TM 5-2410-241-10

TM 5-2410-241-10 TECHNICAL MANUAL OPERATOR’S MANUAL FOR

D7R SERIES II DOZER TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R SERIES II DOZER TYPE II WITH RIPPER (NSN 2410-01-565-2603)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY 31 OCTOBER 2011

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TM 5-2410-241-10

WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. In the event of injury, seek medical attention in accordance with FM 4-25.11. Also included in the summary are explanations of safety and hazardous materials icons used within the technical manual. EXPLANATION OF SAFETY WARNING ICONS

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

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

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

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

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

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

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

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

HEAVY PARTS - Heavy object pinning human figure against wall shows that heavy moving parts present a danger to life or limb.

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

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EXPLANATION OF HAZARDOUS MATERIALS ICONS – CONTINUED BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

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

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

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

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

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

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FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11. GENERAL SAFETY WARNINGS DESCRIPTION

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WARNING

COMPRESSED AIR

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Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel.

WARNING

HEARING PROTECTION

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

WARNING

HOT COMPONENTS Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts.

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GENERAL SAFETY WARNINGS DESCRIPTION — CONTINUED

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WARNING MACHINE OPERATION

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

PRESSURIZED COOLING SYSTEM

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• DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system, and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warning may cause injury to personnel.

WARNING

SLAVE STARTING ENGINE When slave starting the engine: –

Use NATO slave cable that does NOT have loose or missing insulation.

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DO NOT proceed if suitable cable is not available.

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DO NOT use civilian-type jumper cables.

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DO NOT allow disabled machine and booster vehicle to come in contact with each other at any time during slave starting.

Failure to follow these warnings may result in injury or death to personnel.

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GENERAL SAFETY WARNINGS DESCRIPTION — CONTINUED

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WARNING

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• DO NOT operate arctic heater when machine is running. • DO NOT operate arctic heater in confined spaces due to exhaust gases. • Avoid exposure to hot exhaust gases. • Failure to follow these warnings may result in injury or death to personnel.

WARNING DO NOT operate winch without safety screen installed protecting rear cab window. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION

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WARNING

BATTERIES • To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or injury to personnel. –

EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

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SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.

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INTERNAL. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.

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CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

• CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals, and related accessories contain lead and lead components. These chemicals are known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION — CONTINUED

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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!!! • Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result from severe exposure. • Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when the engine is operated. –

DO NOT operate engine in enclosed areas.

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DO NOT idle engine without adequate ventilation.

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BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control

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If you see another person with exhaust poisoning symptoms: • Remove person from area. • Expose to fresh air. • Keep person warm. • DO NOT permit physical exercise. • Administer Cardiopulmonary Resuscitation (CPR) if necessary. • Notify a medic.

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

• CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION — CONTINUED

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WARNING

CARC PAINT

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• Take the following precautions before grinding, cutting, or welding any equipment that has been CARC-coated: –

Wear protective equipment (e.g., goggles, gloves, apron) when grinding or sanding CARC-coated equipment. Do not leave any skin exposed.

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Use high-efficiency air purifying respirators when grinding or sanding CARCcoated equipment.

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Never weld or cut CARC-coated equipment; grind or sand off CARC paint completely before welding.

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CARC paint contains isocyanate (HDI) which is highly irritating to the skin and respiratory system. High concentrations of HDI can produce itching and reddening of the skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, HDI can cause coughing, shortness of breath, pain during respiration, increased sputum production, and chest tightness.

• Failure to follow these warnings may result in injury or death to personnel.

WARNING

HAZARDOUS WASTE DISPOSAL

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

WARNING

HYDRAULIC SYSTEM PRESSURE • DO NOT disconnect or remove any hydraulic system line or fitting unless the engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel. • Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid from penetrating the skin. Failure to do so may cause injury or death to personnel.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION — CONTINUED

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WARNING

CBRN EXPOSURE

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

To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

WARNING

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

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION — CONTINUED

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WARNING 0000

WORK SAFETY • Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment. To prevent this, refer to your Unit’s authorized cleaning and solvents list for further instructions. • Solvents can burn easily, may give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death to personnel, keep away from open fire and use in a well-ventilated area. If solvent gets on skin or clothing, wash immediately with soap and water.

WARNING DO NOT operate winch without safety screen installed protecting rear cab window. Failure to follow this warning may result in injury or death to personnel or damage to equipment.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

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NOTE: Zero in the “Change No.” column indicates an original page or work package. Date of issue for the original manual is: Original.... 31 October 2011 TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 38 AND TOTAL NUMBER OF WORK PACKAGES IS 22, CONSISTING OF THE FOLLOWING: Page/WP No.

Change No.

Page/WP No.

Change No.

Front Cover . . . . . . . . . . . . . . . . . . . . . . 0

Chapter 4 title page (2 pgs) . . . . . . . . . . 0

Warning Summary (10 pgs). . . . . . . . . . 0

WP 0011 (4 pgs) . . . . . . . . . . . . . . . . . . 0

i through viii (8 pgs) . . . . . . . . . . . . . . . . 0

WP 0012 (48 pgs) . . . . . . . . . . . . . . . . . 0

Chapter 1 title page (2 pgs) . . . . . . . . . . 0

Chapter 5 title page (2 pgs) . . . . . . . . . . 0

WP 0001 (10 pgs) . . . . . . . . . . . . . . . . . 0

WP 0013 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0002 (8 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0014 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0003 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0015 (4 pgs) . . . . . . . . . . . . . . . . . . 0

Chapter 2 title page (2 pgs) . . . . . . . . . . 0

WP 0016 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0004 (28 pgs) . . . . . . . . . . . . . . . . . 0

WP 0017 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0005 (18 pgs) . . . . . . . . . . . . . . . . . 0

WP 0018 (6 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0006 (12 pgs) . . . . . . . . . . . . . . . . . 0

WP 0019 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0007 (14 pgs) . . . . . . . . . . . . . . . . . 0

Chapter 6 title page (2 pgs) . . . . . . . . . . 0

Chapter 3 title page (2 pgs) . . . . . . . . . . 0

WP 0020 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0008 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0021 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0009 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0022 (4 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0010 (8 pgs) . . . . . . . . . . . . . . . . . . 0

Index (4 pgs) . . . . . . . . . . . . . . . . . . . . . 0 Back Cover (2 pgs) . . . . . . . . . . . . . . . . 0

A/(B Blank)

TM 5-2410-241-10

TECHNICAL MANUAL TM 5-2410-241-10

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 31 October 2011

OPERATOR’S MANUAL FOR

D7R SERIES II DOZER TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R SERIES II DOZER TYPE II WITH RIPPER (NSN 2410-01-565-2603)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/TECH PUBS, MS 727, 6501 E. 11 Mile Rd., Warren, MI 48397-5000. The e-mail address is [email protected]. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

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

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TABLE OF CONTENTS

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WP Sequence No.

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Page No.

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How To Use This Manual Chapter 1 - General Information, Equipment Description, and Theory of Operation General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001 Table 1.

Exercise Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001-4

Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002 Figure 1. Figure 2. Figure 3. Figure 4.

D7R Dozer (Left Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-2 D7R Dozer (Left Side) – Continued. . . . . . . . . . . . . . . . . . . . . . . . . 0002-3 D7R Dozer (Right Side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002-4 D7R Dozer (Right Side) – Continued. . . . . . . . . . . . . . . . . . . . . . . . 0002-5

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003 Figure 1. Figure 2. Figure 3. Figure 4.

Engine Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-2 Engine Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-3 Powertrain Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-4 Hydraulic System Control Levers. . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-6

Chapter 2 - Operator Instructions Description and Use of Operator Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25.

Main Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-2 Alternate Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-3 Door Handles and Latches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-4 Operator Seat and Armrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-6 Seat Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-8 Left Joystick Steering, Parking Brake, and Transmission Controls. 0004-8 Right Joystick Dozer Blade Controls. . . . . . . . . . . . . . . . . . . . . . . 0004-10 Winch Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-11 Ripper Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-12 Horn Button, Throttle Control Switch, Arctic Heater Switch, and Hydraulic Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-13 Service Brake Control and Decelerator Pedal. . . . . . . . . . . . . . . . 0004-14 Cab Dome Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-15 Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-16 Incline Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-16 Light Switches and Heater/Air Conditioning Controls. . . . . . . . . . . 0004-17 Window Wiper and Washer Controls. . . . . . . . . . . . . . . . . . . . . . . 0004-18 Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-19 Status Indicators – Upper Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-20 Alert Indicators, Digital Display Window, and Action Lamp – Upper Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-21 Alert Indicators, Digital Display Window, and Operator Switch – Lower Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-22 Auto Kickdown Switch, Auto Shift Switch, and Engine Start Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-23 Auxiliary Action Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-24 Messenger Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-25 Engine Compartment Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-26 24V NATO Slave Receptacle, Engine Compartment

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TABLE OF CONTENTS - CONTINUED

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Lamp and Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-27 Figure 26. Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004-28 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.

Gauges and Digital Display Windows. . . . . . . . . . . . . . . . . . . . . . . . 0005-4 Engine Coolant Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . 0005-5 Upshift and Downshift Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-9 Autoshift Button and Bi-Directional Shift Indicators. . . . . . . . . . . . 0005-10 Auto Kickdown Button and Indicators. . . . . . . . . . . . . . . . . . . . . . . 0005-11 Lower Digital Display Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-14 Messenger Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-15 Messenger Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005-16

Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006 Figure 1. Figure 2. Figure 3. Figure 4.

Slave Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-2 Front Towing Eye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-10 Rear Towing Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-10 Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006-11

Stowage and Decal/Data Plate Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12.

BII Tool Bag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-1 Warning and Message Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-2 Warning and Message Labels – Continued. . . . . . . . . . . . . . . . . . . 0007-4 Warning and Message Labels – Continued. . . . . . . . . . . . . . . . . . . 0007-6 Stencils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-8 Stencils - Continued. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-9 Data Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-10 Data Plates - Continued. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-12 Data Plates - Continued. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-13 Unique Identification Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-13 Unique Identification Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-14 Unique Identification Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007-14

Chapter 3 - Troubleshooting Procedures Troubleshooting Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0008 Troubleshooting Symptom Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010 Chapter 4 - PMCS Maintenance Instructions Preventive Maintenance Checks and Services (PMCS) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . WP 0011 Table 1.

Maintenance Intervals, Symbols and Manhours. . . . . . . . . . . . . . . . 0011-2

Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0012 Table 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Preventive Maintenance Checks and Services (PMCS) .. . . . . . . . . 0012-2 Dozer Blade and Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-3 Coolant Level Sight Gauge and Radiator Pressure Cap and Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-5 Engine Oil Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-6 Ether Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-7 Arctic Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-8 Engine Air Precleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012-9

iii

TM 5-2410-241-10

TABLE OF CONTENTS - CONTINUED

-

WP Sequence No.

-

Page No.

-

Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31.

Washer Fluid Tank and Fuel Filler Cap. . . . . . . . . . . . . . . . . . . . .0012-10 Machine Rear View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-11 Tow Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-12 Hydraulic Tank Sight Gauge and Filler Cap. . . . . . . . . . . . . . . . . .0012-14 Transmission Oil Level Gauge, Filler Tube, and Cap. . . . . . . . . . .0012-16 Dozer Blade and Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-20 Coolant Level Check and Radiator Pressure Cap and Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-22 Ether Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-24 Primary Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . .0012-25 Engine Air Precleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-26 Cab Fresh Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-27 Cab Recirculation Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-29 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-32 Washer Fluid Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-33 Machine Rear View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-34 Winch Oil Level Check and Fill Plugs. . . . . . . . . . . . . . . . . . . . . . .0012-35 Tow Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-36 Hydraulic Tank Sight Gauge and Filler Cap. . . . . . . . . . . . . . . . . .0012-37 Transmission Oil Level Gauge, Filler Tube, and Cap. . . . . . . . . . .0012-39 Pivot Shaft Oil Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-41 Track Pin and Bushing Inspection. . . . . . . . . . . . . . . . . . . . . . . . .0012-42 Engine Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-43 Fuel Tank Water and Sediment Drain Valve and Hose. . . . . . . . .0012-45 Fuel Tank Filler Cap and Screen. . . . . . . . . . . . . . . . . . . . . . . . . .0012-46 Transmission Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0012-47

Chapter 5 - Maintenance Instructions Dome Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0013 Figure 1.

Dome Lamp Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . .0013-1

Engine Primary and Secondary Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.

Engine Air Filter Assembly Cover. . . . . . . . . . . . . . . . . . . . . . . . . . .0014-2 Primary Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0014-2 Secondary Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0014-3 Secondary Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0014-4 Primary Air Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0014-4 Engine Air Filter Assembly Cover. . . . . . . . . . . . . . . . . . . . . . . . . . .0014-5

Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0015 Figure 1. Figure 2. Figure 3.

Ether Starting Aid Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-2 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-3 Ether Starting Aid Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015-4

Flood Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.

Flood Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-1 Disconnecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . .0016-2 Bulb Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-3 Connecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-4 Flood Lamp Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016-5

iv

TM 5-2410-241-10

TABLE OF CONTENTS - CONTINUED

-

WP Sequence No.

-

Page No.

-

Fuel System - Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017 Figure 1.

Fuel System Priming Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017-1

Fuse And Circuit Breaker Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018 Figure 1. Figure 2. Table 1. Figure 3. Figure 4.

Fuse Panel Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-1 Fuse Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-2 Fuse Identification Key.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-3 Fuse and Circuit Breaker Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-4 Fuse Panel Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018-5

Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019 Figure 1.

Window Wiper Blade Replacement. . . . . . . . . . . . . . . . . . . . . . . . .0019-1

Chapter 6 - Supporting Information References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021 Table 1. Table 1. Table 1.

Basic Issue Items (BII). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0021-2 Basic Issue Items (BII) – Continued.. . . . . . . . . . . . . . . . . . . . . . . . .0021-3 Basic Issue Items (BII) – Continued.. . . . . . . . . . . . . . . . . . . . . . . . .0021-4

Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022 Table 1.

Expendable and Durable Items for the D7R Dozers .. . . . . . . . . . . .0022-2

v

TM 5-2410-241-10

HOW TO USE THIS MANUAL NOTE If at any time you are unsure of how to use this manual or you cannot locate the information you need, notify your supervisor. INTRODUCTION

0000

1. This manual is designed to help you operate the Caterpillar D7R Series II Dozers, Type I with Winch and Type II with Ripper, and to perform operator troubleshooting and maintenance on the equipment. 2. This manual is written in work package format: a. Chapters divide the manual into major categories of information (e.g., Introductory Information with Theory of Operation, Operator Instructions, Troubleshooting Procedures, Maintenance Instructions, and Supporting Information). b. Each chapter is divided into work packages, which are identified by a 4-digit number (e.g., 0001, 0002) located in the upper right-hand corner of each page. The work package page number (e.g., 0001-1, 0001-2) is located centered at the bottom of each page. c.

If a change package is issued to this manual, added work packages use a 5th digit to indicate new material. For instance, a work package inserted between WP 0001 and WP 0002 will be numbered WP 0001.1.

3. Read through this manual to become familiar with its organization and contents before attempting to operate or maintain the equipment. CONTENTS OF THIS MANUAL

0000

1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating or performing operator troubleshooting or maintenance on the machine. 2. A Table of Contents, located in the front of the manual, lists all chapters and work packages in the publication. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. 3. The Title Block Page provides Reporting Errors and Recommending Improvements information, with DA Form 2028 addresses for the submittal of corrections to this manual. 4. Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general information on the manual and the equipment. 5. Chapter 2, Operator Instructions, explains and illustrates all operator controls and indicators and contains a Decal and Data Plate Guide. It also describes how to perform all operating procedures for the machine: Operation Under Usual Conditions and Operation Under Unusual Conditions. 6. Chapter 3 covers all Troubleshooting Procedures. WP 0009 contains a Troubleshooting Symptom Index. If the machine malfunctions, this index should always be consulted to locate the appropriate troubleshooting procedure. 7. Chapter 4, PMCS Maintenance Instructions, contains operator-level preventive maintenance instructions for the dozer. 8. Chapter 5, Maintenance Instructions, covers operator level maintenance tasks. Unless another Military Occupational Specialty (MOS) is specified in the Initial Setup of a work package, all tasks are to be performed by Construction Equipment Operator, MOS 21E. 9. Chapter 6 Supporting Information includes: References, Components of End Item (COEI) and Basic Issue Items (BII) Lists, and Expendable and Durable Items List.

vi

TM 5-2410-241-10 FEATURES OF THIS MANUAL

0000

1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid.

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

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

NOTE A NOTE is a statement containing information that will make the procedures easier to perform. 2. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis. 3. Within a procedural step, reference may be made to another work package in this manual or to another manual. These references indicate where you should look for more complete information. a. If you are told: “Service air cleaner (WP 0014),” go to WP 0014 in this manual for instructions on this service. b. If you are told: “For complete information on servicing batteries, refer to TM 9-6140-200-14,” go to the References work package (WP 0020) for complete information. 4. Illustrations are placed after, and close to, the procedural steps to which they apply. Callouts placed on the art are text or numbers. 5. Numbers located at lower right corner of art (e.g., D7R-0001, D7R-0002) are art control numbers and are used for tracking purposes only. 6. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual.

vii/(viii blank)

2 TM 5-2410-241-10

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

10 TM 5-2410-241-10

0001

OPERATOR MAINTENANCE 0 0 0 1

-

GENERAL INFORMATION

SCOPE

0001

Type of Manual. This manual is for use in operating and performing operator troubleshooting and maintenance on the Caterpillar D7R Series II Dozer. Model Numbers and Equipment Names. Tractor-Dozer, Self-Propelled Crawler, Diesel Engine Driven (DED), (T9) Model D7R-II Type I with Winch, or (T9) Model D7R-II Type II with Ripper. Purpose of Equipment. The D7R Dozer is equipped with a blade used for cutting, moving, ditching, and dozing in a forward direction. It is also equipped with a ripper used to break up material, or a winch used to pull or lift loads. MAINTENANCE FORMS, RECORDS, AND REPORTS

0001

Department of the Army (DA) forms and procedures used for equipment maintenance will be those prescribed by (as applicable) PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual; PAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

0001

If your D7R Dozer needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to http:// www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. The Internet form lets you submit a Product Quality Deficiency Report (PQDR). You may also submit your information using an SF Form 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSRD-TAR-E/ PDQR, MS 268, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is [email protected]. The fax number is DSN 786-5666 or Commercial 586-282-5666. CORROSION PREVENTION AND CONTROL (CPC)

0001

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

0001

There are no ozone-depleting substances contained on the machine or used during machine maintenance. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6.

0001-1

0001

TM 5-2410-241-10

0001

PREPARATION FOR STORAGE OR SHIPMENT

0001

General

0001

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

0001

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

0001

0001

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

0001

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

0001

Maintenance Services. Prior to storage, perform the next scheduled PMCS. Inspection. Inspect and approve the equipment prior to storage. Do not place non-mission-capable equipment in storage. Correction of Shortcomings and Deficiencies

0001

Correct all shortcomings and deficiencies prior to storage, or obtain a deferment from the approving authority. Lubrication. Lubricate equipment in accordance with LO 5-2410-241-13.

0001-2

TM 5-2410-241-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED General Cleaning, Painting, and Preservation

0001

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

WARNING

Chemical Agent Resistant Coating (CARC) paint debris may be considered environmentally hazardous during removal. Consult local procedures prior to removal of CARC paint to ensure compliance with local laws. Painting. Remove rust and damaged paint by scraping, wire brushing, sanding, or buffing. Sand to a smooth finish and spot paint as necessary (TB 43-0209). Preservation. After cleaning and drying, immediately coat unpainted wear surfaces with oil or grease, as appropriate.

NOTE •

Place a piece of barrier material between desiccant bags and metal surfaces.

•

Air circulation under draped covers reduces deterioration from moisture and heat.

Weatherproofing. Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install all covers authorized for the equipment. Close and secure all openings except those required for venting and draining. Seal openings to prevent the entry of rain, snow, or dust. Insert desiccant when complete seal is required. Place equipment, and provide blocking or framing, to allow for ventilation and water drainage. Support cover away from item surfaces, which may rust, rot, or mildew. Basic Issue Items (BII) and Additional Authorization List (AAL) Items

0001

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

0001

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

0001-3

TM 5-2410-241-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED Inspection

0001

Inspection will usually be visual and must consist of at least a walk-around examination of all equipment to detect any deficiencies. Inspect equipment in open storage WEEKLY and equipment in covered storage MONTHLY. Inspect all equipment immediately after any severe storm or environmental change. The following are examples of things to look for during a visual inspection: •

Oil leaks.

•

Condition of preservatives, seals, and wraps.

•

Corrosion or other deterioration.

•

Missing or damaged parts.

•

Water in components.

•

Any other readily recognizable shortcomings or deficiencies.

Repair During Administrative Storage

0001

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

0001

Exercise equipment in accordance with Table 1 and the following instructions: Vehicle Major Exercise. De-preserve equipment by removing only that material restricting exercise. Close all drains, remove blocks, and perform all BEFORE operational checks. Make several right and left 90-degree turns. Make several hard-braking stops. While exercising, and when it is convenient and safe, operate all functional components and attachments. Perform all DURING and AFTER operational checks. Scheduled Services. Scheduled services will include inspection per Inspection in this work package, and will be conducted in accordance with PMCS (WP 0012). Lubricate in accordance with instructions in Lubrication Order LO 5-2410-241-13. Corrective Action. Immediately take action to correct shortcomings and deficiencies noted. Record inspection and exercise results on DA Form 2404 or DA Form 5988E. Record and report all maintenance actions on DA Form 2407. After exercising, restore the preservation to the original condition. Replenish lubricants used during exercise and note the amount on DA Form 2408-14. Table 1. Exercise Schedule. Weeks

2

4

6

8

10

12

14

0001

16

18

20

22

24

Scheduled Services

X

Major Exercise

X

Procedures for Common Components and Miscellaneous Items Rotation. Rotate items in accordance with any rotational plan that will keep the equipment in an operational condition and reduce the maintenance effort. Seals. Seals may develop leaks during storage or shortly thereafter. If leaking persists, notify Field Maintenance.

0001-4

0001

TM 5-2410-241-10

0001

PREPARATION FOR STORAGE OR SHIPMENT – CONTINUED Removal of Equipment from Administrative Storage

0001

Activation. Notify Field Maintenance to restore the equipment to normal operating condition. Servicing. Resume the maintenance service schedule in effect at the commencement of storage or service the equipment before the scheduled dates in order to produce a staggered maintenance workload. Preparation of Equipment for Shipment

0001

1. General. a. Machines that have been removed from storage for shipment do not have to be reprocessed if they will reach their destination within the administrative storage period. Reprocess only if inspection reveals any corrosion or if anticipated in-transit weather conditions make it necessary. b. When a machine is received that has already been processed for domestic shipment, as indicated on DD Form 1397, the machine does not have to be reprocessed for storage unless corrosion and deterioration are found during the inspection upon receipt. List on SF Form 364 all discrepancies found because of poor preservation, packaging, packing, marking, handling, loading, storage, or excessive preservation. Repairs that cannot be handled by the receiving unit must have tags attached listing needed repairs. A report of these conditions will be submitted by the unit commander for action by an ordnance maintenance unit. 2. Notify Field Maintenance to remove ether starting aid cylinder, if equipped. 3. After machine is positioned on transporter, park machine (WP 0004). 4. Turn battery disconnect switch to OFF position (WP 0004). 5. Be sure cab doors, access doors, and access covers are secured.

