right Side). 0002

KEY COMPONENT DESCRIPTION

1 Radiator Provides cooling for engine coolant.
2 Centershift Cylinder Allows center point of blade to be shifted outward to either
side to provide more blade reach.
3 Blade Lift Cylinders Raise and lower each side of blade independently.
4 Scarifier Hydraulic Cylinder Raises and lowers scarifier.
5 Scarifier Link Rods Link rods with adjustable height setting.
6 Scarifier Used for breaking up material.
7 Moldboard/Blade Hydraulically controlled with replaceable end bits and cutting
edges.
8 End Bit Replaceable outer edges of blade.
9 Tandem Housing Houses drive gears for tandem wheels.
10 Rear Hitch Pin Attachment point for towing.

0002-5
 TM 5-3805-293-10 0002

EQUIPMENT DATA 0002

Length
Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ft 10 in. (8.49 m)
Width
Overall (blade perpendicular with centerline of machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ft. (3.767 m)
Outside front tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 4 in. (2.54 m)
Outside rear tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ft. 5 in. (2.56 m)
Wheelbase (centerline of front tire to centerline of rear tire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ft. 10 in. (6.7 m)
Height
Top of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ft. 0 in. (3.4 m)
Top of cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft. 9 in. (3.3 m)
Top of exhaust stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 7 in. (2.9 m)
Top of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ft. 9 in. (3.0 m)
Weight (approximate operating)
Without Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,080 lb (17,726 kg)
With Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45,000 lb (20,412 kg)
Engine
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6.6
Variable Horsepower (VHP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 to 153 HP
Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,000 RPM
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 cu. in. (6.6 L)
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct Injection
Cooling system (thermostat opening temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 180°F (70 to 82qC)
Cooling system (thermostat completely open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203qF (95qC)
Transmission
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 speeds forward, 6 reverse CZM1-UP
Range selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction trigger and gear selection buttons on left joystick
Front Axles
Wheel lean angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18q
Rear Axle
Tandem axle spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ft 11.5 in. (1.5 m)

0002-6
 TM 5-3805-293-10 0002

EQUIPMENT DATA – CONTINUED

Service Brakes
Type. . . . . . . . . . . . . . . . . . . . . Multiple disc, oil bathed, hydraulically activated, located at each tandem wheel
Parking Brakes
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multiple disc, spring applied, hydraulically released
Tires
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tubeless
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.00R 24 12PR (G-2)
Inflation
Without Armor Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 psi (241 kPa)
Rear – All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa)
With Armor Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa)
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 psi (379 kPa)
Steering
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic
Turning Radius (frame fully articulated, front wheels NOT leaning) . . . . . . . . . . . . . . . . . . . . 26 ft. 9 in. (8.2 m)
Steering Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.5q
Articulation Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20q
Service Refill Capacities
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 gal. (341 L)
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7 gal. (33 L)
Engine crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 gal. (15.5 L)
Hydraulic system (tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 gal. (64.6 L)
Transmission and differential housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 gal. (53 L)
Tandem housing (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.0 gal. (56.8 L)
All-wheel drive gearbox (each side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 gal. (7 L)
Front wheel spindle bearing housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13 gal. (0.5 L)
Circle drive housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 gal. (7.0 L)
Electrical System
Batteries
Quantity Without Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Quantity With Arctic Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt DC
System voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Volt DC
Blade Range
Circle centershift
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm)
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.8 in. (656 mm)
Blade Sideshift
Hydraulic
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 in. (660 mm)
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1 in. (510 mm)

0002-7
 TM 5-3805-293-10 0002

EQUIPMENT DATA – CONTINUED

Blade Lift (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.8 in. (427 mm)
Blade Shoulder Reach (maximum)
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in. (190.5 cm)
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.6 in. (174.2 cm)
Maximum Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.3 in. (72 cm)
Hydraulic Blade Tip
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40°
Rearward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5°

END OF WORK PACKAGE

0002-8
6

TM 5-3805-293-10 0003

INTRODUCTORY INFORMATION -

0 0 0 3 THEORY OF OPERATION

INTRODUCTION 0003

1. The 120M Motor Grader consists of the following functional systems: engine, powertrain, brakes, electrical,
steering, and hydraulics.
2. This work package explains how the systems and components of the machine work together. A functional
description is provided for each major component and system.
3. The 120M Motor Grader is an all-purpose, medium sized, wheeled vehicle used for spreading and evening
various types of granular material (dirt, stone, sand, etc.). Power is provided by a Caterpillar in-line, six-
cylinder, direct injected, diesel engine. Hydraulically operated implements allow blade positioning for forward
or backward grading, ditch or embankment grading, and snow removal. A scarifier allows loosening of
compacted material prior to grading. Front leaning wheel and frame articulation provide maximum
maneuverability. The grader has a sound-suppressing Rollover Protective Structure (ROPS) cab with
insulation, heater, and windows, which allows for all-weather operation.

0003-1
 TM 5-3805-293-10 0003

ENGINE 0003

1. General. The grader is equipped with a Caterpillar C6.6 Acert VHP turbocharged diesel engine with six in-line
cylinders, generating 153 horsepower @ 2,000 RPM.
2. Fuel System. Diesel fuel is drawn from the tank by a fuel transfer pump, filtered by a primary fuel filter, routed
to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzles into the
engine cylinders. Air is drawn in through dry-type, replaceable filter elements. A check valve removes incoming
dust from the air and routes it out through the exhaust system. The air is routed from the filter assembly to the
turbocharger which pressurizes the air and sends it to the air-to-air aftercooler. The aftercooler, located near
the radiator, reduces the air temperature making it denser. The denser air charge allows for more air and fuel
to be combusted per engine cycle, increasing engine output power.
3. Cooling System. Provides coolant to the engine. Coolant is circulated through the engine by a gear-driven
water pump. The hydraulic oil cooler is located in front of the radiator. The engine oil cooler is integral to the
engine. The transmission oil cooler is located behind an access cover below the left front access door.
4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and
oil pan. The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and
head.
5. Exhaust System. The exhaust system removes exhaust gases from the engine through the exhaust manifold
and turbocharger. The gases flow into exhaust pipes and a muffler to the atmosphere behind the cab.

Figure 1. Engine Components. 0003

0003-2
 TM 5-3805-293-10 0003

ENGINE – CONTINUED

Figure 2. Engine Components. 0003

0003-3
 TM 5-3805-293-10 0003

POWERTRAIN 0003

1. Transmission. Eight speeds are provided in forward and six in reverse. A transmission modulator control
(inching pedal) disengages the transmission from the drive wheels. Inching allows the operator to vary the
machine ground speed while keeping engine speed high for quick implement response.
2. Rear Axle Differential and Lock Differential. A four-wheeled tandem rear axle arrangement houses axle
shafts driven by a lock-unlock equipped differential. The axle shafts turn the final drive sprocket chains through
planetary reduction gears. The sprocket chains then drive the final drive sprockets.
3. Final Drive Assembly. The sprocket chains drive the final drive sprockets and axle shafts which turn the rear
wheel spindles inside the tandem axle housing.

Figure 3. Powertrain Components. 0003

0003-4
 TM 5-3805-293-10 0003

BRAKES 0003

1. General. The oil-bathed, multiple-disc service brakes are hydraulically activated. Each tandem wheel end
contains a service brake unit. A brake wear indicator is easily accessible for checking brake wear. A
compensator maintains consistent brake performance.
2. Service Brakes. A foot pedal is used for engaging multiple disc brake assemblies for each wheel within the
tandem and spindle housings.
3. Parking Brakes. Multiple oil-bathed disc-type located in the transmission case. Electrically actuated by an
ON/OFF switch on the right side of the instrument panel, the parking brake is spring applied and hydraulically
released. The parking brake is integrated into the Operator Presence System to prevent unintended machine
movement while the operator is not in the cab seat.
4. Brake Accumulators. Two brake accumulators, located behind the cab, assist in applying the service brakes.
The accumulator remains charged even after the engine is shut down and provides limited braking ability.

Figure 4. Brake Components. 0003

0003-5
 TM 5-3805-293-10 0003

ELECTRICAL 0003

1. The electrical system, interruptible by a lockable battery disconnect switch, consists of two 12V batteries con-
nected in series with negative grounding, providing 24V to operate the electrical systems and components.
2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to
operate the machine, including a NATO slave receptacle.
3. The major systems comprising the electrical system are:
a. Starting system.
b. Charging systems.
c. Messenger display system.
d. Service, work, and blackout lights.
HYDRAULICS 0003

1. General. The hydraulic system is comprised of a single fluid tank, an implement and steering pump, a brake
and hydraulic fan pump, a secondary steering pump, and a set of bank valves to distribute hydraulic fluid
pressure to the various hydraulically activated systems (braking, steering, articulation, wheel lean, and earth
moving components). The system also contains various control valves, check valves, sensors, and
accumulators to maintain correct pressures. The fluid tank with a sight glass to check fluid level is located
behind the left rear access door. A hydraulic fluid cooler is located in front of the radiator.
2. Steering System. The steering system utilizes hydraulic pressure produced by the implement and steering
pump to actuate steering cylinders. An electric secondary hydraulic steering pump, located below the cab,
provides hydraulic steering pressure in the event of implement and steering pump failure.
3. Steering Cylinders. There are two steering cylinders mounted at the front axle that turn the front wheels. The
cylinders are powered by the hydraulic system and controlled by the steering pump and joystick controls.
4. Wheel Lean Cylinder. The wheel lean cylinder is mounted on the right side of the front axle. It is powered by
the hydraulic system and controlled by a switch on the left joystick. The function of the wheel lean cylinder is to
set the front wheels at an angle. This counteracts blade pressure exerted sideways against the front wheels
when grading or moving heavy material. The wheel lean cylinder also sets front wheel angle to prevent the
front of the machine from slipping sideways and downward when the machine is moving across a slope.
5. Ground Engagement Tools. The scarifier height, blade height, rotation, tilt, sideshift, centershift, and angle
are all hydraulically powered and controlled using joysticks and joystick controls.
6. Brake System. The service brakes are hydraulically activated by pressing down on the foot pedal in the cab.
Hydraulic pressure is provided by the engine driven fan and brake pump located behind the left front access
door. The parking brake is spring actuated and hydraulically released via a switch located on the right side of
the instrument panel activated by the operator.
7. All-Wheel Drive (AWD). All-wheel drive provides machine propulsion to the front tires when commanded by
the operator. The AWD control is located on the right-side control panel. All-wheel drive can be operated in
either CREEP or MANUAL mode by providing hydraulic fluid pressure to hydraulic motors at the front wheels.
When in CREEP mode, the machine is propelled only by the front wheels. Speed in CREEP mode is variable
from 0 to 5 mph (0 to 8 km/h). In MANUAL mode, the front wheels can be commanded to run at 99 percent,
100 percent, or 120 percent of rear wheel speed.

END OF WORK PACKAGE

0003-6
 TM 5-3805-293-10

CHAPTER 2
OPERATOR INSTRUCTIONS
26

TM 5-3805-293-10 0004

OPERATOR MAINTENANCE -

0 0 0 4 DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

GENERAL 0004

Do not attempt to operate the 120M Motor Grader until becoming familiar with the location and use of all controls
and indicators. This work package describes all operator controls and indicators.
MAIN ENTRY AND EXIT 0004

Figure 1. Steps and Handhold – Main Entry and Exit. 0004

KEY COMPONENT DESCRIPTION

1 Handhold Provides hand grips for mounting and dismounting machine.
2 Steps Provide stepped platform for mounting and dismounting
machine.

0004-1
 TM 5-3805-293-10 0004

ALTERNATE EXIT 0004

Figure 2. Alternate Exit. 0004

KEY COMPONENT DESCRIPTION

1 Right Door Provides alternate exit from cab.

0004-2
 TM 5-3805-293-10 0004

ARTICULATION LOCK PIN 0004

Figure 3. Articulation Lock Pin. 0004

KEY COMPONENT DESCRIPTION

1 Articulation Lock Pin
2 Spring Rods
3 Lock Pin Storage Bracket
Prevents machine from articulating. Pin shown installed in rear
frame pocket.
Pull back on spring rod to release lock pin.
Articulation lock pin stowage location during machine opera-
tion.

0004-3
 TM 5-3805-293-10 0004

WHEEL LEAN LOCK BOLT 0004

Figure 4. Wheel Lean Lock Bolt. 0004

0004

KEY COMPONENT DESCRIPTION

1 Wheel Lean Lock Bolt/Nut Locks lean bar to left front axle to prevent front wheels from
tilting. Stowed in BII tool box. Used only during maintenance
repairs. Not for shipping/storage.
2 Lean Bar (left side) Connects both front wheels to lean cylinder.

0004

0004-4
 TM 5-3805-293-10 0004

DOOR HANDLES AND LATCHES 0004

Figure 5. Door Handles. 0004

KEY COMPONENT DESCRIPTION

1 Outer Door Handle Unlatches door from outside cab.
2 Inner Door Handle Unlatches door from inside cab.

0004-5
 TM 5-3805-293-10 0004

DOOR HANDLES AND LATCHES – CONTINUED

Figure 6. Door Latch and Release. 0004

KEY COMPONENT DESCRIPTION

1 Latch Assembly Secures open door to cab.
2 Remote Latch Release Unlatches door from inside cab.

0004-6
 TM 5-3805-293-10
SEAT
KEY COMPONENT
1 Lumbar Support Knob
2 Fore/Aft Lever
3 Seat Height Lever
4 Weight Adjustment Knob
5 Backrest Adjustment Lever
6 Seat Cushion Tilt
0004
0004
Figure 7. Seat. 0004
DESCRIPTION
Rotate knob counterclockwise to increase stiffness of lumbar
support. Rotate knob clockwise to decrease stiffness.
Pull up on lever to adjust seat forward or rearward. Release
lever to lock.
Pull up on lever to adjust seat upward or downward. Release
lever to lock.
Rotate knob clockwise to increase height of seat. Rotate knob
counterclockwise to decrease seat height.
Pull up on lever to adjust seat back lean angle. Release lever
to lock seat back.
Front of seat cushion is pinned in a groove. Grasp seat pan
and rotate “forward-up-and-back” to position seat into a steep
angle.
Grasp seat pan and rotate forward-down-and-back to position
seat at normal angle.
0004-7
 TM 5-3805-293-10 0004

SEAT BELT 0004

Figure 8. Retractable Seat Belt. 0004

KEY COMPONENT DESCRIPTION

1 Seat Belt (Retractable) Secures operator in seat.

0004-8
 TM 5-3805-293-10 0004

WRIST RESTS, ARM PADS, AND CONTROL PODS 0004

Figure 9. Wrist Rests, Arm Pads, and Control Pods. 0004

KEY COMPONENT DESCRIPTION

1 Wrist Rest Height Adjustment Knob
2 Control Pod Fore/Aft Adjustment
Lever
3 Arm Pad Adjustment Knob
4 Control Pod Vertical Adjustment Knob
Pull wrist rest height adjustment knob to allow adjustment of
wrist rest. Release knob to lock. Right side shown, left side
similar.
Pull up on lever to allow fore/aft adjustment of control pods.
Release lever to lock. Left side shown, right side similar.
Turn knob counterclockwise to allow adjustment of arm pads.
Turn knob clockwise to lock. Left side shown, right side similar.
Turn knob counterclockwise to allow height adjustment of
control pods. Turn knob clockwise to lock. Left side shown,
right side similar.

0004-9
 TM 5-3805-293-10 0004

JOYSTICK CONTROLS 0004

Figure 10. Left Joystick Controls. 0004

KEY COMPONENT DESCRIPTION

1 Downshift Switch
2 Wheel Lean Control - LEFT
3 Upshift Switch
4 Wheel Lean Control - RIGHT
5 Automatic Articulation Centering
Control
Depress switch to downshift to desired gear in forward or
reverse.
Press button to lean wheels left. Wheels will remain leaning
after button is released.
Depress switch to upshift to desired gear in forward or
reverse.
Press button to lean wheels right. Wheels will remain leaning
after button is released.
Press and release button to return machine articulation to
CENTER position. Machine will move gradually.
Automatic articulation (centering) can be cancelled by
pressing button again or rotating left joystick.

0004-10
 TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED

KEY COMPONENT DESCRIPTION

6 Steer - LEFT Move left joystick LEFT to turn front wheels to the left. When
joystick is released, front wheels will remain aligned with
joystick.
7 Steer - RIGHT Move left joystick RIGHT to turn wheels to the right. When
joystick is released, front wheels will remain aligned with
joystick.
8 Blade Lower and Blade Float for Left Blade Lower - Push left joystick forward to lower left end of
Side blade. When joystick is released, blade remains in selected
position. Joystick returns to HOLD position.
Blade Float - Push left joystick to the most forward DETENT
position. When joystick is released, blade will remain in float
position until joystick is moved forward or backward. Joystick
returns to HOLD position.
Extra effort may be necessary to push joystick forward into the
FLOAT position.
9 Blade Lift for Left Side Pull left joystick rearward to raise left end of blade. When
joystick is released, blade remains in selected position.
Joystick returns to HOLD position.
10 Articulation Control Articulation Right - Twist left joystick clockwise to move rear
of machine to the right. When joystick is released, articulation
will remain in selected position. Joystick returns to HOLD
position.
Articulation Left - Twist left joystick counterclockwise to move
rear of machine to the left. When joystick is released,
articulation will remain in selected position. Joystick returns to
HOLD position.

0004-11
 TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED 0004

Figure 11. Right Joystick Controls. 0004

0004-12
 TM 5-3805-293-10
JOYSTICK CONTROLS – CONTINUED
KEY COMPONENT
1 Blade Sideshift Control - LEFT
2 Blade Sideshift Control - RIGHT
3 Blade Lower and Blade Float for Right
Side
4 Blade Lift for Right Side
5 Centershift Control - LEFT
6 Centershift Control - RIGHT
7 Blade Pitch Control - FORWARD
8 Blade Pitch Control - BACKWARD
9 Blade Circle Drive Control
10 Horn Button
11 Turn Signal Switch
0004
DESCRIPTION
Move right joystick left to sideshift blade to the left. When
joystick is released, blade sideshift will remain in selected
position. Joystick will return to HOLD position.
Move right joystick right to sideshift blade to the right. When
joystick is released, blade sideshift will remain in selected
position. Joystick will return to HOLD position.
Blade Lower - Push right joystick forward to lower right end of
blade. When joystick is released, blade remains in selected
position. Joystick returns to HOLD position.
Blade Float - Push right joystick to the most forward DETENT
position. When joystick is released, blade will remain in float
position until joystick is moved forward or backward. Joystick
returns to HOLD position.
Extra effort may be necessary to push joystick forward into the
FLOAT position.
Pull right joystick rearward to raise right end of blade. When
joystick is released, blade remains in selected position.
Joystick returns to HOLD position.
Push left side of thumb button to move drawbar left. When
button is released, drawbar remains in selected position.
Button returns to HOLD position.
Push right side of thumb button to move drawbar right. When
button is released, drawbar remains in selected position.
Button returns to HOLD position.
Push top of thumb button to pitch blade forward. When button
is released, blade remains in selected position. Button returns
to HOLD position.
Push bottom of thumb button to pitch blade backward. When
button is released, blade remains in selected position. Button
returns to HOLD position.
Circle Drive Clockwise - Twist right joystick in clockwise
direction to rotate blade clockwise. When joystick is released,
blade remains in selected position. Joystick returns to HOLD
position.
Circle Drive Counterclockwise - Twist right joystick in
counterclockwise direction to rotate blade counterclockwise.
When joystick is released, blade remains in selected position.
Joystick returns to HOLD position.
Press to activate horn.
Push right side of button to activate right turn signal indicator.
Push left side of button to activate left turn signal indicator.
Turn signal will remain ON until switch is manually returned to
center position.
0004-13
 TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED

Figure 12. Joystick Controls. 0004

KEY COMPONENT DESCRIPTION

1 Throttle Resume/Decel Switch
2 Differential Lock Control
3 Transmission Control Switch
Pull trigger switch to resume engine speed previously
selected.
Hold trigger switch to decrease engine speed by
approximately 100 RPM/per second held.
Bump trigger switch to decrease engine speed in 100 RPM
increments.
Push to engage or disengage differential lock. Locks
differential to increase traction in soft or wet ground.
Pull top of switch to engage transmission in REVERSE.
Move switch to middle position to place transmission in
NEUTRAL.
Pull bottom of switch to engage transmission in FORWARD.

0004-14
 TM 5-3805-293-10 0004

MID-MOUNT SCARIFIER CONTROL ROLLER AND ARCTIC HEATER SWITCH 0004

Figure 13. Mid-Mount Scarifier Control. 0004

KEY COMPONENT DESCRIPTION

1 Mid-Mount Scarifier Control Roller
2 Arctic Heater Switch
Extend - Roll thumb wheel down to extend (lower) scarifier.
When thumb wheel is released, scarifier remains in selected
position. Thumb wheel returns to HOLD position.
Retract - Roll thumb wheel up to retract (raise) scarifier. When
thumb wheel is released, scarifier remains in selected
position. Thumb wheel returns to HOLD position.
Press button to activate and deactivate arctic heater.

0004-15
 TM 5-3805-293-10
FORWARD CONTROLS AND INDICATORS
Figure 14. Forward Controls and Indicators.
KEY COMPONENT
1 Centershift Lock Indicator
2 Secondary Steering Test Switch
3 Parking Brake Switch
4 Engine Start Switch
5 Accelerator Control
6 Service Brake Control
7 Transmission Modulator Control
(Inching Pedal)
0004
0004
469-0018
0004
DESCRIPTION
Illuminates when centershift lock is DISENGAGED.
Allows operator to test secondary steering system.
Engages and disengages parking brakes.
Turn switch clockwise to ON position to activate electrical
circuits in cab.
Turn switch clockwise to START position to start engine.
Turn switch counterclockwise to shut off engine and electrical
power.
If engine fails to start, switch must be returned to the OFF
position before attempting to start engine.
Depress pedal to increase engine speed. Release pedal to
decrease engine speed.
Depress pedal to apply service brakes to slow or stop
machine.
Disengages power to the wheels as pedal is depressed. Pedal
fully depressed completely disengages power to wheels.
0004-16
 TM 5-3805-293-10
RIGHT-SIDE CONTROL PANEL
Figure 15. Right-Side Control Panel.
KEY COMPONENT
1 Centershift Lock Switch
2 Defroster Fan Switch
3 Blade Cushion Switch
4 Power Port (12V)
5 Throttle Set/Accel Switch
6 Electrical Coolant Switch
7 Throttle Hold Mode Switch
8 Hazard Flasher Switch
9 Front and Rear Worklight Switch
10 Headlight Dimmer Switch
0004
0004
0004
DESCRIPTION
Push bottom of switch to engage centershift lock. Press red
tab and push top of switch to disengage centershift lock.
Push top of switch to operate defroster fan at HIGH speed.
Move switch to center position for MEDIUM speed. Push bot-
tom of switch for LOW speed.
Machine not equipped with blade cushion option.
Remove cap to access port to power 12V electrical equipment
or accessories.
Allows operator to set speed of throttle.
Push button to turn arctic heater ON. Push button again to turn
OFF.
Allows Operator to set mode for throttle hold function. Mode
options include OFF, AUTOMATIC, and MANUAL.
Push top of switch to activate hazard flashers. Push bottom of
switch to deactivate.
Push top of switch to activate front worklights only. Push bot-
tom of switch to activate front and rear worklights. Move switch
to middle position to deactivate all worklights.
Push top of switch to activate high beams. Push bottom of
switch to deactivate high beams; low beams remain ON.
0004-17
 TM 5-3805-293-10 0004

ALL-WHEEL DRIVE (AWD) CONTROLS 0004

Figure 16. All-Wheel Drive Controls. 0004

.
KEY COMPONENT DESCRIPTION

1 All-Wheel Drive Control
2 All-Wheel Drive Mode Switch
3 Manual Mode Indicator Light
Controls speed (aggression) of front wheels when AWD is
activated.
Three-position switch used to engage all-wheel drive. Turn
switch to left of center for CREEP mode. Turn switch to right of
center for MANUAL mode. Turn switch to center position to
turn off AWD.
Indicator illuminates when MANUAL mode is activated.

0004-18
 TM 5-3805-293-10 0004

HEATING AND AIR CONDITIONING CONTROLS 0004

Figure 17. Heater and Air Conditioning Controls. 0004

KEY COMPONENT DESCRIPTION

1 Fan Speed Switch
2 Temperature Variable Control
3 Air Conditioning Switch
Turn switch counterclockwise to OFF position. Turn switch
clockwise to operate fan at low, medium, high, and maximum
speeds.
To pressurize cab to prevent dust entry when neither heating
nor cooling is desired, adjust fan speed and temperature to
comfortable levels. Do not activate air conditioning.
Adjust temperature from minimum (full left) to maximum (full
right).
Push top of switch to activate air conditioning. Push bottom of
switch to deactivate air conditioning.
To defog windshield, activate air conditioning and adjust fan
speed and temperature to decrease moisture level in cab.

0004-19
 TM 5-3805-293-10 0004

WIPER/WASHER CONTROLS 0004

Figure 18. Wiper/Washer Controls. 0004

KEY COMPONENT DESCRIPTION

1 Left Door Wiper/Washer Control
2 Front Windshield Wiper/Washer
Control
3 Right Door Wiper/Washer Control
Turn knob clockwise one notch to activate intermittent wipers
at long delay. Continue turning knob to decrease delay.
Turn knob to next notch for continuous low wiper speed.
Turn knob to next notch for continuous high wiper speed. Turn
knob all the way left to shut off wipers. Push knob to activate
window washer.
Operates the same as left door wiper/washer control.
Operates the same as left door wiper/washer control.

0004-20
 TM 5-3805-293-10 0004

MONITORING SYSTEM 0004

Figure 19. Monitoring System. 0004

KEY COMPONENT DESCRIPTION

1 Left Turn Signal Indicator Flashes when left turn signal is activated.
2 Left Blade Float Indicator Illuminates when left blade float is activated.
3 Battery Charge Alert Indicator Illuminates when a problem with machine voltage or alternator
is present.
4 Electric Coolant Heater Alert Indicator Illuminates when coolant heater is activated.
5 Engine System Alert Indicator Illuminates when an engine problem is present.
6 Implement System Alert Indicator Illuminates when an implement system problem is present.
7 Throttle Lock Indicator Illuminates when throttle lock is activated.
8 Primary Steering Alert Indicator Illuminates when a steering system problem is present.
9 Action Light Alert Indicator Illuminates when a problem occurs with machine.
10 Analog Tachometer Displays engine speed in revolutions per minute.
11 Parking Brake Indicator Illuminates when parking brakes are engaged.
12 Transmission System Alert Indicator Illuminates when a transmission system problem is present.
13 Differential Lock Indicator Illuminates when differential lock is activated.
14 Secondary Steering System Alert Indi- Illuminates RED when a system problem is present.
cator Illuminates GREEN when system is activated or being tested.
15 High Beam Indicator Illuminates when high beams are activated.
16 Brake System Indicator Illuminates when a general fault occurs in brake system.
17 Operator Not Present Alert Indicator Illuminates when under specific conditions operator is not in
cab.
18 Right Blade Float Indicator Illuminates when right blade float is activated.
19 Right Turn Signal Indicator Flashes when right turn signal is activated.
20 Articulation Angle Gauge Indicates amount of right or left articulation.
21 Fuel Level Gauge Indicates amount of fuel in tank.
22 LCD Display Provides information on ground speed, actual gear and
direction, operator requested gear, service hour meter.
23 Hydraulic Oil Temperature Gauge Indicates hydraulic oil temperature. Red area indicates oil
temperature above 199°F (93ºC).
24 Coolant Temperature Gauge Indicates coolant temperature. Red area indicates coolant
temperature above 225ºF (107ºC).

0004-21
 TM 5-3805-293-10 0004

MESSENGER DISPLAY AND IMPLEMENT LOCKOUT SWITCH 0004

Figure 20. Messenger Display and Implement Lockout Switch. 0004

KEY COMPONENT DESCRIPTION

1 Messenger Display
2 Implement Lockout Switch
Provides machine information through various menus
(Performance Menu, Totals Menu, Settings Menu, Service
Menu), includes a self-diagnostic function test and four distinct
warning categories to alert the operator of a situation requiring
attention.
Push top of switch to lock out implement controls. Push
bottom of switch to unlock implement controls. Implements
must be locked out during transport or while loading to prevent
inadvertent movement.
Note: Steering is not affected by position of switch.

0004-22
 TM 5-3805-293-10 0004

MILITARY LIGHT SWITCH 0004

Figure 21. Military Light Switch. 0004

KEY COMPONENT DESCRIPTION

1 Military Light Switch
2 Mode Switch
3 Unlock Lever
4 Panel Brightness Switch
Controls operation of service, blackout, parking, and
instrument panel lights. When operating in blackout mode,
worklights, service, and directional lights are disabled. Backup
alarm and horn are also disabled in blackout mode.
Used to select desired mode of lighting. Release unlock lever
to change modes.
Lift up to unlock mode switch. Returns to locked position when
released.
Not applicable to 120M.

0004-23
 TM 5-3805-293-10 0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE 0004

Figure 22. Battery Disconnect Switch and Slave Receptacle. 0004

KEY COMPONENT DESCRIPTION

1 Battery Disconnect Switch
2 24V Slave Receptacle
Disconnects batteries from rest of machine. Includes a
mechanical lockout cover to prevent unwanted access to
switch.
Insert disconnect switch key and turn switch clockwise to the
ON position to activate machine electrical system and enable
engine start.
Insert key and turn switch counterclockwise to the OFF
position to deactivate machine electrical systems or to shut
down engine if it must be stopped quickly.
Connection for 24V slave start cable.

0004-24
 TM 5-3805-293-10 0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE – CONTINUED

Figure 23. Arctic Heater Fuel Shutoff Valve. 0004

KEY COMPONENT DESCRIPTION

1 Arctic Heater Fuel Shutoff Valve Lever in horizontal position indicates valve is closed, shutting
off fuel supply from tank.
Lever in vertical position indicates valve is open, allowing fuel
flow from tank to arctic heater.

END OF WORK PACKAGE

0004-25/(26 blank)
34

TM 5-3805-293-10 0005

OPERATOR MAINTENANCE -

OPERATION UNDER USUAL CONDITIONS

0 0 0 5

Scope; Initial Adjustment Before Use; Mounting and Dismounting; Seat, Seat Belt, and Control
Adjustments; Engine Starting and Machine Warm-up; Parking; Articulation Lock Pin Installation;
Messenger Display; Machine Warning Summaries; Joystick Steering; Differential Lock Control;
Transmission Operation; Throttle Hold Mode Switch; Centershift Lock Switch; All-Wheel Drive (AWD);
Slope Operation; Scarifier Operation

INITIAL SETUP

Tools and Special Tools 0 References 0

Strap, Tiedown (WP 0032, Item 18) 0 WP 0004 0

WP 0006 0

WP 0007 0

WP 0013 0

WP 0027 0

WP 0032 0

SCOPE 0005

1. This work package provides instructions on operating the 120M Motor Grader under usual conditions.
2. Refer to WP 0006 for advanced operation instructions and operator tips.
3. Refer to WP 0007 for operating instructions under unusual conditions.
4. Before, during, and after operation, perform applicable Preventive Maintenance Checks and Services (PMCS)
(WP 0013).
INITIAL ADJUSTMENT BEFORE USE 0005

1. Perform all Before PMCS checks and services (WP 0013).

2. Pull back on spring rod and remove articulation lock pin from frame pocket. Stow in lock pin storage bracket
and engage spring rod to lock pin in place.
3. If installed, remove wheel lean lock bolt (WP 0004). Stow in machine-mounted tool box.
4. Turn battery disconnect switch to ON position (WP 0004).

END OF TASK

0005-1
 TM 5-3805-293-10 0005

MOUNTING AND DISMOUNTING 0005

WARNING
• Mount and dismount the machine only at locations that have steps and handholds.
• Clean steps and handholds prior to mounting machine.
• Face machine during mounting and dismounting.
• Maintain three-point contact (two hands and one foot, or one hand and two feet) at all
times.
• Do not mount or dismount a moving machine.
• Do not jump off a moving machine.
• Do not carry tools or supplies when mounting or dismounting machine.
• Do not use any controls as handholds during mounting or dismounting.
• Failure to follow these warnings may result in injury or death to personnel.
1. Open left door.
2. Enter machine from left side and occupy operator’s seat.
3. Close left door.

