tm 5-3805-293-10 motor grader 120m

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M

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TM 5-3805-293-10

TECHNICAL MANUAL

OPERATOR'S MANUAL

FOR

MOTORIZED ROAD GRADERMODEL 120M

(NSN 3805-01-560-2384)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

DECEMBER 2010RQO\/HIW%ODQN

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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 ininjury 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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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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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, andNuclear (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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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.


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.


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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) - 7690-01-474-3533Part Number (PN) - 1709220

Commercial and Government Entity Code (CAGEC) - 11083

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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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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 ArmyElectronic 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 [email protected]. The fax number is DSN 793-0726 or

Commercial (309) 782-0726.

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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 0008Chapter 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 0025Scarifier 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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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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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 areinstructed 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 aConstruction Equipment Operator, Military Occupational Speciality (MOS) 21E.

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CHAPTER 1

GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND

THEORY OF OPERATION

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0001-1

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 andmaintenance 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: [email protected]) 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 bereported 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.

10

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0001-2

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 freeof 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 equipmentin storage.

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0001-3

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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 Preservation0001

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 consideredenvironmentally 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.

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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.

Rotation 0001

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

reduce the maintenance effort.

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 Services01 X

Major Exercise 01 X

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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.

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0001


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.

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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.

(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.

Table 2. Warranty Information.

Warranted

Component

Duration of

Commercial Warranty

Manufacturer

Responsible

Contact

Information

Base Machine (1) 1 Year/Unlimited Hours

(1)

Caterpillar Inc.

Defense and Federal

Products

Phone 309-578-3295

Ground Engaging Tools

(GET)

Not limited by time

Caterpillar Battery (2) 3 Years (2)

Engine Emission

Components (3)

5 Year/3,000 Hours (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

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0001-8

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockwiseDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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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 Reportpsi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 KitTAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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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

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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.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

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


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.

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0002


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


1 Rear Blackout Lights Provide illumination during blackout mode.

2 Rear Work Lights Provide illumination behind machine.

3 Right Rear Access Door Provides access to batteries and refrigerant condenser.

4 Right Front Access Door Provides access to refrigerant compressor

5 Right Front Access Panel Provides access to engine drive belt.

6 Emergency Exit Provides an emergency exit for operator.

7 Work Lights Provide illumination of blade/work area.

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


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.

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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)

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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)

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TM 5-3805-293-10

0003-1

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.

6

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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 fi lter, 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

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ENGINE – CONTINUED

Figure 2. Engine Components. 0003

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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

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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

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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 angleare 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

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CHAPTER 2

OPERATOR INSTRUCTIONS

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0004


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


1 Handhold Provides hand grips for mounting and dismounting machine.

2 Steps Provide stepped platform for mounting and dismounting

machine.

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0004

ALTERNATE EXIT 0004

Figure 2. Alternate Exit. 0004


1 Right Door Provides alternate exit from cab.

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ARTICULATION LOCK PIN 0004

Figure 3. Articulation Lock Pin. 0004


1 Articulation Lock Pin Prevents machine from articulating. Pin shown installed in rear

frame pocket.

2 Spring Rods Pull back on spring rod to release lock pin.

3 Lock Pin Storage Bracket Articulation lock pin stowage location during machine opera-

tion.

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WHEEL LEAN LOCK BOLT 0004

Figure 4. Wheel Lean Lock Bolt. 0004

0004

0004


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.

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DOOR HANDLES AND LATCHES 0004

Figure 5. Door Handles. 0004


1 Outer Door Handle Unlatches door from outside cab.

2 Inner Door Handle Unlatches door from inside cab.

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0004-6

0004

DOOR HANDLES AND LATCHES – CONTINUED

Figure 6. Door Latch and Release. 0004


1 Latch Assembly Secures open door to cab.

2 Remote Latch Release Unlatches door from inside cab.

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TM 5-3805-293-10

0004-8

0004

SEAT BELT 0004

Figure 8. Retractable Seat Belt. 0004


1 Seat Belt (Retractable) Secures operator in seat.

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0004-9

TM 5-3805-293-10 0004

WRIST RESTS, ARM PADS, AND CONTROL PODS 0004

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


1 Wrist Rest Height Adjustment Knob Pull wrist rest height adjustment knob to allow adjustment of

wrist rest. Release knob to lock. Right side shown, left side

similar.

2 Control Pod Fore/Aft Adjustment

Lever

Pull up on lever to allow fore/aft adjustment of control pods.

Release lever to lock. Left side shown, right side similar.

3 Arm Pad Adjustment Knob Turn knob counterclockwise to allow adjustment of arm pads.

Turn knob clockwise to lock. Left side shown, right side similar.

4 Control Pod Vertical Adjustment Knob Turn knob counterclockwise to allow height adjustment of

control pods. Turn knob clockwise to lock. Left side shown,

right side similar.

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TM 5-3805-293-10

0004-10

0004

JOYSTICK CONTROLS 0004

Figure 10. Left Joystick Controls. 0004


1 Downshift Switch Depress switch to downshift to desired gear in forward or

reverse.

2 Wheel Lean Control - LEFT Press button to lean wheels left. Wheels will remain leaning

after button is released.

3 Upshift Switch Depress switch to upshift to desired gear in forward or

reverse.

4 Wheel Lean Control - RIGHT Press button to lean wheels right. Wheels will remain leaning

after button is released.

5 Automatic Articulation Centering

Control

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.

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0004-11

TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED


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

Side

Blade Lower - Push left joystick forward to lower left end of

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.

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0004-13

TM 5-3805-293-10 0004

JOYSTICK CONTROLS – CONTINUED


1 Blade Sideshift Control - LEFT 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.

2 Blade Sideshift Control - RIGHT 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.

3 Blade Lower and Blade Float for Right

Side

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


Extra effort may be necessary to push joystick forward into the

FLOAT position.4 Blade Lift for Right Side Pull right joystick rearward to raise right end of blade. When

joystick is released, blade remains in selected position.


5 Centershift Control - LEFT Push left side of thumb button to move drawbar left. When

button is released, drawbar remains in selected position.

Button returns to HOLD position.

6 Centershift Control - RIGHT Push right side of thumb button to move drawbar right. When

button is released, drawbar remains in selected position.

Button returns to HOLD position.

7 Blade Pitch Control - FORWARD Push top of thumb button to pitch blade forward. When button

is released, blade remains in selected position. Button returnsto HOLD position.

8 Blade Pitch Control - BACKWARD Push bottom of thumb button to pitch blade backward. When

button is released, blade remains in selected position. Button


9 Blade Circle Drive Control 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.


10 Horn Button Press to activate horn.

11 Turn Signal Switch 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.

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0004-17

TM 5-3805-293-10 0004

RIGHT-SIDE CONTROL PANEL 0004

Figure 15. Right-Side Control Panel. 0004


1 Centershift Lock Switch Push bottom of switch to engage centershift lock. Press red

tab and push top of switch to disengage centershift lock.

2 Defroster Fan Switch 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.

3 Blade Cushion Switch Machine not equipped with blade cushion option.

4 Power Port (12V) Remove cap to access port to power 12V electrical equipment

or accessories.

5 Throttle Set/Accel Switch Allows operator to set speed of throttle.

6 Electrical Coolant Switch Push button to turn arctic heater ON. Push button again to turn

OFF.

7 Throttle Hold Mode Switch Allows Operator to set mode for throttle hold function. Mode

options include OFF, AUTOMATIC, and MANUAL.

8 Hazard Flasher Switch Push top of switch to activate hazard flashers. Push bottom of

switch to deactivate.

9 Front and Rear Worklight Switch 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.

10 Headlight Dimmer Switch Push top of switch to activate high beams. Push bottom of

switch to deactivate high beams; low beams remain ON.

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0004-19

TM 5-3805-293-10 0004

HEATING AND AIR CONDITIONING CONTROLS 0004

Figure 17. Heater and Air Conditioning Controls. 0004


1 Fan Speed Switch Turn switch counterclockwise to OFF position. Turn switch

clockwise to operate fan at low, medium, high, and maximumspeeds.

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.

2 Temperature Variable Control Adjust temperature from minimum (full left) to maximum (full

right).

3 Air Conditioning Switch 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.

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TM 5-3805-293-10

0004-20

0004

WIPER/WASHER CONTROLS 0004

Figure 18. Wiper/Washer Controls. 0004


1 Left 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.

2 Front Windshield Wiper/Washer

Control

Operates the same as left door wiper/washer control.

3 Right Door Wiper/Washer Control Operates the same as left door wiper/washer control.

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0004-21

TM 5-3805-293-10 0004

MONITORING SYSTEM 0004

Figure 19. Monitoring System. 0004


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-

cator

Illuminates RED when a system problem is present.

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).

