TM 5-2410-241-10

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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 0000

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 fly-ing 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 dan-ger 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 0000

BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drop of liquid on hand shows that the material will cause burns or 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 0000

WARNING

COMPRESSED AIR 0000

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

WARNING

HEARING PROTECTION 0000

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 0000

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

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MACHINE OPERATION 0000

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 0000

• 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 0000

When slave starting the engine:

– 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 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.

GENERAL SAFETY WARNINGS DESCRIPTION — CONTINUED 0000

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0000

• 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.

GENERAL SAFETY WARNINGS DESCRIPTION — CONTINUED 0000

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION 0000

WARNING

BATTERIES 0000

• 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.

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

– 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.

– 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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CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!!! 0000

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

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

HAZARDOUS MATERIALS WARNINGS DESCRIPTION — CONTINUED 0000

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CARC PAINT 0000

• 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.

– Use high-efficiency air purifying respirators when grinding or sanding CARC-coated equipment.

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

– CARC paint contains isocyanate (HDI) which is highly irritating to 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 0000

• When servicing this equipment, performing maintenance, or disposing of materials such as engine/ hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance.

• Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. • Failure to follow these warnings may result in injury to personnel.

WARNING

HYDRAULIC SYSTEM PRESSURE 0000

• 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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CBRN EXPOSURE 0000

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 0000

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

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0000

WORK SAFETY 0000

• 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

-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

Warning Summary (10 pgs). . . 0

i through viii (8 pgs) . . . 0

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

WP 0001 (10 pgs) . . . 0

WP 0002 (8 pgs) . . . 0

WP 0003 (6 pgs) . . . 0

WP 0004 (28 pgs) . . . 0

WP 0005 (18 pgs) . . . 0

WP 0006 (12 pgs) . . . 0

WP 0007 (14 pgs) . . . 0

WP 0008 (2 pgs) . . . 0

WP 0009 (2 pgs) . . . 0

WP 0010 (8 pgs) . . . 0

WP 0011 (4 pgs) . . . 0

WP 0012 (48 pgs) . . . 0

WP 0013 (2 pgs) . . . 0 WP 0014 (6 pgs) . . . 0 WP 0015 (4 pgs) . . . 0 WP 0016 (6 pgs) . . . 0 WP 0017 (2 pgs) . . . 0 WP 0018 (6 pgs) . . . 0 WP 0019 (2 pgs) . . . 0

WP 0020 (2 pgs) . . . 0

WP 0021 (4 pgs) . . . 0

WP 0022 (4 pgs) . . . 0

Index (4 pgs) . . . 0

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TM 5-2410-241-10 i S R E T R A U Q D A E H L A U N A M L A C I N H C E T Y M R A E H T F O T N E M T R A P E D 0 1 -1 4 2 -0 1 4 2 -5 M T 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)

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any errors, or if you would like to recommend any improve-ments 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 com-ments 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.

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TM 5-2410-241-10

Figure 2. Alternate Exit. . . . 0004-3 Figure 3. Door Handles and Latches. . . . 0004-4 Figure 4. Operator Seat and Armrest. . . 0004-6 Figure 5. Seat Belt. . . . 0004-8 Figure 6. Left Joystick Steering, Parking Brake, and Transmission Controls. 0004-8 Figure 7. Right Joystick Dozer Blade Controls. . . . 0004-10 Figure 8. Winch Control Lever. . . . 0004-11 Figure 9. Ripper Control Lever. . . 0004-12 Figure 10. Horn Button, Throttle Control Switch, Arctic Heater Switch,

and Hydraulic Lockout Switch. . . 0004-13 Figure 11. Service Brake Control and Decelerator Pedal. . . . 0004-14 Figure 12. Cab Dome Lamp Switch. . . . 0004-15 Figure 13. Mirror. . . . 0004-16 Figure 14. Incline Meter. . . . 0004-16 Figure 15. Light Switches and Heater/Air Conditioning Controls. . . . 0004-17 Figure 16. Window Wiper and Washer Controls. . . . 0004-18 Figure 17. Gauges. . . . 0004-19 Figure 18. Status Indicators – Upper Panel. . . . 0004-20 Figure 19. Alert Indicators, Digital Display Window, and Action Lamp –

Upper Panel. . . . 0004-21 Figure 20. Alert Indicators, Digital Display Window, and Operator Switch –

Lower Panel. . . . 0004-22 Figure 21. Auto Kickdown Switch, Auto Shift Switch, and

Engine Start Switch. . . . 0004-23 Figure 22. Auxiliary Action Lamp. . . . 0004-24 Figure 23. Messenger Display. . . . 0004-25 Figure 24. Engine Compartment Doors. . . . 0004-26 Figure 25. 24V NATO Slave Receptacle, Engine Compartment

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TABLE OF CONTENTS - CONTINUED

-Page No.