CAUTION Turbocharger may spin when engine is off due to air flow past machine exhaust pipe. Rotation of turbocharger without engine operation may result in damage to turbocharger. 6. Install exhaust opening cover. 7. Secure machine with tiedowns. END OF TASK

0001-5

TM 5-2410-241-10

0001

ELECTROMAGNETIC PULSE (EMP) EXPOSURE

0001

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

0001

The machine incorporates a CARC painted exterior. Materials used in the machine are metal, rubber, plastic, fabric, and glass. In the event of CBRN contamination, decontaminants for these surfaces and materials are listed in FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. COMMON TOOLS AND EQUIPMENT

0001

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

0001

The machine is warranted for 12 months. The warranty starts on the date found in block 23 of DA Form 2408-9, Equipment Control Record. Report all defects to your supervisor, who will take appropriate action.

0001-6

TM 5-2410-241-10

LIST OF ABBREVIATIONS/ACRONYMS

0001

0001

NOTE Refer to ASME Y14.38-2007, Abbreviations and Acronyms, for standard abbreviations. ABBREVIATION/ACRONYM

DEFINITION

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

0001-7

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LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED ABBREVIATION/ACRONYM

DEFINITION

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

0001-8

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0001

LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED ABBREVIATION/ACRONYM

DEFINITION

V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volt WCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Claim Action WP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Work Package END OF WORK PACKAGE

0001-9/(10 blank)

8 TM 5-2410-241-10

0002

OPERATOR MAINTENANCE 0 0 0

2

-

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

0002

The D7R Series II Dozer, classified as a tractor-dozer, is a self-propelled, fully tracked machine used for high-production earth moving. The tractor-dozer is a self-propelled crawler with equipment such as a dozing blade attachment which cuts, moves, and dozes material through forward motion of the machine, or a mounted attachment that is used to exert a push or a pull force, such as a ripper or towing winch. Additional application may include pushing scrapers during loading. The D7R Dozer has a maximum stabilized drawbar force of 105,820 lb (48,000 kg) and a maximum vertical drawbar load of 52,910 lb (24,000 kg).

WARNING •

When operating equipment without the ROPS/FOPS in the transport modes, operations should be restricted to nearly level surfaces (less than 10% grade and/or side slope).

•

When operating equipment without the ROPS/FOPS in the transport modes, operations should only be conducted in very low speeds (forward or reverse).

•

When operating equipment without ROPS/FOPS in the transport modes, dozing, ripping or winch tasks should be avoided.

•

When operating equipment without ROPS/FOPS in the transport modes, operations should be restricted from areas where heavy objects could fall on the cab area.

•

Failure to follow these Warnings may cause injury or death to personnel.

CAUTION When operating on severe slopes, maintain engine oil level to FULL mark. Engine should never be overfilled with oil. Damage to engine may result. The machine is capable of operating on an ascending or descending slope of up to 60 percent (28 degrees) while maintaining proper lubrication. When operating on severe slopes, quantity of oil in powertrain may be increased up to 10 percent. After work on severe slope is completed, excess oil must be drained from bevel gear case. Notify Field Maintenance. Prolonged operation with additional oil can cause high powertrain oil temperatures. The D7R Dozer has fast, precise blade control without drift; superior visibility, convenience, and safety; and an advanced cab design featuring joysticks for control.

0002-1

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

0002

Figure 1. D7R Dozer (Left Side). KEY

COMPONENT

DESCRIPTION

1

Blade

Used for earth moving.

2

Blade Lift Cylinder

Raises and lowers bulldozer blade.

3

Engine Air Precleaner

Removes debris from intake air.

4

Grab Handle

Provides hand-hold when mounting/dismounting machine.

5

Door Catch

Holds door in full open position.

6

Primary Exit

Door on left side of machine provides primary entry/exit point for operator.

7

Fuel Tank Filler Neck and Cap

Provides means to fill fuel tank and seal tank.

8

Pivot Shaft Oil Reservoir

Provides lubrication to pivot shaft.

9

Battery Compartment

Houses batteries.

10

Fuse and Circuit Breaker Compartment

Accesses fuse and circuit breaker panel.

11

Battery Disconnect Switch Access Cover

Lift cover to access battery disconnect switch.

12

End Bit

Replaceable outer edges of bulldozer blade.

13

Cutting Edge

Replaceable lower edge of bulldozer blade.

0002-2

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. D7R Dozer (Left Side) – Continued. KEY

COMPONENT

DESCRIPTION

1

Left Engine Compartment Door

Provides access to engine for maintenance and repairs.

2

Coolant Level Sight Glass

Provides a means to visually check coolant level.

3

Arctic Heater (if equipped)

Heats engine coolant to assist extreme cold weather starting.

4

Engine Compartment Work Light

Provides illumination in engine compartment.

5

Arctic Heater Battery Case

Houses arctic heater batteries.

6

Step

Provides safe means to climb on and off machine.

7

Grab Handle

Provides hand-hold when mounting/dismounting machine.

8

24V Slave Receptacle

Jump start connection.

9

Engine Oil Level Indicator

Provides a means to check engine oil level.

10

Fuel/Water Separator and Primer

Removes water from fuel and provides a means to manually prime fuel system.

11

Engine Oil Fill Tube

Provides a means to add oil to engine.

0002-3

0002

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 3. D7R Dozer (Right Side). KEY

COMPONENT

DESCRIPTION

1

Ripper

Used for breaking up material.

2

Rear Work Lights

Provides illumination to both front and rear of machine.

3

Hydraulic Tank Oil Fill Cap

Provides means to fill hydraulic tank.

4

Exhaust Pipe

Directs exhaust fumes away from machine.

5

Right Engine Compartment Door

Provides access to engine for maintenance and repairs.

6

Radiator Cap Access Door

Provides access to radiator pressure cap.

7

Blade Lift Cylinder

Raises and lowers bulldozer blade.

8

Tilt Cylinder

Tilts bulldozer blade.

9

Engine Drive Belts

Alternator and fan belts.

10

Recoil Spring Compartment Oil Fill Access Cover

Remove cover to check and fill recoil spring compartment.

11

Transmission Oil Level Indicator and Fill Tube

Provides a means of checking and filling transmission oil level.

12

Final Drive

Transmits power from powertrain to tracks.

13

Hydraulic Oil Tank Sight Gauge

Provides a means to check hydraulic oil level.

0002-4

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 4. D7R Dozer (Right Side) – Continued. KEY

COMPONENT

DESCRIPTION

1

Alternate Exit

Provides alternate exit for operator.

2

Grab Handles

Provides hand-hold when mounting/dismounting machine.

3

Cab Fresh Air Filter

Filters cab incoming air.

4

Fire Extinguisher

Extinguishes fires.

0002-5

0002

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EQUIPMENT DATA

0002

0002

Weight With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67,000 lb (30,391 kg) With Blade, Ripper, and SAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71,500 lb (32,432 kg) Transport with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,500 lb (26,082 kg) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63,500 lb (28,803 kg) With Blade, Winch, and SAS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68,000 lb (30,844 kg) Transport with Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54,000 lb (24,494 kg) Length With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 in. (7,239 mm) Without Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 in. (6,781 mm) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 in. (6,121 mm) Without Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 in. (5,817 mm) Width With Blade and Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 in. (3,683 mm) With Blade and Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 in. (3,683 mm) Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 in. (2,540 mm) Height With Blade and Ripper or Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 in. (3,404 mm) With Blade and Ripper or Winch and SAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 in. (3,531 mm) Transport (exhaust pipe, cab upper, and cab doors removed) . . . . . . . . . . . . . . . . . . . . . . . 112 in. (2,845 mm) Military Load Classification Without Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 With Armor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Grade Ascending Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60% Grade Descending Ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60% Tilt Dozing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 degrees Drawbar Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105,820 lb (48,000 kg) Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in. (76 cm) Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4 in. (417 mm) Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 psi (75.84 kPa) Maximum Speed Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.55 mph (10.5 km/h) Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44 mph (13.5 km/h)

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Engine Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cat 3176C with Electronic Unit Injection Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 HP Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629 cu. in. (10.3 L) Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Injection Cooling System (thermostat opening temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 to 180°F (69 to 82°C) Cooling System (thermostat completely open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197°F (92°C) Powertrain Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronically Controlled Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Forward / 3 Reverse Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Multiple disc, oil bathed, spring applied/hydraulically released Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrically activated, spring applied/hydraulically released Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pivot Capacities Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.5 gal. (479 L) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4 gal. (77.2 L) Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 gal. (31 L) Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 gal. (178 L) Final Drive (each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 gal. (12.8 L) Roller Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 gal. (24.6 L) Pivot Shaft Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 gal. (1.9 L) Attachment Hydraulic System (tank only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 gal. (54.1 L) Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L) Electrical System Batteries Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V dc System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V dc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 MT Alternator Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 amps Arctic Heater Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V dc System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V dc Bulldozer (Blade) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7SU Digging Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7 in. (527 mm)

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Ripper Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,431 lb (3,370 kg) Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Number of Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Winch Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PACCAR Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H110 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Cable Capacity (1 in./25 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 ft. (53.3 m) END OF WORK PACKAGE

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6 TM 5-2410-241-10

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INTRODUCTORY INFORMATION 0

0 0 3

-

THEORY OF OPERATION

INTRODUCTION

0003

The D7R Series II Dozer consists of the following functional systems: engine, powertrain, brakes, electrical, steering, and hydraulics. This work package explains how the systems and components of the machine work together. A functional description is provided for each major component and system. The D7R Dozer is an all-purpose, medium-sized, self-propelled, full-tracked crawler used for cutting, moving, and dozing various types of granular material (dirt, stone, sand, etc.). Power is provided by a Caterpillar in-line, sixcylinder, direct injected, diesel engine. Hydraulically operated implements allow blade positioning for dozing material in a forward direction. A hydraulically operated ripper allows loosening of compacted material prior to dozing. A hydraulically operated winch provides pulling capability. The machine has a sound-suppressing Falling Object Protective Structure (FOPS) cab with insulation, heater, air conditioning, and windows, which allow for allweather operation. A Rollover Protective Structure (ROPS) is mounted on the chassis frame and protects the operator in the event of a rollover.

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ENGINE

0003

General. The machine is equipped with a Caterpillar 3176C turbocharged diesel engine with six in-line cylinders, generating 240 net horsepower @ 2,100 rpm. Fuel System. Diesel fuel is drawn from the tank by a fuel transfer pump, filtered by a primary fuel filter, routed to the fuel injection pump and secondary filter, and then injected through the fuel injector nozzles into the engine cylinders. Air is drawn in through a precleaner, then through primary and secondary dry-type, replaceable filter elements. A hose attached to the air cleaner directs incoming dust from the air filter and routes it out through the exhaust system. The air is routed from the filter assembly to the turbocharger, which pressurizes the air and sends it to the air-to-air aftercooler. The aftercooler, located near the radiator, reduces the air temperature, making it denser. The denser air charge allows for more air and fuel to be combusted per engine cycle, increasing engine output power. Cooling System. Provides coolant to the engine. Coolant is circulated through the engine by a gear-driven water pump. The hydraulic system oil cooler is located next to the radiator and aftercooler. The engine oil cooler is externally mounted to the engine. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan. The engine is lubricated by cooled and pressurized oil that is circulated through the engine block and head. Exhaust System. The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow through exhaust pipes and a muffler to the atmosphere.

Figure 1. Engine Components.

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ENGINE – CONTINUED

Figure 2. Engine Components.

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TM 5-2410-241-10

POWERTRAIN

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Power is transferred from the engine flywheel to the torque divider. The torque divider, consisting of a torque converter and a planetary gear set, transfers power through a driveshaft to the transmission. The transmission has three forward and three reverse speeds. Speed and direction clutches are electronically controlled to transfer power to the bevel and transfer gears, which in turn send power to the steering differential and brake assembly (on right side of machine) and the planetary gear and brake assembly (on left side of machine). These two assemblies transfer power through two outer axle shafts to the final drives, which utilize two planetary gear sets to increase torque. Sprockets on the final drives transfer power to the track assemblies which propel the machine. Steering is accomplished by increasing power (speed) to one track while equally reducing power (speed) to the other track.

Figure 3. Powertrain Components.

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BRAKE SYSTEMS

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General. Both service and parking brake systems share the same oil-bathed, multiple-disc arrangements. One brake assembly is contained in the steering differential and brake assembly located on the right side of the machine. The other brake assembly is contained in the planetary and brake assembly located on the left side of the machine. Both brake assemblies are spring applied, hydraulically released. Service Brakes. A foot pedal is used to apply brakes for slowing and stopping machine. Parking Brake. Parking brake is controlled by an operator-controlled parking brake switch. When parking brake is engaged, hydraulic pressure to brake assemblies is released, causing spring pressure to apply brake. ELECTRICAL SYSTEM

0003

1. The electrical system consists of four 12V batteries connected in series/parallel with negative grounding, providing 24V to operate the electrical systems and components. 2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate the machine, including a NATO slave receptacle. 3. The major systems comprising the electrical system are: a. Starting system. b. Charging systems. c.

Messenger display system and associated electronic control modules.

d. Service and work lights. e. Monitoring system (instrument cluster and gauges).

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IMPLEMENT AND STEERING HYDRAULIC SYSTEM

0003

A hydraulic system controls the steering, dozer blade, ripper (if equipped), and winch (if equipped). Machine utilizes three operator controls levers: steering control lever, dozer blade control lever, and hydraulic control lever (ripper/winch). A single hydraulic fluid tank supplies fluid for all hydraulic systems.

Figure 4. Hydraulic System Control Levers. END OF WORK PACKAGE

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2 TM 5-2410-241-10

CHAPTER 2 OPERATOR INSTRUCTIONS

30 TM 5-2410-241-10 OPERATOR MAINTENANCE 0 0 0 4

DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS

WARNING •

Mount and dismount the machine only at locations that have steps and grab handles.

•

Clean steps and grab handles prior to mounting machine.

•

Face machine during mounting and dismounting.

•

Maintain three-point contact (two hands and one foot, or one hand and two feet) at all times.

•

Do not mount or dismount a moving machine.

•

Do not jump off a moving machine.

•

Do not carry tools or supplies when mounting or dismounting machine.

•

Do not use any controls as grab handles during mounting or dismounting.

•

Failure to follow these warnings may result in injury or death to personnel.

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GENERAL

0004

Do not attempt to operate the D7R Dozer until becoming familiar with the location and use of all controls and indicators. This work package describes all operator controls and indicators. Main Entry and Exit

0004

Figure 1. Main Entry and Exit.

KEY

COMPONENT

0004

DESCRIPTION

1

Door

Main entry and exit point of cab.

2

Grab Handles

Provides hand grips for mounting and dismounting machine.

3

Step

Provides platform for mounting and dismounting machine.

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GENERAL – CONTINUED Alternate Exit

0004

Figure 2. Alternate Exit.

KEY

COMPONENT

0004

DESCRIPTION

1

Right Side Door

Provides alternate exit from cab.

2

Grab Handles

Provides hand grips for dismounting machine.

3

Step

Provides platform for dismounting machine.

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OPERATOR CONTROLS AND INDICATORS

0004

0004

Door Handles and Latches

0004

Figure 3. Door Handles and Latches.

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TM 5-2410-241-10

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OPERATOR CONTROLS AND INDICATORS – CONTINUED Door Handles and Latches – Continued

KEY

0004

COMPONENT

DESCRIPTION

1

Outer Door Handle

Unlatches door from outside of cab.

2

Inner Door Handle

Unlatches door from inside of cab.

3

Door Lock

Enables operator to lock door from inside.

4

Latch Release Lever

Releases latch to allow door to close.

5

Latch

Holds door open.

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OPERATOR CONTROLS AND INDICATORS – CONTINUED Operator Seat and Armrest

0004

Figure 4. Operator Seat and Armrest.

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OPERATOR CONTROLS AND INDICATORS – CONTINUED

KEY

COMPONENT

DESCRIPTION

1

Back Extension

Grasp back extension and pull up to remove.

2

Lumbar Support Knob

Rotate knob counterclockwise to increase stiffness of lumbar support. Rotate knob clockwise to decrease stiffness.

3

Forward/Back Seat Adjustment Lever

Pull up on lever to adjust seat forward or backward. Release lever to lock.

4

Seat Height Adjustment Lever

Pull up on lever to adjust seat upward or downward. Release lever to lock.

5

Weight Adjustment Knob

Adjusts seat suspension to accommodate operators of different sizes. Rotate knob clockwise to increase seat suspension tension for heavier operators. Rotate knob counterclockwise to decrease seat suspension tension for lighter operators.

6

Ride Zone Indicator

Indicates where seat suspension is set. Black bar in yellow zone indicates seat adjustment setting. Adjust weight adjustment knob accordingly.

7

Back Cushion Angle Adjustment Lever

Pull up on lever to release angle adjustment lock. Allow back to spring forward or lean backward to adjust. Release lever to lock.

8

Seat Cushion Tilt

Front of seat cushion is pinned in a groove. Grasp seat pan and rotate “forward-up-and-back” to position seat into a steep angle. Grasp seat pan and rotate “forward-down-and-back” to position seat at nominal angle.

9

Armrest

Loosen two knobs to allow up/down adjustment of right armrest.

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OPERATOR CONTROLS AND INDICATORS – CONTINUED Seat Belt

0004

Figure 5. Seat Belt.

KEY 1

COMPONENT Seat Belt (Retractable)

0004

DESCRIPTION Secures operator in seat.

Left Joystick Steering, Parking Brake, and Transmission Controls.

Figure 6. Left Joystick Steering, Parking Brake, and Transmission Controls.

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OPERATOR CONTROLS AND INDICATORS – CONTINUED Left Joystick Steering, Parking Brake, and Transmission Controls – Continued.

KEY 1

COMPONENT Parking Brake Control Knob

DESCRIPTION Pull knob up to engage parking brake and lock joystick to prevent steering or transmission engagement. Push knob down to disengage parking brake and unlock joystick.

2

Transmission Directional Selector

Rotate joystick twist handle to F (FORWARD) position to engage transmission forward gears. Joystick remains in forward position when released. Rotate joystick twist handle to N (NEUTRAL) position to disengage transmission. Rotate joystick twist handle to R (REVERSE) position to engage transmission reverse gears. Joystick remains in reverse position when released.

3

Steering Control Lever

While traveling in a forward direction: Push joystick forward to steer machine to the left. Pull joystick backward to steer machine to the right. While traveling in a reverse direction: Push joystick forward to steer machine to the right. Pull joystick rearward to steer machine to the left. With transmission in NEUTRAL: Push joystick forward to cause a counterclockwise (counter-rotate) turn. Pull joystick backward to cause a clockwise (counterrotate) turn. Release joystick to return joystick to NO STEER position. Turning speed is proportional to joystick position.

4

Upshift Button

Push button once to manually upshift transmission to next higher gear.

5

Downshift Button

Push button once to manually downshift transmission to next lower gear.

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OPERATOR CONTROLS AND INDICATORS – CONTINUED Right Joystick Dozer Blade Controls

0004

Figure 7. Right Joystick Dozer Blade Controls.

KEY

COMPONENT

DESCRIPTION

1

Hold

Joystick returns to HOLD position when released, except when joystick is in FLOAT position. Dozer blade remains in position.

2

Lower

Push joystick forward to lower dozer blade. Dozer blade lift cylinder speed is proportional to joystick position.

3

Float

Push joystick forward past detent to activate dozer blade float mode. Joystick remains in FLOAT position until operator moves joystick out of detent or until engine is shut down. Float mode allows blade to follow ground contour.

4

Raise

Pull joystick back to raise dozer blade. Dozer blade lift cylinder speed is proportional to joystick position.

5

Tilt Right

Push joystick right to lower right side dozer blade. Release joystick, joystick returns to HOLD position. Dozer blade remains in position.

6

Tilt Left

Pull joystick left to lower left side dozer blade. Release joystick, joystick returns to HOLD position. Dozer blade remains in position.

0004-10

0004

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Winch Control Lever

0004

Figure 8. Winch Control Lever.

KEY

COMPONENT

0004

DESCRIPTION

1

Brake On

Default joystick position. Winch drum held in place by winch brake.

2

Brake Off

Push lever right past detent to release winch brake. Lever will remain in BRAKE OFF position until moved back to BRAKE ON (default) position. Note: Winch does not have free-spool function.

3

Reel In

Move lever forward to reel in cable. Release lever to stop winch. Lever returns to BRAKE ON (default) position. Winch speed is proportional to lever position.

4

Reel Out

Move lever rearward to reel out cable under power. Release lever to stop winch. Lever returns to BRAKE ON (default) position. Winch speed is proportional to lever position.

5

Low Lock Switch

Press switch to activate LOW LOCK. Low lock provides maximum reel-in power while turning at slowest speed.

6

Low Lock Indicator

Illuminates when low lock is activated.

0004-11

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Ripper Control Lever

0004

Figure 9. Ripper Control Lever.

KEY

COMPONENT

0004

DESCRIPTION

1

Hold

Default position for lever. Ripper movement stops.

2

Shank In

Push lever forward to tilt ripper shanks in closer to machine. Release lever, ripper shanks remain in position. Lever returns to HOLD position.

3

Shank Out

Pull lever rearward to tilt ripper shanks out away from machine. Release lever, ripper shanks remain in position. Lever returns to HOLD position.

4

Lower

Push lever right to lower ripper. Release lever, ripper remains in position. Lever returns to HOLD position.

5

Raise

Pull lever to left to raise ripper. Release lever, ripper remains in position. Lever returns to HOLD position.

0004-12

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Horn Button, Throttle Control Switch, Arctic Heater Switch, and Hydraulic Lockout Switch

Figure 10. Horn Button, Throttle Control Switch, Arctic Heater Switch, and Hydraulic Lockout Switch. KEY

COMPONENT

0004

0004

DESCRIPTION

1

Horn Button

Press to activate horn.

2

Throttle Control Switch

Engine high and low idle speeds are factory set and cannot be adjusted. Press top of switch to activate engine high idle. Press bottom of switch to deactivate high idle and resume low engine idle speed. Set maximum operating speed at a point less than high idle as follows: a. Activate high idle. b. Depress deceleration pedal until desired speed is reached. c.

Press and hold top of switch for three seconds, then release.

d. Deceleration pedal will function normally, reducing engine speed from maximum operating speed. To deactivate maximum operating speed, press top of switch to reactivate high idle. 3

Arctic Heater Switch (if equipped)

Press top of switch to activate arctic heater. Switch illuminates when activated. Press bottom of switch to deactivate.

4

Hydraulic Lockout Switch

Press top of switch to deactivate (lock) dozer blade and ripper/ winch controls. Press bottom of switch to activate (unlock) dozer blade and ripper/winch controls.

0004-13

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Service Brake Control and Decelerator Pedal

0004

Figure 11. Service Brake Control and Decelerator Pedal.

KEY 1

COMPONENT Service Brake Control

DESCRIPTION Depress pedal to slow and stop machine. Depress pedal while on a downgrade to prevent engine overspeeding and while changing direction on a steep slope.

2

Decelerator Pedal

Depress pedal to reduce engine speed below maximum operating speed. Depress pedal to override throttle control. Depress pedal to reduce engine speed for directional shifts and while maneuvering in tight locations.

0004-14

0004

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Cab Dome Lamp Switch

0004

Figure 12. Cab Dome Lamp Switch. . KEY 1

COMPONENT Cab Dome Lamp Switch

DESCRIPTION Press top of switch to turn dome lamp on. Press bottom of switch to turn dome lamp off.

0004-15

0004

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Mirror

0004

Figure 13. Mirror. KEY

COMPONENT

0004

DESCRIPTION

1

Mirror

Used to view objects behind machine.