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TM 5-3805-293-10

0004-22

0004

MESSENGER DISPLAY AND IMPLEMENT LOCKOUT SWITCH 0004

Figure 20. Messenger Display and Implement Lockout Switch.0004


1 Messenger Display 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.

2 Implement Lockout Switch 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.

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0004-23

TM 5-3805-293-10 0004

MILITARY LIGHT SWITCH 0004

Figure 21. Military Light Switch. 0004


1 Military Light 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.

2 Mode Switch Used to select desired mode of lighting. Release unlock lever to change modes.

3 Unlock Lever Lift up to unlock mode switch. Returns to locked position when

released.

4 Panel Brightness Switch Not applicable to 120M.

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0004-25/(26 blank)

TM 5-3805-293-10 0004

BATTERY DISCONNECT SWITCH AND SLAVE RECEPTACLE – CONTINUED

Figure 23. Arctic Heater Fuel Shutoff Valve. 0004

END OF WORK PACKAGE


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.

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0005-3

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 !

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TM 5-3805-293-10

0005-4

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 anyWarning 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.



• Shut down engine immediately if engine system indicator or action light indicator comeson. 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.

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0005-5

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 theparking brake is disengaged, and machine is running but not moving. Once the operator returns to the seat, theparking 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 frontwheels. Refer to Joystick Steering in this work package.

END OF TASK

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TM 5-3805-293-10

0005-6

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

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0005-7

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.

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0005-9

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

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TM 5-3805-293-10

0005-10

0005


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

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TM 5-3805-293-10

0005-12

0005


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.

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0005-13

TM 5-3805-293-10 0005


(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 secondarysteering 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.

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TM 5-3805-293-10

0005-14

0005


(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 circledrawbar.

(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.

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0005


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.

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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 engineRPM 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

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0005-20

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

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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 isNOT 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

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0005


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.

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

469-0287

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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

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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 themachine 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 maximumgear, 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 ElectronicTechnician when transmission is in NEUTRAL and the machine is stopped. Changes made are new defaults attime 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 todecrease power to the wheels. A sensor monitors pedal position and varies hydraulic pressure to directionclutches. 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 varyingground 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 loadcondition. If constant stalling occurs, downshifting is advisable.

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

END OF TASK

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0005-26

0005

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

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0005

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

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0005-30

0005

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.

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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 positionwill 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

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TM 5-3805-293-10 0005

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

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0006-2

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

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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

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0006-4

0006

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.


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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.


END OF TASK

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0006-6

0006


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

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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

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0006


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

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TM 5-3805-293-10 0006


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

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0006


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

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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.


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

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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

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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

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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.


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

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7. Lean the front wheels toward the heel.

Figure 28. Leaning Wheels Toward Heel. 0006


Figure 29. Lower Moldboard to Ground. 0006

9. Place the grader in motion.


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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

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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.


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

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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

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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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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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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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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.


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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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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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 willhandle - 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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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.


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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 ditchshould 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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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.


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.”


Figure 51. Positioning Grader. 0006

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NOTE

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

side.





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.


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.


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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.


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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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 pullingto 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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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).


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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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.


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.


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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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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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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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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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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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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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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CAUTION



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.


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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 enginespeed.

• 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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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 Side0006

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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CAUTION



4. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm)above the ground.


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.


NOTE



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.


grader.

13. Circle the moldboard assembly to the right to the desired position.

Figure 81. Setting Blade Position. 0006

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


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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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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Extreme Side Reach 0006

CAUTION



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.


2. Circle the moldboard to 0 degrees to the grader frame and lower the moldboard to approximately 2 in. (50 mm)

above the ground.


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.


NOTE



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.


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.

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TM 5-3805-293-10

0006-48

0006


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

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TM 5-3805-293-10

0007-1

0007


0 0 0 7 OPERATION UNDER UNUSUAL CONDITIONS

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.

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.

INITIAL SETUP

References 0

FM 9-207 0

FM 21-305 0

FM 31-70 0

FM 31-71 0

FM 90-3 0

LO 5-3805-293-13 0

WP 0004 0

WP 0005 0

WP 0013 0

WP 0021 0

WP 0025 0

WP 0025 0

WP 0027 0

14

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TM 5-3805-293-10

0007-2

0007

SLAVE STARTING 0007

WARNING

• When slave starting, use NATO slave cable that does NOT have loose or missinginsulation.

• 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

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0007-3

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








• Shut down engine immediately if engine system indicator or action light indicator comeson. 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.

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TM 5-3805-293-10

0007-4

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 cautionmay 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.








• 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.

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0007-5

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.

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TM 5-3805-293-10

0007-6

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 HEAT0007

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.


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.

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0007-7

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).


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 toRecovery and Towing in this work package.

4. Monitor engine coolant and hydraulic oil temperature gauges on monitor system more frequently duringoperation.

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 allowdust, dirt, or sand to collect on these components as their smooth working surfaces can be damaged by suchabrasive materials.

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TM 5-3805-293-10

0007-8

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.

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0007-9

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 upsidedown 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

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TM 5-3805-293-10

0007-10

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.


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

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0007-11

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.

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0007-12

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 wil l 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 primarysteering 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

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0007-13

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 machinemovement. 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 theparking 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. Damageto equipment may result.

NOTE

• “1F” and “1R” are the only gears available to drive through the parking brake. Upshiftingwill not change selected gear.

• A warning category 3 will activate during machine movement. The event will be logged inMessenger but the alarm should deactivate once the transmission control switch isreturned to NEUTRAL position.

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TM 5-3805-293-10

0007-14

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 beengaged to allow engine to start.

b. Fully depress inching pedal. With parking brake engaged, “1F/1R” will flash on LCD display on monitoringsystem.

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 sincepowertrain is trying to propel machine against engaged parking brake.

e. When desired location is reached, depress inching pedal and move transmission control switch toNEUTRAL position to stop machine.

END OF TASK

END OF WORK PACKAGE

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TM 5-3805-293-10

0008-1

0008


0 0 0 8 STOWAGE AND DECAL/DATA PLATE GUIDE

Stowage, Warning Message Labels, Caution and Notice Message Labels

SCOPE0008

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

14

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TM 5-3805-293-10

0008-2

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

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0008-3

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 readand 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

Start Cables

Explosion Hazard! Improper jumper cable connections can

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.

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0008-4

TM 5-3805-293-10 0008



8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0008-5

TM 5-3805-293-10 0008


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 duringmachine operation may result in serious injury or death.

2 Do Not Weld On the ROPS/FOPSStructure

Structural damage, an overturn, modification, alteration, or improper repair can impair this structure’s protection capabilitythereby voiding this certification.

Do not weld on or drill holes in the structure. This will void thecertification.

This machine has been certified to the standards listed ondecal. 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 seriousburns, injury, or death. To open the cooling system filler cap,stop the engine and wait until the cooling system componentsare cool. Loosen the cooling system pressure cap slowly inorder to relieve the pressure.

4 No Clearance Stay back a safe distance. No clearance for a person in thisarea when the machine turns. Severe injury or death fromcrushing 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 í13°F (í25°C).

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TM 5-3805-293-10

0008-6

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.

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0008-7

TM 5-3805-293-10 0008


Figure 5. Warning Message Label.0008

KEY LABEL INDENTIFICATION 08 WARNING DEFINITION 08

1 CBRN (Chemical, Biological, Radio-

logical and Nuclear).

If CBRN exposure is suspected, all air filter media will be han-

dled by personnel wearing full CBRN protective equipment.

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TM 5-3805-293-10

0008-8

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

Label)

Field Level Maintenance to refer to TM 5-3805-293-23 before

any maintenance is performed on air conditioning system.(Not applicable to operator.)

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0008-9

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) Do not weld or drill on frame. (Not applicable to operator.)

2 Fuel Type Diesel or JP-8 Fuel only

3 Extended Life Coolant Refer to PMCS (WP 0013) before any maintenance is

performed on cooling system.

4 24V Slave Grader equipped with a 24V slave receptacle.

5 Articulation Bearing Identifies location of grease points for articulation bearings.

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0008-11

TM 5-3805-293-10 0008

DATA PLATE 0008

Figure 9. Data Plate. 0008


1 Shipping Data Plate Provides tiedown, lift, and shipping weight information.

2 Lubrication Data Plate Provides lubrication information for machine systems.

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TM 5-3805-293-10

0008-12

0008

UNIQUE IDENTIFICATION (UID) LABELS 0008

Figure 10. UID Labels. 0008

Figure 11. UID Labels – Continued. 0008

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0008-13/(14 blank)

TM 5-3805-293-10 0008

UNIQUE IDENTIFICATION (UID) LABELS – CONTINUED



END OF WORK PACKAGE

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TM 5-3805-293-10

CHAPTER 3

TROUBLESHOOTING PROCEDURES

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TM 5-3805-293-10

0009-1

0009


0 0 0 9 TROUBLESHOOTING INTRODUCTION

GENERAL 0009

1. This chapter provides information for identifying and correcting malfunctions that you may find while operatingthe 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.

4

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0009-2

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.

• Alert indicator activated. 1. Check Messenger system for alert

message.

2. Follow instructions on Messenger

system.

Category 2 Alert

A change in machine operation is

required.

• Alert indicator activated.

• Action light activated.

1. Check Messenger system for alert

message.


system.

