PMCS MAINTENANCE INSTRUCTIONS
INTERIOR CAB
NOTE
Turn battery disconnect switch to ON position prior to entering cab (WP 0004).
22 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 reading in green area.
Pressure gauge needle is in red area.
c. Check for damaged or missing seal.
Seal is broken or missing.
d. Inspect fire extinguisher inspection tag.
Inspection date is not current and/or tag is missing.
23 Before Operator Seat Check seat and seat belt mounting hardware, seat belt buckle, and seat belt for damage or wear (WP 0004).
Seat belt is damaged.
24 Before Rearview
Mirror
Check and adjust rearview mirror (WP 0004).
Mirror broken or missing.
25 Before Indicators and
Gauges
a. Turn the engine start switch from OFF position to ON position to initialize Monitor system automatic self-diagnostic test.
Monitor fails to enter diag-nostic test.
b. Monitor the following:
1. All gauge pointers must sweep left, then right.
Any gauge does not move.
2. All alert indicators must come on momentarily.
Any alert light does not come on.
3. All segments in LCD display must come on momentarily.
LCD display segment(s) is inoperative.
4. Action alarm must sound. Action alarm does not sound.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-18
0012
26 Before Dozer Blade a. Start engine and run at low idle (WP 0005).
b. Move the right joystick to most forward detent. Blade float indicator should be ON in indicators and gauges display.
a. Monitor action lamp and auxiliary action lamp.
b. If action lamp or auxiliary action lamp comes ON and stays on, machine needs service.
Action light or auxiliary action lamp comes on and stays on.
28 Before Digital
Displays and Messenger Dis-play
With engine running, observe the two digital displays and the Messen-ger Display.
Information shows machine is not operating properly or Messenger is not
functioning.
29 Before Hydraulic
Controls
Perform a functional check of hydraulic systems: blade lift/lower, blade tilt, winch, and ripper
(WP 0004).
Class III oil leak is evident.
Any hydraulic system or function does not operate properly.
30 Before Lights Check operation of all flood lights
(WP 0004).
Any lights inoperative if required for mission.
31 Before Wipers and
Washers
Operate all wipers and washers to
verify correct operation (WP 0004). Wipers and washers not operating if required for mission.
32 Before Backup Alarm
and Horn
a. Verify that backup alarm
functions when left joystick is moved to reverse position.
Backup alarm does not function.
b. Check operation of horn. Horn does not function.
33 During Service Brake
Pedal
Move machine forward and test ser-vice brakes.
Check decelerator pedal for proper function and for binding and obstructions.
Machine does not slow or pedal binds when pedal is depressed.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-19
TM 5-2410-241-10 0012
35 During Drive Train a. Monitor machine operation for unusual noise or vibrations from engine and drive train.
b. Listen for unusual squeaking or squealing, indicating dry track joints.
c. Notify Field Maintenance if unusual noises are present.
36 During Dozer Blade a. Monitor blade operation for unusual noise or vibrations.
b. Notify Field Maintenance if unusual noises or vibrations are present.
37 During Overall
Leakage
Watch for evidence of fluid leakage. Class III oil leaks are evi-dent. Any coolant or fuel leak is evident.
38 During Instrument
Panel
a. With machine fully warmed up monitor indicators, gauges, digital displays and messenger display.
Indicators, gauges, or dis-plays indicate an abnormal operation.
b. If action lamp or auxiliary action lamp is ON, machine needs service.
Action light or auxiliary action lamp is ON.
39 During Air Conditioner
or Heater
Check air conditioner and/or heater for damage and verify proper operation.
Damage exists or system does not operate if required for mission.
FRONT AND LEFT SIDE
NOTE
Ensure machine is clean in order to facilitate performance of PMCS procedures.
40 After Overall View a. Check under machine for
evidence of fluid leakages such as oil, coolant, fuel, or hydraulic fluid.
Class III oil or hydraulic leaks are evident. Any cool-ant or fuel leak is evident.
b. Check machine for obvious damage that would impair operation.