END OF TASK

SEAT, SEAT BELT, AND CONTROL ADJUSTMENTS 0005

1. Adjust operator’s seat (WP 0004).

2. Grasp seat belt and pull out of retractor in one continuous motion, then insert catch into buckle. Seat belt
adjusts tension automatically. Make sure belt is positioned low across lap (WP 0004).
3. Adjust wrist rests, control pods, and arm pads (WP 0004).
4. With the aid of an assistant, adjust mirrors to obtain a clear view behind machine.

END OF TASK

0005-2
 TM 5-3805-293-10 0005

ENGINE STARTING AND MACHINE WARM-UP 0005

WARNING

• CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives
the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide
produces symptoms of headache, dizziness, loss of muscular control, apparent
drowsiness, and coma. Permanent brain damage or death can result from severe
exposure.
• Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon
monoxide can become dangerously concentrated under conditions of inadequate
ventilation. The following precautions must be observed to ensure safety of personnel
when the engine of the 120M Grader is operated.
• DO NOT operate engine in enclosed areas.
• DO NOT idle engine without adequate ventilation.
• BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
• If you see another person with exhaust poisoning symptoms:
• Remove person from area.
• Expose to fresh air.
• Keep person warm.
• DO NOT permit physical exercise.
• Administer Cardiopulmonary Resuscitation (CPR) if necessary.
• Notify a medic.
• BE AWARE. The field protective mask for Chemical, Biological, Radiological, Nuclear
(CBRN) protection will not protect you from carbon monoxide poisoning.
• CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive
harm.
The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

0005-3
 TM 5-3805-293-10 0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED

WARNING

Hearing protection is required when standing within 26 ft (8 m) of the 120M Motor Grader
while it is operating. Failure to wear hearing protection may result in hearing loss.

1. Check to make sure all bystanders are clear of machine before starting engine.
2. Place transmission control switch in NEUTRAL (WP 0004).
3. Engage parking brake (WP 0004).

WARNING
Monitoring system will perform an automatic self-diagnostic functional test whenever
engine start switch is turned to ON position. If action alarm does not sound or monitoring
displays are not functioning, do not start or operate machine until cause has been
corrected. Failure to follow this warning may result in injury or death to personnel as any
Warning Category 3 notifications will not be relayed to operator.

NOTE
• Automatic self-diagnostic functional test verifies outputs (gauges, alert indicators, and
alarms) are operating correctly.
• Gauges must sweep to the far right of their scale and then back.
• Alert indicators must come on momentarily.
• All segments of the LCD must come on momentarily.
• Action alarm must sound.
4. Turn engine start switch to ON but do not start engine. Allow monitoring system to perform self-diagnostic func-
tional test (WP 0004).

CAUTION
• When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30
seconds. Allow starting motor to cool for two minutes before cranking again or damage to
starting motor or batteries may result.
• When ambient temperature is between -1°F (-18°C) and -25°F (-32°C), it may be
necessary to crank engine for up to 60 seconds.
• When ambient temperature is between -26°F (-32°C) and -40°F (-40°C), it may be
necessary to crank engine for up to 120 seconds.
• Shut down engine immediately if engine system indicator or action light indicator comes
on. Notify Field Level Maintenance. Failure to follow this caution may result in damage to
engine or other machine systems.

NOTE
If engine fails to start, you must turn ignition switch to the OFF position, then back to ON
and START.

5. Turn and hold engine start switch to START. Release when engine starts.

0005-4
 TM 5-3805-293-10 0005

ENGINE STARTING AND MACHINE WARM-UP – CONTINUED

6. Allow engine to run at low idle speed while observing engine system indicator or action light indicator. If either
indicator comes on during warm-up, shut down engine immediately and notify Field Level Maintenance.
7. Continue to idle machine while monitoring hydraulic oil temperature on Messenger dIsplay. Only operate
machine after hydraulic oil temperature is equal to or greater than 41°F (5°C). If necessary to raise hydraulic oil
temperature, cycle all implement and steering controls to allow warm hydraulic oil to circulate through all
hydraulic lines.

END OF TASK

PARKING 0005

Stopping Machine 0005

1. Choose a level surface to stop machine whenever possible.

2. Decrease engine speed.
3. Apply service brakes to slow machine. Apply transmission modulator pedal and service brakes to stop
machine (WP 0004).
4. Place transmission control switch in NEUTRAL position (WP 0004).
5. Engage parking brake (WP 0004).
6. Lower scarifier to the ground and apply a slight downward pressure (WP 0004).
7. Angle blade to either side, lower onto wood blocks and tilt forward.
8. Lock out hydraulic controls by placing the hydraulic lockout switch in the LOCK position (WP 0004).
Stopping Engine 0005

CAUTION
Stopping the engine immediately after it has been working under load can result in
overheating and accelerated wear of engine components.

1. Operate engine at low idle for five minutes to allow engine and components to cool gradually.
2. Turn engine start switch to OFF (WP 0004).
Leaving Machine 0005

WARNING
Use caution and maintain three-point contact at all times when dismounting machine.
Failure to follow this warning may result in injury or death to personnel.

1. Exit cab through left door.

2. Use steps and hand holds to dismount. Face machine when dismounting (WP 0004).
3. Perform all After PMCS (WP 0013).
4. Turn battery disconnect switch to OFF (WP 0004).
5. Secure machine against vandalism. Lock all covers and compartments.
Operator Presence System 0005

The Operator Presence System automatically engages the parking brake when the operator leaves seat when the
parking brake is disengaged, and machine is running but not moving. Once the operator returns to the seat, the
parking brake must be disengaged by cycling the switch to the ON position then back to OFF position (WP 0004).
If the steering joystick was disturbed during this process, steering joystick will need to be realigned with front
wheels. Refer to Joystick Steering in this work package.
END OF TASK

0005-5
 TM 5-3805-293-10 0005

ARTICULATION LOCK PIN INSTALLATION 0005

1. Start engine.
2. Press automatic articulation centering control on left joystick to align front and rear frames (WP 0004).
3. Shut down engine.
4. Pull back spring rod (Figure 1, Item 1) and remove articulation lock pin (Figure 1, Item 2) from storage bracket
(Figure 1, Item 3).

Figure 1. Articulation Lock Pin in Storage Bracket. 005

5. Insert articulation lock pin (Figure 2, Item 1) into rear frame pocket, pull back spring rod (Figure 2, Item 3) and
ensure pin lower flange (Figure 2, Item 4) contacts rear frame, then release spring rod.
6. Rotate pin until spring rod falls into detent in pin (Figure 2, Item 2).

Figure 2. Articulation Lock Pin Installed. 005

END OF TASK

0005-6
 TM 5-3805-293-10 0005

MESSENGER DISPLAY 0005

The Messenger system provides real-time machine performance and diagnostic data with an easy-to-use inter-
face. The Messenger monitors all system data and alerts the operator to any faults through a digital text display.
The Messenger includes a Performance menu, a Totals menu, a Settings menu, and a Service menu. Each menu
has numerous options which allow the operator to adjust certain settings or monitor specific system data.

Figure 3. Messenger Display 005

1. The digital display area (Figure 3, Item 1) displays system information.

2. The OK button (Figure 3, Item 2) confirms selections after you have made them by scrolling with the Down/
Right button (Figure 3, Item 3) and the Up/Left button (Figure 3, Item 4).
3. The Down/Right button (Figure 3, Item 3) is used to scroll down and/or right through information shown on the
digital display area (Figure 3, Item 1).
4. The Up/Left button (Figure 3, Item 4) is used to scroll up and/or left through information shown on the digital
display area (Figure 3, Item 1).
5. The Back button (Figure 3, Item 5) is used to return to information previously shown on the digital display area
(Figure 3, Item 1).
6. The Implement Lockout switch (Figure 3, Item 6) locks and unlocks implement controls.

0005-7
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

Performance Menu 0005

The default information displayed by the Messenger is the Performance menu (Figure 4).

Figure 4. Performance Menu. 005

The following options are available through the Performance menu.

a. ENGINE SPEED. When scrolling to this option, display shows engine speed in revolutions per minute
(RPM).
b. MPH GROUND SPEED. When scrolling to this option, display shows ground speed in miles per hour
(mph) or kilometers per hour (km/h).
c. ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant tem-
perature in degrees Fahrenheit (°F) or in degrees Celsius (°C).
d. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot
point.
e. FUEL LEVEL. When scrolling to this option, display shows amount of fuel remaining as a percentage of
full.
f. HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature in degrees Fahren-
heit (°F) or in degrees Celsius (°C).
g. REQ GEAR. When scrolling to this option, display shows gear that is selected by operator.
h. ACTUAL GEAR. When scrolling to this option, display shows gear that is currently engaged in transmis-
sion.
i. TOS. When scrolling to this option, display shows transmission output speed.
j. TRANSMISSION OIL TEMPERATURE. When scrolling to this option, display shows transmission oil tem-
perature in degrees Fahrenheit (°F) or in degrees Celsius (°C).
k. IMPLEMENT LOCKOUT SWITCH POSITION. When scrolling to this option, display shows position of
implement lockout switch.
l. IMPLEMENT PILOT SUPPLY SOLENOID. When scrolling to this option, display shows status of imple-
ment pilot supply solenoid.

0005-8
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

m. BLADE LEFT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of
blade left lift cylinder float.
n. BLADE RIGHT LIFT CYLINDER FLOAT STATUS. When scrolling to this option, display shows status of
blade right lift cylinder float.
o. SECONDARY STEERING SYSTEM TEST. When scrolling to this option, display shows status of second-
ary steering system test.
p. SECONDARY STEERING REQUEST SIGNAL. When scrolling to this option, display shows secondary
steering request signal.
q. CHARGE FILTER BYPASS STATUS. When scrolling to this option, display shows status of powertrain fil-
ter bypass.
r. TRANSMISSION MODULATOR CONTROL (INCHING PEDAL) POSITION. When scrolling to this option,
display shows position of transmission modulator control (inching pedal).
Totals Menu 0005

The Totals menu has three sub-menus: Lifetime Totals, Trip Totals, and Trip Reset.

Figure 5. Totals Menu. 005

0005-9
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

1. The following options are available through the Lifetime Totals sub-menu:
a. FORWARD DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of
distance travelled in forward direction in miles or kilometers.
b. REVERSE DISTANCE TRAVELLED. When scrolling to this option, display shows lifetime total of distance
travelled in reverse direction in miles or kilometers.
c. TOTAL FUEL. When scrolling to this option, display shows lifetime total of amount of fuel consumed by
machine.
d. SERVICE HOURS. When scrolling to this option, display shows lifetime total of number of hours machine
has run.
2. The following options are available through the Trip Totals sub-menu:

NOTE
Total Fuel and Service Hours can be reset to zero from each of these screens.

a. TOTAL FUEL. When scrolling to this option, display shows amount of fuel consumed by machine since trip
total has been reset.
b. SERVICE HOURS. When scrolling to this option, display shows total of number of hours machine has run
since trip total has been reset.
3. The following option is available through the Trip Reset sub-menu:
CLEAR TRIP TOTALS. When scrolling to this option, you can reset trip total values.
Settings Menu 0005

The Settings menu has four sub-menus: Monitoring System, Machine, Transmission, and Implement.

Figure 6. Settings Menu. 005

0005-10
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

1. The following options are available through the Monitoring System sub-menu:
a. LANGUAGE. Select this option to change display language.
b. UNITS. Select this option to set the desired measurement system (English or Metric).
c. CONTRAST ADJUST. Select this option to adjust display contrast to improve visibility. A bar graph is dis-
played to show level of contrast.
d. BACKLIGHT ADJUST. Select this option to adjust brightness of Messenger display area, switch lights,
and instrument panel lights for better visibility. Headlights and/or taillights must be turned ON to make
these adjustments. A bar graph is displayed to show level of brightness.
2. The following options are available through the Machine sub-menu:
a. PRODUCT ID. Select this option to view product identification number.
b. EQUIPMENT ID. Select this option to view equipment identification number.
3. The following options are available through the Transmission sub-menu:
a. GEAR SELECTION. When scrolling to this option, display shows gear of transmission.
b. TRANSMISSION INITIAL FORWARD GEAR. When scrolling to this option, display shows initial forward
gear.
c. TRANSMISSION INITIAL REVERSE GEAR. When scrolling to this option, display shows initial reverse
gear.
d. MIN FORWARD AUTOSHIFT GEAR. Not applicable.
e. MIN REVERSE AUTOSHIFT GEAR. Not applicable.
f. MAX FORWARD AUTOSHIFT GEAR. Not applicable.
g. MAX REVERSE AUTOSHIFT GEAR. Not applicable.

NOTE
The following list shows Caterpillar approved lubricants. Refer to Expendable and Durable
Items List (WP 0032) for lubricant options.

h. TRANSMISSION OIL TYPE.When scrolling to this option, display shows viscosity of oil in transmission.
i. TDTO SAE 0W-20. When scrolling to this option, display shows Cat TDTO SAE 0W-20 oil type.
j. TDTO SAE 0W-30. When scrolling to this option, display shows Cat TDTO SAE 0W-30 oil type (OEA-30).
k. TDTO SAE 5W-30. When scrolling to this option, display shows Cat TDTO SAE 5W-30 oil type.
l. TDTO SAE 10W. When scrolling to this option, display shows Cat TDTO SAE 10W oil type (OE/HDO-10).
m. ARCTIC TDTO. When scrolling to this option, display shows Cat Arctic TDTO oil type (OEA-30).
n. TDTO TMS. When scrolling to this option, display shows Cat TDTO TMS oil type.
o. TDTO SAE 30. When scrolling to this option, display shows Cat TDTO SAE 30 oil type (OE/HDO-30).
p. TDTO SAE 50. When scrolling to this option, display shows Cat TDTO SAE 50 oil type.
4. The following option is available through the Implement sub-menu:
AUXILIARY POD STATUS. When scrolling to this option, display shows status of machine implements
(enabled or not enabled).

0005-11
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

Service Menu 0005

The Service menu (Figure 7) has two main sub-menus, Diagnostics/Events and Service Parameters, and numer-
ous sub-sub-menus under Service Parameters for service parameters, system tests, system information, service
tests, calibration, and tattletale.

Figure 7. Service Menu. 005

The following option is available through the Diagnostics/Events sub-menu:

VIEW DIAGNOSTICS. Select this option to view diagnostics/events logged by the monitoring system. A pass-
word is required to change any settings in this menu.
System Parameters Sub-Menu 0005

a. The following options are available through the Monitoring system sub-sub-menu:
(1) BATTERY VOLTAGE. When scrolling to this option, display shows available battery voltage.
(2) FUEL LEVEL. When scrolling to this option, display shows fuel tank fill level.
(3) ALTERNATOR STATUS. When scrolling to this option, display shows status of alternator.
b. The following options are available through the Engine sub-sub-menu:
(1) ENGINE RPM. When scrolling to this option, display shows engine speed in revolutions per minute.
(2) DESIRED ENGINE RPM. When scrolling to this option, display shows desired engine speed in revolu-
tions per minute.
(3) ENGINE OIL PRESSURE. When scrolling to this option, display shows engine oil pressure.
(4) ENGINE COOLANT TEMPERATURE. When scrolling to this option, display shows engine coolant
temperature.
(5) FUEL PRS. When scrolling to this option, display shows fuel pressure.
(6) AIR PRS. When scrolling to this option, display shows intake manifold air pressure.
(7) AIR TEMP. When scrolling to this option, display shows intake manifold air temperature.
(8) ATMOSPHERIC PRS. When scrolling to this option, display shows atmospheric pressure.

0005-12
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

(9) RT TURBO INLET PRS. When scrolling to this option, display shows turbocharger inlet pressure.
(10)THROTTLE POSITION. When scrolling to this option, display shows throttle position.
(11) FUEL VOLUME When scrolling to this option, display shows amount of fuel delivered by fuel injectors.
c. The following options are available through the Transmission sub-sub-menu:
(1) REQ GEAR. When scrolling to this option, display shows gear selected by operator.
(2) ACTUAL GEAR. When scrolling to this option, display shows actual gear engaged in transmission.
(3) TOS. When scrolling to this option, display shows transmission output speed.
(4) TRANS OIL TEMP. When scrolling to this option, display shows transmission oil temperature.
(5) CHARGE FILTER. When scrolling to this option, display shows status of charge filter bypass for trans-
mission.
(6) TRANSMISSION MODULATOR CONTROL (INCHING PEDAL) POS. When scrolling to this option,
display shows position of inching pedal.
d. The following options are available through the Steering sub-sub-menu:
(1) STEERING CONTROL POS. When scrolling to this option, display shows position of steering control.
(2) STEERING DUTY CYCLE. When scrolling to this option, display shows status of steering signal for
duty cycle.
(3) LEFT CYL EXT. When scrolling to this option, display shows position of left steering cylinder.
(4) RIGHT CYL EXT. When scrolling to this option, display shows position of right steering cylinder.
(5) SECONDARY STEERING POS. When scrolling to this option, display shows position of secondary
steering test switch.
(6) SECONDARY STEERING TEST. When scrolling to this option, display shows status of secondary
steering test.
(7) SECONDARY STEERING SIGNAL. When scrolling to this option, display shows status of command
signal for the secondary steering.
(8) SECONDARY STEERING RELAY. When scrolling to this option, display shows status of secondary
steering relay.
e. The following options are available through the Implement sub-sub-menu:
(1) HYD OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature.
(2) HYD OIL PRS. When scrolling to this option, display shows main hydraulic oil pressure.
(3) LOCKOUT POS. When scrolling to this option, display shows position of implement lockout switch.
(4) PILOT SUPPLY. When scrolling to this option, display shows status of implement pilot supply solenoid.
(5) BLADE LEFT LIFT POS. When scrolling to this option, display shows lift position for left side of blade.
(6) BLADE LEFT LIFT CYL. When scrolling to this option, display shows status of blade float function for
left lift cylinder.
(7) BLADE RIGHT LIFT POS. When scrolling to this option, display shows lift position for right side of
blade.
(8) BLADE RIGHT LIFT CYL. When scrolling to this option, display shows status of blade float function
for right lift cylinder.
(9) WHEEL LEFT LEAN POS. When scrolling to this option, display shows wheel lean (left) position.
(10)WHEEL RIGHT LEAN POS. When scrolling to this option, display shows wheel lean (right) position.
(11) PITCH FORWARD POS. When scrolling to this option, display shows blade pitch forward position.

0005-13
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

(12)PITCH BACKWARD POS. When scrolling to this option, display shows blade pitch backward position.
(13)SIDESHIFT POS. When scrolling to this option, display shows position of blade sideshift.
(14)CIRCLE LEFT SIDESHIFT POS. When scrolling to this option, display shows left position of circle
drawbar.
(15)CIRCLE RIGHT SIDESHIFT POS. When scrolling to this option, display shows right position of circle
drawbar.
(16)CIRCLE DRIVE POS. When scrolling to this option, display shows position of circle drive.
(17)ARTICULATION POS. When scrolling to this option, display shows position of articulation joint.
(18)AUTO ARTICULATION POS. When scrolling to this option, display shows status of automatic articula-
tion centering control.
f. The following options are available through the Brake sub-sub-menu:
(1) PARK BRAKE SWITCH. When scrolling to this option, display shows status of parking brake switch.
(2) BRAKE SOLENOID. When scrolling to this option, display shows status of parking brake solenoid.
(3) PARK BRAKE PRS. When scrolling to this option, display shows status of parking brake pressure.
(4) PARK BRAKE. When scrolling to this option, display shows park brake status (engaged or
disengaged).
(5) SERVICE BRAKE. When scrolling to this option, display shows status of service brake pedal.
g. The following options are available through the All-Wheel Drive sub-sub-menu;
(1) RIGHT MOTOR SPD. When scrolling to this option, display shows right AWD motor speed.
(2) LEFT MOTOR SPD. When scrolling to this option, display shows left AWD motor speed.
(3) AWD MODE. When scrolling to this option, display shows status of AWD mode.
(4) AWD SWITCH. When scrolling to this option, display shows status of AWD switch.
(5) LEFT DESIRED RATIO. When scrolling to this option, display shows left desired ratio.
(6) LEFT GEAR RATIO. When scrolling to this option, display shows left gear ratio.
(7) RIGHT DESIRED RATIO. When scrolling to this option, display shows right desired ratio.
(8) RIGHT GEAR RATIO. When scrolling to this option, display shows right gear ratio.
(9) LEFT CLUTCH PRESSURE. When scrolling to this option, display shows left clutch pressure.
(10)RIGHT CLUTCH PRESSURE. When scrolling to this option, display shows right clutch pressure.
(11) AWD STATUS. When scrolling to this option, display shows status of AWD system.
(12)HYDRAULIC OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature in
degrees Fahrenheit (ºF) or in degrees Celsius (ºC).
System Test Sub-Menu 0005

SYSTEM SELF TEST. When scrolling to this option, display shows status of system self test.

0005-14
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

System Information Sub-Menu 0005

1. The following information is available through the Engine sub-sub menu:

a. ENGINE SERIAL #. When scrolling to this option, display shows engine serial number.
b. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
c. ECM PART #. When scrolling to this option, display shows ECM part number.
d. SW PART #. When scrolling to this option, display shows software part number.
e. SW RELEASE DATE. When scrolling to this option, display shows software release date.
f. SW DESCRIPTION. When scrolling to this option, display shows software description.
2. The following information is available through the Trans/Chassis sub-sub menu:
a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
b. ECM PART #. When scrolling to this option, display shows ECM part number.
c. SW PART #. When scrolling to this option, display shows software part number.
d. SW RELEASE DATE. When scrolling to this option, display shows software release date.
e. SW DESCRIPTION. When scrolling to this option, display shows software description.
3. The following information is available through the Monitoring System sub-sub menu:
a. EQUIPMENT ID. When scrolling to this option, display shows equipment identification number.
b. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
c. ECM PART #. When scrolling to this option, display shows ECM part number.
d. SW PART #. When scrolling to this option, display shows software part number.
e. SW RELEASE DATE. When scrolling to this option, display shows software release date.
f. SW DESCRIPTION. When scrolling to this option, display shows software description.
4. The following information is available through the Implement System sub-sub menu:
a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
b. ECM PART #. When scrolling to this option, display shows ECM part number.
c. SW PART #. When scrolling to this option, display shows software part number.
d. SW RELEASE DATE. When scrolling to this option, display shows software release date.
e. SW DESCRIPTION. When scrolling to this option, display shows software description.
5. The following information is available through the Implement Control 2 System sub-sub menu:
a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
b. ECM PART #. When scrolling to this option, display shows ECM part number.
c. SW PART #. When scrolling to this option, display shows software part number.
d. SW RELEASE DATE. When scrolling to this option, display shows software release date.
e. SW DESCRIPTION. When scrolling to this option, display shows software description.

0005-15
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

6. The following information is available through the All-Wheel Drive System sub-sub menu:
a. ECM SERIAL #. When scrolling to this option, display shows ECM serial number.
b. ECM PART #. When scrolling to this option, display shows ECM part number.
c. SW PART #. When scrolling to this option, display shows software part number.
d. SW RELEASE DATE. When scrolling to this option, display shows software release date.
e. SW DESCRIPTION. When scrolling to this option, display shows software description.
Service Test Sub-Menu 0005

1. MANUAL LUBE MODE TEST. When scrolling to this option, display shows option to begin manual lube mode
test.
2. STEERING DEAD ENGINE.

NOTE
Press OK when messenger displays NEXT.

a. NEXT. When scrolling to this option, display shows option to begin Steering Dead Engine test.
b. Before test can be performed, the machine must meet the following conditions:
(1) No warnings for primary steering system.
(2) No warnings for secondary steering system.
(3) No warnings for implement systems.
(4) Start switch in ON position.
(5) Engine must be off.
(6) Transmission must be in NEUTRAL.
(7) Parking brake must be engaged.
(8) Operator must be present.
(9) Implements must be locked.
c. The following information is available through the Steering Dead Engine sub-sub menu:
(1) ABORT. When scrolling to this option, display shows option to end Steering Dead Engine test.
(2) NEXT. When scrolling to this option, display shows option to continue Steering Dead Engine test.
(3) CALIBRATION INITIALIZING. When scrolling to this option, display shows Steering Dead Engine test
has started.
d. When test begins, use left joystick to move front wheels. Secondary steering pump will be activated for a
maximum of ten seconds. To cancel test, press ABORT button on Messenger or turn start switch to the
OFF position.
Calibration 0005

NOTE
The transmission fill calibration is to be performed by Field Level Maintenance only.
Calibration could take up to 45 minutes to complete. If calibration is interrupted or aborted,
old calibration numbers will remain.

TRANSMISSION FILL CALIBRATION. When scrolling to this option, display shows option to begin transmission
fill calibration.

0005-16
 TM 5-3805-293-10 0005

MESSENGER DISPLAY – CONTINUED

Tattletale 0005

The following information is available through the Tattletale sub-sub-menu:

a. TATTLETALE MODE ACTIVE. When scrolling to this option, display shows tattletale mode is active.
b. OIL TEMP. When scrolling to this option, display shows hydraulic oil temperature.
c. ENGINE COOLANT TEMP. When scrolling to this option, display shows engine coolant temperature.
d. ENGINE SPEED. When scrolling to this option, display shows engine speed.
e. ARTICULATION ANGLE. When scrolling to this option, display shows degree of angle at articulation pivot
point.
f. FUEL LEVEL. When scrolling to this option, display shows fuel tank fill level.

END OF TASK

MACHINE WARNING SUMMARIES 0005

The Monitoring System provides three warning categories. The first warning category requires only operator
awareness. The second warning category requires a change to machine operation or performance of maintenance
to system. The third warning category requires immediate shutdown of machine.
Warning Category 1 0005

In this category, only the alert indicator comes on. This category alerts the operator that the machine system needs
attention.
Warning Category 2 0005

In this category, the alert indicator and action light come on. This category requires a change in machine operation.
The Messenger system will display a message. If action is required, instruction will be listed.
Warning Category 2S 0005

In this category, the alert indicator and action light come on and action alarm sounds at a steady rate. This cate-
gory requires an immediate change in machine operation. The Messenger system will display a message. If action
is required, instruction will be listed.
Warning Category 3 0005

In this category, the alert indicator and action light come on and action alarm sounds at a pulse rate. This category
requires immediate shutdown of machine to prevent injury or death. This category requires immediate shutdown of
machine to prevent severe damage to the machine. The Messenger system will display a message. If action is
required, instruction will be listed.

END OF TASK

0005-17
 TM 5-3805-293-10 0005

JOYSTICK STEERING 0005

NOTE
Failure to properly align left (steering) joystick causes inability to steer machine, inability to
disengage parking brake, and inability to shift transmission out of NEUTRAL position.

Before operating machine, align left joystick in relation to steering angle of front wheels.
1. Start engine.
2. Move left joystick slowly and smoothly left or right to closely match steering angle of front wheels to synchro-
nize joystick to front wheels.
3. During alignment, note the following conditions:
a. Joystick alignment event disappears from Messenger display.
b. Steering system alert indicators not illuminated on monitoring system.
c. Front wheels move with movement of left joystick.

END OF TASK

0005-18
 TM 5-3805-293-10 0005

DIFFERENTIAL LOCK CONTROL 0005

CAUTION
• Do not engage the differential lock control at high speeds.
• Do not turn machine with differential lock engaged.
• Do not engage the differential lock control while one wheel is spinning. Decrease engine
RPM until the wheel stops spinning. Anticipate using the differential lock before wheel
slippage occurs.
• Failure to follow these cautions will result in damage to machine.

NOTE
• In areas of high resistance, it may be necessary to turn the machine slightly in order to aid
in unlocking the differential lock. Decreasing the engine RPM may also be helpful.
• Differential lock can be engaged while machine is in motion.
• Anticipate need for use of differential lock before wheel slippage occurs.
1. Engage differential lock by pushing switch on right joystick to increase traction on soft or wet ground (Figure 8).
Differential lock indicator will illuminate on monitoring system when differential locks.
2. Continue grading.
3. Disengage differential lock by pushing switch on right joystick again.

Figure 8. Differential Lock Control and Indicator. 005

END OF TASK

0005-19
 TM 5-3805-293-10 0005

TRANSMISSION OPERATION 0005

The transmission has eight forward gears, six reverse gears, and inching capability through the use of a transmis-
sion modulator pedal. Shifting can be performed by either launching the machine from NEUTRAL or sequential
speed shifting. Shuttle shifting (changing direction quickly) is also possible.
Before operator takes control of machine, the following events must occur:
1. Parking brake must be engaged.
2. Operator must be present in seat.
3. Transmission control switch must be in NEUTRAL position.
4. Left joystick must be aligned with front wheels.
5. Operator disengages parking brake.

WARNING
DO NOT leave operator seat while machine is in motion. Operator Presence System will
not respond. Failure to follow this warning may result in injury of death to personnel.

NOTE
Parking brake will automatically engage if the operator leaves the seat while the machine
is stopped and parking brake is not already engaged.

6. To re-establish operational control after parking brake has been automatically set, operator must return to seat
and reset parking brake by pushing top of parking brake switch, then pushing bottom of switch (Figure 9). Park-
ing brake will disengage and allow operator to regain operational control.
7. If steering joystick was disturbed during step 6, repeat steps 1 though 5.

Figure 9. Parking Brake Switch. 005

0005-20
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TRANSMISSION OPERATION – CONTINUED

Moving Machine from NEUTRAL Using Automodulation 0005

CAUTION
• Avoid automodulation while machine is under load.
• Selecting forward gears six through eight or reverse gears five or six is
NOT recommended.
• Failure to follow these cautions may result in damage to equipment.

NOTE
• Forward gears one through five and reverse gears one through four are recommended for
automodulation.
• Do not change engine speed while automodulating. Harsh shifting will result.
Automodulation entails shifting into forward or reverse gear by moving transmission control switch from NEUTRAL
position to either FORWARD or REVERSE position (Figure 10). Transmission initial gear will engage smoothly via
direction clutch. If initial gear is not desired, use upshift or downshift switch to select desired gear.

Figure 10. Transmission Control Switch. 005

0005-21
 TM 5-3805-293-10 0005

TRANSMISSION OPERATION – CONTINUED

Moving Machine from NEUTRAL Using Transmission Modulation Control (Inching Pedal) 0005

1. Fully depress inching pedal (Figure 11).

2. Select direction and desired gear.
3. Release inching pedal slowly to launch machine.

469-0287

Figure 11. Transmission Modulation Control (Inching Pedal). 005

0005-22
 TM 5-3805-293-10 0005

TRANSMISSION OPERATION – CONTINUED

Sequential Speed Shifting 0005

Sequential speed shifting allows the operator to change transmission gears while the machine is in motion. Activat-
ing Upshift and Downshift switches as desired will result in obtaining optimum ground speed for the operation
being performed (Figure 12). Speed shifting can be performed at any loading as shifts are automatically compen-
sated based on engine load.
Upshifts can occur at any engine speed but should be matched to load. Several shifts can be commanded at one
time, although there is a delay between shifts.
Downshifting requires engine speed to be less than full throttle to prevent engine overspeeding. Downshift control
requests are computer controlled. If engine speed is too high, engine speed is reduced to allow downshift to occur.
Upon shift completion, throttle control is returned to the operator.

Figure 12. Transmission Upshift and Downshift Buttons. 005

0005-23
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TRANSMISSION OPERATION – CONTINUED

Shuttle Shifting 0005

CAUTION
Do not perform shuttle shifting while using scarifier or while towing heavy load. Damage to
equipment may result.

Shuttle shifting, also known as directional shifting, allows operator to change machine direction quickly. Shuttle
shifting is performed by moving the transmission control switch from FORWARD to REVERSE position or from
REVERSE to FORWARD position WITHOUT stopping in the NEUTRAL position (Figure 13). If switch remains in
NEUTRAL position for more than 0.2 seconds, transmission will shift into NEUTRAL. The shifts shown in Table 1
are allowed.

Table 1. Shuttle Shifting.