Category 2S Alert

Immediate change in machine

operation is required.



• Action alarm sounds at a

steady rate.

1. Check Messenger system for alert

message.


system.

Category 3 Alert

Immediate need to shut down

machine.



• Action alarm sounds at a

pulse rate.

WARNING

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 alertmessage.


system.

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0009-3/(4 Blank)

TM 5-3805-293-10 0009

MONITORING SYSTEM WARNINGS – CONTINUED

Figure 14. Alert Indicators. 09


1 Battery Charge Alert Indicator Illuminates when a problem with machine voltage or alternator

is present.

2 Electric Coolant Heater Alert Indicator Illuminates when coolant heater is activated.

3 Engine System Alert Indicator Illuminates when an engine problem is present.

4 Implement System Alert Indicator Illuminates when an implement system problem is present.

5 Primary Steering Alert Indicator Illuminates when a steering system problem is present.

6 Action Light Alert Indicator Illuminates when a problem occurs with machine.

7 Parking Brake Indicator Illuminates when parking brakes are engaged.

8 Transmission System Alert Indicator Illuminates when a transmission system problem is present.

9 Secondary Steering System Alert Indi-cator Illuminates RED when a system problem is present.Illuminates GREEN when system is activated or being tested.

10 Brake System Indicator Illuminates when a general fault occurs in brake system.

11 Operator Not Present Alert Indicator Illuminates when under specific conditions operator is not in

cab.

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TM 5-3805-293-10

0010-1

0010


0 0 1 0 OPERATOR TROUBLESHOOTING SYMPTOM INDEX

Malfunction/Symptom Troubleshooting Procedure Page

ELECTRICAL SYSTEM00010

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

ENGINECoolant 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

2

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TM 5-3805-293-10

0011-1

0011


0 0 1 1 TROUBLESHOOTING PROCEDURES

Electrical System, Engine, Hydraulic System, Steering, Transmission, All-Wheel Drive

INITIAL SETUP

Materials/Parts 0

Goggles, Industrial (WP 0032, Item 10) 0

Gloves, Chemical and Oil Protective (WP

0032, Item 9) 0

References 0

LO-5-3805-293-13 0

WP 0004 0

WP 0005 0

WP 0013 0

WP 0014 0

WP 00180

WP 0019 0

References - Continued 0

WP 0020 0

WP 0022 0

WP 0023 0

WP 0025 0

Equipment Conditions 0

Machine parked on level ground(WP 0005) 0

Blade and scarifier lowered to ground(WP 0005) 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.





14

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0011-2

TM 5-3805-293-10 0011

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.


Step 2. Check for blown fuse(s) at fuse panel.



4. DEFROSTER FAN INOPERATIVE.

Check for blown fuse at fuse panel.



5. DIFFERENTIAL LOCK INOPERATIVE.




6. DIRECTIONAL TURN SIGNALS INOPERATIVE.

Step 1. Ensure STOP LIGHT or SER DRIVE function has been selected on military light switch (WP

0004).



Step 2. Check electrical connector at lamp assembly.

a. Reconnect connectors, if required.

b. If connectors are okay, go to Step 3.



If problem persists, notify Field Level Maintenance.

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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0011-3

TM 5-3805-293-10 0011


7. DOME LAMP INOPERATIVE.


0004).



Step 2. Check for burned out or defective bulb.

a. Replace bulb (WP 0020).





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.


Step 2. Check lights for disconnected or damaged connectors.


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.


Step 2. Check lights for disconnected or damaged connectors.



10. HEATER AND AIR CONDITIONING INOPERATIVE.




11. HIGH BEAMS INOPERATIVE.

a. Ensure SER DRIVE function has been selected on military light switch (WP 0004).


MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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TM 5-3805-293-10

0011-4

0011


12. HORN INOPERATIVE.


0004).






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.




14. MONITOR SYSTEM INOPERATIVE.




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

INOPERATIVE.


0004).






Step 3. Check wiring harness connector is properly connected to worklight.

If fault is found, notify Field Level Maintenance.

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0011-5

TM 5-3805-293-10 0011


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.


Step 2. Check lights for disconnected connections or damage.



17. TAILLIGHTS INOPERATIVE.

Ensure SER DRIVE function has been selected on military light switch (WP 0004).

a. Select SER DRIVE.


18. WINDSHIELD WIPER, LEFT DOOR WIPER, OR RIGHT DOOR WIPER INOPERATIVE.




MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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TM 5-3805-293-10

0011-6

0011

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 apressurized 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.


Step 1. Check coolant level in coolant tank (WP 0013).

a. Fill coolant tank to specifications (WP 0013).


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.

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0011-8

0011


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.


Step 2. Verify battery disconnect switch is turned to ON position.

a. Turn battery disconnect switch to ON position.


Step 3. Check circuit breakers (WP 0019).

a. Reset circuit breakers (WP 0019).


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).


Step 3. Check for water in fuel (WP 0013).

a. Drain fuel/water separator (WP 0022).


6. ENGINE STARTS BUT DIES.




Step 2. Check for water in fuel (WP 0013).

a. Drain fuel/water separator (WP 0022).


7. EXCESSIVE EXHAUST SMOKE AT NORMAL OPERATING TEMPERATURE.

Check air filters (WP 0014).



MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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0011-9

TM 5-3805-293-10 0011


8. EXCESSIVE OIL CONSUMPTION.

Step 1. Check for misreading of oil level.

a. Accurately measure oil level.


Step 2. Check air filters (WP 0014).



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.





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 fi lters (WP 0014).



10. LOW ENGINE OIL PRESSURE.

Check engine oil level.

a. Fill oil to specification (LO 5-3805-293-13).


MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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TM 5-3805-293-10

0011-10

0011

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.


Step 2. Check hydraulic fluid level (LO 5-3805-293-13).

a. Add hydraulic fluid as necessary (LO 5-3805-293-13).


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.





MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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0011-11

TM 5-3805-293-10 0011

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).



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).



4. MACHINE TURNS SLOWLY IN BOTH DIRECTIONS AFTER REACHING OPERATING TEMPERATURE.

Check hydraulic oil level (LO 5-3805-293-13).



MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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TM 5-3805-293-10

0011-12

0011

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).



6. STEERING IS ERRATIC.




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).


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).


Step 2. Check circuit breakers (WP 0018).

a. Reset circuit breakers (WP 0018).


MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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0011-13/(14 blank)

TM 5-3805-293-10 0011

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

MALFUNCTION

TEST OR INSPECTION

CORRECTIVE ACTION

0.

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TM 5-3805-293-10

CHAPTER 4

PMCS INSTRUCTIONS

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

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

GENERAL00012

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 operationor 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.

4

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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.

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

INITIAL SETUP

Tools and Special Tools0

Basic Issue Items (WP 0031) 0

Materials/Parts 0

Antifreeze (WP 0032, Item 1) 0

Cleaning Compound, Solvent, Type III (WP

0032, Item 2) 0

Cleaning Compound, Windshield (WP 0032,

Item 3) 0

Detergent, General Purpose, Liquid (WP

0032, Item 4) 0

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

Item 5) 0

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

Fuel, Turbine, Aviation (WP 0032, Item 8) 0

Grease, Automotive and Artillery (GAA) (WP

0032, Item 11) 0

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

Oil, Lubricating, OE/HDO-30 (WP 0032, Item

13) 0

Oil, Lubricating, OE/HDO-15W/40 (WP 0032,

Item 15) 0

Oil, Lubricating, OEA Arctic (WP 0032, Item

16) 0

Rag, Wiping (WP 0032, Item 17) 0

0

References0

WP 0004 0

WP 0005 0

WP 0010 0

WP 0014 0

WP 0015 0

WP 0017 0

WP 0019 0

WP 0021 0

WP 0022 0

WP 0024 0

WP 00260

WP 0027 0

WP 0032 0

LO 5-3805-293-13 0

Equipment Conditions 0

Machine parked on level ground (WP 0005) 0

Blade and scarifier lowered to ground

(WP 0005) 0

Parking brake engaged (WP 0004) 0

56

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Table 1. Preventive Maintenance Checks and Services (PMCS)

with Lubrication Information.

ITEMNO. INTERVAL

MAN-HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURENOT FULLY MISSION

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

evidence of leakage or damage.

Class III leaks or damage

that would impair operation

are evident.

2 Before All-Wheel

Drive Hoses

Check all-wheel drive (AWD) hoses

and fittings for damage or leaks.



are evident.

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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

underinflation.

Tire pressure appears low.

4 Before Lights Check left front work light,

headlight, front turn signal light,

and blackout light for missing or

damaged components.

Missing or damaged

components if required for

mission.

5 Before Fuel Tank

Filler Cap

Ensure fuel tank filler cap is

present and secure.

Missing fuel tank filler cap.

Figure 1. Fuel Tank Filler Cap. 0013

6 Before Below

Operator

Compartment

Check hoses, cables, and

connections below left side of

operator compartment for damage

or leaks.

