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TM 5-2410-233-10 - Liberated Manuals

1. FM 31 70 Chemical and Biological Contamination Avoidance FM 3 3 Desert Operations FM 90 3 First Aid FM 4 25 11 NBC Decontamination FM 3 5 Northern Operations FM 31 71 Nuclear Contamination Avoidance FM 3 3 1 Operations and Maintenance of Ordnance Materiel in Cold Weather FM 9 207 Recovery and Battlefield Damage Assessment and Repair
2. 0013 00 2 Theory of Operation 0003 00 3 H High Altitude Operation 0006 00 5 I Initial Adjustments and Daily Checks 0005 00 1 L List Abbreviations 0001 00 2 Additional Authorization List AAL 0018 00 1 Basic Issue Items BII 0017 00 1 Components of End Item COEI 0017 00 1 Expendable and Durable Items 0019 00 1 Nomenclature Cross Reference 0001 00 2 Location and Description of Major Components
3. 0010 00 4 ELECTRICAL SYSTEM Alternator Output Low Unsteady or Not Charging 0010 00 3 ENGINE Engine Fails to Crank When Switch is Turned to Start 0010 00 1 Engine Fails to Start When Engine Cranks 0010 00 1 Engine Hard to Start or Stalls Frequently 0010 00 1 Engine Overheats 0010 00 2 Engine Runs Erratically and Vibrates 0010 00 2 Low Engine Power 0010 00 2 TRANSMISSION Tractor Will Not Move 0010 00 3 WINCH Winch Fails
4. 121 in 3 10 m Weights With Fuel and Lubricants With Winch and Dozer 49 400 lb 22 428 kg With Ripper and Dozer 54 220 lb 24 220 kg Capacities Engine Crankcase With Filter 29 qt 27 4 l Transmission Bevel Gear and Steering Clutch Compartments 148 qt 140 l Fuel Tank 115 gal 435 3 l Radiator 48 qt 45 4 l Final Drive Each 36 qt 34 1 l Hydraulic System 112 qt 106 0 l Hydraulic Tank
5. mechanically operated clutches dual brake pedals Brakes band type Electrical System System Voltage 24 volts Batteries Quantity 2 Voltage 12 volts each CCA 1200 Starter Rating 24 volts Alternator Rating 24 volts 50 amp Winch Manufacturer Hyster Weight 3 080 lb 1 398 kg Power Source
6. 0006 00 3 In Extreme Heat 0006 00 4 In Sandy or Dusty Conditions 0006 00 5 TM 5 2410 233 10 Index 3 INDEX Continued Subject Work Package Page O Continued Operate Continued Portable Fire Extinguisher 0005 00 15 Ripper 0005 00 13 Scarifier 0005 00 10 Tractor 0005 00 4 Winch 0005 00 11 Ozone Depleting Substances 0001 00 2 P Power Train Theory of Operation
7. 0016 00 1 WP 0017 00 Components of End Item COEI and Basic Issue Items BII Lists 0017 00 1 WP 0018 00 Additional Authorization List AAL 0018 00 1 WP 0019 00 Expendable and Durable Items List 0019 00 1 WP 0020 00 Warranty Information 0020 00 1 Index Index 1 TM 5 2410 233 10 iii HOW TO USE THIS MANUAL NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need notify your supervisor INTRODUCTION 1 A Service Life Extension Program SLEP has been implemented on selected D7F Tractors 2 The major differences for the operator between a non SLEP and SLEP tractor are as follows a A non SLEP tractor is equipped with either a model D333 or early model 3306 engine These engines use glow plugs for cold weather starting In addition there is no oil sampling valve for engine oil sampling b A SLEP tractor is equipped with a later model 3306 engine with an ether starting aid system and an engine oil sampling valve Some SLEP tractors may be equipped with a transmission oil
8. 0002 00 1 Data 0002 00 7 Equipment Improvement Recommendation EIRs Reporting 0001 00 1 Evacuation and Recovery Tractor 0006 00 2 Expendable and Durable Items List 0019 00 1 Extreme Cold Operate in 0006 00 3 Extreme Heat Operate in 0006 00 4 TM 5 2410 233 10 Index 2 INDEX Continued Subject Work Package Page F Fire Extinguisher Operation 0005 00 15 Fording 0006 00 5 Fuel System Priming 0013 00 3 Refueling
9. hydraulic pump on engine auxiliary drive Drum Size Barrel Diameter 12 in 30 5 cm Flange Diameter 22 5 in 57 2 cm Barrel Length 12 37 in 31 4 cm Wipe Rope 1 inch 200 ft 61 m long Ripper Manufacturer Caterpillar Inc Weight 7 515 lb 3 412 kg Number of Shanks 3 END OF WORK PACKAGE TM 5 2410 233 10 0003 00 1 THEORY OF OPERATION 0003 00 INTRODUCTION This work package explains how components of the D7F Tractor work together A functional description of equipment operation is given for the power train engine lubrication system fuel system engine cooling system steering and brake sys tem electrical s