ENGINE SPEED
SHUTTLE SHIFT OPERATOR INPUT
CONDITIONS FOR SHIFT

1 Forward to 1 Reverse Entire engine speed range Transmission Control Switch

1 Reverse to 1 Forward
2 Forward to 2 Reverse Entire engine speed range Transmission Control Switch
2 Reverse to 2 Forward
3 Forward to 3 Reverse Entire engine speed range Transmission Control Switch
3 Reverse to 3 Forward
4 Forward to 3 Reverse Less than 1,500 RPM Transmission Control Switch
4 Reverse to 3 Forward

Figure 13. Transmission Control Switch. 005

0005-24
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TRANSMISSION OPERATION – CONTINUED

Programmable Transmission Initial Gear Setting 0005

The initial gear is the gear that engages when the transmission control switch is engaged in FORWARD or
REVERSE position without selecting a specific gear. Each direction can have only one initial gear, and each direc-
tion can use different initial gears. Initial gears can be the same as but not higher than what is set as maximum
gear. Initial gear setting can be changed using the Messenger system when transmission is in NEUTRAL and the
machine is stopped. Changes made are new defaults at time of change or after a power cycle.
Programmable Transmission Maximum Gear Setting 0005

The maximum gear is the highest gear the transmission will shift into. Each direction can have only one maximum
gear, and each direction can use different maximum gears. For FORWARD position, gears 3 through 8 are avail-
able. In REVERSE Position, gears 3 through 6 are available. Initial gear setting can be changed using Electronic
Technician when transmission is in NEUTRAL and the machine is stopped. Changes made are new defaults at
time of change or after a power cycle
Transmission Modulator Control (inching pedal) 0005

The transmission modulator control (inching pedal) disengages power to the wheels. Press pedal in order to
decrease power to the wheels. A sensor monitors pedal position and varies hydraulic pressure to direction
clutches. When the pedal is fully depressed, power to the wheels will be disengaged.
The inching pedal can be used in all load conditions and provides the operator with speed control between two dis-
tinct gears. This is useful when the operator demands high engine speed for quick implement control while varying
ground speed.

CAUTION
• Avoid prolonged use of the inching pedal when moving heavy loads. Shift into lower gear
to match load condition. Failure to follow this caution may result in equipment damage.
• Do not use inching pedal as a clutch for directional changes. Machine is designed to
“shuttle shift”. Failure to follow this caution may result in equipment damage.
If the inching function is used in high load conditions, the operator should shift into a gear matched for that load
condition. If constant stalling occurs, downshifting is advisable.

Figure 14. Transmission Modulation Control (Inching Pedal). 005

END OF TASK

0005-25
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THROTTLE HOLD MODE SWITCH 0005

The Throttle Hold Mode switch allows the operator to set a throttle hold mode function. Modes which can be
selected include AUTOMATIC, OFF, and MANUAL.

NOTE
The indicator light for the throttle lock will be illuminated when the throttle is locked during
AUTOMATIC or MANUAL mode.

To Select AUTOMATIC Mode 0005

1. Push top of Throttle Hold Mode switch (Figure 15).

2. Use accelerator control to increase engine speed to desired RPM. Push in top of Throttle Set/Accel switch to
set the throttle at the current engine speed.
3. Use Throttle Set/Accel Switch and/or Throttle Resume/Decel switch to change throttle setting.
4. The throttle setting of AUTOMATIC mode will be suspended and engine speed will adjust to setting of acceler-
ator control if either of the following conditions occur:
a. Accelerator control is moved more than 20 percent.
b. Service brakes are applied.
5. Push top of Throttle Set/Accel Switch to resume preset engine speed.
6. Resume feature will be disabled if any of the following conditions occur:
a. Switch is moved to OFF mode.
b. Switch is moved to MANUAL mode.
c. Engine start switch is moved to OFF position.
d. Engine is stalled.

Figure 15. Throttle Hold Mode Switch and Throttle Resume/Decel Switch. 005

0005-26
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THROTTLE HOLD MODE SWITCH – CONTINUED

To Select MANUAL Mode 0005

WARNING
Applying service brakes or pressing accelerator control will not disengage throttle lock.
Failure to follow this warning may result in injury or death to personnel.
1. Push bottom of Throttle Hold Mode switch.
2. Use accelerator control to increase engine speed to desired RPM. Push in top of throttle Set/Accel switch to
set throttle at current engine speed.
3. Use Throttle Set/Accel switch and/or Throttle Resume/Decel switch to change throttle setting.
4. Engine speed will increase if accelerator control is pressed past throttle setting. When accelerator control is
released, engine will return to preset engine speed.

NOTE
The resume feature will not be available after the throttle lock is disengaged.

5. To disengage throttle lock:

a. Move throttle Hold/Mode switch to OFF position.
b. Move engine start switch to OFF position.

0005-27
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THROTTLE HOLD MODE SWITCH – CONTINUED

To Select OFF Mode 0005

Move switch to middle position. Throttle will only be operated by accelerator control.

END OF TASK

CENTERSHIFT LOCK SWITCH 0005

WARNING

Personal injury could result from the sudden movement of the blade when centershift lock
pin is released. Before releasing centershift lockpin, be sure all personnel are clear of
blade area, circle and blade are centered under machine, and blade is lowered to ground.

1. Use right joystick centershift control to shift drawbar left or right as required. Move drawbar to desired direction
and position. Place both left and right sides of blade in FLOAT position to ground moldboard.
2. Press red tab to unlock then move centershift lock switch to DISENGAGED position (push top of switch) (Fig-
ure 16). When switch is in DISENGAGED position, an indicator light will illuminate on monitoring system.

Figure 16. Centershift Controls and Indicator. 005

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CENTERSHIFT LOCK SWITCH – CONTINUED

3. To move link bar to first hole or second hole on either side of center, proceed to Step a. To move link bar to
third hole or farthest hole on either side of center, proceed to Step c.
a. Make sure that left side of blade and right side of blade are in FLOAT position. Move right joystick
centershift control in the opposite direction from what was used to position the drawbar in Step 1. As
centershift cylinder moves, linkage will roll freely. Also, link bar will move sideways.
b. Proceed to step 4.
c. Move left side and right side of blade out of FLOAT position.
d. Simultaneously move right joystick centershift control left, and lower right side of blade by moving right joy-
stick forward. Simultaneously, raise left side of blade by moving left joystick backward.
4. Line up centershift lock pin with desired hole in link bar. Use centershift indicator on right lift arm to check align-
ment.

NOTE
If centershift lock indicator light does not turn off, move link bar slightly to align hole with
centershift lock pin.

5. Move centershift lock switch to ENGAGED position (push bottom of switch). Monitoring system centershift lock
indicator light should go off when centershift lock pin is engaged.
6. Sideshift link bar toward desired direction. Use blade lift cylinders to adjust blade angle.

Figure 17. Centershift Indicator. 005

END OF TASK

0005-29
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ALL-WHEEL DRIVE (AWD) 0005

All-wheel drive (AWD) allows the operator to choose which wheels propel the machine and how fast the front
wheels turn in relation to the rear wheels. All-Wheel Drive is controlled by an AWD Mode Switch (CREEP {turtle},
OFF {circle}, and MANUAL {hand} positions) and an AWD Control Dial (minus, circle, and plus signs) (Figure 18).
• With AWD off, only tandem wheels propel the machine. Machine speed is controlled by the accelerator
pedal.
• When AWD is activated and CREEP mode engaged, only the front tires propel the machine. Front wheel
speed (zero to 5 mph {8km/h}) is controlled by the AWD Control Dial. Creep mode provides very precise
speed control when fine blading around obstacles, and prevents rear wheels from damaging finished sur-
faces due to driving force of rear wheels.
• When AWD is activated and MANUAL mode engaged, all six wheels propel the machine. Front wheel
speed (98 to 120 percent of rear wheel speed) is controlled by the AWD Control Dial. The center detent is
100% or 1:1 front wheel speed to rear wheel speed. Higher aggression (101% to 120%) allows more
power to be transmitted through the front wheels, providing better steering control in low traction conditions
and when bank sloping when trying to keep front wheels on slope while rear wheels are on level ground.

Figure 18. All-Wheel Drive Controls. 005

Operating Machine in Creep Mode 0005

1. Before turning AWD Mode switch to CREEP position, the machine must meet the following conditions:
a. Machine stopped (zero ground speed).
b. Engine running.
c. Parking brake switch set to ENGAGED position.
d. Transmission control switch set to NEUTRAL position.
2. Turn AWD Mode switch to CREEP position.
a. Rear transmission will be neutralized.
b. AWD indicator will illuminate.
3. Disengage parking brake (WP 0004).
4. Move Transmission Control switch to desired direction (FORWARD or REVERSE). When in CREEP mode,
power is supplied only to the front wheels.

0005-30
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ALL-WHEEL DRIVE (AWD) – CONTINUED

5. Turn AWD Control Dial to desired speed.
a. Turn control dial counterclockwise to decrease front wheel speed. Placing the dial in the full
counterclockwise position will bring the machine to a stop.
b. Turn the control dial to the center (detent) position to set front wheel speed at 2.5 mph (4 km/h).
c. Turn the control dial clockwise to increase front wheel speed. Placing the dial to the full clockwise position
will set front wheel speed to a maximum of 5 mph (8 km/h).
6. Depressing transmission modulator control (inching pedal) proportionally reduces front wheel speed.
a. With pedal fully depressed, machine comes to a stop.
b. With pedal partially released, machine is propelled at speed in proportion to amount pedal is released, up
to speed set on AWD Control Dial.
c. With pedal fully released, machine is propelled at speed set on AWD Control Dial.
Operating Machine in MANUAL Mode 0005

1. Before turning AWD Mode switch to MANUAL position, the machine must meet the following conditions:
a. Actual gear is anything but NEUTRAL, eighth gear FORWARD, or sixth gear REVERSE.
b. Engine running.
c. Parking brake switch set to DISENGAGED position.
d. Inching pedal not fully depressed.
2. Turn AWD Mode switch to MANUAL position. AWD indicator will illuminate.

NOTE
• While in MANUAL mode, amount of speed commanded to front wheels is affected by
available traction.
• Transmission gear is also used to limit aggression. Aggression will be limited to
100 percent in gears above fifth FORWARD and above fourth REVERSE.
3. Turn AWD Control Dial to desired speed.
a. Turning the dial to the full counterclockwise position (negative aggression) front wheels will turn at
99 percent of rear wheel speed.
b. Turn the control dial to the center (detent) position to set front wheel speed at 100 percent of rear wheel
speed.
c. Turning the dial to the full clockwise position (positive aggression) will set front wheel speed at 120 percent
of rear wheel speed.
4. Depressing transmission modulator control (inching pedal) proportionally reduces front wheel speed.
a. With pedal fully depressed, machine comes to a stop.
b. With pedal partially released, machine is propelled at speed in proportion to amount pedal is released, up
to speed set on AWD Control Dial.
c. With pedal fully released, machine is propelled at speed set on AWD Control Dial.

END OF TASK

0005-31
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SLOPE OPERATION 0005

Safe operation depends on a number of factors including machine maintenance, operating speed, terrain condi-
tions, fluid levels, tire inflation pressures, and most importantly–operator skill and judgment. When working on hills
or slopes, consider the following points:
• Speed of travel – At higher speeds, forces of inertia tend to make machine less stable.
• Roughness of terrain or surface – The machine may be less stable on uneven terrain.
• Direction of travel – Avoid operating machine across the slope. When possible, operate the machine up
and down rather than across slopes. Place heaviest end of machine uphill when you are working on an
incline.
• Mounted equipment – Balance of machine may be impeded by the following components: equipment that
is mounted on machine, machine configuration, weights, and counterweights.
• Nature of surface – Ground that has been newly filled with earth may collapse from weight of machine.
• Surface material – Rocks and moisture of surface material may drastically affect machine’s traction and
stability. Rocky surfaces may promote side slipping of machine.
• Slippage due to excessive loads – This may cause downhill tracks or downhill tires to dig into the ground,
which will increase angle of machine.
• Width of tires – Narrower tires further increase digging into ground which causes machine to be less
stable.
• Implements attached to drawbar – This may decrease weight on uphill tires. The decreased weight will
cause machine to be less stable.
• Height of working load of machine – When working loads are in higher positions, stability of machine is
reduced.
• Operating equipment – Be aware of performance features of equipment in operation and effects on
machine stability.
• Operating techniques – Keep all attachments or pulled loads low to ground for optimum stability.
• Machine systems have limitations on slopes – Slopes can affect the proper function and operation of the
various machine systems. These machine systems are needed for machine control on slopes.

END OF TASK

0005-32
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SCARIFIER OPERATION 0005

The scarifier, made of up to 11 shanks with teeth, is used to break up hard ground or material to a regulated depth
to make it ready to grade. The number of shanks/teeth used depends on the consistency of the material being bro-
ken up.
The center five shanks (with teeth) may be removed to allow scarifier assembly to be raised to gain additional
ground clearance when necessary. The remaining shanks can be stowed upside down in the scarifier frame, if
additional clearance is required. Up to five removed scarifier shanks may be stored in the scarifier shank stowage
rack located at the front of the machine. A strap is provided to bind shanks together to avoid loss. Stow shanks in
rack facing every other one backwards to allow stowage of up to five shanks. Refer to Scarifier Tooth and Shank
Maintenance (WP 0027).
Scarifier digging angle can be adjusted to accommodate different needs. Notify Field Level Maintenance if scarifier
digging angle adjustment is required.

Figure 19. Scarifier Shank Stowage Rack. 005

END OF TASK

END OF WORK PACKAGE

0005-33/(34 blank)
48

TM 5-3805-293-10 0006

OPERATOR MAINTENANCE -

0 0 0 6 ADVANCED OPERATION AND OPERATOR TIPS

Scope, Traveling and Earth Moving Operations

INITIAL SETUP

References 0 0

WP 0005 0

WP 0007 0

WP 0013 0

SCOPE 0006

1. This work package provides advanced operation instructions and operator tips for operating the 120M Motor
Grader.
2. Refer to WP 0005 for operating instructions under usual conditions.
3. Refer to WP 0007 for operating instructions under unusual conditions.
4. Before, during, and after operation, perform applicable PMCS (WP 0013).

NOTE
Machine shown in illustrations in this work package represents a generic motor grader.
Functions described are applicable to the 120M Motor Grader.

0006-1
 TM 5-3805-293-10 0006

TRAVELING AND EARTH MOVING OPERATIONS 0006

Turning Around Using Articulation 0006

CAUTION
• Make sure differential lock is unlocked before turning or maneuvering through tight
corners.
• Do not allow the blade to contact the tires when articulating the machine.
• Failure to follow these cautions may result in damage to the machine.

NOTE
AWD set to 120% will reduce turning radius in soft surfaces.

1. Turn left and articulate frame left.

Figure 1. Left Turn - Frame Articulated Left. 0006

0006-2
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

2. Turn right and articulate frame right.

Figure 2. Right Turn - Frame Articulated Right. 0006

END OF TASK

0006-3
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED 0006

Turning Around in Tight Areas 0006

CAUTION
• Make sure differential lock is unlocked before turning or maneuvering through tight corners
(WP 0004).
• Do not allow the blade to contact the tires when articulating the machine.
• Failure to follow this caution may result in damage to the machine.
1. Lean wheels slightly in direction of turn (right for right turn, left for left turn), then turn wheels.

Figure 3. Turning in a Tight Area. 0006

2. Travel as far forward as possible.

Figure 4. Turning in a Tight Area. 0006

0006-4
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

3. Turn front wheels in the opposite direction. Back machine as far as possible to line it up with new direction of
travel.

Figure 5. Turning in a Tight Area. 0006

4. Turn wheels to new travel direction. Travel forward and straighten wheels after turn is completed.

Figure 6. Turning in a Tight Area. 0006

END OF TASK

0006-5
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Backing Out of a Drop-off or Ditch 0006

NOTE
This procedure is for backing out of a drop-off or ditch on the left side. Reverse articulation
and turning direction if drop-off or ditch is on right side.

1. Stop machine. Raise blade and implements.

Figure 7. Backing Out of Drop-Off or Ditch. 0006

2. Articulate right while moving back slowly.

Figure 8. Articulating Right While Backing Slowly. 0006

3. Turn left while moving back slowly.

Figure 9. Steering Left While Backing Slowly. 0006

0006-6
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

4. Continue to back out until machine is completely out of drop-off or ditch.

Figure 10. Backing Out of Drop-Off or Ditch. 0006

END OF TASK

Grading Around an Object 0006

1. Press transmission modulator pedal to move machine slowly (inch) around an object.

Figure 11. Approaching Object. 0006

NOTE
Grade as close to the object as possible to minimize hand cleanup.

2. Grade close to object.

Figure 12. Grading Close to Object. 0006

0006-7
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

3. While traveling in a straight line, adjust blade sideshift and/or drawbar centershift to grade around object.

Figure 13. Sideshifting Blade to Avoid Object. 0006

4. When passing object, begin to move blade back to center position.

5. Once past object, blade should be back in original position.

Figure 14. Grading Past Object. 0006

END OF TASK

0006-8
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Grading on an “S” Curve 0006

CAUTION
Do not allow the blade to contact the tires when articulating the machine. Failure to follow
this caution may result in damage to the machine.

1. Articulate left, turn left, and sideshift right.

Figure 15. Entering “S” Curve. 0006

2. Turn straight and move sideshift as necessary.

Figure 16. Center of “S” Curve. 0006

3. Articulate right, turn right and sideshift left.

Figure 17. Reversing Direction on “S” Curve. 0006

0006-9
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

4. Continue to grade.

Figure 18. Exiting “S” Curve. 0006

END OF TASK

Scarifying Operations 0006

CAUTION
• When using the scarifier, the frame must be straight.
• When carrying the scarifier in the fully raised position, do not allow the scarifier beam or
shanks to contact the drawbar.
• Raise the scarifier when turning. Failure to follow these cautions may cause damage to
machine.
• Do not reverse the scarifier teeth. They may impact frame.

NOTE
• If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce
number of shanks being used.
• Use all shanks in light material, fewer shanks in heavier material.
• Break up paving by digging under surface and lifting scarifier.
1. Position the grader outside the working area of the project to configure the grader for scarifying.
2. Raise the scarifier log all the way up.
3. Raise the moldboard 4-6 in. (100-150 mm) off the surface and pitch the blade halfway.
4. Circle the blade to a 25-30 degree angle.
5. Centershift until the heel cylinder is straight up and down.
6. Fully raise the moldboard 4-6 in. (100-150 mm) above the surface.
7. Lower the scarifier log to the surface.
8. Place the grader in forward motion.
9. Lower the scarifier log as it crosses the project starting point and penetrate the surface
10. Scarify the entire length of the area to a minimum depth of 6 in. (150 mm).
11. Raise the scarifier log at the finish point.
12. Exit the project area, pull off at a 45 degree angle, and stop the grader.
13. Return to the starting point, ensuring you are not backing over the scarified area, and reposition the grader for
a second scarifying pass.
14. Overlap teeth on subsequent passes.
15. Repeat until completed.

END OF TASK

0006-10
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Right-Hand Grading 0006

NOTE
During right-hand grading, left lift (heel) cylinder will be vertical, and right lift (toe) cylinder
will be slightly angled.

1. Position the grader outside the working area of the project approximately 12-18 in. (30-45 cm) from the right
boundary of the project area.
2. Raise the scarifier log all the way up.
3. Lower the moldboard to within 4-6 in. (100-150 mm) from the surface. This will provide unrestricted movement
and prevent metal-to-metal contact.
4. Pitch the blade half way.

Figure 19. Pitch Blade Half Way. 0006

5. Circle the blade counterclockwise to a 25-30 degree angle with the toe facing the right front tire.
6. Centershift the circle assembly to the left until the heel cylinder is straight up and down.

Figure 20. Adjusting Centershift. 0006

0006-11
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

7. Lean the front wheels toward the heel.

Figure 21. Leaning Wheels Toward Heel. 0006

8. Lower the moldboard to the ground.

Figure 22. Lower Moldboard to Ground. 0006

9. Place the grader in motion.

Figure 23. Place Grader in Motion. 0006

0006-12
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

10. As the moldboard crosses the project start line, apply enough down pressure on both heel and toe to penetrate
the surface 0.5 in. (12 mm).

Figure 24. Adjust Moldboard to Penetrate Surface. 0006

11. Maintain a straight course, adjusting the moldboard slightly to carry the material the length of the project.

NOTE
Feathering is a process accomplished by raising the moldboard in 1/2 to 1 inch
increments, while in a forward motion. Two or three seconds are recommended between
each upward adjustment until all the material in front of the moldboard passes under it.

12. Be sure to feather the material out at the end of the pass.

Figure 25. Feathering Material. 0006

13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side.
14. Stop the grader and straighten the front wheels.
15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles.
16. Position the grader to straddle the windrow just made and back up straight to the start point. Ensure the
windrow is between the wheels, and do not drive on top of it.
17. Stop the grader just outside the boundary line.

END OF TASK

0006-13
 TM 5-3805-293-10 0006

TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Left-Hand Grading 0006

NOTE
During left-hand grading, right lift (heel) cylinder will be vertical and left lift (toe) cylinder
will be slightly angled.

1. Position the grader outside the working area of the project centered on the previous windrow of the project
area.
2. Raise the scarifier log all the way up.
3. Lower the moldboard to within 4-6 in. (100-150 mm) of the surface.
4. Pitch the blade half way.

Figure 26. Pitch Blade Halfway. 0006

5. Circle the blade clockwise to a 25-30 degree angle with the toe facing the left front tire.
6. Centershift the circle assembly to the right until the heel cylinder is straight up and down.

Figure 27. Adjusting Centershift. 0006

0006-14
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

7. Lean the front wheels toward the heel.

Figure 28. Leaning Wheels Toward Heel. 0006

8. Lower the moldboard to the ground.

Figure 29. Lower Moldboard to Ground. 0006

9. Place the grader in motion.

Figure 30. Place Grader in Motion. 0006

0006-15
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

10. As the moldboard crosses the project start line, apply enough down pressure on both heel and toe to penetrate
the surface 0.5 in. (12 mm).

Figure 31. Adjust Moldboard to Penetrate Surface. 0006

11. Maintain a straight course, adjusting the moldboard slightly to carry the material the length of the project.

NOTE
Feathering is a process accomplished by raising the moldboard in 1/2 to 1 inch
increments, while in a forward motion. Two or three seconds are recommended between
each upward adjustment until all the material in front of the moldboard passes under it.

12. Be sure to feather the material out at the end of the pass.

Figure 32. Feathering Material. 0006

0006-16
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

13. After the material is feathered to a smooth termination, pull off at a 45 degree angle to the toe side.
14. Stop the grader and straighten the front wheels.

WARNING
Never back the grader with the front tires leaned. Steering accuracy is compromised. After
completing each general position, always return the front wheels to straight up and down
position prior to executing the next position. Failure to follow this warning may result in
personal injury or death.

15. Raise both lift cylinders until the moldboard is high enough to clear all obstacles.
16. Execute a three-point turn toward the toe and position the grader to straddle the windrow just made. Ensure
the windrow is between the wheels, and do not drive on top of it.
17. Stop the grader just outside the boundary line.

END OF TASK

Center Windrow 0006

1. Position the grader to straddle the last windrow made.

2. Raise the scarifier log all the way up.
3. Raise the moldboard 4-6 in. (100-150 mm) off the surface and pitch the blade halfway.
4. Circle the blade to 0 degree angle.
5. Centershift the circle assembly until both lift cylinders are equally spaced to the main frame.
6. Lower the moldboard to half the height of the windrow to be spread.

NOTE
Do not lean the front wheels. The wheels will remain straight during this grading method.

7. Place the grader in forward motion, making only minor adjustments to the moldboard.
8. Continue to the end of the project or until material in front of the moldboard passes under it.

END OF TASK

0006-17
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Road Building - “V” Ditch Method 0006

NOTE
The steps in this procedure are for one side of the road. Repeat these steps for the
opposite side.

1. Position the grader outside the working area of the project to configure the grader for “V” ditching.
2. Place the grader into ditching position as follows;
a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.
b. Pitch the blade halfway.
c. Center the blade on the circle by side shifting if needed.
d. Center shift until the heel cylinder is straight up and down.
e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire.
f. Raise the heel cylinder all the way up.
g. Lean the front wheels toward the heel.
3. Perform a marking cut followed by a ditching (heavy) cut.

Figure 33. Marking and Ditching Cuts. 0006

4. Continue until a desired depth is reached or a slope of 3:1 is achieved.

Figure 34. Ditch Cuts. 0006

0006-18
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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

5. Spread to center.

Figure 35. Center Windrow Position. 0006

6. Clean shoulder and spread to center.

Figure 36. Leveling the Area. 0006

7. Slope and cut back side of ditch and then clean bottom.

Figure 37. Cutting Back Side of Ditch. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

8. Make a ditching pass to clean and shape inside slope.

Figure 38. Cleaning and Shaping Inside Slope. 0006

9. Finish shoulder pass.

Figure 39. Finishing Shoulder Pass. 0006

10. Level and finish.

Figure 40. Leveling and Finishing. 0006

END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Right-Hand “V” Ditching 0006

CAUTION
• Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow
this caution may result in damage to machine.
• Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls
may be forced against the back slope, causing tire sidewall damage and also forcing dirt
between the tire and rim, causing air loss and flat tires.

NOTE
• Steps 1 through 7 pertain to making a “Marking Cut.”
• Ditching is normally done on the right side of the grader as it has greater reach to this side.
1. Position the grader outside the working area of the project.

Figure 41. Positioning Grader. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

2. Place the grader into ditching position as follows;
a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.
b. Pitch the blade halfway.
c. Center the blade on the circle by side shifting if needed.
d. Center shift until the heel cylinder is straight up and down.
e. Rotate the moldboard so the toe is just behind the outside edge of the right front tire.
f. Raise the heel cylinder all the way up.
g. Lean the front wheels toward the heel.

Figure 42. Leaning Wheels Toward the Heel. 0006

NOTE
The grader is now in the ditching position. Align the right front tire on top of the proposed
ditch line. Make a visual check to finish point of the ditch. Maintain control of the grader
and do not permit it to deviate from the proposed ditch line.

3. Place the grader in motion and as the right front tire passes over the starting point of the ditch, lower the toe.

Figure 43. Adjusting Blade to Deliver Material. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTE
At this point, the primary concern is to follow the proposed ditch line. Example: If stakes
are utilized, ensure the right front tire is directly in line with the next stake.

5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward
movement until the rear tires pass over and off the marking cut.
6. Straighten the front wheels and steer the grader to the right approximately 45 degrees to the ditch.
7. Back the grader along the outside edge of the windrow to the start point.

NOTE
• After the initial marking cut, ensure quality control on all remaining cuts. The marking cut
provides and excellent track for the grader to follow. The grader is set up already for the
ditching cut to follow.
• Steps 8 through 13 pertain to making “Ditching Cuts.”
8. Pull forward and stop the grader just as the right front tire enters the marking cut.

Figure 44. Positioning Right Front Tire and Right End of Blade. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

9. Lean the front tires toward the heel.

Figure 45. Leaning Wheels. 0006

10. Place the grader in forward motion and apply as much down pressure to the toe of the blade as the grader will
handle - cut depth should not exceed 4-6 in. (100-150 mm).

CAUTION
Attempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pulling
to one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TO
STEER OUT OF THE PULL.

11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching
cuts until the desired depth is achieved.

Figure 46. Reposition Grader. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

12. Repeat ditch cut as necessary.

Figure 47. Repeat Ditch Cut as Necessary. 0006

13. Back the grader along the outside edge of the windrow to the start point.

NOTE
• Steps 14 through 26 pertain to cleaning the shoulder of the ditch.
• This task is accomplished by placing the grader in the wide side reach position.
14. Position the grader so the right front tire is approximately 12-15 in. (30-38 cm) to the left of the ditch center line
and stop the grader.
15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the
moldboard to 0 degrees.
16. Center shift all the way to the right.
17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface.
18. Blade side shift all the way right.

CAUTION
Do not adjust the moldboard height, especially the heel (left lift) cylinder. The view is
obscured because the heel is under the main frame of the grader.

19. Circle the moldboard counterclockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside
edge of the right front tire (approximately a 45 degree angle).

Figure 48. Setting Blade to Deliver Material. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

20. Place the grader in forward motion and maintain a position and course so the tow of the moldboard passes
directly over the center of the ditch.
21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 49. Lower the Blade to the Ground. 0006

22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the
moldboard passes under it or is windrowed off the heel.
23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTION
Do not back the grader in the wide reach position. A safety factor is apparent; the
moldboard would be extended out past the tires. By placing the moldboard in the right
hand general grading position, the safety factor is minimized and the moldboard is
positioned to execute the next maneuver.

24. Stop the grader and place the moldboard in the right hand general grading position.
25. Ensure the front wheels are straight up and down prior to backing the grader.
26. Back the grader to the starting point by straddling the windrow.

NOTE
Steps 27 through 33 pertain to skimming the surface to spread material towards center
establishing a crown in the road.

27. Stop the grader outside the starting point of the project and lean the wheels toward the heel.
28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the
surface.

Figure 50. Adjusting Blade to Deliver Material. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

29. Place the grader in forward motion and maintain a straight course by keeping the grader centered on the
windrow.

NOTE
With the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditch
should pass under and off the heel of the moldboard, thereby establishing the crown of the
road.

30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road.
31. At the end of the pass, ensure the material is feathered prior to stopping the grader.
32. Straighten the front wheels and raise both lift cylinders all the way up.
33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch
on the other side of the project area going the opposite direction.

NOTE
Steps 34 through 39 pertain to “Center Windrow Positioning.”

34. Position the grader in the center windrow.

35. Lower the blade to approximately 4-6 in. (100-150 mm) above the ground.
36. Circle the blade until it is at a 0 degree angle.
37. Lateral shift the circle assembly until the cylinders are in a V shape.
38. Position the front wheels straight up and down.
39. Lower the blade to half the height of the windrow.

NOTE
• Steps 40 through 42 pertain to “Leveling the Area.”
• Determine which of the following procedures is applicable to the current task. Proceed to
the step indicated.
Right to Left - go to Step 40

Left to Right - go to Step 41

Center to Right/Center to Left - go to Step 42

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

40. Right to Left
a. Beginning at the right side of the area boundary, blade the material from the right side to the left side.
b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material
along the left boundary.
41. Left to Right
a. Beginning at the left side of the area boundary, blade the material from the left side to the right side.
b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material
along the right boundary.
42. Center to Right / Center to Left
a. Beginning at approximately the center line of the area, blade (level) the material from the center starting
point to the left boundary line.
b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the
right boundary line.

END OF TASK

Left-Hand “V” Ditching 0006

CAUTION
• Make sure the blade is lowered to the ground before adjusting centershift. Failure to follow
this caution may result in damage to machine.
• Make sure frame is in straight alignment. If the machine is articulated, the tire sidewalls
may be forced against the back slope, causing tire sidewall damage and also forcing dirt
between the tire and rim, causing air loss and flat tires.

NOTE
Steps 1 through 7 pertain to making a “Marking Cut.”

1. Position the grader outside the working area of the project.

Figure 51. Positioning Grader. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

NOTE
Ditching is normally done on the right side of the grader as it has greater reach to this
side.

2. Place the grader into ditching position as follows;

a. Raise the moldboard 4-6 in. (100-150 mm) off the surface to allow unrestricted movement.
b. Pitch the blade halfway.
c. Center the blade on the circle by side shifting if needed.
d. Centershift until the heel cylinder is straight up and down.
e. Rotate the moldboard so the toe is just behind the outside edge of the left front tire.
f. Raise the heel cylinder all the way up.
g. Lean the front wheels toward the heel.

Figure 52. Leaning Wheels Toward the Heel. 0006

NOTE
The grader is now in the ditching position. Align the right front tire on top of the proposed
ditch line. Make a visual check to finish point of the ditch. Maintain control of the grader
and do not permit it to deviate from the proposed ditch line.

3. Place the grader in motion and as the left front tire passes over the starting point of the ditch, lower the toe.

Figure 53. Place Grader in Motion. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

4. Apply enough pressure on the toe to penetrate the surface 3-4 in. (75-100 mm).

NOTE
At this point, the primary concern is to follow the proposed ditch line. Example: If stakes
are utilized, ensure the left front tire is directly in line with the next stake.

5. At the completion of the marking cut, feather the material and raise the toe all the way. Continue forward
movement until the rear tires pass over and off the marking cut.
6. Straighten the front wheels and steer the grader to the left approximately 45 degrees to the ditch.
7. Back the grader along the outside edge of the windrow to the start point.

NOTE
• After the initial marking cut, ensure quality control on all remaining cuts. The marking cut
provides and excellent track for the grader to follow. The grader is set up already to the
ditching cut to follow.
• Steps 8 through 13 pertain to making “Ditching Cuts.”
8. Pull forward and stop the grader just as the left front tire enters the marking cut.

Figure 54. Tire Position. 0006

9. Lean the front tires toward the heel.

Figure 55. Wheels Placed for Continued Ditching. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

10. Place the grader in forward motion and apply as much down pressure to the toe of the blade as the grader will
handle - not to exceed 4-6 in. (100-150 mm).