2

Knob

Loosen knob to allow mirror adjustment. Tighten knob to lock mirror in desired position.

Incline Meter

0004

Figure 14. Incline Meter. KEY 1

COMPONENT Incline Meter

0004

DESCRIPTION Shows angle of machine while traversing an incline.

0004-16

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Light Switches and Heater/Air Conditioning Controls

0004

Figure 15. Light Switches and Heater/Air Conditioning Controls. KEY 1

COMPONENT Rear-Facing Floodlight Switch

0004

DESCRIPTION Press top of switch to activate rear-facing floodlights when main light switch is in either floodlight or headlight position. Press bottom of switch to deactivate.

2

Main Light Switch

Turn switch counterclockwise to OFF position. Turn switch clockwise one detent to activate dash panel lights. Turn switch clockwise to second detent to activate forwardfacing rear floodlights. Turn switch clockwise to third detent to activate headlights.

3

Temperature Control

Adjust temperature from minimum (full left) to maximum (full right).

4

Fan Speed Switch

Turn switch counterclockwise to OFF position. Turn switch clockwise to operate fan at low, medium, high, and max speeds. To pressurize cab and prevent dust entry when neither heating or cooling is desired, adjust fan speed and temperature to comfortable levels. Do not activate air conditioning.

5

Air Conditioning Switch

Push top of switch to activate air conditioning. Turn Temperature Control switch counterclockwise to close heater valve. Push bottom of switch to deactivate air conditioning. To defog windshield, activate air conditioning and adjust fan speed and temperature to decrease moisture level in cab.

0004-17

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Window Wiper and Washer Controls

0004

Figure 16. Window Wiper and Washer Controls.

KEY

COMPONENT

1

Front Window Wiper/Washer Control

2

Left Door Window Wiper/Washer Control

3

Right Door Window Wiper/Washer Control

4

Rear Window Wiper/Washer Control

DESCRIPTION For all wiper controls; Turn control knob clockwise to first detent to turn wipers on LOW speed. Turn control knob clockwise to second detent to turn wipers on HIGH speed. Turn knob counterclockwise to turn wipers off. Push knob to activate washers.

0004-18

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Gauges

0004

Figure 17. Gauges.

KEY 1

COMPONENT Engine Coolant Temperature

0004

DESCRIPTION Indicates engine coolant temperature. Red area indicates coolant temperature too high at 225ºF (107ºC).

2

Torque Converter Oil Temperature

Indicates powertrain oil temperature at torque converter outlet. Red area indicates oil temperature too high at 265ºF (129ºC).

3

Fuel Level

Indicates relative amount of fuel in fuel tank. Red area indicates 10 percent fuel remaining.

4

Hydraulic Oil Temperature

Indicates hydraulic oil temperature. Red area indicates oil temperature too high at 215ºF (102ºC).

0004-19

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Status Indicators – Upper Panel

0004

Figure 18. Status Indicators – Upper Panel.

KEY

COMPONENT

DESCRIPTION

1

Parking Brake

Illuminates when parking brake is engaged.

2

Hydraulic Lockout

Illuminates when hydraulic lockout switch has been activated.

3

Auto Kickdown

Illuminates when auto kickdown has been activated.

4

Bidirectional Shift - 2F/1R

Illuminates when second gear forward to first gear reverse bidirectional shift setting is enabled.

5

Bidirectional Shift - 2F/2R

Illuminates when second gear forward to second gear reverse bidirectional shift setting is enabled.

6

Bidirectional Shift - 1F/2R

Illuminates when first gear forward to second gear reverse bidirectional shift setting is enabled.

0004-20

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Alert Indicators, Digital Display Window, and Action Lamp – Upper Panel

Figure 19. Alert Indicators, Digital Display Window, and Action Lamp – Upper Panel.

KEY

COMPONENT

DESCRIPTION

1

Engine Oil Pressure

Illuminates when engine oil pressure is too low. If action lamp also comes on, shut off engine immediately.

2

Charging System

Flashes when charging system voltage is too high or too low.

3

Inlet Manifold Temperature

Flashes when intake air temperature is too high. If action lamp also flashes, change in machine operation is required.

4

Fuel Level

Illuminates when fuel level is at ten percent of total tank capacity.

5

Digital Display Window

Displays engine rpm, gear selection and direction of travel, and indication of engine overspeed. Tachometer will flash continuously, indicating engine overspeed greater than 2,800 rpm. Additionally, action alarm will sound if engine attains speed over 3,000 rpm.

6

Action Lamp

Flashes when other alert indicators illuminate when machine system malfunction occurs.

0004-21

0004

0004

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Alert Indicators, Digital Display Window, and Operator Switch – Lower Panel

Figure 20. Alert Indicators, Digital Display Window, and Operator Switch – Lower Panel. . KEY

COMPONENT

DESCRIPTION

1

Air Filter Restriction

Illuminates when air filter restriction exists.

2

Brake System

Illuminates when problem exists in brake system.

3

Powertrain Oil Filter Bypass

Illuminates when oil flow is bypassing transmission oil filter due to filter restriction.

4

Transmission System

Illuminates when problem exists in transmission system.

5

Engine System

Illuminates when problem exists in engine system.

6

Implement System

Illuminates when problem exists in implement system (dozer blade, ripper, or winch).

7

Operator Switch

Press switch briefly to change display mode from Service Meter mode, Travel Distance mode, or Service Code mode. Also used to stop tachometer flashing when engine overspeed occurs (engine speed greater than 2,800 rpm). Engine speed must be reduced to below 2,600 rpm and button must be pressed before a 30-second timer expires.

8

Digital Display Window

Provides information in three modes: Service Meter mode, Travel Distance mode, and Service Code mode.

0004-22

0004

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Auto Kickdown Switch, Auto Shift Switch, and Engine Start Switch

0004

Figure 21. Auto Kickdown Switch, Auto Shift Switch, and Engine Start Switch.

KEY 1

COMPONENT Auto Shift Switch

DESCRIPTION Press switch once to enable bidirectional shift mode in First Gear Forward to Second Gear Reverse setting. Press switch second time to enable Second Gear Forward to Second Gear Reverse setting. Press switch third time to enable Second Gear Forward to First Gear Reverse setting. Pressing switch continuously will scroll through all settings, then turn off bidirectional shift mode. Appropriate indicator on upper display module will illuminate, signifying which setting is active.

2

Auto Kickdown Switch

Press auto kickdown switch to enable auto kickdown mode (transmission automatic downshifting) and activate first set point. Auto kickdown indicator illuminates when mode is enabled. Press switch again to activate second set point. Press switch again to disable auto kickdown mode. Auto kickdown indicator shuts off when mode is disabled.

3

Engine Start Switch

Turn switch clockwise one detent to ON position to activate cab circuits and initiate monitoring system self-diagnostic functional test. Turn switch clockwise to START position to start engine. Release switch when engine starts. Turn switch counterclockwise to OFF position to stop engine and deactivate cab circuits.

0004-23

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0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Auxiliary Action Lamp

0004

Figure 22. Auxiliary Action Lamp.

KEY 1

COMPONENT Auxiliary Action Lamp

DESCRIPTION Flashes when other alert indicators illuminate when machine system malfunction occurs.

0004-24

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Messenger Display

0004

Figure 23. Messenger Display.

KEY

COMPONENT

DESCRIPTION

1

Messenger Display

Provides information on service codes through a SERVICE CODES menu used by Field Maintenance to diagnose machine system malfunction.

2

OK Button

Press OK button to enter menu choice.

3

Scroll Buttons

Press to scroll left/up or right/down through menus.

4

Return Button

Press to return to previous menu.

0004-25

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Engine Compartment Doors

0004

Figure 24. Engine Compartment Doors.

KEY

COMPONENT

DESCRIPTION

1

Left Engine Compartment Door

Provides access to engine for maintenance and repairs.

2

Right Engine Compartment Door

Provides access to engine for maintenance and repairs.

0004-26

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED 24V NATO Slave Receptacle, Engine Compartment Lamp and Switch

0004

Figure 25. 24V NATO Slave Receptacle, Engine Compartment Lamp and Switch.

KEY

COMPONENT

DESCRIPTION

1

Primer Pump

Manual fuel primer to aid engine starting.

2

Engine Compartment Lamp Switch

Activates engine compartment lamp.

3

Engine Compartment Lamp

Illuminates engine compartment.

4

24V NATO Slave Receptacle

Connection for 24V NATO slave start cable.

5

Fuel Valve, Arctic Heater

Manual valve to shut off fuel to arctic heater. Valve shown closed: Turn lever on valve so it is parallel with valve to open. Turn lever on valve so it is perpendicular to valve to close.

0004-27

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Battery Disconnect Switch

0004

Figure 26. Battery Disconnect Switch. . KEY 1

COMPONENT Battery Disconnect Switch

DESCRIPTION Disconnects batteries from rest of machine. Includes a mechanical lockout cover to prevent unwanted access to switch. Insert disconnect switch key and turn switch clockwise to the ON position to activate machine electrical system and enable engine start. Insert key and turn switch counterclockwise to the OFF position to deactivate machine electrical systems.

0004-28

0004

TM 5-2410-241-10

0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED Winch Hitch Pin

0004

Figure 27. Winch Hitch Pin.

0004

0004

KEY 1

COMPONENT Hitch Pin

DESCRIPTION Secures towed equipment to hitch. Equipped with lanyard with retention pin to secure pin in place.

END OF WORK PACKAGE

0004-29/(30 blank)

18 TM 5-2410-241-10

0005

OPERATOR MAINTENANCE

-

OPERATION UNDER USUAL CONDITIONS Scope; Initial Adjustment Before Use; Mounting and Dismounting; Seat, Seat Belt, and Mirror Adjustments; Engine Starting and Machine Warm-Up; Stopping Machine; Stopping Engine; Leaving Machine; Machine Operation–Transmission, Speed, and Steering Controls; Gear Selection; Bulldozer Blade Operation; Winch Operation; Ripper Operation; Lower Digital Display Window; Machine Warning Summaries 0 0 0

5

INITIAL SETUP References TB 43-0142 WP 0004 WP 0006 WP 0012

0

0

0

0

0

0

SCOPE

0005

This work package provides instructions on operating the D7R Dozer, Type I with Winch and Type II with Ripper, under usual conditions. Refer to WP 0006 for operating instructions under unusual conditions. Before, during, and after operation, perform applicable Operator Preventive Maintenance Checks and Services (PMCS) (WP 0012). INITIAL ADJUSTMENT BEFORE USE

0005

Perform all Before Operator PMCS procedures (WP 0012). Turn battery disconnect switch to ON position (WP 0004). MOUNTING AND DISMOUNTING

0005

WARNING •

Mount and dismount the machine only at locations with steps and grab handles.

•

Clean steps and grab handles prior to mounting machine.

•

Face machine during mounting and dismounting.

•

Maintain three-point contact (two hands and one foot, or one hand and two feet) at all times.

•

Do not mount or dismount a moving machine.

•

Do not jump off a moving machine.

•

Do not carry tools or supplies when mounting or dismounting machine.

•

Do not use any controls as grab handles during mounting or dismounting.

•

Failure to follow these warnings may result in injury or death to personnel.

1. Open left door. 2. Enter machine from left side and occupy operator’s seat. 3. Close left door. END OF TASK

0005-1

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0005

SEAT, SEAT BELT, AND MIRROR ADJUSTMENTS

0005

1. Adjust operator’s seat (WP 0004). 2. Grasp seat belt and pull it out of retractor in one continuous motion, then insert catch into buckle. Seat belt adjusts tension automatically. Make sure belt is positioned low across lap (WP 0004). 3. Adjust mirror as necessary (WP 0004). END OF TASK OPERATIONAL INFORMATION

0005

Engine Starting and Machine Warm-Up

0005

WARNING

•

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

•

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

•

Carbon monoxide occurs in the exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when the engine of the D7R Dozer is operated.

•

DO NOT operate engine in enclosed areas.

•

DO NOT idle engine without adequate ventilation.

•

BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control

•

If you see another person with exhaust poisoning symptoms: • Remove person from area. • Expose to fresh air. • Keep person warm. • DO NOT permit physical exercise. • Administer Cardiopulmonary Resuscitation (CPR) if necessary. • Notify a medic.

•

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

•

CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

0005-2

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION – CONTINUED Engine Starting and Machine Warm-Up – Continued

WARNING

Hearing protection is required when standing within 20 ft (6 m) of the machine while it is operating. Failure to wear hearing protection may result in hearing loss. 1. Check to make sure all bystanders are clear of machine and briefly sound horn before starting engine. 2. Ensure left joystick is in NO STEER position and parking brake is engaged (WP 0004). 3. Ensure transmission direction selector (left joystick twist handle) is in NEUTRAL position (WP 0004).

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

NOTE •

The automatic self-diagnostic functional test verifies that all outputs (gauges, alert indicators, and alarms) are operating correctly.

•

Alert and status indicators in upper and lower panels must illuminate briefly.

•

Action lamp must illuminate briefly.

•

Auxiliary action lamp must illuminate briefly.

•

Gauges must sweep to vertical, then left, right, and finally settle at current actual value.

•

Upper digital display window must show readouts in the following sequence: (a) “888888888888” (b) “0 RPM P”

•

Lower digital display window must show readouts in the following sequence; (a) “Deg C”, “kPa”, “miles”, “kilometers”, “rpm”, and “liters” (b) “X 10” (c) Hourglass symbol for service meter (d) “888.8.8.8” (e) Current service meter value

0005-3

0005

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION – CONTINUED Engine Starting and Machine Warm-Up – Continued

Figure 1. Gauges and Digital Display Windows.

0005

0005

NOTE Monitoring system self-diagnostic functional test takes approximately 10 seconds to complete. 4. Turn engine start switch to ON position, but do not start engine. Allow monitoring system to perform selfdiagnostic functional test.

CAUTION •

Do not crank engine for more than 30 seconds. Allow starting motor to cool for two minutes before cranking again or damage to starting motor or batteries may result.

•

Shut down engine if engine oil pressure does not register on gauge or if engine oil pressure indicator remains lit 10 seconds after start up.

•

Failure to follow this caution may result in engine damage.

5. Turn and hold engine start switch to START. Release engine start switch when engine starts. 6. Allow engine to warm up at low idle for five minutes. 7. Slowly operate hydraulics (blade and implements) to allow warm hydraulic oil to circulate through all hydraulic cylinders and lines (WP 0004). 8. Begin machine operation only after engine coolant temperature gauge begins to move.

0005-4

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION – CONTINUED Engine Starting and Machine Warm-Up – Continued

Figure 2. Engine Coolant Temperature Gauge.

0005

0005

END OF TASK PARKING

0005

Stopping Machine

0005

CAUTION Do not engage parking brakes to stop machine unless an emergency exists. Failure to follow this caution may result in damage to parking brake system.

NOTE Park machine on a level surface. If it is necessary to park on a grade, chock tracks securely. 1. Apply service brakes to stop machine (WP 0004). 2. Place transmission direction selector in NEUTRAL position (WP 0004). 3. Engage parking brakes (WP 0004). 4. Lower attachments (bulldozer blade and ripper) to ground and apply slight downward pressure (WP 0004). 5. Engage hydraulic lockout control (WP 0004). END OF TASK

0005-5

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION – CONTINUED Stopping Engine

0005

CAUTION Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of engine components. 1. Operate engine at low idle for five minutes to allow engine and components to cool gradually. 2. Turn engine start switch to OFF position (WP 0004). END OF TASK Leaving Machine

0005

WARNING Use caution and maintain three-point contact at all times when dismounting machine. Failure to follow this warning may result in injury or death to personnel. 1. Exit cab through left door. 2. Use steps and hand holds to dismount. Face machine when dismounting. 3. Turn battery disconnect switch to OFF position (WP 0004). 4. Perform all After Operator PMCS procedures (WP 0012). 5. Secure machine against vandalism. Lock all covers and compartments. END OF TASK

0005-6

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION

0005

Machine Operation – Transmission, Speed, and Steering Control

WARNING •

To prevent injury, make sure that no maintenance work is being performed on or near machine.

•

Keep machine under control at all times in order to prevent injury. Reduce engine speed when you maneuver in tight quarters or when you break over a rise.

•

Select gear range that is appropriate before you start downhill. Do not change gears when you are going downhill. Do not allow engine to overspeed when you are unloaded and moving down a slope. Watch tachometer and use service brakes. Use service brakes near the top of slope to prevent excessive engine speed.

•

When you drive down a grade, use same gear used when driving up the grade.

•

Machine will turn (counter-rotate) when transmission is in NEUTRAL, parking brake is disengaged, and left joystick (steering lever) is pushed forward or pulled rearward.

•

Ensure all personnel are clear of machine before disengaging parking brake.

•

Engage parking brake to lock left joystick and prevent machine movement.

•

Do not allow riders on machine.

•

If machine begins to sideslip, discard load and turn machine downhill.

•

Whenever possible, operate machine up and down slopes, not across slope.

•

Failure to follow these warnings may result in injury or death to personnel.

WARNING Always use a ground guide when moving machine up or down a ramp when loading/ unloading. Failure to use a ground guide may result in an accident, causing death or injury to personnel or damage to equipment. 1. After engine is warmed up, raise bulldozer blade and ripper to clear any unexpected obstacles (WP 0004). 2. Hold service brake pedal down and disengage parking brakes (WP 0004).

NOTE When parking brake is engaged, transmission defaults to neutral. When parking brake is disengaged, transmission will stay in neutral until desired direction and gear are selected. 3. Rotate transmission direction selector to desired direction (WP 0004).

0005-7

0005

TM 5-2410-241-10

0005

OPERATIONAL INFORMATION – CONTINUED

CAUTION Although gear changes and directional changes at full engine speed are possible, deceleration and/or braking when you change direction is highly recommended. Failure to follow this caution may result in powertrain component failure. 4. Press upshift or downshift button to engage desired gear (WP 0004). 5. Release service brake to allow machine movement.

NOTE •

Turning speed is proportional to amount of joystick travel.

•

When joystick is released, it will return to NO STEER position and machine will proceed in a straight line.

Machine Operation – Transmission, Speed, and Steering Control 6. Steer machine as follows: a. While traveling in a forward direction: (1) Push left joystick forward to turn left. (2) Pull left joystick rearward to turn right. b. While traveling in a reverse direction: (1) Pull left joystick rearward to turn left. (2) Push left joystick forward to turn right. 7. Set maximum operating speed at point less than high idle as follows: a. Press top of throttle control switch to set high idle (WP 0004). b. Depress decelerator pedal until desired speed is reached (WP 0004). c.

Press and hold top of throttle control switch for three seconds. Maximum operating speed is now set. •

Decelerator pedal will function normally, reducing engine speeds when depressed.

•

To return to high idle, press top of throttle control switch.

•

To return to low idle, press bottom of throttle control switch.

CAUTION Although directional changes at full engine speed are possible, deceleration and/or braking when you change direction is recommended. Failure to follow this caution may result in powertrain component failure. 8. Change direction of travel as follows: a. Depress decelerator pedal or brake pedal to decrease engine/machine speed (WP 0004). b. Rotate transmission direction selector forward or rearward (WP 0004). c.

Release decelerator pedal or brake pedal to increase engine/machine speed.

d. Use upshift or downshift switches to select desired gear (WP 0004). END OF TASK

0005-8

0005

TM 5-2410-241-10

GEAR SELECTION

0005

0005

Manual Mode

0005

Manual mode is active by default when machine is started. Transmission forward and reverse gear selection can be commanded by the operator while the machine is stopped or moving. Each time upshift button (Figure 3, Item 1) or downshift button (Figure 3, Item 2) is pressed, transmission will upshift or downshift one gear. Selected gear is displayed in the upper digital display window.

Figure 3. Upshift and Downshift Buttons. Bi-Directional Shifting

0005

0005

Bi-directional shifting allows the operator to choose which gear is engaged when forward and reverse are selected. Three factory presets are available: •

First Gear Forward To Second Gear Reverse When transmission is shifted into FORWARD position, first gear will engage. When transmission is shifted into REVERSE position, second gear will engage.

•

Second Gear Forward To Second Gear Reverse When transmission is shifted into FORWARD position, second gear will engage. When transmission is shifted into REVERSE position, second gear will engage.

•

Second Gear Forward To First Gear Reverse. When transmission is shifted into FORWARD position, second gear will engage. When transmission is shifted into REVERSE position, first gear will engage.

0005-9

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0005

GEAR SELECTION – CONTINUED Bi-Directional Shifting – Continued

0005

To activate one of the three bi-directional shift modes, press and release the autoshift button (Figure 4, Item 1) until the desired mode is activated, identified by one of three indicators (Figure 4, Items 2, 3, or 4) being illuminated within the upper display window (Figure 4, Item 5). To deactivate bi-directional shifting, press and release the autoshift button until all three display window indicators are off.

Figure 4. Autoshift Button and Bi-Directional Shift Indicators. Auto Kickdown

0005

0005

Auto kickdown mode will automatically downshift the transmission to a lower gear when a significant load increase is detected. Once the load has been reduced, operator can return to a desired gear by manually upshifting. The transmission will not automatically upshift. Auto kickdown functions in forward and reverse, and has two modes: low and high. In LOW mode, auto kickdown will occur with a lighter load. In HIGH mode, auto kickdown will not occur until a heavier load is encountered. The auto kickdown indicator (Figure 5, Item 2) will illuminate when either mode is activated. When the machine is started, auto kickdown will return to the mode selected when the machine was last shut off. • To activate auto kickdown in LOW mode, press and release auto kickdown button (Figure 5, Item 1) until LO appears in the upper digital display window (Figure 5, Item 3) along with a set of double arrows pointing down. •

To activate auto kickdown in HIGH mode, press and release auto kickdown button (Figure 5, Item 1) until HI appears in the upper digital display window (Figure 5, Item 3) along with a set of double arrows pointing up.

•

To deactivate auto kickdown, press and release auto kickdown button (Figure 5, Item 1) until all auto kickdown indicators are off.

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0005

GEAR SELECTION – CONTINUED Auto Kickdown – Continued

0005

Figure 5. Auto Kickdown Button and Indicators.

0005

END OF TASK BULLDOZER BLADE OPERATION

0005

WARNING Be sure all persons are clear of machine before beginning bulldozing operation. Failure to follow this warning may result in injury or death to personnel.

NOTE Bulldozer blade is factory set to a NEUTRAL pitch angle which, under most circumstances, will provide ample bulldozing capacity. Blade can be adjusted to provide more or less pitch angle based on bulldozing requirements. Pitching blade back causes blade to carry more material. Pitching blade forward causes blade to carry less material. If bulldozer blade pitch angle must be adjusted, notify Field Maintenance. 1. Push right joystick forward from HOLD position to lower blade to working depth as machine enters work site (WP 0004). 2. Move right joystick right or left to tilt blade as necessary during bulldozing operation (WP 0004). 3. Push right joystick forward past detent into FLOAT position to allow blade to follow ground contour if applicable (WP 0004). 4. Pull right joystick back from HOLD position to raise blade (WP 0004). 5. Continue bulldozing work site, adjusting blade depth and tilt as work progresses, until desired grade is obtained. END OF TASK

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0005

WINCH OPERATION

0005

WARNING •

Personal injury or death can result from unexpected movement of objects. Be sure all persons are clear of cable and objects before a machine is winched or moved. A safe distance of at least one and a half times working length of cable should be maintained. Tail end of a moving object can throw debris at bystanders.

•

When reeling in objects, be sure all personnel are clear of load.