10. turbocharged 4 stroke cycle Horsepower 208 2 000 RPM Engine RPM 2 100 high idle 670 low idle Cylinders 6 Fuel System Model D333 and Early Model 3306 precombustion chambers glow plugs Later Model 3306 direct injection TM 5 2410 233 10 0002 00 8 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA CONTINUED Transmission Manufacturer Caterpillar Inc Type powershift manual Range Selection neutral N 3 speeds forward and 3 speeds reverse Steering and Brake System Steering Type
11. 0006 00 1 Troubleshooting Instructions 0008 00 1 Procedures 0010 00 1 Symptom Index 0009 00 1 W Warranty Information 0020 00 1 Winch Hydraulic System Theory of Operation 0003 00 6 Winch Operation 0005 00 11 By Order of the Secretary of the Army PETER J SCHOOMAKER General United States Army Chief of Staff Official DISTRIBUTION To be distributed in accordance with the initial distribution requirements for IDN 251930 require ments for TM 5 2410 233 10 0435101 TM 5 2410 233 10 15 March 2005 0017 00 2 Part number supplied for item 2 is incorrect 1 July 2005 Operator s Manual for Tractor Full Tracked Low Speed DED Medium Drawbar Pull D7F TM 5 2410 233 10 15 March 2005 Operator s Manual for Tractor Full Track
12. Basic Issue Items C Centigrade or Celsius TM 5 2410 233 10 0001 00 3 GENERAL INFORMATION CONTINUED 0001 00 LIST OF ABBREVIATIONS CONTINUED ABBREVIATION DEFINITION CCA Cold Cranking Amps cm Centimeter COEI Components of End Item F Fahrenheit GVWR Gross Vehicle Weight Rating IAW In Accordance With
13. FM 9 43 2 Rigging Techniques Procedures and Applications FM 5 125 TECHNICAL MANUALS Operator s Unit Direct Support and General Support Maintenance Manual for Lead Acid Storage Batteries TM 9 6140 200 14 Procedures for Destruction of Equipment to Prevent Enemy Use Mobility Equipment Command TM 750 244 3 OTHER PUBLICATIONS Abbreviations and Acronyms ASME Y14 38 1999 Army Medical Department Expendable Durable Items CTA 8 100 Expendable Durable Items Except Medical Class V Repair Parts and Heraldic Items CTA 50 970 END OF WORK PACKAGE TM 5 2410 233 10 0016 00 2 This Page Intentionally Left Blank TM 5 2410 233 10 0017 00 1 COMPONENTS OF END ITEM COEI AND BASIC ISSUE ITEMS BII LISTS 0017 00 SCOPE This work package lists COEI and BII for the D7F Tractor to help you inventory items required for safe and efficient operation GENERAL The COEI and BII information is divided into the following lists 1 Table 1 Compo
14. 88 qt 83 2 l Winch 38 qt 36 0 l Speeds Forward 1st 0 2 2 mph 0 3 5 kph 2nd 0 3 9 mph 0 6 3 kph 3rd 0 5 9 mph 0 9 5 kph Reverse 1st 0 2 7 mph 0 4 3 kph 2nd 0 4 7 mph 0 7 6 kph 3rd 0 7 1 mph 0 11 4 kph Engine Manufacturer Caterpillar Inc Type
15. 0005 00 10 Shut Down Tractor 0005 00 14 Slave Start Tractor 0006 00 1 Start Engine 0005 00 2 Steering and Brake System Theory of Operation 0003 00 5 Storage or Shipment Preparation for 0001 00 2 Stowage Guide 0007 00 1 T Theory of Operation Cooling System Engine 0003 00 4 Electrical System 0003 00 5 Fuel System 0003 00 3 Lubrication System Engine 0003 00 2 Machine Hydra
16. 0003 00 1 Preparation for Storage or Shipment 0001 00 2 Preventive Maintenance Checks and Services PMCS Introduction 0011 00 1 Table 0012 00 1 R References 0016 00 1 Refueling 0013 00 2 Reporting Equipment Improvement Recommendations EIRs 0001 00 1 Ripper Hydraulic System Theory of Operation 0003 00 6 Ripper Operation 0005 00 13 S Sandy or Dusty Conditions Operate in 0006 00 5 Scarifier Operation
17. 33 After Belly Pans Look under tractor and check for damage to belly pans Check for loose or missing mounting bolts Belly pan is missing severely bent or loose 34 After 0 3 Hours Tracks a Inspect tracks on right side of machine for damaged shoes and missing or loose bolts Check master link for missing or loose bolts Any bolts are missing or loose b Check recoil mechanism access cover for damage and loose or missing bolt Access cover is damaged and cannot be securely closed c Check all rock guards for damage and loose or missing bolts Guard is missing or loose d Check idler and rollers for wear leaks damage and loose or missing hardware Notify your supervisor if any leaks are evident Damaged or worn idlers or rollers are evident Loose or missing hardware is noted e Inspect track pins for evidence of leaking oil Any wetness in area of track pin bushings indicates a problem Notify your supervisor ROLLERS IDLER ROCK GUARDS RECOIL MECHANISM ACCESS COVER SPROCKET SEGMENT 386 678 RIGHT SIDE IS SHOWN LEFT SIDE IS THE SAME TM 5 2410 233 10 0012 00 22 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 34 Con t WA