CAUTION
Attempting to cut more than 4-6 in. (100-150 mm) will result in the grader stalling or pulling
to one side. Lift the toe in the event that either should happen. DO NOT ATTEMPT TO
STEER OUT OF THE PULL.

11. If the desired depth was not achieved, reposition the grader to the starting point and make additional ditching
cuts until the desired depth is achieved.

Figure 56. Reposition Grader. 0006

12. Repeat ditch cut as necessary.

Figure 57. Repeat Ditch Cut as Necessary. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

13. Back the grader along the outside edge of the windrow to the start point.

NOTE
• Steps 14 through 26 pertain to cleaning the shoulder of the ditch.
• This task is accomplished by placing the grader in the wide side reach position.
14. Position the grader so the left front tire is approximately 12-15 in. (30-38 cm) to the right of the ditch center line
and stop the grader.
15. Adjust the height of the blade to approximately 4-6 in. (100-150 mm) off the surface and then rotate the
moldboard to 0 degrees.
16. Centershift all the way to the left.
17. Readjust the height of the blade to approximately 2 in. (50 mm) off the surface.
18. Blade side shift all the way left.

CAUTION
Do not adjust the moldboard height, especially the heel (right) lift cylinder. The view is
obscured because the heel is under the main frame of the grader.

19. Circle the moldboard clockwise until the toe is approximately 12-15 in. (30-38 cm) from the outside edge of the
left front tire (approximately a 45 degree angle).

Figure 58. Adjusting Blade to Deliver Material. 0006

20. Place the grader in forward motion and maintain a position and course so the toe of the moldboard passes
directly over the center of the ditch.
21. Apply enough down pressure on the toe side to skim the material from the shoulder. Do not cut the shoulder.

Figure 59. Lowering Blade to the Ground. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

22. As the grader passes the finishing point of the ditch, continue forward until all the material in front of the
moldboard passes under it or is windrowed off the heel.
23. Continue forward until enough space is available to position the grader to back up to straddle the windrow.

CAUTION
Do not back the grader in the wide reach position. A safety factor is apparent; the
moldboard would be extended out past the tires. By placing the moldboard in the left hand
general grading position, the safety factor is minimized and the moldboard is positioned to
execute the next maneuver.

24. Stop the grader and place only the moldboard in the left hand general grading position.
25. Ensure the front wheels are straight up and down prior to backing the grader.
26. Back the grader to the starting point by straddling the windrow.

NOTE
Steps 27 through 33 pertain to skimming the surface to spread material towards center
establishing a crown in the road.

27. Stop the grader outside the starting point of the project and lean the wheels toward the heel.
28. Adjust the heel approximately 2-3 in. (50-75 mm) off the surface and ensure that the toe is just touching the
surface.

Figure 60. Adjusting Blade to Deliver Material. 0006

29. Place the grader in forward motion and maintain a straight course by keeping the grader centered on the
windrow.

NOTE
With the heel raised approximately 2-3 in. (50-75 mm), the loose material from the ditch
should pass under and off the heel of the moldboard, thereby establishing the crown of the
road.

30. Skim the shoulder of the road with the toe and spread the windrow to form the surface of the road.
31. At the end of the pass, ensure the material is feathered prior to stopping the grader.
32. Straighten the front wheels and raise both lift cylinders all the way up.
33. Reposition the grader at the finishing end of the project. The grader should be positioned to establish a V-ditch
on the other side of the project area going the opposite direction.

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

NOTE
Steps 34 through 39 pertain to “Center Windrow Positioning.”

34. Position the grader in the center windrow.

35. Lower the blade to approximately 4-6 in. (100-150 mm) above the ground.
36. Circle the blade until it is at a 0 degree angle.
37. Lateral shift the circle assembly until the cylinders are in a V shape.
38. Position the front wheels straight up and down.
39. Lower the blade to half the height of the windrow.

NOTE
• Steps 40 through 42 pertain to “Leveling the Area.”
• Determine which of the following procedures is applicable to the current task then proceed
to the step indicated.
Right to Left - go to Step 40

Left to Right - go to Step 41

Center to Right/Center to Left - go to Step 42

40. Right to Left

a. Beginning at the right side of the area boundary, blade the material from the right side to the left side.
b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material
along the left boundary.
41. Left to Right
a. Beginning at the left side of the area boundary, blade the material from the left side to the right side.
b. Ensure the grader is centered on the windrow for each consecutive pass, leaving a windrow of material
along the right boundary.
42. Center to Right / Center to Left
a. Beginning at approximately the center line of the area, blade (level) the material from the center starting
point to the left boundary line.
b. Reposition the grader to the center line again, blade (level) the material from the center starting point to the
right boundary line.

END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Ditch Back Sloping 0006

CAUTION
Make sure blade is lowered to ground before retracting the centershift lock pin. Failure to
follow this caution may result in damage to machine.

1. Position grader outside of the ditch.

2. Circle moldboard to 0 degrees to the grader frame and lower moldboard to approximately 2 in. (50 mm) above
the ground.
3. Side shift the moldboard all the way to the right.
4. Centershift circle assembly all the way to the right.

CAUTION
Lower moldboard as needed to prevent metal-to-metal contact between lift arm and
frame.

5. Lower moldboard to the ground.

NOTE
Activating blade float will relieve all pressure from the moldboard.

6. Retract centershift lock pin.

7. Using right and left blade control levers, position the centershift saddle to the far left centershift position.
8. Place the centershift lockpin into the far left centershift position.

NOTE
You may have to move the blade controls to completely seat the centershift lockpin.

9. Move the centershift lock lever to the LOCKED position, and then back to the INDEX and RUN position.
10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the
grader.

Figure 61. Adjusting Blade. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

11. Circle the moldboard assembly to the right to the desired position.
12. Position the heel of the moldboard in front of the right rear tire.

Figure 62. Heel Position. 0006

13. Lower the toe to the desired degree of slope.

Figure 63. Positioning Blade. 0006

14. Lean wheels into the slope for a heavier cut, and away from the slope for a lighter cut.

Figure 64. Leaning Wheels IN for Heavier Cut. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

15. Reverse procedures to return the moldboard to general grading position.

Figure 65. Leaning Wheels AWAY for Lighter Cut. 0006

END OF TASK

Grading in a Wet Ditch 0006

1. Articulate machine so front wheels and blade are in ditch. Steer with front wheels.

NOTE
This method may be used to avoid obstructions whenever cleaning old ditches, which may
have tree overhangs, rock ledges, etc.

2. Keep rear wheels on shoulder to prevent wheel slippage in wet or soft material in ditch.

Figure 66. Positioning Wheels to Prevent Slippage. 0006

END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Flat Bottom Ditching 0006

1. If no “V” ditch exists, build a “V” ditch to desired depth of flat bottom ditch.

NOTE
The shoulder slope should be flatter than normal, ending at the finished shoulder line.

2. Tip blade forward.

Figure 67. Pitching Blade. 0006

CAUTION
Make sure the blade is lowered to the ground before retracting the centershift lock pin.
Failure to follow this caution may result in damage to machine.

3. Move centershift lock pin to right-center position.

4. Have right front tire in bottom of “V” ditch.

Figure 68. Positioning Tire in Bottom of Ditch. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

5. Set blade so toe is inside right front tire at desired width of flat bottom ditch.

Figure 69. Setting Blade. 0006

6. Lower right lift cylinder to set depth of cut.

Figure 70. Lowering Right Lift Cylinder. 0006

7. Raise left lift cylinder to set desired shoulder slope.

8. Lean front wheels to the left. Cut second “V” ditch to same depth or slightly above first one.

Figure 71. Raising Left Lift Cylinder and Leaning Wheels. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

9. Cut a flat bottom. Set right lift cylinder to required depth.

Figure 72. Setting Right Lift Cylinder and Cutting Bottom. 0006

10. Set left lift cylinder as required.

Figure 73. Setting Left Lift Cylinder. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

CAUTION
Make sure the blade is lowered to the ground before retracting the centershift lock pin.
Failure to follow this caution may result in damage to machine.

11. Move centershift lock pin to far-right position.

12. Start right front tire in bottom of first “V” ditch.
13. Set right end of blade at bottom of backslope.

Figure 74. Positioning Right Front Tire and Right End of Blade. 0006

14. Lower right lift cylinder so point of blade is on established grade of ditch.

Figure 75. Positioning Blade. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

15. Lower left lift cylinder to desired depth of cut. Lean front wheels to left.
16. Set blade at a sharp angle and move material up the slope of ditch.
17. Spread windrow and finish final grade.

Figure 76. Finishing Final Grade. 0006

END OF TASK

Grading on a 3-to-1 Slope 0006

WARNING
• Only an experienced operator should operate the machine on a steep side slope.
• Never fully articulate the machine uphill on steep slopes.
• Failure to follow these warnings may cause injury to personnel or damage to equipment.

NOTE
• When working on steep slopes, operate the machine in first gear, at a reduced engine
speed.
• When working on slopes, use the accelerator to control the speed of the machine.
• When operating on extreme slopes, use crab steering to keep the back of the grader on
the downhill side of cut.
1. Articulate frame to place frame in an offset position for maximum stability.

Figure 77. Articulating Frame for Stability. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

2. Use crab steering when front of machine tends to slip due to heavy side load on blade.

Figure 78. Crab Steering to Overcome Heavy Load. 0006

END OF TASK

High Bank Cuts - Right Side 0006

1. Clean roadbed to ensure roadbed at base of cut is uniform.

Figure 79. Cleaning Roadbed. 0006

2. If material is hard, slope roadbed slightly in to bank to keep machine from sliding away from bank.
3. Pitch blade 3/4 to full position forward.

Figure 80. Pitching Blade Forward. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

CAUTION
Make sure the blade is lowered to the ground before retracting the centershift lock pin.
Failure to follow this caution may result in damage to machine.

4. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm)
above the ground.
5. Side shift the moldboard all the way to the right.
6. Centershift the circle assembly all the way to the right.

CAUTION
Lower the moldboard as needed to prevent metal-to-metal contact between the lift arm
and frame.

7. Lower the moldboard to the ground.

NOTE
Activating blade float will relieve all pressure from the moldboard.

8. Retract centershift lock pin.

9. Using right and left joysticks, position the centershift saddle to the far left centershift position.
10. Place the centershift lockpin into the far left centershift position.

NOTE
You may need to move the blade controls to completely seat the centershift lockpin.

11. Press the centershift lock switch to engage and lock centershift lockpin.
12. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the
grader.
13. Circle the moldboard assembly to the right to the desired position.

Figure 81. Setting Blade Position. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

14. Lower left lift cylinder to set heel of blade at bottom of slope and in line with outer edge of rear tire.

Figure 82. Positioning Blade. 0006

15. Ensure right rear tires are in “V” at base of slope.

Figure 83. Positioning Right Rear Tire. 0006

16. Lower right lift cylinder to set desired degree of bank slope.
17. Move into cut gradually.

Figure 84. Beginning Cut. 0006

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

NOTE
The wheels should be near the vertical position.

18. Lean wheels toward slope for a heavier cut.

Figure 85. Leaning Wheels In for Heavier Cut. 0006

NOTE
The procedure shown is for right side. Position blade opposite to that shown for left side.

19. Lean wheels away from slope for a lighter cut. Keep material from slope moved to outside of rear wheels.

Figure 86. Leaning Wheels Away for Lighter Cut. 0006

END OF TASK

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TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Extreme Side Reach 0006

CAUTION
Make sure the blade is lowered to the ground before retracting the centershift lock pin.
Failure to follow this caution may result in damage to machine.

NOTE
The following steps are for extreme side reach to the right. For extreme left side reach,
position the centershift lock pin and blade to the far left.

1. Position the grader outside the working area of the project.

2. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm)
above the ground.
3. Side shift the moldboard all the way to the right.
4. Centershift the circle assembly all the way to the right.

CAUTION
Lower the moldboard as needed to prevent metal-to-metal contact between the lift arm
and frame.

5. Lower the moldboard to the ground.

NOTE
Activating blade float will relieve all pressure from the moldboard.

6. Retract centershift lock pin.

7. Using right and left joysticks, position the centershift saddle to the far left centershift position.
8. Place the centershift lockpin into the far left centershift position.

NOTE
You may need to move the blade controls to completely seat the centershift lockpin.

9. Press the centershift lock switch to engage lockpin.

10. Raise the toe of the blade while lowering the heel as needed to bring the moldboard out to the right side of the
grader.
Circle the moldboard assembly to the right to the desired position.

11. Move centershift lock pin to far right position.

12. Sideshift blade to far right position.
13. Centershift circle assembly to far right position.
14. Circle the blade to the desired angle.
15. Lower blade to desired depth to deliver material to side.

0006-47
 TM 5-3805-293-10 0006

TRAVELING AND EARTH MOVING OPERATIONS – CONTINUED

Mid-Mounted Scarifier Operation 0006

CAUTION
• When using the scarifier, the frame must be straight.
• When carrying the scarifier in the fully raised position, do not allow the scarifier beam or
shanks to contact the drawbar.
• Raise the scarifier when turning.
• Do not reverse the scarifier teeth. They may impact frame.
• Failure to follow these cautions may cause damage to machine.

NOTE
• If material begins to accumulate in front of scarifier, reduce depth of scarifier or reduce
number of shanks being used.
• Use all shanks in light material, fewer shanks in heavier material.
• Break up paving by digging under surface and lifting scarifier.
1. Enter material gradually, while traveling in a straight line.
2. Keep scarifier as deep as conditions permit. Match travel speed to load.
3. All teeth can remain in scarifier when level grading with blade.
4. Clean scarifier when material begins to accumulate.

END OF TASK

END OF WORK PACKAGE

0006-48
14

TM 5-3805-293-10 0007

OPERATOR MAINTENANCE -

OPERATION UNDER UNUSUAL CONDITIONS

0 0 0 7

Slave Starting, Extreme Cold, Extreme Heat, Mud or Soft Surfaces, Sandy or Dusty Areas, Saltwater
Areas, High Altitudes, Snow and Ice, Fording, Recovery and Towing Techniques, Operating Portable
Fire Extinguisher, Secondary Steering, Stopping Engine if an Electrical Malfunction Occurs, Moving
Machine Out of Danger.

INITIAL SETUP

References 0 WP 0004 0

FM 9-207 0
WP 0005 0

FM 21-305 0
WP 0013 0

FM 31-70 0
WP 0021 0

FM 31-71 0
WP 0025 0

FM 90-3 0
WP 0025 0

LO 5-3805-293-13 0
WP 0027 0

GENERAL 0007

WARNING
This machine has been designed to operate safely and efficiently within the limits
specified in this TM. Operation beyond these limits is prohibited in accordance with
FM 21-305 without written approval from: Commander, U.S. Army Tank-Automotive and
Armaments Command, ATTN: AMSTA-DSA-CS, Warren, MI 48397-5000.

This section contains instructions for safely operating the 120M Motor Grader under unusual conditions. In addition
to normal preventive maintenance, special care must be taken to keep the machine operational in extreme
temperatures and other environmental conditions.

0007-1
 TM 5-3805-293-10 0007

SLAVE STARTING 0007

WARNING

• When slave starting, use NATO slave cable that does NOT have loose or missing
insulation.
• DO NOT proceed if suitable cable is not available.
• DO NOT use civilian-type jumper cables.
• DO NOT allow disabled and booster machines to come in contact with each other at any
time during slave starting. Failure to follow these warnings may cause injury or death to
personnel.

NOTE
Ensure that both disabled machine and booster machine are equipped with serviceable
NATO slave receptacles.

1. Remove cover from slave receptacle (Figure 1, Item 1) on disabled machine and booster machine.
2. Connect slave cable to booster machine slave receptacle.
3. Connect other end of slave cable to slave receptacle of disabled machine, located on left side of engine
compartment.
4. Turn battery disconnect switch of disabled machine to ON position.
5. Start booster machine and run at a speed just above idle.
6. Wait approximately five minutes, then crank disabled machine. If engine fails to crank, notify Field Level
Maintenance.
7. After starting disabled machine, return booster machine to idle.
8. Remove slave cable from disabled machine, then from booster machine.
9. Replace cover on slave receptacle (Figure 1, Item 1).

Figure 1. Slave Receptacle. 0007

0007-2
 TM 5-3805-293-10 0007

END OF TASK

EXTREME COLD 0007

General 0007

Extreme cold causes many problems that an operator must be aware of, such as:
1. Lubricants can thicken and congeal.
2. Batteries may freeze or lose their electrical efficiency.
3. Electrical insulation may crack and cause short circuits.
4. Fuel may not readily atomize for combustion.
5. Various materials will become hard, brittle, and easily damaged.
6. Cooling system requires adequate protection from extreme cold.
7. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use.
8. Refer to FM 9-207, FM 31-70, and FM 31-71 for additional cold weather operational information.
Checks 0007

1. Perform all Before PMCS checks and services (WP 0013).

2. Lubricate in accordance with LO 5-3805-293-13.
3. Check to ensure tires and ground engaging tools are not frozen to ground.
4. Drain a small amount of fuel from the fuel/water separator to ensure fuel is not gelled (WP 0013).

CAUTION
If oil is too cold to drip off oil level gauge, do not attempt to start engine. Notify Field Level
Maintenance.

5. Check engine and transmission/differential oils to ensure they are thin enough to flow. Oil must be thin enough
to drip from oil level gauge (dipstick).
6. Ensure ether starting aid cylinder is in place and not empty (WP 0021).
Starting Procedures – Machine NOT Equipped with Arctic Kit 0007

CAUTION
• When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30
seconds. Allow starting motor to cool for two minutes before cranking again or damage to
starting motor or batteries may result.
• When ambient temperature is between -1°F (-18°C) and -25°F (-32°C), it may be
necessary to crank engine for up to 60 seconds.
• When ambient temperature is between -26°F (-32°C) and -40°F (-40°C), it may be
necessary to crank engine for up to 120 seconds.
• Shut down engine immediately if engine system indicator or action light indicator comes
on. Notify Field Maintenance. Failure to follow this caution may result in damage to engine
or other machine systems.
1. Start engine (WP 0005).
2. Check that oil pressure light on instrument panel goes out within 10 seconds of engine starting.
3. Allow engine to idle for at least five minutes before moving machine.

0007-3
 TM 5-3805-293-10 0007

EXTREME COLD – CONTINUED

Starting Procedures – Machine Equipped with Arctic Kit 0007

CAUTION
• At temperatures nearing -40°F (-40°C), it is necessary to shut off the arctic heater at least
30 seconds before attempting to start the machine’s engine. Failure to follow this caution
may result in internal damage to the heater or localized boiling of the coolant in the heater
body which may cause a heater hose to come off.
• When ambient temperature is above 0°F (-18°C), do not crank engine for more than 30
seconds. Allow starting motor to cool for two minutes before cranking again or damage to
starting motor or batteries may result.
• When ambient temperature is between -1°F (-18°C) and -25°F (-32°C), it may be
necessary to crank engine for up to 60 seconds.
• When ambient temperature is between -26°F (-32°C) and -40°F (-40°C), it may be
necessary to crank engine for up to 120 seconds.
• Shut down engine immediately if engine system indicator or action light indicator comes
on. Notify Field Maintenance. Failure to follow this caution may result in damage to engine
or other machine systems.

NOTE
• If engine coolant heater has not been started for several months, or if heater is being
started for the first time, it may take several attempts to start.
• If engine coolant heater fails to start at first attempt, it will automatically attempt to start a
second time. If heater still does not start, it will shut down.
• During operation, engine coolant heater continually senses supply voltage. If voltage is too
low or too high, heater will automatically shut down. If this occurs, notify Field Level
Maintenance.
1. Activate engine coolant heater as follows:
a. Turn battery disconnect switch to ON position (WP 0004).
b. Activate engine coolant heater switch (WP 0004).
2. Allow heater to run up to 40 minutes.
3. Push engine coolant heater button to turn heater off, then wait at least 30 seconds.

CAUTION
At temperatures of less than -25°F (-32°C), be sure to keep starter engaged until engine
speed approaches 500 rpm. Multiple short (15-second) start attempts at cold
temperatures can result in engine bearing damage due to inadequate lubrication.

4. Start engine (WP 0005).

5. Check that engine oil pressure light on monitor system registers pressure within 10 seconds of engine starting.
6. Allow engine to idle for at least five minutes before moving machine.

0007-4
 TM 5-3805-293-10 0007

EXTREME COLD – CONTINUED

Machine Operation 0007

1. Move machine approximately 100 yards (91 m) in both forward and reverse directions to exercise transmission
and powertrain.
2. Test brakes and vehicle controls carefully.
3. Slowly exercise ground engaging tools to warm hydraulic oil. Cycle each control several times. Monitor
Messenger until transmission oil temperature reaches 41°F (5°C) (WP 0005).
4. Operate machine under light loads until machine is sufficiently warmed up (warm air blows from heater vents).
5. Frequently monitor Messenger system, alert indicators, and gauges. Take appropriate action if a problem is
noted, and if necessary, notify Field Level Maintenance.
Parking Machine 0007

1. Clean snow, ice, and mud from machine as soon as possible after shutdown.
2. When possible, park in sheltered area, or if shelter is not available, park machine so radiator is not facing the
wind.
3. If shelter is not available, park machine on dry, high ground, and place planks or dunnage under tires and
ground engaging tools to make a raised and relatively dry platform.
4. Perform all After PMCS checks and services (WP 0013).

END OF TASK

SNOW PLOWING 0007

Snow plowing should be performed as soon after snow falls as possible. Plowing techniques vary greatly
depending on amount of snow and type of plowing required. The information provided here is a limited overview of
snow plowing techniques and procedures.
Operating Speed 0007

Generally, increased road speed is required to ensure snow is pushed off and away from road while retaining
control of machine. Too much speed may cause machine to bounce and cause a choppy road surface.
Use of Tire Chains 0007

1. Install chains either on rear tires only, or on both front and rear tires, when plowing in slippery conditions.
2. Reduce travel speeds with tire chains installed.
3. Use bungee cords to keep chains tight around tire. Check chains often during operation.
4. Avoid excessive tire spin with chains installed to prevent damage to road surface.
5. Avoid driving on hard surface roads with chains installed to prevent chain and tire wear.

0007-5
 TM 5-3805-293-10 0007

SNOW PLOWING – CONTINUED

Use of Moldboard 0007

CAUTION
Tip moldboard forward to prevent cutting into road surface and causing damage to
equipment.

1. Tip moldboard forward to prevent damage to road surface and machine. This allows the cutting edge to ride
over road surface, instead of cutting into it, which could cause damage to machine and the road surface.
2. When plowing over asphalt or frozen ground, use blade float to allow moldboard to move freely over uneven
surfaces, and prevent road damage.
Use of All Wheel Drive (AWD) 0007

All wheel drive provides additional steering and traction control, and reduces the need for tire chains.

END OF TASK

EXTREME HEAT 0007

General 0007

Extreme heat causes problems that an operator must be aware of, such as: 0007

1. Fuel expands. Do not fill tanks more than 80% full to allow for expansion.
2. Be alert for the possibility of overheating.
3. It is important to maintain engine speed to circulate engine coolant to help engine cooling.
4. Air filter elements will require checking more frequently. They will require cleaning or replacement if ENGINE
SYSTEM indicator illuminates on the monitor system.
Checks 0007

1. Perform all Before PMCS checks and services (WP 0013).

2. Lubricate in accordance with LO 5-3805-293-13.
Machine Operation 0007

1. During very hot weather operation, avoiding continuous high engine RPM will help prevent machine from
overheating. Alter operating procedures accordingly.
2. Check coolant level in coolant tank at frequent intervals throughout any single work shift (WP 0013).
3. Keep radiator and grille free of bugs, dust, dirt, mud, and other foreign matter. Clean frequently if necessary
(WP 0025).
4. Monitor engine coolant temperature gauge. Red range on gauge indicates coolant temperature is above 225°F
(107°C). If coolant temperature indicator comes on, machine may be operated at three-fourths workload until
indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field Level
Maintenance.
5. Monitor hydraulic oil temperature gauge. Red range on gauge indicates coolant temperature is above 199°F
(93°C). If hydraulic oil temperature indicator comes on, machine may be operated at three-fourths workload
until indicator goes off. If indicator remains on longer than ten minutes, shut down machine and notify Field
Level Maintenance.
6. Refer to FM 90-3 for additional extreme heat operation information.

0007-6
 TM 5-3805-293-10 0007

EXTREME HEAT – CONTINUED

Parking 0007

1. When possible, park machine under cover. Refer to WP 0005.

2. Perform all After PMCS checks and services (WP 0013).

END OF TASK

MUD OR SOFT SURFACES 0007

1. Before entering mud or other soft surfaces, check conditions and engage all-wheel drive and differential lock
(WP 0005). Select appropriate transmission gear range. Enter soft area at a medium speed for gear range
selected.
2. Maintain steady pressure on accelerator pedal to keep machine rolling until solid ground is reached. Do not
accelerate to point where wheels spin, if possible.
3. If machine gets stuck, try to pull out slowly in a low gear. Boards, dunnage, or similar materials may be placed
under tires to provide traction.
4. Clean and inspect for proper lubrication.

END OF TASK

SANDY OR DUSTY AREAS 0007

Checks 0007

1. Perform all Before PMCS checks and services (WP 0013).

2. Lubricate in accordance with LO 5-3805-293-13.
3. Check radiator for build-up of sand/dirt/debris often. Clean when necessary (WP 0025).
Machine Operation 0007

1. Maintain steady speeds with transmission in lower gears.

2. Engage differential lock and AWD when required (WP 0005).
3. Keep machine rolling through sand without straining engine or powertrain. If machine gets stuck, refer to
Recovery and Towing in this work package.
4. Monitor engine coolant and hydraulic oil temperature gauges on monitor system more frequently during
operation.
5. If ENGINE SYSTEM indicator illuminates on the monitor system, check and clean or replace engine air filter
elements.
6. Check hydraulic cylinders, circle top, centershift linkage, and articulation cylinders frequently. Do not allow
dust, dirt, or sand to collect on these components as their smooth working surfaces can be damaged by such
abrasive materials.

0007-7
 TM 5-3805-293-10 0007

SANDY OR DUSTY AREAS – CONTINUED

Parking 0007

1. Park machine (WP 0005).

2. Perform all After PMCS checks and services (WP 0013).
3. Clean spouts on fuel containers and areas around filler cap and filler tube before adding fuel.
4. Cover windshield to guard against sand blasting.

END OF TASK

SALTWATER AREAS 0007

1. Keep the machine as clean as possible. Wash down with fresh water after use.
2. Inspect wiring connections closely for corrosion.
3. Keep lubrication points clean and well lubricated.
4. Check machine frequently for rust/corrosion. Clean and spot paint as necessary.

END OF TASK

HIGH ALTITUDES 0007

NOTE
Engine operates at less than peak performance at high altitudes.

1. Coolant level and engine indicators must be watched closely.

2. Add coolant if necessary.

END OF TASK

SNOW AND ICE 0007

1. Fuel tank should be kept full. Keep snow and ice away from fuel filler.
2. Clean snow away from outside indicators.
Driving 0007

1. Engage differential lock as required and accelerate slowly to avoid spinning tires.
2. Drive at slower speeds.
3. Give signals sooner.
4. Apply brakes sooner to give early warning of intention to stop. This will also help to avoid skidding.
5. Maintain double the normal distance from the machine ahead.
6. Keep windshields, mirrors, and lights clean and free of snow and ice.
7. If approaching a difficult stretch of road, stop and inspect road carefully before driving on it.
8. Select transmission gear range that best suits road condition.
Stopping 0007

1. Ease up on accelerator, leaving machine in gear.

2. Apply service brakes lightly and evenly. DO NOT pump service brake pedal.
3. Always avoid sudden braking.

0007-8
 TM 5-3805-293-10 0007

Parking 0007

If parking on icy, slushy, wet, or muddy surfaces, place boards, dunnage, or other materials that will provide
traction underneath tires. This will guard against tires freezing to the ground or becoming pocketed in ice, and will
provide some traction when machine is started and moving again.

END OF TASK

FORDING 0007

The 120M Motor Grader can ford water up to 30 in. (76 cm) including height of wake.

CAUTION
Do not ford even the narrowest stream more than 30 in. (76 cm) deep. Failure to follow
this caution may result in damage to machine.

1. Check depth of water at its deepest point.

2. Ensure the bottom is stable enough for fording.
3. Remove center five scarifier shanks and stow in scarifier shank stowage rack. Flip remaining shanks upside
down in scarifier frame (WP 0027).
4. Start engine and allow it to fully warm up (WP 0005).
5. Ensure engine system indicator and action light indicator are not illuminated, and all gauges are indicating
proper machine operation (WP 0005).
6. Raise scarifier and blade to their maximum height (WP 0005).

WARNING
During fording operation, if blade is not set perpendicular to centerline of machine, force of
the water could cause operator to lose control of machine. Failure to follow this warning
may result in injury or death to personnel.

7. Set blade perpendicular to centerline of machine.

NOTE
Fording speed should not exceed 3-4 mph (5-6 km/h). Once in the water, do not stop until
the opposite bank is reached.

8. Engage transmission in low gear (WP 0005).

9. Release parking brake (WP 0005).
10. Enter water slowly to minimize waves and backsplash and continue across body of water WITHOUT
STOPPING until the opposite bank is reached.
11. If machine stalls, refer to Recovery and Towing Techniques in this work package.
12. Once machine is out of water, lubricate machine completely IAW LO 5-3805-293-13.

END OF TASK

0007-9
 TM 5-3805-293-10 0007

RECOVERY AND TOWING TECHNIQUES 0007

WARNING
• Ensure recovery line is strong enough (rated capacity of 150% of gross weight of the
towed machine) and is in good condition.
• Attach recovery line only to towing connection points provided on frame.
• DO NOT have tension on the recovery line when inspecting it.
• DO NOT jerk on recovery line; it may break.
• DO NOT allow riders on machine being recovered.
• Failure to follow these warnings may result in injury or death to personnel.

CAUTION
• Recovery of a disabled machine with engine stopped may cause transmission damage.
Transmission will not have lubrication.
• If further evacuation is necessary, notify Field Level Maintenance to tow or haul machine
to convenient location for repairs.

NOTE
Towing must be performed by Field Level Maintenance.

Towing With a Running Engine 0007

If the engine is running, the machine can be towed for a short distance. The powertrain and the steering system
must be operable for towing with engine running.
1. Fasten tow line or tow bar to front or rear towing connection points on frame (Figure 2 and Figure 3).

Figure 2. Front Towing Connection Points. 0007

0007-10
 TM 5-3805-293-10 0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED

Figure 3. Rear Towing Connection Points. 0007

2. Disengage parking brake.

3. Place transmission control switch in NEUTRAL position.
4. Raise attachments off the ground.
5. Tow machine as required.
Towing With a Dead Engine 0007

CAUTION
Towing of a disabled machine with the engine stopped may cause transmission damage.
The transmission will not have lubrication. Do not tow a disabled machine any farther than
is necessary to reach a convenient location for repairs.

NOTE
If the brakes are in good operating condition, the machine has limited wheel brake ability.
The pedal effort is high due to the lack of hydraulic boost.

1. Turn on secondary steering pump on stopped machine. You can steer machine while secondary steering
pump is on. Secondary steering pump will be activated for a maximum of ten seconds. While secondary
steering pump is activated you can use left joystick to align front wheels of machine.

WARNING
When the driveshaft is removed, the machine has NO parking brake. The machine can roll
and cause personal injury or death. Block the wheels securely so that the machine cannot
move.

2. If you suspect internal transmission failure or driveline failure, remove driveshaft located between the
differential and transmission.

0007-11
 TM 5-3805-293-10 0007

RECOVERY AND TOWING TECHNIQUES – CONTINUED

3. Fasten tow line or tow bar to front or rear towing connection points on frame (Figure 2 or Figure 3).
4. Remove wheel blocks. Tow machine slowly. Do not tow machine faster than 1.2 mph (2 km/h).

END OF TASK

OPERATING PORTABLE FIRE EXTINGUISHER 0007

1. Remove fire extinguisher from storage.

2. Hold fire extinguisher upright. Stand back 8 ft (2.4 m) from base of fire, point nozzle toward fire, and pull safety
pin.
3. Squeeze lever, discharging chemical at base of fire. Use a side-to-side motion to spread chemical.
4. After using fire extinguisher, order new fire extinguisher.