•

A minimum of five complete wraps of cable must be maintained on winch drum. Do not handle a load with a winch drum that has less than five wraps.

•

Do not operate winch under loads that exceed maximum rated bare drum line pull. If excessive loads are encountered, use a multi-part line and sheave blocks. Any attempt to exceed capacity of one winch is extremely hazardous. Never try to couple two or more machines together.

•

Do not jerk loads and avoid sudden shock to loads. These types of operations cause heavy loads in excess of winch rated capacity, which in turn may result in cable failure or winch failure.

•

Winch is not designed or intended to be used for lifting or moving persons.

•

Do not release winch brake to reel out a suspended load. Use only reel-out function.

•

Wear leather gloves when handling winch cable.

•

NEVER attempt to maintain cable tension by allowing cable to slip through your hands. Use hand-over-hand technique only.

•

Keep hands and clothing away from winch drum and rollers.

•

Verify ground is stable before winching in a load.

•

Failure to follow these warnings may result in death or injury to personnel.

CAUTION Warm-up procedures are mandatory when ambient temperature is below 40ºF (4ºC). Failure to follow this caution may result in damage to equipment.

NOTE •

Winch speeds are proportional to control lever position. Greater movement of lever causes winch to operate faster.

•

Always attempt to line up rear of machine with load so load can be winched in a straight path. This avoids unnecessary strain and wear on winch side rollers, and helps wind cable onto drum in level layers.

•

Maintain a sufficient clearance between machine and load to allow machine to turn.

•

Winch is not equipped with free spool function.

•

Refer to TB 43-0142 for winch cable inspection procedures.

1. Operate winch reel-in/reel-out functions without a load during machine warm-up to circulate hydraulic fluid throughout the winch system (WP 0004). 2. If working on a hill, either drive up to top of hill and turn around, then drive downhill past object and align machine with object, or drive up hill backwards towards object, aligning machine with object. 3. Engage parking brakes (WP 0004).

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0005

WINCH OPERATION – CONTINUED 4. Use reel-out function to unwind enough cable under power to safely and securely fasten cable hook to load (WP 0004). 5. Secure cable to load. 6. Tighten cable by first ensuring drum is not rotating, then move winch reel control lever forward to reel in load (WP 0004). 7. An alternate method of reeling out cable is to reel out enough cable to hook to a load or stationary object as described above. Move winch control lever outward to BRAKE OFF position, then drive machine away. Lever will stay in BRAKE OFF position until moved back to BRAKE ON position by operator (WP 0004). 8. When precise load handling is required, activate LOW LOCK switch (WP 0004). Low lock indicator will illuminate when activated. This provides maximum amount of torque to pull load at slow speed. Release switch to return to full auto speed. END OF TASK RIPPER OPERATION

0005

CAUTION DO NOT operate machine in reverse while ripper is in a lowered position. Damage to equipment will occur.

NOTE Ripper control lever will return to HOLD position when released. Ripper will remain in position when control lever is released. 1. Adjust shank in or out according to conditions required for operation (WP 0004). 2. Lower ripper to desired depth (WP 0004). 3. Drive machine in forward direction to break up material. 4. Raise ripper at end of path (WP 0004). 5. Continue ripping operation, adjusting ripper depth as work progresses, until all material is suitably broken up. END OF TASK

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LOWER DIGITAL DISPLAY WINDOW

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The lower digital display window (Figure 6, Item 1) provides service hour, travel distance, and service code information. The display mode button (Figure 6, Item 2) located next to the display allows user to change between information modes.

Figure 6. Lower Digital Display Window. Service Meter Mode

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The Service Meter Mode is the default mode when machine is started. Digital display window shows total operating hours of machine to determine maintenance intervals. An hourglass symbol is shown on display while this mode is active. If service codes are stored, “SERV CODE” will be displayed in upper right corner of display window and an action indicator will be flashing. Travel Distance Mode

0005

Press display mode button once to change display to Travel Distance Mode. Digital display window shows distance traveled in forward and in reverse separately, and a total distance of travel. When travel distance mode is active, display will continuously scroll and show the following: •

total number of miles traveled.

•

F (forward direction)

•

miles traveled in forward gears

•

R (reverse direction)

•

miles traveled in reverse gears

If service codes are stored, “SERV CODE” will be displayed in upper right corner of display window and an action indicator will be flashing. Service Code Mode

0005

Press display mode button once more to change display to Service Codes Mode. Digital display window will show any stored codes. If codes are stored, notify Field Maintenance. END OF TASK

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MESSENGER DISPLAY

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The messenger display system provides stored service code information and monitor settings information. Default screen displays Service Codes and Monitoring Settings menu choices.

Figure 7. Messenger Display.

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1. Digital display area (Figure 7, Item 1) displays system information. 2. OK button (Figure 7, Item 2) confirms selections. 3. Down/Right button (Figure 7, Item 3) is used to scroll down and/or right through information shown on digital display area (Figure 7, Item 1). 4. Up/Left button (Figure 7, Item 4) is used to scroll up and/or left through information shown on the digital display area (Figure 7, Item 1). 5. Back button (Figure 7, Item 5) is used to return to previous screen from any screen. Service Codes

0005

1. Press Down/Right button (Figure 7, Item 3) or Up/Left button (Figure 7, Item 4) to highlight Service Codes menu. 2. Press OK button (Figure 7, Item 2) to enter Service Codes menu and display all stored service codes. 3. Press Down/Right button or Up/Left button to scroll through codes. 4. Press Back button (Figure 7, Item 5) to return to default screen.

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MESSENGER DISPLAY – CONTINUED Monitor Settings

0005

1. Press Down/Right button (Figure 8, Item 3) or Up/Left button (Figure 8, Item 4) to highlight Monitor Settings menu. 2. Press OK button (Figure 8, Item 2) to enter Contrast sub-menu. 3. Press Down/Right button (Figure 8, Item 3) or Up/Left button (Figure 8, Item 4) to adjust Messenger display (Figure 8, Item 1) contrast. Press OK button to confirm selection and return to Contrast sub-menu. 4. Press Down/Right button once to scroll to Backlight sub-menu. 5. Press Down/Right button (Figure 8, Item 3) or Up/Left button (Figure 8, Item 4) to adjust Messenger display backlighting. Press OK button to confirm selection and return to Backlight sub-menu.

Figure 8. Messenger Display. 6. Press Down/Right button once to scroll to Monitoring System Information sub-menu. The following information is available; a. Equipment ID - Identifies that systems are configured for a D7R Dozer. b. ECM Serial Number - Identifies ECM serial number. c.

ECM Part Number - Identifies ECM part number.

d. SW Part Number - Identifies software part number. e. SW Release Date - Identifies software release date by month and year (XX/XX). f.

SW Description - Identifies software description as being written for the D7R Dozer.

END OF TASK

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MACHINE WARNING SUMMARIES

0005

0005

The Monitoring System provides three warning categories. The first warning category requires only operator awareness. The second warning category requires a change to machine operation or performance of maintenance to a system. The third warning category requires immediate shutdown of machine. Refer to chart in WP 0008. It identifies the alert indicators and actions required for each warning category. END OF TASK END OF WORK PACKAGE

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12 TM 5-2410-241-10

0006

OPERATOR MAINTENANCE

-

OPERATION UNDER UNUSUAL CONDITIONS General, Slave Starting, Operation in Extreme Cold, Operation in Extreme Heat, Operation in Mud or on Soft Surfaces, Operation in Sandy or Dusty Areas, Operation in Salt Water Areas, Operation at High Altitudes, Operation in Snow and on Ice, Fording, Recovery and Towing, Operation Using Night Vision Devices, Operating Portable Fire Extinguisher, Stopping Engine if an Electrical Malfunction Occurs, Equipment Lowering With Engine Stopped 0 0 0 6

INITIAL SETUP References AR 70-1 FM 9-207 FM 31-70 FM 31-71

0

References - Continued

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FM 90-3 WP 0001 WP 0004 WP 0012 LO 5-2410-241-13

GENERAL

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0006

WARNING •

This machine has been designed to operate safely and efficiently within the limits specified in this TM. Operation beyond these limits is prohibited in accordance with AR 70-1 without written approval from: Commander, U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-DSA-CS, Warren, MI 48397-5000.

•

Always use a ground guide when moving machine up or down a ramp when loading/ unloading. Failure to use a ground guide may result in an accident, causing death or injury to personnel or damage to equipment.

This section contains instructions for safely operating the D7R Dozer, Type I with Winch and Type II with Ripper, under unusual conditions. In addition to normal preventive maintenance, special care must be taken to keep the machine operational in extreme temperatures and other environmental conditions.

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SLAVE STARTING

0006

WARNING •

When slave starting, use NATO slave cable that does NOT have loose or missing insulation.

•

DO NOT proceed if suitable cable is not available.

•

DO NOT use civilian-type jumper cables.

•

DO NOT allow disabled and booster machines to come in contact with each other at any time during slave starting. Failure to follow these warnings may cause injury or death to personnel.

NOTE Ensure that both disabled machine and booster machine are equipped with serviceable NATO slave receptacles. 1. Remove cover from slave receptacle (Figure 1, Item 1) on disabled machine and booster machine. 2. Connect slave cable to booster machine slave receptacle. 3. Connect other end of slave cable to slave receptacle of disabled machine, located on left side of the engine compartment. 4. Turn battery disconnect switch of disabled machine to ON position (WP 0004). 5. Start booster machine and run at a speed just above idle. 6. Wait approximately five minutes, then start disabled machine. If engine fails to start, notify Field Maintenance. 7. After starting disabled machine, return booster machine to idle. 8. Remove slave cable from disabled machine, then from booster machine. 9. Replace covers on slave receptacles.

Figure 1. Slave Receptacle. END OF TASK

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TM 5-2410-241-10

0006

OPERATION IN EXTREME COLD

0006

General

0006

WARNING The heater will heat the cab only to 40ºF (4ºC) during arctic conditions. Additional cold weather gear needs to be worn. Failure to comply may result in serious injury or death.

NOTE Refer to FM 9-207, Operation and Maintenance of Ordnance Materiel in Cold Weather, FM 31-70, Basic Cold Weather Manual, and FM 31-71, Northern Operations, for additional information on cold weather operation and maintenance. Extreme cold causes many problems that you as an operator must be aware of, such as; 1. Lubricants thicken or congeal. 2. Batteries may freeze or lose their electrical efficiency. 3. Electrical insulation may crack and cause short circuits. 4. Fuel may not readily atomize for combustion. 5. Various materials will become hard, brittle, and easily damaged. 6. The cooling system requires adequate protection from extreme cold. 7. Fuels, lubricants, and antifreeze compounds require special storage, handling, and use. 8. Any water in the fuel/water separator may freeze if not drained. 9. Tracks may be frozen to ground. Checks

0006

1. Perform all Before PMCS procedures (WP 0012). 2. Lubricate in accordance with LO 5-2410-241-13. 3. Check to ensure tracks, blade, and ripper (if equipped) are not frozen to ground. 4. Drain a small amount of fuel from the fuel/water separator to ensure fuel is not gelled (WP 0012).

CAUTION If oil is too cold to drip from oil level gauge (dipstick), do not attempt to start engine. Notify Field Maintenance. 5. Check that engine and transmission oils are thin enough to flow. Oil must be thin enough to drip from oil level gauge (dipstick). 6. Ensure ether starting aid cylinder is in place and not empty (WP 0015). Starting Procedures - Machine NOT Equipped with Arctic Kit 1. Start engine (WP 0005). 2. Check that oil pressure light on instrument panel goes out within 10 seconds of engine starting. 3. Allow engine to idle for at least five minutes before moving machine.

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OPERATION IN EXTREME COLD – CONTINUED Starting Procedures - Machine Equipped with Arctic Kit

CAUTION •

At temperatures nearing -40ºF (-40ºC), it is necessary to shut off the arctic heater at least 30 seconds before attempting to start the machine’s engine. Failure to follow this caution may result in internal damage to the heater or localized boiling of the coolant in the heater body, which may cause a heater hose to come off.

•

The arctic heater requires a cool-down period after the machine has started. If for some reason the engine is immediately shut down after the arctic heater has been used, the battery disconnect switch must remain ON for at least five minutes to allow the arctic heater to cool. Failure to follow this caution may result in damage to equipment.

NOTE •

Ensure engine start switch is in the OFF position (WP 0004).

•

If arctic heater has not been started for several months, or if heater is being started for the first time, it may take several attempts to start.

•

If arctic heater fails to start at first attempt, it will automatically attempt to start a second time. If heater still does not start, it will shut down.

•

During operation, arctic heater continually senses supply voltage. If voltage is too low or too high, heater will automatically shut down. If this occurs, notify Field Maintenance.

1. Open arctic heater fuel valve (WP 0004). 2. Activate arctic heater as follows: a. Turn battery disconnect switch to ON position (WP 0004). b. Activate arctic heater switch (WP 0004). 3. Allow heater to run up to 40 minutes. 4. Push arctic heater switch to turn heater off, then wait at least 30 seconds. 5. Shut off arctic heater fuel valve (WP 0004).

CAUTION At temperatures of less than -25ºF (-32ºC), be sure to keep starter engaged until engine speed approaches 500 rpm. This could take up to 120 seconds. Multiple, short (15second) start attempts at cold temperatures can damage engine bearings damage due to inadequate lubrication, and the engine may fail to start. 6. Start engine (WP 0005). 7. Check that engine oil pressure gauge on monitor system registers pressure within 10 seconds of engine starting. Shut engine off immediately if oil pressure does not register. Notify Field Maintenance. 8. Allow engine to idle for at least five minutes before moving machine.

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TM 5-2410-241-10

0006

OPERATION IN EXTREME COLD – CONTINUED Machine Operation

0006

CAUTION DO NOT attempt to break tracks loose under engine power. DO NOT move machine with large frozen lumps of material in tracks. Failure to follow this caution may result in damage to equipment. 1. If tracks are frozen to ground, notify Field Maintenance. 2. Move machine approximately 100 yards (91 m) in both forward and reverse directions to exercise transmission and powertrain. 3. Test brakes and vehicle controls carefully. 4. Slowly exercise ground engaging tools to warm hydraulic oil. Cycle each control several times. 5. Operate machine under light loads until machine is sufficiently warmed up (warm air blows from heater vents). 6. Frequently monitor alert indicators and gauges. Take appropriate action if a problem is noted, and if necessary, notify Field Maintenance. Parking Machine

0006

1. Clean snow, ice, and mud from machine as soon as possible after shutdown. 2. When possible, park in sheltered area, or if shelter is not available, park machine so radiator is not facing the wind. 3. If shelter is not available, park machine on dry, high ground, and place planks or dunnage under tracks and ground engaging tools to make a raised and relatively dry platform. 4. Perform all After PMCS procedures (WP 0012). 5. If machine is to be parked for long periods of time, prepare machine for long-term storage (WP 0001). END OF TASK OPERATION IN EXTREME HEAT

0006

General

0006

Extreme heat causes problems that you as an operator must be aware of, such as: 1. Fuel expands. Do not fill tanks more than 80 percent full to allow for expansion. 2. Be alert for the possibility of overheating. 3. It is important to maintain engine speed to circulate engine coolant to help engine cooling. 4. Air filter elements will require checking more frequently. They will require cleaning or replacement if air filter restriction indicator illuminates on the monitor system. Checks

0006

1. Perform all Before PMCS procedures (WP 0012). 2. Lubricate in accordance with LO 5-2410-241-13.

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TM 5-2410-241-10

0006

OPERATION IN EXTREME HEAT – CONTINUED Machine Operation

0006

1. During very hot weather operation, avoiding continuous high engine RPM will help prevent machine from overheating. Alter operating procedures accordingly. 2. Check coolant level in coolant tank at frequent intervals throughout any single work shift (WP 0012). 3. Keep radiator and grille free of bugs, dust, dirt, mud, and other foreign matter. Clean frequently if necessary. 4. Monitor engine coolant temperature gauge. Red range on gauge indicates coolant temperature is above 225°F (107°C). If coolant temperature indicator comes on, you may operate at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, notify Field Maintenance. 5. Monitor hydraulic oil temperature gauge. Red range on gauge indicates coolant temperature is above 215°F (102°C). If hydraulic oil temperature indicator comes on, you may operate at three-fourths workload until indicator goes off. If indicator remains on longer than ten minutes, notify Field Maintenance. 6. Monitor torque converter oil temperature gauge. Red range on gauge indicates torque converter oil temperature is above 265°F (129°C). If torque converter oil temperature indicator comes on, you may operate at threefourths workload until indicator goes off. If indicator remains on longer than ten minutes, notify Field Maintenance. 7. Refer to FM 90-3 for additional extreme heat operation information. Parking Machine

0006

1. When possible, park machine under cover (WP 0005). 2. Perform all After PMCS procedures (WP 0012). 3. If machine is to be parked for long periods of time, prepare machine for long-term storage (WP 0001). END OF TASK OPERATION IN MUD OR ON SOFT SURFACES

0006

1. Before entering mud or other soft surfaces, check conditions and ensure that area may be entered safely. Select appropriate engine and ground speeds for conditions. 2. Maintain steady ground speed to keep machine rolling until solid ground is reached. Do not accelerate to point where tracks spin, if possible. 3. If machine gets stuck, try to pull out slowly. Refer to Recovery and Towing in this work package. 4. Notify Field Maintenance to clean and inspect for proper lubrication. END OF TASK OPERATION IN SANDY OR DUSTY AREAS

0006

Checks

0006

1. Perform all Before PMCS procedures (WP 0012). 2. Lubricate in accordance with LO 5-2410-241-13. 3. Check radiator often for build-up of sand, dirt, and debris. Clean as required. Machine Operation

0006

1. Maintain steady speeds with transmission in lower gears.

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0006

OPERATION IN SANDY OR DUSTY AREAS – CONTINUED 2. Keep machine rolling through sand without straining engine or powertrain. If machine gets stuck, refer to Recovery and Towing in this work package. 3. Monitor engine coolant, hydraulic oil temperature, and torque converter oil gauges on monitor system more frequently during operation (WP 0004). 4. If air filter restriction indicator illuminates on the monitor system, check and clean or replace engine air filter elements (WP 0014). 5. Check hydraulic cylinders frequently. Do not allow dust, dirt, or sand to collect on these items, as the smooth, polished working surfaces can be damaged from the abrasive nature of the elements (WP 0012). Parking

0006

1. Park machine (WP 0005). 2. Perform all After PMCS procedures (WP 0012). 3. Clean spouts on fuel containers and areas around filler cap and filler tube before adding fuel. 4. Cover windshield and other cab windows to guard against sand blasting. 5. If machine is to be parked for long periods of time, prepare machine for long-term storage (WP 0001). END OF TASK OPERATION IN SALTWATER AREAS

0006

CAUTION To ensure salt residue has been removed, all rock guards and belly pans must be removed and surrounding areas thoroughly flushed with fresh water. Notify Field Maintenance. 1. Keep the machine as clean as possible. Wash down with fresh water after use. 2. Inspect wiring connections closely for corrosion. 3. Keep lubrication points clean and well lubricated IAW LO 5-2410-241-13. END OF TASK OPERATION AT HIGH ALTITUDES

0006

NOTE Engine operates at less than peak performance at high altitudes. 1. Coolant level and engine indicators must be watched closely (WP 0012). 2. Add coolant if necessary (WP 0012). END OF TASK OPERATION IN SNOW AND ON ICE

0006

1. Fuel tank should be kept full. Keep snow and ice away from fuel filler (WP 0012). 2. Clean snow away from outside indicators.

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OPERATION IN SNOW AND ON ICE – CONTINUED Driving

0006

1. Accelerate slowly to avoid spinning tracks. 2. Drive at slower speeds. 3. Give signals sooner. 4. Slow down sooner to give early warning of intention to stop. This will also help to avoid skidding. 5. Keep windshields and lights clean and free of snow and ice. 6. Select engine and ground speeds that best suit conditions (WP 0004). Stopping

0006

1. Depress service brake control pedal to slow machine (WP 0004). 2. DO NOT pump service brake control pedal. 3. Once machine has stopped, rotate transmission directional control to NEUTRAL position (WP 0004). 4. Engage parking brake (WP 0004). Parking

0006

If parking on icy, slushy, wet, or muddy surfaces, place boards, dunnage, or other materials below tracks to help guard against tracks freezing to the ground or becoming pocketed in ice. END OF TASK FORDING

0006

The D7R Dozer can ford water up to 30 in. (76 cm), including height of wake.

CAUTION Do not ford even the narrowest stream if it is more than 30 in. (76 cm) deep. Failure to follow this caution may result in damage to machine. 1. Check depth of water at its deepest point. 2. Ensure the bottom is stable enough for fording. 3. Start engine and allow it to fully warm up (WP 0005). 4. Ensure all alert indicators and Action Light Indicator are not illuminated, and all gauges are indicating proper machine operation (WP 0004). 5. Raise ripper and blade to their maximum height (WP 0004).

NOTE Fording speed should not exceed 3–4 mph (5–6 km/h). Once in the water, do not stop until the opposite bank is reached. 6. Engage transmission in low gear (WP 0004). 7. Release parking brake (WP 0004). 8. Enter water slowly to minimize waves and backsplash, and continue across body of water WITHOUT STOPPING until the opposite bank is reached. 9. If machine stalls, refer to Recovery and Towing in this work package. 10. Once machine is out of water, lubricate machine completely IAW LO 5-2410-241-13. END OF TASK

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RECOVERY AND TOWING (OPERATIONAL MACHINE)

WARNING •

Ensure recovery line is strong enough (has a rated capacity of 150% of gross weight of the towed machine) and is in good condition.

•

Attach recovery line only to towing connection points provided on frame.

•

DO NOT have tension on the recovery line when inspecting it.

•

DO NOT jerk on recovery line; it may break.

CAUTION •

Recovery of a disabled machine with engine stopped may cause transmission damage. Transmission will not have lubrication.

•

If further evacuation is necessary, notify Field Maintenance to tow or haul machine to convenient location for repairs.

NOTE Towing a non-operational machine must be performed by Field Maintenance.

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TM 5-2410-241-10

0006

RECOVERY AND TOWING (OPERATIONAL MACHINE) – CONTINUED 1. Attach tow cable to towing eye (Figure 2, Item 1) on front of machine if towing from front. 2. Attach tow cable to towing eyes (Figure 3, Item 1) on rear of machine if towing from rear.

Figure 2. Front Towing Eye.

Figure 3. Rear Towing Eyes. END OF TASK

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TM 5-2410-241-10

OPERATION USING NIGHT VISION DEVICES

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WARNING Do not turn on dome lamp while wearing night vision devices. Failure to follow this warning may cause momentary blindness, resulting in possible loss of machine control, injury, or death to personnel. After machine is started, adjust Messenger display backlight setting to lowest possible setting (WP 0005), eliminating most ambient light within the machine cab to allow for use of night vision devices. END OF TASK OPERATING PORTABLE FIRE EXTINGUISHER

0006

1. Remove fire extinguisher from bracket (WP 0002). 2. Hold fire extinguisher upright. Stand back 8 ft (2.4 m) from base of fire, point nozzle toward fire, and pull safety pin. 3. Squeeze lever, discharging chemical at base of fire. Use a side-to-side motion to spread chemical. 4. After using fire extinguisher, order new fire extinguisher. END OF TASK STOPPING ENGINE IF AN ELECTRICAL MALFUNCTION OCCURS

0006

1. Ensure parking brake is engaged (WP 0004). 2. Turn engine start switch to OFF position (WP 0004). 3. Turn battery disconnect switch (Figure 4, Item 1) to OFF position. 4. Notify Field Maintenance.