18. TM 5 2410 233 10 0004 00 16 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED END OF WORK PACKAGE KEY CONTROL OR INDICATOR FUNCTION 44 Blade Tilt Brace Adjusting Bar Used to adjust length of tilt brace 45 Circuit Breaker Reset Switch Press switch to reset circuit breaker that protects starting and charging circuits 386 020 45 386 695 44 TM 5 2410 233 10 0005 00 1 OPERATION UNDER USUAL CONDITIONS 0005 00 GENERAL WARNING Your hearing can be permanently damaged if you are exposed to constant high noise levels of 85 DB or greater Hearing protection is required when operating machine or when working on machine while it is operating Failure to wear hearing protection may result in hearing loss 1 This work package contains instructions for safely operating the D7F Tractor under usual conditions Unusual conditions are defined and described in WP 0006 00 2 Refer to WP 0004 00 for the location and function of all controls and indicators required for machine operation INITIAL ADJUSTMENTS AND DAILY CHECKS 1 Perform Before operation Preventive Maintenance Checks and Services PMCS WP 0012 00 WARNING Use caution and maintain three point contact at all times when mounting machine to avoid injury or death 2 Face machine to mount use grabhandles and maintain three point contact at all times 3 Occupy seat Adjust se
19. Injection Pump Housing The injection pump housing contains six fuel injection pumps which send an exact amount of fuel to the injection nozzles 7 Fuel Injection Nozzle The nozzles turn the stream of fuel into a fine spray which permits good combustion in the cylin ders There is one nozzle for each cylinder 8 Governor The governor is attached to the fuel injection pump housing It controls the amount of fuel needed by the engine to maintain a desired engine speed The governor is controlled by the governor control lever in the operator station 386 469 FUEL TANK PRIMARY FUEL FILTER PRIMING PUMP TRANSFER PUMP GOVERNOR FUEL INJECTION INJECTION SECONDARY NOZZLE PUMP HOUSING FUEL FILTER TM 5 2410 233 10 0003 00 4 THEORY OF OPERATION CONTINUED 0003 00 ENGINE COOLING SYSTEM 1 Radiator The radiator has a filler cap which permits adding coolant to the system Coolant circulates through the radiator to be cooled after leaving the cylinder block 2 Water Pump The water pump draws coolant from the radiator and sends it through the engine oil cooler and then through the transmission oil cooler From the transmission oil cooler coolant enters the cylinder block to cool the engine and then returns to the radiator 3 Engine Oil Cooler Coolant passes through water passages and cools the oil going through the oil passages of the cooler 4 Transmission Oil Cooler Coolant passes through the wat
20. Sq Inches Sq Centimeters 6 451 Sq Feet Sq Meters 0 093 Sq Yards Sq Meters 0 836 Sq Miles Sq Kilometers 2 590 Acres Sq Hectometers 0 405 Cubic Feet Cubic Meters 0 028 Cubic Yards Cubic Meters 0 765 Fluid Ounces Milliliters 29 573 Pints Liters 0 473 Quarts Liters 0 946 Gallons Liters 3 785 Ounces Grams 28 349 Pounds Kilograms 0 454 Short Tons Metric Tons 0 907 Pound Feet Newton Meters 1 356 Pounds per Sq Inch Kilopascals 6 895 Miles per Gallon Kilometers per Liter 0 425 Miles per Hour Kilometers per Hour 1 609 To Change To Multiply By Centimeters Inches 0 394 Meters Feet 3 280 Meters Yards 1 094 Kilometers Miles 0 621 Sq Centimeters Sq Inches 0 155 Sq Meters Sq Feet 10 764 Sq Meters Sq Yards 1 196 Sq Kilometers Sq Miles 0 386 Sq Hectometers Acres 2 471 Cubic Meters Cubic Feet 35 315 Cubic Meters Cubic Yards 1 308 Milliliters Fluid Ounces 0 034 Liters Pints 2 113 Liters Quarts 1 057 Liters Gallons 0 264 Grams Ounces 0 035 Kilograms Pounds 2 205 Metric Tons Short Tons 1 102 Newton Meters Pound Feet 0 738 Kilopascals Pounds per Sq Inch 0 145 Kilometers per Liter Miles per Gallon 2 354 Kilometers per Hour Miles per Hour 0 621 PIN 005387 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am t
