6675 TM 5 348 13 And P

User Manual: 6675

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TM 5-6675-348-13&P

TECHNICAL MANUAL

OPERATOR’S,

UNIT AND

DIRECT SUPPORT

MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS

AND SPECIAL TOOLS LIST)

Laser Leveling

Equipment (LLE)

USED WITH MODEL 130G Grader,

D7F, D7G, D7H, and D7R Dozers,

613B and 621B Scrapers,

and HYEX

Contract No. DAAE07-01-C-T009

HEADQUARTERS, DEPARTMENT OF THE ARMY NOVEMBER 2005

Approved for public release;

distribution is unlimited.

INTRODUCTION 1-1

GRADIO® DISPLAY SYSTEM (D7F, D7G, D7H,

AND D7R DOZERS AND 613B AND 621B

SCRAPERS) 2-1

BLADE PRO® MOTOR GRADER CONTROL

SYSTEM (130G GRADER) 3-1

BUCKET-PRO™ SYSTEM (HYEX) 4-1

1145-2 LASER TRANSMITTER, 1275 LASER

RECEIVER, AND ELEVATING BASE AND TRIPOD,

USED WITH 130G GRADER, D7F, D7G, D7H, AND

D7R DOZERS, 613B AND 621B SCRAPERS, AND

HYEX 5-1

REFERENCES A-1

MAINTENANCE ALLOCATION CHART

(MAC) B-1

REPAIR PARTS AND SPECIAL TOOLS LIST

(RPSTL) C-1

COMPONENTS OF END ITEM AND BASIC

ISSUE ITEMS LISTS D-1

ADDITIONAL AUTHORIZED LIST E-1

EXPENDABLE/DURABLE SUPPLIES AND

MATERIALS LIST F-1

DECAL GUIDE G-1

ILLUSTRATED LIST OF MANUFACTURED

ITEMS H-1

TORQUE LIMITS J-1

MANDATORY REPLACEMENT PARTS K-1

TM 5-6675-348-13&P

Degreasing Solvent (MIL-PRF-680, Type II) is TOXIC and flammable. Wear protective goggles and

gloves, use only in a well-ventilated area, avoid contact with skin, eyes, and clothes, and do not

breathe vapors. Keep away from heat or flame. Never smoke when using solvent; the flash point for

degreasing solvent type II is 200º F (93º C). Failure to comply may result in injury or death to

personnel.

If personnel become dizzy while using cleaning solvent, immediately get fresh air and medical help.

If solvent contacts skin or clothes, flush with cold water. If solvent contacts eyes, immediately flush

eyes with water and get immediate medical attention. Do not use diesel fuel, gasoline, or benzene

(benzol) for cleaning.

Adhesives, solvents, and sealing compounds burn easily and give off vapors that are harmful to the

skin and clothing. To avoid injury or death, keep away from open fire when using these materials,

and use only in well-ventilated areas. If adhesives, solvents, or sealing compounds contact the skin

or clothing, wash immediately with soap and water, and rinse thoroughly. Failure to comply may

result in injury or death to personnel.

Unsafe welding practices can cause serious injury from fire, explosions, or harmful agents. Allow

only authorized personnel to weld or cut metals, and follow safety precautions in TC 9-237.

Protective clothing and goggles must be worn, adequate protective equipment must be used, a

suitable fire extinguisher must be kept nearby, and requirements of TC 9-237 must be strictly

followed. Failure to comply may result in serious injury or death to personnel.

Allow solder to cool before handling wire. Failure to comply may result in injury to personnel.

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

cough, shortness of breath, pain during respiration, increased sputum production, and chest

tightness. The following precautions must be taken whenever using CARC paint:

TM 5-6675-348-13&P

ALWAYS use air line respirators when using CARC paint, unless air sampling shows exposure to

be below standards. Use chemical cartridge respirator if air sampling is below standards.

DO NOT let skin or eyes come in contact with CARC paint. Always wear protective equipment

(gloves, ventilation mask, safety goggles, etc.).

DO NOT use CARC paint without adequate ventilation.

NEVER weld or cut CARC-coated materials.

DO NOT grind or sand painted equipment without high-efficiency air purifying respirators in use.

BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after initial

exposure. Seek medical help immediately if symptoms are detected.

Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber gloves, and

do not smoke when performing maintenance on batteries. Injury will result if acid contacts skin or

eyes. Wear rubber apron to prevent damage to clothing.

Remove all jewelry, such as rings, dog tags, bracelets, etc. If jewelry contacts Battery Terminal, a

direct short may result in instant heating of tools, damage to equipment, and injury or death to

personnel.

Exercise extreme caution when working under tilt platform. Falling platform could result in serious

injury or death to personnel.

TM 5-6675-348-13&P

c/(d Blank)

Turn battery disconnect switch OFF prior to performing maintenance in immediate battery area or

working on electrical system. Failure to comply can result in electrical shock to personnel or damage

to equipment.

Always disconnect the negative (-) battery cable before servicing the battery or positive (+) battery

cable. Failure to comply can result in electrical shock to personnel or damage to electrical system.

Do not allow battery cable ends to contact each other or the machine. Failure to comply can result

in damage to battery or electrical system.

Do not smoke when using cleaning solvent. Never use it near an open flame. Be sure there is a fire

extinguisher nearby and use cleaning solvent only in a well-ventilated area.

Use caution when using cleaning solvents. Cleaning solvents evaporate quickly and can irritate

exposed skin if solvents contact skin. In cold weather, contact of exposed skin with cleaning solvents

can cause frostbite.

Do not start or move Blade Pro® Motor Grader Control System while anyone is under the 130G

Grader. Failure to comply could result in severe injury or death to personnel.

Keep all personnel and equipment away from blade during calibration. Blade may move suddenly,

causing injury or death to personnel, or damage to equipment.

To avoid injury to personnel, ensure 130G Grader is shut OFF and blade is on the ground.

Do not look into 1145-2 Laser Transmitter for a long period of time. Failure to comply may cause

injury to personnel.

TM 5-6675-348-13&P

A/(B Blank)

INSERT LATEST UPDATED PAGES / WORK PACKAGES. DESTROY SUPERSEDED DATA.

LIST OF EFFECTIVE PAGES / WORK PACKAGES

NOTE: The portion of text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes

to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded

areas.

Dates of issue for original and changed pages / work packages are:

Original......... 0... 30 November 2005

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 24 AND TOTAL

NUMBER OF WORK PACKAGE PAGES IS 436 CONSISTING OF THE FOLLOWING:

Page / WP

No. *Change

No. Page / WP

No. *Change

No. Page / WP

No. *Change

No.

Front Cover 0 5-1 — 5-32 0 D-1 — D-2 0

a — d 0 A-1 — A-2 0 E-1 — E-2 0

A — B 0 B-1 — B-10 0 F-1 — F-2 0

i — iv 0 C-1 — C-4 0 G-1 — G-4 0

1-1 — 1-6 0 FIG. 1 — FIG. 56-1 0 H-1 — H-2 0

2-1 — 2-32 0 KITS-1 — KITS-6 0 J-1 — J-8 0

3-1 — 3-124 0 INDEX-1 — INDEX-4 0 K-1 — K-2 0

4-1 — 4-76 0

*Zero in this column indicates an original page.

TM 5-6675-348-13&P

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 5-6675-348-13&P Washington, DC, 30 November 2005

OPERATOR’S, UNIT AND DIRECT SUPPORT

MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

FOR

LASER LEVELING EQUIPMENT (LLE)

USED WITH MODEL 130G Grader, D7F, D7G, D7H,

and D7R Dozers, 613B and 621B Scrapers, and HYEX

Contract No. DAAE07-01-C-T009

TABLE OF CONTENTS

Page

CHAPTER 1 INTRODUCTION...................................................................................................... 1-1

CHAPTER 2 GRADIO® DISPLAY SYSTEM (D7F, D7G, D7H, AND D7R DOZERS AND 613B

AND 621B SCRAPERS) .......................................................................................... 2-1

Section I Gradio® Display System General Information........................................................ 2-1

Section II Gradio® Display System Preventive Maintenance Checks and Services (PMCS). 2-6

Section III Gradio® Display System Operation.......................................................................... 2-10

Section IV Gradio® Display System Troubleshooting ............................................................... 2-13

Section V Gradio® Display System Maintenance..................................................................... 2-19

CHAPTER 3 BLADE PRO® MOTOR GRADER CONTROL SYSTEM (130G GRADER)........... 3-1

Section I Blade Pro® Motor Grader Control System General Information............................ 3-2

Section II Blade Pro® Motor Grader Control System PMCS ................................................... 3-16

Section III Blade Pro® Motor Grader Control System Operation............................................. 3-22

Section IV Blade Pro® Motor Grader Control System Troubleshooting................................... 3-60

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes, or if you know of a way to

improve the procedures, please let us know. Submit your DA Form 2028 (Recommended

Changes to Publications and Blank Forms), through the Internet, on the Army Electronic

Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil. If you need

a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is

located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click

on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments

and better manage the DA Form 2028 program. You may also mail, fax, or e-mail your letter or

DA Form 2028 direct to: AMSTA-LC-LPIT / TECH PUBS, TACOM-RI, 1 Rock Island Arsenal,

IL, 61299-7630. The e-mail address is TACOM-TECH-PUBS@ria.army.mil. The fax number is

(DSN) 793-0726 or Commercial (309) 782-0726.

TM 5-6675-348-13&P

TABLE OF CONTENTS (CONT)

Page

CHAPTER 3 BLADE PRO® MOTOR GRADER CONTROL SYSTEM (130G GRADER)

(CONTINUED)

Section V Blade Pro® Motor Grader Control System Troubleshooting Error Messages........ 3-70

Section VI Blade Pro® Motor Grader Control System Error Log ............................................. 3-72

Section VII Blade Pro® Motor Grader Control System Maintenance........................................ 3-82

CHAPTER 4 BUCKET-PRO™ SYSTEM (HYEX)......................................................................... 4-1

Section I Bucket-Pro™ System Introduction........................................................................... 4-2

Section II Bucket-Pro™ System PMCS ..................................................................................... 4-4

Section III Bucket-Pro™ System Operation............................................................................... 4-8

Section IV Bucket-Pro™ System Troubleshooting..................................................................... 4-30

Section V Bucket-Pro™ System Maintenance.......................................................................... 4-37

CHAPTER 5 1145-2 LASER TRANSMITTER, 1275 LASER RECEIVER, AND ELEVATING BASE

AND TRIPOD, USED WITH 130G GRADER, D7F, D7G, D7H, AND D7R DOZERS,

613B AND 621B SCRAPERS, AND HYEX.............................................................. 5-1

Section I General Information.................................................................................................. 5-1

Section II 1145-2 Laser Transmitter, 1275 Laser Receiver, and Elevating Base and

Tripod PMCS.............................................................................................................. 5-15

Section III Operation.................................................................................................................... 5-19

Section IV 1145-2 Laser Transmitter Troubleshooting ............................................................. 5-27

APPENDIX A REFERENCES .......................................................................................................... A-1

APPENDIX B MAINTENANCE ALLOCATION CHART (MAC)................................................... B-1

Section I Introduction................................................................................................................ B-1

Section II MAC............................................................................................................................ B-4

Section III Tool and Test Equipment Requirements .................................................................. B-9

Section IV Remarks ..................................................................................................................... B-9

APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL)........................................ C-1

Section I Introduction................................................................................................................ C-1

Section II Repair Parts List........................................................................................................ C-3

Section III Cross-Reference Indexes........................................................................................ Index-1

APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LISTS ................... D-1

APPENDIX E ADDITIONAL AUTHORIZED LIST........................................................................ E-1

APPENDIX F EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST......................... F-1

Section I Introduction................................................................................................................ F-1

Section II Expendable and Durable Items................................................................................. F-2

APPENDIX G DECAL GUIDE.......................................................................................................... G-1

Section I Introduction................................................................................................................ G-1

Section II Decals ......................................................................................................................... G-2

APPENDIX H ILLUSTRATED LIST OF MANUFACTURED ITEMS........................................... H-1

APPENDIX J TORQUE LIMITS...................................................................................................... J-1

Section I Introduction................................................................................................................ J-1

Section II Torque Limits............................................................................................................. J-1

APPENDIX K MANDATORY REPLACMENT PARTS................................................................... K-1

Section I Introduction................................................................................................................ K-1

Section II Mandatory Replacement Parts.................................................................................. K-1

TM 5-6675-348-13&P

iii

LIST OF TABLES

Number Title Page

2-1. Gradio® Display System Equipment Data ................................................................................ 2-5

2-2. Gradio® Display System Operator’s PMCS (Before/After) ....................................................... 2-8

2-3. Gradio® Display System Fault Index......................................................................................... 2-13

2-4. Gradio® Display System Troubleshooting ................................................................................. 2-14

3-1. Blade Pro® Motor Grader Control System Operator Interface Box Light Indicators ............. 3-8

3-2. Blade Pro® Motor Grader Control System Operator Interface Box Controls.......................... 3-11

3-3. Blade Pro® Motor Grader Control System Equipment Data.................................................... 3-15

3-4. Blade Pro® Motor Grader Control System Operator’s PMCS (Before/After)........................... 3-19

3-5. Blade Pro® Motor Grader Control System PMCS (Quarterly)................................................. 3-21

3-6. Blade Pro® Motor Grader Control System Fault Index............................................................ 3-60

3-7. Blade Pro® Motor Grader Control System Troubleshooting..................................................... 3-61

3-8. Error Messages............................................................................................................................ 3-71

3-9. Error Log...................................................................................................................................... 3-72

3-10. Error-to-Source Relationships .................................................................................................... 3-74

4-1. Bucket-Pro™ System Operator’s PMCS (Before/After)............................................................. 4-6

4-2. CUSTOMIZE Menu Options....................................................................................................... 4-17

4-3. System Alarms............................................................................................................................. 4-25

4-4. Bucket-Pro™ System Fault Index..............................................................................................4-30

4-5. Bucket-Pro™ System Troubleshooting....................................................................................... 4-31

5-1. 1145-2 Laser Transmitter, 1275 Laser Receiver, and Elevating Base

and Tripod System Operator’s PMCS (Before/After)............................................................. 5-18

5-2. 1145-2 Laser Transmitter Fault Index....................................................................................... 5-27

5-3. 1145-2 Laser Transmitter Troubleshooting ............................................................................... 5-28

B-1 Gradio® Control System Maintenance Allocation Chart.......................................................... B-4

B-2 Blade Pro® Motor Grader Control System Maintenance Allocation Chart ............................. B-5

B-3 Bucket-Pro™ Control System Maintenance Allocation Chart.................................................. B-7

B-4 Transmitter Control System Maintenance Allocation Chart.................................................... B-8

J-1 Torque Limits for Wet Flange Nuts............................................................................................J-2

J-2 Torque Limits for Wet Socket Head Capscrews......................................................................... J-2

J-3 Torque Limits for Dry Fasteners................................................................................................ J-4

J-4 Torque Limits for Wet Fasteners................................................................................................ J-5

J-5 Torque Limits for 37-Degree Flare Hose Connections............................................................... J-7

J-6 Torque Limits for 45-Degree Flare Hose Connections............................................................... J-7

J-7 Torque Limits for ORS Preformed Packing Face Seal Hose Connections................................ J-8

J-8 Torque Limits for NPSM Swivel Connections............................................................................ J-8

K-1 Mandatory Replacement Parts - Gradio®.................................................................................. K-1

K-2 Mandatory Replacement Parts - Blade Pro®............................................................................. K-2

K-3 Mandatory Replacement Parts - Bucket-Pro™.......................................................................... K-2

TM 5-6675-348-13&P

HOW TO USE THIS MANUAL

This manual is for commercially available equipment that has been approved for military use. This is a

Commercial Off-The-Shelf (COTS) Manual with supplemental data to support military-specific maintenance. This manual is

designed to help operate and maintain the Laser Leveling Equipment. Listed below are some of the features included in this

manual to help locate and use the needed information:

• A front cover Table of Contents is provided for quick reference to chapters and sections that will

be used often.

• Warning, caution, and note headings, subject headings, and other essential information are

printed in bold type, making them easier to see.

• In addition to text, there are exploded-view illustrations showing how to take a component off and

put it back on. Cleaning and inspection criteria are also included where necessary.

• Chapter 1 of this manual describes the Laser Leveling Equipment and provides equipment data.

• Chapter 2 of the manual describes the Gradio® Display System, used with dozers and scrapers.

• Chapter 3 of the manual describes the Blade Pro® Motor Grader Control System, used with

130G Graders.

• Chapter 4 of the manual describes the Bucket-Pro™ System, used with Hydraulic Excavator

(HYEX).

• Chapter 5 of the manual describes the use of the 1145-2 Laser Transmitter and Tripod, that can

be used with the Gradio® Display System, the Blade Pro® Motor Grader Control System, or the

Bucket-Pro™ System.

• Appendix A covers the References used in this manual.

• Appendix B covers the Maintenance Allocation Chart (MAC).

• Appendix C covers the Repair Parts and Special Tools List (RPSTL).

• Appendix D covers the Components of End Item (COEI) and Basic Issue Items (BII) Lists.

• Appendix E covers the Additional Authorized List (AAL).

• Appendix F covers the Expendable/Durable Supplies and Materials List.

• Appendix G covers the Decal Guide.

• Appendix H covers the Illustrated List of Manufactured Items.

• Appendix J covers the Torque Limits.

• Appendix K covers the Mandatory Replacement Parts.

Follow these guidelines when using this manual:

• Read all WARNINGS and CAUTIONS before performing any procedures.

• Read through this manual and become familiar with the contents.

• Read the entire procedure before attempting to perform any maintenance task.

TM 5-6675-348-13&P

1-1

CHAPTER 1

INTRODUCTION

Content Para Page

Scope........................................................................................................................................... 1-1 1-1

Maintenance Forms and Records.............................................................................................. 1-2 1-1

Equipment Improvement Report and Maintenance Digest (EIR MD) and Equipment

Improvement Report and Maintenance Summary (EIR MS)............................................. 1-3 1-2

Submitting Quality Deficiency Reports (QDR)........................................................................ 1-4 1-2

Destruction of Army Materiel to Prevent Enemy Use............................................................. 1-5 1-2

Warranty Information ............................................................................................................... 1-6 1-2

Reference Information............................................................................................................... 1-7 1-3

1-1. SCOPE.

a. Type of Manual/Model Numbers/Equipment Name.

This manual is used for operation, maintenance, and installation of Laser Leveling Equipment used on

the 130G Grader, the D7F, D7G, D7H, and D7R Dozers, the 613B and 621B Scrapers, and the HYEX.

b. Purpose of Equipment.

The laser diode emits a thin, round beam of light. Energy in this light is at a wavelength that will

activate light-sensitive cells in the receiver.

The mechanism in the laser rotates the beam at a constant 600 revolutions per minute. The light beam

remains perpendicular to the axis of rotation at all times.

As the beam rotates about the axis, it describes a “plane” similar to a CD-ROM, with a radius of

1,000 ft (305 m). In theory, the beam does not waver from the plane.

As the rotating beam strikes the receiver, it activates cells at 600 times per minute (10 times per

second). This happens so fast that it gives the appearance of a solid plane of light. This solid plane of

light establishes a reference above ground. It can be adjusted up or down by mounting the laser on a

tripod.

The Laser Transmitter mounted in relation to the cutting edge (on mast) allows the Operator to

“transfer” the plane to the ground the Operator is working. It does this by showing the Operator which

direction to move the cutting edge to keep the distance from the ground to the light plane constant.

1-2. MAINTENANCE FORMS AND RECORDS.

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by

DA PAM 738-750, The Army Maintenance Management System (TAMMS) (Maintenance Management

UPDATE).

TM 5-6675-348-13&P

1-2

1-3. EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD) AND

EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE SUMMARY (EIR MS).

The quarterly Equipment Improvement Report and Maintenance Digest (EIR MD), TB 43-0001-62 series,

contains valuable field information on equipment covered in this manual. Information in the TB 43-0001-62

series is compiled from some of the Equipment Improvement Reports that have been prepared on equipment

covered in this manual. Many of these articles result from comments, suggestions, and improvement

recommendations that were submitted to the EIR program. The TB 43-0001-62 series contains information

on equipment improvements, minor alterations, proposed Modification of Work Orders (MWOs), warranties

(if applicable), actions taken on recommendation submitted on the DA Form 2028 (Recommended Changes

and Blank Forms), and advance information on proposed changes that may affect this manual. Significant

maintenance articles, including minor alterations and field-fixes, are republished in the Equipment

Improvement Report and Maintenance Summary (EIR MS) for TACOM Equipment (TM 43-0143). Refer to

the TB 43-0001-62 series and TM 43-0143 periodically for the most current and authoritative information on

the equipment. The information will help maintenance personnel to do a better job and will advise them of

the latest changes to this manual. Also refer to DA PAM 310-1, Consolidated Index of Army Publications and

Blank Forms, and Appendix A, References, of this manual.

1-4. SUBMITTING QUALITY DEFICIENCY REPORTS (QDR).

If your equipment needs improvement, let us know. Send us a QDR. 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.

Put it on an SF368 (Quality Deficiency Report). Mail it to:

Commander

U.S. Army Tank-automotive and Armaments Command

ATTN: AMSTA-TR-PQDR

Warren, MI 48397-5000

A reply will be sent to you.

1-5. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.

Refer to TM 750-244-6 for instructions covering destruction of Army materiel to prevent enemy use.

1-6. WARRANTY INFORMATION.

Trimble warrants all manufactured products to be free of defects in materials and workmanship for a period

of one (1) year from the date the product is put into service. Components not manufactured by Trimble, but

sold as a part of the system, will carry a 90-day warranty, or the manufacturer warranty, whichever is greater.

Trimble warrants all installations on all heavy construction equipment to be free of defects in materials and

workmanship for a period of one (1) year from the date the installation is completed. This Installation

Warranty will apply only when Trimble personnel or authorized personnel conduct the installation.

The Trimble warranty for products and/or installation is valid worldwide.

Trimble or its Authorized Service Center will repair or replace, at its option, any defective part or component

of which notice has been given during the warranty period.

This warranty does not cover any evidence of neglect, abuse, accident, or any attempt to repair equipment by

other than factory-authorized personnel and/or parts authorized in this manual. For nonwarranty repairs, the

cost of the repair and, if required, travel and per diem expenses to and from the place where repairs are made

will be charged to the purchaser at the prevailing rates.

TM 5-6675-348-13&P

1-3

Customers should send unit(s), freight prepaid, to the nearest Authorized Service Center for warranty

repairs. In countries with Trimble Service Centers, the repaired units will be returned, freight prepaid, to the

customer.

Warranties for specific models of Laser Leveling Equipment may exceed one (1) year, and may cover use and/

or abuse. For details on these warranties, consult that model’s operating instructions manual.

Trimble will not be held responsible for any consequential loss or damage of any kind.

Checking and maintaining calibration of all equipment is the responsibility of the user.

Trimble policy for repair turnaround time for all Department of Defence (DoD) Agencies has been in effect

since 1994. This policy is as follows:

•In-House Repairs: Completed in 1 to 48 hours, depending on the extent of service required.

If the repairs required are extensive and the Trimble Service Center is unable to complete the repair within

48 hours, that DoD Agency will be offered a loaner to use until that repair is completed. If that item is under

warranty, there will be no cost to that agency. If that item is not under warranty, a rental fee may apply.

NOTENOTE

This policy covers service work conducted at Trimble Service Centers anywhere in the world.

•On-Site/On-Machine (Grader, Dozer, Scraper, Paver, etc.) Repairs: Completed in 1 to 48 hours,

depending on the extent of service required. Does not include travel time to site where repairs are to be

conducted.

If the repairs required are extensive and the on-site Trimble Service personnel are unable to complete the

repair within 48 hours, that DoD Agency will be offered a loaner to use until that repair is completed. If that

item is under warranty, there will be no cost to that agency. If that item is not under warranty, a rental fee

may apply.

NOTENOTE

This policy covers service work conducted by Trimble Service Centers anywhere in the world.

Warranty: Standard commercial warranty is one (1) year on parts, labor, and installation from the date of

installation (In Service date).

1-7. REFERENCE INFORMATION.

This listing includes a nomenclature cross-reference list and a list of abbreviations used in this manual.

a. Abbreviations.

AEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Army Electronic Product Support

AAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List

AISI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automated Integrated Survey Instrument

amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amperes

ANSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . American National Standards Institute

AOAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Oil Analysis Program

BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Issue Item

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centigrade

CAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity

TM 5-6675-348-13&P

1-4

CBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical, Biological, Radiological

CKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit

cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter

COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item

COTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial Off-The-Shelf

cps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycles Per Second

CTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Table of Allowance

DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department of the Army

DoD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Department of Defense

EIR -MD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Report and Maintenance Digest

EIR -MS . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Report and Maintenance Summary

F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit

ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foot

HDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isocyanate

HYEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Excavator

in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inch

I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Diameter

O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Diameter

kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram

LACV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift and Articulation Check Valve

lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound-Foot

lb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound

LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display

LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light-Emitting Diode

LLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser Leveling Equipment

m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter

MAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Allocation Chart

mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter

N·m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meters

NPSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Pipe Straight Mechanical

NSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Stock Number

OC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-Condition

OL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over Limit

ORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-Ring Seal

PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services

QDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quality Deficiency Reports

rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions Per Minute

RPSTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Parts and Special Tools List

SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Society of Automotive Engineers

SMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Source, Maintenance, and recoverability

TACOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank-automotive and Armaments Command

TAMMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System

TM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Manual

TMDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test, Measurement, and Diagnostic Equipment

U/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit of Measure

UOC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Usable on Code

v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts

Vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts alternating current

Vdc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts direct current

TM 5-6675-348-13&P

1-5/(1-6 Blank)

b. Definitions of Technical Terms.

Actual Blade Slope – The monitored slope of the blade, which is used to calculate desired cross-slope.

Actual blade slope and desired cross-slope are equal only when the blade is perpendicular to the

machine’s direction of travel.

Benchmark – A point of reference from which measurements may be made.