Damage that would impair operation is evident.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-20
0012
41 After Belly Guard
Bolts
Check belly guard bolts to ensure none are loose.
One or more belly guard bolts is missing.
42 After Lights Check front flood lights for missing
or damaged components.
a. Check dozer blade, cutting edge and end bits for damage or
excessive wear.
b. Check blade mounting for debris, damage or missing components.
a. Check left lift cylinder for debris, leakage, or damage.
b. Check left lift cylinder mounting for damage or missing components.
c. Check left lift cylinder lines and fittings for leakage or damage.
Class III leak, or damaged, inoperative, missing, or excessively worn compo-nents that would impair oper-ation are evident.
Figure 12. Dozer Blade and Lift Cylinder
.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-21
TM 5-2410-241-10 0012
45 After Coolant Level
WARNING
• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system, and escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let out any pressure from cooling system, then remove cap. Failure to follow this warning may cause serious burns.
• Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.
CAUTION
• Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not pro-vide proper engine protection and engine and/or cooling 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 and requires no 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-mixed antifreeze in the same cooling system.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-22
0012
45 (Cont.)
After Coolant Level a. Open left front access door.
b. Check coolant level on coolant tank sight glass. If coolant level completely fills the sight glass, coolant level is okay. If coolant level can be seen in sight glass, coolant level is low.
c. Open radiator pressure cap access door and clean area around cap.
d. Remove cap and add coolant (WP 0022, Item 1) to maintain level between bottom of filler tube and top of sight glass.
e. Clean and inspect, then install pressure cap.
f. Close cap access door.
Coolant level is low, cap is damaged, or any coolant leak is evident.
Figure 13. Coolant Level Check and Radiator Pressure Cap and Access Door.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-23
TM 5-2410-241-10 0012
46 After 0.2 Engine Oil
Level
CAUTION
• Engine oil level gauge has oil level markings on both sides.
One side is for checking when engine is stopped; the other side is for checking when engine is running at low idle with oil warm.
• Be sure to check correct side of gauge. Over- or under-filled engine crankcase may cause engine damage.
a. Clean area around engine oil level gauge and fill cap.
b. Remove oil level gauge, clean, and reinstall. Remove oil level gauge and check level of oil.
Maintain oil level between the marks on oil level gauge.
c. Add oil (WP 0022, Items 11, 15, or 16) as required through filler opening. Refer to LO 5-2410-241-13 for proper oil based on outside temperature.
d. Clean oil filler cap, then reinstall.
Oil level is low or cap is damaged.
47 After Ether Cylinder a. Inspect ether cylinder and retaining clamp.
b. Remove ether cylinder and shake to check if cylinder is empty (WP 0015). Install new cylinder if required.
c. If ether cylinder is not present, ensure cap is installed on ether valve.
Missing, damaged, or inop-erative components if required for mission.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
Figure 14. Ether Cylinder.
0012
48 After Engine
Primary Air Filter
WARNING
If CBRN exposure is suspected, personnel wearing protec-tive equipment must handle all air cleaner media. Contami-nated 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.
Inspect engine primary air filter ele-ment. Refer to WP 0014.
Engine primary air filter ele-ment missing, damaged, or plugged with dirt.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-25
TM 5-2410-241-10 0012
49 After Primary Fuel
Filter/Water
Separator
WARNING
• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system.
• 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 these warnings may cause injury or death to personnel or damage to equipment.
a. Inspect primary fuel filter/water separator bowl for water.
b. If water is present, open drain valve and drain water into a suitable container.
c. Close drain valve.
d. Close left front access door.
Excessive amount of water or any fuel leak is evident.
Figure 15. Primary Fuel Filter/Water Separator.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-26
0012
50 After Engine Air
Precleaner
a. Inspect engine air precleaner assembly for dirt, debris, and damage.
b. If precleaner requires cleaning, notify Field Maintenance.
Precleaner extremely dirty, damaged, or missing.
Figure 16. Engine Air Precleaner.