21. h Shut down engine WP 0005 00 35 After Turbocharger Visually check for oil leaks at turbo charger Check for black soot between turbocharger and muffler Any oil leaks or soot are evident 36 After Exhaust System Check for evidence of leaks Ensure mounting is secure Any exhaust leaks are evident 37 After Engine Air Precleaner Check precleaner for damage Ensure precleaner is securely installed and housing is free of debris Precleaner is damaged or clogged TM 5 2410 233 10 0012 00 24 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 38 After 0 2 Hours Fuel Tank WARNING DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing damage to machine and injury or death 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 result in injury to personnel or equipment damage Ensure fire extinguisher is in fuel servicing area NOTE Use a suitable container to capture draining water or sediment Disp
22. 1 This involves working tractor within the trench formed when successive passes are made in the same slot 2 For maximum possible loads slot dozing is preferred 3 Slot dozing is used in stockpiling and high production bulldozing d Side by Side Dozing 1 Move two or more machines side by side when moving large quantities of loose material 2 Keep blades close together and machines parallel to each other e Tilt Dozer Ditching 1 Tilt blade and work with low side of blade in center of ditch 2 Level blade when required depth and slope are reached f Straight Dozer Ditching 1 Tilt blade to cut shallow V ditches 2 For larger ditches doze at right angles to center line of ditch 3 When desired depth is reached doze length of ditch to smooth sides and bottom g Straight Dozer Backfilling Push material at a 90 degree angle to fill in ditch h Push Loading Scrapers 1 Position blade cutting edge slightly above ground level 2 Use reinforced plate at center of blade to contact scraper WARNING Make gradual contact with scraper push block Ensure contact is made with a moving scraper Ensure contact is made squarely Injury to scraper operator could occur if contact is too forceful Damage to scraper tires could occur if contact is not made squarely 3 Gradually contact push block of scraper while scraper is moving Ensure contact is made squarely with scraper push block
23. 32 33 TM 5 2410 233 10 0004 00 12 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 34 Fuel Level Dipstick Indicates level of fuel in tank Markings on dipstick are FULL 1 4 1 2 and 3 4 KEY CONTROL OR INDICATOR FUNCTION 35 Fuel Tank Drain Valve and Hose Use valve to drain water and sediment from fuel tank Located on left side of fuel tank Turn valve to the left to open and to the right to close 36 Fuel Shutoff Valve Turn valve to the right to OFF position to shut off fuel supply from fuel tank to rest of fuel system Valve is normally turned left to ON 386 014 34 386 014 35 36 TM 5 2410 233 10 0004 00 13 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 37 Engine Oil Sampling Valve Used by Unit Maintenance to obtain engine oil sample 38 Engine Oil Level Dipstick Indicates level of oil in engine crankcase a With engine shut down and cold COLD CHECK level should be within cross hatched area on side of dipstick labeled SAFE STARTING RANGE WITH ENGINE STOPPED AND OIL COLD b With engine at low idle and warm HOT CHECK level should be at FULL mark on side of dipstick labeled ENGINE RUNNING AT LOW IDLE WITH OIL WARM 37 386 013 38 TM 5 2410 233 10 0004 0
24. FUEL PRESSURE GAUGE 386 128 386 044 FUEL PRIMING PUMP PLUNGER TM 5 2410 233 10 0013 00 4 This Page Intentionally Left Blank TM 5 2410 233 10 0014 00 1 AIR CLEANER SERVICE 0014 00 THIS WORK PACKAGE COVERS Service INITIAL SETUP Materials Parts Detergent Item 3 WP 0019 00 Rag wiping Item 12 WP 0019 00 Equipment Condition Engine OFF WP 0004 00 Item 12 WARNING If NBC exposure is suspected personnel wearing protective equipment should handle all air cleaner media Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures Refer to FM 3 3 Chemical and Biological Contamination Avoidance FM 3 5 NBC Decontamination FM 9 204 Nuclear Contamination Avoidance NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel Failure to follow this warning may cause injury or death SERVICE CAUTION Never service air cleaner with engine running Engine damage could result if service is performed with engine running 1 Loosen two eye bolts and remove cover from air cleaner housing EYE BOLT COVER AIR CLEANER EYE BOLT 386 296 HOUSING TM 5 2410 233 10 0014 00 2 AIR CLEANER SERVICE CONTINUED 0014 00 SERVICE CONTINUED 2 Inspect gasket on inside of cover If damaged notify Unit Maintenance 3 Remove primary filter element from air cleaner housing 4 Thoro
25. PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE FRONT AND LEFT SIDE 1 Before Overall View a Check on ground under tractor for evidence of fluid leakage such as oil coolant or fuel Class III leaks are evident b Check tractor for obvious damage that would impair operation Damage that would impair operation is evident c Check for evidence of fluid leakage at tractor belly pans Class III leaks are evident 2 Before Lift Cylinders Tilt Cylinder and Lines and Fittings a Check lift cylinders on both sides at front of machine for leakage Also check tilt cylinder on left side of machine Class III leaks are evident b Check exposed tilt cylinder and lift cylinder lines for leaks Class III leaks are evident CHECK FOR LEAKS AT BELLY PANS 386 712 CHECK FOR LEAKS AT BELLY PANS TM 5 2410 233 10 0012 00 3 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 3 Before Ether Starting Aid System 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 fume
26. kg Kilogram km Kilometer kPa Kilopascal kph Kilometers per Hour L Liter mm Millimeter PMCS Preventive Maintenance Checks and Services ROPS Rollover Protec
27. or is not corrected by the listed corrective actions notify your supervisor 6 When troubleshooting a malfunction a Locate the symptom or symptoms in WP 0009 00 that best describe the malfunction b Turn to the page in WP 0010 00 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 DO NOT perform any maintenance task unless the troubleshooting procedure tells you to do so EXPLANATION OF COLUMNS The columns in Table 1 in WP 0010 00 are defined as follows 1 MALFUNCTION A visual or operational indication that something is wrong with the equipment 2 TEST OR INSPECTION A procedure to isolate the problem in a system or component 3 CORRECTIVE ACTION A procedure to correct the problem END OF WORK PACKAGE TM 5 2410 233 10 0008 00 2 This Page Intentionally Left Blank TM 5 2410 233 10 0009 00 1 TROUBLESHOOTING SYMPTOM INDEX 0009 00 Malfunction Symptom Troubleshooting Procedure Page EARTHMOVING EQUIPMENT COMPONENTS Bulldozer Blade Fails to Raise or Lower 0010 00 4 Ripper Fails to Raise or Lower
28. 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED KEY COMPONENT DESCRIPTION 18 Winch Driven by winch hydraulic pump mounted on engine auxiliary drive Controls operated from operator seat 19 Drawbar Pin Used for towing compaction equipment scrapers etc KEY COMPONENT DESCRIPTION 20 Ripper Rear mounted implement with three shanks used to loosen soil or rip through hard compacted surfaces Ripper controls are operated from operator seat 18 19 386 003 20 19 TM 5 2410 233 10 0002 00 7 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT DATA Dimensions Length With Ripper 287 in 7 29 m With Winch 232 in 5 89 m Width With Dozer Blade 133 in 3 38 m Without Dozer Blade 105 in 2 67 m Ground Clearance 14 7 in 37 34 cm Height
29. 0002 00 4 Lubrication Chart 0011 00 5 General Procedures 0011 00 3 Key 0011 00 4 M Machine Hydraulic System Theory of Operation 0003 00 6 Maintenance Forms Records and Reports 0001 00 1 Major Components Location and Description of 0002 00 4 N Nomenclature Cross Reference List 0001 00 2 O Operate At High Altitude 0006 00 5 Bulldozer Blade 0005 00 6 In Deep Mud or Salt Water 0006 00 5 In Extreme Cold