Figure 4. Battery Disconnect Switch. END OF TASK

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TM 5-2410-241-10

0006

EQUIPMENT LOWERING WITH ENGINE STOPPED If engine is inoperable and bulldozer blade or ripper has not been lowered to ground, use the following method to lower equipment to ground.

WARNING Be sure all personnel are clear of equipment while equipment is being lowered. Failure to follow this warning may result is injury or death to personnel.

CAUTION Lower equipment to ground slowly or damage to equipment may occur.

NOTE For a short period of time after engine is shut down, accumulator pressure is available to provide power necessary to lower bulldozer blade and/or ripper. If accumulator pressure has bled down, Field Maintenance must be notified. 1. Turn battery disconnect switch ON (WP 0004). 2. Push bottom of implement lockout switch (WP 0004). 3. Turn engine start switch to ON position (WP 0004). 4. To lower bulldozer blade, push right joystick forward (WP 0004). 5. To lower ripper, push ripper control lever to right (WP 0004). 6. Push top of implement lockout switch after implement has been lowered. 7. Turn engine start switch to OFF position. 8. Turn battery disconnect switch OFF (WP 0004). 9. Notify Field Maintenance. END OF TASK END OF WORK PACKAGE

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14 TM 5-2410-241-10

0007

OPERATOR MAINTENANCE

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STOWAGE AND DECAL/DATA PLATE GUIDE Stowage, Warning and Message Labels, Stencils, and Data Plates 0 0 0 7

SCOPE

0007

This work package identifies BII stowage, warning and message labels, stencils, and data plates. STOWAGE

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Basic Issue Items (BII)

0007

Stow all basic issue items (BII) tools in tool bag, and stow tool bag in compartment in right fender. Refer to WP 0021 for complete list of BII.

Figure 1. BII Tool Bag.

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WARNING AND MESSAGE LABELS

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

Figure 2. Warning and Message Labels.

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WARNING AND MESSAGE LABELS – CONTINUED . KEY

LABEL IDENTIFICATION

DEFINITION

1

Air Filter Identification

To avoid engine damage, use only Caterpillar radial seal air filters as replacement filters. Refer to WP 0014 for air filter removal and installation procedures.

2

CBRN Exposure

WARNING. If CBRN exposure is suspected, all air filter media will be handled by personnel wearing full CBRN protective equipment. Failure to comply could result in serious injury or death.

3

Do Not Weld on the ROPS/FOPS Structure

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

4

Pivot Shaft Oil

Identifies pivot shaft oil fill location.

5

Improper Connections For Jump

Explosion Hazard! Improper jumper cable connections can cause an explosion resulting in serious injury or death. Batteries may be located in separate compartments. Refer to WP 0006 for the correct slave starting procedure.

Start Cables

6

Hearing Protection Required

WARNING: High-intensity noise. Ear protection required when operating this vehicle or within 26 feet of this vehicle when operating.

7

High Voltage

WARNING: Shock Hazard. Could cause serious injury or death.

8

No Step

WARNING: Fall hazard, do not step. Could cause serious injury, or death.

9

Explosive Hazard

WARNING: Vapor Explosion. Could cause serious injury or death.

10

Hot Coolant Under Pressure

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

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TM 5-2410-241-10

0007

WARNING AND MESSAGE LABELS – CONTINUED

Figure 3. Warning and Message Labels – Continued.

0007-4

0007

TM 5-2410-241-10

WARNING AND MESSAGE LABELS – CONTINUED

KEY 1

LABEL IDENTIFICATION

DEFINITION

Hydraulic Oil

Identifies hydraulic oil fill location.

0007-5

0007

TM 5-2410-241-10

0007

WARNING AND MESSAGE LABELS – CONTINUED

Figure 4. Warning and Message Labels – Continued.

0007-6

0007

TM 5-2410-241-10

0007

WARNING AND MESSAGE LABELS – CONTINUED . KEY

LABEL IDENTIFICATION

WARNING DEFINITION

1

Air Conditioning System (Caution Label)

Field Maintenance to refer to TM 5-2410-241-23 before any maintenance is performed on air conditioning system.

2

High Pressure Hydraulics

WARNING: High pressure cylinder. Read and understand the service manual before doing service or maintenance on equipment. Could cause serious injury or death.

3

Blade Control

Depicts blade actions based on joystick position.

4

Seat Belt

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

5

Ripper Control (Type II)

Depicts ripper actions based on joystick position.

6

Winch Control (Type I)

Depicts winch actions based on joystick position and identifies low lock function.

7

Steering

If the engine is running, machine will turn when the steering lever is moved with the transmission in neutral or in gear. Engage the steering control lock by applying the parking brake.

8

General Safety Warning

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the operation and maintenance manuals. Failure to follow the instructions or heed the warnings could result in injury or death.

9

Spare 175A Fuse

Spare 175-amp alternator fuse stored behind cover.

10

Service Information

Provides machine information relative to service.

0007-7

TM 5-2410-241-10

0007

STENCILS

0007

Figure 5. Stencils.

KEY

0007

STENCIL IDENTIFICATION

DEFINITION

1

Cab Lift/Tie

Indicates where to attach lift sling and tiedowns for cab.

2

ROPS Lift/Tie

Indicates where to attach lift sling and tiedowns for ROPS.

3

Lift Here

Indicates where to attach lift sling on machine.

4

Blade Lift/Tie

Indicates where to attach lift sling and tiedowns for blade.

5

Tie Here

Indicates where to attach tiedowns at front of machine.

6

Push Arm Lift/Tie

Indicates where to attach lift sling and tiedowns for push arms.

7

Tiedown (Type I with Winch)

Indicates where to attach tiedowns at rear of machine.

8

Tie Here (Type II with Ripper)

Indicates where to attach tiedowns at rear of machine.

9

Military Load Classification

Identifies the minimum class of route, bridge, or raft that the machine is authorized to use.

0007-8

TM 5-2410-241-10

0007

STENCILS – CONTINUED

Figure 6. Stencils - Continued.

KEY

0007

STENCIL IDENTIFICATION

DEFINITION

1

Lift Here

Indicates where to attach lift sling on machine.

2

Slave 24V dc

Indicates location of slave start receptacle, system voltage, and type.

3

Diesel or JP-8 Fuel Only

Indicates location of fuel fill and types of fuels allowed for use.

4

Tie Here

Indicates where to attach lift tiedowns for machine.

5

Push Arm Lift/Tie

Indicates where to attach lift sling and tiedowns for push arms.

6

Blade Lift/Tie

Indicates where to attach lift sling and tiedowns for blade.

0007-9

TM 5-2410-241-10

DATA PLATES

0007

0007

Figure 7. Data Plates.

0007-10

0007

TM 5-2410-241-10

0007

DATA PLATES – CONTINUED

KEY

DATA PLATES

DEFINITION

1

Lubrication Plate

Indicates machine lubrication schedule.

2

Warranty Plate

Provides machine warranty date information.

3

Bulldozer Blade Serial Number Plate

Provides blade identification information.

4

Transmission Serial Number Plate

Provides transmission identification information.

5

Ripper Serial Number Plate

Provides ripper identification information.

6

Do Not Weld on the ROPS/FOPS Structure

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

0007-11

TM 5-2410-241-10

0007

DATA PLATES – CONTINUED

Figure 8. Data Plates - Continued.

KEY

DATA PLATES

DEFINITION

1

Shipping Data Plate

Graphic demonstrating D7R Dozer, Type I with Winch, shipping information.

2

Shipping Data Plate

Graphic demonstrating D7R Dozer, Type II with Ripper, shipping information.

0007-12

0007

TM 5-2410-241-10

0007

DATA PLATES – CONTINUED

Figure 9. Data Plates - Continued. KEY 1

LABEL IDENTIFICATION

DEFINITION

Winch Data Plate

Provides winch identification information.

Figure 10. Unique Identification Labels.

0007-13

0007

0007

TM 5-2410-241-10

0007

DATA PLATES – CONTINUED

Figure 11. Unique Identification Labels.

Figure 12. Unique Identification Labels. END OF WORK PACKAGE

0007-14

0007

0007

2 TM 5-2410-241-10

CHAPTER 3 TROUBLESHOOTING PROCEDURES

2 TM 5-2410-241-10

0008

OPERATOR MAINTENANCE 0 0 0 8

-

TROUBLESHOOTING INTRODUCTION

GENERAL

0008

1. This chapter provides information for identifying and correcting malfunctions that you may find while operating the D7R Dozer. 2. The Troubleshooting Symptom Index (WP 0009) lists common malfunctions which may occur and refers you to the proper page in WP 0010 for a troubleshooting procedure. 3. If you are unaware of the location of an item mentioned in troubleshooting, refer to Equipment Description and Data (WP 0002) or Description and Use of Operator’s Controls and Indicators (WP 0004). 4. Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of this manual. 5. This chapter cannot list all malfunctions that may occur, nor all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify Field Maintenance. 6. When troubleshooting a malfunction: a. Locate the symptom or symptoms in Troubleshooting Symptom Index (WP 0009) that best describes the malfunction. If the appropriate symptom is not listed, notify Field Maintenance. b. Turn to the page in Troubleshooting Procedures (WP 0010) where the troubleshooting procedures for the malfunction in question are described. Headings at the top of each page show how each troubleshooting procedure is organized: Malfunction, Test or Inspection (in step number order), and Corrective Action. c.

Perform each step in the order listed until the malfunction is corrected and the item being inspected is operational. DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so.

EXPLANATION OF HEADINGS

0008

The headings in WP 0010 are defined as follows: a. MALFUNCTION. A visual or operational indication that something is wrong with the equipment. b. TEST OR INSPECTION. A procedure to isolate the problem in a system or component. c.

CORRECTIVE ACTION. A procedure to correct the problem.

0008-1

TM 5-2410-241-10

0008

MACHINE WARNING SUMMARIES

WARNING Warning Level 1 Machine system needs attention.

Warning Level 2 A change in machine operation is required.

Warning Level 3 Immediate need to shut down machine.

0008

ALERT INDICATORS The following indicators may flash: •

Charging System

•

Fuel Level

•

Air Filter Restriction

•

Implement System

•

Engine System

•

Transmission System

•

Brake System

1. Action lamp will flash. 2. The following indicators may flash: •

Inlet Manifold Temperature

•

Powertrain Oil Filter Bypass

•

Engine System

•

Transmission System

•

Brake System

•

Engine Overspeed

1. Action lamp will flash. 2. Action alarm will sound. 3. The following indicators may flash:

ACTION REQUIRED 1. Immediate action not required. 2. Check applicable system at earliest opportunity.

1. Change in machine operation or performance of maintenance immediately required or damage to machine may result. 2. If SERV CODE appears in lower digital display window, notify Field Maintenance.

WARNING Failure to follow this warning may result in injury or death to personnel or damage to equipment.

•

Engine Oil Pressure

1. Shut down machine immediately.

•

Charging System

•

Engine System

•

Transmission System

2. If SERV CODE appears in lower digital display window, notify Field Maintenance.

•

Brake System

•

Engine Overspeed

END OF WORK PACKAGE

0008-2

CAUTION Engine overspeed does not require immediate shutdown. Engine speed must be reduced immediately or damage to machine may result. Action alarm will sound until engine speed is reduced.

2 TM 5-2410-241-10

0009

OPERATOR MAINTENANCE 0

0 0 9

-

TROUBLESHOOTING SYMPTOM INDEX Troubleshooting Procedure Page

Malfunction/Symptom ELECTRICAL SYSTEM

0009

Bulldozer Blade Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-1 Dome Lamp Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-1 Heater/Air Conditioning Fan Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-1 Heater and Air Conditioning Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-1 Horn Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-1 Monitor Display Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-2 Monitor System Panel Lights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-2 One or More Lights Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-2 Ripper Inoperative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-2 Winch Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-2 Window Washers Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-3 Windshield Wiper, Side Wipers, or Rear Window Wipers Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-3 ENGINE SYSTEM Coolant Temperature Too High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-4 Engine Cannot Reach Top Engine RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-5 Engine Cranks But Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-5 Engine Does Not Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-6 Engine Does Not Idle Properly, Misfires, or Runs Rough After Warmup Period. . . . . . . . . . . . . . . . . . . . . . . . 0010-6 Engine Starts But Dies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-6 Excessive Exhaust Smoke at Normal Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-7 Excessive Oil Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-7 Intermittent Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-7 Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-7 HYDRAULIC SYSTEM Travel Time for Blade Lift, Angle, or Tilt Cylinders is Slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-8 Travel Time for Ripper is Slow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-8 Winch Operates Inconsistently or Winch Brake Does Not Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010-8

0009-1/(2 blank)

8 TM 5-2410-241-10 OPERATOR MAINTENANCE TROUBLESHOOTING PROCEDURES Electrical System, Engine, Hydraulic System 0 0 1 0

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ELECTRICAL SYSTEM 1. BULLDOZER BLADE INOPERATIVE. Step 1.

Step 2.

Ensure hydraulic lockout switch is in unlocked (active) position (WP 0004). a.

Press bottom of hydraulic lockout switch.

b.

If problem persists, go to step 2.

Check hydraulic fluid level. a.

Add fluid (WP 0012).

b.

If problem persists, notify Field Maintenance.

2. DOME LAMP INOPERATIVE. Step 1.

Step 2.

3.

Check for burned out or defective bulb. a.

Replace bulb (WP 0013).

b.

If problem persists, go to step 2.

Check for blown fuse (fuse 16) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

HEATER/AIR CONDITIONING FAN INOPERATIVE. Check for blown fuse (fuse 14) or open circuit breaker at fuse panel. a.

Replace fuse or reset circuit breaker (WP 0018).

b.

If problem persists, notify Field Maintenance.

4. HEATER AND AIR CONDITIONING INOPERATIVE. Check for blown fuse (fuse 14) or open circuit breaker at fuse panel. a.

Replace fuse or reset circuit breaker (WP 0018).

b.

If problem persists, notify Field Maintenance.

5. HORN INOPERATIVE. Check for blown fuse (fuse 13) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

0010-1

0010

-

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ELECTRICAL SYSTEM – CONTINUED 6. MONITOR DISPLAY INOPERATIVE. Check for blown fuse (fuse 3) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

7. MONITOR SYSTEM PANEL LIGHTS INOPERATIVE. Check for blown fuse (fuse 3) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

8. ONE OR MORE LIGHTS INOPERATIVE. Step 1.

Step 2.

Check for burned out or defective bulb(s). a.

Replace bulb(s) (WP 0016).

b.

If problem persists, go to step 2.

Check for blown fuse(s) (fuses 8, 9, or 16) at fuse panel. a.

Replace fuse(s) (WP 0018).

b.

If problem persists, notify Field Maintenance.

9. RIPPER INOPERATIVE. Step 1.

Step 2.

Ensure hydraulic lockout switch is in unlocked (active) position (WP 0004). a.

Press bottom of hydraulic lockout switch.

b.

If problem persists, go to step 2.

Check hydraulic fluid level. a.

Add fluid (WP 0012).

b.

If problem persists, notify Field Maintenance.

10. WINCH INOPERATIVE. Step 1.

Step 2.

Ensure hydraulic lockout switch is in unlocked (active) position (WP 0004). a.

Press bottom of hydraulic lockout switch.

b.

If problem persists, go to step 2.

Check hydraulic fluid level. a.

Add fluid (WP 0012).

b.

If problem persists, notify Field Maintenance.

0010-2

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ELECTRICAL SYSTEM – CONTINUED 11. WINDOW WASHERS INOPERATIVE. Step 1.

Step 2.

Ensure window washer fluid tank is not empty. a.

Add Cleaning compound, windshield (WP 0012).

b.

If problem persists, go to step 2.

Check for blown fuse (fuse 1) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

12. WINDSHIELD WIPER, SIDE WIPERS, OR REAR WINDOW WIPERS INOPERATIVE. Check for blown fuse (fuse 1) at fuse panel. a.

Replace fuse (WP 0018).

b.

If problem persists, notify Field Maintenance.

0010-3

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ENGINE SYSTEM

WARNING

•

Do not perform fuel system checks, inspections or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

•

Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.

CAUTION Do not crank engine for longer than 30 seconds. Allow starter motor to cool for two minutes before cranking again or damage to equipment may result. 1.

COOLANT TEMPERATURE TOO HIGH.

WARNING

•

DO NOT service the cooling system unless engine has been allowed to cool down. This is a pressurized system and escaping steam or hot coolant will cause serious burns.

•

DO NOT remove cooling system pressure cap when engine is hot. Allow engine to cool down. Remove pressure cap slowly to relieve system pressure.

•

Wear protective eye, hand, and skin protection when handling coolant.

•

Failure to follow these warnings may result in injury or death to personnel. Check coolant level on coolant tank (WP 0012). a.

Fill coolant tank to specifications (WP 0012).

b.

If problem persists, notify Field Maintenance.

0010-4

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ENGINE SYSTEM – CONTINUED 2. ENGINE CANNOT REACH TOP ENGINE RPM. Step 1.

Step 2.

Step 3.

Check for diagnostic service codes. a.

If diagnostic service codes are present, notify Field Maintenance.

b.

If no diagnostic service codes are present, go to step 2.

Check fuel supply. a.

Add fuel as necessary (WP 0012).

b.

Verify fuel is not solidified (ambient temperatures below 32°F [0°C]).

c.

If problem persists, go to step 3.

Check air filters. a.

Clean or replace air filters (WP 0014).

b.

If problem persists, notify Field Maintenance.

3. ENGINE CRANKS BUT WILL NOT START. Step 1.

Step 2.

Step 3.

Step 4.

Check for diagnostic service codes. a.

If diagnostic service codes are present, notify Field Maintenance.

b.

If there are no diagnostic codes, go to step 2.

Verify fuel level. a.

Add fuel as necessary (WP 0012).

b.

If problem persists, go to step 3.

Check air filters. a.

Clean or replace air filters (WP 0014).

b.

If problem persists, go to step 4.

Check circuit breakers. a.

Reset circuit breakers (WP 0018).

b.

If problem persists, notify Field Maintenance.

0010-5

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ENGINE SYSTEM – CONTINUED 4. ENGINE DOES NOT CRANK. Step 1.

Step 2.

Step 3.

Verify parking brake is engaged and transmission control switch is in NEUTRAL position. a.

Engage parking brake and twist left joystick to NEUTRAL position (WP 0004).

b.

If problem persists, go to step 2.

Verify battery disconnect switch is turned to ON position. a.

Turn battery disconnect switch to ON position (WP 0004).

b.

If problem persists, go to step 3.

Check key switch fuse(s) (fuses 14 and 19) at fuse panel. a.

Replace fuse(s) if blown (WP 0018).

b.

If problem persists, or if fuse continues to blow, notify Field Maintenance.

5. ENGINE DOES NOT IDLE PROPERLY, MISFIRES, OR RUNS ROUGH AFTER WARMUP PERIOD. Step 1.

Step 2.

Step 3.

Check for diagnostic service codes. a.

If diagnostic service codes are present, notify Field Maintenance.

b.

If there are no diagnostic service codes, go to step 2.

Check air filters. a.

Clean or replace air filters (WP 0014).

b.

If problem persists, go to step 3.

Check for water in fuel. a.

Drain primary fuel filter/water separator (WP 0012).

b.

If problem persists, notify Field Maintenance.

6. ENGINE STARTS BUT DIES. Step 1.

Step 2.

Step 3.

Check for diagnostic service codes. a.

If diagnostic service codes are present, notify Field Maintenance.

b.

If there are no diagnostic service codes, go to step 2.

Check for water in fuel. a.

Drain primary fuel filter/water separator (WP 0012).

b.

If problem persists, go to step 3.

Prime fuel system. a.

Prime fuel system (WP 0017).

b.

Attempt to start engine.

c.

If problem persists, notify Field Maintenance.

0010-6

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

ENGINE SYSTEM – CONTINUED 7. EXCESSIVE EXHAUST SMOKE AT NORMAL OPERATING TEMPERATURE. a.

Check air filters.

b.

Clean or replace air filters (WP 0014).

c.

If problem persists, notify Field Maintenance.

8. EXCESSIVE OIL CONSUMPTION. Step 1.

Step 2.

Step 3.

Check for misreading of oil level. a.

Accurately measure oil level.

b.

If problem persists, go to step 2.

Check air filters. a.

Clean or replace air filters (WP 0014).

b.

If problem persists, go to step 3.

Check for loose or leaking oil lines and oil leaks. a.

Tighten loose connections.

b.

If problem persists or leaks are found, notify Field Maintenance.

9. INTERMITTENT ENGINE SHUTDOWN. Step 1.

Step 2.

Check for diagnostic service codes. a.

If diagnostic service codes are present, notify Field Maintenance.

b.

If there are no diagnostic service codes, go to step 2.

Check air filters. a.

Clean or replace air filters (WP 0014).

b.

If problem persists, notify Field Maintenance.

10. LOW ENGINE OIL PRESSURE. Check engine oil level. a.

Fill oil to specification (WP 0012).

b.

If problem persists, notify Field Maintenance.

0010-7

0010

TM 5-2410-241-10

MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 0.

HYDRAULIC SYSTEM

WARNING

Wear safety goggles when performing any hydraulic maintenance procedures. Failure to follow this warning may result in injury or death to personnel. 1.

TRAVEL TIME FOR BLADE LIFT, ANGLE, OR TILT CYLINDERS IS SLOW. Step 1.

Step 2.

Check blade hydraulic cylinders for buildup of debris. a.

Clean debris.

b.

If problem persists, go to step 2.

Check hydraulic fluid level. a.

Add hydraulic fluid as necessary (WP 0012).

b.

If problem persists, notify Field Maintenance.

2. TRAVEL TIME FOR RIPPER IS SLOW. Step 1.

Step 2.

Check ripper area for buildup of debris. a.

Clean debris.

b.

If problem persists, go to step 2.

Check hydraulic fluid level. a.

Add hydraulic fluid as necessary (WP 0012).

b.

If problem persists, notify Field Maintenance.

3. WINCH OPERATES INCONSISTENTLY OR WINCH BRAKE DOES NOT RELEASE. Check hydraulic fluid level. a.

Fill winch to specification (WP 0012).

b.

If problem persists, notify Field Maintenance.

END OF WORK PACKAGE

0010-8

0010

2 TM 5-2410-241-10

CHAPTER 4 PMCS MAINTENANCE INSTRUCTIONS

4 TM 5-2410-241-10

0011

OPERATOR MAINTENANCE 0 0 1 1

-

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL

00011

1. To ensure that the D7R Dozer is ready for operation at all times, it must be inspected on a regular basis so that defects may be found and corrected before they result in injury, damage, or equipment failure. 2. The PMCS table in WP 0012 contains systematic instructions on inspections, lubrications, services, tests, and corrections to be performed by the operator to keep the equipment in good operating condition and ready for its primary mission. EXPLANATION OF TABLE ENTRIES

00011

1. Item No. Column. Numbers in this column are for reference. When completing DA Form 2404 or DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order that you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the Procedure column: a. Before procedures must be done immediately before you operate the dozer. b. During procedures must be done while you are operating the dozer. c.

After procedures must be done immediately after you have operated the dozer.

d. Weekly or Every 50 Engine Hours procedures must be done once every week or after every 50 hours of machine operation. e. Monthly or Every 250 Engine Hours procedures must be done once every month or after every 250 hours of machine operation. f.