Calculated Cross-Slope – The cross-slope is calculated by using the information provided by the

machine-mounted sensors and calculated with the Blade Pro® Motor Grader Control System.

Desired Cross-Slope – The slope that is marked on the job plans. This may be referenced from the

centerline of the road to the 1/4 crown, from shoulder to shoulder, or from shoulder to ditch, depending

on the plans. This is the slope entered into the Blade Pro® Motor Grader Control System’s Operator

Interface Box.

Elevation – The height above or below a set point.

Mainfall – The slope of the machine in the direction of travel.

Percent Slope – The change in elevation between two points divided by the distance between the

points and multiplied by 100.

Plane – A flat or level surface.

Resultant Cross-Slope – The measured slope perpendicular to the direction of the machine’s travel.

Slope – The change in elevation between two points in relation to the measured distance between the

points (e.g., 1/4 in. per 1 ft [6.4 mm per 30.5 cm]).

Elevation A Elevation B–

Distance

---------------------------------------------------------------100×Percent (%) Slope=

TM 5-6675-348-13&P

2-1

CHAPTER 2

GRADIO® DISPLAY SYSTEM

(D7F, D7G, D7H, AND D7R DOZERS

AND 613B AND 621B SCRAPERS)

Content Para Page

Gradio® Display System General Information ................................................................... Section I 2-1

Scope........................................................................................................................................... 2-1 2-1

Equipment Characteristics, Capabilities, and Features.......................................................... 2-2 2-1

Location and Description of Major Components...................................................................... 2-3 2-3

Equipment Data ........................................................................................................................ 2-4 2-5

Gradio® Display System Preventive Maintenance Checks and Services (PMCS).......... Section II 2-6

PMCS Procedures...................................................................................................................... 2-5 2-6

Shortened Maintenance Instructions....................................................................................... 2-6 2-7

Additional Maintenance Inspections........................................................................................ 2-7 2-8

PMCS Column Entry Explanation ........................................................................................... 2-8 2-8

Gradio® Display System Operator’s PMCS Table................................................................... 2-9 2-8

Gradio® Display System Operation.................................................................................. Section III 2-10

Gradio® Display System Installation of Components............................................................. 2-10 2-10

Gradio® Display System Setup................................................................................................. 2-11 2-11

Gradio® Display System Operation ......................................................................................... 2-12 2-12

Gradio® Display System Troubleshooting........................................................................ Section IV 2-13

Gradio® Display System Troubleshooting Instructions.......................................................... 2-13 2-14

Gradio® System Troubleshooting Instructions........................................................................ 2-14 2-16

Gradio® Display System Maintenance.............................................................................. Section V 2-19

Gradio® Display System Installation for Dozer ...................................................................... 2-15 2-19

Gradio® Display System Installation for Scrapers.................................................................. 2-16 2-26

SECTION I. GRADIO® DISPLAY SYSTEM GENERAL INFORMATION

2-1. SCOPE.

Chapter 2 is used for operation, maintenance, and installation of the Gradio® Display System used on the

D7F, D7G, D7H, and D7R Dozers and the 613B and 621B Scrapers.

2-2. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. Characteristics. The RT2S Laser Receiver and DR2 Display are ideal for applications where the

RT2S Laser Receiver must be mounted many feet from the Operator (or at an inconvenient location),

such as on Dozers and Scrapers. The cableless feature means the DR2 Display can be mounted

optimally without routing the cables around or through complex or articulating machine joints.

The MM2E Manual Mast is used in machine control applications where changes in the benchmark

elevations are minimal and when manual adjustments of the RT2S Laser Receiver’s height do not

present a safety risk.

TM 5-6675-348-13&P

2-2

The RM2E-3 Rigid Mast is used in machine control applications where changes in the benchmark

elevations are minimal and when manual adjustments of the RT2S Laser Receiver’s height do not

present a safety risk.

b. Capabilities.

(1) The Gradio® Display System is capable of operating in temperatures from -20 to 140° F

(-29 to 60° C).

(2) Normal Gradio® Display System operating range (between RT2S Laser Receiver and DR2 Display)

is up to a 100-ft (30.5 m) radius.

c. Features.

(1) The RT2S Laser Receiver is an omnidirectional, 360-degree receiver that accepts signals from the

600-rpm rotating lasers.

(2) The RT2S Laser Receiver translates and sends elevation information to the DR2 Display via low-

power radio communication.

12-/24-Vdc bulbs may be used. To avoid damage to equipment, ensure proper bulb is

installed for machine’s electrical system.

(3) Five channels of grade data (high coarse, high fine, on-grade, low fine, and low coarse) are

displayed for the Operator through bright lenses in the DR2 Display.

(4) The RT2S Laser Receiver is a self-contained, battery-powered unit that can be mounted in an

optimum position without concern for cable routing and subsequent cable damage.

(5) The MM2E Manual Mast provides a mount for the RT2S Laser Receiver to slip over and clamp into

place.

(6) The MM2E Manual Mast has increment/decrement mast tape to indicate changes in position of the

MM2E Manual Mast.

(7) The RM2E-3 Rigid Mast has increment/decrement mast tape to indicate changes in position of the

RM2E-3 Rigid Mast.

(8) The RM2E-3 Rigid Mast Quick-Release Pin enables easy removal of the RM2E-3 Rigid Mast from

the mast mount.

(9) The RM2E-3 Rigid Mast Lanyard Chain connects the Quick-Release Pin to the RM2E-3 Rigid Mast

tube to prevent loss when disconnected.

TM 5-6675-348-13&P

2-3

2-3. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

(1) BATTERY DOOR. Holds four alkaline,

C-size batteries.

(2) ON/OFF SWITCH. Used to turn the

RT2S Laser Receiver ON and OFF.

12-/24-vdc bulbs may be used. To avoid

damage to equipment, ensure 24-v bulbs

are installed for 24-v electrical system

and 12-v bulbs are installed for

12-v electrical system.

(3) RT2S LASER RECEIVER CLAMP.

“Universal” design allows RT2S Laser

Receiver to be mounted on 1 1/2-in. to

2-in. (3.81 cm to 5.1 cm) diameter round

tubing or 1 1/2-in. to 1 3/4-in. (3.81 cm to

4.45 cm) square tubing.

(4) OVERLOAD PROTECTION. A 5-amp

fuse is used to protect the DR2 Display.

(5) DISPLAY CONTROL SWITCH. Turns the

DR2 Display on in either bright or dim

DR2 Display mode for day or night use.

(6) CHANNEL INDICATION. Designates

channel configuration of the RT2S

Laser Receiver or the DR2 Display. Channels must match for proper operation. Matching channels

have the same color heat shrink tubing on the antenna.

(7) OPERATOR SETUP LAMPS. Light-emitting diodes (LED) on the back of the DR2 Display reflect

activity of the DR2 Display panel lights. This allows for one-soldier setup.

(8) GRADE INDICATOR LAMPS. Used to communicate grade information to the Operator.

(9) OUT-OF-BEAM INDICATOR. LEDs on the DR2 Display panel indicate which direction the

RT2S Laser Receiver must be moved to intercept the laser beam.

TM 5-6675-348-13&P

2-4

(10) MM2E MANUAL MAST. A manually telescoping

receiver mount with increment/decrement tape on

the telescoping mast tube, that allows RT2S Laser

Receiver to be positioned at known intervals.

(11) RM2E-3 RIGID MAST. A rigid receiver mount with

increment/decrement tape, that allows the RT2S

Laser Receiver to be moved at known intervals.

TM 5-6675-348-13&P

2-5

2-4. EQUIPMENT DATA.

Table 2-1. Gradio® Display System Equipment Data

Model Item

DIMENSIONS

RT2S Laser

Receiver Length: 11.3 in. (28.7 cm)

Width: 4.5 in. (11.4 cm)

Depth: 7.9 in. (20.1 cm)

DR2 Display Length: 13.5 in. (34.3 cm)

Width: 5.0 in. (12.7 cm)

Depth: 6.5 in. (16.5 cm)

MAST HEIGHT

MM2E Manual

Mast Retracted: 4.9 ft (1.5 m)

Extended: 8.8 ft (2.7 m)

RM2E-3 Rigid

Mast 3.9 ft (1.2 m)

ANTENNA LENGTH

RT2S Laser

Receiver Height: 7.2 in. (18.3 cm)

DR2 Display Height: 7.2 in. (18.3 cm)

WEIGHT

RT2S Laser

Receiver 5.1 lb. (2.3 kg)

DR2 Display 7.3 lb. (3.3 kg)

MM2E Manual

Mast 33 lb. (15 kg)

RM2E-3 Rigid

Mast 6 lb. (2.7 kg)

TAPE INCREMENTS

MM2E Manual

Mast 0.01 ft (0.0030 m)

RM2E-3 Rigid

Mast 0.01 ft (0.0030 m)

ELECTRICAL SYSTEM

RT2S Laser

Receiver Four C-size alkaline batteries provide 40 to 60 hours of use. Ni-Cad batteries (supplied

with charging kit) provide 24 hours of use per overnight charge. DO NOT TRY TO

CHARGE ALKALINE BATTERIES.

DR2 Display 12 or 24 Vdc from electrical system

TM 5-6675-348-13&P

2-6

SECTION II. GRADIO® DISPLAY SYSTEM PREVENTIVE

MAINTENANCE CHECKS AND SERVICES (PMCS)

Preventive Maintenance Checks and Services (PMCS) means systematic caring for, inspecting, and servicing

equipment to keep it in good condition and to help prevent breakdowns. As the Operator, your mission is to:

a. Be sure to perform your PMCS each time you operate the Gradio® Display System. Always do

your PMCS in the same order so it becomes a habit. Once you’ve had some practice, you’ll

quickly spot anything wrong.

b. Do your Before PMCS just before you operate the Gradio® Display System. Pay attention to

WARNINGS, CAUTIONS, and NOTES.

c. Do your During PMCS while you operate the Gradio® Display System. Pay attention to

WARNINGS, CAUTIONS, and NOTES.

d. Do your After PMCS right after operating the Gradio® Display System. Pay attention to

WARNINGS, CAUTIONS, and NOTES.

e. Do your Weekly PMCS once a week.

f. Use DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet) to

record any faults that you don’t immediately fix.

2-5. PMCS PROCEDURES.

a. The PMCS Table (Table 2-2.) lists inspections and care required to keep your Gradio® Display

System in good operating condition. This table is set up so you can do Before and After PMCS

while walking around the equipment.

b. The “Interval” column tells you when to do a certain check or service.

c. The “Procedure” column tells you how to do required checks and services. Carefully follow these

instructions.

d. The “Not Fully Mission Capable If” column tells you when your Gradio® Display System is

nonmission capable and why the Gradio® Display System cannot be used.

e. When something looks wrong that you cannot fix, write down the problem on your

DA Form 2404 or DA Form 5988-E. Immediately report the problem to your supervisor.

f. When you do your PMCS, you will always need a rag or two. Following are checks that are

common to the entire Gradio® Display System.

TM 5-6675-348-13&P

2-7

• Degreasing Solvent (MIL-PRF-680, Type II) is TOXIC and flammable. Wear protective

goggles and gloves, use only in a well-ventilated area, avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when

using solvent; the flash point for degreasing solvent type II is 200º F (93º C). Failure to

comply may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention. Do not

use diesel fuel, gasoline, or benzene (benzol) for cleaning.

• Adhesives, solvents, and sealing compounds burn easily and give off vapors that are

harmful to the skin and clothing. To avoid injury or death, keep away from open fire

when using these materials, and use only in well-ventilated areas. If adhesives, solvents,

or sealing compounds contact the skin or clothing, wash immediately with soap and

water, and rinse thoroughly. Failure to comply may result in injury or death to personnel.

(1) Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious

problem. Clean as you work. Use degreasing solvent (MIL-PRF-680, type II) on all metal surfaces.

Use soap and water when you clean rubber or plastic material.

(2) Rust and Corrosion. Check Gradio® Display System brackets for rust and corrosion. When any

bare metal or corrosion exists, clean surface and apply a coat of paint. Report bare metal or

corrosion to your supervisor.

(3) Bolts, Nuts, and Screws. Check all bolts, nuts, and screws for obvious looseness, missing, bent, or

broken condition. You can’t check them all with a tool, but look for chipped paint, bare metal, or

rust around bolt heads. When you find a bolt, nut, or screw you think is loose, tighten it or report it

to your supervisor.

(4) Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. When you

find a bad weld, report it to your supervisor.

(5) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and

loose or broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.

(6) Hydraulic Lines and Fittings. Look for wear, damage, and leaks; ensure clamps and fittings are

tight. Stains around a fitting or connector can mean a leak. If a leak comes from a loose fitting or

connector, tighten it. If something is broken or worn out, report it to Unit Maintenance.

(7) When you check operating conditions, check to see if component is serviceable.

2-6. SHORTENED MAINTENANCE INSTRUCTIONS.

Local conditions of extreme heat, dust, cold, or wetness dictate that service intervals shall be shortened.

TM 5-6675-348-13&P

2-8

2-7. ADDITIONAL MAINTENANCE INSPECTIONS.

Additional maintenance inspections are required for the following reasons:

a. Prolonged storage. Inspect Gradio® Display System components that have been stored for a

period of 3 months or more.

b. Initial preparation upon receipt.

c. Preparation for storage.

2-8. PMCS COLUMN ENTRY EXPLANATION.

a. Item No. Column. The checks and services are numbered in interval order showing a walk-around

sequence around the Gradio® Display System. Use these numbers in the “Item No.” column on

DA Form 2404 or DA Form 5988-E when recording faults that you don’t immediately fix.

b. Interval Column. This column indicates when the lubrication, check, and/or service should be

performed.

c. Location, Item to Check/Service Column. The underlined items listed in this column are divided into

groups indicating the portion of the equipment of which they are a part (e.g., brakes, fuel, engine).

Under these groupings, a few common words are used to identify the specific item being checked.

d. Procedure Column. This column contains procedures required to perform the checks and services.

e. Not Fully Mission Capable If Column. This column contains the criteria that cause the equipment to

be classified as NOT READY/AVAILABLE because of an inability to perform its primary mission. An

entry in this column will:

(1) Identify conditions that make the equipment not available for readiness reporting purposes.

(2) Deny use of the equipment until corrective maintenance has been performed.

2-9. GRADIO® DISPLAY SYSTEM OPERATOR’S PMCS TABLE.

Table 2-2. Gradio® Display System Operator’s PMCS (Before/After)

Item

No. Interval

Location

Procedure Not Fully Mission

Capable If:

Item to

Check/Service

1. Before/After Gradio®

Display System

RT2S Laser

Receiver

Wipe dirt and dust from all metal components

with dry cloth.

Inspect housing of the RT2S Laser Receiver for

damage or cracks.

Inspect windows for cracks, scratches, and dirt.

Clean windows with clean water and soft cloth.

Check antenna for breaks or cuts that will

allow antenna to rotate.

Windows are

cracked.

Antenna rotates.

TM 5-6675-348-13&P

2-9

2. Before/After Gradio®

Display System

DR2 Display

Wipe dirt and dust from all metal components

with dry cloth.

Inspect windows for cracks, scratches, and dirt.

Clean windows with clean water and soft cloth.

Inspect bottom mounting hole of DR2 Display

for dirt and debris.

To avoid damage to equipment, fuse must

be replaced with 5-amp fuse.

Ensure overload protection fuse in DR2

Display is not burned out.

Check antenna for breaks or cuts that will

allow antenna to rotate.

Check bulbs for operation.

Windows are

cracked.

Fuse is burned out.

Antenna rotates.

Bulbs do not

operate.

3. Before/After Electrical

Cables Ensure electrical cables are not frayed,

cracked, or exposed. Cables are frayed,

cracked, or exposed

wires are evident.

4. Before/After Electrical

Connections Ensure connector on back of DR2 Display is

free of dirt and damage. Connector is

damaged.

5. Before/After MM2E Manual

Mast Ensure MM2E Manual Mast will extend and

retract. MM2E Manual

Mast will not extend

or retract.

6. Before/After MM2E Manual

Mast Mounting

Plate

Check welds for cracks or breaks. Any welds are

cracked or broken.

7. Before/After RM2E-3 Rigid

Mast Check RM2E-3 Rigid Mast for damage. RM2E-3 Rigid Mast

is bent.

8. Before/After RM2E-3 Rigid

Mast Mounting

Bracket

Check welds for cracks or breaks. Any welds are

cracked or broken.

9. Before/After Voltage

Protection

Cable

Ensure cable is not frayed, cracked, or exposed. Cable is frayed,

cracked, or exposed

wires are evident.

Table 2-2. Gradio® Display System Operator’s PMCS (Before/After) (Cont)

Item

No. Interval

Location

Procedure Not Fully Mission

Capable If:

Item to

Check/Service

TM 5-6675-348-13&P

2-10

SECTION III. GRADIO® DISPLAY SYSTEM OPERATION

2-10. GRADIO® DISPLAY SYSTEM INSTALLATION OF COMPONENTS.

a. DR2 Display.

• The color of the shrink tubing on

the antenna indicates the

frequency of the display and must

match in color with the heat shrink

tubing on the antenna of the RT2S

Laser Receiver. If the heat shrink

tubing does not match, the Gradio®

Display System will not operate.

• Two adjacent frequency systems

will/can cross-communicate. If

two adjacent frequencies cross-

communicate, the Gradio®Display

System will not operate properly.

(1) Attach DR2 Display (1) to mounting

bracket (2) with screw (3).

(2) Connect Power Cable (4) to back of

DR2 Display (1).

(3) Adjust DR2 Display bright/dim

switch (5) as needed.

b. RT2S Laser Receiver.

The color of the shrink tubing on the

antenna indicates the frequency of the

display and must match in color with

the heat shrink tubing on the antenna

of the RT2S Laser Receiver. If the heat

shrink tubing does not match, the

Gradio® Display System will not

operate.

(1) Turn on RT2S Laser Receiver (6).

(2) Slide RT2S Laser Receiver (6) over

MM2E Manual Mast (7).

(3) Rotate RT2S Laser Receiver Knob (8)

clockwise to secure RT2S Laser

Receiver (6) to MM2E Manual

Mast (7).

TM 5-6675-348-13&P

2-11

2-11. GRADIO® DISPLAY SYSTEM

SETUP.

a. Setup for Dozer.

(1) Place cutting edge (1) on benchmark.

(2) If finished grade is benchmark

elevation, move RT2S Laser

Receiver (2) up/down using MM2E

Manual Mast (3), and adjust until

ON-GRADE symbol (4) (solid green

bar) appears on DR2 Display (5).

NOTE

Moving the RT2S Laser Receiver up on

the MM2E Manual Mast lowers the

blade cutting edge. Moving the RT2S

Laser Receiver down on the

MM2E Manual Mast raises the blade

cutting edge.

(3) If finished grade is below benchmark

elevation, raise RT2S Laser

Receiver (2) using MM2E Manual

Mast (3).

Example: If the final grade is 2 in.

(5.1 cm) below benchmark, raise RT2S

Laser Receiver 2 in. (5.1 cm).

(4) Secure MM2E Manual Mast (3) by

rotating MM2E Manual Mast Adjusting Knob (6) clockwise.

(5) After making a short pass, check grade with 1275 Laser Receiver (7) on Grade Rod (8) (refer to

Chapter 5). Adjust machine-mounted RT2S Laser Receiver (2) up/down using MM2E Manual Mast

to desired grade, if needed.

TM 5-6675-348-13&P

2-12

b. Setup for Scraper.

(1) Place cutting edge (1) on

benchmark.

(2) If finished grade is benchmark

elevation, move RT2S Laser

Receiver (2) up/down on Scraper

Rigid Mast (3), adjust until

ON-GRADE symbol (4) (solid

green bar) appears on DR2

Display (5).

NOTE

Moving the RT2S Laser

Receiver (2) up on the Scraper

Rigid Mast (3) lowers the blade

cutting edge. Moving the RT2S

Laser Receiver (2) down on the

Scraper Rigid Mast (3) raises

the blade cutting edge.

(3) If finished grade is below

benchmark elevation, raise

RT2S Laser Receiver (2) on

Scraper Rigid Mast (3).

Example: If the final grade is

2 in. (5.1 cm) below benchmark, raise RT2S Laser Receiver 2 in. (5.1 cm).

(4) Secure RT2S Laser Receiver (2) by rotating RT2S Laser Receiver (2) Adjusting Knob (6) clockwise.

(5) After making a short pass, check grade with 1275 Laser Receiver (7) on Grade Rod (8) (Refer to

Chapter 5). Adjust machine-mounted RT2S Laser Receiver (2) up/down on Scraper Rigid Mast (3)

to desired grade, if needed.

2-12. GRADIO® DISPLAY SYSTEM OPERATION.

The RT2S Laser Receiver determines if cutting edge is too high, too low, or on grade in relation to the

benchmark. When the RT2S Laser Receiver transmits the grade information to the DR2 Display, the DR2

Display shows the Operator which direction the cutting edge should be adjusted (raised/lowered), if needed.

Ideal grade indication to maintain during normal operation is flashing yellow high (down) arrow, or flashing

(green) On-Grade Bar. It is not desirable to cut below grade.

During Gradio® Display System operations using the RT2S Laser Receiver, watch the DR2 Display and

operate the Dozer or Scraper normally.

Grade Indicator Lamp Correction Indicated Distance from Grade

Solid High Arrow Coarse Lower 0.11 to 0.28 ft (0.03 to 0.09 m)

Flashing High Arrow Fine Lower 0.015 to 0.11 ft (0.005 to 0.03 m)

Flashing On-Grade Bar None ±0.015 ft (±0.005 m)

Flashing Low Arrow Fine Raise 0.015 to 0.11 ft (0.005 to 0.03 m)

Solid Low Arrow Coarse Raise 0.11 to 0.28 ft (0.03 to 0.09 m)

TM 5-6675-348-13&P

2-13

SECTION IV. GRADIO® DISPLAY SYSTEM TROUBLESHOOTING

This section covers Gradio® Display System troubleshooting. The Gradio® Display System Fault Index, Table

2-3., lists faults for the Gradio® Display System.

Table 2-3. Gradio® Display System Fault Index

Fault

No. Description Page

2-1. Gradio® Display System Does Not Operate ....................................................................................2-14

TM 5-6675-348-13&P

2-14

2-13. GRADIO® DISPLAY SYSTEM TROUBLESHOOTING INSTRUCTIONS.

Table 2-4. Gradio® Display System Troubleshooting

Malfunction

Test or InspectionCorrective Action

FAULT 2-1. GRADIO® DISPLAY SYSTEM DOES NOT OPERATE.

Step 1. Ensure 1145-2 Laser Transmitter is correctly set up and operating

(Chapter 5). Verify with RT2S Laser Receiver.

If 1145-2 Laser Transmitter is correctly set up and operating, go to Step 2.

If 1145-2 Laser Transmitter is not correctly set up and operating, go to Chapter 5.

Step 2. Check bright/dim switch (1) on DR2 Display for proper position.

If bright/dim switch is in wrong position, move switch to correct position.

If bright/dim switch is damaged or faulty, return switch to manufacturer.

Dash number on back of RT2S Laser Receiver must match dash number on the DR2

Display. If dash numbers are not the same, the equipment will fail to operate.

Step 3. Check RT2S Laser Receiver ON/OFF switch (2) and channel compatibility with

DR2 Display.

If dash numbers are not the same, replace with compatible parts.

TM 5-6675-348-13&P

2-15

Step 4. Check 5-amp fuse (3) on rear of DR2 Display.

To avoid damage to equipment, fuse must be replaced with 5-amp fuse.

If fuse is faulty, replace.

Step 5. Check battery, terminals, and connections (4) in RT2S Laser Receiver.

NOTE

As battery output degrades, display may exhibit the following symptoms: loss of flashing

on grade or flashing fine correction (solid light will appear), abnormal display, or loss of all

lights (5).

If symptoms occur, replace batteries.

Step 6. Check Power Cable, at DR2 Display end, for 22 to 28 Vdc (Para 2-14).

If voltage is faulty, replace Power Cable.

Step 7. Check for good connection at Power Cable connector (6).

If cable connection is poor, properly connect Power Cable connector (6).

Table 2-4. Gradio® Display System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

2-16

2-14. GRADIO® SYSTEM TROUBLESHOOTING INSTRUCTIONS.

a. Measurements Required for Troubleshooting.

Use properly sized test leads and ensure care is used when checking for resistance,

continuity, or voltage at connectors, or damage to equipment may result.

(1) Resistance measurements.

(a) Connect red test lead to Volt-Ohm input connector and black lead to COM input connector on

meter.

(b) Set function/range switch to desired Ohm position. If magnitude of resistance is not known,

set switch to highest range, then reduce until satisfactory reading is obtained.

(d) Connect test leads to circuit being measured. When measuring high resistance, be careful not

to contact adjacent points, even if insulated. Some insulators have relatively low insulation

resistance, which can affect resulting measurement.

(e) Read resistance value on digital display.

(2) Continuity checks.

(a) Place function/range switch in any Ohm range.

NOTE

Some meters show “1+m”, or simply “1” when function/range switch is in any Ohm position.

(b) Connect red test lead to Volt-Ohm input connector and black lead to COM input connector on

meter. When test leads are separated or measuring an out-of-range resistance, digital display

will indicate “OL” (Over Limit).

When continuity is established, Ohm symbol will appear in upper left corner of digital display.

If contact in wire is maintained long enough (about 1/4 second), the OL will disappear and

resistance value of wire or circuit will appear next to symbol.

(d) If multimeter does not work in this manner, learn how it operates before performing trouble-

shooting.

(3) Voltage measurements.

(a) Connect red test lead to Volt-Ohm input connector and black lead to COM input connector on

meter. If DC-AC switch is present, ensure it is set to DC position.

(b) Set function/range switch to desired voltage position. If magnitude of voltage is not known, set

switch to range which will be able to read most voltages seen on equipment (typically, 200-V

range will do). Reduce range until satisfactory reading is obtained.

TM 5-6675-348-13&P

2-17

b. General Wire Test Procedures.

Use properly sized test leads and ensure care is used when checking for resistance,

continuity, or voltage at connectors, or damage to equipment may result.

(1) Wire voltage drop test.

(a) Disconnect connector from component (e.g., light, relay, motor, etc.) at working end of circuit.