-Lamp and Switch. . . . 0004-27 Figure 26. Battery Disconnect Switch. . . . 0004-28

Operation Under Usual Conditions . . . WP 0005 Figure 1. Gauges and Digital Display Windows. . . 0005-4

Figure 2. Engine Coolant Temperature Gauge. . . . 0005-5 Figure 3. Upshift and Downshift Buttons. . . . 0005-9 Figure 4. Autoshift Button and Bi-Directional Shift Indicators. . . . 0005-10 Figure 5. Auto Kickdown Button and Indicators. . . . 0005-11 Figure 6. Lower Digital Display Window. . . . 0005-14 Figure 7. Messenger Display. . . . 0005-15 Figure 8. Messenger Display. . . . 0005-16

Operation Under Unusual Conditions . . . WP 0006 Figure 1. Slave Receptacle. . . . 0006-2

Figure 2. Front Towing Eye. . . . 0006-10 Figure 3. Rear Towing Eyes. . . . 0006-10 Figure 4. Battery Disconnect Switch. . . . 0006-11

Stowage and Decal/Data Plate Guide. . . WP 0007 Figure 1. BII Tool Bag. . . . 0007-1

Figure 2. Warning and Message Labels. . . . 0007-2 Figure 3. Warning and Message Labels – Continued. . . . 0007-4 Figure 4. Warning and Message Labels – Continued. . . . 0007-6 Figure 5. Stencils. . . . 0007-8 Figure 6. Stencils - Continued. . . . 0007-9 Figure 7. Data Plates. . . . 0007-10 Figure 8. Data Plates - Continued. . . . 0007-12 Figure 9. Data Plates - Continued. . . . 0007-13 Figure 10. Unique Identification Labels. . . . 0007-13 Figure 11. Unique Identification Labels. . . . 0007-14 Figure 12. 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. Preventive Maintenance Checks and Services (PMCS) .. . . 0012-2

Figure 1. Dozer Blade and Lift Cylinder. . . . 0012-3 Figure 2. Coolant Level Sight Gauge and Radiator Pressure Cap and

Access Door. . . . 0012-5 Figure 3. Engine Oil Level Check. . . . 0012-6 Figure 4. Ether Cylinder. . . . 0012-7 Figure 5. Arctic Heater. . . . 0012-8 Figure 6. Engine Air Precleaner. . . 0012-9

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TABLE OF CONTENTS - CONTINUED

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Figure 7. Washer Fluid Tank and Fuel Filler Cap. . . . .0012-10 Figure 8. Machine Rear View. . . .0012-11 Figure 9. Tow Pin. . . . .0012-12 Figure 10. Hydraulic Tank Sight Gauge and Filler Cap. . . . .0012-14 Figure 11. Transmission Oil Level Gauge, Filler Tube, and Cap. . . . .0012-16 Figure 12. Dozer Blade and Lift Cylinder. . . . .0012-20 Figure 13. Coolant Level Check and Radiator Pressure Cap and

Access Door. . . . .0012-22 Figure 14. Ether Cylinder. . . . .0012-24 Figure 15. Primary Fuel Filter/Water Separator. . . . .0012-25 Figure 16. Engine Air Precleaner. . . . .0012-26 Figure 17. Cab Fresh Air Filter. . . .0012-27 Figure 18. Cab Recirculation Filter. . . .0012-29 Figure 19. Batteries. . . . .0012-32 Figure 20. Washer Fluid Tank. . . . .0012-33 Figure 21. Machine Rear View. . . .0012-34 Figure 22. Winch Oil Level Check and Fill Plugs. . . . .0012-35 Figure 23. Tow Pin. . . . .0012-36 Figure 24. Hydraulic Tank Sight Gauge and Filler Cap. . . . .0012-37 Figure 25. Transmission Oil Level Gauge, Filler Tube, and Cap. . . . .0012-39 Figure 26. Pivot Shaft Oil Level Check. . . . .0012-41 Figure 27. Track Pin and Bushing Inspection. . . . .0012-42 Figure 28. Engine Drive Belt Inspection. . . .0012-43 Figure 29. Fuel Tank Water and Sediment Drain Valve and Hose. . . . .0012-45 Figure 30. Fuel Tank Filler Cap and Screen. . . . .0012-46 Figure 31. 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. Engine Air Filter Assembly Cover. . . . .0014-2

Figure 2. Primary Air Filter Element. . . . .0014-2 Figure 3. Secondary Air Filter Element. . . . .0014-3 Figure 4. Secondary Air Filter Element. . . . .0014-4 Figure 5. Primary Air Filter Element. . . . .0014-4 Figure 6. Engine Air Filter Assembly Cover. . . . .0014-5

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

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

Flood Lamp Bulb Replacement . . . WP 0016 Figure 1. Flood Lamp Removal. . . . .0016-1

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

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TABLE OF CONTENTS - CONTINUED

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

Fuse And Circuit Breaker Maintenance . . . WP 0018 Figure 1. Fuse Panel Access. . . . .0018-1

Figure 2. Fuse Chart. . . . .0018-2 Table 1. Fuse Identification Key.. . . .0018-3 Figure 3. Fuse and Circuit Breaker Panel. . . . .0018-4 Figure 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. Basic Issue Items (BII). . . .0021-2 Table 1. Basic Issue Items (BII) – Continued.. . . .0021-3 Table 1. 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

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vi

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 Support-ing 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 mate-rial. 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 Occu-pational 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.