Class III oil or hydraulic fluid

leaks are present. Any fuel

leakage is evident. Damage


is evident.


with Lubrication Information - Continued.

ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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7 Before Arctic Heater

(if equipped)

Check arctic heater fuel line

(Figure 2, Item 1), coolant hoses

(Figure 2, Item 2), grommets

(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.

Class III leaks or damaged

or missing components if

required for mission.

Figure 2. Arctic Heater. 0013

8 Before 0.2 Engine Oil

Level Check

a. Open left front access door.

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

clean and reinstall. Remove oillevel gauge and check level of oil.

Maintain oil level between the

marks on oil level gauge (Figure 3,

Item 3).

Oil level is below or above

crosshatch area on gauge,or fill cap missing.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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TM 5-3805-293-10 0013

8

(Cont.)

Before 0.2 Engine Oil

Level Check

d. Add oil as required through filler

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



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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9 Coolant Level

ChecksWARNING

• 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, thenremove 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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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9

(Cont.)

Before Coolant Level

Checks

Check coolant level in coolant tank

(Figure 4, Item 1). Maintain level

between FULL mark and ADD

mark on coolant tank.

Coolant level is below ADD

mark.

Figure 4. Coolant Tank Level. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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10 Before Transmission/

Differential Oil

Level Check

a. Clean area around transmission

oil level gauge/fill cap (dipstick).

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,

and check level of oil.

Oil level does not register

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



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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11 Before Hydraulic TankSight Gauge

a. Open left rear access door.

b. Clean area around hydraulictank sight gauge.

c. Check oil level is visible in sightgauge.

NOTE

Proceed to the following steps only if oil level is not visible

in sight gauge.

d. Operate machine until oil iswarm (WP 0005).

Oil is not visible on sightgauge, oil level is above

MAX mark on sight gauge,

or fill cap missing.

e. Clean area around hydraulic oilfiller cap.

f. Maintain oil level above the MINmark on sight gauge.

g. Add oil (WP 0032, Items 18 or 21) as required through hydraulicoil filler cap. Refer to LO 5-3805-

293-13 for proper grade of oilbased on ambient temperature.

Figure 6. Hydraulic Oil Level Check. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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12 Before NATO

Receptacle

a. Ensure NATO slave receptacle

cover is installed.

b. Close left rear access door.

13 Before Left Rear Tires WARNING



result in serious injury or death to personnel, or damage to

equipment.


inflated in a safety cage. Notify Field Level Maintenance.Failure to follow this warning may result in serious injury or



underinflation.


REAR

14 Before Rear of

Machine

a. Check for damage to rear

blackout light, taillights, turn signal

lights, backup lights and rear

worklight.

Missing or damaged


mission.

b. Check radiator grille, backupalarm, and towing pin for debris

and damage.

Missing or damagedcomponents if required for

mission.

c. Check under engine

compartment for evidence of fluid

leakages such as oil, coolant, fuel,

and hydraulic fluid.



leakage is evident.

d. Check rear of machine for

obvious damage that would impair

operation.

Missing or damaged


mission.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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RIGHT SIDE

15 Before Right Rear

TiresWARNING




equipment.




death to personnel or damage to equipment.

Visually check tires for under-

inflation.


16 Before Overall View Check right side of machine for

evidence of leakage or damage.



are present.

17 Before Right Rear

Access Door

a. Open right rear access door.

b. Visually check for loose,

damage, cracked components, or evidence of leaks.

c. Close right rear access door.



are evident.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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

b. Remove ether cylinder and

shake to check if cylinder is empty

(WP 0021). Install new cylinder if

required (WP 0021).

Missing or damaged


mission.

c. If no ether cylinder is present,

ensure cap is installed on ether

valve.

Figure 7. Ether Cylinder. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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TM 5-3805-293-10 0013

19 Before Engine

Compartment

a. Visually check for loose,

damage, cracked components, or

evidence of leaks.

b. Close right front access door.



are evident.

20 Before Below

Operator

Compartment

a. Check hoses and connections

below right side of operator

compartment for damage or leaks.

b. Check cables for fraying or

damage.



leakage is evident. Damage


is evident.

21 Before Right Front

TireWARNING




equipment.






underinflation.


22 Before Lights Check right front work light,

headlight, blackout drive light,

blade work light, and front turn

signal light for missing or damaged

components.

Missing or damaged

components if necessary

for mission.

CAB

INTERIOR

23 Before Battery

Disconnect

Switch

Turn battery disconnect switch to

ON position.

24 Before Fire

Extinguisher

a. Visually check for missing or

damaged fire extinguisher. Ensure

it is securely stowed in mounting

bracket.

Fire extinguisher is missing

or damaged.

b. Check gauge for pressure

reading in green area on gauge.

Pressure gauge needle is in

red area.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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0013

24

(Cont.)

Before Fire

Extinguisher

c. Check for damaged or missing

seal.

Seal is broken or missing.

d. Inspect fire extinguisher

inspection tag.

Inspection date is notcurrent and/or tag ismissing.

25 Before Operator Seat Check seat and seat belt mounting

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).

Seat belt is damaged.

Figure 8. Seat Belt Inspection. 0013

26 Before Rearview

Mirror and

Side View

Mirrors

Check and adjust inside rearview

mirror. With an assistant, check

and adjust side view mirrors.

27 Before Lights With an assistant, check operationof lights (service and blackout light,brake lights, turn signals and worklights) (WP 0005).

Any lights do not function, if required for mission.

28 Before Wipers andWashers (if

equipped)

Operate all wipers and washers toverify correct operation (WP 0004).

Wipers and washers notoperating if required for mission.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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29 Before Backup Alarm

and Horn

a. Verify that backup alarm

functions when transmission is

placed in R (Reverse) (WP 0005).

Backup alarm does not

function.

b. Check operation of horn (WP

0005).

Horn does not function.

NOTE

Monitor system self-diagnostic test takes approximately

10 seconds to complete.

30 Before Monitor System

Indicators and

Gauges

a. Turn engine start switch fromOFF position to ON position (do not

start engine) to initialize self-

diagnostic test.

Fails to enter diagnostictest.

b. Monitor the following:

1. All gauges must sweep to far

right position, then return.

Any gauge does not move.

Figure 9. Monitor System Display - Gauges. 0013

2. All alert indicators mustcome on momentarily.

Any alert light does notcome on.

3. All segments in LCD display

must come on momentarily.

LCD display segment(s)

inoperative

4. The action alarm must

sound.

Action alarm does not

sound.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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31 Before Left and Right

Blade Float

Indicators

WARNING

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

most forward detent (WP 0005).

Blade float indicators should be ON

in display.

Blade float indicators do not

come ON.

32 Before Action Light

Indicator

a. Run engine at low idle (WP

0005).

b. Monitor action light indicator in

display.

c. If action light indicator is ON,

machine needs service.

Action light indicator is ON.

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

0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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33 Before Messenger

Display

With engine running, observe the

Messenger display.

Messenger displays error

message or Messenger is

not operating.

Figure 11. Messenger Display. 0013

34 Before Differential

Lock

Push control button on right

joystick. Indicator light should go

ON (WP 0004).

Differential lock indicator

inoperative.

35 Before Hydraulic

Controls

Perform a functional check of all

hydraulic systems: blade lift,

centershift, circle drive, blade tilt,

steering, wheel lean, and scarifier

(WP 0005).

Class III oil leak is evident.

Any hydraulic system or

function does not operate

properly.

36 Before Brake

Accumulator

a. Start engine and run for no less

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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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0013

36

(Cont.)

Before Brake

Accumulator

e. If brake system indicator light

illuminates with less than five

applications, notify Field Level

Maintenance.

Brake system indicator light

illuminates with less than

five applications.

37 Before Pedals Check accelerator pedal, service

brake pedal, and transmission

modulator control pedal for binding

and obstructions.

Pedal binds or does not

operate properly.

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

38 During Brakes Check service brakes for pulling,

grabbing, or reduced braking

capacity.

Brakes pull, grab, or do not

operate properly.

39 During Steering Check for smooth, controlled

steering without pulling or drifting.

Steering is erratic.

40 During Drive Train Monitor grader operation for

unusual noise or vibrations from

engine, transmission, drive shafts,

axles, and wheels.

Unusual noises or

vibrations are present.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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41 During Blade and

Scarifier

Monitor blade and scarifier

operations for unusual noise or

vibrations.

Unusual noises or

vibrations present.

42 During Overall

Leakage

Watch for evidence of fluid

leakage.



leakage is evident.

43 During Instrument

Panel

a. With machine fully warmed up,

monitor indicators and gauges and

Messenger Display.

Gauges and warnings

indicate an abnormal

reading.

b. If action light indicator is

flashing, troubleshoot system (WP0010).

Any flashing of action light

indicator.

44 During Air

Conditioner,

Heater and

Defroster Fan

Check air conditioner, heater and

defroster fan for correct operation.

Damaged or does not

operate if required for

mission.