(b) Check connector terminal(s) for damage. Repair or replace connector as necessary.

(d) Check for required voltage at working end of wire.

1If required voltage is not measured at working end of wire, go to Step (e).

2If required voltage is measured at working end of wire, fault has not been isolated.

Continue with fault isolation tests or notify supervisor.

(e) Disconnect first connector in line from working end of wire to power source.

(f) Check for required voltage at working end of wire.

1If required voltage is not measured at working end of wire, go to Step (g).

2If required voltage is measured at working end of wire, fault is in the section of wire that

was most recently disconnected. Repair wire and perform voltage test again.

(g) Repeat Steps (d) and (e) until all sections of suspect wire are tested.

(2) Wire continuity test.

(a) Disconnect wire from component (e.g., light, relay, motor, etc.) at working end of circuit and

from power end of circuit.

(b) Set equipment conditions that will create desired circuit.

1If continuity is not measured, go to Step (d).

2If continuity is measured, fault has not been isolated. Continue with fault isolation tests

or notify supervisor.

(d) Disconnect first connector from working end of wire in line to power source.

(e) Check continuity.

1If continuity is not measured, go to Step (f).

2If continuity is measured, fault is in section of wire most recently disconnected. Repair

wire and perform continuity test again.

(f) Repeat Steps (d) and (e) until all sections of suspect wire are tested.

TM 5-6675-348-13&P

2-18

(3) Wire harness shorting wires test.

(a) Disconnect wire harness connector with wire suspected of damage.

(b) Set multimeter select switch to Ohm.

(d) Connect negative (-) multimeter lead to all terminals in harness connector.

1If continuity is measured, suspect wire and wire where continuity is measured are

shorting together. Repair wires.

2If continuity is not measured, all wires are OK.

(4) Wire repair. Refer to TM 43-0158 for detailed instructions concerning electrical wiring repairs.

Wire harness repair is limited to splicing and taping of wires at Unit Maintenance. If wire harness

cannot be repaired, notify Direct Support Maintenance.

TM 5-6675-348-13&P

2-19

SECTION V. GRADIO® DISPLAY SYSTEM MAINTENANCE

2-15. GRADIO® DISPLAY SYSTEM INSTALLATION FOR DOZER.

This Task Covers:

a. Installation. b. Follow-On Maintenance.

INITIAL SETUP

Models

D7F Dozer (TM 5-2410-233-Series)

D7G Dozer (TM 5-2410-237-Series)

D7H Dozer

D7R Dozer

Tools and Special Tools

Tool Kit, Automotive Maintenance, Common

No. 2, Item 2, Appendix B

Tool Kit, Electric, Item 3, Appendix B

Tool Kit, Welders, Item 4, Appendix B

Materials and Parts

Cloth, Lint-Free, Item 3, Appendix F

Paint, Spray, Black, Item 8, Appendix F

Rags, Wiping, Item 9, Appendix F

Solder, Lead-Tin Alloy Item 10, Appendix F

Tags, Identification, Item 13, Appendix F

Ties, Cable, Item 15, Appendix F

Kit, Voltage Protection, Item 1, Appendix K

Label, Warning, Welding/Jump Starting;

Item 2, Appendix K

Mount, MM2E Manual Mast, Item 3,

Appendix K

Personnel Required

MOS 62B

MOS 44B

Equipment Condition

Engine OFF

(TM 5-2410-233-Series)

(TM 5-2410-237-Series).

Seat removed

(TM 5-2410-233-Series)

(TM 5-2410-237-Series).

Main Power Cable disconnected

(TM 5-3805-233-Series)

(TM 5-3805-237-Series).

TM 5-6675-348-13&P

2-20

a. Installation.

The leveling procedure must be

performed on a hard surface, such as

concrete or asphalt. Failure to

comply will cause the system to not

operate properly.

NOTE

To ease leveling of the blade, park

the Dozer on level ground.

(1) Using a straightedge and level on top

edge of blade (1), level blade.

(2) Measure and mark center of

blade (1).

(3) Cut two 8-in. (20.3 cm) metal

plates (3) at a 45-degree angle.

Unsafe welding practices can cause

serious injury from fire, explosions, or

harmful agents. Allow only

authorized personnel to weld or cut

metals, and follow safety precautions

in TC 9-237. Protective clothing and

goggles must be worn, adequate

protective equipment must be used, a

suitable fire extinguisher must be

kept nearby, and requirements of

TC 9-237 must be strictly followed.

Failure to comply may result in

serious injury or death to personnel.

NOTE

This procedure is repeated on both sides

of Mast Mount. Left side is shown.

(4) Center and level Mast Mount (2) at

center of Blade (1) and weld.

(5) Weld two metal plates (3) to Mast

Mount (2) and Blade (1).

TM 5-6675-348-13&P

2-21

(6) Install Connector Holder (4) and screw (5) in

Display Mount (6).

(7) Tighten screw (5).

(8) Locate Display Mount (6) 6 in. (15.2 cm) from

rear edge of Engine Cover (7) and 4 in.

(10 cm) from Air Cleaner Cover (8).

(9) Mark two holes for Display Mount (6)

installation on Engine Cover (7).

(10) Center punch and drill two 1/2-in. (13 mm)

holes in Engine Cover (7).

(11) Install Loop Clamp (9) 12 in. (30.5 cm) from

female end of Power Cable (10).

NOTE

Display Mount Plate installs under

Engine Cover.

(12) Install Display Mount (6), two

lockwashers (11), hex head bolts (12), Loop

Clamp (9), and Display Mount Plate (13) on

Engine Cover (7).

(13) Tighten hex head bolts (12).

(14) Remove two hex head bolts (14),

lockwashers (15), and flat washers (16) from

Engine Cover (7).

(15) Install two Loop Clamps (9) on Power

Cable (17).

(16) Install two Loop Clamps (9) on Engine

Cover (7) with two previously removed flat

washers (16), lockwashers (15), and hex head

bolts (14).

(17) Tighten hex head bolts (14).

TM 5-6675-348-13&P

2-22

NOTE

Steps (18) and (19) require the aid

of an assistant.

(18) Route Power Cable (17) through

Engine Compartment (18), under

floorboards (19), through front side of

Seat Compartment (20).

NOTE

• Install cable ties as needed.

• Leave excess Power Cable coiled

and Power Cable tied under seat.

(19) Route Power Cable (17) through left

side of Seat Compartment (21) and

along existing Battery Cables (22) into

Battery Box (23).

(20) Strip approximately 12 in. (30.5 cm) of

insulation from end of Power

Cable (17).

TM 5-6675-348-13&P

2-23

Allow solder to cool before handling wire.

Failure to comply may result in injury to

personnel.

(21) Solder two connections (24) to Red Wire (25)

and Black Wire (26).

(22) Remove two nuts (27).

(23) Install Red Wire (25) on Positive (+) Battery

Terminal (28).

(24) Install Black Wire (26) on Negative (-) Battery

Terminal (29).

(25) Install and tighten nuts (27).

(26) Drill one 1/2-in. (13 mm) hole (30) in lower left

corner of Battery Box (23), approximately

1 in. (2.54 cm) from side and 4 in. (10 cm) from

bottom.

TM 5-6675-348-13&P

2-24

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 cough, shortness of breath, pain during respiration, increased sputum

production, and chest tightness. The following precautions must be taken whenever using

CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

(27) Remove paint from hole (30) in Battery

Box (23).

(28) Install Voltage Protection Cable (31),

washer (32), and nut (33).

(29) Tighten nut (33).

(30) Apply black spray paint to Diode

connection (31).

TM 5-6675-348-13&P

2-25

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent damage to clothing.

• Remove all jewelry, such as rings, dog tags, bracelets, etc. If jewelry contacts Battery

Terminal, a direct short may result in instant heating of tools, damage to equipment,

and injury or death to personnel.

• Exercise extreme caution when working under tilt platform. Falling platform could

result in serious injury or death to personnel.

• Turn Battery Disconnect Switch OFF prior to performing maintenance in immediate

battery area or working on electrical system. Failure to comply can result in electrical

shock to personnel or damage to equipment.

• Always disconnect the negative (-) Battery Cable before servicing the battery or positive

(+) Battery Cable. Failure to comply can result in electrical shock to personnel or damage

to electrical system.

• Do not allow Battery Cable ends to contact each other or the machine. Failure to comply

can result in damage to battery or electrical system.

(31) Install Voltage Protection Cable (31) on

Negative (-) Battery Terminal (29) with

nut (27).

(32) Tighten nut (27) on Negative (-) Battery

Terminal (29).

b. Follow-On Maintenance.

(1) Install Seat

(TM 5-2410-233-Series)

(TM 5-2410-237-Series).

(2) Connect Main Power Cable

(TM 5-2410-233-Series)

(TM 5-2410-237-Series).

(3) Start Engine

(TM 5-2410-233-Series)

(TM 5-2410-237-Series).

END OF TASK

TM 5-6675-348-13&P

2-26

2-16. GRADIO® DISPLAY SYSTEM INSTALLATION FOR SCRAPERS.

This Task Covers:

a. Installation. b. Follow-On Maintenance.

INITIAL SETUP

Models

613B Scraper (TM 5-3805-260-Series)

621B Scraper (TM 5-3805-248-Series)

Tools and Special Tools

Tool Kit, Automotive Maintenance, Common

No. 2, Item 2, Appendix B

Tool Kit, Electric, Item 3, Appendix B

Tool Kit, Welders, Item 4, Appendix B

Materials and Parts

Cloth, Lint-Free, Item 3, Appendix F

Paint, Spray, Black, Item 8, Appendix F

Rags, Wiping, Item 9, Appendix F

Solder, Item 10, Appendix F

Tags, Identification, Item 13, Appendix F

Ties, Cable, Item 15, Appendix F

Kit, Voltage Protection, Item 1, Appendix K

Label, Warning, Welding/Jump Starting,

Item 2, Appendix K

Mount, RM2E Rigid Mast, Item 4, Appendix K

Personnel Required

MOS 62B

MOS 44B

Equipment Condition

Engine OFF

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

Wheels chocked

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

Main Power Cable disconnected

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

TM 5-6675-348-13&P

2-27

a. Installation.

Unsafe welding practices can cause serious injury from fire, explosions, or harmful agents.

Allow only authorized personnel to weld or cut metals, and follow safety precautions in

TC 9-237. Protective clothing and goggles must be worn, adequate protective equipment

must be used, a suitable fire extinguisher must be kept nearby, and requirements of

TC 9-237 must be strictly followed. Failure to comply may result in serious injury or death

to personnel.

(1) Weld supplied Rigid Mast Mount (1),

holes up, to right side of Bowl (2).

(2) Install Connector Holder (3) and

screw (4) on Display Mount (5).

(3) Tighten screw (4).

NOTE

• The Display Mount should be

mounted in clear view from the

Operator’s Seat.

• Steps (4) through (10) require the

aid of an assistant.

• Position connector holder towards

front of Scraper.

(4) Place Display Mount (5) on Hood (6).

TM 5-6675-348-13&P

2-28

(5) Use existing hole in Hood (6) for left side of

Display Mount hole (7). Right side hole

located 12 in. (30.5 cm) from right side of

Hood (6).

(6) Mark right side Display Mount (5) hole

on Hood (6).

(7) Center punch and drill 1/2-in. (13 mm)

hole (7) in Hood (6).

(8) Install Display Mount (5), Loop

Clamp (8), two bolts (9), Display Mount

Plate (10) to Hood (6).

(9) Leave approximately 12 in. (30.5 cm) of

Power Cable (11) past Loop Clamp (8).

(10) Tighten bolts (9).

(11) Attach Power Cable (11) to Connector

Holder (3).

TM 5-6675-348-13&P

2-29

(12) Remove two bolts (12).

(13) Install Power Cable (11), two Loop

Clamps (8), and existing bolts (12).

(14) Tighten bolts (12).

(15) Strip approximately 12 in. (30.5 cm) of

insulation from end of Power

Cable (11).

(16) Route Power Cable (11) into left side of

Battery Box (13).

Allow solder to cool before handling

wire. Failure to comply may result in

injury to personnel.

(17) Solder two connections (14) to Red

Wire (15) and Black Wire (16).

TM 5-6675-348-13&P

2-30

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 cough, shortness of breath, pain during respiration, increased sputum

production, and chest tightness. The following precautions must be taken whenever using

CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

(18) Drill one 1/2-in. (13 mm) hole (17) in rear corner of Battery Box (13), approximately 1 1/2-in.

(3.81 cm) from rear of Battery Box and 1 in. (2.54 cm) down from top.

(19) Clean paint from hole (17) in Battery Box (13).

(20) Install Diode Protection Cable (18), washer (19), and nut (20).

(21) Tighten nut (20).

(22) Using black spray paint, paint hole (17) in Battery Box (13).

TM 5-6675-348-13&P

2-31/(2-32 Blank)

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result if

acid contacts skin or eyes. Wear rubber apron to prevent damage to clothing.

• Remove all jewelry, such as rings, dog tags, bracelets, etc. If jewelry contacts Battery

Terminal, a direct short may result in instant heating of tools, damage to equipment,

and injury or death to personnel.

• Exercise extreme caution when working under tilt platform. Falling platform could

result in serious injury or death to personnel.

• Turn battery disconnect switch OFF prior to performing maintenance in immediate

battery area or working on electrical system. Failure to comply can result in electrical

shock to personnel or damage to equipment.

• Always disconnect the negative (-) battery cable before servicing the battery or positive

(+) battery cable. Failure to comply can result in electrical shock to personnel or damage

to electrical system.

• Do not allow battery cable ends to contact each other or the machine. Failure to comply

can result in damage to battery or electrical system.

(23) Install Red Wire (15) and nut (21) to

Positive (+) Battery Terminal (22).

(24) Tighten nut (21).

(25) Install Black Wire (16) and Diode

Protection Cable (18) to Negative (-)

Battery Terminal (23) with nut (24).

Coil excess Power Cable (11) and Diode

Protection Cable (18) in Battery

Box (13).

(26) Tighten nut (24).

b. Follow-On Maintenance.

(1) Connect Main Power Cable

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

(2) Start Engine

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

(3) Remove Chocks

(TM 5-3805-260-Series)

(TM 5-3805-248-Series).

END OF TASK

TM 5-6675-348-13&P

3-1

CHAPTER 3

BLADE PRO® MOTOR GRADER CONTROL SYSTEM

(130G GRADER)

Content Para Page

Blade Pro® Motor Grader Control System General Information............................................... Section I 3-2

Scope...................................................................................................................................................... 3-1 3-2

Equipment Characteristics, Capabilities, and Features.................................................................. 3-2 3-2

Location and Description of Major Components............................................................................... 3-3 3-5

Blade Pro® Motor Grader Control System Mounting and Adjustments ....................................... 3-4 3-13

Blade Pro® Motor Grader Control System Specifications............................................................... 3-5 3-14

Blade Pro® Motor Grader Control System PMCS ..................................................................... Section II 3-16

Blade Pro® Motor Grader Control System PMCS Introduction..................................................... 3-6 3-16

PMCS Procedures................................................................................................................................. 3-7 3-16

Shortened Maintenance Instructions................................................................................................. 3-8 3-17

Additional Maintenance Inspections.................................................................................................. 3-9 3-18

Leakage Classification and Definition............................................................................................... 3-10 3-18

General Lubrication Instructions....................................................................................................... 3-11 3-18

PMCS Column Entry Explanation..................................................................................................... 3-12 3-19

Blade Pro® Motor Grader Control System Operator’s PMCS Table.............................................. 3-13 3-19

Blade Pro® Motor Grader Control System Operation.............................................................. Section III 3-22

Blade Pro® Motor Grader Control System General Information................................................... 3-14 3-22

Blade Pro® Motor Grader Control System Sensor Calibration....................................................... 3-15 3-22

Blade Pro® Motor Grader Control System Valve Calibration......................................................... 3-16 3-29

Moving Blade Pro® Motor Grader Control System Components from Grader to Grader ........... 3-17 3-35

Blade Pro® Motor Grader Control System Operation Description................................................. 3-18 3-40

Automatic Cross-Slope and Manual Elevation ................................................................................. 3-193-41

Automatic Elevation (Tracer® Sonic Grade Controller) and Cross-Slope...................................... 3-20 3-42

Dual Automatic Elevation (Tracer® Sonic Grade Controller R2S-S

Laser Receiver with EMZE-24 Electric Mast).............................................................................. 3-21 3-45

Automatic Elevation (EM2E-24 Electric Mast And R2S-S Laser Receiver) and Cross-Slope..... 3-22 3-47

Blade Pro® Motor Grader Control System User Options in Setup Mode...................................... 3-23 3-49

Programming Blade Pro® Motor Grader Control System User Options....................................... 3-24 3-50

Blade Pro® Motor Grader Control System Troubleshooting.................................................... Section IV 3-60

Blade Pro® Motor Grader Control System Troubleshooting Error Messages......................... Section V 3-70

Test/Error Log Feature ........................................................................................................................ 3-25 3-70

Blade Pro® Motor Grader Control System Error Log............................................................... Section VI 3-72

MG2P-35 Error Log.............................................................................................................................. 3-26 3-72

Configure for Transport....................................................................................................................... 3-27 3-81

Blade Pro® Motor Grader Control System Maintenance....................................................... Section VII 3-82

Blade Cutting Edge Inspection........................................................................................................... 3-28 3-82

Blade Lift Cylinder Sockets Inspection.............................................................................................. 3-29 3-82

Wear Strips (Circle Top) Inspection.................................................................................................... 3-30 3-83

Hose Tray Backlash Adjustment........................................................................................................ 3-31 3-83

Circle Slide Shoe Inspection................................................................................................................ 3-32 3-84

Blade Backlash Adjustment................................................................................................................ 3-33 3-85

Wear Strip and Shim Replacement.................................................................................................... 3-34 3-86

Blade Pro® Motor Grader Control System Installation................................................................... 3-35 3-87

TM 5-6675-348-13&P

3-2

SECTION I. BLADE PRO® MOTOR GRADER CONTROL SYSTEM GENERAL

INFORMATION

3-1. SCOPE.

Chapter 3 is used for operation and maintenance of the Blade Pro® Motor Grader Control System used on the

130G Grader with the Tracer® Sonic Grade Controller or the R2S-S Laser Receiver with EM2E-24 Electric

Mast flexibility.

3-2. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. Characteristics.

(1) The Blade Pro® Motor Grader Control System automatically controls elevation and/or cross-slope

of the 130G Grader’s cutting edge with an Operator Interface Box. Three essential precision

sensors, read by the Blade Pro® Motor Grader Control System, accurately determine the blade’s

cross-slope relative to the direction of travel. The Blade Slope Sensor is mounted in the frame

pocket of the rotation circle to determine the blade's slope. The Circle Rotation Sensor is mounted

at the hydra-swivel component to determine the blade’s rotation. The Mainfall Slope Sensor is

mounted on right side of Gooseneck Panel of the 130G Grader to measure the slope in the direction

of travel. The blade's actual cross-slope is compared to the desired cross-slope, and is corrected as

needed.

(2) Tracer® Sonic Grade Controller uses sonic

technology to establish an elevation reference

(e.g., a curb and gutter, a string line, a previous

pass, or an existing surface). Once elevation is set,

any elevation deviations are sent to the Remote

Interface Box. The Remote Interface Box provides

correction outputs to hydraulic valve to maintain

relative distance between Tracer® Sonic Grade

Controller and reference surface.

TM 5-6675-348-13&P

3-3

(3) The R2S-S Laser Receiver is an omnidirectional,

360-degree receiver that detects the position of

the laser reference plane and transmits these

signals to the Remote Interface Box. These

signals are processed to indicate the relative

position of the R2S-S Laser Receiver to the laser

reference plane.

(4) The EM2E-24 Electric Mast is a telescoping

mount driven by an electric motor. The EM2E-24

Electric Mast electronically measures vertical

movement and sends the signals to the Remote

Interface Box for processing.

b. Capabilities.

(1) The blade's elevation on one or both sides can be

controlled by using the Tracer® Sonic Grade

Controller to trace an existing surface, a string

line, a curb and gutter, or a previous pass. The

R2S-S Laser Receiver with EM2E-24 Electric

Mast, in combination with the 1145-2 Laser

Transmitter, provides a constant grade reference

up to 1,000 ft (305 m) away from the 1145-2

Laser Transmitter.

(2) The Tracer® Sonic Grade Controller replaces

contact-type followers that often give inaccurate

or inconsistent results.

c. Features.

(1) The Blade Pro® Motor Grader Control System’s automatic blade control is achieved through the

Hydraulic Control Valve. The Hydraulic Control Valve provides electrical-to-hydraulic interface for

controlling the blade’s elevation and cross-slope.

NOTE

Initial installation of these system components is to be conducted by Direct Support

personnel.

(2) Installation kits for the Blade Pro® Motor Grader Control System provides all the necessary cables,

hydraulic hoses, hydraulic fittings, mounting brackets, and fasteners to ensure proper installation

and operation.

TM 5-6675-348-13&P

3-4

(3) The Tracer® Sonic Grade Controller features:

(a) Temperature compensation - Automatically compensates for temperature changes that occur

on the job. Ensures consistent results from dawn to dusk.

(b) Rugged housing - Built to withstand the harsh environment of a construction job site.

position in reference to grade.

(d) Out-of-range indication - Flashing High and Low lamps indicate reference is higher than

elevation set point. Solid High and Low lamps indicate that reference is lower than elevation

set point.

(e) Plug compatibility between the Tracer® Sonic Grade Controller, the R2S-S Laser Receiver,

and the EM2E-24 Electric Mast.

(f) The Operator can lock on to a new reference elevation by pressing the RESET button.

(4) The R2S-S Laser Receiver features:

(a) Electrical connection - A control box, and a 7-pin electric mast or a stand-alone display

interface connector.

(b) Receiver clamp - Allows the receiver to slide over the mast and securely clamp into place.

(5) The EM2E-24 Electric Mast features:

(a) The EM2E-24 Electric Mast is used on 130G Graders that require remote adjustment of the

R2S-S Laser Receiver's height from the cab of the 130G Grader and when a numerical display

of the EM2E-24 Electric Mast movement is required.

(b) Receiver plug - Provides a mount for the R2S-S Laser Receiver to slip over and clamp into

place.

1One 10-pin control box interface connector

2One 7-socket receiver interface connector

(d) Electrical connector cap - Seals the electrical connector to make it water and dust resistant.

TM 5-6675-348-13&P

3-5

3-3. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

Figure 3-1. Blade Pro® Motor Grader Control System Component Placement

(1) TRACER® SONIC GRADE CONTROLLER POLE. Mounts to the end of the blade to provide

mounting for the Tracer® Sonic Grade Controller. Tracer® Sonic Grade Controller poles are stowed

in the Tracer® Clamp and Base Mount Assembly when not in use.

(2) COIL CORD FROM TRACER® SONIC GRADE CONTROLLER

TO REMOTE INTERFACE BOX. This cable is also used when connecting to EM2E-24 Electric

Mast.

(3) TRACER® SONIC GRADE CONTROLLER. Establishes an elevation reference.

(4) BRACKET FOR TRACER® SONIC GRADE CONTROLLER. Locks to the pole mount and attaches

to the Tracer® Sonic Grade Controller. Allows for adjustment of the Tracer® Sonic Grade Controller

to be parallel with the cutting edge.

TM 5-6675-348-13&P

3-6

Figure 3-2. Blade Pro® Motor Grader Control System Mast Component Placement

(1) R2S-S LASER RECEIVER. Detects the laser beam and sends correction signals to the Remote

Interface Box. Corrections are then sent to raise/lower the grader blade.

(2) EM2E-24 ELECTRIC MAST. This is a telescoping mast for the R2S-S Laser Receiver, and is

mounted to the top edge of the blade. The EM2E-24 Electric Mast, with the R2S-S Laser Receiver,

electronically measures vertical movement and sends signals to the Remote Interface Box for

processing.

(3) MAST RISER. Attaches between the mast mount and the shock mount. Adds to the overall height

of the mast assembly to ensure the R2S-S Laser Receiver’s height over the cab can be obtained.

(4) MAST MOUNT. Used to connect the mast assembly to the machine blade. The unit is adjustable so

that the EM2E-24 Electric Mast can be put in plumb position if the blade is rolled.

(5) SHOCK MOUNT. Attaches to the EM2E-24 Electric Mast as part of the mast assembly. Protects

the EM2E-24 Electric Mast and the R2S-S Laser Receiver from vibration.

(6) COIL CORD FROM EM2E-24 ELECTRIC MAST TO REMOTE INTERFACE BOX.

(7) COIL CORD FROM R2S-S LASER RECEIVER TO EM2E-24 ELECTRIC MAST.

TM 5-6675-348-13&P

3-7

a. Remote Interface Box. Central controller and

processor for all sensors, inputs, and elevation

devices. Output signals are provided to the

control valves and the Operator Interface Box.

b. Operator Interface Box. Located in front of the

Operator; provides easy access to all Blade Pro®

Motor Grader Control System control functions.

(1) The operating status is indicated with

Light-Emitting Diodes (LEDs) (2) and (3),

which indicate the operating status of the

right and left sides.

Green (2) Indicator Automatic

Operation

Red (3) Indicator Manual Operation

Solid Green (2) with Flashing Red (3)

Inactive Automatic

(2) The Operator Interface Box uses bright

LEDs to indicate the blade’s position relative

to the desired grade. Operation status

windows (7) use a back-lighted Liquid

Crystal Display (LCD) to indicate

percent (%) slope, direction of slope,

elevation, and error messages. Customized

functions and features can also be displayed

when in SETUP mode.

TM 5-6675-348-13&P

3-8

LCD Display Symbols

Percent Slope* 0.0%

Rise/Run* 1/4 in. (0.64 cm)

Direction of Slope > Blade is rising to the left

< Blade is rising to the right

Elevation Elevation device is in range

Elevation device is out of range or is not hooked up

* Display symbol is user-selectable.

NOTE

The Mainfall Slope Sensor and the Blade

Slope Sensor are the same and can be

interchanged. Calibration is required if

interchanged.

c. Mainfall Slope Sensor. Measures the slope

of the 130G Grader in the direction of travel.

d. Blade Slope Sensor. Measures the actual

slope across the blade.