Every 500 Engine Hours or 3 Months procedures must be done every 500 hours of machine operation or every three months.

g. Every 1,000 Engine Hours or 6 Months procedures must be done every 1,000 hours of machine operation or every six months. h. Every 2,000 Engine Hours or 1 Year procedures must be done every 2,000 hours of machine operation or every two years. 3. Item to Check/Service Column. This column lists the item to be checked or serviced.

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

0011-1

TM 5-2410-241-10

0011

GENERAL PMCS PROCEDURES

00011

1. Intervals (on-condition or hardtime) and the related manhour times are based on normal operation. The manhour time specified is the time you need to do all the services prescribed for a particular interval. Change the hardtime interval if your lubricants are contaminated or if you are operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The hardtime interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxicity material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to follow this warning may cause injury or death to personnel. 2. The lowest level of maintenance authorized to lubricate a point is indicated by one of the following symbols as appropriate: Operator/Crew (C). 3. The time specified is the time required to perform all services at the particular interval (on-condition or hardtime).

NOTE When equipment is scheduled for PMCS other than daily services, you must also perform all earlier PMCS procedures. For example, if you are performing the 1,000-hour interval, you would also perform all steps included in the daily, 50-hour, 250-hour, and 500-hour maintenance intervals.

Table 1. Maintenance Intervals, Symbols and Manhours. Symbol

Interval Daily 50 Hours or Weekly 250 Hours or Monthly 500 Hours or Quarterly 1,000 Hours or Semiannually 2,000 Hours or Annually

D

0

W

0

M

0

Q

0

S

0

A

0

0011-2

0011

Manhour 0

0

0

0

0

0

1.1 1.5 0.5 3.0 2.0 0.5

0

0

0

0

0

0

TM 5-2410-241-10

0011

GENERAL PMCS PROCEDURES – CONTINUED 4. Always perform PMCS in the same order so it gets to be a habit. Once you have had some practice, you will spot anything wrong in a hurry. If the equipment does not perform as required, refer to the appropriate troubleshooting procedure in Chapter 3. 5. If anything looks wrong and you cannot fix it, write it on your DA Form 2404 or DA Form 5988-E. If you find something seriously wrong, IMMEDIATELY notify Field Maintenance. 6. Before performing PMCS, read all the checks required for the applicable interval and prepare all that is needed to make all the checks. You will always need a rag (WP 0022, Item 19) or two.

WARNING

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

CAUTION Be especially careful when cleaning electrical system components, including lighting. Damage or impaired operation could result if this caution is not observed. a. Keep Equipment Clean. Dirt, grease, oil, and debris may cover up a serious problem. Clean as you work and as needed. Use cleaning compound, solvent, type III (WP 0022, Item 3) on all metal surfaces. Use detergent, general purpose, liquid (WP 0022, Item 5) and water when you clean rubber, plastic, and painted surfaces. Spot paint as required to prevent corrosion. b. Hazardous Waste Disposal. Ensure all spills are cleaned up and disposed of IAW local policy and ordinances. c.

Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply light coating of oil, lubricating preservative, corrosion inhibitor (WP 0022, Item 17), and notify Field Maintenance.

d. Bolts, Nuts, and Screws. Ensure that they are not loose, missing, bent, or broken. Report loose, missing, or damaged bolts, nuts, and screws to Field Maintenance. e. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. Report bad welds to Field Maintenance. f.

Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Report loose connections and faulty wiring to Field Maintenance.

g. Hoses, Lines, and Fittings. Look for wear and damage. Check for loose clamps and fittings. Report any worn, damaged, or loose hoses, lines, and fittings to Field Maintenance. h. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your machine. The following are definitions of the types, or classes, of leaks you need to know to determine the status of your machine. Learn and be familiar with them, and remember, when in doubt, notify Field Maintenance.

0011-3

TM 5-2410-241-10

0011

GENERAL PMCS PROCEDURES – CONTINUED

CAUTION EXCEPT FOR ANY TYPE OF FUEL OR COOLANT LEAK, operation is allowable with Class I and Class II leakage. WHEN IN DOUBT, NOTIFY FIELD MAINTENANCE. When operating with Class I or Class II leaks, check fluid levels more frequently. Any type of fuel or coolant leak, or any Class III leaks, must be reported immediately to Field Maintenance. Failure to do this will result in damage to machine and/or components.

NOTE •

Notify Field Maintenance of any leaks you cannot fix.

•

Use a drain pan to collect draining or leaking fluid. Dispose of all fluids IAW Unit SOP.

•

Contain and clean up any spilled or leaked fluids IAW Unit SOP. Leakage Definitions for PMCS Class I

Leakage indicated by wetness or discoloration, but not great enough to form drops.

Class II

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

Class III

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

LUBRICATION PROCEDURES

00011

NOTE •

Refer to Lubrication Order 5-2410-241-13 for tables, localized views, and procedural notes.

•

While reading this manual, keep in mind that right and left designations are as if you were sitting in the operator’s seat.

1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under extreme conditions, lubricants should always be changed more frequently. When in doubt, notify Field Maintenance. 2. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat or cold. Keep container covers clean and DO NOT allow dust, dirt, or other foreign material to mix with lubricants. Keep all lubrication equipment clean and ready for use. All stored lubricants must be properly labeled and IAW hazmat requirements. 3. Maintain a good record of all lubrication performed and report any problems noted during lubrication. Refer to PAM 750-8 for maintenance forms and procedures to record and report any findings. 4. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fittings with a clean rag (WP 0022, Item 19). After lubrication, wipe off excess oil or grease to prevent accumulation of foreign matter. 5. Refer to FM 9-207 for lubrication instructions in cold weather. 6. Refer to AR 70-12 for use of standardized lubricants. END OF WORK PACKAGE

0011-4

48 TM 5-2410-241-10

0012

OPERATOR MAINTENANCE 0

0 1 2

-

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP Tools and Special Tools Basic Issue Items (WP 0022)

0

0

Materials/Parts Antifreeze (coolant) (WP 0022, Item 1) Cleaning compound, solvent, type III (WP 0022, Item 3) Cleaning compound, windshield (WP 0022, Item 4) Detergent, general purpose, liquid (WP 0022, Item 5) Diesel fuel: DL-1 grade, winter (WP 0022, Item 6) Diesel fuel: DF-2 grade, regular (WP 0022, Item 7) Fuel, turbine: aviation (WP 0022, Item 8) Grease: automotive and artillery (GAA) (WP 0022, Item 9) Oil, lubricating preservative, corrosion inhibitor (WP 0022, Item 17) Oil, lubricating, OE/HDO 10 (WP 0022, Item 12) Oil, lubricating, OEA-30 Arctic (WP 0022, Item 11)

0

0

0

0

0

0

0

0

0

0

0

0

0012-1

Materials/Parts - Continued Oil, lubricating, OE/HDO 30 (WP 0022, Item 13) Oil, lubricating, CHDO-40 (WP 0022, Item 14) Oil, lubricating, CHDO-5W/40 (WP 0022, Item 15) Oil, lubricating, OE/HDO-15/40 (WP 0022, Item 16) Rag, wiping (WP 0022, Item 18) References LO 5-2410-241-13 TB 43-0142 WP 0005 WP 0013 WP 0014 WP 0015 WP 0020 WP 0021 Equipment Conditions Machine parked on level ground (WP 0004) Implements lowered to ground (WP 0004) Parking brake engaged (WP 0004)

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS).

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

NOTE • Review all WARNINGs, CAUTIONs, and NOTEs before performing PMCS and operating the machine. • Perform all PMCS if: 1. You are the assigned operator but have not operated the machine since the last weekly checks. 2. You are operating the machine for the first time. • Unless otherwise indicated, perform PMCS with machine parked on level ground, parking brake applied, blade lowered to the ground, tracks blocked, and engine shut down. • If leakage is detected during performance of PMCS, further investigation is required to determine location and cause of leak. • Walk around machine and look for any obvious leaks or damage. FRONT AND LEFT SIDE 1

Before

Lights

Check front flood lights for missing Missing, damaged, or inopor damaged components. erative components if required for mission.

2

Before

Dozer Blade, Cutting Edges, End Bits, Blade Mounting

a. Check dozer blade, cutting edges, and end bits for damage or excessive wear. b. Check blade mounting for debris, damage, or missing components.

Damaged, missing, inoperative, or excessively worn components that would impair operation are evident.

3

Before

Left Lift Cylinder

a. Check left lift cylinder for debris, leakage, or damage. b. Check left lift cylinder mounting for damage or missing components. c. Check left lift cylinder, lines, and fittings for leakage or damage.

Class III leaks, damaged, missing, inoperative, or excessively worn components that would impair operation are evident.

0012-2

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 4

MANINTERVAL HOURS Before

ITEM TO CHECK/ SERVICE Overall View

PROCEDURE a. Check left side of machine for evidence of leakage or damage. b. Check for evidence of fluid leakage or damage at front belly guard.

NOT FULLY MISSION CAPABLE IF: Any fuel or coolant leak, or any Class III leak or damage that would impair operation is evident. One or more belly guard bolts missing.

Figure 1. Dozer Blade and Lift Cylinder. 0012

5

Before

Belly Guard Bolts

Check belly guard bolts to ensure none are loose.

0012-3

One or more belly guard bolts missing.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 6

MANINTERVAL HOURS Before

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Coolant Level

WARNING

• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let out any pressure from cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

CAUTION • Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection. Engine and/or cooling system damage may occur. • Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE • Some antifreeze is pre-mixed and requires no water. • Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. • It is allowable to mix traditional and pre-mixed antifreeze in the same cooling system.

0012-4

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

6 Before (Cont.)

ITEM TO CHECK/ SERVICE Coolant Level

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Open left front access door. Coolant level is low or cap is b. Check coolant level on coolant damaged, or any coolant leak is evident. tank sight glass. If coolant level completely fills the sight glass, coolant level is okay. If coolant level can be seen in sight glass, coolant level is low. c. Open radiator pressure cap access door and clean area around cap. d. Remove cap and add coolant (WP 0022, Item 1) to maintain level between bottom of filler tube and top of sight glass. e. Clean and inspect, then install pressure cap. f. Close cap access door.

Figure 2. Coolant Level Sight Gauge and Radiator Pressure Cap and Access Door. 0012

0012-5

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

CAUTION • Engine oil level gauge has oil level markings on both sides. One side is for checking when engine is stopped; the other side is for checking when engine is running at low idle with oil warm. • Be sure to check correct side of gauge. Over- or underfilled engine crankcase may cause engine damage. 7

Before

0.2

Engine Oil Level

a. Clean area around engine oil Oil level is low or Class III level gauge (dipstick) and fill cap. leak is evident. b. Remove oil level gauge, clean, and reinstall. Remove oil level gauge and check level of oil. Maintain oil level between the marks on oil level gauge. c. Add oil (WP 0022, Items 11, 15, or 16) as required through filler opening. Refer to LO 5-2410-24113 for proper oil based on outside temperature. d. Clean oil filler cap, then reinstall.

Figure 3. Engine Oil Level Check. 0012

0012-6

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 8

MANINTERVAL HOURS Before

ITEM TO CHECK/ SERVICE

PROCEDURE

Ether Cylinder a. Inspect ether cylinder and retaining clamp. b. Remove ether cylinder and shake to check if cylinder is empty (WP 0015). Install new cylinder if required. c. If no ether cylinder is present, ensure cap is installed on ether valve.

NOT FULLY MISSION CAPABLE IF: Missing or damaged components if required for mission.

Figure 4. Ether Cylinder. 0012

0012-7

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 9

MANINTERVAL HOURS Before

ITEM TO CHECK/ SERVICE Arctic Heater (if equipped)

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Check arctic heater (Figure 5, Any fuel leak or coolant leak Item 1) coolant lines and connec- is evident. tions (Figure 5, Item 2), fuel lines and connections (Figure 5, Item 3), air intake tube (Figure 5, Item 4), and exhaust tube and mounting (Figure 5, Item 5). b. Close left front access door.

Figure 5. Arctic Heater. 0012

10

Before

Engine Air Precleaner

a. Inspect engine air precleaner assembly for dirt, debris, and damage. b. If precleaner requires cleaning, notify Field Maintenance.

0012-8

Precleaner extremely dirty, damaged, or missing.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

10 Before (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Engine Air Precleaner

Figure 6. Engine Air Precleaner.

0012-9

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

11

Before

Washer Fluid Tank

a. Open access cover. b. Check washer fluid tank level. c. Inspect tank for damage. d. Remove washer fluid filler cap. e. Add windshield cleaning compound (WP 0022, Item 4). f. Install filler cap. g. Close access cover.

Tank is empty or damaged if necessary for mission.

12

Before

Fuel Tank Filler Check fuel tank filler cap for damCap age and ensure it is properly installed and latched.

Fuel tank filler cap is missing or damaged.

Figure 7. Washer Fluid Tank and Fuel Filler Cap. 0012

0012-10

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

REAR 13

Before

Overall View

a. Check rear of machine for Class III leaks or damaged evidence of leakage or damage. components if necessary for mission. b. Check ground below machine and inspect belly guards for evidence of fluid leaks. c. Check undercarriage for obvious signs of damage.

14

Before

Lights

Check rear worklights for missing or Missing, damaged, or inopdamaged components. erative components if required for mission.

Figure 8. Machine Rear View.

0012-11

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF: Class III leaks, damaged or inoperative components that would impair operation, or missing/worn ripper tips if required for mission.

15

Before

Ripper

a. Check ripper hydraulic cylinders for leaks. b. Check frame and tips for debris, excessive wear, damage, or missing components.

16

Before

Winch

Check winch assembly for damage, Class III leaks, damaged or fluid leaks, wear, or visible cable inoperative components if required for mission. damage. Refer to TB 43-0142.

17

Before

Tow Pin (Type I Check tow pin (Figure 9, Item 1), Damaged or missing compodozers only) two cotter pins (Figure 9, Item 2), nents if required for mission. and winch frame (Figure 9, Item 3) at tow pin brackets for damage or missing components.

Figure 9. Tow Pin. 0012

0012-12

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

RIGHT SIDE 18

Before

19

Before

Overall View

0.2

Check right side of machine for evi- Class III leak or damage that dence of leakage or damage. would impair operation is evident.

Hydraulic Tank Sight Gauge

WARNING

• At operating temperature, hydraulic tank is hot and under pressure. Do not remove hydraulic tank filler cap when engine is running. Remove the filler cap only after it is cool enough to touch with bare hands. • Remove filler cap slowly to relieve pressure. • Failure to follow these warnings may result in injury or death to personnel. a. Check hydraulic fluid level on Hydraulic fluid level is low. sight gauge. b. Clean area around hydraulic tank filler cap and slowly remove hydraulic tank filler cap. c. Add hydraulic oil (WP 0022, Item 11, 12, 13 or 16) to maintain level between full mark and add mark on sight gauge. Refer to LO 5-2410241-13 for proper oil based on outside temperature. d. Install hydraulic tank filler cap.

0012-13

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

19 Before (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Hydraulic Tank Sight Gauge

Figure 10. Hydraulic Tank Sight Gauge and Filler Cap. 0012

0012-14

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 20

MANINTERVAL HOURS Before

0.2

ITEM TO CHECK/ SERVICE Transmission System Oil Level

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

CAUTION • Transmission oil level gauge has oil level markings on both sides. One side is for checking when fluid is cold with engine stopped, the other side is for checking when fluid is hot with engine at idle. • Checking fluid when hot is preferred and more accurate. Checking fluid when cold should be used for reference only. • Be sure you check correct side of gauge. Over- or underfilled transmission may cause transmission to overheat or not perform properly, or damage system components. Transmission oil level is low, a. Open right side upper access or Class III leak is evident. cover. b. Clean area around transmission oil level gauge and filler cap. c. Remove oil level gauge, wipe it clean then reinstall. d. Remove gauge and check fluid level. Maintain oil within OPR ZONE (operating zone) markings. e. Remove oil filler tube cap. f. Add oil (WP 0022, Items 11, 12, 13, or 16) through filler tube. Refer to LO 5-2410-241-13 for proper oil based on outside temperature. g. Install oil filler tube cap. h. Close access cover.

0012-15

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

20 Before (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Transmission System Oil Level

Figure 11. Transmission Oil Level Gauge, Filler Tube, and Cap. 0012

21

Before

Right Lift Cylinder

a. Check right lift cylinder for debris, leakage, or damage. b. Check right lift cylinder mounting for damage or missing components. c. Check right lift cylinder lines and fittings for leakage or damage.

0012-16

Class III leaks, or damaged, inoperative, missing or excessively worn components that would impair operation are evident.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

CAB INTERIOR

NOTE Turn battery disconnect switch to ON position prior to entering cab (WP 0004). 22

Before

Fire Extinguisher

a. Visually check for missing or Fire extinguisher is missing damaged fire extinguisher. Ensure it or damaged. is securely stowed in mounting bracket. b. Check gauge for reading in green area.

Pressure gauge needle is in red area.

c. Check for damaged or missing seal.

Seal is broken or missing.

d. Inspect fire extinguisher inspection tag.

Inspection date is not current and/or tag is missing.

23

Before

Operator Seat Check seat and seat belt mounting Seat belt is damaged. hardware, seat belt buckle, and seat belt for damage or wear (WP 0004).

24

Before

Rearview Mirror

25

Before

Indicators and a. Turn the engine start switch from Monitor fails to enter diagnostic test. Gauges OFF position to ON position to initialize Monitor system automatic self-diagnostic test.

Check and adjust rearview mirror (WP 0004).

Mirror broken or missing.

b. Monitor the following: 1. All gauge pointers must sweep left, then right.

Any gauge does not move.

2. All alert indicators must come Any alert light does not come on momentarily. on. 3. All segments in LCD display LCD display segment(s) is inoperative. must come on momentarily. 4. Action alarm must sound.

0012-17

Action alarm does not sound.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 26

MANINTERVAL HOURS Before

ITEM TO CHECK/ SERVICE Dozer Blade

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Start engine and run at low idle (WP 0005). b. Move the right joystick to most Blade float indicator does forward detent. Blade float indicator not come on. should be ON in indicators and gauges display.

27

Before

Action Lamp and Auxiliary Action Lamp

a. Monitor action lamp and auxiliary action lamp. b. If action lamp or auxiliary action Action light or auxiliary action lamp comes on and lamp comes ON and stays on, machine needs service. stays on.

28

Before

With engine running, observe the Information shows machine Digital Displays and two digital displays and the Messen- is not operating properly or Messenger Dis- ger Display. Messenger is not play functioning.

29

Before

Hydraulic Controls

Perform a functional check of hydraulic systems: blade lift/lower, blade tilt, winch, and ripper (WP 0004).

Class III oil leak is evident. Any hydraulic system or function does not operate properly.

30

Before

Lights

Check operation of all flood lights (WP 0004).

Any lights inoperative if required for mission.

31

Before

Wipers and Washers

Operate all wipers and washers to Wipers and washers not verify correct operation (WP 0004). operating if required for mission.

32

Before

Backup Alarm a. Verify that backup alarm Backup alarm does not and Horn functions when left joystick is moved function. to reverse position. b. Check operation of horn.

Horn does not function.

33

During

Service Brake Move machine forward and test ser- Brakes DO NOT slow/stop Pedal vice brakes. machine or pedal binds when pedal is depressed.

34

During

Decelerator Pedal

Check decelerator pedal for proper Machine does not slow or function and for binding and pedal binds when pedal is obstructions. depressed.

0012-18

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

35

During

Drive Train

a. Monitor machine operation for unusual noise or vibrations from engine and drive train. b. Listen for unusual squeaking or squealing, indicating dry track joints. c. Notify Field Maintenance if unusual noises are present.

36

During

Dozer Blade

a. Monitor blade operation for unusual noise or vibrations. b. Notify Field Maintenance if unusual noises or vibrations are present.

37

During

Overall Leakage

Watch for evidence of fluid leakage. Class III oil leaks are evident. Any coolant or fuel leak is evident.

38

During

Instrument Panel

a. With machine fully warmed up monitor indicators, gauges, digital displays and messenger display.

Indicators, gauges, or displays indicate an abnormal operation.

b. If action lamp or auxiliary action Action light or auxiliary lamp is ON, machine needs service. action lamp is ON. 39

During

Air Conditioner Check air conditioner and/or heater Damage exists or system or Heater for damage and verify proper does not operate if required operation. for mission. FRONT AND LEFT SIDE

40

After

Overall View

NOTE Ensure machine is clean in order to facilitate performance of PMCS procedures. a. Check under machine for Class III oil or hydraulic evidence of fluid leakages such as leaks are evident. Any cooloil, coolant, fuel, or hydraulic fluid. ant or fuel leak is evident. b. Check machine for obvious damage that would impair operation.

0012-19

Damage that would impair operation is evident.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

41

After

Belly Guard Bolts

Check belly guard bolts to ensure none are loose.

One or more belly guard bolts is missing.

42

After

Lights

Check front flood lights for missing Missing, damaged, or inopor damaged components. erative components if required for mission.

43

After

Dozer Blade, Cutting Edges, End Bits, Blade Mounting

a. Check dozer blade, cutting edge and end bits for damage or excessive wear. b. Check blade mounting for debris, damage or missing components.

Blade damaged or missing, or blade cutting edges and/ or end bits worn to within 1 inch (25 mm) of blade.

44

After

Left Lift Cylinder

a. Check left lift cylinder for debris, leakage, or damage. b. Check left lift cylinder mounting for damage or missing components. c. Check left lift cylinder lines and fittings for leakage or damage.

Class III leak, or damaged, inoperative, missing, or excessively worn components that would impair operation are evident.

Figure 12. Dozer Blade and Lift Cylinder. 0012

0012-20

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 45

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Coolant Level

WARNING

• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system, and escaping steam or hot coolant will cause serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let out any pressure from cooling system, then remove cap. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

CAUTION • Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection and engine and/or cooling system damage may occur. • Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE • Some antifreeze is pre-mixed and requires no water. • Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. • It is allowable to mix traditional and pre-mixed antifreeze in the same cooling system.

0012-21

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

45 After (Cont.)

ITEM TO CHECK/ SERVICE Coolant Level

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Open left front access door. Coolant level is low, cap is b. Check coolant level on coolant damaged, or any coolant leak is evident. tank sight glass. If coolant level completely fills the sight glass, coolant level is okay. If coolant level can be seen in sight glass, coolant level is low. c. Open radiator pressure cap access door and clean area around cap. d. Remove cap and add coolant (WP 0022, Item 1) to maintain level between bottom of filler tube and top of sight glass. e. Clean and inspect, then install pressure cap. f. Close cap access door.

Figure 13. Coolant Level Check and Radiator Pressure Cap and Access Door. 0012

0012-22

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 46

MANINTERVAL HOURS After

0.2

ITEM TO CHECK/ SERVICE Engine Oil Level

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

CAUTION • Engine oil level gauge has oil level markings on both sides. One side is for checking when engine is stopped; the other side is for checking when engine is running at low idle with oil warm. • Be sure to check correct side of gauge. Over- or underfilled engine crankcase may cause engine damage. a. Clean area around engine oil Oil level is low or cap is level gauge and fill cap. damaged. b. Remove oil level gauge, clean, and reinstall. Remove oil level gauge and check level of oil. Maintain oil level between the marks on oil level gauge. c. Add oil (WP 0022, Items 11, 15, or 16) as required through filler opening. Refer to LO 5-2410-24113 for proper oil based on outside temperature. d. Clean oil filler cap, then reinstall.