45 After Overall View NOTE

Ensure machine is clean in order to facilitate

performance of PMCS inspections.

a. Check under machine for

evidence of fluid leakages such asoil, coolant, fuel, or hydraulic fluid.


leaks are present. Any fuelleakage is evident.

b. Check machine for obvious

damage that would impair

operation.

Damage that would impair

operation is evident.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

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LEFT SIDE

46 After Left Front

Wheel and

Tire

WARNING




equipment.

• If tire pressure is more than 4 psi low, tires must beinflated in a safety cage. Notify Field Level Maintenance.



a. Check tires for cuts or bulges in

tread or sidewall area. Check for

uneven wear and foreign material

embedded in tread or sidewall

area.

Tire has cuts, bulges, or

foreign material in tread or

sidewall area or other


operation.

b. Clean area around valve stem,

then remove valve stem cap.

Valve stem damaged.

c. Check tire inflation pressure

with tire pressure gauge. Refer to

WP 0002 for proper tire inflation

pressures.

Tire inflation pressure more

than 4 psi low.

d. Check for loose or missing lug

bolts.

Loose, or two or more

missing lug bolts.

e. Check wheel for damage. Wheel damaged.

47 After Steering a. Check steering linkage for

cracks, distortion, or damage.

Cracks or distortion in

steering linkage that would

impair operation.

b. Check left front steering cylinder

and hoses for damage or leaks.


that would impair operation.48 After Drawbar a. Check drawbar and drawbar

pivot point for damage.

Class III leaks or damagethat would impair operation.

b. Check all hoses and fittings for

leaks.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-21

TM 5-3805-293-10 0013

49 After Scarifier Check scarifier frame, link sockets,

and teeth for excessive wear (WP

0026 and WP 0027), damage, or

missing components.

Damage that would impair operation, or missing sixscarifier teeth if required for mission.

50 After Hydraulic

Cylinders

a. Check scarifier hydraulic

cylinder and hoses for damage or

leaks.


b. Check left blade lift cylinder and

hoses for damage or leaks.


c. Check centershift cylinder and



that would impair operation.

51 After Circle Drive Check all circle drive and circle

drive components for leaks,

damage or debris. Remove debris.


52 After Blade, Cutting

Edges, and

End Bits

a. Check entire blade for damage

or distortion.

Damage or distortion.

b. Check all cutting edges and end

bits for damage or loose bolts.

Damage or loose bolts.

c. Check all cutting edges and end

bits for excessive wear (WP 0019).

Cutting edge or end bits are

worn to within 3/4 in.

(19 mm) of blade.

d. Check sideshift cylinder for

debris, damage, or leaks. Remove

debris.



53 After Blade Work

Lights

Ensure blade work lights are

present and securely mounted.

Missing or damaged


for mission.

54 After Left Door Check left door for damage or

missing components.

Missing or damaged


for mission.

55 After Left Mirror andStep Check left side mirror and step for damage or missing components. Missing or damagedcomponents if necessary

for mission.

56 After Rollover

Protective

Structure

(ROPS)

Check ROPS for damage and

loose or missing mounting bolts.

Loose or missing ROPS

bolts or damage to

structure.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-22

0013

57 After RefuelingWARNING

• 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 exposedskin 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

filler cap for damage or leaks.

Any fuel leaks or damage

are noted.

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



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-23

TM 5-3805-293-10 0013

57

(Cont.)

After Refueling b. Remove filler cap. Inspect filler

cap, gasket, and screen for

damage.

Filler cap, gasket or screen

is missing or damaged.

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

Lock Pin

Check articulation lock pin is

present in lock pin storage bracket.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-24

0013

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

Secondary Air

Filters

a. Remove air filter cover.

b. Ensure primary air filter is

present.

c. Remove primary and secondary

air filters.

Missing or damaged air

filter components.

d. Inspect and clean or replace

filters (WP 0014).

e. Install secondary and primaryair filters.

f. Install air filter cover.

Figure 15. Air Filters and Cover. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-25

TM 5-3805-293-10 0013

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

0022).

Excessive amounts of water

in fuel.

Figure 16. Fuel/Water Separator. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-26

0013

61 After 0.2 Transmission/

Differential Oil

Level Check

a. Clean area around transmission

oil level gauge/fill cap.

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

Level Check


b. Clean area around engine oillevel gauge (dipstick) (Figure 18,

Item 2) and fill cap (Figure 18, Item

1).

Class III oil leak or damageis evident.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-27

TM 5-3805-293-10 0013

62

(Cont.)

After 0.2 Engine Oil

Level Check

c. Add oil (WP 0032, Items 18 or

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.

Fill cap missing.

Figure 18. Engine Oil Level Check. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-28

0013

63 After Arctic Heater

(if equipped)

Check arctic heater fuel line

(Figure 19, Item 1), coolant hoses

(Figure 19, Item 2), grommets

(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.

Class III leaks or damaged

or missing components if

required for mission.

Figure 19. Arctic Heater. 0013

64 After Left Rear

Wheels and

Tires

WARNING




equipment.





a. Check tires for cuts or bulges intread or sidewall area. Check for uneven wear and foreign materialembedded in tread or sidewallarea.

Tire has cuts, bulges, or foreign material in tread or sidewall area or other damage that would impair operation.

b. Clean area around valve stems,then remove valve stem caps.

Valve stem damaged.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-29

TM 5-3805-293-10 0013

64

(Cont.)

After Left Rear

Wheels and

Tires

c. Check tire inflation pressurewith tire pressure gauge. Refer toWP 0002 for proper tire inflationpressures.

Tire inflation pressure morethan 4 psi low.

d. Check for loose or missing lugbolts.

Loose or two or moremissing lug bolts.

e. Check wheels for damage. Wheel damaged.

65 After Left Tandem

Housing

Check for damage and leaks from

tandem housing.

Class III oil leak or damage

is evident.

66 After Coolant Level

Checks WARNING

• DO NOT service cooling system unless engine has beenallowed to cool down. This is a pressurized coolingsystem and escaping steam or hot coolant will causeserious burns.

• DO NOT remove cooling system radiator cap whenengine is hot. Allow engine to cool down. Loosen cap tofirst stop and let any pressure out of cooling system, thenremove cap. Failure to follow this warning may causeserious burns.

• Wear effective eye, hand, and skin protection whenhandling coolants. Failure to do so may cause injury topersonnel.

CAUTION

• Do not add water to pre-mixed antifreeze. If water isadded to pre-mixed antifreeze, it will be diluted and will notprovide 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 notrequire mixing with water.

• Traditional antifreeze requires mixing with an equalamount of water. Mix antifreeze and water before addingto machine cooling system to ensure proper 1:1 ratio isused.

• It is allowable to mix traditional and pre-mix antifreezetypes in the same cooling system.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-30

0013

66

(Cont.)

After Coolant Level

Checks

a. Check coolant level in coolant

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

Sight Gauge

a. Open left rear access door.

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 21) as required through filler tube.

Refer to LO 5-3805-293-13 for

proper oil based on ambient

temperature.

Fill cap missing.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-32

0013

69

(Cont.)

After Rear of

Machine

c. Check under enginecompartment for evidence of fluidleakages such as oil, coolant, fuel,and hydraulic fluid.

Class III oil or hydraulic fluidleaks are present. Any fuelleakage is evident. Damagethat would impair operationis evident.

d. Check machine for obviousdamage that would impair operation.

Damage that would impair operation is evident.

e. Check rear support bracketsmounted on rear bumper for damaged or missing components.

Missing or damagedcomponent if required for mission.

f. Check for presence of hitch pin. Missing or damaged

component if required for

mission.

RIGHT SIDE

AND FRONT

70 After Refrigerant

Condenser

and Hydraulic

Oil Cooler


b. Check condenser and cooler for

debris and damage.

Refrigerant condenser and/

or hydraulic oil cooler damage.




ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-33

TM 5-3805-293-10 0013

70

(Cont.)

After Refrigerant

Condenser

and Hydraulic

Oil Cooler

Figure 22. Refrigerant Condenser and Hydraulic Oil Cooler. 0013

71 After Right Rear

Wheels and

Tires

WARNING




equipment.









area.





operation.

b. Clean area around valve stems,

then remove valve stem caps.

Valve stem damaged.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-34

0013

71

(Cont.)

After Right Rear

Wheels and

Tires




pressures.


than 4 psi low.


bolts.

Loose or two or more

missing lug bolts.

e. Check wheels for damage. Wheel damaged.

72 After Right

Tandem

Housing

Check for damage and leaks from

right side tandem housing.

Class III oil leak or damage

is evident.

73 After Right Front

Access Door

Visually check exhaust system, air

intake system components, and

turbocharger air tubes for

looseness, damage, or missing

components.

Missing, damaged, or loose

components.

74 After Frame

Articulation

Point Area

WARNING

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

between moving components of frame articulation point. Remove

obstructions and check for

damage.


operation is evident.

75 After Rollover

Protective

Structure

(ROPS)

Check ROPS for damage and

loose or missing mounting bolts.

One loose or missing

ROPS bolt or damage to

structure.

76 After Right Door Check right door for damage or

missing components.

Missing or damaged


for mission.

