2
TM 5-2410-241-10
0008-1
0008
OPERATOR MAINTENANCE
-0 -0 -0 8TROUBLESHOOTING 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 0010for 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.
2
0008-2
TM 5-2410-241-10 0008
MACHINE WARNING SUMMARIES 0008
END OF WORK PACKAGE
WARNING ALERT INDICATORS ACTION REQUIRED
Warning Level 1
2. Check applicable system at earliest opportunity.
Warning Level 2
A change in machine operation is required.
1. Change in machine operation or per-formance of maintenance immedi-ately required or damage to machine may result.
2. If SERV CODE appears in lower dig-ital display window, notify Field Main-tenance.
Warning Level 3
Immediate need to shut down machine.
Failure to follow this warning may result in injury or death to personnel or damage to equipment.
1. Shut down machine immediately.
2. If SERV CODE appears in lower dig-ital display window, notify Field Main-tenance.
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.
0009-1/(2 blank)
TM 5-2410-241-10 0009
OPERATOR MAINTENANCE
-0 -0 -0 9TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting Procedure Page
TM 5-2410-241-10
0010-1
0010
OPERATOR MAINTENANCE
-0 -0 1 -0TROUBLESHOOTING PROCEDURES
Electrical System, Engine, Hydraulic System
Step 1. 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.
Step 2. Check hydraulic fluid level.
a. Add fluid (WP 0012).
b. If problem persists, notify Field Maintenance.
2. DOME LAMP INOPERATIVE.
Step 1. Check for burned out or defective bulb.
a. Replace bulb (WP 0013).
b. If problem persists, go to step 2.
Step 2. Check for blown fuse (fuse 16) at fuse panel.
a. Replace fuse (WP 0018).
b. If problem persists, notify Field Maintenance.
3. 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.
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TM 5-2410-241-10
0010-2
0010
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. Check for burned out or defective bulb(s).
a. Replace bulb(s) (WP 0016).
b. If problem persists, go to step 2.
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. 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.
Step 2. Check hydraulic fluid level.
a. Add fluid (WP 0012).
b. If problem persists, notify Field Maintenance.
10. WINCH INOPERATIVE.
Step 1. 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.
Step 2. Check hydraulic fluid level.
a. Add fluid (WP 0012).
b. If problem persists, notify Field Maintenance.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
0010-3
TM 5-2410-241-10 0010
ELECTRICAL SYSTEM – CONTINUED 11. WINDOW WASHERS INOPERATIVE.
Step 1. Ensure window washer fluid tank is not empty.
a. Add Cleaning compound, windshield (WP 0012).
b. If problem persists, go to step 2.
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.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
TM 5-2410-241-10
0010-4
0010
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.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
0010-5
TM 5-2410-241-10 0010
ENGINE SYSTEM – CONTINUED 2. ENGINE CANNOT REACH TOP ENGINE RPM.
Step 1. 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.
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.
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. 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.
Step 2. Verify fuel level.
a. Add fuel as necessary (WP 0012).
b. If problem persists, go to step 3.
Step 3. Check air filters.
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to step 4.
Step 4. Check circuit breakers.
a. Reset circuit breakers (WP 0018).
b. If problem persists, notify Field Maintenance.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
TM 5-2410-241-10
0010-6
0010
ENGINE SYSTEM – CONTINUED 4. ENGINE DOES NOT CRANK.
Step 1. 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.
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.
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. 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.
Step 2. Check air filters.
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to step 3.
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. 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.
Step 2. Check for water in fuel.
a. Drain primary fuel filter/water separator (WP 0012).
b. If problem persists, go to step 3.
Step 3. Prime fuel system.
a. Prime fuel system (WP 0017).
b. Attempt to start engine.
c. If problem persists, notify Field Maintenance.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
0010-7
TM 5-2410-241-10 0010
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. Check for misreading of oil level.
a. Accurately measure oil level.
b. If problem persists, go to step 2.
Step 2. Check air filters.
a. Clean or replace air filters (WP 0014).
b. If problem persists, go to step 3.
Step 3. Check for loose or leaking oil lines and oil leaks.
a. Tighten loose connections.
b. If problem persists or leaks are found, notify Field Maintenance.
9. INTERMITTENT ENGINE SHUTDOWN.
Step 1. 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.
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.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
TM 5-2410-241-10
0010-8
0010
END OF WORK PACKAGE
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. Check blade hydraulic cylinders for buildup of debris.
a. Clean debris.
b. If problem persists, go to step 2.
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. Check ripper area for buildup of debris.
a. Clean debris.
b. If problem persists, go to step 2.
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.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
0.
TM 5-2410-241-10