0012
51 After Cab Fresh Air
Filter
WARNING
If CBRN exposure is suspected, personnel wearing protec-tive equipment must handle all air cleaner media. Contami-nated 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.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-27
TM 5-2410-241-10 0012
51 (Cont.)
After
WARNING
Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel.
Cab Fresh Air Filter
a. Loosen two knobs and remove filter cover.
b. Remove restrictor plate.
c. Remove filter.
d. Using a shop light, inspect filter.
e. Clean filter using a maximum of 30 psi (205 kPa) compressed air.
f. Inspect filter for tears or other damage.
g. Replace filter if damaged.
h. Install filter.
i. Install restrictor plate.
j. Install cover and tighten knobs.
Cab fresh air filter missing or damaged if necessary for mission.
Figure 17. Cab Fresh Air Filter. 0012 Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-28
0012
52 After Cab
Recircula-tion Filter
WARNING
If CBRN exposure is suspected, personnel wearing protec-tive equipment must handle all air cleaner media. Contami-nated 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.
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.
a. Open left cab door.
b. Remove two knobs and recirculation filter.
c. Using a shop light, inspect filter.
d. Clean filter using a maximum of 30 psi (207 kPa) compressed air.
e. Inspect filter for tears or other damage.
f. Replace filter if damaged.
g. Install filter and two knobs.
h. Close cab door.
Filter damaged or missing if necessary for mission.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-29
TM 5-2410-241-10 0012
52 (Cont.)
After Cab
Recircula-tion Filter
Figure 18. Cab Recirculation Filter.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
NO. INTERVAL MAN-HOURS
LOCATION ITEM TO CHECK/
SERVICE PROCEDURE NOT FULLY MISSION
CAPABLE IF:
TM 5-2410-241-10
0012-30
0012
53 After Batteries and
Battery Cables
WARNING
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other igni-tion sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to per-sonnel.
• 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 proce-dures may cause death or serious injury to personnel.
• DO NOT use compressed air to clean batteries. Use a clean, dry rag.
CAUTION
To reduce battery damage, check battery compartment for corrosion (greenish/white powder) and DO NOT jerk or pull on battery cables during visual inspection. Failure to follow this caution may result in damage to equipment.
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure.
Failure to follow this warning may cause injury or death to personnel.
NOTE
Arctic heater battery box cover weighs approximately 50 lb (23 kg).
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-31
a. With assistance, remove arctic heater battery box cover, if equipped.
b. Open battery compartment cover.
c. Check battery holddowns for looseness or damage.
d. Inspect batteries for cracked cases and evidence of leaking.
Holddown is loose or dam-aged.
Battery cases are cracked or leaks are evident.
NOTE
Original equipment batteries are maintenance-free and do not have removable caps.
e. Check for missing, broken, split, or frayed battery cables.
f. Check for damaged battery posts.
g. If equipped with
non-maintenance free batteries, check electrolyte level in each cell. If level is low, fill with distilled water to bottom of filler opening. Close battery compartment cover.
Damage is noted.
Damage is noted.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-32
0012
53 (Cont.)
After Batteries and
Battery Cables
Figure 19. Batteries.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
NO. INTERVAL MAN-HOURS
LOCATION ITEM TO CHECK/
SERVICE PROCEDURE NOT FULLY MISSION
CAPABLE IF:
0012-33
TM 5-2410-241-10 0012
54 After Washer Fluid
Tank
a. Open access cover.
b. Check washer fluid tank level.
c. Remove washer fluid filler cap.
d. Add windshield cleaning compound (WP 0022, Item 4).
e. Install filler cap.
f. Close access cover.
Tank is empty or damaged if necessary for mission.
Figure 20. Washer Fluid Tank.
0012
55 After Overall VIew a. Check rear of machine for evidence of leakage or damage.
b. Check ground below machine and inspect belly guards for evidence of fluid leaks.
c. Check undercarriage for obvious signs of damage.
Class III oil leak, any fuel or coolant leak, or damaged components are evident if necessary for mission.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-34
0012
56 After Lights Check rear worklights for missing or
damaged components.
Missing, damaged, or inoperative components if required for mission.