77 After Right Mirror Check right side mirror for damage

or missing components.

Missing or damaged

component.

78 After Blade Work

Lights

Ensure blade work lights are

present and securely mounted and

not damaged.

Work lights damaged or

missing if required for

mission.

79 After Hydraulic

Cylinders

a. Check right lift cylinder and






ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-35

TM 5-3805-293-10 0013

79

(Cont.)

After Hydraulic

Cylinders

b. Check centershift cylinder and




c. Check sideshift cylinder and




80 After Circle Drive a. Check all circle drive

components for damage or debris.

Remove debris.

Damage to circle drive that

would impair operation.

b. Check circle drive for damage

or leaks.



81 After Scarifier Check scarifier frame, link rod, andteeth for excessive wear, damage,

or missing components (WP 0026,

WP 0027).

Damage that would impair operation or missing six

scarifier teeth, if required for

mission.

82 After Drawbar a. Check drawbar and drawbar

pivot point for damage.


operation.

b. Check all hoses and fittings for

damage or leaks.



83 After Steering a. Check steering linkage for

cracks, distortion, or damage.

Cracks or distortion to

steering linkage that would

impair operation.

b. Check right front steering

cylinder and hoses for damage or

leaks.



84 After Right Front

Wheel and

Tire

WARNING




equipment.

• If tire pressure is more than 4 psi low, tires must beinflated in a safety cage. Notify Field Level Maintenance.







area.





operation.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-36

0013

84

(Cont.)

After Right Front

Wheel and

Tire

b. Clean area around valve stems,

then remove valve stem caps.

Valve stem damaged.




pressures.


than 4 psi low.


bolts.

Loose, or two or more

missing lug bolts.

e. Check for damage. Wheel damaged.

85 After 0.2 Circle Drive

Pinion Teeth

a. Clean dirt and old lubricant from

circle drive pinion teeth and from

blade circle.

b. Check pinion teeth and blade

circle for missing or damaged gear

teeth.

Teeth missing or damaged

if required for mission.

c. Using GAA (WP 0032, Item 16),

lubricate IAW LO 5-3805-293-13.

Figure 23. Circle Drive Lubrication. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-37

TM 5-3805-293-10 0013

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

Every 100

Engine

Hours

Inside Cab Air

Filter WARNING


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


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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-38

0013

87

(Cont.)

Biweekly or

Every 100

Engine

Hours

Inside Cab Air

Filter

a. Loosen two thumb screws

(Figure 25, Item 1) on filter cover

(Figure 25, Item 2).

Filter missing if required for

mission.

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



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-39

TM 5-3805-293-10 0013

88 Biweekly or

Every 100

Engine

Hours

Secondary

SteeringWARNING

Ensure immediate area around machine, specifically in

front of machine, is free of all personnel. Failure to follow


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, andthen 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,

Item 2) is illuminated after

secondary steering switch is

released, test has failed. Notify


Secondary steering fails

test.

Figure 26. Secondary Steering Test. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-40

0013

LEFT SIDE

89 Biweekly or

Every 100

Engine

Hours

Outside Cab

Air Filter WARNING


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


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

Every 100

Engine

Hours

Outside Cab

Air Filter

a. Loosen thumb screw (Figure

27, Item 3) and open outside cab

air filter access cover (Figure 27,

Item 2).

Filter missing if required for

mission.

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 pleatsor 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).



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-41

TM 5-3805-293-10 0013

89

(Cont.)

Biweekly or

Every 100

Engine

Hours

Outside Cab

Air Filter

g. Tighten thumb screw (Figure

27, Item 3).

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

Every 100

Engine

Hours

Fuel Tank

Water and

Sediment

a. Articulate machine RIGHT, then

shut off engine (WP 0005).



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-42

0013

90

(Cont.)

Biweekly or

Every 100

Engine

Hours

Fuel Tank

Water and

Sediment

b. Place a suitable container under

fuel tank.

c. Open the drain valve and allow

water and sediment to drain.

Drain valve damaged or

tank contains excessive

water or sediment. Notify


d. Close drain valve.

e. Start engine. Center machine

articulation, then shut off engine(WP 0005).

Figure 28. Fuel Tank Drain. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-43

TM 5-3805-293-10 0013

RIGHT SIDE

AND REAR

91 Monthly BatteriesWARNING

• To avoid injury, eye protection and acid-resistant glovesmust 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.


b. Check battery holddown for

looseness or damage.

Holddown is loose or

damaged.

c. Inspect battery for a cracked

case and evidence of leaking.

Battery case is cracked or

leaks are evident.

d. Check for missing, broken, split,

or frayed battery cables.

Damage is noted.

e. Check for damaged battery

posts.

Damage is noted.

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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-44

0013

91

(Cont.)

Monthly Batteries g. Close right rear access door.

92 Monthly Arctic

Batteries (if

equipped)

WARNING

• To avoid injury, eye protection and acid-resistant glovesmust be worn when working around batteries. DO NOTsmoke, 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 jewelrysuch as rings, ID tags, watches, and bracelets. If jewelryor a tool contacts a battery terminal, a direct short willresult in instant heating, damage to equipment, and injuryto personnel.

• Sulfuric acid contained in batteries can cause seriousburns. If battery corrosion or electrolyte makes contactwith skin, eyes, or clothing, take immediate action to stopthe 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 aclean, dry rag.

a. Disengage two arctic batterycover latches, and with the aid of

an assistant, remove cover.

b. Check battery holddowns for



missing.

c. Inspect batteries for cracked

cases and evidence of leaking.

Battery case(s) cracked or

leaks are evident.


or frayed battery cables or

connectors.

Damage is noted.


posts.

Damage is noted.

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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-45

TM 5-3805-293-10 0013

92

(Cont.)

Monthly Arctic

Batteries (if

equipped)

g. With the aid of an assistant,

install cover, then engage two

latches.

93 Monthly All Systems -

Machine

Exercise

WARNING

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 fromfull 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.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-46

0013

93

(Cont.)

Monthly All Systems -

Machine

Exercise

d. Move machine and operate all

controls through full motion, to

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

sockets for wear (WP 0015).

Cylinder sockets in need of

adjustment if required for

mission.

7. Check centershift cylinder

sockets for wear (WP 0017).

Cylinder sockets in need of


mission.

8. Check scarifier link sockets

for wear (WP 0026).

Link sockets in need of


mission.

9. Check moldboard wear

strips (WP 0024).

Moldboard wear strips worn

if required for mission.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-47

TM 5-3805-293-10 0013

RIGHT SIDE

AND REAR

94 Initial 500

Engine

Hours (or

at first oil

change)

Batteries and

Battery CablesWARNING

• To avoid injury, eye protection and acid-resistant glovesmust be worn when working around batteries. DO NOTsmoke, 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 jewelrysuch as rings, ID tags, watches, and bracelets. If jewelryor a tool contacts a battery terminal, a direct short willresult in instant heating, damage to equipment, and injuryto personnel.



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 tofollow this caution may result in damage to equipment.


b. Check battery holddown for


Holddown is loose or damaged.

c. Inspect battery for a crackedcase and evidence of leaking.

Battery case is cracked or leaks are evident.

NOTE

Original equipment batteries are maintenance-free, and

do not have removable caps.


or frayed battery cables.

Damage is noted.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-48

0013

94

(Cont.)

Initial 500

Engine

Hours (or

at first oil

change)

Batteries and

Battery Cables


posts.

Damage is noted.

f. If equipped with non-maintenance-free batteries, checkelectrolyte level in each cell. If levelis low, fill with distilled or cleandrinking water to bottom of filler opening. Close right rear access

door.95 Initial 500

Engine

Hours (or

at first oil

change)

Arctic

Batteries (if

equipped)

WARNING

• To avoid injury, eye protection and acid-resistant glovesmust be worn when working around batteries. DO NOTsmoke, 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 jewelrysuch as rings, ID tags, watches, and bracelets. If jewelry

or a tool contacts a battery terminal, a direct short willresult in instant heating, damage to equipment, and injuryto personnel.



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 tofollow 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



missing.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-51

TM 5-3805-293-10 0013

97

(Cont.)

Every 500

Engine

Hours or 3

Months

Service Brake

Holding Ability

c. Raise blade slightly (WP 0004).

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

modulator control. Machine should

not move and engine should stall.

Service brakes do not hold.

98 Every 500

Engine

Hours or 3

Months

Parking Brake

Holding AbilityWARNING

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

Level Maintenance.

Parking brake does not

hold.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-52

0013

99 Every 500

Engine

Hours or 3

Months

Fuel System

Prime


b. Turn engine start switch to ON

position for 2 minutes.

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

of fuel after 2 minutes, notify FieldLevel Maintenance.

Fuel system does not

prime.

f. Close left front access door.

100 Every 500

Engine

Hours or 3

Months

Exhaust

System

Engine and exhaust system components may be

extremely hot after engine is shut down. Do not touch any

part of the exhaust system until engine has cooled down

sufficiently. Failure to follow this warning may result in

injury to personnel.

a. Open right front access door.

b. Check exhaust system pipes,

clamps, and muffler for looseness,

leakage, or damage.