END OF TASK

SECONDARY STEERING 0007

WARNING
• Personal injury or death can occur if steering is lost completely during operation.
• Do not continue to operate the machine using secondary steering. If the secondary
steering activates during operation, immediately park machine in a safe location. Notify
Field Level Maintenance.
• The machine’s batteries must have a normal charge and the secondary steering electrical
system must be in proper working condition. A low charge condition, or any defect in the
battery, battery cells, or electrical circuit can cause loss of secondary steering and could
result in personal injury and/or damage to the machine.

CAUTION
Once secondary steering system has been activated, it should remain on no longer than
one minute. This should be sufficient time to safely steer machine to a stop. When the
machine is stopped, turn engine start switch to OFF position to turn off secondary
steering. Prolonged use of secondary steering system (longer than one minute) will cause
electric motor to overheat and cause damage to its components. If secondary steering
system is activated for longer than one minute, replace the pump, motor, and relay. Also,
wiring must be inspected for damage due to overheating. Notify Field Level Maintenance.

1. The secondary steering pump will activate automatically when the main steering power source fails, such as a
primary steering pump failure or engine failure. The secondary steering control will activate automatically when
the primary steering control system fails. Engine start switch must be in ON position for this system to operate.
2. The primary steering system pressure indicator will illuminate when there is a problem with the primary
steering system.
3. The secondary steering system indicator will be amber in color when secondary steering system is active or
secondary steering system is being tested. Alert indicator will be red in color when a problem with secondary
steering system exists.
4. If a problem exists with the primary steering system or the secondary steering system, an alert indicator and an
action light come on and an action alarm sounds at a pulse rate. Notify Field Level Maintenance.

END OF TASK

0007-12
 TM 5-3805-293-10 0007

STOPPING ENGINE IF AN ELECTRICAL MALFUNCTION OCCURS 0007

1. Ensure parking brake is engaged.

2. Turn engine start switch to OFF position.
3. Turn battery disconnect switch (Figure 4, Item 1) to OFF position.
4. Notify Field Level Maintenance.

Figure 4. Battery Disconnect Switch. 0007

END OF TASK

MOVING MACHINE OUT OF DANGER 0007

The machine can be moved out of danger by allowing the operator to override steering alignment and parking
brake engagement.
WARNING
Driving through the parking brake will cause the front wheels to auto-align upon machine
movement. Avoid traveling excessive distances while driving through the parking brake.
Extreme heat and wear will severely shorten the life of the parking brake. The loss of the
parking brake system could result in injury or death to personnel.

CAUTION
Do not use wheel lean lock bolt and bracket to center the wheel lean of machine. Damage
to equipment may result.

NOTE
• “1F” and “1R” are the only gears available to drive through the parking brake. Upshifting
will not change selected gear.
• A warning category 3 will activate during machine movement. The event will be logged in
Messenger but the alarm should deactivate once the transmission control switch is
returned to NEUTRAL position.

0007-13
 TM 5-3805-293-10 0007

MOVING MACHINE OUT OF DANGER – CONTINUED

To drive through the parking brake:
a. Start engine. Transmission control switch must be in NEUTRAL position and parking brake must be
engaged to allow engine to start.
b. Fully depress inching pedal. With parking brake engaged, “1F/1R” will flash on LCD display on monitoring
system.
c. Select direction of travel on transmission control switch.
d. Raise engine speed to full throttle, then release inching pedal. Machine movement will be jerky since
powertrain is trying to propel machine against engaged parking brake.
e. When desired location is reached, depress inching pedal and move transmission control switch to
NEUTRAL position to stop machine.

END OF TASK

END OF WORK PACKAGE

0007-14
14

TM 5-3805-293-10 0008

OPERATOR MAINTENANCE -

STOWAGE AND DECAL/DATA PLATE GUIDE

0 0 0 8

Stowage, Warning Message Labels, Caution and Notice Message Labels

SCOPE 0008

This work package identifies BII stowage, decals and data plate.
STOWAGE 0008

Basic Issue Items (BII) 0008

Stow all basic issue items (BII) in tool box (Figure 1, Item 1) located on drawbar above mid-mount scarifier (Figure
1, Item 2). Refer to WP 0031 for complete list of BII.

Figure 1. Tool Box. 0008

0008-1
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS 0008

WARNING
Failure to follow the warning safety messages listed here may result in injury or death to
personnel.

Figure 2. Warning Message Labels. 0008

0008-2
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

KEY LABEL IDENTIFICATION 08 WARNING DEFINITION 08

1 Lift Here Identifies proper location to attach lift device to machine.

2 Do Not Operate Do not operate or work on this machine unless you have read
and understand the instructions and warnings in this manual.
3 Unplanned Blade Movement Personal injury could result from sudden movement of the
blade when the centershift lock pin is released. To prevent
unexpected blade movement and possible injury, lower the
blade to the ground before you unlock the centershift linkage.
See WP 0005 for complete instructions before releasing the
centershift lockpin.
4 Tie Down Identifies proper location to attach tie-down to machine.
5 No Clearance Stay back a safe distance. No clearance for a person in this
area when the machine turns. Severe injury or death from
crushing could occur.
6 Improper Connections for Jump Explosion Hazard! Improper jumper cable connections can
Start Cables cause an explosion resulting in serious injury or death.
Batteries may be located in separate compartments. Refer to
WP 0007 for the correct slave starting procedure.

0008-3
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

Figure 3. Warning Message Labels. 0008

0008-4
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

KEY LABEL IDENTIFICATION 08 WARNING DEFINITION 08

1 Seat Belt A seat belt should be worn at all times during machine opera-
tion to prevent serious injury or death in the event of an acci-
dent or machine overturn. Failure to wear a seat belt during
machine operation may result in serious injury or death.

2 Do Not Weld On the ROPS/FOPS Structural damage, an overturn, modification, alteration, or

Structure improper repair can impair this structure’s protection capability
thereby voiding this certification.
Do not weld on or drill holes in the structure. This will void the
certification.
This machine has been certified to the standards listed on
decal. Maximum mass of machine, which includes operator
and attachments without a payload, should not exceed mass
listed on decal.

3 Engine Coolant Cooling system is pressurized. Hot coolant can cause serious
burns, injury, or death. To open the cooling system filler cap,
stop the engine and wait until the cooling system components
are cool. Loosen the cooling system pressure cap slowly in
order to relieve the pressure.

4 No Clearance Stay back a safe distance. No clearance for a person in this

area when the machine turns. Severe injury or death from
crushing could occur.

5 No Clearance Connect the steering frame lock between the front and the
rear frames before lifting, transporting, or servicing the
machine in the articulation area. Disconnect the steering
frame lock and secure the steering frame lock before
resuming operation. Severe injury or death could occur.
6 Accumulator Cold ambient temperatures could result in loss of secondary
braking capability due to inadequate hydraulic accumulator
nitrogen pre-charge. Loss of secondary braking system as
well as main hydraulic pressure will result in little or no braking
capability.
Perform a brake accumulator check anytime machine has
been idle for longer than two hours below 13°F (25°C).

0008-5
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

Figure 4. Warning Message Labels. 0008

KEY LABEL INDENTIFICATION 08 WARNING DEFINITION 08

1 Recoil Spring Housing contains a highly compressed spring that can cause
injury or death. Only trained Field Level Maintenance person-
nel may disassemble parking brake housing.

0008-6
 TM 5-3805-293-10 0008

WARNING MESSAGE LABELS – CONTINUED

Figure 5. Warning Message Label. 0008

KEY LABEL INDENTIFICATION 08 WARNING DEFINITION 08

1 CBRN (Chemical, Biological, Radio- If CBRN exposure is suspected, all air filter media will be han-
logical and Nuclear). dled by personnel wearing full CBRN protective equipment.

0008-7
 TM 5-3805-293-10 0008

CAUTION AND NOTICE MESSAGE LABELS 0008

CAUTION
Failure to follow cautions listed may result in damage to equipment.

Figure 6. Additional Message Labels. 0008

KEY LABEL IDENTIFICATION 08 LABEL DEFINITION 08

1 Air Conditioning System (Caution Field Level Maintenance to refer to TM 5-3805-293-23 before
Label) any maintenance is performed on air conditioning system.
(Not applicable to operator.)

0008-8
 TM 5-3805-293-10 0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED

Figure 7. Additional Message Labels. 0008

KEY LABEL IDENTIFICATION 08 LABEL DEFINITION 08

1 Do Not Weld or Drill (Caution Label)
2 Fuel Type
3 Extended Life Coolant
4 24V Slave
5 Articulation Bearing
Do not weld or drill on frame. (Not applicable to operator.)
Diesel or JP-8 Fuel only
Refer to PMCS (WP 0013) before any maintenance is
performed on cooling system.
Grader equipped with a 24V slave receptacle.
Identifies location of grease points for articulation bearings.

0008-9
 TM 5-3805-293-10 0008

CAUTION AND NOTICE MESSAGE LABELS – CONTINUED

Figure 8. Additional Message Labels. 0008

KEY COMPONENT DESCRIPTION

1 Cooling System Drain
2 Hydraulic Tank Drain
3 Engine Oil Drain
Identifies location of engine coolant drain valve. (Not
applicable to operator.)
Identifies location of hydraulic fluid tank drain valve. (Not
applicable to operator.)
Identifies location of engine oil drain valve. (Not applicable to
operator.)

0008-10
 TM 5-3805-293-10 0008

DATA PLATE 0008

Figure 9. Data Plate. 0008

KEY COMPONENT DESCRIPTION

1 Shipping Data Plate Provides tiedown, lift, and shipping weight information.
2 Lubrication Data Plate Provides lubrication information for machine systems.

0008-11
 TM 5-3805-293-10 0008

UNIQUE IDENTIFICATION (UID) LABELS 0008

Figure 10. UID Labels. 0008

Figure 11. UID Labels – Continued. 0008

0008-12
 TM 5-3805-293-10 0008

UNIQUE IDENTIFICATION (UID) LABELS – CONTINUED

Figure 12. UID Labels – Continued. 0008

Figure 13. UID Labels – Continued. 0008

END OF WORK PACKAGE

0008-13/(14 blank)
 TM 5-3805-293-10

CHAPTER 3
TROUBLESHOOTING PROCEDURES
4

TM 5-3805-293-10 0009

OPERATOR MAINTENANCE -

0 0 0 9 TROUBLESHOOTING INTRODUCTION

GENERAL 0009

1. This chapter provides information for identifying and correcting malfunctions that you may find while operating
the 120M Motor Grader.
2. WP 0010, Troubleshooting Symptom Index lists common malfunctions which may occur and refers you to the
proper page in WP 0011 for a troubleshooting procedure.
3. If you are unaware of the location of an item mentioned in troubleshooting, refer to WP 0002, Equipment
Description and Data or WP 0004, Description and Use of Operator Controls and Indicators.
4. Before performing troubleshooting, read and follow all safety instructions found in the warning summary at the
front of this manual.
5. This chapter cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a
malfunction is not listed, or is not corrected by the listed corrective actions, notify Field Maintenance.
6. When troubleshooting a malfunction:
a. Locate the symptom or symptoms in WP 0010, Troubleshooting Index that best describes the malfunction.
If the appropriate symptom is not listed, notify Field Maintenance.
b. Turn to the page in WP 0011, Troubleshooting Procedures where the troubleshooting procedures for the
malfunction in question are described. Headings at the top of each page show how each troubleshooting
procedure is organized: Malfunction, Test or Inspection (in step number order), and Corrective Action.
c. Perform each step in the order listed until the malfunction is corrected and the item being inspected is
operational. DO NOT perform any maintenance task unless the troubleshooting procedure tells you
to do so.
EXPLANATION OF HEADINGS 0009

The headings in WP 0011 are defined as follows:

a. MALFUNCTION. A visual or operational indication that something is wrong with the equipment.
b. TEST OR INSPECTION. A procedure to isolate the problem in a system or component.
c. CORRECTIVE ACTION. A procedure to correct the problem.

0009-1
 TM 5-3805-293-10 0009

MONITORING SYSTEM WARNINGS 0009

The Monitoring System provides three warning categories. The first warning category requires only operator
awareness. The second warning category requires a change to machine operation or the performance of mainte-
nance to the system. The third warning category requires immediate shutdown of the machine.
0009

Table 1.

WARNING ALERT TO OPERATOR ACTION REQUIRED

Category 1 Alert
Machine system needs attention.
Category 2 Alert
A change in machine operation is
required.
Category 2S Alert
Immediate change in machine
operation is required.
• Alert indicator activated.
• Alert indicator activated.
• Action light activated.
• Alert indicator activated.
• Action light activated.
• Action alarm sounds at a
steady rate.
1. Check Messenger system for alert
message.
2. Follow instructions on Messenger
system.
1. Check Messenger system for alert
message.
2. Follow instructions on Messenger
system.
1. Check Messenger system for alert
message.
2. Follow instructions on Messenger
system.

Category 3 Alert • Alert indicator activated. WARNING

Immediate need to shut down • Action light activated.
machine.
• Action alarm sounds at a
pulse rate.
Failure to follow this warning may result
in injury or death to personnel or damage
to equipment.
1. Shut down machine immediately.
2. Check Messenger system for alert
message.
3. Follow instructions on Messenger
system.

0009-2
 TM 5-3805-293-10 0009

MONITORING SYSTEM WARNINGS – CONTINUED

Figure 14. Alert Indicators. 09

KEY COMPONENT DESCRIPTION

1 Battery Charge Alert Indicator
2 Electric Coolant Heater Alert Indicator
3 Engine System Alert Indicator
4 Implement System Alert Indicator
5 Primary Steering Alert Indicator
6 Action Light Alert Indicator
7 Parking Brake Indicator
8 Transmission System Alert Indicator
9 Secondary Steering System Alert Indi-
cator
10 Brake System Indicator
11 Operator Not Present Alert Indicator
Illuminates when a problem with machine voltage or alternator
is present.
Illuminates when coolant heater is activated.
Illuminates when an engine problem is present.
Illuminates when an implement system problem is present.
Illuminates when a steering system problem is present.
Illuminates when a problem occurs with machine.
Illuminates when parking brakes are engaged.
Illuminates when a transmission system problem is present.
Illuminates RED when a system problem is present.
Illuminates GREEN when system is activated or being tested.
Illuminates when a general fault occurs in brake system.
Illuminates when under specific conditions operator is not in
cab.

0009-3/(4 Blank)
2

TM 5-3805-293-10 0010

OPERATOR MAINTENANCE -

0 0 1 0 OPERATOR TROUBLESHOOTING SYMPTOM INDEX

Malfunction/Symptom Troubleshooting Procedure Page

ELECTRICAL SYSTEM 00010

Backup Alarm Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1

All Ground Engaging Tools Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-1
Certain Ground Engaging Tools Inoperative – Others Operate Properly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
Defroster Fan Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
Differential Lock Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
Directional Turn Signals Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-2
Dome Lamp Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
Headlight(s) Inoperative when SER Drive or Park Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
Parking Light(s) Inoperative When SER Drive or Park Functions are Selected. . . . . . . . . . . . . . . . . . . . . . . . 0011-3
Heater and Air Conditioning Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
High Beams Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-3
Horn Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
Monitor System Backlight Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
Monitor System Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-4
Primary Blade Worklights, Secondary Blade Worklights, or Rear Worklights Inoperative. . . . . . . . . . . . . . . . 0011-4
Stoplights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
Taillights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
Windshield Wiper, Left Door Wiper, or Right Door Wiper Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-5
ENGINE
Coolant Temperature Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-6
Engine Cannot Reach Top Engine RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7
Engine Cranks But Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-7
Engine Does Not Crank When Start Switch Is Engaged.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8
Engine Does Not Idle Properly, Misfires, or Runs Rough After Warmup Period. . . . . . . . . . . . . . . . . . . . . . . . 0011-8
Engine Starts But Dies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8
Excessive Exhaust Smoke at Normal Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-8
Excessive Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9
Engine Quits While Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9
Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9
HYDRAULIC SYSTEM 00010

Travel Time for Blade Lift Cylinders is Slow, Hydraulic Oil Temperature Equal to or Greater
Than 32°F (0°C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-9
Travel Time for Scarifier is Slow, Hydraulic Oil Temperature Equal to or Greater Than 32°F (0°C). . . . . . . . 0011-10

0010-1
 TM 5-3805-293-10 0010

STEERING
Machine Slowly Drifts In Either Direction, Wanders, Or Pulls To One Side On Level Pavement. . . . . . . . . . 0011-11
Machine Steering is Slow or Responds Intermittently. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-11
Machine Turns Correctly During Normal Driving Conditions, but Turns Slowly with a Load.. . . . . . . . . . . . . 0011-11
Machine Turns Slowly in Both Directions After Reaching Operating Temperature. . . . . . . . . . . . . . . . . . . . . 0011-11
Machine Turns Slowly in One Direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12
Steering is Erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12
TRANSMISSION
Slow or Erratic Transmission Engagement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12
Transmission Does Not Operate in Any Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-12
ALL-WHEEL DRIVE
Wheel Speed or Engine Speed Surges at High Aggression Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011-13

END OF WORK PACKAGE

0010-2
14

TM 5-3805-293-10 0011

OPERATOR MAINTENANCE -

0 0 1 1 TROUBLESHOOTING PROCEDURES
Electrical System, Engine, Hydraulic System, Steering, Transmission, All-Wheel Drive

INITIAL SETUP

Materials/Parts 0 References - Continued 0

Goggles, Industrial (WP 0032, Item 10) 0 WP 0020 0

Gloves, Chemical and Oil Protective (WP WP 0022 0

0032, Item 9) 0
WP 0023 0

References 0
WP 0025 0

LO-5-3805-293-13 0
Equipment Conditions 0

WP 0004 0
Machine parked on level ground
WP 0005 0
(WP 0005) 0

WP 0013 0
Blade and scarifier lowered to ground
WP 0014 0
(WP 0005) 0

WP 0018 0

WP 0019 0

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ELECTRICAL SYSTEM
1. BACKUP ALARM INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE has been selected on military light switch (WP 0004).
a. Select STOP LIGHT or SER DRIVE.
b. If problem persists, go to Step 2.
Step 2. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
2. ALL GROUND ENGAGING TOOLS INOPERATIVE.
Step 1. Check that implement lockout switch is in UNLOCK position (WP 0004).
a. Push bottom of implement lockout switch.
b. If problem persists, go to Step 2.
Step 2. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.

0011-1
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ELECTRICAL SYSTEM – CONTINUED

3. CERTAIN GROUND ENGAGING TOOLS INOPERATIVE – OTHERS OPERATE PROPERLY.
Step 1. Check that implement lockout switch is in UNLOCK position (WP 0004).
a. Push bottom of implement lockout switch.
b. If problem persists, go to Step 2.
Step 2. Check for blown fuse(s) at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
4. DEFROSTER FAN INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
5. DIFFERENTIAL LOCK INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
6. DIRECTIONAL TURN SIGNALS INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP
0004).
a. Select STOP LIGHT or SER DRIVE.
b. If problem persists, go to Step 2.
Step 2. Check electrical connector at lamp assembly.
a. Reconnect connectors, if required.
b. If connectors are okay, go to Step 3.
Step 3. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
If problem persists, notify Field Level Maintenance.

0011-2
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ELECTRICAL SYSTEM – CONTINUED

7. DOME LAMP INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP
0004).
a. Select STOP LIGHT or SER DRIVE.
b. If problem persists, go to Step 2.
Step 2. Check for burned out or defective bulb.
a. Replace bulb (WP 0020).
b. If problem persists, go to Step 3.
Step 3. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
8. HEADLIGHT(S) INOPERATIVE WHEN SER DRIVE OR PARK FUNCTIONS ARE SELECTED.
Step 1. Ensure SER DRIVE or STOP LIGHT function has been selected on military light switch (WP
0004).
a. Select SER DRIVE or STOP LIGHT.
b. If problem persists, go to Step 2.
Step 2. Check lights for disconnected or damaged connectors.
a. Reconnect connectors, if required.
b. If connectors are secure or if damage is found, notify Field Level Maintenance.
9. PARKING LIGHT(S) INOPERATIVE WHEN SER DRIVE OR PARK FUNCTIONS ARE SELECTED.
Step 1. Ensure STOP LIGHT function has been selected on military light switch (WP 0004).
a. Select STOP LIGHT.
b. If problem persists, go to Step 2.
Step 2. Check lights for disconnected or damaged connectors.
a. Reconnect connectors, if required.
b. If connectors are secure or if damage is found, notify Field Level Maintenance.
10. HEATER AND AIR CONDITIONING INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
11. HIGH BEAMS INOPERATIVE.
a. Ensure SER DRIVE function has been selected on military light switch (WP 0004).
b. If problem persists, notify Field Level Maintenance.

0011-3
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ELECTRICAL SYSTEM – CONTINUED

12. HORN INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP
0004).
a. Select STOP LIGHT or SER DRIVE.
b. If problem persists, go to Step 2.
Step 2. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, go to Step 3.
Step 3. Check wiring harness connector is properly connected to horn.
a. Reconnect connector, if required.
b. If connector is okay or if harness damage is found, notify Field Level Maintenance.
13. MONITOR SYSTEM BACKLIGHT INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.
14. MONITOR SYSTEM INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.

15. PRIMARY BLADE WORKLIGHTS, SECONDARY BLADE WORKLIGHTS, OR REAR WORKLIGHTS

INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP
0004).
a. Select STOP LIGHT or SER DRIVE.
b. If problem persists, go to Step 2.
Step 2. Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, go to Step 3.
Step 3. Check wiring harness connector is properly connected to worklight.
If fault is found, notify Field Level Maintenance.

0011-4
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ELECTRICAL SYSTEM – CONTINUED

16. STOPLIGHTS INOPERATIVE.
Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch
(WP 0004).
a. Select SER DRIVE or PARK.
b. If problem persists, go to Step 2.
Step 2. Check lights for disconnected connections or damage.
a. Reconnect connectors, if required.
b. If connectors are secure or if damage is found, notify Field Level Maintenance.
17. TAILLIGHTS INOPERATIVE.
Ensure SER DRIVE function has been selected on military light switch (WP 0004).
a. Select SER DRIVE.
b. If problem persists, notify Field Level Maintenance.
18. WINDSHIELD WIPER, LEFT DOOR WIPER, OR RIGHT DOOR WIPER INOPERATIVE.
Check for blown fuse at fuse panel.
a. Replace fuse (WP 0023).
b. If problem persists, notify Field Level Maintenance.

0011-5
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ENGINE

WARNING

• Do not perform fuel system checks, inspections or maintenance while smoking or near fire,
flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equip-
ment.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel,
promptly wash exposed skin and change fuel-soaked clothing. Failure to follow this warning
may result in injury or death to personnel.

CAUTION
Do not crank engine for longer than 30 seconds. Allow starter motor to cool for two minutes before
cranking again or damage to equipment may result.

1. COOLANT TEMPERATURE TOO HIGH.

WARNING

• Do NOT service the cooling system unless engine has been allowed to cool down. This is a
pressurized system and escaping steam or hot coolant will cause serious burns.
• Do NOT remove cooling system pressure cap when engine is hot. Allow engine to cool down.
Remove pressure cap slowly to relieve system pressure.
• Wear protective eye, hand, and skin protection when handling coolant.
• Failure to follow these warnings may result in injury or death to personnel.
Step 1. Check coolant level in coolant tank (WP 0013).
a. Fill coolant tank to specifications (WP 0013).
b. If problem persists, go to Step 2.
Step 2. Check radiator for dirt, debris, or damaged fins.
a. Clean dirt and debris from radiator (WP 0025).
b. If problem persists or if fins are damaged, notify Field Level Maintenance.

0011-6
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ENGINE – CONTINUED
2. ENGINE CANNOT REACH TOP ENGINE RPM.
Step 1. Check for diagnostic codes (WP 0005).
a. If diagnostic codes are present, notify Field Level Maintenance.
b. If no diagnostic codes are present, go to Step 2.
Step 2. Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to Step 3.
Step 3. Check fuel supply.
a. Verify fuel is not solidified (temperatures below 32°F (0°C)).
b. Add fuel (WP 0013).
c. If problem persists, notify Field Level Maintenance.

3. ENGINE CRANKS BUT WILL NOT START.

Step 1. Check for diagnostic codes (WP 0005).
a. If diagnostic codes are present, notify Field Level Maintenance.
b. If there are no diagnostic codes, go to Step 2.
Step 2. Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to Step 3.
Step 3. Verify fuel level.
a. Add fuel as necessary (WP 0013).
b. If problem persists, go to Step 4.
Step 4. Check circuit breakers.
a. Reset circuit breakers (WP 0018).
b. If problem persists, notify Field Level Maintenance.

0011-7
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ENGINE – CONTINUED
4. ENGINE DOES NOT CRANK WHEN START SWITCH IS ENGAGED.
Step 1. Verify parking brake is engaged and transmission control switch is in NEUTRAL position.
a. Engage parking brake and move transmission control switch to NEUTRAL.
b. If problem persists, go to Step 2.
Step 2. Verify battery disconnect switch is turned to ON position.
a. Turn battery disconnect switch to ON position.
b. If problem persists, go to Step 2.
Step 3. Check circuit breakers (WP 0019).
a. Reset circuit breakers (WP 0019).
b. If problem persists, notify Field Level Maintenance.

5. ENGINE DOES NOT IDLE PROPERLY, MISFIRES, OR RUNS ROUGH AFTER WARMUP PERIOD.
Step 1. Check for diagnostic codes (WP 0005).
a. If diagnostic codes are present, notify Field Level Maintenance.
b. If there are no diagnostic codes, go to Step 2.
Step 2. Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to Step 3.
Step 3. Check for water in fuel (WP 0013).
a. Drain fuel/water separator (WP 0022).
b. If problem persists, notify Field Level Maintenance.
6. ENGINE STARTS BUT DIES.
Step 1. Check for diagnostic codes (WP 0005).
a. If diagnostic codes are present, notify Field Level Maintenance.
b. If there are no diagnostic codes, go to Step 2.
Step 2. Check for water in fuel (WP 0013).
a. Drain fuel/water separator (WP 0022).
b. If problem persists, notify Field Level Maintenance.
7. EXCESSIVE EXHAUST SMOKE AT NORMAL OPERATING TEMPERATURE.
Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, notify Field Level Maintenance.

0011-8
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ENGINE – CONTINUED
8. EXCESSIVE OIL CONSUMPTION.
Step 1. Check for misreading of oil level.
a. Accurately measure oil level.
b. If problem persists, go to Step 2.
Step 2. Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to Step 3.
Step 3. Check for loose or leaking oil lines and oil leaks.
If loose or leaking oil lines or leaks are found, notify Field Level Maintenance.
9. ENGINE QUITS WHILE RUNNING.
Step 1. Check fuel level on gauge and in Messenger (WP 0005).
a. Add fuel if low.
b. If problem persists, go to Step 2.
Step 2. Check for diagnostic codes (WP 0005).
a. If diagnostic codes are present, notify Field Level Maintenance.
b. If there are no diagnostic codes, go to Step 3.
Step 3. Check fuel/water separator bowl for presence of fuel and that fuel is not gelled.
a. If fuel is not present or is gelled, notify Field Level Maintenance.
b. If fuel is present and not gelled, go to Step 4.
Step 4. Check air filters (WP 0014).
a. Clean or replace air filters (WP 0014).
b. If problem persists, notify Field Level Maintenance.
10. LOW ENGINE OIL PRESSURE.
Check engine oil level.
a. Fill oil to specification (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.

0011-9
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

HYDRAULIC SYSTEM

WARNING

Wear safety goggles when performing any hydraulic maintenance procedures. Failure to follow
this warning may result in injury or death to personnel.
NOTE
It is normal for hydraulic functions to operate slowly when hydraulic oil is very cold (less than 32°F
(0°C). Allow machine additional time to warm up if required.
1. TRAVEL TIME FOR BLADE LIFT CYLINDERS IS SLOW, HYDRAULIC OIL TEMPERATURE EQUAL TO
OR GREATER THAN 32°F (0°C).
Step 1. Check blade hydraulic cylinder for buildup of debris.
a. Remove debris.
b. If problem persists, go to Step 2.
Step 2. Check hydraulic fluid level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.

2. TRAVEL TIME FOR SCARIFIER IS SLOW, HYDRAULIC OIL TEMPERATURE EQUAL TO OR GREATER
THAN 32°F (0°C).
Step 1. Check scarifier area for buildup of debris.
a. Remove debris.
b. If problem persists, go to Step 2.
Step 2. Check hydraulic fluid level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.

0011-10
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

STEERING
WARNING
• Hitch and steering movement can reduce clearances suddenly. Stop engine before servicing.
Failure to follow this warning may result in injury or death to personnel.
• Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Failure to fol-
low this warning may result in serious injury or death to personnel, or damage to equipment.
• If tire pressure is more than 4 psi low, tires must be inflated in a safety cage. Notify Field Level
Maintenance. Failure to follow this warning may result in serious injury or death to personnel,
or damage to equipment.
1. MACHINE SLOWLY DRIFTS IN EITHER DIRECTION, WANDERS, OR PULLS TO ONE SIDE ON LEVEL
PAVEMENT.
Step 1. Check tire pressures (WP 0013).
a. If tire inflation pressure is from 1 to 4 psi low, inflate to specifications (WP 0013).
b. If tire inflation pressure is more than 4 psi low, notify Field Level Maintenance.
c. If problem persists, notify Field Level Maintenance.
Step 2. Check steering linkage and hydraulic cylinders for damage.
If damage is found, notify Field Level Maintenance.
2. MACHINE STEERING IS SLOW OR RESPONDS INTERMITTENTLY.
Check hydraulic fluid level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.

3. MACHINE TURNS CORRECTLY DURING NORMAL DRIVING CONDITIONS, BUT TURNS SLOWLY WITH
A LOAD.
Step 1. Check for oil leaks at steering cylinders.
a. If leaks are found, notify Field Level Maintenance.
b. If no leaks are found and problem persists, go to Step 2.
Step 2. Check hydraulic oil level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.
4. MACHINE TURNS SLOWLY IN BOTH DIRECTIONS AFTER REACHING OPERATING TEMPERATURE.
Check hydraulic oil level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.

0011-11
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

STEERING – CONTINUED
5. MACHINE TURNS SLOWLY IN ONE DIRECTION.
Step 1. Check for oil leaks at steering cylinders.
a. If leaks are found, notify Field Level Maintenance.
b. If no leaks are found and problem persists, go to Step 2.
Step 2. Check hydraulic oil level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.
6. STEERING IS ERRATIC.
Step 1. Check hydraulic fluid level (LO 5-3805-293-13).
a. Add hydraulic fluid as necessary (LO 5-3805-293-13).
b. If problem persists, go to Step 2.
Step 2. Check for air bubbles in hydraulic reservoir.
If bubbles are found, notify Field Level Maintenance.

TRANSMISSION
NOTE
Before checking oil level, ensure machine is parked on level ground, parking brake is engaged,
transmission control switch is in the NEUTRAL position, and the engine is warmed up and at low
idle.
1. SLOW OR ERRATIC TRANSMISSION ENGAGEMENT.
Step 1. Check transmission fluid level (LO 5-3805-293-13).
a. Add fluid as necessary (LO 5-3805-293-13).
b. If problem persists, notify Field Level Maintenance.
2. TRANSMISSION DOES NOT OPERATE IN ANY GEAR.
Step 1. Check transmission fluid level (LO 5-3805-293-13).
a. Add fluid as necessary (LO 5-3805-293-13).
b. If problem persists, go to Step 2.
Step 2. Check circuit breakers (WP 0018).
a. Reset circuit breakers (WP 0018).
b. If problem persists, notify Field Level Maintenance.

0011-12
 TM 5-3805-293-10 0011

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.

ALL-WHEEL DRIVE
WHEEL SPEED OR ENGINE SPEED SURGES AT HIGH AGGRESSION SETTINGS.
Machine being operated in sand or similar loose, dry conditions.
Reduce aggression to a maximum of 100 percent.