47

After

Ether Cylinder a. Inspect ether cylinder and retaining clamp. b. Remove ether cylinder and shake to check if cylinder is empty (WP 0015). Install new cylinder if required. c. If ether cylinder is not present, ensure cap is installed on ether valve.

0012-23

Missing, damaged, or inoperative components if required for mission.

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

47 After (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Ether Cylinder

Figure 14. Ether Cylinder. 0012

48

After

Engine Primary Air Filter

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precaution and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel. Inspect engine primary air filter ele- Engine primary air filter element. Refer to WP 0014. ment missing, damaged, or plugged with dirt.

0012-24

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 49

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Primary Fuel Filter/Water Separator

WARNING

• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. • Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. • Failure to follow these warnings may cause injury or death to personnel or damage to equipment. a. Inspect primary fuel filter/water Excessive amount of water separator bowl for water. or any fuel leak is evident. b. If water is present, open drain valve and drain water into a suitable container. c. Close drain valve. d. Close left front access door.

Figure 15. Primary Fuel Filter/Water Separator. 0012

0012-25

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 50

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE Engine Air Precleaner

NOT FULLY MISSION CAPABLE IF:

PROCEDURE a. Inspect engine air precleaner assembly for dirt, debris, and damage. b. If precleaner requires cleaning, notify Field Maintenance.

Precleaner extremely dirty, damaged, or missing.

Figure 16. Engine Air Precleaner. 0012

51

After

Cab Fresh Air Filter

WARNING

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

0012-26

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

PROCEDURE

51 After (Cont.)

NOT FULLY MISSION CAPABLE IF:

WARNING

Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel. Cab Fresh Air Filter

a. Loosen two knobs and remove Cab fresh air filter missing or damaged if necessary for filter cover. mission. b. Remove restrictor plate. c. Remove filter. d. Using a shop light, inspect filter. e. Clean filter using a maximum of 30 psi (205 kPa) compressed air. f. Inspect filter for tears or other damage. g. Replace filter if damaged. h. Install filter. i. Install restrictor plate. j. Install cover and tighten knobs.

Figure 17. Cab Fresh Air Filter.

0012-27

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 52

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE

PROCEDURE

Cab Recirculation Filter

NOT FULLY MISSION CAPABLE IF:

WARNING

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

CAUTION • Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean or dry filter element. Failure to follow this caution may result in damage to filter element. • Filter element must be completely dry before installation. Failure to follow this caution may result in damage to equipment. Filter damaged or missing if a. Open left cab door. necessary for mission. b. Remove two knobs and recirculation filter. c. Using a shop light, inspect filter. d. Clean filter using a maximum of 30 psi (207 kPa) compressed air. e. Inspect filter for tears or other damage. f. Replace filter if damaged. g. Install filter and two knobs. h. Close cab door.

0012-28

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

52 After (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Cab Recirculation Filter

Figure 18. Cab Recirculation Filter. 0012

0012-29

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 53

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Batteries and Battery Cables

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may cause death or serious injury to personnel. • DO NOT use compressed air to clean batteries. Use a clean, dry rag.

CAUTION To reduce battery damage, check battery compartment for corrosion (greenish/white powder) and DO NOT jerk or pull on battery cables during visual inspection. Failure to follow this caution may result in damage to equipment.

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury or death to personnel.

NOTE Arctic heater battery box cover weighs approximately 50 lb (23 kg).

0012-30

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

53 After (Cont.)

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Batteries and a. With assistance, remove arctic Battery Cables heater battery box cover, if equipped. b. Open battery compartment cover. c. Check battery holddowns for looseness or damage. d. Inspect batteries for cracked cases and evidence of leaking.

Holddown is loose or damaged. Battery cases are cracked or leaks are evident.

NOTE Original equipment batteries are maintenance-free and do not have removable caps. e. Check for missing, broken, split, Damage is noted. or frayed battery cables. f. Check for damaged battery Damage is noted. posts. g. If equipped with nonmaintenance free batteries, check electrolyte level in each cell. If level is low, fill with distilled water to bottom of filler opening. Close battery compartment cover.

0012-31

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

53 After (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Batteries and Battery Cables

Figure 19. Batteries. 0012

0012-32

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 54

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE Washer Fluid Tank

PROCEDURE a. Open access cover. b. Check washer fluid tank level. c. Remove washer fluid filler cap. d. Add windshield cleaning compound (WP 0022, Item 4). e. Install filler cap. f. Close access cover.

NOT FULLY MISSION CAPABLE IF: Tank is empty or damaged if necessary for mission.

Figure 20. Washer Fluid Tank. 0012

55

After

Overall VIew

a. Check rear of machine for evidence of leakage or damage. b. Check ground below machine and inspect belly guards for evidence of fluid leaks. c. Check undercarriage for obvious signs of damage.

0012-33

Class III oil leak, any fuel or coolant leak, or damaged components are evident if necessary for mission.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 56

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE Lights

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Check rear worklights for missing or Missing, damaged, or damaged components. inoperative components if required for mission.

Figure 21. Machine Rear View. 0012

57

After

Ripper

a. Check ripper hydraulic cylinders for leaks. b. Check frame and tips for debris, excessive wear, damage, or missing components.

0012-34

Class III leak or damage that would impair operation is evident, ripper inoperative, or ripper tips are missing or worn if required for mission.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 58

MANINTERVAL HOURS After

0.2

ITEM TO CHECK/ SERVICE Winch

PROCEDURE a. Check winch assembly for damage, fluid leaks, wear, or visible cable damage. Refer to TB 43-0142, Safety Inspection and Testing Of Lifting Devices. b. Clean area around oil level check plug and filler plug. c. Remove oil level check plug. If oil level is correct, oil should trickle from plug opening. d. Remove oil filler plug. Add oil (WP 0022, Items 11, 12, or 13) as required through filler plug opening. Refer to LO 5-2410-241-13 for proper oil based on outside temperature. e. Install oil filler plug and oil level check plug.

NOT FULLY MISSION CAPABLE IF: Class III leak or damage that would impair operation is evident, winch inoperative if required for mission. Oil level low if required for mission.

Figure 22. Winch Oil Level Check and Fill Plugs. 0012

0012-35

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 59

MANINTERVAL HOURS After

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Tow Pin (Type I Check tow pin (Figure 23, Item 1), Damaged or missing compodozers only) two cotter pins (Figure 23, Item 2), nents if required for mission. and winch frame (Figure 23, Item 3) at tow pin holes for damage or missing components.

Figure 23. Tow Pin. 0012

RIGHT SIDE 60

After

61

After

Overall View

0.2

Check right side of machine for evi- Class III oil leak, any fuel or dence of leakage or damage. coolant leak, or damage that would impair operation is evident.

Hydraulic Tank Sight Gauge

WARNING

• At operating temperature, hydraulic tank is hot and under pressure. Do not remove hydraulic tank filler cap when engine is running. Remove the filler cap only after it is cool enough to touch with bare hands. • Remove filler cap slowly to relieve pressure. • Failure to follow these warnings may result in injury or death to personnel.

0012-36

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

61 After (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Hydraulic Tank a. Check hydraulic fluid level on Hydraulic fluid level is low. Sight Gauge sight gauge. b. Clean area around hydraulic tank filler cap and slowly remove hydraulic tank filler cap. c. Add hydraulic fluid (WP 0022, Items 11, 12, or 13) to maintain level between FULL mark and ADD mark on sight gauge. Refer to LO 5-2410241-13 for proper oil based on outside temperature. d. Install hydraulic tank filler cap.

Figure 24. Hydraulic Tank Sight Gauge and Filler Cap. 0012

0012-37

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 62

MANINTERVAL HOURS After

0.2

ITEM TO CHECK/ SERVICE Transmission System Oil Level

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

CAUTION • Transmission oil level gauge has oil level markings on both sides. One side is for checking when fluid is cold with engine stopped, the other side is for checking when fluid is hot with engine at idle. • Checking fluid when hot is preferred and more accurate. Checking fluid when cold should be used for reference only. • Be sure you check correct side of gauge. Over- or underfilled transmission may cause transmission to overheat, not perform properly, or damage system components.

Transmission System Oil Level

Transmission oil level is low. a. Open right side upper access cover. b. Clean area around transmission oil level gauge and filler cap. c. Remove oil level gauge, wipe it clean then reinstall. d. Remove gauge and check fluid level. Maintain oil within OPR ZONE (operating zone) markings. e. Remove oil filler tube cap. f. Add oil (WP 0022, Items 11, 12, or 13) through filler tube. Refer to LO 5-2410-241-13 for proper oil based on outside temperature. g. Install oil filler tube cap and secure. h. Close access cover.

0012-38

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

62 After (Cont.)

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Transmission System Oil Level

Figure 25. Transmission Oil Level Gauge, Filler Tube, and Cap. 0012

0012-39

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

63

After

Right Lift Cylin- a. Check right lift cylinder for der debris, leakage, or damage. b. Check right lift cylinder mounting for damage or missing components. c. Check right lift cylinder lines and fittings for leakage or damage.

64

After

Refueling

Class III leak, damaged, missing, or excessively worn components that would impair operation are evident.

WARNING

• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow this warning may cause injury to personnel or damage to equipment. • Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing.

NOTE • Place portable fire extinguisher within reach prior to refueling. • DO NOT overfill fuel tank. If fuel starts foaming from fuel tank, stop IMMEDIATELY to avoid fuel spillage. a. Check fuel tank, filler tube, Any fuel leak is evident or strainer, and filler cap for damage or damage is noted. leaks. b. Inspect filler cap gasket for damage. c. Add fuel (WP 0022, Items 6, 7, or 8) to tank. DO NOT overfill. d. Reinstall filler cap and secure.

0012-40

Filler cap or gasket is missing or damaged.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 65

MANINTERVAL HOURS Weekly

0.2

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Pivot Shaft Oil a. Open access door on left fender. Oil level gauge missing or Level damaged. b. Clean area around oil level gauge (dipstick). c. Remove oil level gauge, clean, and reinstall. Remove oil level gauge and check level of oil. Maintain oil level within the crosshatch area on oil level gauge. d. Add oil (WP 0022, Items 11, 13, or 16) as required through filler opening. Refer to LO 5-2410-24113 for proper oil based on outside temperature. e. Reinstall oil level gauge and secure. f. Close access door.

Figure 26. Pivot Shaft Oil Level Check. 0012

0012-41

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 66

MANINTERVAL HOURS Weekly

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Track Pins and Bushings

WARNING

Track pins and bushings can become very hot to the touch if joint is dry (lacking lubrication). It is possible to burn skin if there is more than brief contact with these components. Failure to follow this warning may result in injury to personnel.

CAUTION This inspection must be performed as soon as the machine is shut down. If not done immediately, track pins and bushings will cool down and not provide accurate inspection results. a. Check each pin and bushing on Pin and bushing damaged. both track assemblies for excessive heat. b. Mark pins that exhibit excessive heat. Notify Field Maintenance.

Figure 27. Track Pin and Bushing Inspection. 0012

0012-42

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 67

MANINTERVAL HOURS Every 250 Engine Hours or Monthly

ITEM TO CHECK/ SERVICE Engine Drive Belts

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

a. Open right side engine access Engine drive belts loose, door. missing, or damaged. b. Inspect three engine drive belts for looseness, fraying, or cracking. c. Notify Field Maintenance if belts require service. d. Close access door.

Figure 28. Engine Drive Belt Inspection.

0012-43

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued. LOCATION ITEM NO. 68

MANINTERVAL HOURS Every 250 Engine Hours or Monthly

ITEM TO CHECK/ SERVICE

NOT FULLY MISSION CAPABLE IF:

PROCEDURE

Fuel Tank Water and Sediment Drain

WARNING

• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. • Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. • Failure to follow these warnings may cause injury or death to personnel or damage to equipment.

NOTE Place portable fire extinguisher within reach prior to servicing fuel system. a. Place suitable container below fuel tank drain hose. b. Open drain valve and allow water and sediment to drain. c. Continue draining until only fuel drains from hose, then close drain valve. d. Dispose of drained fluids IAW unit SOP.

0012-44

0012

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

68 Every 250 (Cont.) Engine Hours or Monthly

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Fuel Tank Water and Sediment Drain

Figure 29. Fuel Tank Water and Sediment Drain Valve and Hose. 0012

0012-45

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 69

MANINTERVAL HOURS Every 500 Engine Hours or 3 Months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Fuel Tank Filler a. Remove fuel tank filler cap and Filler cap is missing or Cap Filter and screen. damaged. Screen b. Inspect filler cap, gasket, and screen for damage. c. Clean cap and screen using solvent cleaning compound (WP 0023, Item 3). Air dry, then reinstall screen and cap.

Figure 30. Fuel Tank Filler Cap and Screen. 0012

70

Every 500 Engine Hours or 3 Months

Window Wipers a. Inspect wipers for damage. Wipers are missing or b. Operate wipers and washers to damaged. check for streaking. c. Replace wipers if required. (WP 0019).

71

Every 1,000 Engine Hours or 6 Months

Transmission Breather

a. Open right side upper access cover. b. Unscrew breather. c. Clean breather using solvent cleaning compound, (WP 0023, Item 3). Air dry, then reinstall strainer. d. Close access cover.

0012-46

Breather is missing or damaged.

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO.

MANINTERVAL HOURS

71 Every 1,000 (Cont.) Engine Hours or 6 Months

ITEM TO CHECK/ SERVICE

PROCEDURE

NOT FULLY MISSION CAPABLE IF:

Transmission Breather

Figure 31. Transmission Breather. 0012

72

Every 1,000 Engine Hours or 6 Months

Rollover Protective Structure (ROPS)

Check ROPS for damage and loose Loose or missing ROPS or missing mounting bolts. bolts or damage to structure.

0012-47

TM 5-2410-241-10

0012

Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.

0012

LOCATION ITEM NO. 73

MANINTERVAL HOURS Every 2,000 Engine Hours or Yearly

ITEM TO CHECK/ SERVICE

PROCEDURE

Engine Air Filters

NOT FULLY MISSION CAPABLE IF:

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precaution and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may result in injury or death to personnel. Replace air filter elements (WP 0014). END OF WORK PACKAGE

0012-48

Air filter elements missing or damaged.

2 TM 5-2410-241-10

CHAPTER 5 MAINTENANCE INSTRUCTIONS

2 TM 5-2410-241-10

0013

OPERATOR MAINTENANCE 0 0 1

3

-

DOME LAMP BULB REPLACEMENT Removal, Installation

INITIAL SETUP Materials/Parts

0

Dome lamp bulb

Estimated Time to Complete

0

Equipment Condition

0.2 Hr

0

0

0

Machine parked (WP 0005)

0

REMOVAL

00013

1. Remove dome lamp cover (Figure 1, Item 1) from dome lamp. 2. Remove dome lamp bulb (Figure 1, Item 2) by pushing in slightly and turning bulb to the left to disengage bulb locking lugs. Pull bulb out of socket (Figure 1, Item 3). Discard bulb. END OF TASK INSTALLATION

00013

1. Install new bulb (Figure 1, Item 2) in socket (Figure 1, Item 3), push in slightly, and turn bulb clockwise to the right to engage bulb locking lugs. 2. Install cover (Figure 1, Item 1).

Figure 1. Dome Lamp Bulb Replacement. END OF TASK END OF WORK PACKAGE

0013-1/(2 blank)

0013

6 TM 5-2410-241-10

0014

OPERATOR MAINTENANCE 0 0 1

4

-

ENGINE PRIMARY AND SECONDARY AIR FILTER ELEMENTS MAINTENANCE Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Work Light Materials/Parts Rag, wiping (WP 0022, Item 18) Element, Primary, Air Filter Element, Secondary, Air Filter

0

Equipment Condition Machine parked (WP 0005) Left front access door opened (WP 0004)

0

0

0

0

0

0

Estimated Time to Complete

0

0.2 Hr

0

0

0

REMOVAL

00014

WARNING

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

CAUTION Do not remove secondary air filter element until after the air filter housing is cleaned and then only if it is being replaced. This will reduce the possibility of dirt entering the engine. Failure to follow this caution may result in damage to equipment.

NOTE •

Primary air filter element should be replaced yearly.

•

Replace secondary air filter element if: (A) primary air filter element has been cleaned three times since the secondary element has been replaced, (B) exhaust smoke is black even after primary element has been replaced, or (C) the secondary element has been in service for one year.

0014-1

TM 5-2410-241-10

0014

REMOVAL – CONTINUED 1. Disengage two latches (Figure 1, Item 2) and remove engine air filter assembly cover (Figure 1, Item 1).

Figure 1. Engine Air Filter Assembly Cover.

0014

2. Remove primary air filter element (Figure 2, Item 1) from housing (Figure 2, Item 2).

Figure 2. Primary Air Filter Element. END OF TASK

0014-2

0014

TM 5-2410-241-10

CLEANING AND INSPECTION

0014

00014

1. Using a clean rag, clean inside of air filter housing.

CAUTION •

Do not tap or strike air filter elements to remove dust. Damage to air filter elements may result.

•

Do not wash the air filter element.

•

Do not use air filter elements with damaged pleats, gaskets, or seals. Dirt entering engine will cause damage to engine components.

•

Do not attempt to clean a secondary air filter element. If damaged, or light cannot pass through it, it must be replaced.

•

Do not use compressed air at pressure greater than 30 psi (207 kPa) to clean primary element.

•

Do not remove secondary filter until you have a new one ready to install.

•

Failure to follow these cautions may result in damage to equipment.

NOTE Use either low pressure compressed air or a vacuum to clean primary air filter element. Direct airflow from inside element and up and down pleats rather than across pleats. 2. With assistance from Field Maintenance, clean primary element. 3. Inspect primary element for tears, holes, damaged pleats, gaskets, or seals. Discard if damaged. 4. Inspect element using a work light. Light should be visible through the element when light is placed inside element. If necessary, compare to a new element to confirm results. 5. Remove secondary air filter element (Figure 3, Item 1) from housing (Figure 3, Item 2) and discard.

Figure 3. Secondary Air Filter Element. END OF TASK

0014-3

0014

TM 5-2410-241-10

INSTALLATION

0014

00014

1. Install secondary air filter element (Figure 4, Item 1).

Figure 4. Secondary Air Filter Element.

0014

2. Install primary air filter element (Figure 5, Item 1).

Figure 5. Primary Air Filter Element.

0014-4

0014

TM 5-2410-241-10

0014

INSTALLATION – CONTINUED 3. Position engine air filter cover (Figure 6, Item 1) and engage two latches (Figure 6, Item 2).

Figure 6. Engine Air Filter Assembly Cover.

0014

END OF TASK FOLLOW-ON TASKS

00014

Close left front access door. END OF TASK END OF WORK PACKAGE

0014-5/(6 blank)

4 TM 5-2410-241-10

0015

OPERATOR MAINTENANCE 0 0 1 5

-

ETHER STARTING AID CYLINDER REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Materials/Parts Rag, wiping (WP 0022, Item 18) Ether starting aid cylinder (1)

0

0

0

Equipment Condition Machine parked (WP 0005) Estimated Time to Complete 0.2 Hr

0015-1

0

0

0

0

TM 5-2410-241-10

0015

WARNING

Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated area away from heat, open flames, or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause serious injury or death to personnel. REMOVAL

00015

1. Loosen clamp (Figure 1, Item 2). 2. Unscrew ether starting aid cylinder (Figure 1, Item 1) from valve (Figure 1, Item 3). Discard empty cylinder IAW local regulations and unit SOP.

Figure 1. Ether Starting Aid Cylinder.

0015-2

0015

TM 5-2410-241-10

0015

REMOVAL – CONTINUED 3. Remove gasket (Figure 2, Item 1) from valve (Figure 2, Item 2). Discard gasket.

Figure 2. Gasket.

0015

END OF TASK CLEANING AND INSPECTION

00015

Clean valve of any dirt or debris. Inspect valve for any damage. If damage is present, notify Field Maintenance. END OF TASK INSTALLATION

00015

1. Install new gasket (Figure 2, Item 1) on valve (Figure 2, Item 2).

0015-3

TM 5-2410-241-10

INSTALLATION

0015

00015

2. Install ether starting aid cylinder (Figure 3, Item 1) onto valve (Figure 3, Item 3). 3. Tighten clamp (Figure 3, Item 2).

Figure 3. Ether Starting Aid Cylinder. END OF TASK END OF WORK PACKAGE

0015-4

0015

6 TM 5-2410-241-10

0016

OPERATOR MAINTENANCE 0

0 1 6

-

FLOOD LAMP BULB REPLACEMENT Removal, Installation

INITIAL SETUP Tools

0

WRENCH, ADJUSTABLE, 12-INCH LONG (WP 0021, Item 6) Materials/Parts

Machine parked (WP 0004) 0

0

Rag, wiping (WP 0022, Item 18) Bulb

Equipment Condition Estimated Time to Complete 0.2 Hr

0

0

0

0

0

0

REMOVAL

00016

1. Remove bolt (Figure 1, Item 1) and open grille (Figure 1, Item 2). 2. Disengage and remove outer band clamp (Figure 1, Item 4) and pull lamp (Figure 1, Item 3) from grommet (Figure 1, Item 5).

Figure 1. Flood Lamp Removal.

0016-1

0016

TM 5-2410-241-10

0016

REMOVAL – CONTINUED 3. Disconnect black wire connector (Figure 2, Item 1) from lamp assembly (Figure 2, Item 4). 4. Disengage white wire (Figure 2, Item 2) from plastic retainer (Figure 2, Item 3), then disconnect white wire from lamp assembly (Figure 2, Item 4). Place lamp assembly on suitable bench.

Figure 2. Disconnecting Lamp Connectors.

0016-2

0016

TM 5-2410-241-10

0016

REMOVAL – CONTINUED 5. Disengage bale wires (Figure 3, Item 4) from lugs (Figure 3, Item 5). 6. Remove bulb (Figure 3, Item 2) from lamp assembly (Figure 3, Item 1).

Figure 3. Bulb Assembly Removal.

0016

END OF TASK INSTALLATION

00016

CAUTION Do not touch the glass surface of a halogen bulb with bare fingers, as the surface will be exposed to the salts and oils in the hand. If glass is touched, it must be cleaned immediately with a gentle solvent such as alcohol. Failure to follow this caution will result in early bulb failure. 1. Install bulb (Figure 3, Item 2) into lamp assembly (Figure 3, Item 1), feeding the white wire under the plastic retainer (Figure 3, Item 3). 2. Secure bulb in place by engaging bale wires (Figure 3, Item 4) under lugs (Figure 3, Item 5).

0016-3

TM 5-2410-241-10

0016

INSTALLATION – CONTINUED 3. Connect black connector (Figure 4, Item 1) to lamp assembly (Figure 4, Item 4). 4. Engage white wire (Figure 4, Item 2) to plastic retainer (Figure 4, Item 3), then connect white wire to lamp assembly (Figure 4, Item 4).

Figure 4. Connecting Lamp Connectors.

0016-4

0016

TM 5-2410-241-10

0016

INSTALLATION – CONTINUED 5. Install lamp assembly (Figure 5, Item 3) into grommet (Figure 5, Item 5). 6. Position and engage band clamp (Figure 5, Item 4) around grommet. 7. Close grille (Figure 5, Item 2) and install bolt (Figure 5, Item 1).