Table 3-1. Blade Pro® Motor Grader Control System Operator Interface Box Light Indicators

Type of Grade LED Indicator

Coarse Lower Solid Yellow (4)

Medium Lower Flashing Yellow (4)

Fine Lower Flashing Yellow and Green (4 and 5)

ON GRADE Flashing Green (5)

Fine Raise Flashing Yellow and Green (5 and 6)

Medium Raise Flashing Yellow (6)

Coarse Raise Solid Yellow (6)

TM 5-6675-348-13&P

3-9

e. Circle Rotation Sensor. Measures the angle

of the blade relative to the 130G Grader’s

A-frame. When the blade is perpendicular to

the A-frame, 0-degree rotation is achieved.

f. Tracer® Sonic Grade Controller. Mounted at

the top outside edge of the blade, the Tracer®

Sonic Grade Controller uses sonic waves or

an R2S-S Laser Receiver to determine the

location and distance to a reference surface.

Once the Tracer® Sonic Grade Controller has

been locked onto a reference (e.g., a string

line, a curb and gutter, or a previous pass),

any change in the set point distance causes a

correction signal to be sent to the Remote

Interface Box.

g. R2S-S Laser Receiver. Detects the laser

beam and sends correction signals to the

Remote Interface Box. Corrections are then

sent to raise/lower the grader blade.

TM 5-6675-348-13&P

3-10

h. EM2E-24 Electric Mast. This is a telescoping mast

for the R2S-S Laser Receiver, and is mounted to

the top edge of the blade. The EM2E-24 Electric

Mast, with the R2S-S Laser Receiver,

electronically measures vertical movement and

sends signals to the Remote Interface Box for

processing.

i. Hydraulic Control Valves. Accepts signals from

the Remote Interface Box and provides

proportional correction rates for raising and

lowering on both sides of the blade.

NOTE

Initial installation of these system

components is to be conducted by

Direct Support personnel.

j. Blade Pro® Motor Grader Control System

Features, Functions, and Specifications. The

Remote Interface Box (1) provides necessary

system electrical interface to the Blade Slope

Sensor, the Mainfall Slope Sensor, the Circle

Rotational Sensor, the Tracer® Sonic Grade

Controller, the R2S-S Laser Receiver, and the

EM2E-24 Electric Mast. All signal processing and

control outputs occur at the Remote Interface

Control Box. Control signals are provided to the

Hydraulic Control Valves. Communications output

is provided between the Remote Interface Control

Box and the Operator Interface Box for display

information and to allow the Operator to interface

with the system. All programmable functions are

stored at the Remote Interface Control Box in

nonvolatile memory. If power loss occurs, all settings are kept.

TM 5-6675-348-13&P

3-11

(1) Left-Side Connections.

(a) 10-Socket (Left Elevation Input)

(b) 3-Socket (Load Sensing Valve)

Slope Sensors)

(d) 5-Socket (Mainfall Slope Sensors)

(e) 7-Socket (Left Hydraulic Valve)

(2) Right-Side Connections.

(a) 10-Socket (Right Elevation Input)

(b) 8-Socket (Operator Interface Box)

(d) 7-Socket (Right Hydraulic Valve)

(e) Overload Protection (Fuse)

Table 3-2. Blade Pro® Motor Grader Control System Operator Interface Box Controls

Key Controls or

Indicator

Function

1. OFF/ON/SET-UP: In left position System is OFF.

In center position System is ON.

In right position Operator has access to the following SET-UP functions:

Elevation Reference, Customize, Test, Slope Speed, and

Elevation Speed. (For more information on SET-UP

options, refer to Section III)

TM 5-6675-348-13&P

3-12

2. OPERATION MODE

SWITCH: Selects the

side(s) of the blade to be

controlled by elevation

or slope.

In left position Elevation controls the left side of the blade. The cross-slope

controls the right side of the blade.

In center position Elevation controls the left side of the blade.

Elevation controls the right side of the blade.

In right position Cross-slope controls the left side of the blade.

Elevation controls the right side of the blade.

3. DIRECTION OF

SLOPE: Changes the blade’s direction of slope. The blade slope

symbol > < will change in the display window to show the

direction of the slope.

4. INCREASE/

DECREASE: The value in the display window always increases when

toggled up. The value in the display window always

decreases when toggled down. The left Increase/Decrease

switch operates the left display window. The right

Increase/Decrease switch operates the right display

window. Note that when you adjust the cross-slope value,

the number will not go below 0.0%. This makes sure the

Increase/Decrease switch always operates the same way.

(For applications that adjust through 0.0%, refer to

Para 3-23)

Table 3-2. Blade Pro® Motor Grader Control System Operator Interface Box Controls (Cont)

Key Controls or

Indicator

Function

TM 5-6675-348-13&P

3-13

3-4. BLADE PRO® MOTOR GRADER CONTROL SYSTEM MOUNTING AND ADJUSTMENTS.

a. Operator Interface Box.

(1) Serial Communication Connector

(2) Mounting Knob

(3) Remote Switch Connector

b. Operator Interface Box Removal.

(1) Disconnect Remote Switch Connector (3) from back

of Operator Interface Box (4).

(2) Disconnect Serial Communication Connector (1)

from back of Operator Interface Box (4).

(3) Loosen mounting knob (2) on back of Operator Interface Box (4).

5. RIGHT/LEFT (R/L)

SWITCH: Provides remote switching of the system from automatic to

manual operation at the manual control levers.

6. RESET SWITCH: Resets Tracer® Sonic Grader Controller reference to a new

surface or object.

7. REMOTE SWITCH: Function of the switch is selected in SETUP mode.

Options include Elevation Offsets, Slope Offsets, and Auto

Raise/Lower. (For further details on these options, refer to

Para 3-23)

Table 3-2. Blade Pro® Motor Grader Control System Operator Interface Box Controls (Cont)

Key Controls or

Indicator

Function

TM 5-6675-348-13&P

3-14

(4) Pull Operator Interface Box (4) up from

mounting bracket (5).

(5) Attach loose connectors (1) and (3) to

provided dust covers (6) and (7) on side of the mounting bracket (5).

c. Operator Interface Box Viewing Angle Adjustment.

(1) Loosen mounting knob (2) on back of Operator Interface Box (4).

(2) Rotate Operator Interface Box (4) for best viewing angle, then tighten mounting knob (2).

3-5. BLADE PRO® MOTOR GRADER CONTROL SYSTEM SPECIFICATIONS.

Blade Slope Sensor Resolution 0.01% slope

Mainfall Slope Sensor Resolution 0.01% slope

Circle Rotation Sensor Resolution 0.1 degree

Articulation Sensor Resolution 0.1 degree

Cross-Slope Resolution 0.01% slope

*Cross-Slope Accuracy 1/4 in./10 feet

Cross-Slope Range ±19.99%

* System accuracy is affected by the tightness of the machine. (Refer to Para 3-23 for more

information about determining the machine’s slope.)

TM 5-6675-348-13&P

3-15

Table 3-3. Blade Pro® Motor Grader Control System Equipment Data

Model Item

DIMENSIONS

ST2-20 Height: 9.0 in. (22.9 cm)

Width: 4.25 in. (10.8 cm)

Depth: 2.75 in. (7.0 cm)

R2S-S Height: 11.4 in. (29 mm)

Width: 4.60 in. (11.7 cm)

Depth: 5.8 in. (14.7 cm)

WEIGHT

ST2-20 3.5 lb. (1.6 kg)

R2S-S 2.9 lb. (1.3 kg)

ELECTRICAL SYSTEM

ST2-20 Input: 10 to 30 Vdc

R2S-S Input: 10 to 30 Vdc

Connector: Standard Military Type (Mil Spec. C-5015)

Operating Temperature: -20 to 160° F (-28.9 to 71.1° C)

Bulbs: 12-/24-volt bulbs. Ensure proper bulb is installed for machine’s electrical system.

TEMPERATURE

ST2-20 Operating Temperature Range: -20 to 160° F (-28.9 to 71.1° C)

R2S-S Operating Temperature Range: -20 to 160° F (-28.9 to 71.1° C)

SPECIFICATIONS

ST2-20 Correction Window: ±0.20 ft (6.1 cm)

On Grade Dead Bands:Narrow: ±0.015 ft (±0.46 cm)

Operating Distance: Max. 43 in. (109 cm)

Min. 8 in. (20.3 cm)

Sonic Cone Angle: 6 degrees (inclusive)

R2S-2 Vertical Sensing Range: 0.61 ft (18.6 cm)

Beam Acceptance Angle: 360 degrees

On Grade Dead Band*: ±0.015 ft (±0.46 cm)

*Typical reading with Laser Transmitters

TM 5-6675-348-13&P

3-16

SECTION II. BLADE PRO® MOTOR GRADER CONTROL SYSTEM PMCS

3-6. BLADE PRO® MOTOR GRADER CONTROL SYSTEM PMCS INTRODUCTION.

Preventive Maintenance Checks and Services (PMCS) means systematic caring for, inspecting, and servicing

equipment to keep it in good condition and to prevent breakdowns. As a Blade Pro® Motor Grader Control

System Operator, your mission is to:

a. Be sure to perform your PMCS each time you operate the Blade Pro® Motor Grader Control

System. Always do your PMCS in the same order so it becomes a habit. Once you’ve had some

practice, you’ll quickly spot anything wrong.

b. Do your Before PMCS just before you operate the Blade Pro® Motor Grader Control System. Pay

attention to WARNINGS, CAUTIONS, and NOTES.

c. Do your During PMCS while you operate the Blade Pro® Motor Grader Control System. Pay attention

to WARNINGS, CAUTIONS, and NOTES.

d. Do your After PMCS right after operating the Blade Pro® Motor Grader Control System. Pay attention

to WARNINGS, CAUTIONS, and NOTES.

e. Do your Weekly PMCS once a week.

f. Use DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet) to

record any faults that you don’t immediately fix.

3-7. PMCS PROCEDURES.

a. PMCS Tables (Table 3-4., Table 3-5., and Table 3-7.) list inspections and care required to keep

your Blade Pro® Motor Grader Control System in good operating condition. These tables are set

up so you can do Before and After PMCS while walking around the Blade Pro® Motor Grader

Control System.

b. The “Interval” column tells you when to do a certain check or service.

c. The “Procedure” column tells you how to do required checks and services. Carefully follow these

instructions.

d. The “Not Fully Mission Capable If” column tells you when your Blade Pro® Motor Grader

Control System is nonmission capable and why the Blade Pro® Motor Grader Control System

cannot be used.

e. When something looks wrong that you cannot fix, write down the problem on your

DA Form 2404 or DA Form 5988-E. Immediately report the problem to your supervisor.

f. When you do your PMCS, you will always need a rag or two. Following are checks that are

common to the entire Blade Pro® Motor Grader Control System.

TM 5-6675-348-13&P

3-17

• Degreasing Solvent (MIL-PRF-680, Type II) is TOXIC and flammable. Wear protective

goggles and gloves, use only in a well-ventilated area, avoid contact with skin, eyes, and

clothes, and do not breathe vapors. Keep away from heat or flame. Never smoke when

using solvent; the flash point for degreasing solvent type II is 200º F (93º C). Failure to

comply may result in injury or death to personnel.

• If personnel become dizzy while using cleaning solvent, immediately get fresh air and

medical help. If solvent contacts skin or clothes, flush with cold water. If solvent contacts

eyes, immediately flush eyes with water and get immediate medical attention. Do not

use diesel fuel, gasoline, or benzene (benzol) for cleaning.

• Do not smoke when using cleaning solvent. Never use it near an open flame. Be sure

there is a fire extinguisher nearby and use cleaning solvent only in a well-ventilated

area.

• Use caution when using cleaning solvents. Cleaning solvents evaporate quickly and can

irritate exposed skin if solvents contact skin. In cold weather, contact of exposed skin

with cleaning solvents can cause frostbite.

(1) Keep It Clean. Dirt, grease, oil, and debris only get in the way and may cover up a serious problem.

Clean as you work. Use degreasing solvent (MIL-PRF-680, Type II) on all metal surfaces. Use soap

and water when you clean rubber or plastic material.

(2) Rust and Corrosion. Check Blade Pro® Motor Grader Control System brackets for rust and

corrosion. When any bare metal or corrosion exits, clean surface and apply a coat of paint. Report

bare metal or corrosion to your supervisor.

(3) Bolts, Nuts, and Screws. Check all bolts, nuts, and screws for obvious looseness, missing, bent, or

broken condition. You can’t check them all with a tool, but look for chipped paint, bare metal, or

rust around bolt heads. When you find a bolt, nut, or screw you think is loose, tighten it or report it

to your supervisor.

(4) Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. When you

find a bad weld, report it to your supervisor.

(5) Electric Wires and Connectors. Look for cracked, frayed, or broken insulation, bare wires, and

loose or broken connectors. Tighten loose connectors. Report any damaged wires to your supervisor.

(6) Hydraulic Lines and Fittings. Look for wear, damage, and leaks; ensure clamps and fittings are

tight. Stains around a fitting or connector can mean a leak. If a leak comes from a loose fitting or

connector, tighten it. If something is broken or worn out, report it to Unit Maintenance.

(7) When you check operating conditions, check to see if component is serviceable.

3-8. SHORTENED MAINTENANCE INSTRUCTIONS.

Local conditions of extreme heat, dust, cold, or wetness dictate that service intervals shall be shortened.

TM 5-6675-348-13&P

3-18

3-9. ADDITIONAL MAINTENANCE INSPECTIONS.

Additional maintenance inspections are required for the following reasons:

a. Prolonged storage. Inspect 130G Grader control components that have been stored for a period

of 3 months or longer.

b. Initial preparation upon receipt.

c. Preparation for storage.

3-10. LEAKAGE CLASSIFICATION AND DEFINITION.

It is necessary for you to know how fluid leakage affects the status of the Blade Pro® Motor Grader Control

System. Following are types/classes of leakage that Operator needs to know to be able to determine the status

of the Blade Pro® Motor Grader Control System. Learn these leakage definitions and remember – when in

doubt, notify your supervisor.

• Equipment operation is allowable with minor leakages (Class I or II) with exception of fuel leakage.

Of course, consideration must be given to fluid capacity in the item/system being checked/inspected.

When in doubt, notify your supervisor.

• When operating with Class I and II leaks, continue to check fluid levels as required in your PMCS.

• Any fuel leak or Class III leaks should be reported immediately to your supervisor.

a. CLASS I – Leakage of fluid (as indicated by wetness or discoloration) not great enough to form

drops.

b. CLASS II – Leakage of fluid great enough to form drops, but not enough to cause drops to drip

from item being checked/inspected.

c. CLASS III – Leakage of fluid great enough to form drops that fall from item being checked/

inspected.

3-11. GENERAL LUBRICATION INSTRUCTIONS.

Do not start or move Blade Pro® Motor Grader Control System while anyone is under the

130G Grader. Failure to comply could result in severe injury or death to personnel.

a. Intervals. Intervals (On-condition or hard-time) and related man-hour times are based on normal

operation. Man-hour time specified is time needed to do all services prescribed for a particular interval.

On-condition (OC) oil sample intervals shall be applied unless changed by the Army Oil Analysis

Program (AOAP) laboratory. Change hard-time interval when lubricants are contaminated or when

you are operating equipment under adverse operating conditions, including longer-than-usual

operating hours. Calendar interval will be extended during periods of low activity.

When extended, adequate preservation precautions must be taken. Hard-time intervals will be applied

in the event AOAP laboratory support is not available. Hard-time intervals must be applied during the

warranty period. Intervals shown in this lubrication section are based on calendar and hourly times or

calendar times and mileage. An example of a calendar and hourly lubrication is: M/60 HR, in which M

stands for monthly and 60 HR stands for 60 hours of 130G Grader operation. Lubrication is to be

performed at whichever interval occurs first for the 130G Grader. Special lubrication intervals and

services are shown by the use of an asterisk (*) symbol.

TM 5-6675-348-13&P

3-19

3-12. PMCS COLUMN ENTRY EXPLANATION.

a. Item No. Column. The checks and services are numbered in interval order showing a walk-around

sequence around the Blade Pro® Motor Grader Control System. Use these numbers in the “Item No.”

column on DA Form 2404 or DA Form 5988-E when recording faults that you don’t immediately fix.

b. Interval Column. This column indicates when the lubrication, check, and/or service should be

performed.

c. Location, Item to Check/Service Column. The underlined items listed in this column are divided into

groups indicating the portion of the equipment of which they are a part (e.g., brakes, fuel, and engine).

Under these groupings, a few common words are used to identify the specific item being checked.

d. Procedure Column. This column contains procedures required to perform the checks and services.

e. Not Fully Mission Capable If Column. This column contains the criteria that cause the equipment to

be classified as NOT READY/AVAILABLE because of an inability to perform its primary mission. An

entry in this column will:

(1) Identify conditions that make the equipment not available for readiness reporting purposes.

(2) Deny use of the equipment until corrective maintenance has been performed.

3-13. BLADE PRO® MOTOR GRADER CONTROL SYSTEM OPERATOR’S PMCS TABLE.

Table 3-4. Blade Pro® Motor Grader Control System Operator’s PMCS (Before/After)

Item

No. Interval

Location

Procedure Not Fully Mission

Capable If:

Item to

Check/Service

1. Before/After Hydraulic Tubes

and Fittings Check all hydraulic tubes and fittings

for leaks. Class III leaks are evident.

2. Before/After PSV2 Hydraulic

Valves Check all hydraulic valves for leaks. Class III leaks are evident.

3. Before/After Hydraulic Hoses Check all hydraulic hoses for leaks. Class III leaks are evident.

4. Before/After Electrical

Cables and Coil

Cords

Check all electrical cables to ensure

none are frayed, cracked, or exposed.

Check electrical connections to ensure

they are free of dirt, debris, and

damage.

Check all screws and nuts for

tightness.

Ensure dust caps are in place when

electrical connections are not being

used.

Frayed, cracked, or

exposed wires are evident.

Connectors are damaged.

TM 5-6675-348-13&P

3-20

5. Before/After Remote

Interface Box

To avoid damage to equipment,

fuse must be replaced with

25-amp fuse.

Check 25-amp fuses to ensure they are

not burned out.

Check left and right socket connectors

for any dirt, debris, or damaged

connections.

Check nuts and screws for tightness.

Fuse is blown. Replace

before operating.

Dirt, debris, and/or

damaged connectors are

present.

Nuts or screws are loose.

6. Before/After Mainfall Slope

Sensor and

Blade Slope

Sensors

Check electrical connectors for any

dirt, debris, or damage. Connectors are damaged.

7. Before/After Circle Rotation

Sensor Check electrical connectors for dirt,

debris, or damage.

Check screws for tightness.

Connectors are damaged.

8. Before/After Tracer® Sonic

Grade

Controller

Check electrical connectors and

transducer for dirt, debris, or damage.

Wipe dirt and dust from housing covers

with damp cloth. Inspect exterior for

damage or cracks.

Wipe dirt and dust from transducer,

using soft cloth or low-pressure air.

Connectors are damaged.

Transducer is soiled,

dented, or foil inside is

ripped.

9. Before/After R2S-S Laser

Receiver Check electrical connections for dirt,

debris, or damage.

Wipe dirt and dust from metal housing

cover with damp cloth.

Inspect windows for cracks and ensure

black dust seal is still in place.

Clean windows with clean water or

general purpose cleaner and soft cloth.

Check and clean breather hole.

Connectors are damaged.

Windows are cracked or

black dust seal is missing.

Breather hole is plugged.

Table 3-4. Blade Pro® Motor Grader Control System Operator’s PMCS (Before/After) (Cont)

Item

No. Interval

Location

Procedure Not Fully Mission

Capable If:

Item to

Check/Service

TM 5-6675-348-13&P

3-21

10. Before/After EM2E-24

Electric Mast Check cap seal for wear and play.

Check electrical connectors, dust cover,

screw, and hardware for damage.

Connectors are damaged.

11. Before/After Operator

Interface Box Wipe dirt and dust from all metal

components with damp cloth.

Clean screen with general purpose

cleaner and soft cloth.

Inspect exterior for cracks and any

damage to any electrical connectors. Connectors are damaged.

12. Before/After Mast Mount

Base Check all welds for cracks. Welds are cracked.

Table 3-5. Blade Pro® Motor Grader Control System PMCS (Quarterly)

Item

No. Interval

Location

Procedure

Not Fully

Mission

Capable If:

Item to

Check/Service

1. Quarterly Blade Pro® Sensor Calibration Refer to Para 3-15

2. Quarterly Valve Calibration Refer to Para 3-16

Table 3-4. Blade Pro® Motor Grader Control System Operator’s PMCS (Before/After) (Cont)

Item

No. Interval

Location

Procedure Not Fully Mission

Capable If:

Item to

Check/Service

TM 5-6675-348-13&P

3-22

SECTION III. BLADE PRO® MOTOR GRADER CONTROL SYSTEM OPERATION

3-14. BLADE PRO® MOTOR GRADER CONTROL SYSTEM GENERAL INFORMATION.

Operator Interface Box Controls and Indicators.

1. Display Window.

2. Above-Grade Indicator (2) (Yellow)

3. On-Grade Indicator (2) (Green)

4. Below-Grade Indicator (2) (Yellow)

5. Mode Switch

6. Slope Switch

7. ON/OFF/SET-UP Switch

8. RESET Button (2)

9. Increase/Decrease Switch (2)

10. Manual LED (2) (Red)

11. Automatic LED (2) (Green)

12. Quick Instruction Cards

3-15. BLADE PRO® MOTOR GRADER CONTROL SYSTEM SENSOR CALIBRATION.

NOTE

• Sensor calibration requires the aid of an assistant.

• Valve calibration and sensor calibration settings are specific for the make, model,

bumper number, and serial number once calibration is completed.

a. Circle Rotation Sensor Calibration.

(1) Rotate and align chisel marks on 130G Grader’s Rotation Circle to draw bar reference.

(2) Place cutting edge firmly on ground.

(3) Loosen two bolts (1) on Rotation

Sensor (1.1).

TM 5-6675-348-13&P

3-23

(4) Set ON/OFF/SET-UP Switch (2) to SETUP

position.

(5) Toggle left Increase/Decrease (3) switch

down until TEST MODE is displayed in

left window and RESET is displayed in

right window.

(6) Push Slope switch (4) right, while at the

same time pushing right RESET button (5)

in, and right Increase/Decrease switch (3)

down. INSTALL will be displayed in the

left window.

(7) Toggle left Increase/Decrease switch (3)

down until SENSORS is displayed in left

window.

(8) Press left RESET button (5). BLADE will

appear in left window.

TM 5-6675-348-13&P

3-24

(9) Toggle left Increase/Decrease switch (3)

down until ROTATION is displayed in left

window.

(10) Manually turn Rotation Sensor (1.1) until

display reads 0.00 +/- 4.00 degrees.

(11) Tighten two bolts (1) on Rotation

Sensor (1.1).

b. 130G Grader Setup.

(1) Start 130G Grader (TM 5-3805-261-10).

NOTE

To ease sensor calibration, park

130G Grader on level ground.

(2) Park 130G Grader (6) on solid material

such as concrete, asphalt, or compacted

soil.

(3) Align front tires (7) vertically and position

A-frame draw bar (8) directly centered

under main frame of 130G Grader (6).

(4) Align 130G Grader (6) so that no

articulation (9) is in 130G Grader (6).

(5) Rotate and align circle marks (10) to

A-frame draw bar (8) reference.

(6) Place cutting edge firmly on ground until

cylinder sockets are not supporting any

weight. Cylinder rods (11) should rotate

freely.

(7) Mark position of blade (12) edges and

center front tires (7), then mark a line

approximately 2 ft (61 cm) long that is

parallel to wheels. Mark center of rear

tandems (13), then mark a line 2 ft (61 cm)

long that is parallel to wheels.

TM 5-6675-348-13&P

3-25

c. Blade Pro® Motor Grader Control System Sensor Calibration.

• Sensor calibration must be done when you change cutting edges or tires and/or remove/

install sensors from one grader to another grader.

• Sensor calibration should be redone if 130G Grader is not cutting to proper grade.

NOTE

Below is the calibration procedure for

FULL CALIBRATE.

(1) Set OFF/ON/SET-UP switch (2) to

SET-UP.

Left Display Right Display

REFERENCE 0.00

(2) Toggle left Increase/Decrease toggle

switch (3) down until following

appears:

Left Display Right Display

CALIBRATE RESET

(3) Press left RESET button (5) to enter

CALIBRATE.

Left Display Right Display

FULL CALIBRATE

TM 5-6675-348-13&P

3-26

(4) Press left RESET button (5) to enter

FULL CALIBRATE.

Left Display Right Display

INITIAL POSITION

Do not disturb 130G Grader while

averaging sensors, or calibration will

not be correct.

NOTE

After pressing the left RESET button,

AVERAGING SENSORS will appear

and flash for 5 seconds. The system

has calibrated the Circle Rotation

Sensor and has stored the first reading

for the Blade Slope Sensor and the

Mainfall Slope Sensor.

(5) Press left RESET button (5) to

calibrate initial position.

Left Display Right Display

AVERAGING SENSORS

(6) Raise blade (12), turn 130G Grader (6)

180 degrees, and position blade (12) on

marks made in the previous step. Place

blade firmly on ground so that

Cylinder Rods (11) are not supporting

any weight. Cylinder Rods (11) should

rotate freely.

TM 5-6675-348-13&P

3-27

(7) Press left RESET button (5) to

calibrate BLADE Sensor.

Left Display Right Display

BLADE POSITION

Do not disturb 130G Grader while

averaging sensors, or calibration will

not be correct.

NOTE

AVERAGING BLADE will appear and

flash for 5 seconds. The system has

now stored a second reading for the

Blade Slope Sensor.

Left Display Right Display

AVERAGING BLADE

(8) Raise blade (12) and position

130G Grader (6) on wheel mark (7)

and wheel mark (13) made in previous

step. Place blade (12) firmly on ground

so that cylinders are not supporting

any weight. Cylinder rods (11) should

rotate freely.

(9) Press left RESET button (5) to

calibrate Mainfall Slope Sensor.