Looseness, damage or

leaks are noted.



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-53

TM 5-3805-293-10 0013

CAB

101 Every

1,000

Engine

Hours or 6

Months

Rollover

Protective

Structure

(ROPS)

a. Check ROPS for drilled holes,

corrosion, loose, damaged, or

missing mounting hardware. Notify

Field Level Maintenance to

retorque/replace mounting

hardware.

Loose, damaged, or

missing mounting hardware

is noted.

b. Check ROPS for any signs of cracking in base metal or welded

areas.

Any signs of damage or cracked welds are noted.

Figure 30. ROPS Hardware. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0013-54

0013

LEFT SIDE

102 Every

2,000

Engine

Hours or 2

Years

Cooling

System

Pressure Cap

WARNING

• 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).



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-55

TM 5-3805-293-10 0013

102

(Cont.)

Every

2,000

Engine

Hours or

2 Years

Cooling

System

Pressure Cap

Figure 31. Cooling System Pressure Cap Access Door. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0013-56

TM 5-3805-293-10 0013

END OF WORK PACKAGE

102

(Cont.)

Every

2,000

Engine

Hours or

2 Years

Cooling

System

Pressure Cap

b. Clean area around cooling

system pressure cap.

c. Remove cooling system

pressure cap.

d. Clean cooling system pressure

cap and inspect cap and cap seals

for damage. Replace cooling

system pressure cap if damaged.

Cooling system pressure

cap is damaged.

e. Install cooling system pressure

cap.f. Close cooling system pressure

cap access door.

Figure 32. Cooling System Pressure Cap Seals. 0013



ITEM

NO. INTERVAL

MAN-

HOURS

LOCATION

ITEM TOCHECK/

SERVICE PROCEDURE

NOT FULLY MISSION

CAPABLE IF:

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

CHAPTER 5

MAINTENANCE INSTRUCTIONS

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0014-1

0014


0 0 1 4 AIR FILTER ELEMENTS MAINTENANCE

Removal, Cleaning and Inspection, Installation

INITIAL SETUP

Tools and Special Tools 0

Work Light 0

Materials/Parts 0


Equipment Condition 0

Machine parked (WP 0005) 0

Left front access door opened (WP 0004) 0

Estimated Time to Complete 0

0.2 Hr 0

4

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0014-2

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0014-3

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).

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0014-4

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10 0015

0015-1/(2 blank)


0 0 1 5 BLADE LIFT CYLINDER SOCKET INSPECTION

Inspection

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

INITIAL SETUP

Personnel 0

Two 0


Engine running (WP 0005) 0

0

Equipment Condition - Continued 0


Blade rotated 90 degrees to frame and

lowered to ground (WP 0005) 0


0.1 Hr 0

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0016-1

0016


0 0 1 6 BRAKE ACCUMULATOR TEST

Testing

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 twohours 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

INITIAL SETUP




0.1 Hr 0

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0016-2

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0018-1

0018


0 0 1 8 CIRCUIT BREAKER RESET

Reset

RESET 00018

1. Identify correct circuit breaker for inoperative system/circuit.

Figure 1. Circuit Breakers. 00018

INITIAL SETUP


Ignition ON (WP 0004) 0

Left front access door open (WP 0002) 0


0.1 Hr 0


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 whenignition is in ON position.

7 80 Amp Circuit Breaker Load Circuit - Feeds power to fuses in cab that are

continuously on.

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0018-2

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10 0019

0019-1/(2 blank)


0 0 1 9 CUTTING EDGES AND END BITS INSPECTION

Inspection

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

INITIAL SETUP



Blade tilted forward (WP 0004) 0

Blade lowered onto wooden blocks 0


0.1 Hr 0

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10 0020

0020-1/(2 blank)


0 0 2 0 DOMELAMP BULB REPLACEMENT

Removal, Installation

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

INITIAL SETUP




0.2 Hr 0

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0021-1

0021


0 0 2 1 ETHER STARTING AID CYLINDER REPLACEMENT

Removal, Cleaning and Inspection, Installation

INITIAL SETUP

Materials/Parts 0


Cylinder, Engine Starting (Ether) (WP 0032,

Item 7) 0


0



Right front access door open 0

4

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0021-2

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 INSPECTION00021

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0021-3/(4 blank)

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 awell-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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0022-1

0022


0 0 2 2 FUEL/WATER SEPARATOR DRAIN

Drain Fuel/Water Separator

DRAIN FUEL/WATER SEPARATOR 00022

WARNING

Fuel leaking or spilled onto hot surfaces or electrical components can cause a fire. Failureto 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

INITIAL SETUP 0



Left front access door open (WP 0002) 0


0.2 Hr 0

2

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0022-2

0022

FOLLOW-ON TASK 00022

Close left front access door.

END OF TASK

END OF WORK PACKAGE

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0023-1

0023


0 0 2 3 FUSE REPLACEMENT

Replacement

INITIAL SETUP




0.2 Hr 0

4

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0023-2

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0023-3

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 HornF35 -- NOT USED

F36 15 Implement Controller #2

F37 15 12V Converter

F38 15 Blackout

F39 -- NOT USED

F40 15 Heater Unit

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10

0023-4

0023


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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TM 5-3805-293-10 0024

0024-1/(2 blank)


0 0 2 4 MOLDBOARD WEAR STRIPS INSPECTION

Inspection

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

INITIAL SETUP

Personnel Required 0

Three 0


Moldboard rotated 90 degrees to frame and

lowered to ground (WP 0005) 0

Equipment Condition - Continued 0




0.1 Hr 0

2

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TM 5-3805-293-10

0025-1

0025


0 0 2 5 RADIATOR CLEANING

Removal, Cleaning, Installation

WARNING

Allow engine to cool before cleaning radiator. Failure to follow this warning may result ininjury 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

INITIAL SETUP

Materials/Parts 0





0.4 Hr 0

4

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0025-2

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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0025-3/(4 blank)

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

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TM 5-3805-293-10 0026

0026-1/(2 blank)


0 0 2 6 SCARIFIER LINK SOCKET INSPECTION

Inspection

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

INITIAL SETUP


0.1 Hr 0

Personnel Required 0

Two 0




0

2

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TM 5-3805-293-10

0027-1

0027


0 0 2 7 SCARIFIER TOOTH AND SHANK MAINTENANCE

Inspection, Replacement

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

INITIAL SETUP

Tools and Special Tools 0

Hammer (WP 0031, Item 6) 0

Tooth Removing Tool, Scarifier (WP 0031,

Item 16) 0

Material/Parts 0



Scarifier lowered onto 4-6 in. (100-150 mm)

wood blocks (WP 0005) 0



0.4 Hr 0

4

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0027-2

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

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0027-3

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).

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0027-4

TM 5-3805-293-10 0027


WARNING

DO NOT allow shank to fall from scarifier frame. Failure to follow this warning may resultin 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

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TM 5-3805-293-10

0029-1

0029


0 0 2 9 WINDOW WIPER BLADE REPLACEMENT

Replacement

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.

INITIAL SETUP


Machine parked, battery disconnect switch in

ON position (WP 0005) 0

Front windshield wiper stopped in center of

glass (WP 0004) 0


0.3 Hr 0

2

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0029-2

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.

Figure 1. Windshield Wiper Replacement. 00029

END OF TASK

END OF WORK PACKAGE

469-0311

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TM 5-3805-293-10

CHAPTER 6

SUPPORTING INFORMATION

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TM 5-3805-293-10

0030-1

0030


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

2

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TM 5-3805-293-10

0030-2

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

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TM 5-3805-293-10

0031-1

0031


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.

4

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0031-2

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)

ILLUS

NUMBER

(2)

NSN

(3)

DESCRIPTION, PART NUMBER/(CAGEC)

(4)

UOC

(5)

U/I

(6)

QTY

RQR

1 5140-01-524-7563 Bag, Tool 1

211-0136/(11083)

EA 1

2 5306-01-438-9715 Bolt, Machine 2

8T0670/(11083)EA 1

3 4210-01-493-8162 Extinguisher, Fire 3

B500T/(54905)EA 1

44910-01-545-3635 Gauge, Tire Pressure

4

1P-545/(11083) EA 1

5 – Glass Hammer 5

8Y-6379 (11083)

EA 1

6 5120-00-061-8546 Hammer 6

11677028-3/(19207)

EA 1

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0031-3

TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

(1)

ILLUSNUMBER

(2)

NSN

(3)


(4)

UOC

(5)

U/I

(6)

QTYRQR

7 4930-00-253-2478 Lubricating Gun, Hand 7

1142/(1PL57)EA 1

8 Lubrication Order 8

LO 5-3805-293-13 (19207)EA 1

9 Manual, Operator’s 9

TM 5-3805-293-10 (19207)EA 1

10 5310-01-565-6246 Nut, Self-Locking, Hexagon 10

7X0851/(11083)EA 1

11 5340-01-181-2579 Padlock and Keys 11

5P8502/(11083)

EA 3

12 5315-01-579-3794 Pin, Grooved, Head (Articulation Lock Pin)12

2520977/(11083)EA 1

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0031-4

TM 5-3805-293-10 0031

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) - Continued. 031

END OF WORK PACKAGE

(1)

ILLUS

NUMBER

(2)

NSN

(3)


(4)

UOC

(5)

U/I

(6)

QTY

RQR13 5120-01-335-1562 Pliers, Slip Joint, 9.25 in. 13

91ACP/(55719)

EA 1

14 5120-01-528-9361 Screwdriver, Flat Tip 14

6V-7935/(11083)EA 1

15 – Strap 15

XXXXX (11083)

EA 1

16 3805-00-423-9746 Tooth Removing Tool, Scarifier 16

6B-3260/(11083)EA 1

17 9905-00-148-9546 Warning Device Kit, Highway 17

11669000 (19207)

EA 1

18 5120-01-518-2402 Wrench, Adjustable, 12-inch long 18

214-7330/(11083)EA 1

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TM 5-3805-293-10

0032-1

0032


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.