END OF WORK PACKAGE

0011-13/(14 blank)
 TM 5-3805-293-10

CHAPTER 4
PMCS INSTRUCTIONS
4

TM 5-3805-293-10 0012

OPERATOR MAINTENANCE -

0 0 1 2 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL 00012

1. To ensure that the 120M Motor Grader is ready for operation at all times, it must be inspected on a regular
basis so that defects may be found and corrected before they result in injury, damage, or equipment failure.
2. The PMCS Table in WP 0013 contains systematic instructions on inspections, lubrications, services, tests, and
corrections to be performed by the operator to keep the equipment in good operating condition and ready for
its primary mission.
EXPLANATION OF TABLE ENTRIES 00012

1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form
5988-E, Equipment Inspection and Maintenance Worksheet, include the item number for the check/service
indicating a fault. Item numbers also appear in the order that you must perform checks and services for the
interval listed.
2. Interval Column. This column tells you when you must perform the procedure in the Procedure column:
a. Before procedures must be done immediately before you operate the grader.
b. During procedures must be done while you are operating the grader.
c. After procedures must be done immediately after you have operated the grader.
d. Biweekly or Every 100 Service Hours procedures must be done once every two weeks or after every
100 hours of machine operation.
e. Initial 500 Service Hours (or at first oil change) procedures must be done after the first 500 hours of
machine operation or at the first engine oil change.
f. Every 500 Service Hours or 3 Months procedures must be done every 500 hours of machine operation or
every three months.
g. Every 1,000 Service Hours or 6 Months procedures must be done every 1,000 hours of machine operation
or every six months.
h. Every 2,000 Service Hours or 2 Years procedures must be done every 2,000 hours of machine operation
or every two years.
i. Yearly procedures must be done once each year.
3. Item to Check/Service Column. This column lists the item to be checked or serviced.

NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be
observed. WARNINGs and CAUTIONs appear before applicable procedures. You must
observe these WARNINGs to prevent injury or death to yourself and others, and
CAUTIONs to prevent your equipment from being damaged.
4. Procedure Column. This column gives the procedure you must perform to check or service the item listed in
the Item to Check/Service column, to know if the equipment is ready and available for its intended mission. You
must perform the procedure at the time stated in the Interval column.
5. Not Fully Mission Capable If: Column. Information in this column tells you what faults will keep your equip-
ment from being capable of performing its primary mission. If you perform check/service procedures that show
faults listed in this column, the equipment is not mission-capable. Follow standard operating procedures for
maintaining the equipment or reporting equipment failure.

0012-1
 TM 5-3805-293-10 0012

GENERAL PMCS PROCEDURES 00012

1. Intervals (on-condition or hardtime) and the related manhour times are based on normal operation. The
manhour time specified is the time you need to do all the services prescribed for a particular interval. Change
the hardtime interval if your lubricants are contaminated or if you are operating the equipment under adverse
operating conditions, including longer-than-usual operating hours. The hardtime interval may be extended
during periods of low activity. If extended, adequate preservation precautions must be taken.
2. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will
spot anything wrong in a hurry. If the equipment does not perform as required, refer to the appropriate trouble-
shooting procedure in Chapter 3.
3. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find
something seriously wrong, IMMEDIATELY report it to your supervisor.
4. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare
all that is needed to make all the checks. You will always need a rag (Item 17, WP 0032) or two.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and

low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves
and goggles. Use in well-ventilated areas. Keep away from open flames and other
sources of ignition. Failure to follow this warning may result in injury or death to personnel.

CAUTION
Be especially careful when cleaning electrical system components including lighting.
Damage or impaired operation could result if this caution is not observed.
a. Keep Equipment Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem.
Clean as you work and as needed. Use solvent cleaning compound (Item 2, WP 0032) on all metal
surfaces. Use detergent (Item 4, WP 0032) and water when you clean rubber, plastic, and painted
surfaces. Spot paint as required to prevent corrosion.
b. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing,
or damaged bolts, nuts, and screws to your supervisor.
c. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. Report bad welds to
your supervisor.
d. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken
connectors. Report loose connections and faulty wiring to your supervisor.
e. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any
worn, damaged, or loose hoses, lines, and fittings to your supervisor.

0012-2
 TM 5-3805-293-10 0012

FLUID LEAKAGE 00012

NOTE
Notify Field Level Maintenance of any leaks the operator cannot fix.
It is necessary for you to know how fluid leakage affects the status of the 120M Motor Grader. Following are types/
classes of leakage you need to know to be able to determine the status of the 120M Motor Grader. Learn these
leakage definitions and remember - when in doubt, notify your supervisor. Equipment operation is allowed with
minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being checked/
inspected. When in doubt, notify your supervisor.
When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS.
Class III leaks should be reported immediately to your supervisor.

Leakage Definitions for PMCS

Class I Seepage of fluid as indicated by wetness or discoloration, not great

enough to form drops.

Class II Leakage of fluid great enough to form drops, but not enough to cause
drops to drip from the item being checked/inspected.

Class III Leakage of fluid great enough to form drops that fall from the item being
checked/inspected.

GENERAL LUBRICATION PROCEDURES 00012

NOTE
Refer to Lubrication Order (LO 5-3805-293-13).
1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When
operating under extreme conditions, lubricants should always be changed more frequently. When in doubt,
notify your supervisor.
2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep
container covers clean and do not allow dust, dirt, or other foreign material to mix with lubricants. Keep all
lubrication equipment clean and ready for use.
3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to
DA PAM 750-8 for maintenance forms and procedures to record and report any findings.
4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe
lubrication fittings with a clean Rag, Wiping (WP 0032, Item 17). After lubrication, wipe off excess oil or grease
to prevent accumulation of foreign matter.
5. Refer to FM 9-207 for lubrication instructions in cold weather.
6. Refer to AR 70-12 for use of standardized lubricants.

END OF WORK PACKAGE

0012-3/(4 blank)
56

TM 5-3805-293-10 0013

OPERATOR MAINTENANCE -

0 0 1 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP

Tools and Special Tools 0 References 0

Basic Issue Items (WP 0031) 0 WP 0004 0

Materials/Parts 0
WP 0005 0

Antifreeze (WP 0032, Item 1) 0

WP 0010 0

Cleaning Compound, Solvent, Type III (WP WP 0014 0

0032, Item 2) 0
WP 0015 0

Cleaning Compound, Windshield (WP 0032, WP 0017 0

Item 3) 0
WP 0019 0

Detergent, General Purpose, Liquid (WP WP 0021 0

0032, Item 4) 0
WP 0022 0

Diesel Fuel, DF-1 Grade, Arctic (WP 0032, WP 0024 0

Item 5) 0

WP 0026 0

Diesel Fuel, DF-2 Grade (WP 0032, Item 6) 0

WP 0027 0

Fuel, Turbine, Aviation (WP 0032, Item 8)

WP 0032
0

Grease, Automotive and Artillery (GAA) (WP

LO 5-3805-293-13 0

0032, Item 11) 0

Lubricant, Dry Film (WP 0032, Item 12) 0

Equipment Conditions 0

Oil, Lubricating, OE/HDO-30 (WP 0032, Item Machine parked on level ground (WP 0005) 0

13) 0
Blade and scarifier lowered to ground
Oil, Lubricating, OE/HDO-15W/40 (WP 0032, (WP 0005) 0

Item 15) 0
Parking brake engaged (WP 0004) 0

Oil, Lubricating, OEA Arctic (WP 0032, Item

16) 0

Rag, Wiping (WP 0032, Item 17) 0

0013-1
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

NOTE
• Review all WARNINGs, CAUTIONs, and NOTEs before
performing PMCS and operating the machine.
• Perform all PMCS checks if:
– You are the assigned operator but have
not operated the machine since the last
weekly checks.
– You are operating the machine for the
first time.
• Unless otherwise indicated, perform PMCS with machine
parked on level ground, parking brake applied,
transmission in N (Neutral), blade lowered to the ground,
wheels blocked, and engine shut down.
• If leakage is detected during performance of PMCS,
further investigation is required to determine location and
cause of leak.
• Walk around machine and look for any obvious leaks or
damage.
• During walk around, also visually check tires for low
inflation, damage, and debris.

LEFT SIDE

1 Before Overall View Check left side of machine for Class III leaks or damage
evidence of leakage or damage. that would impair operation
are evident.
2 Before All-Wheel Check all-wheel drive (AWD) hoses Class III leaks or damage
Drive Hoses and fittings for damage or leaks. that would impair operation
are evident.

0013-2
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

3 Before Left Front Tire WARNING

• Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death, or damage to equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
Visually check tire for Tire pressure appears low.
underinflation.
4 Before Lights Check left front work light, Missing or damaged
headlight, front turn signal light, components if required for
and blackout light for missing or mission.
damaged components.
5 Before Fuel Tank Ensure fuel tank filler cap is Missing fuel tank filler cap.
Filler Cap present and secure.

Figure 1. Fuel Tank Filler Cap. 0013

6 Before Below Check hoses, cables, and Class III oil or hydraulic fluid
Operator connections below left side of leaks are present. Any fuel
Compartment operator compartment for damage leakage is evident. Damage
or leaks. that would impair operation
is evident.

0013-3
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

7 Before Arctic Heater Check arctic heater fuel line Class III leaks or damaged
(if equipped) (Figure 2, Item 1), coolant hoses or missing components if
(Figure 2, Item 2), grommets required for mission.
(Figure 2, Item 3), electrical
harness and connector (Figure 2,
Item 4), and exhaust tube (Figure
2, Item 5) for leaks, damaged or
missing components.

Figure 2. Arctic Heater. 0013

8 Before 0.2 Engine Oil a. Open left front access door.

Level Check
b. Clean area around engine oil
level gauge (dipstick) (Figure 3,
Item 2) and fill cap (Figure 3,
Item 1).
c. Remove oil level gauge, wipe Oil level is below or above
clean and reinstall. Remove oil crosshatch area on gauge,
level gauge and check level of oil. or fill cap missing.
Maintain oil level between the
marks on oil level gauge (Figure 3,
Item 3).

0013-4
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

8 Before 0.2 Engine Oil d. Add oil as required through filler

(Cont.) Level Check opening. Refer to LO 5-3805-293-
13 for proper grade of oil based on
ambient temperature. Clean oil
filler cap, then reinstall.

Figure 3. Oil Level Gauge (Dipstick) and Fill Cap. 0013

0013-5
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

9 Coolant Level
Checks
WARNING

• DO NOT service cooling system unless engine has been

allowed to cool down. This is a pressurized cooling
system and escaping steam or hot coolant will cause
serious burns.
• DO NOT remove cooling system radiator cap when
engine is hot. Allow engine to cool down. Loosen cap to
first stop and let any pressure out of cooling system, then
remove cap. Failure to follow this warning may cause
serious burns.
• Wear effective eye, hand, and skin protection when
handling coolants. Failure to do so may cause injury to
personnel.
CAUTION
• Do not add water to pre-mixed antifreeze. If water is
added to pre-mixed antifreeze, it will be diluted and will not
provide proper engine protection and engine and/or cool-
ing system damage may occur.
• Be sure to identify the type of antifreeze being added, or
engine and/or cooling system damage may occur.
NOTE
• Some antifreeze is pre-mixed with water and does not
require mixing with water.
• Traditional antifreeze requires mixing with an equal
amount of water. Mix antifreeze and water before adding
to machine cooling system to ensure proper 1:1 ratio is
used.
• It is allowable to mix traditional and pre-mix antifreeze
types in the same cooling system.

0013-6
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

9 Before Coolant Level Check coolant level in coolant tank Coolant level is below ADD
(Cont.) Checks (Figure 4, Item 1). Maintain level mark.
between FULL mark and ADD
mark on coolant tank.

Figure 4. Coolant Tank Level. 0013

0013-7
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

10 Before Transmission/ a. Clean area around transmission

Differential Oil oil level gauge/fill cap (dipstick).
Level Check
b. Start engine and run engine at
low idle (WP 0005).
c. Remove oil level gauge/fill cap,
wipe, clean, and reinstall.
d. Remove oil level gauge/fill cap, Oil level does not register
and check level of oil. on gauge, or fill cap
missing.
NOTE
Proceed to next step only if oil does not register on gauge.
e. Add oil (WP 0032, Items 18 or
21) as required through oil filler
tube. Refer to LO 5-3805-293-13
for proper grade of oil based on
ambient temperature.
f. Stop engine (WP 0005).
g. Close left front access door.

Figure 5. Transmission/Differential Oil Level Check. 0013

0013-8
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

11 Before Hydraulic Tank a. Open left rear access door.

Sight Gauge
b. Clean area around hydraulic
tank sight gauge.
c. Check oil level is visible in sight
gauge.
NOTE
Proceed to the following steps only if oil level is not visible
in sight gauge.
d. Operate machine until oil is Oil is not visible on sight
warm (WP 0005). gauge, oil level is above
MAX mark on sight gauge,
or fill cap missing.
e. Clean area around hydraulic oil
filler cap.
f. Maintain oil level above the MIN
mark on sight gauge.
g. Add oil (WP 0032, Items 18 or
21) as required through hydraulic
oil filler cap. Refer to LO 5-3805-
293-13 for proper grade of oil
based on ambient temperature.

Figure 6. Hydraulic Oil Level Check. 0013

0013-9
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

12 Before NATO a. Ensure NATO slave receptacle

Receptacle cover is installed.
b. Close left rear access door.
13 Before Left Rear Tires WARNING
• Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
Visually check tire for Tire pressure appears low.
underinflation.

REAR

14 Before Rear of a. Check for damage to rear Missing or damaged

Machine blackout light, taillights, turn signal components if required for
lights, backup lights and rear mission.
worklight.
b. Check radiator grille, backup Missing or damaged
alarm, and towing pin for debris components if required for
and damage. mission.
c. Check under engine Class III oil or hydraulic fluid
compartment for evidence of fluid leaks are present. Any fuel
leakages such as oil, coolant, fuel, leakage is evident.
and hydraulic fluid.
d. Check rear of machine for Missing or damaged
obvious damage that would impair components if required for
operation. mission.

0013-10
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

RIGHT SIDE

15 Before Right Rear WARNING

Tires
• Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel or damage to equipment.
Visually check tires for under- Tire pressure appears low.
inflation.
16 Before Overall View Check right side of machine for Class III leaks or damage
evidence of leakage or damage. that would impair operation
are present.
17 Before Right Rear a. Open right rear access door. Class III leaks or damage
Access Door b. Visually check for loose, that would impair operation
damage, cracked components, or are evident.
evidence of leaks.
c. Close right rear access door.

0013-11
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

18 Before Ether Cylinder a. Open right front access door.

b. Remove ether cylinder and Missing or damaged
shake to check if cylinder is empty components if required for
(WP 0021). Install new cylinder if mission.
required (WP 0021).
c. If no ether cylinder is present,
ensure cap is installed on ether
valve.

Figure 7. Ether Cylinder. 0013

0013-12
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

19 Before Engine a. Visually check for loose, Class III leaks or damage
Compartment damage, cracked components, or that would impair operation
evidence of leaks. are evident.
b. Close right front access door.
20 Before Below a. Check hoses and connections Class III oil or hydraulic fluid
Operator below right side of operator leaks are present. Any fuel
Compartment compartment for damage or leaks. leakage is evident. Damage
b. Check cables for fraying or that would impair operation
damage. is evident.

21 Before Right Front WARNING

Tire
• Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
Visually check tire for Tire pressure appears low.
underinflation.
22 Before Lights Check right front work light, Missing or damaged
headlight, blackout drive light, components if necessary
blade work light, and front turn for mission.
signal light for missing or damaged
components.

CAB
INTERIOR

23 Before Battery Turn battery disconnect switch to

Disconnect ON position.
Switch
24 Before Fire a. Visually check for missing or Fire extinguisher is missing
Extinguisher damaged fire extinguisher. Ensure or damaged.
it is securely stowed in mounting
bracket.
b. Check gauge for pressure Pressure gauge needle is in
reading in green area on gauge. red area.

0013-13
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

24 Before Fire c. Check for damaged or missing Seal is broken or missing.

(Cont.) Extinguisher seal.
d. Inspect fire extinguisher Inspection date is not
inspection tag. current and/or tag is
missing.
25 Before Operator Seat Check seat and seat belt mounting Seat belt is damaged.
hardware (Figure 8, Item 1), seat
belt buckle (Figure 8, Item 2), and
seat belt (Figure 8, Item 3) for
damage or wear (WP 0004).

Figure 8. Seat Belt Inspection. 0013

26 Before Rearview Check and adjust inside rearview

Mirror and mirror. With an assistant, check
Side View and adjust side view mirrors.
Mirrors
27 Before Lights With an assistant, check operation Any lights do not function, if
of lights (service and blackout light, required for mission.
brake lights, turn signals and work
lights) (WP 0005).
28 Before Wipers and Operate all wipers and washers to Wipers and washers not
Washers (if verify correct operation (WP 0004). operating if required for
equipped) mission.

0013-14
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

29 Before Backup Alarm a. Verify that backup alarm Backup alarm does not
and Horn functions when transmission is function.
placed in R (Reverse) (WP 0005).

b. Check operation of horn (WP Horn does not function.

0005).
NOTE
Monitor system self-diagnostic test takes approximately
10 seconds to complete.
30 Before Monitor a. Turn engine start switch from Fails to enter diagnostic
System OFF position to ON position (do not test.
Indicators and start engine) to initialize self-
Gauges diagnostic test.
b. Monitor the following:
1. All gauges must sweep to far Any gauge does not move.
right position, then return.

Figure 9. Monitor System Display - Gauges. 0013

2. All alert indicators must Any alert light does not

come on momentarily. come on.
3. All segments in LCD display LCD display segment(s)
must come on momentarily. inoperative
4. The action alarm must Action alarm does not
sound. sound.

0013-15
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

31 Before Left and Right WARNING

Blade Float
Indicators Blade must be lowered before activating blade float.
Failure to follow this warning may result in injury to
personnel.
NOTE
If engine fails to start, turn ignition switch to the OFF
position, and retry.
a. Start engine and run engine at
low idle (WP 0005).
b. Move right and left joysticks to Blade float indicators do not
most forward detent (WP 0005). come ON.
Blade float indicators should be ON
in display.
32 Before Action Light a. Run engine at low idle (WP
Indicator 0005).
b. Monitor action light indicator in
display.
c. If action light indicator is ON, Action light indicator is ON.
machine needs service.

Figure 10. Monitor System Display - Action Light and Blade Float Indicators.

0013

0013-16
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

33 Before Messenger With engine running, observe the Messenger displays error
Display Messenger display. message or Messenger is
not operating.

Figure 11. Messenger Display. 0013

34 Before Differential Push control button on right Differential lock indicator

Lock joystick. Indicator light should go inoperative.
ON (WP 0004).
35 Before Hydraulic Perform a functional check of all Class III oil leak is evident.
Controls hydraulic systems: blade lift, Any hydraulic system or
centershift, circle drive, blade tilt, function does not operate
steering, wheel lean, and scarifier properly.
(WP 0005).
36 Before Brake a. Start engine and run for no less
Accumulator than one minute to increase
accumulator pressure.
b. Stop engine.
c. Turn ignition switch to ON
position. DO NOT start engine.
d. Fully depress service brake
slowly a minimum of five
applications.

0013-17
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

36 Before Brake e. If brake system indicator light Brake system indicator light
(Cont.) Accumulator illuminates with less than five illuminates with less than
applications, notify Field Level five applications.
Maintenance.
37 Before Pedals Check accelerator pedal, service Pedal binds or does not
brake pedal, and transmission operate properly.
modulator control pedal for binding
and obstructions.

Figure 12. Accelerator, Brake, and Transmission Pedals. 0013

38 During Brakes Check service brakes for pulling, Brakes pull, grab, or do not
grabbing, or reduced braking operate properly.
capacity.
39 During Steering Check for smooth, controlled Steering is erratic.
steering without pulling or drifting.
40 During Drive Train Monitor grader operation for Unusual noises or
unusual noise or vibrations from vibrations are present.
engine, transmission, drive shafts,
axles, and wheels.

0013-18
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

41 During Blade and Monitor blade and scarifier Unusual noises or

Scarifier operations for unusual noise or vibrations present.
vibrations.
42 During Overall Watch for evidence of fluid Class III oil or hydraulic fluid
Leakage leakage. leaks are present. Any fuel
leakage is evident.
43 During Instrument a. With machine fully warmed up, Gauges and warnings
Panel monitor indicators and gauges and indicate an abnormal
Messenger Display. reading.
b. If action light indicator is Any flashing of action light
flashing, troubleshoot system (WP indicator.
0010).
44 During Air Check air conditioner, heater and Damaged or does not
Conditioner, defroster fan for correct operation. operate if required for
Heater and mission.
Defroster Fan
45 After Overall View NOTE
Ensure machine is clean in order to facilitate
performance of PMCS inspections.
a. Check under machine for Class III oil or hydraulic fluid
evidence of fluid leakages such as leaks are present. Any fuel
oil, coolant, fuel, or hydraulic fluid. leakage is evident.
b. Check machine for obvious Damage that would impair
damage that would impair operation is evident.
operation.

0013-19
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

LEFT SIDE

46 After Left Front WARNING

Wheel and
Tire • Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
a. Check tires for cuts or bulges in Tire has cuts, bulges, or
tread or sidewall area. Check for foreign material in tread or
uneven wear and foreign material sidewall area or other
embedded in tread or sidewall damage that would impair
area. operation.
b. Clean area around valve stem, Valve stem damaged.
then remove valve stem cap.
c. Check tire inflation pressure Tire inflation pressure more
with tire pressure gauge. Refer to than 4 psi low.
WP 0002 for proper tire inflation
pressures.
d. Check for loose or missing lug Loose, or two or more
bolts. missing lug bolts.
e. Check wheel for damage. Wheel damaged.
47 After Steering a. Check steering linkage for Cracks or distortion in
cracks, distortion, or damage. steering linkage that would
impair operation.
b. Check left front steering cylinder Class III leaks or damage
and hoses for damage or leaks. that would impair operation.
48 After Drawbar a. Check drawbar and drawbar Class III leaks or damage
pivot point for damage. that would impair operation.
b. Check all hoses and fittings for
leaks.

0013-20
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

49 After Scarifier Check scarifier frame, link sockets, Damage that would impair
and teeth for excessive wear (WP operation, or missing six
0026 and WP 0027), damage, or scarifier teeth if required for
missing components. mission.
50 After Hydraulic a. Check scarifier hydraulic Class III leaks or damage
Cylinders cylinder and hoses for damage or that would impair operation.
leaks.
b. Check left blade lift cylinder and Class III leaks or damage
hoses for damage or leaks. that would impair operation.
c. Check centershift cylinder and Class III leaks or damage
hoses for damage or leaks. that would impair operation.
51 After Circle Drive Check all circle drive and circle Class III leaks or damage
drive components for leaks, that would impair operation.
damage or debris. Remove debris.
52 After Blade, Cutting a. Check entire blade for damage Damage or distortion.
Edges, and or distortion.
End Bits
b. Check all cutting edges and end Damage or loose bolts.
bits for damage or loose bolts.
c. Check all cutting edges and end Cutting edge or end bits are
bits for excessive wear (WP 0019). worn to within 3/4 in.
(19 mm) of blade.
d. Check sideshift cylinder for Class III leaks or damage
debris, damage, or leaks. Remove that would impair operation.
debris.
53 After Blade Work Ensure blade work lights are Missing or damaged
Lights present and securely mounted. components if necessary
for mission.
54 After Left Door Check left door for damage or Missing or damaged
missing components. components if necessary
for mission.
55 After Left Mirror and Check left side mirror and step for Missing or damaged
Step damage or missing components. components if necessary
for mission.
56 After Rollover Check ROPS for damage and Loose or missing ROPS
Protective loose or missing mounting bolts. bolts or damage to
Structure structure.
(ROPS)

0013-21
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

57 After Refueling
WARNING

• DO NOT smoke or permit any open flame in area of

machine while you are servicing fuel system. Be sure
hose nozzle is grounded against filler tube during refueling
to prevent static electricity. Failure to follow this warning
may cause injury to personnel or damage to equipment.
• Operating personnel must wear fuel-resistant gloves when
handling fuels. If exposed to fuel, promptly wash exposed
skin and change fuel-soaked clothing.

NOTE
• Place portable fire extinguisher within reach prior to
refueling.
• DO NOT overfill fuel tank. If fuel starts foaming from fuel
tank, stop IMMEDIATELY to avoid fuel spillage.
• Observe sight glass while adding fuel to ensure fuel spill-
age due to overfilling does not occur.
a. Check fuel tank, filler tube, and Any fuel leaks or damage
filler cap for damage or leaks. are noted.

Figure 13. Fuel Tank, Filler Tube, Sight Glass, and Cap. 0013

0013-22
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

57 After Refueling b. Remove filler cap. Inspect filler Filler cap, gasket or screen
(Cont.) cap, gasket, and screen for is missing or damaged.
damage.
c. Reinstall screen.
d. Add fuel (WP 0032, Items 11,
12, or 15) to tank. DO NOT overfill.
Reinstall filler cap and secure.

Figure 14. Filler Cap, Gasket, and Screen. 0013

58 After Articulation Check articulation lock pin is

Lock Pin present in lock pin storage bracket.

0013-23
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

WARNING

If CBRN exposure is suspected, personnel wearing pro-

tective equipment must handle all air cleaner media. Con-
taminated filters must be handled using adequate
precaution and must be disposed of by trained personnel.
Consult your CBRN Officer or CBRN NCO for appropriate
handling or disposal procedures. Failure to follow this
warning may result in injury or death to personnel.
59 After Primary and a. Remove air filter cover.
Secondary Air
Filters
b. Ensure primary air filter is
present.
c. Remove primary and secondary Missing or damaged air
air filters. filter components.
d. Inspect and clean or replace
filters (WP 0014).
e. Install secondary and primary
air filters.
f. Install air filter cover.

Figure 15. Air Filters and Cover. 0013

0013-24
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

60 After Fuel/ Water

Separator
WARNING

Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. Failure to follow this
warning may cause injury to personnel or equipment
damage.
Drain fuel/water separator (WP Excessive amounts of water
0022). in fuel.

Figure 16. Fuel/Water Separator. 0013

0013-25
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

61 After 0.2 Transmission/ a. Clean area around transmission

Differential Oil oil level gauge/fill cap.
Level Check
b. Start engine and run engine at
low idle (WP 0005). Remove oil
level gauge/fill cap, clean, and
reinstall.
c. Remove oil level gauge/fill cap
and check level of oil. Maintain oil
level between marks on oil level
gauge/fill cap.
d. Add oil (WP 0032, Item 18 or
21) as required through oil filler
tube.
e. Stop engine (WP 0005).

Figure 17. Transmission/Differential Oil Level Check. 0013

62 After 0.2 Engine Oil a. Open left front access door.

Level Check
b. Clean area around engine oil Class III oil leak or damage
level gauge (dipstick) (Figure 18, is evident.
Item 2) and fill cap (Figure 18, Item
1).

0013-26
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

62 After 0.2 Engine Oil c. Add oil (WP 0032, Items 18 or Fill cap missing.
(Cont.) Level Check 21) as required through oil filler cap
opening. Refer to LO 5-3805-293-
13 for proper grade of oil based on
ambient temperature. Clean oil
filler cap, then reinstall.

Figure 18. Engine Oil Level Check. 0013

0013-27
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

63 After Arctic Heater Check arctic heater fuel line Class III leaks or damaged
(if equipped) (Figure 19, Item 1), coolant hoses or missing components if
(Figure 19, Item 2), grommets required for mission.
(Figure 19, Item 3), electrical
harness and connector (Figure 19,
Item 4), and exhaust tube (Figure
19, Item 5) for leaks, damaged or
missing components.

Figure 19. Arctic Heater. 0013

64 After Left Rear WARNING

Wheels and
Tires • Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
a. Check tires for cuts or bulges in Tire has cuts, bulges, or
tread or sidewall area. Check for foreign material in tread or
uneven wear and foreign material sidewall area or other
embedded in tread or sidewall damage that would impair
area. operation.
b. Clean area around valve stems, Valve stem damaged.
then remove valve stem caps.

0013-28
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

64 After Left Rear c. Check tire inflation pressure Tire inflation pressure more
(Cont.) Wheels and with tire pressure gauge. Refer to than 4 psi low.
Tires WP 0002 for proper tire inflation
pressures.
d. Check for loose or missing lug Loose or two or more
bolts. missing lug bolts.
e. Check wheels for damage. Wheel damaged.
65 After Left Tandem Check for damage and leaks from Class III oil leak or damage
Housing tandem housing. is evident.
66 After Coolant Level
Checks
WARNING

• DO NOT service cooling system unless engine has been

allowed to cool down. This is a pressurized cooling
system and escaping steam or hot coolant will cause
serious burns.
• DO NOT remove cooling system radiator cap when
engine is hot. Allow engine to cool down. Loosen cap to
first stop and let any pressure out of cooling system, then
remove cap. Failure to follow this warning may cause
serious burns.
• Wear effective eye, hand, and skin protection when
handling coolants. Failure to do so may cause injury to
personnel.
CAUTION
• Do not add water to pre-mixed antifreeze. If water is
added to pre-mixed antifreeze, it will be diluted and will not
provide proper engine protection and engine and/or cool-
ing system damage may occur.
• Be sure to identify the type of antifreeze being added, or
engine and/or cooling system damage may occur.
NOTE
• Some antifreeze is pre-mixed with water and does not
require mixing with water.
• Traditional antifreeze requires mixing with an equal
amount of water. Mix antifreeze and water before adding
to machine cooling system to ensure proper 1:1 ratio is
used.
• It is allowable to mix traditional and pre-mix antifreeze
types in the same cooling system.

0013-29
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

66 After Coolant Level a. Check coolant level in coolant

(Cont.) Checks tank (Figure 20, Item 1). Maintain
level between FULL mark and ADD
mark on the coolant tank (Figure
20, Item 1).
b. Close left front access door.

Figure 20. Coolant Tank. 0013

67 After 0.2 Hydraulic Tank a. Open left rear access door.

Sight Gauge
b. Clean area around hydraulic
tank sight gauge and hydraulic oil
filler cap.
c. Maintain oil level above MIN
mark on sight gauge.
d. Add oil (WP 0032, Items 18 or Fill cap missing.
21) as required through filler tube.
Refer to LO 5-3805-293-13 for
proper oil based on ambient
temperature.

0013-30
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

67 After 0.2 Hydraulic Tank

(Cont.) Sight Gauge

Figure 21. Hydraulic Oil Tank. 0013

68 After NATO a. Ensure NATO slave receptacle

Receptacle cover is installed.
b. Close left rear access door.

REAR

69 After Rear of
Machine
WARNING

Wear suitable eye protection and keep face and eyes

away from exhausting air tank drain valves. Failure to do
so may cause injury to personnel.
a. Check for damage to rear Damage that would impair
blackout light, taillights, turn signal operation is evident.
lights, and rear work light.
b. Check radiator grille and Damage that would impair
backup alarm for debris and operation is evident.
damage.

0013-31
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

69 After Rear of c. Check under engine Class III oil or hydraulic fluid
(Cont.) Machine compartment for evidence of fluid leaks are present. Any fuel
leakages such as oil, coolant, fuel, leakage is evident. Damage
and hydraulic fluid. that would impair operation
is evident.
d. Check machine for obvious Damage that would impair
damage that would impair operation is evident.
operation.
e. Check rear support brackets Missing or damaged
mounted on rear bumper for component if required for
damaged or missing components. mission.
f. Check for presence of hitch pin. Missing or damaged
component if required for
mission.

RIGHT SIDE
AND FRONT

70 After Refrigerant a. Open right rear access door.

Condenser b. Check condenser and cooler for Refrigerant condenser and/
and Hydraulic debris and damage. or hydraulic oil cooler
Oil Cooler damage.
c. Close right rear access door.

0013-32
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

70 After Refrigerant
(Cont.) Condenser
and Hydraulic
Oil Cooler

Figure 22. Refrigerant Condenser and Hydraulic Oil Cooler. 0013

71 After Right Rear WARNING

Wheels and
Tires • Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
a. Check tires for cuts or bulges in Tire has cuts, bulges, or
tread or sidewall area. Check for foreign material in tread or
uneven wear and foreign material sidewall area or other
embedded in tread or sidewall damage that would impair
area. operation.
b. Clean area around valve stems, Valve stem damaged.
then remove valve stem caps.

0013-33
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

71 After Right Rear c. Check tire inflation pressure Tire inflation pressure more
(Cont.) Wheels and with tire pressure gauge. Refer to than 4 psi low.
Tires WP 0002 for proper tire inflation
pressures.
d. Check for loose or missing lug Loose or two or more
bolts. missing lug bolts.
e. Check wheels for damage. Wheel damaged.
72 After Right Check for damage and leaks from Class III oil leak or damage
Tandem right side tandem housing. is evident.
Housing
73 After Right Front Visually check exhaust system, air Missing, damaged, or loose
Access Door intake system components, and components.
turbocharger air tubes for
looseness, damage, or missing
components.
74 After Frame WARNING
Articulation
Point Area Hitch and steering movement can reduce clearances
suddenly and cause injury to personnel. Always stop
engine BEFORE working in area of hitch link.
Visually check for any obstructions Damage that would impair
between moving components of operation is evident.
frame articulation point. Remove
obstructions and check for
damage.
75 After Rollover Check ROPS for damage and One loose or missing
Protective loose or missing mounting bolts. ROPS bolt or damage to
Structure structure.
(ROPS)
76 After Right Door Check right door for damage or Missing or damaged
missing components. components if necessary
for mission.
77 After Right Mirror Check right side mirror for damage Missing or damaged
or missing components. component.
78 After Blade Work Ensure blade work lights are Work lights damaged or
Lights present and securely mounted and missing if required for
not damaged. mission.
79 After Hydraulic a. Check right lift cylinder and Class III leaks or damage
Cylinders hoses for damage or leaks. that would impair operation.