Left Display Right Display

MAINFALL POSITION

TM 5-6675-348-13&P

3-28

NOTE

AVERAGING MAINFALL Sensor will

appear and flash for 5 seconds. The

system has now stored a second

reading for the Mainfall Slope Sensor.

Left Display Right Display

AVERAGING MAINFALL

(10) The Blade Pro® Motor Grader Control

System is asking for verification that

new calibration values are to be used.

If new calibration values are not to be

used, press left Increase/Decrease

toggle switch (3) down and no change

will be made to previous calibration.

Left Display Right Display

ACCEPT CALIBRATE

NOTE

If new settings are to be used, press

left RESET button.

Left Display Right Display

CALIBRATION COMPLETE

(11) Press left RESET button (5) to exit

calibration.

Left Display Right Display

EXIT CALIBRATE

(12) Move OFF/ON/SET-UP switch (2) to

ON position.

TM 5-6675-348-13&P

3-29

3-16. BLADE PRO® MOTOR GRADER CONTROL SYSTEM VALVE CALIBRATION.

a. 130G Grader Setup.

(1) Start 130G Grader (1) (TM 5-3805-261-10).

NOTE

To ease 130G Grader setup, park

grader on level surface.

(2) Park 130G Grader (1) on solid material such as

concrete, asphalt, or compacted soil.

b. Blade Pro® Motor Grader Control System Valve Calibration.

• Valve calibration is required whenever you change hoses, lift cylinders, or any other

repairs to the hydraulic system. Failure to perform valve calibration could result in

improper equipment performance or damage to equipment.

• Perform the sensor calibration procedures prior to performing the valve calibration

procedures. Failure to comply could result in improper 130G Grader performance.

• Operate the machine until the hydraulic oil has reached normal operating temperature

before starting the valve calibration. Failure to comply could result in improper Blade

Pro® Motor Grader Control System performance.

NOTE

•BladePro

® Setup will be displayed across both windows for a few seconds, then

REFERENCE and 0.00 will be displayed.

• Ensure 130G Grader is on level ground, A-frame is centered, and blade is perpendicular

to frame.

• Valve calibration and sensor calibration settings are specific for the make, model,

bumper number, and serial number once calibration is completed.

(1) Position OFF/ON/SET-UP switch (2) in

SET-UP position.

(2) Operate left Increase/Decrease toggle

switch (3) down until CALIBRATION

appears in the left window (4). Press

left RESET button (5) to enter this

menu.

TM 5-6675-348-13&P

3-30

(3) FULL and CALIBRATE will be

displayed in the windows (4).

(4) Operate left Increase/Decrease toggle

switch (3) until VALVE CALIBRATE is

displayed in windows (4).

(5) To enter into valve calibration, hold

Slope switch (6) to the left and, at the

same time, press left RESET

button (5). Release both switches at

the same time.

TM 5-6675-348-13&P

3-31

NOTE

• At this point, the blade needs to be

set up for calibration. Determine

which side (left or right) of blade is

going to be calibrated first. Side

shift blade to opposite side, then

move both cylinders to center of

ram.

• If VALVE TEST appears in

windows, repeat Step (5).

• VALVE CALIBRATE will flash

three times across windows (4) and

SET ALL will appear in left

window.

(6) Select which side control valve will be

calibrated first. To enter into this

menu, press left or right RESET

button (5) for side you want to

calibrate. NOTE

• This should be the same side that

is side-shifted all the way to one

side.

•↑ LIMIT should be displayed in the

left window.

(7) Set upper limit, using blade’s

R/L Switch (6), on side

to be calibrated, to lift blade

until cylinder is almost fully

retracted.

(8) Press RESET button (5) for side to be

calibrated. AVERAGING SENSORS will

flash across windows (4).

TM 5-6675-348-13&P

3-32

Keep all personnel and equipment away from blade during calibration. Blade may move

suddenly, causing injury or death to personnel, or damage to equipment.

• Do not disturb 130G grader while averaging sensors, or calibration will not be correct.

• Left or right RESET Button must be held in for duration of calibration. Failure to comply

could result in improper 130G Grader performance.

NOTE

• The system is requesting that

the upper limit be set.

•↓ LIMIT should be displayed in

the left window.

• WARM-UP should be displayed

in left window and AUTO in right

window.

• System is requesting that lower

limit be set. Set lower limit, using

blade's manual lever, and lower

blade until approximately 1 to 3 in.

(2.54 to 7.6 cm) above ground.

(9) Press RESET button (5) for side to be

calibrated. AVERAGING SENSORS will

flash across windows (4).

TM 5-6675-348-13&P

3-33

NOTE

• Start calibrating control valves by push-

ing left or right RESET Button or by

holding the Remote Offset Switch. This

switch is located on articulation control

lever.

• If the following calibration cannot be

performed at any time, contact Trimble

Navigation.

• This section of valve calibration is called

warm-up period and usually lasts

approximately 3 minutes. Numbers will

be displayed in the right window during

this section and they should range from

0.00% to 3.50%. If after 3 minutes a mes-

sage appears across both windows

indicating VALVE ERROR.

• The next section displayed in the left

window after the warm-up section is

completed is MAXIMUM.

• The correct number displayed in the

right window will be 3.00% ±0.10%. If

this number is not achieved, the

system will not move to the next

cycle. Repeat Step (1).

• After MAXIMUM cycle has reached

its proper calibration number, the

next section displayed in the left

window is MEDIUM.

• The correct number for this cycle will

be 1.00% ±0.01%. If this number is not

achieved, the system will not move to

the next cycle.

• Next section that will be displayed in

the window after MEDIUM has

reached its calibration number is

MINIMUM. Correct calibration

number for this cycle will be 0.25%

±0.01%. If this number is not

achieved, the system will not move to

next cycle.

TM 5-6675-348-13&P

3-34

• Final section displayed in window

after MINIMUM has reached its

proper calibration number is

BALANCE. Correct calibration

number for this cycle will be 1.00%

±0.01. If this number is not achieved,

the system will not finish calibrating.

• Once BALANCE cycle has reached its

proper calibration number, SET ALL

will again be displayed in window.

(10) At this time, the Remote Offset Switch

located on the articulation control lever

can be released and valve calibration

complete for that side.

(11) Now it is time to calibrate the other side.

Prepare for this by using Blade Side Shift

Lever to move blade all the way to the

other side of grader. Repeat Steps (7)

through (10).

NOTE

When the final cycle of BALANCE has

completed, CALIBRATION COMPLETE

will display across both windows and

valve calibration will be complete.

(12) Exit Valve Calibration by positioning

OFF/ON/SET-UP switch (2) back to ON,

or center position.

TM 5-6675-348-13&P

3-35

3-17. MOVING BLADE PRO® MOTOR GRADER CONTROL SYSTEM COMPONENTS FROM

GRADER TO GRADER.

a. Blade Pro® Motor Grader Control System Components.

1. Remote Interface Box

2. Mainfall Slope Sensor

3. Tracer® Sonic Grade Controller

4. Mast Mount

5. Mast Riser

6. Shock Mount

7. EM2E-24 Electric Mast

8. Blade Slope Sensor

9. R2S-S Laser Receiver

TM 5-6675-348-13&P

3-36

b. Remove.

To avoid injury to personnel, ensure 130G Grader is shut off and blade is on the ground.

NOTE

Note location and placement of components prior to removal. This will aid in installation.

(1) Remove 6-pin connector (1) and 8-socket

connector (2) from Operator Interface Box (3).

(2) Place 6-pin connector (1) and 8-socket

connector (2) onto Connector Holders (4) located

on mounting bracket (5).

(3) Loosen knob (6) on back of Operator Interface

Box (3) holding it to mounting bracket (5).

Remove Operator Interface Box (3).

(4) Remove Blade Slope Sensor Cable (7) from Blade

Slope Sensor (8) and secure to Connector

Holder (9).

(5) Remove two socket head screws (10) and Blade

Slope Sensor (8) located in pocket (11) of

130G Grader's Rotation Circle (12).

NOTE

Socket head screws are used to protect

the threads of the Slope Sensor Plate.

(6) Install two socket head screws (13) in Slope

Sensor Plate (14).

TM 5-6675-348-13&P

3-37

(7) Remove Mainfall Slope Sensor Cable (15) from Mainfall Slope Sensor (16) and secure Mainfall

Slope Sensor Cable (15) to Connector Holder (17).

(8) Remove two socket head screws (18) and Mainfall Sensor (16) located on right side of

130G Grader’s gooseneck (19).

NOTE

Socket head screws are used to protect the threads of the Mainfall Slope Sensor Mounting

Plate.

(9) Install two socket head screws (20) in Mainfall Slope Sensor Mounting Plate (21).

NOTE

• Tag and mark all cables before

disconnecting.

• Step (10) applies to both sides of the

machine. The right side is shown.

(10) Remove Connectors (22), (23), and (24),

two bolts (25), washers (26), and Remote

Box Mounting clamp (27) from Remote

Interface Box (28) located under

130G Grader’s gooseneck (19).

(11) Install Connectors (22), (23), and (24) onto

Connector Holders (29), (30), and (31).

TM 5-6675-348-13&P

3-38

c. Install.

NOTE

Step (1) applies to both sides of the machine. The right side is shown.

(1) Install Remote Interface Box (28) under

130G Grader’s Gooseneck (19) with two

washers (26), bolts (25), and Remote Box

Mounting clamp (27).

(2) Tighten bolts (25).

(3) Remove Connectors (22), (23), and (24) from

Connector Holders (29), (30), and (31).

(4) Connect Connectors (22), (23), and (24) to

Remote Interface Box (28).

(5) Remove Mainfall Slope Sensor Cable (15)

from Connector Holder (17).

(6) Remove two socket head screws (20) from

Mainfall Slope Sensor Mounting

Plate (21).

TM 5-6675-348-13&P

3-39

To ensure proper Blade-Pro® Motor

Grader Control System operation,

ensure all sensor plates are clean and

free of debris before bolting any

sensors down.

(7) Install Mainfall Slope Sensor (16),

located on right side of the

130G Grader’s Gooseneck (19), on

Mainfall Slope Sensor Mounting

Plate (21) with two socket head

screws (18).

(8) Tighten socket head screws (18).

To avoid damage to equipment,

ensure cable connector is clean

and dry.

(9) Install Mainfall Slope Sensor Cable (15)

on Mainfall Sensor (16).

(10) Remove Blade Slope Sensor Cable (7) from

Connector Holder (9).

(11) Remove two socket head screws (13) from

Slope Sensor Plate (14).

(12) Install Blade Slope Sensor (8) in

pocket (11) of 130G Grader's Rotation

Circle (12) with two socket head

screws (10).

(13) Tighten socket head screws (10).

(14) Install Blade Slope Sensor Cable (7) on

Blade Slope Sensor (8).

TM 5-6675-348-13&P

3-40

NOTE

Operator Interface Box mounts on bracket at top of grader console.

(15) Loosen knob (6) and slide Operator

Interface Box (3) into groove on

mounting bracket (5). Tighten

knob (6) after correct position of

Operator Interface Box (3) has been

adjusted.

(16) Remove 6-pin connector (1) and

8-socket connector (2) from Connector

Holders (4) located on mounting

bracket (5).

(17) Install 6-pin connector (1) and

8-socket connector (2) on Operator

Interface Box (3).

(18) After all these procedures have been completed, do a final walk around 130G Grader to ensure all

connectors are properly tightened and that all bolts are tight.

(19) Calibrate sensors and valves (refer to Para 3-15 and Para 3-16).

3-18. BLADE PRO® MOTOR GRADER CONTROL SYSTEM OPERATION DESCRIPTION.

Operator Interface Box. Puts all control

functions within easy reach of the Operator. One

Mode Switch is required to select operating

configuration.

(1) Mode switch (1) position and operating

configurations available:

(2) Selected operating mode is shown in two

display windows. The left window is for the130G Grader’s left side and the right window is for the

130G Grader’s right side. Left and right Increase/Decrease switches (2) and (3) adjust for elevation

and slope values. Change blade slope direction, using bottom center Slope Switch (4). Set Tracer®

Sonic Grade Controller to a reference surface by pressing RESET button (5) for side controlled by

the Tracer® Sonic Grade Controller. Two remote switches, located on the left and right manual

control levers, provide control of automatic or manual operation for the left and right sides.

(3) When desired cross-slope is entered into the Operator Interface Box, the Remote Interface Box

reads Mainfall Slope Sensor, Blade Slope Sensors, and Circle Rotation Sensor, and calculates cross-

slope. Calculated cross-slope is compared to the desired cross-slope. If an error is determined, LED

Grade Indicator displays type of correction (i.e., fine, medium, or coarse) and direction (raise or

lower) required to reach desired cross-slope. With Blade Pro® Motor Grader Control System in

automatic operation, the displayed correction is sent to hydraulic valves to reposition the blade to

desired slope. This operating speed provides very fast, smooth response to changing grade

conditions.

Switch Position Left Side Right Side

Left Position Elevation Cross-Slope

Center Position Elevation Elevation

Right Position Cross-Slope Elevation

TM 5-6675-348-13&P

3-41

3-19. AUTOMATIC CROSS-SLOPE AND MANUAL ELEVATION.

a. General Information.

Automatic Cross-Slope and Manual Elevation allows the Operator to manually control the

elevation on the left side of the blade and the cross-slope on the right side of the blade is automatically

controlled. Cross-slope and manual elevation setup can be applied on projects that will use existing

elevations but require a cross-slope for drainage (e.g., tank trails and dirt road upgrades).

b. Setting Up the Blade Pro® Motor Grader Control System.

(1) Set OFF/ON/SET-UP switch (1) to ON position.

NOTE

If previous slope was 0.0, no slope symbol (<) will be shown.

(2) Set Mode switch (2) to left position.

Left Display Right Display

I 0.00 > 0.1%

(3) Enter desired cross-slope in right display window by using right Increase/Decrease switch (3).

Left Display Right Display

I 0.00 < 2.0%

(4) Change blade slope direction switch (4) to match desired slope, if required.

Left Display Right Display

I 0.00 < 0.0%

TM 5-6675-348-13&P

3-42

(5) Toggle right R/L switch (5) forward.

NOTE

• Right green automatic indicator

will be illuminated in upper right

corner of Operator Interface Box.

• Left red manual indicator should still

be illuminated in left-hand corner of

Operator Interface Box.

• Automatic operation will now start.

• If return pass is on same side of road

crown, toggle Mode switch to right.

The cross-slope-controlled side is now

left side and blade slope direction is automatically changed.

3-20. AUTOMATIC ELEVATION (TRACER® SONIC GRADE CONTROLLER) AND CROSS-SLOPE.

a. General Information.

Automatic Elevation and Cross-Slope automatically controls both the elevation on the left side of

the blade and the cross-slope on the right side of blade.

b. Setting Up the Blade Pro® Motor Grader Control System.

(1) Adjust blade (1) to desired roll.

(2) Set OFF/ON/SET-UP switch (2) to ON

position.

TM 5-6675-348-13&P

3-43

(3) Set Mode switch (3) to left position.

Left Display Right Display

I 0.00 > 2.0%

(4) Enter desired cross-slope value into right

display window, using right

Increase/Decrease switch (4).

Left Display Right Display

I 0.00 < 2.0%

(5) Change direction of Slope switch (5), if

required, to match desired direction of slope.

Left Display Right Display

I 0.00 < 2.0%

NOTE

• Right green automatic indicator will

be illuminated in upper right

corner of Operator Interface Box.

• The left red manual indicator should

still be illuminated in left-hand corner of

Operator Interface Box.

(6) Toggle right R/L Switch (6) forward.

TM 5-6675-348-13&P

3-44

(7) Adjust Tracer® Sonic Grade Controller

side of blade so that it is 18 to 24 in.

(46 to 61.0 cm) above desired elevation.

(8) Center Tracer® Sonic Grade Controller (7)

over elevation reference by loosening base

tube clamp studs.

(9) Position tube vertically and center it

directly over elevation reference.

(10) Plumb Tracer® Sonic Grade Controller (8)

over elevation reference by loosening

locking knob on back of mounting arm.

(11) Vertically align Tracer® Sonic Grade

Controller (8) for plumb over reference

surface.

(12) Press left RESET button (9) to lock

Tracer® Sonic Grade Controller (8) onto

reference.

NOTE

• Left green automatic indicator will

be illuminated in upper left corner

of Operator Interface Box.

• Both right and left green automatic

indicators will be illuminated.

(13) Press left R/L switch (6) forward.

TM 5-6675-348-13&P

3-45

NOTE

• If return pass is to be on same side of crown, position Mode switch to right. The Tracer®

Sonic Grade Controller now controls right side and cross-slope left.

• Blade’s slope direction is changed automatically to match desired slope.

• If the Remote Interface Box right-side Tracer® Sonic Grade Controller has not been set

to reference elevation, press right RESET button once blade has been set to reference.

(14) The elevation of Tracer® Sonic Grade

Controller can be changed by using the left

Increase/Decrease switch (4) once the cut

has been started.

3-21. DUAL AUTOMATIC ELEVATION (TRACER® SONIC GRADE CONTROLLER R2S-S

LASER RECEIVER WITH EMZE-24 ELECTRIC MAST).

a. General Information.

Dual Automatic Elevation automatically controls elevation on both sides of the blade.

b. Setting up the Blade Pro® Motor Grader Control System.

(1) Start 130G Grader (TM 5-3805-261-10).

(2) Adjust blade (1) to desired roll.

(3) Adjust mast swivel mount (2) until mast (3)

is plumb.

TM 5-6675-348-13&P

3-46

(4) Set OFF/ON/SET-UP switch (4) to ON position.

(5) Position Tracer® Sonic Grade Controller (5) on

left side of blade over a known elevation point.

(6) Enter zero cross-slope, using Increase/

Decrease switch (6) on right side of

Operator Interface Box (7).

(7) Place R/L Switch (8) on right side in

automatic position. Automatic

Indicator (9) should be green.

(8) Adjust Increase/Decrease switch (6) on

left side of Operator Interface Box (7)

until display is on grade, center green bar

only.

NOTE

Reference will be displayed when OFF/

ON/SET-UP switch is placed in SET-UP

position.

(9) Position OFF/ON/SET-UP switch (4) to

SET-UP position.

(10) Use Increase/Decrease switch (6) on right

side of Operator Interface Box (7) to enter

actual elevation of bottom edge of blade.

(11) Position OFF/ON/SET-UP switch (4) back

to ON position.

TM 5-6675-348-13&P

3-47

(12) Position Mode switch (10) to far right

position.

(13) Position right side of blade (1) over

known elevation point.

(14) Place R/L switch (8) on left side into

automatic mode with zero cross-slope.

Automatic Indicator (9) should be green.

(15) Adjust Increase/Decrease switch (6) on

right side of Operator Interface Box (7)

until center green bar (11) is illuminated

indicating on grade.

NOTE

Reference will be displayed on Operator

Interface Box.

(16) Position OFF/ON/SET-UP switch (4) to

SET-UP position.

(17) Use Increase/Decrease switch (6) on right

side of Operator Interface Box (7) to enter

actual elevation of bottom edge of blade.

(18) Place OFF/ON/SET-UP switch (4) back to ON position.

(19) Position Mode switch (10) to center position.

(20) Using right and left Increase/Decrease switches (6), raise or lower mast to desired elevation.

(21) Place right and left Auto/Manual switches (8) to Auto position.

(22) Begin grading (TM 5-3805-261-10).

3-22. AUTOMATIC ELEVATION (EM2E-24 ELECTRIC MAST AND R2S-S LASER RECEIVER) AND

CROSS-SLOPE.

a. General Information.

Automatic Elevation and Cross-Slope automatically controls elevation on the left and right side of

the blade, and positions switch to the far left position.

b. Setting up the Blade Pro® Motor Grader

Control System.

(1) Start 130G Grader (TM 5-3805-261-10).

(2) Adjust blade (1) to desired roll.

TM 5-6675-348-13&P

3-48

(3) Adjust mast swivel mount (2) until

mast (3) is plumb.

(4) Set OFF/ON/SET-UP switch (4) to ON

position.

(5) Position left side of blade (1) over known

elevation point.

(6) Enter desired cross-slope, using Increase/

Decrease switch (5) on right side of

Operator Interface Box (6). Ensure slope

direction is correct direction of Slope

switch (7).

(7) Place R/L switch (8) on right side in

automatic position. Automatic

Indicator (9) should be green.

(8) Adjust Increase/Decrease switch (5) on

left side of Operator Interface Box (6)

until center green bar (10) is illuminated,

indicating on grade.

(9) Position OFF/ON/SET-UP switch (4) to

SET-UP position.

NOTE

REFERENCE will be displayed on

Operator Interface Box.

(10) Use Increase/Decrease switch (5) on right

side of Operator Interface Box (6) to enter

actual elevation of bottom edge of blade.

(11) Place OFF/ON/SET-UP switch (4) back to

ON position.

NOTE

Both LEDs should be green.

(12) Place R/L switch (8) on left side to

automatic position, and cycle the switch

through MANUAL and back to AUTO.

(13) Begin grading (TM 5-3805-261-10).

TM 5-6675-348-13&P

3-49

3-23. BLADE PRO® MOTOR GRADER CONTROL SYSTEM USER OPTIONS IN SETUP MODE.

a. Reference. Allows a reference elevation (benchmark or sea-level elevation) to be entered into the

elevation display window. The reference elevation does not change the elevation of the blade; only the

numeric value in the display window is changed.

b. Customize. Allows the Operator to customize certain system functions and features. Functions are

OFFSETS, BEEPER ALERTS, and SLOPE DISPLAY. These functions can be turned on or off, or can

be changed through the Customize program.

c. Remote Switch. Three functions are available in OFFSET program: Slope Offset, Elevation Offset,

and Auto Raise/Lower. Only one OFFSET function can be selected at any given time. Selected

OFFSET function is activated by using Remote switch.

(1) Slope Offset allows Remote switch to function in adjusting desired cross-slope in increments of

0.1% to 19.9%. When Remote switch is toggled forward, programmed offset value is added to

displayed cross-slope value. Slope of blade is increased by same value. When Remote switch is

toggled toward Operator, programmed offset value is subtracted from displayed cross-slope value

and slope of blade is decreased by same value. Slope offset allows cross-slope to be transitioned

through zero.

(2) Elevation Offset allows Remote switch to function in adjusting Tracer® Sonic Grade Controller or

EMZE-24 Electric Mast elevation from 0.01 to 3.98 ft (0.003 to 1.213 m). When Remote switch is

toggled toward Operator, programmed offset value is added to displayed elevation value. The

blade’s elevation is raised by same value. When Remote switch is toggled forward, programmed

offset value is subtracted from displayed elevation value and blade’s elevation is lowered by same

value.

(3) Auto Raise/Lower allows Remote switch to automatically raise blade to a selectable relative

distance above grade and switches system into inactive automatic operation. Toggling Remote

switch in opposite direction automatically lowers blade to a selectable distance and switches

system into automatic control. If system does not reach desired elevation range, it will remain in

inactive auto mode and blade will have to be manually lowered and switched to automatic

operation.

d. Beeper. Beeper is used to alert the Operator that certain events are occurring. These functions can be

turned on or off depending on Operator’s preference.

Beeper On/Off. With the beeper ON, a single beep is emitted when:

• Remote switch is toggled.

• A serial communication error is detected.

• A sensor error is detected.

• An out-of-range error occurs (See Section V, Blade Pro® Motor Grader Control System

Troubleshooting Error Messages).

(1) Beeper I (Elevation).

(a) Two short beeps are emitted when elevation device is in a fine correction for more than

2 seconds or if a medium or coarse valve correction signal is sent. This alerts the Operator

that the cut is not to grade. A second pass or ripping the material may be required.

(b) Three short beeps are emitted if Tracer® Sonic Grade Controller or Laser Receiver loses its

reference. For example, if a string line is used as a grade reference and Tracer® Sonic Grade

Controller is moved off string line, then three short beeps are emitted to alert Operator.

TM 5-6675-348-13&P

3-50

(2) Beeper < (Cross-Slope). Two short beeps are emitted when cross-slope-controlled side of blade

remains in a fine correction for more than 2 seconds. If a medium or coarse correction signal is

indicated, two short beeps are emitted with no delay. This alerts the Operator that the slope has

not been cut correctly. A second pass or ripping the material may be required to cut to grade.

e. Slope. % Slope or Rise/Run Display. Allows the Operator to select how cross-slope is displayed in

display window. Options are percent slope (5) or rise/run (e.g., 1/4 in. per foot (6 mm per meter) is

displayed as 1/4” in English; 6 mm per meter is displayed as 6 mm/m metric).

f. Test. Activates all LCD segments and LED indicator lights. Visual display shows any missing LCD

segments or burned-out LED indicators. The test feature also displays errors that may have occurred.

3-24. PROGRAMMING BLADE PRO® MOTOR GRADER CONTROL SYSTEM USER OPTIONS.

a. General Information.

NOTE

SET-UP can be exited from any point in the SET-UP menu by positioning the OFF/ON/SET-

UP switch back to the ON position.

(1) Switches used in SET-UP Mode.

(a) To enter SET-UP, position the OFF/ON/

SET-UP switch (1) to SET-UP position.

NOTE

Left Increase/Decrease switch controls

the menu displayed in left display

window.

(b) Toggle left Increase/Decrease switch (2)

down to move next item in menu.

(d) Use left RESET Button (3) to enter or exit selected menu displayed in left display window.

(e) Right Increase/Decrease switch (4) changes feature from ON to OFF or value displayed in

right window (for example: ON to OFF or 1.25 to 1.26).

(f) SET-UP can be exited from any point in the SET-UP menu by positioning the

OFF/ON/SET-UP switch (1) back to the ON position.

TM 5-6675-348-13&P

3-51

b. Reference Elevation.

Below are instructions for setting a reference elevation into the Operator Interface Box.

When changing reference elevation in SET-UP, new reference elevation will be displayed only on side

of Operator Interface Box in relation to Mode switch (1) position.

To enter a different reference elevation into left side position, move Mode switch (1) to the left.

Left Display Right Display

+ 0.00 < 2.0%

(1) Position OFF/ON/SET-UP switch (2) to

the right SET-UP position.