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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

man-ual. 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 Ref-erences 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.

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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT

DESCRIPTION, AND THEORY OF OPERATION

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TM 5-2410-241-10 0001-1 0001 OPERATOR MAINTENANCE -0 -0 -0 1GENERAL 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 Com-mand. 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 0001

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6.

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0001-2

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 defi-ciencies 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 0001

Storage Site 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, mainte-nance, 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.

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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.

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TM 5-2410-241-10 0001

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.

Procedures for Common Components and Miscellaneous Items 0001

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.

Table 1. Exercise Schedule. 0001

Weeks 2 4 6 8 10 12 14 16 18 20 22 24

Scheduled Services X

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TM 5-2410-241-10 0001

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.

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0001-6

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.

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LIST OF ABBREVIATIONS/ACRONYMS 0001

NOTE

Refer to ASME Y14.38-2007, Abbreviations and Acronyms, for standard abbreviations.

ABBREVIATION/ACRONYM DEFINITION

A. . . Ampere AAR . . . Association of American Railroads 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

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0001-8

0001 LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED

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

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TM 5-2410-241-10 0001

LIST OF ABBREVIATIONS/ACRONYMS – CONTINUED

V. . . Volt WCA. . . Warranty Claim Action WP . . . .Work Package

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0002-1

0002

OPERATOR MAINTENANCE

-0 -0 -0 2EQUIPMENT 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 attach-ment 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.

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0002-2

0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 0002

Figure 1. D7R Dozer (Left Side). 0002

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

Compart-ment

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.

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TM 5-2410-241-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 2. D7R Dozer (Left Side) – Continued. 0002

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.

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TM 5-2410-241-10

0002-4

0002 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 3. D7R Dozer (Right Side). 0002

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.

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TM 5-2410-241-10 0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

Figure 4. D7R Dozer (Right Side) – Continued. 0002

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.

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0002-6

0002

EQUIPMENT DATA 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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TM 5-2410-241-10 0002

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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TM 5-2410-241-10 0002-8 0002 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)

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TM 5-2410-241-10 0003-1 0003 INTRODUCTORY INFORMATION -0 -0 -0 3THEORY OF OPERATION INTRODUCTION 0003

The D7R Series II Dozer consists of the following functional systems: engine, powertrain, brakes, electrical, steer-ing, and hydraulics.

This work package explains how the systems and components of the machine work together. A functional descrip-tion 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, six-cylinder, 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 all-weather 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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0003-2

TM 5-2410-241-10 0003

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.

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TM 5-2410-241-10 0003

ENGINE – CONTINUED

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0003-4

0003

POWERTRAIN 0003

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.

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0003-5

0003

BRAKE SYSTEMS 0003

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, pro-viding 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.

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TM 5-2410-241-10 0003

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. 0003

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CHAPTER 2 OPERATOR INSTRUCTIONS

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0004-1

0004

OPERATOR MAINTENANCE

-0 -0 -0 4DESCRIPTION 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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0004-2

0004

GENERAL 0004

Do not attempt to operate the D7R Dozer until becoming familiar with the location and use of all controls and indi-cators. This work package describes all operator controls and indiindi-cators.

Main Entry and Exit 0004

Figure 1. Main Entry and Exit. 0004

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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TM 5-2410-241-10 0004

GENERAL – CONTINUED

Alternate Exit 0004

Figure 2. Alternate Exit. 0004

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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TM 5-2410-241-10 0004

OPERATOR CONTROLS AND INDICATORS 0004

Door Handles and Latches 0004

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0004-5

TM 5-2410-241-10 0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED

Door Handles and Latches – Continued 0004

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.

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TM 5-2410-241-10

0004-6

0004 OPERATOR CONTROLS AND INDICATORS – CONTINUED

Operator Seat and Armrest 0004

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0004-7

TM 5-2410-241-10 0004

OPERATOR CONTROLS AND INDICATORS – CONTINUED

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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TM 5-2410-241-10

0004-8

0004 OPERATOR CONTROLS AND INDICATORS – CONTINUED

Seat Belt 0004

Figure 5. Seat Belt. 0004

Left Joystick Steering, Parking Brake, and Transmission Controls. 0004

Figure 6. Left Joystick Steering, Parking Brake, and Transmission Controls. 0004