0013-34
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

79 After Hydraulic b. Check centershift cylinder and Class III leaks or damage
(Cont.) Cylinders hoses for damage or leaks. that would impair operation.
c. Check sideshift cylinder and Class III leaks or damage
hoses for damage or leaks. that would impair operation.
80 After Circle Drive a. Check all circle drive Damage to circle drive that
components for damage or debris. would impair operation.
Remove debris.
b. Check circle drive for damage Class III leaks or damage
or leaks. that would impair operation.
81 After Scarifier Check scarifier frame, link rod, and Damage that would impair
teeth for excessive wear, damage, operation or missing six
or missing components (WP 0026, scarifier teeth, if required for
WP 0027). mission.

82 After Drawbar a. Check drawbar and drawbar Damage that would impair
pivot point for damage. operation.
b. Check all hoses and fittings for Class III leaks or damage
damage or leaks. that would impair operation.
83 After Steering a. Check steering linkage for Cracks or distortion to
cracks, distortion, or damage. steering linkage that would
impair operation.
b. Check right front steering Class III leaks or damage
cylinder and hoses for damage or that would impair operation.
leaks.
84 After Right Front WARNING
Wheel and
Tire • Improperly inflated tires can cause excessive heat buildup
resulting in blowouts. Failure to follow this warning may
result in serious injury or death to personnel, or damage to
equipment.
• If tire pressure is more than 4 psi low, tires must be
inflated in a safety cage. Notify Field Level Maintenance.
Failure to follow this warning may result in serious injury or
death to personnel, or damage to equipment.
a. Check tires for cuts or bulges in Tire has cuts, bulges, or
tread or sidewall area. Check for foreign material in tread or
uneven wear and foreign material sidewall area or other
embedded in tread or sidewall damage that would impair
area. operation.

0013-35
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

84 After Right Front b. Clean area around valve stems, Valve stem damaged.
(Cont.) Wheel and then remove valve stem caps.
Tire
c. Check tire inflation pressure Tire inflation pressure more
with tire pressure gauge. Refer to than 4 psi low.
WP 0002 for proper tire inflation
pressures.
d. Check for loose or missing lug Loose, or two or more
bolts. missing lug bolts.
e. Check for damage. Wheel damaged.
85 After 0.2 Circle Drive a. Clean dirt and old lubricant from
Pinion Teeth circle drive pinion teeth and from
blade circle.
b. Check pinion teeth and blade Teeth missing or damaged
circle for missing or damaged gear if required for mission.
teeth.
c. Using GAA (WP 0032, Item 16),
lubricate IAW LO 5-3805-293-13.

Figure 23. Circle Drive Lubrication. 0013

0013-36
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

86 After 0.2 Circle Top Apply dry film lubricant (WP 0032,
Item 17) IAW LO 5-3805-293-13.

Figure 24. Circle Top Lubrication. 0013

CAB
INTERIOR

87 Biweekly or Inside Cab Air

Every 100 Filter
WARNING
Engine
Hours

If CBRN exposure is suspected, personnel wearing pro-

tective equipment must handle all air cleaner media. Con-
taminated filters must be handled using adequate
precautions and must be disposed of by trained person-
nel. Consult your CBRN Officer or CBRN NCO for appro-
priate handling or disposal procedures. Failure to follow
this warning may result in injury or death to personnel.
CAUTION
Do not use compressed air at pressure greater than 30 psi
(207 kPa) to clean or dry filter element. Failure to follow
this caution may result in damage to equipment.

0013-37
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

87 Biweekly or Inside Cab Air a. Loosen two thumb screws Filter missing if required for
(Cont.) Every 100 Filter (Figure 25, Item 1) on filter cover mission.
Engine (Figure 25, Item 2).
Hours
b. Remove filter cover (Figure 25,
Item 2).
c. Remove filter element and
clean with either pressurized air or
nonsudsing detergent.
d. Rinse the filter and allow to dry.
e. Inspect filter for damaged pleats
or a damaged seal. If filter is
damaged, replace filter.
f. Install the filter element.
g. Install filter cover (Figure 25,
Item 2).
h. Tighten two thumb screws
(Figure 25, Item 1).

Figure 25. Inside Cab Air Filter. 0013

0013-38
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

88 Biweekly or Secondary WARNING

Every 100 Steering
Engine Ensure immediate area around machine, specifically in
Hours front of machine, is free of all personnel. Failure to follow
this warning may result in injury or death to personnel.
NOTE
To protect secondary steering pump, secondary steering
test will automatically shut off if switch is held in TEST
position for more than 10 seconds.
a. Ensure parking is engaged,
transmission is in NEUTRAL, and
then start engine (WP 0005).
b. Push top of secondary steering
switch (Figure 26, Item 1) and hold
(TEST position).
c. With secondary steering switch
in TEST position, use left joystick
to steer left, steer right, and steer
center. Verify front wheels turn with
each steering position.
d. Release secondary steering
switch.
e. If alert indicator (Figure 26, Secondary steering fails
Item 2) is illuminated after test.
secondary steering switch is
released, test has failed. Notify
Field Level Maintenance.

Figure 26. Secondary Steering Test. 0013

0013-39
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

LEFT SIDE

89 Biweekly or Outside Cab

Every 100 Air Filter
WARNING
Engine
Hours

If CBRN exposure is suspected, personnel wearing pro-

tective equipment must handle all air cleaner media. Con-
taminated filters must be handled using adequate
precautions and must be disposed of by trained person-
nel. Consult your CBRN Officer or CBRN NCO for appro-
priate handling or disposal procedures. Failure to follow
this warning may result in injury or death to personnel.
CAUTION
• Do not use compressed air at pressure greater than 30 psi
(207 kPa) to clean or dry filter element. Failure to follow
this caution may result in damage to filter element.
• Filter element must be completely dry before installation.
Failure to follow this caution may result in damage to
equipment.
Biweekly or Outside Cab a. Loosen thumb screw (Figure Filter missing if required for
Every 100 Air Filter 27, Item 3) and open outside cab mission.
Engine air filter access cover (Figure 27,
Hours Item 2).
b. Remove filter element (Figure
27, Item 1) and clean with either
pressurized air or nonsudsing
detergent.
c. Rinse filter and allow to dry.
d. Inspect filter for damaged pleats
or a damaged seal. If filter is
damaged, replace filter.
e. Install filter element.
f. Close outside cab air filter
access cover (Figure 27, Item 2).

0013-40
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

89 Biweekly or Outside Cab g. Tighten thumb screw (Figure

(Cont.) Every 100 Air Filter 27, Item 3).
Engine
Hours

Figure 27. Outside Cab Air Filter. 0013

WARNING

Fuel leaked or spilled onto hot surfaces or electrical com-

ponents can cause a fire. Failure to follow this warning
may cause injury to personnel or damage to equipment.
90 Biweekly or Fuel Tank a. Articulate machine RIGHT, then
Every 100 Water and shut off engine (WP 0005).
Engine Sediment
Hours

0013-41
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

90 Biweekly or Fuel Tank b. Place a suitable container under

(Cont.) Every 100 Water and fuel tank.
Engine Sediment
Hours
c. Open the drain valve and allow Drain valve damaged or
water and sediment to drain. tank contains excessive
water or sediment. Notify
Field Level Maintenance.
d. Close drain valve.
e. Start engine. Center machine
articulation, then shut off engine
(WP 0005).

Figure 28. Fuel Tank Drain. 0013

0013-42
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

RIGHT SIDE
AND REAR

91 Monthly Batteries
WARNING

• To avoid injury, eye protection and acid-resistant gloves

must be worn when working around batteries. DO NOT
smoke, use open flame, make sparks, or create other igni-
tion sources around batteries. If a battery is giving off
gases, it can explode and cause injury. Remove all jewelry
such as rings, ID tags, watches, and bracelets. If jewelry
or a tool contacts a battery terminal, a direct short will
result in instant heating, damage to equipment, and injury
to personnel.
• Sulfuric acid contained in batteries can cause serious
burns. If battery corrosion or electrolyte makes contact
with skin, eyes, or clothing, take immediate action to stop
the corrosive burning effects. Failure to follow these pro-
cedures may cause death or serious injury to personnel.
• DO NOT use compressed air to clean batteries. Use a
clean, dry rag.
a. Open right rear access door.
b. Check battery holddown for Holddown is loose or
looseness or damage. damaged.
c. Inspect battery for a cracked Battery case is cracked or
case and evidence of leaking. leaks are evident.
d. Check for missing, broken, split, Damage is noted.
or frayed battery cables.
e. Check for damaged battery Damage is noted.
posts.
f. Check electrolyte level in each
cell unless equipped with
maintenance-free batteries. If level
is low, fill with distilled or clean
drinking water to bottom of filler
opening.

0013-43
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

91 Monthly Batteries g. Close right rear access door.

(Cont.)
92 Monthly Arctic
Batteries (if
WARNING
equipped)

• To avoid injury, eye protection and acid-resistant gloves

must be worn when working around batteries. DO NOT
smoke, use open flame, make sparks, or create other igni-
tion sources around batteries. If a battery is giving off
gases, it can explode and cause injury. Remove all jewelry
such as rings, ID tags, watches, and bracelets. If jewelry
or a tool contacts a battery terminal, a direct short will
result in instant heating, damage to equipment, and injury
to personnel.
• Sulfuric acid contained in batteries can cause serious
burns. If battery corrosion or electrolyte makes contact
with skin, eyes, or clothing, take immediate action to stop
the corrosive burning effects. Failure to follow these pro-
cedures may cause death or serious injury to personnel.
• DO NOT use compressed air to clean batteries. Use a
clean, dry rag.
a. Disengage two arctic battery
cover latches, and with the aid of
an assistant, remove cover.
b. Check battery holddowns for Holddown is loose or
looseness or damage. missing.
c. Inspect batteries for cracked Battery case(s) cracked or
cases and evidence of leaking. leaks are evident.
d. Check for missing, broken, split, Damage is noted.
or frayed battery cables or
connectors.
e. Check for damaged battery Damage is noted.
posts.
f. Check electrolyte level in each
cell unless equipped with
maintenance-free batteries. If level
is low, fill with distilled or clean
drinking water to bottom of filler
opening.

0013-44
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

92 Monthly Arctic g. With the aid of an assistant,

(Cont.) Batteries (if install cover, then engage two
equipped) latches.
93 Monthly All Systems -
Machine
WARNING
Exercise

If machine is parked indoors, DO NOT run engine unless

exhaust fumes are vented to the outside. Failure to follow
this warning may cause injury or death due to carbon
monoxide poisoning.
NOTE
• DO NOT exercise machine if it has been operated
within the past month.
• Ensure Before operation PMCS has been performed.
a. Start engine and run at idle for
five minutes (WP 0005).
NOTE
If temperature is below 32°F (0°C), operate controls prior
to moving machine.
b. After machine has idled for five
minutes, begin to operate all
controls slowly (WP 0004):
1. transmission in all ranges
including reverse;
2. differential lock and center
shift lock engaged and disengaged;
3. parking and service brakes
applied and released;
4. steering and wheel lean from
full left to full right; and
5. all grader hydraulic controls
(blade lift, blade side shifts, blade
centershift, blade tilt, and scarifier).
c. Operate controls for another
five minutes.

0013-45
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

93 Monthly All Systems - d. Move machine and operate all

(Cont.) Machine controls through full motion, to
Exercise bring all systems to operating
temperature.
e. Move machine and continue to
operate all controls through full
motion for 30 minutes remove bolt
after machine systems have
reached operating temperature.
f. Stop machine and allow to idle
for five minutes.
g. Shut down engine.
h. Perform After operation PMCS.
6. Check blade lift cylinder Cylinder sockets in need of
sockets for wear (WP 0015). adjustment if required for
mission.
7. Check centershift cylinder Cylinder sockets in need of
sockets for wear (WP 0017). adjustment if required for
mission.
8. Check scarifier link sockets Link sockets in need of
for wear (WP 0026). adjustment if required for
mission.
9. Check moldboard wear Moldboard wear strips worn
strips (WP 0024). if required for mission.

0013-46
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

RIGHT SIDE
AND REAR

94 Initial 500 Batteries and

Engine Battery Cables
WARNING
Hours (or
at first oil
change)
• To avoid injury, eye protection and acid-resistant gloves
must be worn when working around batteries. DO NOT
smoke, use open flame, make sparks, or create other igni-
tion sources around batteries. If a battery is giving off
gases, it can explode and cause injury. Remove all jewelry
such as rings, ID tags, watches, and bracelets. If jewelry
or a tool contacts a battery terminal, a direct short will
result in instant heating, damage to equipment, and injury
to personnel.
• Sulfuric acid contained in batteries can cause serious
burns. If battery corrosion or electrolyte makes contact
with skin, eyes, or clothing, take immediate action to stop
the corrosive burning effects. Failure to follow these pro-
cedures may cause death or serious injury to personnel.
• DO NOT use compressed air to clean batteries. Use a
clean, dry rag.
CAUTION
To reduce battery damage, check battery compartment for
corrosion (greenish/white powder) and DO NOT jerk or
pull on battery cables during visual inspection. Failure to
follow this caution may result in damage to equipment.
a. Open right rear access door.
b. Check battery holddown for Holddown is loose or
looseness or damage. damaged.
c. Inspect battery for a cracked Battery case is cracked or
case and evidence of leaking. leaks are evident.

NOTE
Original equipment batteries are maintenance-free, and
do not have removable caps.
d. Check for missing, broken, split, Damage is noted.
or frayed battery cables.

0013-47
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

94 Initial 500 Batteries and e. Check for damaged battery Damage is noted.
(Cont.) Engine Battery Cables posts.
Hours (or
at first oil
change)
f. If equipped with non-
maintenance-free batteries, check
electrolyte level in each cell. If level
is low, fill with distilled or clean
drinking water to bottom of filler
opening. Close right rear access
door.
95 Initial 500 Arctic
Engine Batteries (if
WARNING
Hours (or equipped)
at first oil
change)
• To avoid injury, eye protection and acid-resistant gloves
must be worn when working around batteries. DO NOT
smoke, use open flame, make sparks, or create other igni-
tion sources around batteries. If a battery is giving off
gases, it can explode and cause injury. Remove all jewelry
such as rings, ID tags, watches, and bracelets. If jewelry
or a tool contacts a battery terminal, a direct short will
result in instant heating, damage to equipment, and injury
to personnel.
• Sulfuric acid contained in batteries can cause serious
burns. If battery corrosion or electrolyte makes contact
with skin, eyes, or clothing, take immediate action to stop
the corrosive burning effects. Failure to follow these pro-
cedures may cause death or serious injury to personnel.
• DO NOT use compressed air to clean batteries. Use a
clean, dry rag.
CAUTION
To reduce battery damage, check battery compartment for
corrosion (greenish/white powder) and DO NOT jerk or
pull on battery cables during visual inspection. Failure to
follow this caution may result in damage to equipment.
a. Disengage two arctic battery
cover latches, and with the aid of
an assistant, remove cover.
b. Check battery holddowns for Holddown is loose or
looseness or damage. missing.

0013-48
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

95 Initial 500 Arctic c. Inspect batteries for cracked Battery case(s) cracked or
(Cont.) Engine Batteries (if cases and evidence of leaking. leaks are evident.
Hours (or equipped)
at first oil
change)
d. Check for missing, broken, split, Damage is noted.
or frayed battery cables or
connectors.
e. Check for damaged battery Damage is noted.
posts.
f. If equipped with non-
maintenance-free batteries, inspect
electrolyte level in each cell. If level
is low, fill with distilled or clean
drinking water to bottom of filler
opening.
g. With the aid of an assistant,
install cover, then engage two
latches.

BOTH SIDES

96 Every 500 0.2 Tandem Drive a. Clean surface area around the
Engine Oil Level oil check plug.
Hours or 3 b. Remove oil check plug.
Months
c. When tandem drive oil is full, oil Tandem drive oil level is
should trickle from check plug low.
opening. Notify Field Level
Maintenance if oil level is low.
d. Replace oil check plug.

0013-49
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

96 Every 500 0.2 Tandem Drive

(Cont.) Engine Oil Level
Hours or 3
Months

Figure 29. Tandem Drive Oil Level Check. 0013

97 Every 500 Service Brake

WARNING
Engine Holding Ability
Hours or 3
Months

Be ALERT for personnel in the area while operating

machine. Always check to ensure area is clear of person-
nel and obstructions before starting engine, moving
machine, or lowering or raising blade. Failure to follow this
warning may cause injury or death to personnel or dam-
age to equipment.
CAUTION
Allow machine to fully warm up (warm air blows from
heater vents) before performing this test. Failure to follow
this caution may result in damage to equipment.
a. Fasten seat belt before testing
brakes (WP 0005).
b. Start engine (WP 0004).

0013-50
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

97 Every 500 Service Brake c. Raise blade slightly (WP 0004).

(Cont.) Engine Holding Ability
Hours or 3
Months
d. Depress transmission
modulator control (WP 0004).
e. Fully apply service brake (WP
0004).
f. Select FIFTH SPEED
FORWARD (WP 0004).
g. Set throttle Hold Mode switch to
MANUAL (WP 0004).
h. Push and hold top of throttle
SET/ACCEL switch to set engine at
high idle speed.
i. Gradually release transmission Service brakes do not hold.
modulator control. Machine should
not move and engine should stall.
98 Every 500 Parking Brake
WARNING
Engine Holding Ability
Hours or 3
Months

Be ALERT for personnel in the area while operating

machine. Always check to ensure area is clear of person-
nel and obstructions before starting engine, moving
machine, or lowering or raising blade. Failure to follow this
warning may cause injury or death to personnel or dam-
age to equipment.
a. Test brakes on hard, packed
dirt.
b. Fasten seat belt before testing
brakes.
c. Position the machine on a slope
of 20 percent.
d. Engage parking brake control.
Release the service brake control.
e. If machine moves, notify Field Parking brake does not
Level Maintenance. hold.

0013-51
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

99 Every 500 Fuel System a. Open left front access door.

Engine Prime b. Turn engine start switch to ON
Hours or 3 position for 2 minutes.
Months
c. Verify water separator is full of
fuel.
d. If water separator is not full of
fuel, turn engine start switch OFF,
then turn engine start switch ON.
e. If water separator is still not full Fuel system does not
of fuel after 2 minutes, notify Field prime.
Level Maintenance.
f. Close left front access door.
100 Every 500 Exhaust Engine and exhaust system components may be
Engine System extremely hot after engine is shut down. Do not touch any
Hours or 3 part of the exhaust system until engine has cooled down
Months sufficiently. Failure to follow this warning may result in
injury to personnel.
a. Open right front access door.
b. Check exhaust system pipes, Looseness, damage or
clamps, and muffler for looseness, leaks are noted.
leakage, or damage.
c. Close right rear access door.

0013-52
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

CAB

101 Every Rollover a. Check ROPS for drilled holes, Loose, damaged, or
1,000 Protective corrosion, loose, damaged, or missing mounting hardware
Engine Structure missing mounting hardware. Notify is noted.
Hours or 6 (ROPS) Field Level Maintenance to
Months retorque/replace mounting
hardware.
b. Check ROPS for any signs of Any signs of damage or
cracking in base metal or welded cracked welds are noted.
areas.

Figure 30. ROPS Hardware. 0013

0013-53
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

LEFT SIDE

102 Every Cooling

2,000 System
WARNING
Engine Pressure Cap
Hours or 2
Years
• Personal injury can result from hot coolant, steam, and
alkali.
• At operating temperature, engine coolant is hot and under
pressure. The radiator and all lines to heaters or the
engine contain hot coolant or steam. Any contact can
cause severe burns.
• Remove filler cap slowly to relieve pressure only when
engine is stopped and radiator cap is cool enough to touch
with your bare hand.
• Do not attempt to tighten hose connections when the
coolant is hot as the hose can come off causing burns.
• Cooling system conditioner contains alkali. Avoid contact
with skin and eyes.
a. Open cooling system pressure
cap access door (Figure 31,
Item 1).

0013-54
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

102 Every Cooling

(Cont.) 2,000 System
Engine Pressure Cap
Hours or
2 Years

Figure 31. Cooling System Pressure Cap Access Door. 0013

0013-55
 TM 5-3805-293-10 0013

Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information - Continued.

LOCATION

ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:

102 Every Cooling b. Clean area around cooling

(Cont.) 2,000 System system pressure cap.
Engine Pressure Cap c. Remove cooling system
Hours or pressure cap.
2 Years
d. Clean cooling system pressure Cooling system pressure
cap and inspect cap and cap seals cap is damaged.
for damage. Replace cooling
system pressure cap if damaged.
e. Install cooling system pressure
cap.
f. Close cooling system pressure
cap access door.

Figure 32. Cooling System Pressure Cap Seals. 0013

END OF WORK PACKAGE

0013-56
 TM 5-3805-293-10

CHAPTER 5
MAINTENANCE INSTRUCTIONS
4

TM 5-3805-293-10 0014

OPERATOR MAINTENANCE -

AIR FILTER ELEMENTS MAINTENANCE

0 0 1 4

Removal, Cleaning and Inspection, Installation

INITIAL SETUP

Tools and Special Tools 0 Equipment Condition 0

Work Light 0 Machine parked (WP 0005) 0

Left front access door opened (WP 0004) 0

Materials/Parts 0

Rag, Wiping (WP 0032, Item 17) 0

Estimated Time to Complete 0

0.2 Hr 0

0014-1
 TM 5-3805-293-10 0014

REMOVAL 00014

NOTE
• Replace the secondary air filter element if: (A) primary air filter element has been replaced
three times since the secondary element has been replaced, (B) exhaust smoke is black
even after primary element has been replaced, or (C) the secondary element has been in
service for one year.
• If hose comes off dust ejector, be sure to connect it during installation.
1. Disengage three latches (Figure 1, Item 1) and remove engine air filter cover (Figure 1, Item 2).

CAUTION
Do not remove secondary air filter element (Figure 1, Item 4) until after the air filter
housing is cleaned, and then only if it is being replaced. This will reduce the possibility of
dirt entering the engine. Failure to follow this caution may result in damage to equipment.

2. Remove primary air filter element (Figure 1, Item 3).

Figure 1. Air Filter Housing and Elements. 0014

END OF TASK

0014-2
 TM 5-3805-293-10 0014

CLEANING AND INSPECTION 00014

1. Clean inside of air filter housing.

CAUTION
• Do not tap or strike air filter element to remove dust. Damage to air filter element may
result.
• Do not wash the air filter element.
• Do not use air filter elements with damaged pleats, gaskets, or seals. Dirt entering engine
will cause damage to engine components.
• Do not attempt to clean a secondary air filter element.
• Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean primary
element.
• Failure to follow these cautions may result in damage to equipment.

NOTE
Use either low pressure compressed air or a vacuum to clean primary air filter element.
Direct airflow from inside element and up and down pleats rather than across pleats.

2. With assistance from Field Level Maintenance personnel, clean primary element.
3. Inspect primary element for tears, holes, damaged pleats, gaskets, or seals. Discard if damaged.
4. Inspect element using a work light. Light should be visible through the element when light is placed inside ele-
ment. If necessary, compare to a new element to confirm results.

CAUTION
Do not remove secondary air filter element until you have the new element ready to install.
This will reduce the possibility of dirt entering the engine. Failure to follow this caution may
result in damage to equipment.

5. Remove secondary air filter element (Figure 1, Item 4). Discard element.

END OF TASK

INSTALLATION 00014

1. Install secondary air filter element (Figure 1, Item 4).

2. Install primary air filter element (Figure 1, Item 3).

0014-3
 TM 5-3805-293-10 0014

INSTALLATION – CONTINUED
3. Position engine air filter cover (Figure 2, Item 1) ensuring proper orientation, and engage three latches (Figure
2, Item 2).
4. Check, and if necessary, connect hose to dust ejector (Figure 2, Item 3).
5. Close left front access door (WP 0004).

Figure 2. Air Filter Housing Cover. 0014

END OF TASK

END OF WORK PACKAGE

0014-4
2

TM 5-3805-293-10 0015

OPERATOR MAINTENANCE -

0 0 1 5 BLADE LIFT CYLINDER SOCKET INSPECTION

Inspection

INITIAL SETUP

Personnel 0 Equipment Condition - Continued 0

Two 0
Parking brake engaged (WP 0004) 0

Blade rotated 90 degrees to frame and

Equipment Condition 0

lowered to ground (WP 0005) 0

Engine running (WP 0005) 0

Estimated Time to Complete 0

0.1 Hr 0

INSPECTION 00015

NOTE
Perform this inspection on both left- and right-side blade lift cylinders.

1. Operate blade lift cylinders slowly while having an assistant observe socket connections (Figure 1, Item 1) at
top of circle (drawbar/blade) (Figure 1, Item 2).
2. Observe sockets for movement without circle movement, indicating adjustment required.
3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Blade Lift Cylinder Socket. 00015

END OF TASK

END OF WORK PACKAGE

0015-1/(2 blank)
2

TM 5-3805-293-10 0016

OPERATOR MAINTENANCE -

0 0 1 6 BRAKE ACCUMULATOR TEST

Testing

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Machine parked (WP 0005) 0 0.1 Hr 0

TESTING 00016

WARNING
• Cold ambient temperatures could result in loss of secondary braking capability due to
inadequate hydraulic accumulator nitrogen pre-charge. Loss of the secondary braking
system as well as main hydraulic pressure will result in little or no braking capability and a
potential for injury or death.
• Perform a brake accumulator check anytime machine has been idle for longer than two
hours below -13°F (-25°C). Failure to follow these warnings may result in injury or death to
personnel.

NOTE
Alert indicator will illuminate when brake accumulator pressure is below operational
standard.

1. Move engine start switch to ON position. Alert indicator (Figure 1, Item 1) will come on if accumulator pressure
is below operational standard.

Figure 1. Brake Accumulator Indicator. 00016

0016-1
 TM 5-3805-293-10 0016

TESTING – CONTINUED 00016

2. Start engine and run for at least one minute to increase accumulator pressure. Alert indicator should go off
when pressure increases.
3. Shut down engine after one minute or when indicator goes off, whichever is longer.
4. With ignition in ON position, apply and release service brake pedal a minimum of five times, to decrease
accumulator pressure, until alert indicator illuminates.
5. Notify Field Level Maintenance if alert indicator illuminates before the minimum five applications of the service
brake pedal.

END OF TASK

END OF WORK PACKAGE

0016-2
2

TM 5-3805-293-10 0017

OPERATOR MAINTENANCE -

0 0 1 7 CENTERSHIFT CYLINDER SOCKET INSPECTION

Inspection

INITIAL SETUP

Personnel 0 Equipment Condition - Continued 0

Two 0 Parking brake engaged (WP 0004) 0

Moldboard rotated 90 degrees to frame and

Equipment Condition 0

lowered to ground (WP 0005) 0

Engine running (WP 0005) 0

0
Estimated Time to Complete 0

0.1 Hr 0

INSPECTION 00017

1. Operate centershift cylinder (Figure 1, Item 1) slowly while having an assistant observe lower socket connec-
tion (Figure 1, Item 3) at top of circle (Figure 1, Item 4) and then upper socket connection (Figure 1, Item 2) at
centershift bar (Figure 1, Item 5).
2. Observe socket for movement without circle movement.
3. If socket moves without circle moving, notify Field Level Maintenance adjustment is required.

Figure 1. Centershift Cylinder Socket. 00017

END OF TASK

END OF WORK PACKAGE

0017-1/(2 blank)
2

TM 5-3805-293-10 0018

OPERATOR MAINTENANCE -

0 0 1 8 CIRCUIT BREAKER RESET

Reset

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Ignition ON (WP 0004) 0 0.1 Hr 0

Left front access door open (WP 0002) 0

RESET 00018

1. Identify correct circuit breaker for inoperative system/circuit.

Figure 1. Circuit Breakers. 00018

KEY COMPONENT DESCRIPTION

1 20 Amp Circuit Breaker Not used.
2 15 Amp Circuit Breaker Transmission and chassis control systems.
3 15 Amp Circuit Breaker Ignition circuit.
4 20 Amp Circuit Breaker Engine control system.
5 150 Amp Circuit Breaker Alternator circuit.
6 80 Amp Circuit Breaker Main - Feeds power to fuses in cab that are turned on when
ignition is in ON position.
7 80 Amp Circuit Breaker Load Circuit - Feeds power to fuses in cab that are
continuously on.

0018-1
 TM 5-3805-293-10 0018

RESET – CONTINUED
2. Push button to reset circuit breaker. Button should remain pushed in. This indicates circuit breaker was reset
successfully.

Figure 2. Fast Speed Blower Circuit Breaker. 00018

3. If button does not remain in, notify Field Level Maintenance.

END OF TASK

FOLLOW-ON TASKS 00018

1. Close left front access door (WP 0002).

2. Turn ignition OFF (WP 0005).

END OF TASK

END OF WORK PACKAGE

0018-2
2

TM 5-3805-293-10 0019

OPERATOR MAINTENANCE -

0 0 1 9 CUTTING EDGES AND END BITS INSPECTION

Inspection

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Machine parked (WP 0005) 0 0.1 Hr 0

Blade tilted forward (WP 0004) 0

Blade lowered onto wooden blocks 0

INSPECTION 00019

1. Visually inspect cutting edges (Figure 1, Item 2), and end bits (Figure 1, Item 1) for damage or excessive wear.
2. Notify Field Level Maintenance if cutting edges or end bits are damaged or worn to within approximately 3/4 in.
(19 mm) (approximately the width of your thumb) of the blade.

Figure 1. Cutting Edges and End Bits. 00019

END OF TASK

END OF WORK PACKAGE

0019-1/(2 blank)
2

TM 5-3805-293-10 0020

OPERATOR MAINTENANCE -

0 0 2 0 DOMELAMP BULB REPLACEMENT

Removal, Installation

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Machine parked (WP 0005) 0 0.2 Hr 0

REMOVAL 00020

1. Remove domelamp cover (Figure 1, Item 1) from domelamp.

2. Remove domelamp bulb (Figure 1, Item 2) by pushing in slightly and turning bulb left to disengage bulb locking
lugs. Pull bulb out of socket.

END OF TASK

INSTALLATION 00020

1. Install bulb (Figure 1, Item 2) in socket, push in slightly, and turn bulb right to engage bulb locking lugs.
2. Install cover (Figure 1, Item 1).

Figure 1. Domelamp Bulb Replacement. 00020

END OF TASK

END OF WORK PACKAGE

0020-1/(2 blank)
4

TM 5-3805-293-10 0021

OPERATOR MAINTENANCE -

0 0 2 1 ETHER STARTING AID CYLINDER REPLACEMENT

Removal, Cleaning and Inspection, Installation

INITIAL SETUP

Materials/Parts 0 Equipment Condition 0

Rag, Wiping (WP 0032, Item 17) 0 Machine parked (WP 0005) 0

Cylinder, Engine Starting (Ether) (WP 0032, Right front access door open 0

Item 7) 0

Goggles, Industrial (WP 0032, Item 10) 0

0021-1
 TM 5-3805-293-10 0021

REMOVAL 00021

1. Loosen clamp (Figure 1, Item 2).

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in a
well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid
contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate
the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek
medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow
this warning may cause serious injury or death to personnel.
2. Unscrew and remove ether starting aid cylinder (Figure 1, Item 1) from valve (Figure 1, Item 3). Discard empty
cylinder IAW local regulations and Unit SOP.
3. Remove gasket from valve (Figure 1, Item 3). Discard gasket.

Figure 1. Ether Starting Aid Cylinder. 0021

END OF TASK

CLEANING AND INSPECTION 00021

Clean valve (Figure 1, Item 3) of any dirt or debris. Inspect valve for any damage. If damage is present, notify Field
Level Maintenance.