Left Display Right Display

REFERENCE 0.00

(2) Use right Increase/Decrease switch (3) to

change displayed value until desired

value is displayed.

Left Display Right Display

REFERENCE 1.25

(3) If no additional changes are required,

position OFF/ON/SET-UP switch (2) back

to ON position.

Left Display Right Display

I +1.25 2.0%

TM 5-6675-348-13&P

3-52

(4) To enter a different reference elevation

into both the left and right windows:

(a) Position Mode switch (1) to left

position.

Left Display Right Display

+ 0.00 < 1.9%

(b) Position OFF/ON/SET-UP

switch (2) to SET-UP position.

Left Display Right Display

REFERENCE 0.00

switch (3) to change elevation value

in right display window for desired

reference elevation for left side of

blade.

Left Display Right Display

REFERENCE 1.25

(d) Position OFF/ON/SET-UP

switch (2) back to ON position.

Left Display Right Display

+ 1.25 < 1.9%

TM 5-6675-348-13&P

3-53

(e) Position Mode switch (1) to right

position.

Left Display Right Display

+ 0.00 <1.9%

(f) Position OFF/ON/SET-UP switch (2)

to SET-UP position.

(g) Use right Increase/Decrease

switch (3) to change value in right

display window for desired reference

elevation for right side of blade.

Left Display Right Display

REFERENCE 1.05

(h) Position OFF/ON/SET-UP switch (2)

back to the ON position.

Left Display Right Display

I 1.25 I 1.05

(i) Position Mode switch (1) to center

position.

c. Customize.

To enter CUSTOMIZE:

(1) Position OFF/ON/SET-UP switch (1) to

right SET-UP position.

Left Display Right Display

REFERENCE 00.00

TM 5-6675-348-13&P

3-54

(2) Toggle left Increase/Decrease switch (2)

down until CUSTOMIZE appears.

Left Display Right Display

CUSTOMIZE < RESET

(3) Press left RESET button (3) to enter

CUSTOMIZE.

d. Offset.

To enter OFFSET:

(1) Press left RESET button (1).

Left Display Right Display

OFFSET OFF

(2) If an OFFSET function was previously

selected, then that OFFSET function will

be shown.

(3) Press right Increase/Decrease switch (2)

down until desired OFFSET function

appears in right window.

Left Display Right Display

OFFSET OFF

OFFSET AUTO

OFFSET ELEVATION

OFFSET SLOPE

TM 5-6675-348-13&P

3-55

(4) With desired OFFSET function displayed

in right display window, toggle left

Increase/Decrease switch (3) down.

Left Display Right Display

OFFSET (TYPE) OFFSET (VALUE)

Left Display Right Display

OFFSETS NONE

AUTO >>>

ELEVATION | + 0.01 (+0.005) Metric

SLOPE < 0.1%

(5) Toggle right Increase/Decrease switch (2)

to select desired OFFSET VALUE. Note

that for AUTO RAISE/LOWER, each >

equals about 3 seconds of blade travel.

(6) With desired OFFSET VALUE entered,

toggle left Increase/Decrease switch (3)

down.

Left Display Right Display

EXIT <<< RESET

TM 5-6675-348-13&P

3-56

(7) Press left RESET button (4) to exit

OFFSETS.

e. Beeper.

To enter BEEPER:

(1) Press left RESET button (1).

Left Display Right Display

BEEPER ON

(2) To turn beeper OFF, toggle right

Increase/Decrease switch (2).

Left Display Right Display

BEEPER OFF

(3) Toggle left Increase/Decrease switch (3)

down to enter BEEPER (elevation).

Left Display Right Display

I BEEPER ON

TM 5-6675-348-13&P

3-57

(4) To turn BEEPER OFF, toggle right

Increase/Decrease switch (2).

Left Display Right Display

I BEEPER OFF

(5) Toggle left Increase/Decrease switch (3)

down to enter BEEPER < (slope).

Left Display Right Display

BEEPER ON

(6) To turn BEEPER < OFF, toggle right

Increase/Decrease switch (2) down.

Left Display Right Display

BEEPER OFF

(7) Toggle left Increase/Decrease switch (3)

down.

Left Display Right Display

EXIT BEEPER

(8) To exit BEEPER, press left RESET

button (1).

Left Display Right Display

SLOPE PERCENT

TM 5-6675-348-13&P

3-58

f. Percent Slope and Rise/Run.

To change the display from PERCENT

SLOPE to RISE/RUN:

(1) Toggle right Increase/Decrease switch (1)

down.

Left Display Right Display

SLOPE RISE/RUN

(2) Toggle left Increase/Decrease switch (2)

to exit PERCENT SLOPE RISE/RUN.

Left Display Right Display

EXIT CUSTOMIZE

(3) To exit Customize, press left RESET

button (3).

Left Display Right Display

CALIBRATE < RESET

(4) Calibrate Blade Pro® Motor Grader

Control System (Para 3-15 and Para 3-16)

or toggle left Increase/Decrease switch (2)

down to enter Test mode.

TM 5-6675-348-13&P

3-59

g. Test

(1) Press and hold left RESET button (1) to

enter self-test mode.

Left Display Right Display

TEST MODE <RESET

NOTE

• All LED segments will be activated.

This checks for inactive segments.

• All LEDs will be illuminated. This

checks for burned out LEDs.

• When RESET button is released,

Operator Interface Box will show any

error codes that have occurred since

the last power up. Refer to Blade

Pro® Motor Grader Control System

Troubleshooting Error Messages in

Section V.

(2) Toggle the OFF/ON/SET-UP switch (2) to

ON position to begin normal operation.

TM 5-6675-348-13&P

3-60

SECTION IV. BLADE PRO® MOTOR GRADER CONTROL SYSTEM

TROUBLESHOOTING

While the Blade Pro® Motor Grader Control System is a highly accurate system, you may encounter problems as

you work in the field. Use this section to troubleshoot your problems. You may want to have a qualified

maintenance person troubleshoot and fix any problems.

Table 3-6. Blade Pro® Motor Grader Control System Fault Index

Fault

No. Description Page

3-1. Operator Interface Box Will Not Turn On.........................................................................................................3-61

3-2. Auto and Manual LEDs Are Lit on Same Side of Control Box.........................................................................3-62

3-3. Right/Left Switches in Auto Position, But Automatic Control Is Not Functioning.........................................3-63

3-4. Blade Undercuts or Pulls Into a Cut..................................................................................................................3-63

3-5. Tracer® Sonic Grade Controller Will Not Reset ...............................................................................................3-64

3-6. Cross-Slope Side Does Not Cut Desired Slope ..................................................................................................3-65

3-7. Tracer® Sonic Grade Controller Keeps Losing Reference................................................................................3-66

3-8. Hydraulic Control Valves Do Not Raise or Lower in Automatic Mode, But Blade Operates Manually ........3-67

3-9. Blade Pro® Motor Grader Control System Leaves Waves in the Material......................................................3-69

TM 5-6675-348-13&P

3-61

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting

Malfunction

Test or InspectionCorrective Action

FAULT 3-1. OPERATOR INTERFACE BOX WILL NOT TURN ON.

If connections are wet, the Remote Interface Box will be damaged.

Step 1. Check Cable (1) connector from Operator Interface Box to Remote Interface Box for

tightness and/or dirt.

Remove and inspect Cable (1) to ensure connector is clean and dry. Securely

reconnect Cable.

Step 2. Check Cable (1) from Operator Interface Box to Remote Interface Box for damage.

If Cable (1) is damaged, replace it.

Step 3. Check Power Cable (2) connector.

Remove and inspect Power Cable (2) to ensure connector are clean and dry.

Securely reconnect Power Cable (2).

Step 4. Check Power Cable (2) for damage.

If Power Cable (2) is damaged, replace it.

To avoid damage to equipment, fuse must be replaced with a 25-amp fuse.

Step 5. Check for fuses (3) in Remote Interface Box.

Step 6. Inspect fuses (3) on Remote Interface Box. Ensure they have not blown and are securely in

place. If fuses (3) are faulty, replace them.

TM 5-6675-348-13&P

3-62

FAULT 3-1. OPERATOR INTERFACE BOX WILL NOT TURN ON. (Cont)

Step 7. Check for a good ground on pins B and C of Power Cable (2).

If a good ground is not found, replace Power Cable (2).

Step 8. Check for 22 to 28 Vdc on pins A and D of Power Cable (2).

If 22 to 28 Vdc is not found on pins A and B, check and service batteries, if needed

(TM 5-3805-261-20).

If batteries are serviceable, replace Power Cable (2).

FAULT 3-2. AUTO AND MANUAL LEDs ARE LIT ON SAME SIDE OF CONTROL BOX.

Step 1. Check Automatic and Manual LEDs light at same time when Blade Pro® Motor Grader

Control System is turned on and you cannot grade in Automatic.

Place R/L Switches (1) in Manual position, then place them in Automatic position.

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-63

FAULT 3-3. RIGHT/LEFT SWITCHES IN AUTO POSITION, BUT AUTOMATIC CONTROL

IS NOT FUNCTIONING.

Step 1. Check Automatic and Manual LEDs light at same time when Blade Pro® Motor Grader

Control System is turned on and you cannot grade in Automatic.

Place R/L Switches (1) in Manual position, then place them in Automatic

position.

FAULT 3-4. BLADE UNDERCUTS OR PULLS INTO A CUT.

Step 1. When cutting variable compacted material, check if blade undercuts material that is less

compacted.

Roll blade forward to less aggressive cutting position.

If condition persists, contact Direct Support Maintenance.

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-64

FAULT 3-5. TRACER® SONIC GRADE CONTROLLER WILL NOT RESET.

Step 1. Ensure Tracer® Sonic Grade Controller (1) is within its operating range.

Adjust Tracer® Sonic Grade Controller (1) to within 8 to 42 in. (20.3 to 107 cm) of

reference surface.

Step 2. Ensure Tracer® Sonic Grade Controller (1) is directly over reference surface.

Ensure Tracer® Sonic Grade Controller (1) is vertical and plumb over reference

surface. Adjust Tracer® Sonic Grade Controller (1) over reference surface.

If connections are wet, the Remote Interface Box will be damaged.

Step 3. Check Tracer® Sonic Grade Controller (1) cable connectors for looseness and/or moisture.

Ensure all connectors are clean and dry. Securely reconnect Tracer® Sonic Grade

Controller (1) cable.

Step 4. Check Coil Cable (3) between Tracer® Sonic Grade Controller (1) and Remote Interface Box

for damage.

If Coil Cable (3) is damaged, replace it.

Step 5. Check Transducer screen (2) on bottom of Tracer® Sonic Grade Controller (1) for dirt.

Clean Transducer screen (2).

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-65

FAULT 3-6. CROSS-SLOPE SIDE DOES NOT CUT DESIRED SLOPE.

Step 1. The 130G Grader (1) may not be able to cut material at the depth you are trying to cut.

Try making several passes to remove material.

Step 2. The 130G Grader (1) may need to be calibrated.

Perform full calibration (Para 3-15 and Para 3-16).

NOTE

Excessive 130G Grader mechanical wear can give the Blade Pro® Motor Grader Control

System false sensor readings.

Step 3. Check 130G Grader (1) for excessive mechanical wear.

Inspect 130G Grader (1) for wear (Section VII).

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-66

FAULT 3-7. TRACER® SONIC GRADE CONTROLLER KEEPS LOSING REFERENCE.

Step 1. Ensure Tracer® Sonic Grade Controller (1) is within its operating range.

Adjust Tracer® Sonic Grade Controller (1) to within 8 to 42 in. (20 to 107 cm) of

reference surface (2).

Step 2. Ensure Tracer® Sonic Grade Controller (1) is directly over reference surface (2).

Ensure Tracer® Sonic Grade Controller (1) is vertical and plumb over reference

surface (2). Adjust Tracer® Sonic Grade Controller (1) over reference surface.

Step 3. Tracer® Sonic Grade Controller (1) is not following string line closely enough.

Line up Tracer® Sonic Grade Controller (1) over reference surface (2).

If using a string line, tie a brightly colored ribbon onto Tracer® Sonic Grade

Controller Pole (3), marking your line of sight where pole intersects string line.

Step 4. Tracer® Sonic Grade Controller (1) is tracing something other than what you thought.

Carefully align Tracer® Sonic Grade Controller (1), then place a pencil between

reference and ground. If the Tracer® Sonic Grade Controller (1) gives you a

correction signal, you are not picking up the correct reference.

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-67

FAULT 3-8. HYDRAULIC CONTROL VALVES DO NOT RAISE OR LOWER IN AUTOMATIC MODE,

BUT BLADE OPERATES MANUALLY.

Step 1. Check R/L Switches (1) for proper operation.

Put R/L Switches (1) in Auto position. If green automatic LED does not light,

replace R/L Switches (1).

If connectors are wet, the Remote Interface Box will be damaged.

Step 2. Remove Hydraulic Valve Cable connector (3) to ensure it is clean, dry, and free from damage.

If Hydraulic Valve Cable connector (3) is damaged or broken, replace connectors.

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-68

FAULT 3-8. HYDRAULIC CONTROL VALVES DO NOT RAISE OR LOWER IN AUTOMATIC MODE,

BUT BLADE OPERATES MANUALLY. (Cont)

To avoid damage to equipment, fuse must be replaced with a 25-amp fuse.

Step 3. Check fuse (2) in Remote Interface Box.

If fuse (2) is faulty, replace.

Do not start or move Blade Pro® Motor Grader Control System while anyone is under the

130G Grader. Failure to comply could result in severe injury or death to personnel

Step 4. With 130G Grader running and while clear of moving parts of 130G Grader, press

rubber-covered buttons (4) on ends of Valve Spools (5) to ensure Valve Spools (5) are not

frozen. Blade should move up and down when each rubber-covered button (4) is pressed.

If Valve Spools are frozen, replace Proportional Valve Assembly (Para 3-35).

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-69

FAULT 3-9. BLADE PRO® MOTOR GRADER CONTROL SYSTEM LEAVES WAVES IN THE

MATERIAL.

Step 1. Ensure 130G Grader’s hydraulic fluid has reached operating temperature.

Step 2. Ensure Hydraulic Valves are calibrated properly.

Perform Hydraulic Valve calibration (Para 3-16).

Step 3. If error is not corrected, contact Trimble Navigation.

Table 3-7. Blade Pro® Motor Grader Control System Troubleshooting (Cont)

Malfunction

Test or InspectionCorrective Action

TM 5-6675-348-13&P

3-70

SECTION V. BLADE PRO® MOTOR GRADER CONTROL SYSTEM

TROUBLESHOOTING ERROR MESSAGES

While the Blade Pro® Motor Grader Control System is a highly accurate system, you may see error messages

displayed as you work in the field. Use this section to troubleshoot your error messages. You may find you can

fix your problem on your own, or call Trimble Navigation.

3-25. TEST/ERROR LOG FEATURE.

Test/Error Log feature activates all LCD and LED lights, so you can see any burned out LCD or LED lights. It

also records any errors that may have occurred and gives you a total. This error log will go away when you

turn the control box off, so if the Blade Pro® Motor Grader Control System has been giving you errors, do not

turn Operator Interface Box off until you have resolved the problem or contacted Direct Support

Maintenance.

To run Test/Error Log feature:

(1) Position OFF/ON/SET-UP switch to SET-UP position. Reference and reference number appear in

display windows.

(2) Press left switch down until Test Mode < RESET appears in display windows.

(3) Press left RESET button. Blade Pro® Motor Grader Control System runs self-test. Make note of

any lights that have burned out, any error numbers, and total number of error messages.

(4) Turn OFF/ON/SET-UP switch to ON position.

TM 5-6675-348-13&P

3-71

NOTE

Record Error log number. This will be needed by Direct Support maintenance to

troubleshoot your system.

Table 3-8. Error Messages

ERROR MESSAGE WHAT TO DO ABOUT IT

ART. FAULT Check articulation sensor to ensure it is firmly in place. Ensure cable is firmly

connected and is not cut or broken.

ART. OFF Call Trimble Navigation.

ART.>>RANGE 130G Grader has been articulated too far. Call your Trimble Navigation.

BLADE FAULT Check Cross-Slope Sensor to ensure it is firmly in place. Ensure cable is firmly

connected and is not cut or broken.

BLADE OFF Call Blade Pro® Motor Grader Control System Authorized Service Center.

BLADE>>RANGE Check Cross-Slope Sensor to ensure it is firmly in place. Ensure cable is firmly

connected and is not cut or broken.

ELEVATION FAULT Call Trimble Navigation.

ELEVATION >> RANGE Your Tracer® Sonic Grade Controller is too close or far from the reference.

Adjust distance, then press RESET button for side Tracer® Sonic Grade

Controller is on.

HARDWARE FAULT Call Trimble Navigation.

MAINFALL OFF Call Trimble Navigation.

MAINFALL FAULT Check Mainfall Slope Sensor to ensure it is firmly in place. Ensure cable is

firmly connected and is not cut.

MAINFALL >> RANGE 130G Grader is on a slope that is too steep for Mainfall Slope Sensor to

measure. Move grader to less steep area, then re-evaluate.

ROTATION FAULT Check Circle Rotation Sensor to ensure it is firmly in place. Ensure cable is

firmly connected and is not cut.

ROTATION OFF Call Trimble Navigation.

ROTATION >> RANGE Blade has been rotated too far. Carefully rotate blade back to within the 0 to

96° range. If blade has not been rotated too far, your Circle Rotation Sensor

may be loose. Ensure Circle Rotation Sensor is firmly attached.

SERIAL ERROR Call Trimble Navigation.

SYSTEM FAULT Call Trimble Navigation.

VALVE ERROR Call Trimble Navigation.

VALVE FAULT Call Trimble Navigation.

VALVE OFF Call Trimble Navigation.

TM 5-6675-348-13&P

3-72

SECTION VI. BLADE PRO® MOTOR GRADER CONTROL SYSTEM ERROR LOG

3-26. MG2P-35 ERROR LOG.

Table 3-9. Error Log

Level 1 Errors Display Messages

Blade slope signal detected with sensor OFF. BLADE OFF

Mainfall signal detected with sensor OFF. MAINFALL OFF

Rotation angle signal detected with sensor OFF. ROTATION OFF

Articulation angle signal detected with sensor OFF. ART. OFF

Level 2 Errors Display Messages

Valve type not selected. VALVE OFF

Blade slope signal frequency too low with sensor ON. BLADE FAULT

Blade slope signal frequency too high with sensor ON. BLADE FAULT

Blade slope signal value too low with sensor ON. BLADE» RANGE

Blade slope signal value too high with sensor ON. BLADE» RANGE

Mainfall signal frequency too low with sensor ON. MAINFALL FAULT

Mainfall signal frequency too high with sensor ON. MAINFALL FAULT

Mainfall signal value too low with sensor ON. MAINFALL» RANGE

Mainfall signal value too high with sensor ON. MAINFALL» RANGE

Rotation angle signal frequency too low with sensor ON. ROTATION FAULT

Rotation angle signal frequency too high with sensor ON. ROTATION FAULT

Rotation angle signal value too low with sensor ON. ROTATION» RANGE

Rotation angle signal value too high with sensor ON. ROTATION» RANGE

Articulation angle signal frequency too low with sensor ON. ART. FAULT

Articulation angle signal frequency too high with sensor ON. ART. FAULT

Articulation angle signal value too low with sensor ON. ART.» RANGE

Articulation angle signal value too high with sensor ON. ART.» RANGE

Level 3 Errors Display Messages

Operator Interface Box serial transmission check sum fault detected. SERIAL ERROR

Operator Interface Box serial transmission bad ID number detected. SERIAL ERROR

Operator Interface Box serial transmission incomplete packet

detected. SERIAL ERROR

Operator Interface Box serial transmission framing fault detected. SERIAL ERROR

Operator Interface Box serial transmission noise detected. SERIAL ERROR

Operator Interface Box serial transmission overrun detected. SERIAL ERROR

TM 5-6675-348-13&P

3-73

Level 4 Errors Display Messages

Left fine lower valve voltage incorrect. VALVE ERROR

Left medium lower valve voltage incorrect. VALVE ERROR

Left coarse lower valve voltage incorrect. VALVE ERROR

Left fine raise valve voltage incorrect. VALVE ERROR

Left medium raise valve voltage incorrect. VALVE ERROR

Left coarse raise valve voltage incorrect. VALVE ERROR

Load sense valve voltage incorrect. VALVE ERROR

Right fine lower valve voltage incorrect. VALVE ERROR

Right medium lower valve voltage incorrect. VALVE ERROR

Right coarse lower valve voltage incorrect. VALVE ERROR

Right fine raise valve voltage incorrect. VALVE ERROR

Right medium raise valve voltage incorrect. VALVE ERROR

Right coarse raise valve voltage incorrect. VALVE ERROR

Unloading valve voltage incorrect. VALVE ERROR

Left valve driver overload detected. VALVE FAULT

Right valve driver overload detected. VALVE FAULT

Left EM2E-24 Electric Mast motor driver overload detected. ELEVATION FAULT

Right EM2E-24 Electric Mast motor driver overload detected. ELEVATION FAULT

Power supply overload detected. SYSTEM FAULT

Level 5 Errors Display Messages

Left elevation length increase too slow or stopped. ELEVATION >> RANGE

Left elevation length decrease too slow or stopped. ELEVATION >> RANGE

CPU reset during left elevation length change. ELEVATION FAULT

Right elevation length increase too slow or stopped. ELEVATION>> RANGE

Right elevation length decrease too slow or stopped. ELEVATION>> RANGE

CPU reset during right elevation length change. ELEVATION FAULT

Left driver board type incorrect. HARDWARE FAULT

Right driver board type incorrect. HARDWARE FAULT

Left driver board mode incorrect. HARDWARE FAULT

Right driver board mode incorrect. HARDWARE FAULT

Remote Interface Box RAM fault detected. HARDWARE FAULT

Remote Interface Box ROM fault detected. HARDWARE FAULT

Remote Interface Box EEPROM fault detected. HARDWARE FAULT

Table 3-9. Error Log (Cont)

TM 5-6675-348-13&P

3-74

Table 3-10. Error-to-Source Relationships

Level 1 Errors Abbreviation Error #

Blade slope signal detected with sensor OFF.

User turned OFF Blade Slope Sensor but did not disconnect it.

Remote Interface Box CPU board.

Blade On 1

Mainfall signal detected with sensor OFF.

User turned OFF Mainfall Slope Sensor but did not disconnect it.

Remote Interface Box CPU board.

Mainfall On 2

Rotation angle signal detected with sensor OFF.

User turned OFF rotation Angle Sensor but did not disconnect it.

Remote Interface Box CPU board.

Rotation On 3

Articulation angle signal detected with sensor OFF.

User turned OFF articulation Angle Sensor but did not disconnect it.

Remote Interface Box CPU board.

Articulation

On 4

Level 2 Errors Abbreviation Error #

Valve type not selected.

User did not yet select a valve type.

Remote Interface Box CPU board.

No Valve

Selected 5

Blade slope signal frequency too low or stopped with sensor ON.

Blade Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Blade Slow

Blade slope signal frequency too high with sensor ON.

Blade Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Blade Fast

Blade slope signal value too low with sensor ON.

Blade Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Blade Low

Blade slope signal value too high with sensor ON.

Blade Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Blade High

Mainfall signal frequency too low or stopped with sensor ON.

Mainfall Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Mainfall Slow

TM 5-6675-348-13&P

3-75

Level 2 Errors (Cont) Abbreviation Error #

Mainfall signal frequency too high with sensor ON.

Mainfall Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Mainfall Fast

Mainfall signal value too low with sensor ON.

Mainfall Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Mainfall Low

Mainfall signal value too high with sensor ON.

Mainfall Slope Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Mainfall High

Rotation angle signal frequency too low or stopped with sensor ON.

Rotation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Rotation Slow

Rotation angle signal frequency too high with sensor ON.

Rotation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Rotation Fast

Rotation angle signal value too low with sensor ON.

Rotation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Rotation Low

Rotation angle signal value too high with sensor ON.

Rotation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Rotation High

Articulation angle signal frequency too low or stopped with sensor ON.

Articulation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Articulation

Slow 18

Articulation angle signal frequency too high with sensor ON.

Articulation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Articulation

Fast 19

Articulation angle signal value too low with sensor ON.

Articulation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Articulation

Low 20

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-76

Level 3 Errors Abbreviation Error #

Articulation angle signal value too high with sensor ON.

Articulation Angle Sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Articulation

High 21

Operator Interface Box serial transmission check sum fault detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Serial Check

Sum 22

Operator Interface Box serial transmission ID number out of range detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Serial ID

Operator Interface Box serial transmission incomplete packet detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Serial Packet

Operator Interface Box serial transmission framing fault detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Serial Frame

Operator Interface Box serial transmission noise detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Serial Noise

Operator Interface Box serial transmission overrun detected.

Remote Interface Box CPU board. Serial

Overrun 27

Level 4 Errors Abbreviation Error #

Left fine lower valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left fine lower valve or cable.

Left Lower

Fine 28

Left medium lower valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left medium lower valve or cable.

Left Lower

Medium 29

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-77

Level 4 Errors (Cont) Abbreviation Error #

Left coarse lower valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left coarse lower valve or cable.

Left Lower

Coarse 30

Left fine raise valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left fine raise valve or cable.

Left Raise

Fine 31

Left medium raise valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left medium raise valve or cable.

Left Raise

Medium 32

Left coarse raise valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Left coarse raise valve or cable.

Left Raise

Coarse 33

Load sense valve voltage incorrect.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box left driver board.

Load sense valve or cable.

Load Sense

Valve 34

Right fine lower valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right fine lower valve or cable.

Right Lower

Fine

Right medium lower valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right medium lower valve or cable.

Right Lower

Medium

Right coarse lower valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right coarse lower valve or cable.

Right Lower

Coarse

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-78

Level 4 Errors (Cont) Abbreviation Error #

Right fine raise valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right fine raise valve or cable.

Right Raise

Fine

Right medium raise valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right medium raise valve or cable.

Right Raise

Medium

Right coarse raise valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Right coarse raise valve or cable.

Right Raise

Coarse

Unloading valve voltage incorrect.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Remote Interface Box right driver board.