Figure 21. Machine Rear View.
0012
57 After Ripper a. Check ripper hydraulic cylinders
for leaks.
b. Check frame and tips for debris, excessive wear, damage, or missing components.
Class III leak or damage that would impair operation is evident, ripper inoperative, or ripper tips are missing or worn if required for mission.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
NO. INTERVAL MAN-HOURS
LOCATION ITEM TO CHECK/
SERVICE PROCEDURE NOT FULLY MISSION
CAPABLE IF:
0012-35
TM 5-2410-241-10 0012
58 After 0.2 Winch a. Check winch assembly for
damage, fluid leaks, wear, or visible cable damage. Refer to
TB 43-0142, Safety Inspection and Testing Of Lifting Devices.
b. Clean area around oil level check plug and filler plug.
c. Remove oil level check plug. If oil level is correct, oil should trickle from plug opening.
d. Remove oil filler plug. Add oil (WP 0022, Items 11, 12, or 13) as required through filler plug opening.
Refer to LO 5-2410-241-13 for proper oil based on outside temperature.
e. Install oil filler plug and oil level check plug.
Class III leak or damage that would impair operation is evident, winch inoperative if required for mission.
Oil level low if required for mission.
Figure 22. Winch Oil Level Check and Fill Plugs.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
TM 5-2410-241-10
0012-36
0012
59 After Tow Pin (Type I
dozers only)
Check tow pin (Figure 23, Item 1), two cotter pins (Figure 23, Item 2), and winch frame (Figure 23, Item 3) at tow pin holes for damage or miss-ing components.
Damaged or missing compo-nents if required for mission.
Figure 23. Tow Pin.
0012
RIGHT SIDE
60 After Overall View Check right side of machine for evi-dence of leakage or damage.
Class III oil leak, any fuel or coolant leak, or damage that would impair operation is evident.
61 After 0.2 Hydraulic Tank
Sight Gauge
WARNING
• At operating temperature, hydraulic tank is hot and under pressure. Do not remove hydraulic tank filler cap when engine is running. Remove the filler cap only after it is cool enough to touch with bare hands.
• Remove filler cap slowly to relieve pressure.
• Failure to follow these warnings may result in injury or death to personnel.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
0012-37
TM 5-2410-241-10 0012
61 (Cont.)
After Hydraulic Tank
Sight Gauge
a. Check hydraulic fluid level on sight gauge.
b. Clean area around hydraulic tank filler cap and slowly remove hydraulic tank filler cap.
c. Add hydraulic fluid (WP 0022, Items 11, 12, or 13) to maintain level between FULL mark and ADD mark on sight gauge. Refer to LO 5-2410-241-13 for proper oil based on outside temperature.
d. Install hydraulic tank filler cap.
Hydraulic fluid level is low.
Figure 24. Hydraulic Tank Sight Gauge and Filler Cap.
0012
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. 0012
ITEM
NO. INTERVAL MAN-HOURS
LOCATION ITEM TO CHECK/
SERVICE PROCEDURE NOT FULLY MISSION
CAPABLE IF:
TM 5-2410-241-10
• Transmission oil level gauge has oil level markings on both sides. One side is for checking when fluid is cold with engine stopped, the other side is for checking when fluid is hot with engine at idle.
• Checking fluid when hot is preferred and more accurate.
Checking fluid when cold should be used for reference only.
• Be sure you check correct side of gauge. Over- or under-filled transmission may cause transmission to overheat, not perform properly, or damage system components.
Transmission System Oil Level
a. Open right side upper access cover.
b. Clean area around transmission oil level gauge and filler cap.
c. Remove oil level gauge, wipe it clean then reinstall.
d. Remove gauge and check fluid level. Maintain oil within OPR ZONE (operating zone) markings.
e. Remove oil filler tube cap.
f. Add oil (WP 0022, Items 11, 12, or 13) through filler tube. Refer to LO 5-2410-241-13 for proper oil based on outside temperature.
g. Install oil filler tube cap and
g. Install oil filler tube cap and