END OF TASK

0021-2
 TM 5-3805-293-10 0021

INSTALLATION 00021

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke, and make sure you are in a
well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid
contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate
the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek
medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow
this warning may cause serious injury or death to personnel.

Ensure gasket is properly seated in valve prior to installing cylinder. If gasket is not
properly seated, ether will escape from valve. Seek medical attention immediately if ether
is inhaled or causes eye irritation. Failure to follow this warning may cause serious injury
or death to personnel.

CAUTION
Make sure gasket is positioned correctly on ether starting aid cylinder before installing.
Failure to follow this caution may result in damage to gasket and ether leakage.
1. Install new gasket on valve (Figure 1, Item 3).
2. Install ether starting aid cylinder (Figure 1, Item 1) on valve.
3. Tighten clamp (Figure 1, Item 2).

END OF TASK

FOLLOW-ON TASK 00021

Close right front access door.

END OF TASK

END OF WORK PACKAGE

0021-3/(4 blank)
2

TM 5-3805-293-10 0022

OPERATOR MAINTENANCE -

0 0 2 2 FUEL/WATER SEPARATOR DRAIN

Drain Fuel/Water Separator

INITIAL SETUP 0

Equipment Condition 0 Estimated Time to Complete 0

Machine parked (WP 0005) 0 0.2 Hr 0

Left front access door open (WP 0002) 0

DRAIN FUEL/WATER SEPARATOR 00022

WARNING

Fuel leaking or spilled onto hot surfaces or electrical components can cause a fire. Failure
to follow this warning may cause injury or death to personnel and damage to equipment.

1. Place a suitable container beneath fuel/water separator bowl (Figure 1, Item 1).
2. If hose is not already connected to bowl, connect suitable hose (Figure 1, Item 2) to nipple on bowl and place
open end into container.
3. Open fuel/water separator drain valve (Figure 1, Item 3) and allow water and sediment to drain into container.
4. Close valve once all water and sediment have drained from bowl.
5. Remove container and hose.
6. Dispose of fuel IAW local regulations and Unit SOP.

Figure 1. Fuel/Water Separator. 0022

END OF TASK

0022-1
 TM 5-3805-293-10 0022

FOLLOW-ON TASK 00022

Close left front access door.

END OF TASK

END OF WORK PACKAGE

0022-2
4

TM 5-3805-293-10 0023

OPERATOR MAINTENANCE -

0 0 2 3 FUSE REPLACEMENT
Replacement

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Machine parked (WP 0005) 0 0.2 Hr 0

0023-1
 TM 5-3805-293-10 0023

REPLACEMENT 00023

NOTE
• Replace fuses with same type and amperage rating.
• Fuse panel is located on cab floor left of operator’s seat.
1. Identify fuse requiring replacement.

Figure 1. Fuse Identification. 00023

0023-2
 TM 5-3805-293-10 0023

REPLACEMENT – CONTINUED

Fuse Number Amperage Rating Circuit

F1 15 LH Door Wiper
F2 15 Rear Flood
F3 10 Differential Lock
F4 20 Blade Flood #2
F5 15 Powered Seat - not used
F6 10 Defroster Fan
F7 10 Accugrade
F8 -- NOT USED
F9 10 Pin Puller / Cushion
F10 15 HVAC
F11 -- NOT USED
F12 10 WAVES - not used
F13 -- NOT USED
F14 20 Blade Floods
F15 15 RH Door Wiper
F16 10 Turn Relays
F17 10 Quicklube - not used
F18 -- NOT USED
F19 -- NOT USED
F20 15 Front Wiper
F21 15 Condenser Fan Relay #1
F22 -- NOT USED
F23 -- NOT USED
F24 -- NOT USED
F25 15 Condenser Fan Relay #2
F26 -- NOT USED
F27 -- NOT USED
F28 15 AWD Controller
F29 15 Implement Controller #1
F30 10 Dash Cluster
F31 10 Dome Lamp
F32 10 Backlighting
F33 -- NOT USED
F34 10 Horn
F35 -- NOT USED
F36 15 Implement Controller #2
F37 15 12V Converter
F38 15 Blackout
F39 -- NOT USED
F40 15 Heater Unit

0023-3
 TM 5-3805-293-10 0023

REPLACEMENT – CONTINUED
2. Remove fuse panel cover (Figure 2, Item 1).

Figure 2. Fuse Panel Cover. 00023

3. Remove blown fuse.

4. Install new fuse.

NOTE
Notify Field Level Maintenance if new fuse blows when component is turned on or if same
fuse blows frequently.
5. Install fuse panel cover.

END OF TASK

END OF WORK PACKAGE

0023-4
2

TM 5-3805-293-10 0024

OPERATOR MAINTENANCE -

0 0 2 4 MOLDBOARD WEAR STRIPS INSPECTION

Inspection

INITIAL SETUP

Personnel Required 0 Equipment Condition - Continued 0

Three 0 Parking brake engaged (WP 0004) 0

Engine running (WP 0005) 0

Equipment Condition 0

Moldboard rotated 90 degrees to frame and Estimated Time to Complete 0

lowered to ground (WP 0005) 0

0.1 Hr 0

INSPECTION 00024

1. Operate moldboard lift cylinders slowly while an assistant observes moldboard (Figure 1, Item 1) and circle
assembly (Figure 1, Item 2).
2. Observe circle assembly for movement without moldboard movement.
3. If circle assembly moves without moldboard moving, notify Field Level Maintenance that further inspection is
required.

Figure 1. Moldboard Wear Strip Inspection. 00024

END OF TASK

END OF WORK PACKAGE

0024-1/(2 blank)
4

TM 5-3805-293-10 0025

OPERATOR MAINTENANCE -

RADIATOR CLEANING
0 0 2 5

Removal, Cleaning, Installation

INITIAL SETUP

Materials/Parts 0 Estimated Time to Complete 0

Rag, Wiping (WP 0032, Item 17) 0 0.4 Hr 0

Equipment Condition 0

Machine parked (WP 0005) 0

WARNING

Allow engine to cool before cleaning radiator. Failure to follow this warning may result in
injury to personnel.

REMOVAL 00025

1. Open left rear access door (Figure 1, Item 1).

2. Remove two bolts (Figure 1, Item 3) from left rear access panel (Figure 1, Item 2) and open panel.

Figure 1. Left Rear Access Door and Panel. 0025

0025-1
 TM 5-3805-293-10 0025

REMOVAL – CONTINUED
3. Remove two bolts (Figure 2, Item 1) from right rear access panel (Figure 2, Item 2) and open panel.
4. Open right rear access door (Figure 2, Item 3).

Figure 2. Right Rear Access Door and Panel. 0025

END OF TASK

CLEANING 00025

WARNING

Cooling fins on radiator and other cooler assemblies can be very sharp. Be sure to wear
protective gloves while working near these components. Failure to follow this warning
could result in injury to personnel.

CAUTION
Cooling fins on radiator and other cooler assemblies are easily bent and damaged, which
can result-in reduced air flow and cooling capacity. Use caution when working near these
components to avoid bending cooling fins. Failure to follow this caution may result in
damage to equipment.

Remove dirt and debris from around radiator.

END OF TASK

0025-2
 TM 5-3805-293-10 0025

INSTALLATION 00025

1. Close right rear access door (Figure 2, Item 3).

2. Close right rear access panel (Figure 2, Item 2) and install two bolts (Figure 2, Item 1).
3. Close left rear access panel (Figure 3, Item 2) and install two bolts (Figure 3, Item 3).
4. Close left rear access door (Figure 3, Item 1).

Figure 3. Left Rear Access Door and Panel. 0025

END OF TASK

END OF WORK PACKAGE

0025-3/(4 blank)
2

TM 5-3805-293-10 0026

OPERATOR MAINTENANCE -

0 0 2 6 SCARIFIER LINK SOCKET INSPECTION

Inspection

INITIAL SETUP

Estimated Time to Complete 0 Equipment Condition 0

0.1 Hr 0 Engine running (WP 0005) 0

Parking brake engaged (WP 0004) 0

Personnel Required 0

Two 0

INSPECTION 00026

1. Slowly operate scarifier up and down, making very light contact with ground, while having an assistant observe
both scarifier link sockets (Figure 1, Item 1) on each side of machine.
2. Observe sockets (Figure 1, Item 1) for movement without scarifier movement, indicating adjustment is
required.
3. Notify Field Level Maintenance if adjustment is required.

Figure 1. Scarifier Link Sockets. 00026

END OF TASK

END OF WORK PACKAGE

0026-1/(2 blank)
4

TM 5-3805-293-10 0027

OPERATOR MAINTENANCE -

0 0 2 7 SCARIFIER TOOTH AND SHANK MAINTENANCE

Inspection, Replacement

INITIAL SETUP

Tools and Special Tools 0 Equipment Condition 0

Hammer (WP 0031, Item 6) 0 Scarifier lowered onto 4-6 in. (100-150 mm)
Tooth Removing Tool, Scarifier (WP 0031, wood blocks (WP 0005) 0

Item 16) 0 Machine parked (WP 0005) 0

Material/Parts 0 Estimated Time to Complete 0

Goggles, Industrial (WP 0032, Item 10) 0 0.4 Hr 0

INSPECTION 00027

1. Visually inspect scarifier teeth (Figure 1, Item 2) for excessive wear. Replace tooth when worn to dashed line
(Figure 1, Item 3) shown in illustration.
2. Visually inspect shanks (Figure 1, Item 1) for cracks or breakage.
3. Proceed to Replacement in this work package if teeth or shanks require replacement.

Figure 1. Scarifier Tooth and Shank Inspection. 0027

END OF TASK

0027-1
 TM 5-3805-293-10 0027

REPLACEMENT 00027

WARNING

Eye protection is required when replacing scarifier teeth to protect against flying particles.
Failure to follow this warning may result in injury to personnel.

1. Using tooth removing tool (Figure 2, Item 2) and a hammer, drive tooth (Figure 2, Item 1) off shank.

Figure 2. Scarifier Tooth Removal. 0027

0027-2
 TM 5-3805-293-10 0027

REPLACEMENT – CONTINUED 00027

2. Clean dirt and debris from shank.

WARNING
DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may result
in injury to personnel.

NOTE
Be sure rubber grommet (Figure 3, Item 5) remains with lock pin.

3. Using tooth removing tool (Figure 3, Item 3) pry up lock pin (Figure 3, Item 2) and remove.

Figure 3. Scarifier Shank Lock Pin Removal. 0027

4. Remove shank (Figure 3, Item 1) from scarifier (Figure 3, Item 4).

5. Install shank (Figure 3, Item 1) on scarifier (Figure 3, Item 4).
6. Install lock pin with grommet (Figure 3, Item 2) on scarifier (Figure 3, Item 4).

0027-3
 TM 5-3805-293-10 0027

REPLACEMENT – CONTINUED

WARNING

DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may result
in injury to personnel.

7. Position and drive tooth (Figure 4, Item 2) onto shank (Figure 4, Item 1) to secure.

Figure 4. Scarifier Tooth and Shank Installation. 0027

END OF TASK

END OF WORK PACKAGE

0027-4
2

TM 5-3805-293-10 0028

OPERATOR MAINTENANCE -

0 0 2 8 WINDOW WASHER TANK CHECK AND FILL

Check and Fill

INITIAL SETUP

Materials/Parts 0 Equipment Condition 0

Cleaning Compound, Windshield (WP 0032, Machine parked (WP 0005) 0

Item 3) 0

Rag, Wiping (WP 0032, Item 17) 0

Estimated Time to Complete 0

0.1 Hr 0

CHECK AND FILL 00028

NOTE
• Windshield washer tank is located inside the cab and left of operator’s seat.
• Fluid level can be viewed through transparent tank.
• Fill opening is outside machine at rear of left door.
1. Check fluid level in tank (Figure 1, Item 1).
2. Clean tank fill cap (Figure 1, Item 2) and surrounding area.
3. Remove tank fill cap (Figure 1, Item 2).
4. Fill tank with windshield cleaning compound.
5. Install tank fill cap (Figure 1, Item 2).

Figure 1. Windshield Washer Tank. 0028

END OF TASK

END OF WORK PACKAGE

0028-1/(2 blank)
2

TM 5-3805-293-10 0029

OPERATOR MAINTENANCE -

0 0 2 9 WINDOW WIPER BLADE REPLACEMENT

Replacement

INITIAL SETUP

Equipment Condition 0 Estimated Time to Complete 0

Machine parked, battery disconnect switch in 0.3 Hr 0

ON position (WP 0005) 0

Front windshield wiper stopped in center of

glass (WP 0004) 0

CAUTION
The wiper arm is spring-loaded. Do not let go of arm after blade has been removed.
Carefully lower arm to glass or glass may break.

NOTE
Except for positioning front windshield wiper blade in center of glass for access,
replacement is identical for all wiper blades.

0029-1
 TM 5-3805-293-10 0029

REPLACEMENT 00029

NOTE
If front wiper is not being replaced, skip step 1 and go directly to step 2.

1. Position windshield wiper in center of windshield as follows:

a. Turn ignition switch to ON position (WP 0004). Do not start engine.
b. Activate front wiper (WP 0004).
c. When wiper is positioned in center of windshield, turn ignition switch to OFF position.
2. Raise wiper arm (Figure 1, Item 1) and blade (Figure 1, Item 4) up away from glass.
3. Squeeze release tab (Figure 1, Item 2) and remove blade (Figure 1, Item 4) from arm (Figure 1, Item 1).
4. Position new blade (Figure 1, Item 4) on arm (Figure 1, Item 1) and secure pivot insert (Figure 1, Item 3) to
blade.

469-0311

Figure 1. Windshield Wiper Replacement. 00029

END OF TASK

END OF WORK PACKAGE

0029-2
 TM 5-3805-293-10

CHAPTER 6
SUPPORTING INFORMATION
2

TM 5-3805-293-10 0030

OPERATOR MAINTENANCE -

0 0 3 0 REFERENCES

SCOPE 00030

This work package lists all publication indexes, forms, field manuals, technical manuals, and other publications ref-
erenced in this manual and which apply to operation and operator maintenance of the 120M Motor Grader.
PUBLICATION INDEXES 00030

The following indexes should be consulted frequently for the latest changes or revisions and for new publications
relating to material covered in this technical manual.
Consolidated Army Publications and Forms Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30
The Army Maintenance Management System (TAMMS) Users Manual . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8
FORMS 00030

NOTE
Refer to DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual,
for instructions on the use of maintenance forms.
Accident-Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518
Equipment Control Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404
Equipment Inspection Maintenance Worksheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 5988-E
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 91
Processing and Deprocessing Record for Shipment, Storage, and
Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397
Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 368
Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SF Form 364
Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14
Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2258
FIELD MANUALS 00030

Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 55-30

Basic Cold Weather Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70
Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-3
Earthmoving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-434
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11
Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 21-305-20
Multiservice Helicopter Sling Load: Basic Operations and Equipment . . . . . . . . . . . . . . . . . . . . . . . . FM 4-20.197
Multiservice Helicopter Sling Load: Single-Point Load Rigging Procedures . . . . . . . . . . . . . . . . . . . . FM 4-20.198
Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and
Nuclear Contamination Avoidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3
Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and
Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5

0030-1
 TM 5-3805-293-10 0030

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71

Operations and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 9-207
Railway Operating and Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-21
Recovery and Battle Damage Assessment and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-30.31
Rigging Techniques, Procedures, and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-125
TECHNICAL BULLETINS 00030

Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment,

and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209
TECHNICAL MANUALS 00030

Operator’s, Unit, Direct Support, and General Support Maintenance

Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14
Operator’s, Unit Maintenance Manual for Laser Leveling Equipment . . . . . . . . . . . . . . . . . . TM 5-6675-348-13&P
Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility
Equipment Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-3
OTHER PUBLICATIONS 00030

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-2007

Army Logistics Readiness and Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 700-138
Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100
Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items). . . . . . . . . . . CTA 50-970
Field and Garrison Furnishings and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 50-909
Lubrication Order for Motorized Road Grader Model 120M . . . . . . . . . . . . . . . . . . . . . . . . . . . .LO 5-3805-293-13
Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and Logistic Support . . .AR 70-12

END OF WORK PACKAGE

0030-2
4

TM 5-3805-293-10 0031

OPERATOR MAINTENANCE -

0 0 3 1 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

INTRODUCTION 0031

Scope 00031

This work package lists COEI and BII for the 120M Motor Grader to help you inventory items for safe and efficient
operation of the equipment.
General 00031

The COEI and BII information is divided into the following lists:
a. Components of End Item (COEI). This list is for information purposes only and is not authority to
requisition replacements. These items are part of the 120M Motor Grader. As part of the end item, these
items must be with the end item whenever it is issued or transferred between property accounts. Items of
COEI are removed and separately packaged for transportation or shipment only when necessary.
Illustrations are furnished to help you find and identify the items.
b. Basic Issue Items (BII). These essential items are required to place the 120M Motor Grader in operation,
operate it, and perform emergency repairs. Although shipped separately packaged, BII must be with the
120M Motor Grader during operation and when it is transferred between property accounts. Listing these
items is your authority to request/requisition them for replacement based on authorization of the end item
by the TOE/MTOE. Illustrations are furnished to help you find and identify the items.
Explanation of Columns in the COEI List and BII List 00031

Column (1) Illus Number. Gives you the number of the item illustrated.
Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for
requisitioning purposes.
Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters)
followed by a minimum description when needed. The stowage location of COEI and BII is also included in this
column. The last line below the description is the part number and the Commercial and Government Entity
Code (CAGEC) (in parentheses).
Column (4) Usable On Code (UOC). When applicable, gives you a code if the item you need is not the same
for different models of equipment.
Column (5) U/I Unit of Issue. Indicates the physical measurement or count of the item as issued per the
National Stock Number shown in Column (2).
Column (6) Qty Rqr. Indicates the quantity required.

0031-1
 TM 5-3805-293-10 0031

COEI LIST 0031

NOTE
There are no COEI for the 120M Motor Grader.
BII LIST 0031

Table 1. Basic Issue Items (BII). 031

(1) (2) (3) (4) (5) (6)

ILLUS QTY
NUMBER NSN DESCRIPTION, PART NUMBER/(CAGEC) UOC U/I RQR
1 5140-01-524-7563 Bag, Tool 1 EA 1
211-0136/(11083)
2 5306-01-438-9715 Bolt, Machine 2
EA 1
8T0670/(11083)
3 4210-01-493-8162 Extinguisher, Fire 3
EA 1
B500T/(54905)
4 4910-01-545-3635 Gauge, Tire Pressure 4 EA 1
1P-545/(11083)
5 – Glass Hammer 5 EA 1
8Y-6379 (11083)
6 5120-00-061-8546 Hammer 6 EA 1
11677028-3/(19207)

0031-2
 TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

(1) (2) (3) (4) (5) (6)

ILLUS QTY
NUMBER NSN DESCRIPTION, PART NUMBER/(CAGEC) UOC U/I RQR
7 4930-00-253-2478 Lubricating Gun, Hand 7
EA 1
1142/(1PL57)
8 Lubrication Order 8
EA 1
LO 5-3805-293-13 (19207)
9 Manual, Operator’s 9
EA 1
TM 5-3805-293-10 (19207)
10 5310-01-565-6246 Nut, Self-Locking, Hexagon 10
EA 1
7X0851/(11083)
11 5340-01-181-2579 Padlock and Keys 11 EA 3
5P8502/(11083)
12 5315-01-579-3794 Pin, Grooved, Head (Articulation Lock Pin) 12
EA 1
2520977/(11083)

0031-3
 TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

(1) (2) (3) (4) (5) (6)

ILLUS QTY
NUMBER NSN DESCRIPTION, PART NUMBER/(CAGEC) UOC U/I RQR
13 5120-01-335-1562 Pliers, Slip Joint, 9.25 in. 13 EA 1
91ACP/(55719)
14 5120-01-528-9361 Screwdriver, Flat Tip 14
EA 1
6V-7935/(11083)
15 – Strap 15 EA 1
XXXXX (11083)
16 3805-00-423-9746 Tooth Removing Tool, Scarifier 16
EA 1
6B-3260/(11083)
17 9905-00-148-9546 Warning Device Kit, Highway 17 EA 1
11669000 (19207)
18 5120-01-518-2402 Wrench, Adjustable, 12-inch long 18
EA 1
214-7330/(11083)

END OF WORK PACKAGE

0031-4
4

TM 5-3805-293-10 0032

OPERATOR MAINTENANCE -

0 0 3 2 EXPENDABLE AND DURABLE ITEMS LIST

INTRODUCTION
Scope 00032

This work package lists expendable and durable items you will need to operate and maintain the 120M Motor
Grader. This list is for information only and is not authority to requisition the listed items. These items are
authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic
Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department
Expendable/Durable Items.
Explanation of Columns 00032

1. Column (1) Item Number. This number is assigned to the entry in the list and is referenced in the narrative
instructions to identify the item (e.g., Use antifreeze (WP 0032, Item 1)).
2. Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item.
C - Crew
F - Field
3. Column (3) National Stock Number (NSN). This is the National Stock Number assigned to the item, which
you can use to requisition it.
4. Column (4) Item Name Description, Part Number (CAGEC). This column provides the other information
you need to identify the item. The last line below the description is the part number and the Commercial and
Government Entity Code (CAGEC) (in parentheses).
5. Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gal-
lon, dozen, gross, etc.

0032-1
 TM 5-3805-293-10 0032

Table 1. Expendable and Durable Items for the 120M Motor Grader.

(1) (2) (3) (4) (5)

ITEM NATIONAL ITEM NAME, DESCRIPTION,

NUMBER LEVEL STOCK NUMBER PART NUMBER/(CAGEC) U/I

1 C Antifreeze 1

6850-01-383-4068 1 Gallon Bottle GL 1

672 4354 (1QK63)

6850-01-441-3257 5 Gallon Can CN 1

A-A-52624 (58536)
6850-01-383-3918 55 Gallon Drum DR 1

A-A-52624 (58536)
2 C Cleaning Compound, Solvent, Type III 2

MIL-PRF-680/(81349)
6850-01-474-2318 1 Gallon Can CN 2

6850-01-474-2320 5 Gallon Can CN 2

6850-01-474-2321 55 Gallon Drum DR 2

3 C Cleaning Compound, Windshield 3

0854-000/(0FTT5)
6850-00-926-2275 16 Ounce Bottle BT 3

4 C 4 Detergent, General Purpose, Liquid 4

7930-00-282-9699/(83421)
7930-00-282-9699 4 1 Gallon Can CN
4

5 C 5 Diesel Fuel, DF-1 Grade, Arctic 5

ASTM D 975/(81346)

9140-00-286-5286 5 Bulk GL 5

9140-00-286-5287 5 5 Gallon Can CN 5

9140-00-286-5288 5 55 Gallon Drum DR 5

6 C 6 Diesel Fuel, DF-2 Grade 6

ASTM D 975/(81346)
9140-00-286-5294 6 Bulk GL 6

9140-00-286-5295 6 5 Gallon Can CN 6

9140-00-286-5296 6 55 Gallon Drum DR 6

7 C 7 2910-00-646-9727 7 Cylinder, Engine Starting (Ether) 7 DZ 7

MS39254-1/(19207)
8 C 8 9130-01-031-5816 8 Fuel, Turbine, Aviation 8 GL 8

MIL-T-83133 GR JP-8/(81349)

0032-2
 TM 5-3805-293-10 0032

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1) (2) (3) (4) (5)

ITEM NATIONAL ITEM NAME, DESCRIPTION,

NUMBER LEVEL STOCK NUMBER PART NUMBER/(CAGEC) U/I

9 C 9 8415-01-297-6876 9 Gloves, Chemical and Oil Protective 9

326Y/LARDC/(88009)
10 C 10 4240-00-190-6432 10 Goggles, Industrial 10

ANSIZ-1989/(80204)
11 C 11 Grease, Automotive and Artillery (GAA) 11

9150-01-197-7688 11 M-10924-A/(81349)
2-1/4 Ounce Tube TU 11

9150-01-197-7693 11 M-10924-B/(81349)
14 Ounce Cartridge CA 11

9150-01-197-7690 11 M-10924-C/(81349)
1-3/4 Pound Can CN 11

9150-01-197-7692 11 M-10924-E/(81349)
35 Pound Can CN 11

12 C 12 9150-01-089-1697 12 Lubricant, Dry Film 12 GAL 12

MIL-PRF-46147C GL-420 (72657)

13 C 13 Oil, Lubricating, OE/HDO-30 13

MIL-PRF-2104/(81349)
9150-00-186-6681 13 1 Quart Can CN 13

9150-00-188-9858 13 5 Gallon Can CN 13

9150-00-189-6729 13 55 Gallon Drum DR 13

14 C 14 Oil, Lubricating, OE/HDO-40 14 14

9150-00-188-9862 14 55 Gallon Drum DR 14

15 C 15 Oil, Lubricating, OE/HDO-15W/40 15

MIL-PRF-2104/(81349)
9150-01-152-4117 15 1 Quart Can CN 15

9150-01-152-4118 15 5 Gallon Can CN 15

9150-01-152-4119 15 55 Gallon Drum DR

15

16 C 16 Oil, Lubricating, OEA Arctic 16

9150-00-402-4478 MIL-L-46167/(81349) 16

16 1 Quart Can QT 16

9150-00-402-2372 MIL-PRF-46167/(81349) 16

5 Gallon Can GL 16

9150-00-491-7197 16
MIL-PRF-46167/(81349) 16

55 Gallon Drum DR 16

16 16

16 16

0032-3
 TM 5-3805-293-10 0032

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1) (2) (3) (4) (5)

ITEM NATIONAL ITEM NAME, DESCRIPTION,

NUMBER LEVEL STOCK NUMBER PART NUMBER/(CAGEC) U/I

17 C 17 Rag, Wiping 17

7920-00-205-1711/(64067)
7920-00-205-1711 17 50 Pound Bale BL 17

18 C 18 Strap, Tiedown 18

5975-00-903-2284 4 Inch Length, Black, Package of 100 18

18 MS3367-4-0/(96906) HD 18

5975-00-984-6582 6 Inch Length, Black, Package of 100 18

MS3367-1-0/(96906) HD 18

5975-00-935-5946 18
13.35 Inch Minimum Length, Brown 18

MS3367-2-1/(96906) EA 18

19 C 19 Tag, Marker 19

9905-00-537-8954/(64067)
19 9905-00-537-8954 Bundle of 20 BD

END OF WORK PACKAGE

0032-4
 TM 5-3805-293-10

INDEX
Subject WP Sequence No.-Page No.

A
Abbreviations/Acronyms, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-8
Advanced Operation and Operator Tips
Traveling and Earth Moving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-1
Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014-1
All-Wheel Drive, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1
B
Blade Lift
Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015-1
Brake
Accumulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016-1
C
Centershift Cylinder Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017-1
Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination, Threat of . . . . . . . . . . . . . . . WP 0001-10
Circuit Breaker Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018-1
Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0031-1
Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1
Cutting Edges and End Bits Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-1
D
Description and Use of Operator Controls and Indicators
Mounting and Dismounting - Main Entry and Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-1
Description and Use of Operator’s Controls and Indicators
All-Wheel Drive (AWD) Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-18
Alternate Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-2
Battery Disconnect Switch and Slave Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-24
Door Handles and Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-5
Forward Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-16
Frame Lock Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-3
Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-19
Joystick Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-10
Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-22
Mid-Mount Scarifier Control Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-15
Military Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-23
Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-21
Right-Side Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-17
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-7
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-8
Wheel Lean Lock Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-4
Wiper/Washer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-20
Wrist Rests, Arm Pads, and Control Pods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-9
Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1
Domelamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020-1
E
Electrical, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6

INDEX-1
 TM 5-3805-293-10

INDEX - CONTINUED
Subject WP Sequence No.-Page No.
Electromagnetic Pulse (EMP) Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-10
Engine
Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3
Engine, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0003-2
Equipment
Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-6
Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0002-1
Improvement Recommendations (EIR), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1
Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0021-1
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1
F
Fire Extinguisher, Portable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12
Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-9
Fuel/Water Separator Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0022-1
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0023-1
G
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1
H
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
L
List of
Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-8
Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0032-1
M
Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0001-1
Moldboard Wear Strips Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0024-1
O
Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-1
Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-3
High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8
Moving Machine Out of Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13
Mud or Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7
Portable Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12
Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8
Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-7
Secondary Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-12
Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-2
Snow and Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-8
Stopping Engine if Electrical Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0007-13
Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-1
All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-30
Centershift Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-28
Differential Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-19
Engine Starting and Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WP 0005-3

INDEX-2
 TM 5-3805-293-10

INDEX - CONTINUED
Subject WP Sequence No.-Page No.

Initial Adjustment Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1

Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-18
Machine Warning Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-17
Messenger Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-7
Mounting and Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-5
Articulation Lock Pin Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-6
Scarifier Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-33
Seat, Seat Belt, and Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-2
Slope Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-32
Throttle Hold Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-26
Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-20
P
Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4
Preventive Maintenance Checks and Services (PMCS)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013-1
R
Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0025-1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0030-1
Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1
S
Scarifier
Link Socket Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0026-1
Tooth and Shank Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0027-1
Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-2
Stowage and Decal/Data Plate Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008-1
T
Theory of Operation
All-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1
All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2
Engine Starting and Machine Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-2
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-1
Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-4
Threat of Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination . . . . . . . . . . . . . . . WP 0001-10
Traveling and Earth Moving Operations, Advanced Operation and Operator Tips . . . . . . . . . . . . . . . . . WP 0006-1
Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009-1
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011-1
Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010-1

INDEX-3
 TM 5-3805-293-10

INDEX - CONTINUED
Subject WP Sequence No.-Page No.

W
Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028-1
Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022-1

INDEX-4
 RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Date you filled out
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4. this form.

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS Your mailing address
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE Title


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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION S2^{|]

Your Name Your Signature

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command Your address Date you filled out this
ATTN: AMSTA-LCL-MPP/TECH PUBS form
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE 

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PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

Your Name Your Signature

USAPPC V3.00
 RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command

ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
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*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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SUPPORTED

PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00
 RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630

PUBLICATION/FORM NUMBER DATE TITLE 


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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00
 RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630

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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00
 RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630

PUBLICATION/FORM NUMBER DATE TITLE 


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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U.S. Army TACOM Life Cycle Management Command
ATTN: AMSTA-LCL-MPP/TECH PUBS
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
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PART III – REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank
forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE

USAPPC V3.00
By Order of the Secretary of the Army:

GEORGE W. CASEY JR.

*HQHUDO8QLWHG6WDWHV$UP\
&KLHIRI6WDII
Official:



DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: $/0).0,
requirements for TM 5-3805-293-10.
 THE METRIC SYSTEM AND EQUIVALENTS
Linear Measure Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces
1 Kilogram = 1000 Grams = 2.2 Pounds
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Liquid Measure
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces
1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
Temperature
5/9 (°F - 32) = °C
212° Fahrenheit is equivalent to 100° Celsius
90° Fahrenheit is equivalent to 32.2° Celsius
32° Fahrenheit is equivalent to 0° Celsius
9/5 C° +32 = F°

APPROXIMATE CONVERSION FACTORS

To Change To Multiply By To Change To Multiply By

Inches Centimeters 2.540 Centimeters Inches 0.394

Feet Meters 0.305 Meters Feet 3.280

Yards Meters 0.914 Meters Yards 1.094

Miles Kilometers 1.609 Kilometers Miles 0.621

Sq Inches Sq Centimeters 6.451 Sq Centimeters Sq Inches 0.155

Sq Feet Sq Meters 0.093 Sq Meters Sq Feet 10.764

Sq Yards Sq Meters 0.836 Sq Meters Sq Yards 1.196

Sq Miles Sq Kilometers 2.590 Sq Kilometers Sq Miles 0.386

Acres Sq Hectometers 0.405 Sq Hectometers Acres 2.471

Cubic Feet Cubic Meters 0.028 Cubic Meters Cubic Feet 35.315

Cubic Yards Cubic Meters 0.765 Cubic Meters Cubic Yards 1.308

Fluid Ounces Milliliters 29.573 Milliliters Fluid Ounces 0.034

Pints Liters 0.473 Liters Pints 2.113

Quarts Liters 0.946 Liters Quarts 1.057

Gallons Liters 3.785 Liters Gallons 0.264

Ounces Grams 28.349 Grams Ounces 0.035

Pounds Kilograms 0.454 Kilograms Pounds 2.205

Short Tons Metric Tons 0.907 Metric Tons Short Tons 1.102

Pound-Feet Newton-Meters 1.356 Newton-Meters Pound-Feet 0.738

Pounds per Sq Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch

Miles per Gallon Kilometers per Liter 0.425 Kilometers per Liter Miles per Gallon 2.354

Miles per Hour Kilometers per Hour 1.609 Kilometers per Hour Miles per Hour 0.621
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