Unloading valve or cable.

Unloading

Valve

Left valve driver overload detected.

Remote Interface Box CPU board.

Remote Interface Box left driver board.

Remote Interface Box motherboard.

Left fine raise valve or cable.

Left medium raise valve or cable.

Left coarse raise valve or cable.

Load sense valve or cable.

Left Valve

Overload

Right valve driver overload detected.

Remote Interface Box CPU board.

Remote Interface Box right driver board.

Remote Interface Box right driver board fuse.

Remote Interface Box motherboard.

Right fine raise valve or cable.

Right medium raise valve or cable.

Right coarse raise valve or cable.

Unloading valve or cable.

Right Valve

Overload

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-79

Level 4 Errors (Cont) Abbreviation Error #

Left EM2E-24 Electric Mast motor driver overload detected.

Remote Interface Box CPU board.

Remote Interface Box left driver board.

Remote Interface Box motherboard.

Left elevation sensor or cable.

Left EM2E-24

Electric Mast

Overload 44

Right EM2E-24 Electric Mast motor driver overload detected.

Remote Interface Box CPU board.

Remote Interface Box right driver board.

Remote Interface Box right driver board fuse.

Remote Interface Box motherboard.

Right elevation sensor or cable.

Right EM2E-

24 Electric

Mast Overload 45

Power supply overload detected.

Operator Interface Box.

Operator Interface Box cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Blade Slope Sensor or cable.

Mainfall Slope Sensor or cable.

Rotation Angle Sensor or cable.

Articulation Angle Sensor or cable.

Left elevation sensor or cable.

Right elevation sensor or cable.

Power

Overload

Level 5 Errors Abbreviation Error #

Left elevation length increase too slow or stopped.

Left elevation upper length limit reached.

Left elevation sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Left Elevation

Ceiling 47

Left elevation length decrease too slow or stopped.

Left elevation lower length limit reached.

Left elevation sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Left Elevation

Floor 48

CPU reset during left elevation length change.

User turned off system before left elevation sensor stopped.

Left elevation sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Left Elevation

Miscount 49

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-80

Level 5 Errors (Cont) Abbreviation Error #

Right elevation length increase too slow or stopped.

Right elevation upper length limit reached.

Right elevation sensor or cable.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Right

Elevation

Ceiling 50

Right elevation length decrease too slow or stopped.

Right elevation lower length limit reached.

Right elevation sensor or cable.

Remote Interface Box right driver board fuse.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Right

Elevation

Floor 51

CPU reset during right elevation length change.

User turned off system before right elevation sensor stopped.

Right elevation sensor or cable.

Remote Interface Box CPU board.

Remote Interface Box motherboard.

Right

Elevation

Miscount 52

Remote Interface Box left driver board type incorrect.

Remote Interface Box left driver board.

Remote Interface Box CPU board.

Wrong Left

Board 53

Remote Interface Box right driver board type incorrect.

Remote Interface Box right driver board.

Remote Interface Box CPU board.

Wrong Right

Board 54

Remote Interface Box left driver board mode incorrect.

Remote Interface Box left driver board.

Remote Interface Box CPU board.

Wrong Left

Driver 55

Remote Interface Box right driver board mode incorrect.

Remote Interface Box right driver board.

Remote Interface Box CPU board.

Wrong Right

Driver 56

Remote Interface Box CPU RAM fault detected.

Remote Interface Box CPU board. RAM Fault 57

Remote Interface Box CPU ROM fault detected.

Remote Interface Box CPU board. ROM Fault 58

Remote Interface Box CPU EEPROM fault detected.

Remote Interface Box CPU board. EEPROM

Fault 59

Table 3-10. Error-to-Source Relationships (Cont)

TM 5-6675-348-13&P

3-81

3-27. CONFIGURE FOR TRANSPORT.

a. Before Transport.

Blade Pro® Motor Grader Control System components are not designed to be air

dropped. Failure to comply may result in damage to equipment.

When transporting your 130G Grader(s) with Blade Pro® Motor Grader Control System by ship, train, air, or

truck, perform the following procedure:

NOTE

Perform Step (1) if you have an Airborne or Air Mobile grader.

(1) Disconnect the Main Power Cable (9) before sectionalizing your 130G Grader for transportation.

(2) Remove all components listed below, except Circle Rotation Sensor, and store in their carrying

cases during shipment and transportation:

1. Operator Interface Box

2. Remote Interface Box

3. Blade Slope Sensor

4. Mainfall Slope Sensor

5. Tracer® Sonic Grade

Controller

6. EM2E-24 Electric Mast

7. R2S-S Laser Receiver

b. After Transport.

(1) Install all components removed and do a complete calibration of components (1) through (4),

(Para 3-15 and Para 3-16).

TM 5-6675-348-13&P

3-82

SECTION VII. BLADE PRO® MOTOR GRADER CONTROL

SYSTEM MAINTENANCE

NOTE

The following section deals with critical wear and maintenance areas of your 130G Grader

and Blade Pro® Motor Grader Control System.

Consistent accuracy of your Blade Pro® Motor Grader Control System is largely dependent on the

130G Grader’s condition. 130G Grader wear varies with job conditions, Operator skills, and materials. The

130G Grader wear points should be inspected on a regular basis.

3-28. BLADE CUTTING EDGE INSPECTION.

a. Blade Wear Inspection. Uneven blade wear

occurs mainly in three locations: on the

cutting edge, arcing from edges to center

creating an upward bow, and from center

wearing to either end. Blade wear can be

checked by placing the cutting edge on or

slightly above a flat surface, such as concrete

or pavement, and comparing cutting edge to

that surface. Maximum deviation from even

wear should be less than 1/8 in. (3 mm) if

accuracy within 1/100 ft (0.003 m) is desired

(TM 5-3805-261-10).

b. Blade Curvature Inspection. Curvature is a

bowing effect from edges to center, arcing

toward the rear of the machine. Check blade

curvature by placing a straightedge or string

across the corners of the blade and measuring

maximum deviation at center, 1/8 in. (3 mm)

maximum (TM 5-3805-261-10).

3-29. BLADE LIFT CYLINDER SOCKETS

INSPECTION.

Check socket (1) wear by lowering moldboard

to hard surface until ball seats firmly in upper

half of socket. Raise moldboard and measure

distance until ball seats in lower half of socket.

Maximum measured clearance should be less

than 0.040 in. (0.10 cm). Shim replacement or

removal may be necessary

(TM 5-3805-261-20).

TM 5-6675-348-13&P

3-83

3-30. WEAR STRIPS (CIRCLE TOP) INSPECTION.

Wear strips between circle top surface (1) and drawbar

can be checked in a similar manner as that of checking

cylinder sockets. Lower moldboard to hard surface until

blade is loaded with downward pressure.

(1) Measure distance between circle top (2) and

drawbar. Raise moldboard off ground and

measure distance again. Difference between

two measurements should be no more than

0.02 in. (0.05 cm).

3-31. HOSE TRAY BACKLASH ADJUSTMENT.

a. Measure.

(1) Rotate circle (1) clockwise 10 degrees and

mark first mark (2) on circle relative to

A-frame (3).

(2) Rotate circle (1) counterclockwise slowly. Stop

when top plate of hydraulic swivel begins

turning. Place second mark (4) on circle.

(3) Measure distance (5) between mark (2) and

mark (4). Distance should be less than 1/2 in.

(1.3 cm). Refer to Step b. to adjust.

TM 5-6675-348-13&P

3-84

b. Adjust. NOTE

Rotational backlash is recommended to

be less than 1/2 in. (1.3 cm).

(1) If greater than 1/2 in. (1.3 cm), two joints

between Circle Rotation Sensor and circle

can be tightened.

(2) First joint is between hose tray (1) and

hydraulic swivel (2).

(3) Remove existing pin connecting hose tray

to swivel.

(4) Replace pin with 8-in. (20.3 cm) long,

3/4-10, grade 5 bolt (3) and nut (4).

(5) Use 3/4 in. flat washers (5) to remove slack between two parts.

3-32. CIRCLE SLIDE SHOE INSPECTION.

Circle Slide Shoes should also be checked for proper adjustment. Consult your 130G Grader Technical Man-

ual for this procedure (TM 5-3805-261-10).

TM 5-6675-348-13&P

3-85

3-33. BLADE BACKLASH ADJUSTMENT.

a. Measure.

(1) Roll blade (1) to vertical position (2) and

sideshift blade to area of greatest wear on

slide rails (3).

(2) Let right side blade (1) hang in air while left

side blade (1) is placed firmly on ground.

NOTE

• When taking vertical distance measure-

ment, ensure blade roll backlash does

not cause errors in your reading.

• During grading, blade roll backlash is

usually loaded one way and does not

have much effect on cross-slope accuracy.

It will, however, affect elevation accuracy.

(3) Using a straightedge, measure vertical

distance (4) from bottom of circle to top of

slide rail (3) on right side.

(4) Place right side blade (1) firmly on

ground while left side blade (1) hangs in

air and repeat vertical distance

measurements on right side.

(5) Difference between two measurements is

backlash [Step (3) - Step (4) = backlash].

(6) Repeat Steps (2) through (5) on left side.

(7) Side shift blade (1) to area of least wear

on slide rails (3) and repeat Steps (2)

through (6) above.

(8) If vertical distance measurements taken

in Steps (5) for either left or right side are

over 1/8 in. (0.32 mm) greater than

vertical distance measurements from

Step (7), slide rails (3) should be repaired

or replaced. Notify Direct Support

Maintenance.

TM 5-6675-348-13&P

3-86

b. Adjust.

(1) Largest backlash is recommended to be

less than 1/8 in. (0.32 cm). If backlash is

greater than 1/8 in. (0.32 cm), two

joints (7) between circle and blade can be

tightened.

NOTE

More probable points to inspect are

wear strips between blade slide rails

and blade brackets.

(2) Tighten joints after replacing wear strips

and shims.

(3) Tighten blade roll backlash at this time.

(4) After this side has been side shifted to its minimum clearance position, (see Para 3-34), wear strips

can be formed to provide clearance of 0.005 to 0.035 in. (0.013 to 0.089 cm) between sides of rails

and wear strips.

(5) Second joint to inspect is blade pivot pin (8). If movement at pin is 1/32 in. (0.079 cm) or more,

notify Direct Support Maintenance.

3-34. WEAR STRIP AND SHIM REPLACEMENT.

NOTE

• Sensor calibration is required after these procedures (see Para 3-15).

• Use shims as required to obtain 0.005- to 0.035-in. (0.013 to 0.089 cm) clearance between

rails and wear strips at minimum clearance position found by sideshifting moldboard

through full range with shims divided as equally as possible between top and bottom

wear strips.

(1) Install wear strip (9) and shims (10) on

the slide rail (3) and in bracket (11).

(2) Position blocks (12) and install bolts (13).

TM 5-6675-348-13&P

3-87

3-35. BLADE PRO® MOTOR GRADER CONTROL SYSTEM INSTALLATION.

This Task Covers:

a. Installation. b. Follow-On Maintenance.

INITIAL SETUP

Model

130G Grader (TM 5-3805-261-Series)

Tools and Special Tools

Tool Kit, Automotive Maintenance, Common

No. 2, Item 2, Appendix B

Tool Kit, Electric, Item 3, Appendix B

Tool Kit, Welders, Item 4, Appendix B

Materials and Parts

Cloth, Lint-Free, Item 3, Appendix F

Gloves, Chemical Oil Protective, Item 4,

Appendix F

Paint, Spray, Black, Item 8, Appendix F

Rags, Wiping, Item 9, Appendix F

Tags, Identification, Item 13, Appendix F

Ties, Cable, Item 15, Appendix F

Materials and Parts (Cont.)

Base Mounting Block, Item 1, Appendix K

Label, Caution, Rotational Sensor, Item 3,

Appendix K

Label, Chart, Conversion, Item 4, Appendix K

Label, Warning, Welding/Jump Starting,

Item 5, Appendix K

Plate, Tracer Mast Mount, Item 6, Appendix K

Personnel Required

MOS 62B

MOS 44B

Equipment Condition

Engine OFF (TM 5-3805-261-10).

Wheels chocked (TM 5-3805-261-10).

130G Grader setup para (3-15).

TM 5-6675-348-13&P

3-88

a. Installation.

• Ensure 130G Grader is on level ground, all hydraulic implements are lowered to the

ground, transmission control is moved to Neutral, and the lock and emergency brake are

engaged. Failure to comply could result in serious injury to personnel.

• Do not work on hydraulic oil while oil is hot. Failure to comply could result in severe

injury to personnel.

• Prolonged contact with lubricating oil, MIL-L-2105, may cause a skin rash. Skin and

clothing that come in contact with lubricating oil should be thoroughly washed

immediately. Saturated clothing should be removed immediately. Areas in which

lubricating oil is used should be well ventilated to keep fumes to a minimum.

• Hydraulic oil is slippery and can cause falls. To avoid injury, wipe up all spilled hydraulic

oil with rags.

• Remove hydraulic fill cap to vent pressure from hydraulic tank.

• Use Operator’s controls to lower all components and relieve hydraulic system pressure.

Failure to comply may result in serious injury or death to personnel.

NOTE

Retain all items (except bench stock items) removed from 130G Grader for future use.

(1) Remove hydraulic tank fill cap to vent pressure from hydraulic tank (TM 5-3805-261-10).

(2) Install hydraulic tank fill cap.

(3) Remove two screws (1) and Hydraswivel

plate (2) from Hydraswivel (3).

Install Hydraswivel Gaskets and Hydraswivel

Shims in same manner as removed or damage

to equipment could result.

(4) Remove two Hydraswivel Gaskets (4) and (5)

from Hydraswivel plate (2).

(5) Inspect Hydraswivel Gaskets (4) and (5) and

Hydraswivel Shims (6). If damaged, replace.

TM 5-6675-348-13&P

3-89

Failure to replace Hydraswivel Gaskets and Hydraswivel Shims in original positions may

cause leakage or damage to equipment.

(6) Install Hydraswivel Gaskets (4) and (5) into Orientation Disc (7).

(7) Install Hydraswivel Shims (6) under Orientation Disc (7).

(8) Install Orientation Disc (7) to Hydraswivel (3) with Milled Slot (8) positioned toward rear of

130G Grader.

(9) Install two screws (1) in Orientation Disc (7).

(10) Tighten screws (1).

(11) Install Teflon Ring (9) on Circle Rotation Sensor (10).

(12) Line up Dog Bone (11) with Milled Slot (8) in Orientation Disc (7).

NOTE

For ease of calibration, place 2-pin female connector of Circle Rotation Sensor toward rear of

130G Grader.

(13) Install Circle Rotation Sensor (10) onto Orientation Disc (7).

TM 5-6675-348-13&P

3-90

To prevent damage to equipment, lip on bushing must be in slot of Circle Rotation Sensor.

(14) Install three screws (12) and bushings (13) in Circle Rotation Sensor (10) and Orientation Disc (7).

(15) Remove bolt (14) and lockwasher (15). Discard lockwasher (15).

(16) Install Circle Rotation Sensor Arm Mounting Bracket (16), new lockwasher (15), and bolt (14).

(17) Level Circle Rotation Sensor Arm Mounting Bracket (16). Tighten bolt (14).

(18) Align Circle Rotation Sensor Arm (17) on Circle Rotation Sensor (10).

(19) Install screw (18) on Circle Rotation Sensor Arm Mounting Bracket (16).

(20) Tighten screw (18).

(21) Install Circle Rotation Sensor Arm (17), two washers (19), and bolts (20) on Circle Rotation

Sensor (10).

(22) Tighten bolts (20).

(23) Install Circle Rotation Sensor Cable (21) on Circle Rotation Sensor (10).

TM 5-6675-348-13&P

3-91

To prevent damage to equipment, the

Circle Rotation Sensor Cable must be

secured to hydraulic lines with cable

ties approximately every 6 in.

(15.2 cm).

NOTE

Leave approximately 2 in. (5.1 cm) of

slack in Rotation Sensor Cable for

calibration.

(24) Route Circle Rotation Sensor

Cable (21) with existing hydraulic

lines to front of 130G Grader.

NOTE

Gooseneck Panels for both sides of the

130G Grader are removed the same.

The left side is shown.

(25) Remove eight bolts (22) and

washers (23).

(26) Remove Gooseneck

Panels (24) and (25)

and Float Valve (26) from

Gooseneck (27).

(27) Route Circle Rotation Sensor

Cable (21) under Gooseneck

Panel (28).

Do not cable tie Circle Rotation Sensor

Cable Service Loop inside the

Gooseneck. Failure to comply could

result in damage to 130G Grader.

NOTE

Leave approximately 18 in. (46 cm)

hanging past 130G Grader’s Gooseneck

Panel’s rear mounting location.

(28) Create a Service Loop (29) of the extra

Circle Rotation Sensor Cable (21) inside

the Gooseneck (27).

(29) Route Circle Rotation Sensor Cable (21)

with existing hydraulic lines in Gooseneck (27).

TM 5-6675-348-13&P

3-92

(30) Loosen lower Gooseneck retainer

bolt (30).

(31) Remove upper retainer bolt (31),

washer (32), and spacer (33).

(32) Rotate Gooseneck Retainer (34)

90 degrees.

(33) Tighten lower Gooseneck retainer

bolt (30).

(34) Repeat Steps (30) through (33) on right

side of 130G Grader.

• Hydraulic oil is slippery and can

cause falls. To avoid injury, wipe

up all spilled hydraulic oil with

rags.

• Float valve is held in position only

by lines. Use care during line re-

moval to prevent damage to equip-

ment or injury to personnel.

NOTE

• Inspect all hoses, lines, and fittings

for cracks, bends, nicks, dents,

stripped threads, and cuts. Replace

all damaged parts.

• Perform Steps (35) and (36) on right

side of 130G Grader only.

• Tag and mark all hoses prior to

removal.

• Plug holes and cap fittings to prevent

spilling oil.

• Cable tie as needed.

(35) Disconnect two Float Valve Lines (35)

from Float Valve (26).

(36) Pull two Float Valve lines (35) out of

Gooseneck (27).

(37) Temporarily position two Float Valve

Lines (35) over Gooseneck (27).

TM 5-6675-348-13&P

3-93

(38) Disassemble female end of Operator

Cable (36).

NOTE

• Hydraulic hoses for both sides of

130G Grader install the same. The

right side is shown.

• Mark return line short hose before

installation.

• For ease of installation, hold

hydraulic lines toward top of

130G Grader’s Gooseneck while

installing. If hydraulic lines hit an

obstruction during installation, twist

and push lines at the same time.

• Route straight end of hydraulic lines

through Gooseneck from front of

130G Grader to back.

• Steps (40) through (45) require the aid of

an assistant.

(39) Locate Load Sense Line (37).

(40) Push straight end of Load Sense Line (37)

through Gooseneck (27), starting from the

rear and pushing toward the front of the

Gooseneck (27).

(41) Cable tie female end of Operator Cable (36) to

Load Sense Line (37) on straight end of Load

Sense Line (37).

(42) With the aid of an assistant, pull Load Sense

Line (37) until female end of Operator

Cable (36) exits through rear side of

Gooseneck (27).

(43) Remove Load Sense Line (37).

TM 5-6675-348-13&P

3-94

(44) Cable tie Main Power Cable (38) to Operator

Cable (36).7

NOTE

Leave approximately 18 in. (46 cm) of both

cables outside front of Gooseneck.

(45) With the aid of an assistant, pull Operator

Cable (36) until both Main Power Cable (38)

and Operator Cable (36) are hanging through

front and rear of Gooseneck (27).

Hydraulic oil is slippery and can cause

falls. To avoid injury, wipe up all spilled

hydraulic oil with rags.

NOTE

• Inspect all hoses, lines, and fittings for

cracks, bends, nicks, dents, stripped

threads, and cuts. Replace all damaged

parts.

• Tag and mark all existing lines prior

to removal.

• Plug holes and cap fittings to prevent

oil spills.

• Retain 90-degree fittings and T-fittings

for installation of Proportional Valve.

(46) Remove two Float Valve Lines (35), Cylinder

Lines (39), T-fittings (40), and 90-degree

fittings (41) from left Lift and Articulation

Check Valve (LACV) (42).

TM 5-6675-348-13&P

3-95

(47) Route Load Sense Line (37), Return Line (43), and Pressure Line (44) through Gooseneck (27).

(48) Remove two bolts (45) and flat washers (46) from LACV (42).

• Step (49) applies to left side of 130G Grader only.

• Retain Loop Clamp for installation of Proportional Valve.

(49) Remove Loop Clamp (47). NOTE

Do not tighten LACV fittings until all fittings are installed.

(50) Install two T-fittings (48) in LACV (42).

(51) Install two 90-degree block fittings (49) in T-fittings (48).

(52) Install two retained 90-degree fittings (41) in block 90-degree fittings (49).

(53) Install two retained T-fittings (40) in 90-degree fittings (41).

TM 5-6675-348-13&P

3-96

NOTE

Proportional Valve Assembly can be

used on either side of 130G Grader.

(54) Remove three dust plugs (50) from side

of Proportional Valve (51).

Hydraulic oil is slippery and can cause

falls. To avoid injury, wipe up all

spilled hydraulic oil with rags.

To prevent fittings breaking off in

block, do not overtighten fittings.

NOTE

• Lubricate O-rings on O-ring seals to JIC/SAE fittings with clean hydraulic fluid before

installation.

• All other dust fittings should be tightened.

(55) Install two #6 ORS to JIC/SAE fittings (52) on Proportional Valve (51).

(56) Tighten #6 ORS to JIC/SAE fittings (52).

(57) Install #4 ORS to JIC/SAE fitting (53) on Proportional Valve (51).

(58) Tighten #4 ORS to JIC/SAE fitting (53).

TM 5-6675-348-13&P

3-97

NOTE

For ease of installation, do not tighten 90-degree fittings.

(59) Install two 90-degree fittings (54) on Proportional Valve Assembly (51).

To prevent leaks and damage to equipment, ensure all plugs on back side of Proportional

Valve Assembly are tight before installation.

• Loop Clamp is installed on back side of LACV on left side only.

• Rotate Loop Clamp 180 degrees before installation.

(60) Install Loop Clamp (47) and Proportional Valve Assembly (51) with two bolts (45) and flat

washers (46) on LACV (42).

(61) Tighten bolts (45).

TM 5-6675-348-13&P

3-98

To prevent damage to equipment, do not bend or force steel tubes to fit.

(62) Install steel tubes (55) on 90-degree

fittings (54) and T-fittings (48).

(63) Level steel tubes (55).

(64) Tighten 90-degree fittings (54) and

T-fittings (48).

(65) Install Load Sense Line (37) on

#4 JIC/SAE fitting (53).

(66) Tighten Load Sense Line (37).

(67) Install Pressure Line (44) on lower

#6 JIC/SAE fitting (52).

(68) Tighten Pressure Line (44).

(69) Install Return Line (43) on upper

#6 JIC/SAE fitting (52).

(70) Tighten Return Line (43).

TM 5-6675-348-13&P

3-99

(71) Install two Cylinder Lines (39) and two Float Valve Lines (35) to T-fittings (40).

(72) Tighten two Cylinder Lines (39) and Float Valve Lines (35) to T-fittings (40).

(73) Tighten 90-degree fittings (41) and T-fittings (40).

(74) Install gaskets (56) on Hydraulic Valve

Cables marked RAISE (57) and

LOWER (58).

Hydraulic Valve Cables are marked

RAISE and LOWER. Failure to install

Hydraulic Valve Cables in the correct

positions may cause damage to

equipment.

NOTE

Remove protective caps from

Proportional Valve Assembly electrical

terminals before installing Hydraulic

Valve Cables.

(75) Install Hydraulic Valve Cable (RAISE) (57) on Proportional Valve Assembly Terminal (59).

(76) Secure Hydraulic Valve Cable (RAISE) (57) to Proportional Valve Assembly Terminal (59) with

screw (60).

(77) Tighten screw (60).

(78) Install Hydraulic Valve Cable (LOWER) (58) on Proportional Valve Assembly Terminal (61).

(79) Secure Hydraulic Valve Cable (LOWER) (58) to Proportional Valve Assembly Terminal (61) with

screw (62).

(80) Tighten screw (62).

(81) Route Hydraulic Valve Cables (57) and (58) behind Proportional Valve Assembly (51).

(82) Cable tie Hydraulic Valve Cables (57) and (58) together as needed.

TM 5-6675-348-13&P

3-100

(83) Repeat Steps (46) through (81) for

right-side installation.

(84) Temporarily install right-side

Gooseneck Panel (63), six

washers (64), and six bolts (65).

(85) Temporarily install Mainfall Slope

Sensor Bracket (66) to right-side

Gooseneck Panel (63), using existing

bolt (67).

(86) Level, mark, and center punch

Mainfall Slope Sensor Bracket (66)

mounting holes.

(87) Remove bolt (67), Mainfall Slope

Sensor Bracket (66), six bolts (65), six

washers (64), and right-side Gooseneck

Panel (63).

(88) Drill two 1/2-in. (13 mm) holes at

punch marks.

(89) Align Mainfall Slope Sensor Bracket (66)

to bottom of right-side Gooseneck

Panel (63).

(90) Install with two bolts (67),

lockwashers (68), and nuts (69).

(91) Tighten nuts (69).

(92) Install both right-side Gooseneck

Panels (63) and (70) and Float

Valve (26) with eight washers (64) and

bolts (65).

(93) Install two Float Valve lines (35) to Float

Valve (26).

NOTE

Position Scarifier Hydraulic Lines

clockwise as far as possible to allow

clearance for the Remote Interface Box.

(94) Reposition Scarifier Hydraulic Lines (71)

clockwise as far as possible.

TM 5-6675-348-13&P

3-101

NOTE

Leave approximately 16 in. (40.6 cm)

of Mainfall Slope Sensor Cable on

female end, for storage, as shown.

(95) Install Mainfall Slope Sensor Cable (72),

Loop Clamp (73), washer (74), bolt (67) to

Mainfall Slope Sensor Bracket (66).

NOTE

Connector holder mounting screw is larger

than hole in dust cap.

(96) Ream connector holder (75) mounting hole

with rat-tail file.