4

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TM 5-3805-293-10

0032-2

0032

Table 1. Expendable and Durable Items for the 120M Motor Grader.

(1)

ITEM

NUMBER

(2)

LEVEL

(3)

NATIONAL

STOCK NUMBER

(4)

ITEM NAME, DESCRIPTION,

PART NUMBER/(CAGEC)

(5)

U/I

1 C Antifreeze 1

6850-01-383-4068 1 Gallon Bottle

672 4354 (1QK63)

GL 1

6850-01-441-3257 5 Gallon Can

A-A-52624 (58536)

CN 1

6850-01-383-3918 55 Gallon Drum

A-A-52624 (58536)

DR 1

2 C Cleaning Compound, Solvent, Type III 2

MIL-PRF-680/(81349)

6850-01-474-2318

6850-01-474-2320

6850-01-474-2321

1 Gallon Can5 Gallon Can

55 Gallon Drum

CN 2

CN 2

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

9140-00-286-5287 5

9140-00-286-5288 5

Bulk

5 Gallon Can55 Gallon Drum

GL 5

CN 5

DR 5

6 C 6 Diesel Fuel, DF-2 Grade 6

ASTM D 975/(81346)

9140-00-286-5294 6

9140-00-286-5295 6

9140-00-286-5296 6

Bulk

5 Gallon Can

55 Gallon Drum

GL 6

CN 6

DR 6

7 C 7 2910-00-646-9727 7 Cylinder, Engine Starting (Ether) 7

MS39254-1/(19207)

DZ 7

8 C 8 9130-01-031-5816 8 Fuel, Turbine, Aviation 8

MIL-T-83133 GR JP-8/(81349)

GL 8

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0032-3

TM 5-3805-293-10 0032

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

9150-01-197-769011

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

MIL-PRF-46147C GL-420 (72657)

GAL 12

13 C 13 Oil, Lubricating, OE/HDO-30 13

MIL-PRF-2104/(81349)

9150-00-186-6681 13

9150-00-188-9858 13

9150-00-189-6729 13

1 Quart Can

5 Gallon Can

55 Gallon Drum

CN 13

CN 13

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

9150-01-152-4118 15

9150-01-152-4119 15

1 Quart Can

5 Gallon Can

55 Gallon Drum

CN 15

CN 15

DR

15

16 C 16 Oil, Lubricating, OEA Arctic 16

9150-00-402-4478

16

9150-00-402-2372

9150-00-491-7197 16

MIL-L-46167/(81349)

1 Quart CanMIL-PRF-46167/(81349)

5 Gallon CanMIL-PRF-46167/(81349)

55 Gallon Drum

16

QT 16

16

GL 16

16

DR 16

16 16

16 16

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1)

ITEM

NUMBER

(2)

LEVEL

(3)

NATIONAL

STOCK NUMBER

(4)


PART NUMBER/(CAGEC)

(5)

U/I

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


0032-4

TM 5-3805-293-10 0032

END OF WORK PACKAGE

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

18

5975-00-984-6582

5975-00-935-5946 18

4 Inch Length, Black, Package of 100

MS3367-4-0/(96906)6 Inch Length, Black, Package of 100

MS3367-1-0/(96906)13.35 Inch Minimum Length, Brown

MS3367-2-1/(96906)

18

HD 18

18

HD 18

18

EA 18

19 C 19 Tag, Marker 19

9905-00-537-8954/(64067)

19 9905-00-537-8954 Bundle of 20 BD

Table 1. Expendable and Durable Items for the 120M Motor Grader - (Continued).

(1)

ITEM

NUMBER

(2)

LEVEL

(3)

NATIONAL

STOCK NUMBER

(4)


PART NUMBER/(CAGEC)

(5)

U/I

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


INDEX-1

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 0017-1Chemical, 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 0004-24Door 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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


INDEX-2

TM 5-3805-293-10

INDEX - CONTINUED


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

MMaintenance 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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


INDEX-3

TM 5-3805-293-10

INDEX - CONTINUED


Initial Adjustment Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1

Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-18

Machine Warning Summaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-17Messenger 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 0027-1Storage 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 0003-1Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


INDEX-4

TM 5-3805-293-10

INDEX - CONTINUED


W

Window Washer Tank Check and Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0028-1Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022-1

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


CMM CAGS T BCATSA BA MS

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


CMM CAGS T BCATS

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


RECOMMENDED CHANGES TO PUBLICATIONS

AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and

Special Tool Lists (RPSTL) and Supply

Catalogs/Supply Manuals (SC/SM).

DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code)


ATT AMTA-C-M/TC B

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TO: (Forward direct to addressee listed in publication)


ATT AMTA-C-M/TC B1 Rock Island Arsenal Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

PUBLICATION NUMBER DATE TITLE 2SHUDWRUVDQXDOIRU RWRUL]HGRDG

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


RECOMMENDED CHANGES TO PUBLICATIONS

AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is ODISC4.

Use Part II (reverse) for Repair Parts and

Special Tool Lists (RPSTL) and Supply

Catalogs/Supply Manuals (SC/SM).

DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code)


ATT AMTA-C-M/TC B

ock sland Arsenal Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code)

PUBLICATION/FORM NUMBER DATE TITLE 2SHUDWRUVDQXDOIRURWRUL]HGRDG

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TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS

EXTENSION

SIGNATURE

A M B AC A M 0 C 6 C B . AC .00

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


TO: (Forward direct to addressee listed in publication)


ATT AMTA-C-M/TC B1 Rock Island Arsenal Rock Island, IL 61299-7630

FROM: (Activity and location) (Include ZIP Code) DATE

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS

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8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


By Order of the Secretary of the Army:

GEORGE W. CASEY JR.

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Official:

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: ,

requirements for TM 5-3805-293-10.

8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


8/7/2019 TM 5-3805-293-10 MOTOR GRADER 120M


THE METRIC SYSTEM AND EQUIVALENTS

APPROXIMATE CONVERSION FACTORS

Linear Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches

1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches

1 Kilometer = 1000 Meters = 0.621 Miles

Weights

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces1 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

Square Measure

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches

1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet

1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Cubic Measure

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches1 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°

To Change To Multiply By

Inches Centimeters 2.540

Feet Meters 0.305

Yards Meters 0.914

Miles Kilometers 1.609

Sq Inches Sq Centimeters 6.451

Sq Feet Sq Meters 0.093

Sq Yards Sq Meters 0.836

Sq Miles Sq Kilometers 2.590

Acres Sq Hectometers 0.405

Cubic Feet Cubic Meters 0.028

Cubic Yards Cubic Meters 0.765

Fluid Ounces Milliliters 29.573

Pints Liters 0.473

Quarts Liters 0.946

Gallons Liters 3.785

Ounces Grams 28.349

Pounds Kilograms 0.454

Short Tons Metric Tons 0.907

Pound-Feet Newton-Meters 1.356

Pounds per Sq

Inch

Kilopascals 6.895

Miles per Gallon Kilometers per Liter 0.425

Miles per Hour Kilometers per Hour 1.609

To Change To Multiply By

Centimeters Inches 0.394

Meters Feet 3.280

Meters Yards 1.094

Kilometers Miles 0.621

Sq Centimeters Sq Inches 0.155

Sq Meters Sq Feet 10.764

Sq Meters Sq Yards 1.196

Sq Kilometers Sq Miles 0.386

Sq Hectometers Acres 2.471

Cubic Meters Cubic Feet 35.315

Cubic Meters Cubic Yards 1.308

Milliliters Fluid Ounces 0.034

Liters Pints 2.113

Liters Quarts 1.057

Liters Gallons 0.264

Grams Ounces 0.035

Kilograms Pounds 2.205

Metric Tons Short Tons 1.102

Newton-Meters Pound-Feet 0.738

Kilopascals Pounds per Sq

Inch

0.145

Kilometers per Liter Miles per Gallon 2.354

Kilometers per Hour Miles per Hour 0.621

tm 5-3805-293-10 motor grader 120m

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