Figure 5. Flood Lamp Installation. END OF TASK END OF WORK PACKAGE

0016-5/(6 blank)

0016

2 TM 5-2410-241-10

0017

OPERATOR MAINTENANCE 0 0 1 7

-

FUEL SYSTEM - PRIME Prime Fuel System

INITIAL SETUP References

0

WP 0005

Estimated Time to Complete

0

Equipment Condition

0.2 Hr

0

0

0

Battery disconnect switch in ON position (WP 0004)

0

NOTE If the engine does not start, air may be trapped in the fuel lines to the engine. Use the following procedure to purge air from the fuel lines. PRIME FUEL SYSTEM

00017

1. Unlock priming pump plunger (Figure 1, Item 1). 2. Operate plunger until resistance is felt. 3. Push plunger in and hand-tighten to lock plunger in place.

Figure 1. Fuel System Priming Pump.

0017

4. Start engine (WP 0005). 5. If engine fails to start, or if engine starts and misfires or excessive smoke comes from exhaust pipe, additional priming may be required. Repeat steps 1 through 4. 6. If engine runs rough, allow it to run at low idle until it runs smoothly. END OF TASK END OF WORK PACKAGE 0017-1/(2 blank)

6 TM 5-2410-241-10

0018

OPERATOR MAINTENANCE 0 0 1 8

-

FUSE AND CIRCUIT BREAKER MAINTENANCE Removal, Installation

INITIAL SETUP Materials/Parts Fuse (as required)

0

0

0

Equipment Condition Machine parked (WP 0004) Estimated Time to Complete 0.2 Hr

REMOVAL

0

0

0

0

00018

1. Open battery compartment cover (Figure 1, Item 2). 2. Open fuse panel access door (Figure 1, Item 1) and remove fuse cover (Figure 1, Item 3).

Figure 1. Fuse Panel Access.

0018-1

0018

TM 5-2410-241-10

0018

REMOVAL – CONTINUED

NOTE If high amperage alternator fuse must be replaced, notify Field Maintenance. 3. Using the fuse chart (Figure 2) and Fuse Identification Key (Table 1), identify correct fuse or circuit breaker (Figure 3) for inoperative system/circuit.

Figure 2. Fuse Chart.

0018-2

0018

TM 5-2410-241-10

0018

REMOVAL – CONTINUED Table 1. Fuse Identification Key. FUSE NO.

FUSE AMPERAGE RATING

1

15A

Wipers and Ether Start

2

15A

Spare

3

15A

Monitor

4

15A

Spare

5

10A

Spare

6

15A

Auxiliary (switched)

7

10A

Winch and Seat

8

15A

Front Flood Lamps

9

15A

Fuel Tank and ROPS Rear Flood Lamps

10

10A

Converter (switched)

11

15A

ROPS A/C 1 (Not applicable)

12

15A

ROPS A/C 2 (Not applicable)

13

15A

Horn

14

15A

Key Switch/Blower Fan

15

15A

Secondary Brake

16

15A

ROPS FWD Flood Lamps/ Dome Lamp

17

15A

Spare

18

15A

10 Amp Converter

19

15A

Machine ECM

20

15A

Auxiliary (unswitched)

21

15A

Engine ECM

22

20A

20 Amp Converter

23

15A

Spare (unswitched)

24

15A

Spare (unswitched)

COMPONENT

0018-3

0018

TM 5-2410-241-10

0018

REMOVAL – CONTINUED

Figure 3. Fuse and Circuit Breaker Panel. END OF TASK

0018-4

0018

TM 5-2410-241-10

0018

INSTALLATION

00018

NOTE Replace fuses with same type and amperage rating. 1. Replace fuse or push button to reset circuit breaker. Button should remain pushed in. This indicates circuit breaker was reset successfully.

NOTE Notify Field Maintenance if new fuse blows or circuit breaker opens when component is turned on, or if same circuit breaker or fuse blows frequently. 2. Install fuse cover (Figure 4, Item 3), and close fuse panel access door (Figure 4, Item 1) and battery compartment (Figure 4, Item 2).

Figure 4. Fuse Panel Access. END OF TASK END OF WORK PACKAGE

0018-5/(6 blank)

0018

2 TM 5-2410-241-10

0019

OPERATOR MAINTENANCE 0

0 1 9

-

WINDOW WIPER BLADE REPLACEMENT

INITIAL SETUP Materials/Parts

0

Blade, wiper (as required) Equipment Condition

Estimated Time to Complete

0

0.2 Hr

0

0

0

Machine parked (WP 0005)

0

CAUTION The wiper arm is spring-loaded. DO NOT let go of arm after blade has been removed. Carefully lower arm to glass, or glass may break. REPLACEMENT

00019

1. Raise wiper arm and blade (Figure 1, Items 1 and 4) up away from glass. 2. Squeeze release tab (Figure 1, Item 2) and remove blade (Figure 1, Item 4) from arm (Figure 1, Item 1). 3. Position new blade (Figure 1, Item 4) on arm (Figure 1, Item 1) and secure pivot insert (Figure 1, Item 3) to blade.

Figure 1. Window Wiper Blade Replacement. END OF TASK END OF WORK PACKAGE

0019-1/(2 blank)

0019

2 TM 5-2410-241-10

CHAPTER 6 SUPPORTING INFORMATION

2 TM 5-2410-241-10

0020

OPERATOR MAINTENANCE 0

0 2 0

-

REFERENCES

SCOPE

00020

This work package lists all publication indexes, forms, field manuals, technical manuals, and other publications referenced in this manual and which apply to operation and operator maintenance of the D7R Dozers. PUBLICATION INDEXES

00020

The following indexes should be consulted frequently for the latest changes or revisions and for new publications relating to material covered in this technical manual. Consolidated Army Publications and Forms Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30 The Army Maintenance Management System (TAMMS) Users Manual . . . . . . . . . . . . . . . . . . . . . . DA PAM 750-8 FORMS

00020

NOTE Refer to PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, for instructions on the use of maintenance forms. Accident Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518 Depreservation Guide for Vehicles and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2258 Equipment Control Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-9 Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404, DA Form 5988-E Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2407 Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 91 Processing and Deprocessing Record for Shipment, Storage, and Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397 Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368 Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DA Form 2028 Report of Discrepancy (ROD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364 Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14 FIELD MANUALS

00020

Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-30 Basic Cold Weather Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-70 Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 90-3 Earthmoving Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-434 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11 Manual for the Wheeled Vehicle Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 21-305-20 Multiservice Helicopter Sling Load: Basic Operations and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-20.197 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.5

0020-1

TM 5-2410-241-10

0020

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71 Operation and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 9-207 Recovery and Battle Damage Assessment and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-30.31 Rigging Techniques, Procedures, and Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-125 Storage Serviceability Standards: Tracked Vehicles, Wheeled Vehicles, and Component Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 740-98-1 TECHNICAL BULLETINS

00020

Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment, and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209 Safety Inspection and Testing of Lifting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0142 TECHNICAL MANUALS

00020

Operator’s, Unit, Direct Support, and General Support Maintenance Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-6140-200-14 Operator’s, Unit Maintenance Manual for Laser Leveling Equipment . . . . . . . . . . . . . . . . . . . TM 5-6675-348-13&P Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive Command). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-244-6 OTHER PUBLICATIONS

00020

Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ASME Y14.38-2007 Army Acquisition Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-1 Army Logistics Readiness and Sustainability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 700-138 Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 8-100 Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items). . . . . . . . . . . . CTA 50-970 Field and Garrison Furnishings and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTA 50-909 Lubrication Order for the D7R Series II Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LO 5-2410-241-13 Fuels and Lubricants Standardization Policy for Equipment Design, Operation, and Logistic Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-12 END OF WORK PACKAGE

0020-2

4 TM 5-2410-241-10

0021

OPERATOR MAINTENANCE -

0 0

2 1

COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS

SCOPE

0021

This work package lists the Components of End Item (COEI) and Basic Issue Items (BII) for the D7R Dozer to help you inventory items for safe and efficient operation of the equipment. GENERAL

0021

The COEI and BII information is divided into the following lists: a. Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the D7R Dozer. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. b. Basic Issue Items (BII). These essential items are required to place the D7R Dozer in operation, to operate the dozer, and to perform emergency repairs. Although shipped separately packaged, BII must be with the D7R Dozer during operation and when the dozer is transferred between property accounts. Listing these items is your authority to request/requisition them for replacement based on authorization of the end item by the Table of Organization and Equipment/Modified Table of Organization and Equipment (TOE/ MTOE). Illustrations are furnished to help you find and identify the items. EXPLANATION OF COLUMNS IN THE COEI AND BII LISTS

0021

Column (1) Illus Number. Gives you the number of the item illustrated. Column (2) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters), followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line below the description is the part number and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code (UOC). When applicable, gives you a code if the item you need is not the same for different models of equipment. Column (5) U/I Unit of Issue. Indicates the physical measurement or count of the item as issued per the National Stock Number shown in Column (2). Column (6) Qty Rqr. Indicates the quantity required. COEI LIST

0021

NOTE There are no COEI for the D7R Dozer.

0021-1

TM 5-2410-241-10

0021

BII LIST

0021

Table 1. Basic Issue Items (BII).

0021

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER

NSN

DESCRIPTION, PART NUMBER/(CAGEC)

UOC

U/I

QTY RQR

1

4930-00-253-2478

LUBRICATING GUN, HAND 8F-9866/(11083)

EA

1

2

5120-01-498-0127

SCREWDRIVER, PHILLIPS 6V-7934/(11083)

EA

1

3

5120-01-528-9361

SCREWDRIVER, FLAT TIP 6V-7935/(11083)

EA

1

4

5120-01-575-9654

PLIERS, SLIP JOINT 7.5 in. (191.8 mm) 6V-6192 (11083)

EA

1

EA

1

EA

1

5

5140-01-524-7563

BAG, TOOL 211-0136/(11083)

6

5120-01-518-2402

WRENCH, ADJUSTABLE, 12-INCH LONG 214-7330 /(11083)

0021-2

1

2

3

4

4

5

6

TM 5-2410-241-10

0021

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) – Continued.

0021

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER

NSN

DESCRIPTION, PART NUMBER/(CAGEC)

UOC

U/I

QTY RQR

7

4210-01-493-8162

EXTINGUISHER, FIRE B500T/(54905)

EA

1

8

5331-00-741-0674

SEAL 5F1678/(11083)

PK

1

9

5340-01-162-8676

COVER 5H4018/(11083)

PK

1

10

2815-01-654-5737

COVER 5H4019/(11083)

PK

1

11

5331-00-562-1073

RING 4F7391/(11083)

PK

1

EA

1

EA

1

12

LUBRICATION ORDER LO 5-2410-241-13/(19207)

13

MANUAL, OPERATOR’S TM 5-2410-241-10(19207)

0021-3

7

8

9

10

11

12

13

TM 5-2410-241-10

0021

BII LIST – CONTINUED

Table 1. Basic Issue Items (BII) – Continued.

00021

(1)

(2)

(3)

(4)

(5)

(6)

ILLUS NUMBER 14

NSN

DESCRIPTION, PART NUMBER/(CAGEC)

UOC

U/I

QTY RQR

5340-01-580-2020

EA

2

15

5340015796847

CLAMP, LOOP 6Y-9281/(11083)

EA

2

16

5306-01-429-3170

BOLT 8T-4835/(11083)

EA

2

17

2510-01-417-6883

STRAP 9N-4233/(11083)

EA

2

18

5310-01-102-2477

WASHER 5P-8248/(11083)

EA

2

19

5310-01-257-3245

WASHER 8T-2561/(11083)

EA

2

20

5306-01-439-1002

BOLT 7X0326/(11083)

EA

2

21

5310-01-098-0624

WASHER 8T-4223/(11083)

EA

4

22

5310-01-184-3538

NUT 6V-8188/(11083)

EA

2

STRAP, RETAINING 6Y-9280/(11083)

END OF WORK PACKAGE

0021-4

14

15

16

17

18

19

20

21

22

4 TM 5-2410-241-10 OPERATOR MAINTENANCE 0 0

2 2

0022

-

EXPENDABLE AND DURABLE ITEMS LIST

SCOPE

00022

This work package lists expendable and durable items you will need to operate and maintain the D7R Dozers, Type I with Winch and Type II with Ripper. This listing is for informational purposes only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Durable Items. EXPLANATION OF COLUMNS

00022

1.

Column (1) Item Number. This number is referenced in the appropriate work package Initial Setup list or in the narrative instructions to identify the item; e.g., Use antifreeze (WP 0022, Item 1).

2.

Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item. C = Crew F = Maintenance

3.

Column (3) National Stock Number. This is the National Stock Number assigned to the item, which you can use to requisition it.

4.

Column (4) Item Name, Description, CAGEC, and Part Number. This provides the other information you need to identify the item.

5.

Column (5) U/I (Unit of Issue). This column shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.

0022-1

TM 5-2410-241-10

0022

Table 1. Expendable and Durable Items for the D7R Dozers. (1) ITEM NUMBER 1

(2)

(3)

(4)

(5)

LEVEL

NATIONAL STOCK NUMBER

ITEM NAME, DESCRIPTION, CAGEC, AND PART NUMBER

U/I

C

1

1

1

6850-01-383-4068

Antifreeze (coolant)

1

1

1

1

2 3

F C

2

C

6850-01-441-3257 6850-01-383-3918 5340-00-450-5718

3

3

4

4

1

1

2

3

6850-01-474-2318 6850-01-474-2320 6850-01-474-2321 6850-00-926-2275

6

7

C

C

C

5

6

7930-00-282-9699

9

C

C

(58536) A-A-52624 55 Gallon Drum

DR

Cleaning compound, windshield (OFTT5) 0854-000 16 Ounce Bottle

Diesel fuel: DL-1 grade, winter (81346) A-A-52557 Bulk Diesel fuel: DF-2 grade, regular (81346) A-A-52557

7

8

CN

Detergent, general purpose, liquid (83421) 7930-00-282-9699 1 Gallon Can

9140-00-000-0185

9140-00-286-5294 9140-00-286-5295 9140-00-286-5296 8

(58536) A-A-52624 5 Gallon Can

9130-01-031-5816

7

7

Fuel, turbine: aviation (81349) MIL-T-83133 JP-8 Bulk Grease: automotive and artillery (GAA)

9

9150-01-197-7688

9

0022-2

(81349) M-10924-A 2-1/4 Ounce Tube

1

1

1

1

2

1

2

EA 3

2

3

CN CN DR 4

3

3

3

4

4

BT 5

4

5

5

CN 6

5

6

6

GL 7

Bulk 5 Gallon Can 55 Gallon Drum

7

8

1

1 Gallon Can 5 Gallon Can 55 Gallon Drum

3

1

GL

Cleaning compound, solvent, type III (81349) MIL-PRF-680

3

4

1

(1QK63) 672 4354 1 Gallon Bottle

Cap set, protective, dust and moisture seal (19207)/10935405

3

4

5

0022

6

7

GL CN DR 8

7

7

7

8

8

GL 9

8

9

9

TU

9

TM 5-2410-241-10

0022

Table 1. Expendable and Durable Items for the D7R Dozers - Continued. (1) ITEM NUMBER

(2)

(3)

(4)

(5)

LEVEL

NATIONAL STOCK NUMBER

ITEM NAME, DESCRIPTION, CAGEC, AND PART NUMBER

U/I

9150-01-197-7693

9

9150-01-197-7690

9

9150-01-197-7692 10

C

9

C

9150-00-402-4478

11

12

C

12

12

13

C

13

13

C

9150-00-402-2372 9150-00-491-7197

14

9150-01-186-6727 9150-01-496-1966 9150-01-496-1939

C

15

CN

(81349) M-10924-E 35 Pound Can

CN

9150-00-178-4726 9150-00-188-9858 9150-00-189-6729 9150-01-422-8901

9

10

10

CN 11

10

11

GL

(81349) MIL-PRF-46167 55 Gallon Drum

DR

11

11

11

11

11

12

11

12

(81349) M2104-1-10W 1 Quart Can

CN

(81349) MIL-PRF-2104 1 Gallon Can

CN

(81349) MIL-PRF-2104 55 Gallon Drum

DR

12

12

12

12

12

13

12

13

(81349) MIL-PRF-2104 1 quart can

CN

(81349) M2104-3-30W 5 Gallon Can

CN

(81349) M2104-4-30W 55 Gallon Drum

DR

13

13

13

13

13

14

(13873) SAE J2363 55 Gal Drum

0022-3

9

10

(81349) MIL-PRF-46167 5 Gallon Can

Oil, lubricating, CHDO-5W/40

9

9

QT

Oil, lubricating, CHDO-40

9

9

(33358) EMERY3908D 1 Quart Can

Oil, lubricating, OE/HDO 30

14

15

(81349) M-10924-C 1-3/4 Pound Can

Oil, lubricating, OE/HDO 10

13

13

14

11

12

12

CA

Oil, lubricating, OEA-30 Arctic

11

11

(81349) M-10924-B 14 Ounce Cartridge

Oil, lubricating, Type 1 Grade PE-10-1 (81349) MIL-PRF-21260, 5 Gallon Can

10

9150-00-111-3199 11

0022

DR 15

13

TM 5-2410-241-10

0022

Table 1. Expendable and Durable Items for the D7R Dozers - Continued. (1) ITEM NUMBER

(2)

(3)

(4)

(5)

LEVEL

NATIONAL STOCK NUMBER

ITEM NAME, DESCRIPTION, CAGEC, AND PART NUMBER

U/I

9150-01-524-9134

15

9150-01-524-9131

15

9150-01-524-9124 16

C

16

18

19

C

C

17

18

9150-01-152-4117 9150-01-152-4118 9150-00-231-2361

5975-00-935-5946

F

(13873) SAE J2363 5 Gallon Can

CN

(13873) SAE J2363 55 Gallon Drum

DR

9905-00-537-8954

7510-00-040-5895

19

21

16

CN

16

END OF WORK PACKAGE

0022-4

16

16

16

17

17

18

BL 19

19

19

19

HD

6 inch length, black (96906)/MS3367-1-0 package of 100

HD

13.35 inch length, brown (96906)/MS3367-2-1

EA

Tape, pressure sensitive adhesive (81755)/ P5113-3 72 yard long, 1.5 inch wide

15

16

(81349) M2104-3-15W40 5 Gallon Can

Tag, marker (81349)/16742 Bundle of 20

15

15

4 inch length, black (96906)/MS3367-4-0 package of 100

19

15

15

QT

Strap, tiedown, electrical components

19

20

15

(81349) M2104-1-15W40 1 Quart Can

Rag, wiping (64067) 7920-00-205-1711 50 Pound Bale 19

5975-00-984-6582

21

QT

Oil, lubricating preservative, corrosion inhibitor (81349) MIL-PRF-3150 1 Quart

7920-00-205-1711

C

C

(13873) SAE J2363 1 Quart Can

Oil, lubricating, OE/HDO-15/40

5975-00-903-2284

20

15

16

16

17

0022

19

19

19

19

19

20

19

20

20

BD 21

20

21

21

RL

21

TM 5-2410-241-10

Index Subject

WP Sequence No.-Page No.

A Abbreviations/Acronyms, List of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-7 Air Filter Elements, Engine Primary and Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0014-1

B Brake Systems, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-5

C Chemical, Biological, Radiological and Nuclear (CBRN) Contamination . . . . . . . . . . . . . . . . . . . . . . . WP 0001-6 Components of End Item (COEI) and Basic Issue Items (BII) Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0021-1 Corrosion Prevention and Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

D Decal/Data Plate Guide, Stowage and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and Use of Operator’s Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Destruction of Army Materiel to Prevent Enemy Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dome Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0007-1 WP 0004-1 WP 0001-1 WP 0013-1

E Electrical System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electromagnetic Pulse (EMP) Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Primary and Secondary Air Filter Elements Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Characteristics, Capabilities, and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Improvement Recommendations (EIRs), Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Starting Aid Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0003-5 WP 0001-6 WP 0014-1 WP 0003-2 WP 0002-1 WP 0002-6 WP 0001-1 WP 0002-1 WP 0015-1 WP 0022-1

F Fire Extinguisher, Portable, Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-11 Flood Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0016-1 Fording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-8 Fuel System - Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0017-1 Fuse and Circuit Breaker Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0018-1

G General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

I Implement and Steering Hydraulic System, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0003-6

Index-1

TM 5-2410-241-10

Index - Continued Subject

WP Sequence No.-Page No.

L List Abbreviations/Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-7 Expendable and Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0022-1

M Maintenance Forms, Records, and Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1 Major Components, Location and Description of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0002-2

O Operation At High Altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-7 In Extreme Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-3 In Extreme Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-5 In Mud or on Soft Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-6 In Saltwater Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-7 In Sandy or Dusty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-6 In Snow and on Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-7 Portable Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-11 Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-1 Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0005-1 Operator Controls and Indicators, Description and of Use of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0004-1 Ozone Depleting Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

P Powertrain, Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WP 0003-4 WP 0001-2 WP 0012-1 WP 0011-1

R Recovery and Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-9 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0020-1 Reporting Equipment Improvement Recommendations (EIR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-1

S Slave Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0006-2 Storage or Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0001-2 Stowage and Decal/Data Plate Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0007-1

T Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement and Steering Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Threat of Chemical, Biological, Radiological, and Nuclear (CBRN) Contamination . . . . . . . . . . . . . . . Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-2

WP 0003-1 WP 0003-5 WP 0003-5 WP 0003-2 WP 0003-6 WP 0003-4 WP 0001-6 WP 0008-1

TM 5-2410-241-10

Index - Continued Subject

WP Sequence No.-Page No.

Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0010-1 Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0009-1

W Window Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0019-1

Index-3/(Index-4 Blank)

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE Date you filled out this form.

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

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command

Your mailing address

ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

TM Number ITEM

PAGE

PARAGRAPH

LINE

FIGURE TABLE NO.

DATE

TITLE

Date of the TM

Title of the TM

RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)

0007-3

Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer.

0018-2

Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).

SAMPLE

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

Your Phone Number

SIGNATURE

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

Date you filled out

Your Address

this form

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER

DATE

Date of the TM

TM Number PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

TITLE

Title of the TM

TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

Your Phone Number

Your Signature APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Operator’s Manual, D7R Series II Dozer, Type 31 October 2011 1 with Winch; Type II with Ripper

PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-10 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-10 PAGE NO.

COLM NO.

LINE NO.

DATE

31 October 2011 NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Operator’s Manual, D7R Series II Dozer, Type 1 with Winch; Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Operator’s Manual, D7R Series II Dozer, Type 31 October 2011 1 with Winch; Type II with Ripper

PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-10 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-10 PAGE NO.

COLM NO.

LINE NO.

DATE

31 October 2011 NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Operator’s Manual, D7R Series II Dozer, Type 1 with Winch; Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Operator’s Manual, D7R Series II Dozer, Type 31 October 2011 1 with Winch; Type II with Ripper

PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-10 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-10 PAGE NO.

COLM NO.

LINE NO.

DATE

31 October 2011 NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Operator’s Manual, D7R Series II Dozer, Type 1 with Winch; Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE Operator’s Manual, D7R Series II Dozer, Type 31 October 2011 1 with Winch; Type II with Ripper

PUBLICATION/FORM NUMBER

DATE

TM 5-2410-241-10 ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER

TM 5-2410-241-10 PAGE NO.

COLM NO.

LINE NO.

DATE

31 October 2011 NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TITLE Operator’s Manual, D7R Series II Dozer, Type 1 with Winch; Type II with Ripper TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff

Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1125505

Distribution: To be distributed in accordance with the initial distribution number (IDN) 257884 requirements for TM 5-2410-241-10.

THE METRIC SYSTEM AND EQUIVALENTS Linear Measure

Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights

Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (°F - 32) = °C 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius 9/5 C° +32 = F°

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour

1.609

Kilometers per Hour

Miles per Hour

0.621

PIN: 086966-000