(97) Install screw (76) and connector

holder (75) to outer rear hole of Mainfall

Slope Sensor Bracket (66).

(98) Install two cable ties around Rotating Eye

Bracket (77).

(99) Route Mainfall Slope Sensor Cable (72)

under Gooseneck (27).

(100) Attach Mainfall Slope Sensor Cable (72)

with two ties secured by cable ties

installed in Step (98).

(101) Route Mainfall Slope Sensor Cable (72)

under left-side Gooseneck (27) toward

rear of 130G Grader.

TM 5-6675-348-13&P

3-102

(102) Install both left-side Gooseneck Panels (24) and (25) and Float Valve (26), using eight flat

washers (23) and bolts (22).

• Both sides of 130G Grader are installed the same.

• Lubricate O-rings on ORS to JIC/SAE fittings with clean hydraulic fluid before installa-

tion.

• Note inlet and outlet side of Check Valve before installation.

(103) Install #4 ORS to JIC/SAE fittings (78) on inlet side of Check Valve (79).

(104) Tighten #4 ORS to JIC/SAE fittings (78).

(105) Install 90-degree fitting (80) on #4 ORS to JIC/SAE fitting (78).

(106) Install #6 ORS to JIC/SAE fitting (81) on outlet side of Check Valve (79).

(107) Tighten #6 ORS to JIC/SAE fitting (81).

(108) Install T-fitting (82) on #6 ORS to JIC/SAE fitting (81).

TM 5-6675-348-13&P

3-103

Hydraulic oil is slippery and can cause falls. To avoid injury, wipe up all spilled hydraulic oil

with rags.

Inspect all hoses, lines, and fittings for cracks, bends, nicks, dents, stripped threads, and

cuts. Replace all damaged parts.

NOTE

• Tag and mark all hoses prior to removal.

• Plug holes and cap fittings to prevent oil spills.

• Cable tie as needed.

• Do not tighten 90-degree fitting or T-fitting on Check Valve until all lines are installed.

(109) Remove Load Sense Line (37) from

fitting (83).

(110) Install T-fitting (82) to fitting (83).

(111) Install original Load Sense Line (37) to

T-fitting (82).

(112) Install new Load Sense Line (84) to

90-degree fitting (80).

(113) Tighten #6 ORS to JIC/SAE fitting (81)

T-fitting (82). Tighten T-fitting (82) to

fitting (83). Tighten original Load Sense

Line (37) to T-fitting (82). Tighten new

Load Sense Line (84) to 90-degree

fitting (80).

(114) Remove plug (85) from Stack Valve (86).

Retain plug (85) for future use.

TM 5-6675-348-13&P

3-104

(115) Install #6 JIC/SAE fitting (87) on

Stack Valve (86).

(116) Tighten #6 JIC/SAE fitting (87).

(117) Install Pressure Line (44) on #6 JIC/SAE

fitting (87).

(118) Tighten Pressure Line (44) to #6 JIC/SAE

fitting (87).

Hydraulic oil is slippery and can cause

falls. To avoid injury, wipe up all spilled

hydraulic oil with rags.

(119) Remove plug (88) from Stack Valve (86).

Retain plug (88) for future use.

(120) Install fitting (89) on Stack Valve (86).

(121) Tighten fitting (89).

(122) Install 90-degree fitting (90) on fitting (89).

(123) Tighten 90-degree fitting (90).

(124) Install Return line (43) on 90-degree

fitting (90).

(125) Repeat Steps (103) through (124) for other

side of 130G Grader.

TM 5-6675-348-13&P

3-105

(126) Loosen Gooseneck lower retainer

bolt (30).

(127) Reposition lower Gooseneck

Retainer (34).

(128) Tighten bolt (30).

(129) Install Gooseneck upper retainer

bolt (31), washer (32), and spacer (33).

(130) Tighten upper retainer bolt (31).

(131) Assemble female end of Operator

Cable (36).

(132) Remove three screws (91), washers (92),

and right side Stack Valve Cover (93).

TM 5-6675-348-13&P

3-106

(133) Cut approximately 1 1/4-in. (3.2 cm) slot,

1 in. (2.54 cm) wide and 1/2 in. (1.3 cm)

deep, in left side of Stack Valve Cover (93).

(134) From under cab, route Operator Cable (36)

over hydraulic lines, under floorboard, and

into cab.

(135) Install right side of Stack Valve Cover (93),

three washers (92), and screws (91) over

Operator Cable (36).

NOTE

For ease of installation, remove only

one screw in column at a time. Work

from floorboard up column.

(136) Remove screws (94) from column (95).

(137) Install Operator Cable (36), Loop

Clamps (96), and bushings (97) on

column (95) with screws (94).

(138) Cable tie Operator Cable (36) to

Steering Column Release Lever (98).

TM 5-6675-348-13&P

3-107

(139) Loosen jam nuts (99) on right-side RAISE/

LOWER Knob (100) and Articulation

Knob (101).

(140) Remove right-side RAISE/LOWER

Knob (100) from right-side RAISE/

LOWER Lever (102).

(141) Remove Articulation Knob (101) from

Articulation Lever (103).

(142) Loosen jam nut (99) on left-side RAISE/

LOWER Knob (104).

(143) Remove left-side RAISE/LOWER

Knob (104) from left-side RAISE/LOWER

Lever (105).

(144) Install second jam nuts (106) on RAISE/

LOWER Control Levers (102), (103),

and (105).

NOTE

R/L Switches are the same and can be

installed on either RAISE/LOWER

Lever.

(145) Install R/L Switch (107) on RAISE/

LOWER Lever (102).

(146) Install Remote Switch (108) on

Articulation Lever (103).

(147) Tighten jam nuts (106) and (99).

TM 5-6675-348-13&P

3-108

(148) Install R/L Switch (109) on left-side

RAISE/LOWER Lever (105).

(149) Tighten jam nuts (106) and (99).

NOTE

• Install cable ties as required.

• The Power Cables for all switches

are routed the same. The Remote

Switch on the Articulation Lever is

shown.

• Steps (150) through (153) apply to

both sides.

(150) Route Remote Switch Cable (110)

from Remote Switch (108), down

Articulation Lever (103), and across to

column (95).

(151) Remove screw (111) from column (95).

(152) Install Remote Switch Cable (110), R/L

Switch Cable (112), Loop Clamp (113),

and screw (111) on steering column (95).

(153) Cut Remote Switch Cable (110) and

R/L Switch Cable (112) to 26 in. (66 cm),

as measured from Loop Clamp (113).

TM 5-6675-348-13&P

3-109

(154) Attach wires to Remote Splice Assembly (114), using wiring schematics.

NOTE

One screw is located on left side of

Operator Control Box.

(155) Remove four screws (115) and

washers (116) from Monitoring System

Control Panel (117).

TM 5-6675-348-13&P

3-110

(156) Install Control Box Mounting

Bracket (118) on Monitoring System

Control Panel (117) with two

screws (115) and washers (116).

(157) Tighten screws (115).

NOTE

Connector holders are different sizes.

The small Connector Holder is

installed on the left and the large

Connector Holder is installed on the

right.

(158) Install two Connector Holders (119)

on Control Box Mounting

Bracket (118) with two washers (120)

and screws (121).

TM 5-6675-348-13&P

3-111

• Remove all jewelry, such as rings, dog tags, bracelets, etc. If jewelry contacts Battery

Terminal, a direct short may result in instant heating of tools, damage to equipment,

and injury or death to personnel.

• Exercise extreme caution when working under tilt platform. Falling platform could

result in serious injury or death to personnel.

• Turn battery disconnect switch OFF prior to performing maintenance in immediate

battery area or working on electrical system. Failure to comply can result in electrical

shock to personnel or damage to equipment.

To avoid damage to Power Cable, it must be routed through Articulation Joint (following

existing electrical cables and hoses). NOTE

Cable tie as needed.

(159) Route Main Power Cable (38) under cab, through Articulation Joint, and up through hole under

Engine Compartment (122).

TM 5-6675-348-13&P

3-112

• Battery acid (electrolyte) is extremely harmful. Always wear safety goggles and rubber

gloves, and do not smoke when performing maintenance on batteries. Injury will result

if acid contacts skin or eyes. Wear rubber apron to prevent damage to clothing.

• Remove all jewelry, such as rings, dog tags, bracelets, etc. If jewelry contacts Battery

Terminal, a direct short may result in instant heating of tools, damage to equipment,

and injury or death to personnel.

• Exercise extreme caution when working under tilt platform. Falling platform could

result in serious injury or death to personnel.

• Turn battery disconnect switch OFF prior to performing maintenance in immediate

battery area or working on electrical system. Failure to comply can result in electrical

shock to personnel or damage to equipment.

• Always disconnect the negative (-) battery cable before servicing the battery or positive

(+) battery cable. Failure to comply can result in electrical shock to personnel or

damage to electrical system.

• Do not allow battery cable ends to contact each other or the machine. Failure to comply

can result in damage to battery or electrical system.

NOTE

Cable tie as required.

(160) Route Main Power Cable (38) into

Engine Compartment (122).

TM 5-6675-348-13&P

3-113

NOTE

Cable tie as required.

(161) Route two Red Wires (123) through Engine Compartment (122), following path of right-side

Battery Cable (124), to right side of Battery Box (125).

(162) Install two connectors (126) and nut (127) on positive Battery Terminal (128).

(163) Tighten nut (127).

(164) Remove bell housing bolt (129).

NOTE

For proper operation, a good ground is essential.

(165) Install bell housing bolt (129) and Black Wire connectors (130).

(166) Tighten bell housing bolt (129).

TM 5-6675-348-13&P

3-114

• 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 cough, shortness of breath, pain during

respiration, increased sputum production, and chest tightness. The following

precautions must be taken whenever using CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

(167) Remove paint from hole (131) at rear of left side of Battery Box (125).

(168) Install Voltage Protection Cable (132), internal star-washer (133), flat washer (134), and nut (135)

through hole (131) in Battery Box (125).

(169) Tighten nut (135).

(170) Apply black spray paint to Diode connection (132).

(171) Install Voltage Protection Cable (132) on negative Battery Terminal (136) with nut (137).

(172) Loop all excess Voltage Protection Cable (132) in Battery Box (125).

TM 5-6675-348-13&P

3-115

(173) Start 130G Grader (138) (TM 5-3805-261-10).

(174) Park 130G Grader (138) on solid material, such as concrete, asphalt, or compacted soil.

(175) Align front tires (139) vertically and position A-frame draw bar (140) directly centered under

main frame of 130G Grader (138).

(176) Align 130G Grader (138) so that holes in articulation area (141) are aligned.

NOTE

To simplify the welding procedure, roll blade fully forward.

(177) Adjust blade (142) and measure distance from front A-frame (143) to outside corners of

Moldboard (144). Dimensions (A) and (B) should be the same.

(178) Float blade until cylinder knuckles (145) are not supporting any weight. Cylinder knuckles (145)

should rotate freely.

(179) Shut OFF 130G Grader (138) (TM 5-3805-261-10).

TM 5-6675-348-13&P

3-116

• Unsafe welding practices can cause serious injury from fire, explosions, or harmful

agents. Allow only authorized personnel to weld or cut metals, and follow safety

precautions in TC 9-237. Protective clothing and goggles must be worn, adequate

protective equipment must be used, a suitable fire extinguisher must be kept nearby,

and requirements of TC 9-237 must be strictly followed. Failure to comply may result in

serious injury or death to personnel.

• 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 cough, shortness of breath, pain during

respiration, increased sputum production, and chest tightness. The following

precautions must be taken whenever using CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

NOTE

Position Tracer®/Mast Mounting Plate so threaded holes in Tracer®/Mast Mounting Plate

face front of Moldboard and setscrews face up.

(180) Remove paint from area to be welded.

(181) Weld Tracer®/Mast Mounting Plate (146)

on both sides of Moldboard (144),

approximately 5 3/4 in. (14.60 cm) from

end of Moldboard (144) and

approximately 1/4 in. (0.64 cm) from top

edge of Moldboard (144).

(182) Remove paint from area to be welded.

TM 5-6675-348-13&P

3-117

• Unsafe welding practices can cause serious injury from fire, explosions, or harmful

agents. Allow only authorized personnel to weld or cut metals, and follow safety precau-

tions in TC 9-237. Protective clothing and goggles must be worn, adequate protective

equipment must be used, a suitable fire extinguisher must be kept nearby, and require-

ments of TC 9-237 must be strictly followed. Failure to comply may result in serious

injury or death to personnel.

• CARC paint contains isocyanate (HDI), which is highly irritating to skin and respira-

tory system. High concentrations of HDI can produce symptoms of itching and redden-

ing of skin, a burning sensation in throat and nose, and watering of the eyes. In

extreme concentrations, HDI can cause cough, shortness of breath, pain during respira-

tion, increased sputum production, and chest tightness. The following precautions must

be taken whenever using CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

(183) Weld Tracer® Mounting Block (147)

approximately 1/2 in. (1.3 cm) down and

approximately 1/2 in. (1.3 cm) in from

rear frame crossmember (148) end.

TM 5-6675-348-13&P

3-118

NOTE

Steps (184) through (186) apply to

both sides.

(184) Remove paint from area to be welded.

(185) Before tack welding washer (149), center

rod (150) in existing Hose Tray Rod

Bracket (151).

(186) Weld washer (149) to Hose Tray Rod

Bracket (151).

(187) Install Slope Sensor Mounting

Plate (152) approximately 1/4 in. (0.64 cm)

from front edge of Frame Pocket (153).

(188) Remove paint from area to be welded.

(189) Tack weld rear of Slope Sensor Mounting

Plate (152) in frame pocket (153).

(190) Temporarily install Slope Sensor (154) to

Slope Sensor Mounting Plate (152).

TM 5-6675-348-13&P

3-119

NOTE

• The aid of an assistant is required for

Step (191).

• Measurement is adjusted by movement

of Slope Sensor Mounting Plate.

(191) With the aid of an assistant, square Slope

Sensor Mounting Plate (152) to

Moldboard (144) using straightedge, level,

and measuring tape until distance between

straightedge and Moldboard (144) is equal

within 1/4 in. (0.64 cm) on both sides.

NOTE

Step (192) applies to both sides of vehicle.

(192) Chisel mark on 130G Grader’s Rotation

Circle (155).

(193) Remove Slope Sensor (154) from Slope

Sensor Mounting Plate (152).

TM 5-6675-348-13&P

3-120

Unsafe welding practices can cause serious

injury from fire, explosions, or harmful

agents. Allow only authorized personnel to

weld or cut metals, and follow safety precau-

tions in TC 9-237. Protective clothing and

goggles must be worn, adequate protective

equipment must be used, a suitable fire

extinguisher must be kept nearby, and

requirements of TC 9-237 must be strictly

followed. Failure to comply may result in

serious injury or death to personnel.

(194) Weld front and back of Slope Sensor

Mounting Plate (152) to Frame Pocket (153).

(195) Position and weld Connector Holder (156) to

Frame Pocket (153).

To prevent damage to the Slope Sensor

Cable, allow enough slack in Slope Sensor

Cable at Circle Rotation Sensor connection

to permit circle movement.

NOTE

Allow enough slack at Slope Sensor

Connector to reach Blade Slope Sensor.

(196) Install Slope Sensor Cable (157) to

Connector Holder (156).

NOTE

Allow enough slack in the Slope Sensor

Cable to allow for rotation of the Circle

Frame.

(197) Route Slope Sensor Cable (157) along

hydraulic lines on top of Hose Tray (158),

to Circle Rotation Sensor (10).

(198) Connect Slope Sensor Cable (157) to

Circle Rotation Sensor (10).

(199) Cable tie as needed.

TM 5-6675-348-13&P

3-121

• CARC paint contains isocyanate (HDI), which is highly irritating to skin and respira-

tory system. High concentrations of HDI can produce symptoms of itching and redden-

ing of skin, a burning sensation in throat and nose, and watering of the eyes. In

extreme concentrations, HDI can cause cough, shortness of breath, pain during respira-

tion, increased sputum production, and chest tightness. The following precautions must

be taken whenever using CARC paint:

• ALWAYS use air line respirators when using CARC paint, unless air sampling shows

exposure to be below standards. Use chemical cartridge respirator if air sampling is

below standards.

• DO NOT let skin or eyes come in contact with CARC paint. Always wear protective

equipment (gloves, ventilation mask, safety goggles, etc.).

• DO NOT use CARC paint without adequate ventilation.

• NEVER weld or cut CARC-coated materials.

• DO NOT grind or sand painted equipment without high-efficiency air purifying

respirators in use.

• BE AWARE of CARC paint exposure symptoms; symptoms can occur a few days after

initial exposure. Seek medical help immediately if symptoms are detected.

(200) Prime all new welds with black spray paint.

NOTE

Steps (201) through (207) apply to both sides of the 130G Grader. The right side is shown.

(201) Assemble Remote Box Mounting Clamp (159) to Cable Bracket (160), using two capscrews (161),

lockwashers (162), and hex nuts (163).

(202) Install Connector Holder Assembly (164) on Gooseneck (27) frame. Align with back side of

Gooseneck Panel (28).

(203) Install S-Hook (165) on Blade Lift Hydraulic Cylinder Bracket (166).

TM 5-6675-348-13&P

3-122

(204) Install Cast Clamp (167) to Tracer®/Mast

Mounting Plate (146) with two

lockwashers (168) and screws (169).

(205) Install Cast Clamp (170) to Tracer®/Mast

Mounting Block (147) with two

lockwashers (171) and bolts (172).

(206) Install Base Clamp (173) to Cast

Clamp (170) with two flat washers (174),

bolts (175), and nuts (176). Do not

tighten.

(207) Install Tracer® Tube (177) to Base

Clamp (173).

(208) Place Tracer® Tube (177) in stow

position.

(209) Tighten nuts (176).

TM 5-6675-348-13&P

3-123/(3-124 Blank)

b. Follow-On Maintenance.

(1) Start Engine (TM 5-3805-261-Series).

(2) Check for leaks (TM 5-3805-261-10).

(3) Remove Chocks (TM 5-3805-261-10).

(4) Calibrate (Para 3-15 and Para 3-16).

END OF TASK

TM 5-6675-348-13&P

4-1

CHAPTER 4

BUCKET-PRO™ SYSTEM (HYEX)

Content Para Page

Bucket-Pro™ System Introduction ...................................................................................... Section I 4-2

Scope........................................................................................................................................... 4-1 4-2

Bucket-Pro™ System Equipment Characteristics, Capabilities, and Features..................... 4-2 4-2

Location and Description of Major Components...................................................................... 4-3 4-3

Bucket-Pro™ System PMCS .............................................................................................. Section II4-4

PMCS Introduction.................................................................................................................... 4-4 4-4

PMCS Procedures...................................................................................................................... 4-5 4-4

Shortened Maintenance Instructions....................................................................................... 4-6 4-6

Additional Maintenance Inspections........................................................................................ 4-7 4-6

PMCS Column Entry Explanation ........................................................................................... 4-8 4-6

Bucket-Pro™ System Operator’s PMCS Table......................................................................... 4-9 4-6

Bucket-Pro™ System Operation....................................................................................... Section III 4-8

Button Operation..................................................................................................................... 4-10 4-8

Graphic Display Features........................................................................................................ 4-11 4-8

Graphic Display Contrast........................................................................................................ 4-12 4-9

Bucket-Pro™ System Initialization........................................................................................ 4-13 4-9

Operation Examples................................................................................................................ 4-14 4-10

Reference (Benchmark) Elevation .......................................................................................... 4-15 4-10

Set Cut Depth .......................................................................................................................... 4-16 4-12

Setting Slope Excavation......................................................................................................... 4-17 4-13

Measure Slope.......................................................................................................................... 4-18 4-15

CUSTOMIZE............................................................................................................................ 4-19 4-16

CUSTOMIZE Menu Summary................................................................................................ 4-20 4-17

Cut/Fill ..................................................................................................................................... 4-21 4-18

Switching Grades Lines........................................................................................................... 4-22 4-19

Set Markers.............................................................................................................................. 4-23 4-19

Bucket Reference..................................................................................................................... 4-24 4-21

Laser Reference ....................................................................................................................... 4-25 4-22

Swing Reference....................................................................................................................... 4-26 4-24

Deadband ................................................................................................................................. 4-27 4-24

Set Limit Alarms ..................................................................................................................... 4-28 4-25

Select Bucket............................................................................................................................ 4-29 4-27

Bucket-Pro™ System Troubleshooting............................................................................. Section IV 4-30

Bucket-Pro™ System Maintenance ................................................................................... Section V 4-37

Belly Plate Removal and Installation..................................................................................... 4-30 4-37

Bucket-Pro™ System Installation.......................................................................................... 4-31 4-38

Bucket-Pro™ System Calibration........................................................................................... 4-32 4-64

TM 5-6675-348-13&P

4-2

SECTION I. BUCKET-PRO™ SYSTEM INTRODUCTION

Before operating a HYEX equipped with the Bucket-Pro™ System, be fully aware of

machine and job site safety. Refer to appropriate sections of manufacturer’s Operating

Manual for the HYEX (TM 5-3805-280-10). Read this chapter thoroughly.

4-1. SCOPE.

This chapter is used for operation, maintenance, and installation of the Bucket-Pro™ System used on the

HYEX.

4-2. BUCKET-PRO™ SYSTEM EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND

FEATURES.

a. Characteristics. The Bucket-Pro™ System is a depth-of-cut and grade display system used on the

HYEX.

b. Capabilities. Installation and calibration on a typical midsized HYEX takes approximately 1 day. The

Bucket-Pro™ System is an electromechanical system, so tampering with the hydraulic system of the

HYEX is not required.

c. Features. Standard features include a Dual-Axis Tilt Sensor that constantly compensates for frame

pitch and roll; Angle Sensors that measure boom, stick, and bucket position; Gravity Sensors that are

used on the boom and stick; and an Encoder that measures the bucket angle. A microprocessor control

box and a monochrome LCD, for real-time monitoring of bucket teeth, are also featured. The display

mounts in the cab and provides graphic information on elevation, depth of cut, percent of grade, and

reach. Five push buttons control all modes of operation. A picture of the bucket and stick’s position is in

front of the Operator at all times. Also shown on the display are numerical values, HI/LO/On-Grade

three-light display, and selectable on-grade detector audible tone.

TM 5-6675-348-13&P

4-3

4-3. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

NOTE

Bucket-Pro™ System is equipped with a Dual-Axis Tilt Sensor to compensate for frame

pitching and rolling during operation. Dual-Axis Tilt Sensor must be allowed to reach

operating temperature to function accurately. Warm-up for Dual-Axis Tilt Sensor takes

approximately 10 minutes after Bucket-Pro™ System is powered up.

(1) REMOTE CONTROL BOX. Remote Control Box contains microprocessors and software of your

Bucket-Pro™ System.

(2) ANGLE SENSORS. Three Angle Sensors measure boom, stick, and bucket angles, and feed data to

Remote Control Box.

(3) DUAL-AXIS TILT SENSOR. Dual-Axis Tilt Sensor constantly compensates for movements so that

displayed elevation and grade references remain set up as entered. Dual-Axis Tilt Sensor

constantly compensates for the EM2E-24 Electric Mast rocking out of plumb as the HYEX pitches

and rolls during digging cycle.

(4) GRAPHIC DISPLAY. Graphic LCD display with five buttons interfaces with all Bucket-Pro™

System features and functions.

(5) EM2E-24 ELECTRIC MAST. The EM2E-24 Electric Mast is a telescoping receiver mount driven by

an electric motor.

(6) SHOCK MOUNT. Attaches to the Bucket-Pro™ System and protects from vibration.

(7) 1145-2 TRANSMITTER LASER REFERENCE SYSTEM. (Not Shown) Bucket-Pro™ System Laser

Reference System allows trenching over long distances without having to benchmark Bucket-Pro™

System each time HYEX is moved.

TM 5-6675-348-13&P

4-4

SECTION II. BUCKET-PRO™ SYSTEM PMCS

4-4. PMCS INTRODUCTION.

Preventive Maintenance Checks and Services (PMCS) means systematic caring, inspecting, and servicing

equipment to keep it in good condition and to prevent breakdowns. As a Bucket-Pro™ System Operator, your

mission is to:

a. Be sure to perform your PMCS each time you operate the Bucket-Pro™ System. Always do your

PMCS in the same order so it becomes a habit. Once you’ve had some practice, you’ll quickly

spot anything wrong.

b. Do your Before PMCS just before you operate the Bucket-Pro™ System. Pay attention to

WARNINGS, CAUTIONS, and NOTES.

c. Do your During PMCS while you operate Bucket-Pro™ System. Pay attention to WARNINGS,

CAUTIONS, and NOTES.

d. Do your After PMCS right after operating Bucket-Pro™ System. Pay attention to WARNINGS,

CAUTIONS, and NOTES.

e. Do your Weekly PMCS once a week.

f. Use DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet) to

record any faults that you don’t immediately fix.

4-5. PMCS PROCEDURES.

a. PMCS Table (Table 4-1.) lists inspections and care required to keep your Bucket-Pro™ System

in good operating condition. This table is set up so you can do Before and After PMCS while

walking around the Bucket-Pro™ System.

b. The “Interval” column tells you when to do a certain check or service.

c. The “Procedure” column tells you how to do required checks and services. Carefully follow these

instructions.

d. The “Not Fully Mission Capable If” column tells you when your Bucket-Pro™ System is

nonmission capable and why the Bucket-Pro™ System cannot be used.

e. When something looks wrong that you cannot fix, write down the problem on your

DA Form 2404 or DA Form 5988-E. Immediately report the problem to your Supervisor.

TM 5-6675-348-13&P

4-5

f. When you do your PMCS, you will always need a rag or two. Following are checks that are

common to the entire Bucket-Pro™ System.

• Degreasing Solvent (MIL-PRF-680, Type II) is toxic and flammable. Keep away from

heat or flame. Never smoke when using solvent. The flashpoint for Type II Degreasing

Solvent is 141 °F (61 °C). Wear protective goggles, face shield, and gloves; use only in a

well-ventilated area; avoid contact with skin, eyes, and clothes; and do not breathe

vapors. Failure to comply may result in injury or death to personnel.