30. 7 WP 0019 00 Materials Parts Continued Rag wiping Item 12 WP 0019 00 Personnel Required Two Equipment Condition Tractor parked on level ground WP 0005 00 Page 0005 00 14 ADJUSTMENT NOTE Packed dirt should not be removed from track if packing conditions exist on the job 1 Move machine forward a distance of at least twice its length Allow machine to coast to a stop Do NOT apply brakes Shut down engine 2 Loosen bolt and open recoil mechanism access cover 3 Wipe clean relief valve BOLT ACCESS COVER RELIEF VALVE 386 831 TM 5 2410 233 10 0015 00 2 TRACK ADJUSTMENT CONTINUED 0015 00 ADJUSTMENT CONTINUED WARNING Wear eye protection and keep face clear when venting grease from relief valve during track adjustment NEVER visually inspect relief valve to see if grease is escaping Always observe track to verify it has loos ened Failure to follow this warning could cause eye injury or blindness NOTE If track tension does not release notify Unit Maintenance 4 Open relief valve and allow grease to escape and track tension to release 5 Close relief valve Clean area around fill and relief valves 6 Fill grease gun and connect to fill valve 7 Pump grease into fill valve until track idler moves forward toward front of tractor STOP pumping when track idler stops moving 8 Mark a line on track roller frame 1 2 in 13 mm from rear face of idler bearing su
31. Clean as you work and as needed Use solvent cleaning compound Item 2 WP 0019 00 on all metal surfaces Use detergent Item 3 WP 0019 00 and water when you clean rubber plastic and painted surfaces WARNING When servicing this machine performing maintenance or disposing of materials such as engine coolant hydraulic fluid lubricants battery acids or batteries and CARC paint consult your unit local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 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 a light coat of lubricating oil Item 9 WP 0019 00 Report it to your supervisor d Bolts Nuts and Screws Check bolts nuts and screws for obvious looseness missing bent or broken condition You can t try them all with a tool but look for chipped paint bare metal or rust around bolt heads If you find one is loose notify your supervisor e Welds Look for loose or chipped paint rust or gaps where parts are welded together If you find a bad weld report it to your supervisor f Electric Wires and Connectors Look for cracked or broken insulation bare wires and loose or broken connectors Reconnect loose connectors Ensur
32. WARRANTY INFORMATION CONTINUED 0020 00 END OF WORK PACKAGE TM 5 2410 233 10 0020 00 6 This Page Intentionally Left Blank TM 5 2410 233 10 Index 1 INDEX Subject Work Package Page A Abbreviations List of 0001 00 2 Additional Authorization List AAL 0018 00 1 Air Cleaner Service 0014 00 1 B Basic Issue Items BII List 0017 00 1 Bulldozer Blade Operation 0005 00 6 C Characteristics Capabilities and Features Equipment 0002 00 1 Components of End Item COEI List 0017 00 1 Controls and Indicators 0004 00 1 Corrosion Prevention and Control CPC 0001 0
33. and all implements are clean before parking machine Park in a sheltered area out of the wind Place tracks and implements on planking to keep them from freezing to the ground e If shelter is not available park tractor so it does not face into the wind Cover machine if possible to protect engine accessories and controls from ice and snow CAUTION Do NOT attempt to break tracks loose under engine power Do NOT move tractor with large frozen lumps of material in tracks Failure to follow this caution may cause damage to equipment f If tracks freeze to the ground notify Unit Maintenance OPERATE IN EXTREME HEAT CAUTION Limit engine idling time Under no condition should idling time exceed a maximum of 10 minutes Excessive idling can cause carbon buildup and damage to engine NOTE Refer to FM 90 3 Desert Operations 1 During very hot weather avoid continuous long hard pushes or pulls Allow engine to idle if it becomes overheated If engine does not cool sufficiently after a maximum of 10 minutes of idling shut down and notify Unit Maintenance 2 If water temperature gage indicates in RED zone or engine coolant temperature warning light comes on allow engine to cool down 3 5 minutes at idle Notify Unit Maintenance if engine does not cool down 3 Check cooling system air cleaner service indicator and engine oil level frequently Ensure that radiator is free of debris or foreign matter Perform necessary services
34. and notify Unit Maintenance of any unusual gage readings or problems 4 Clean and lubricate tractor more frequently than indicated in PMCS 5 Park tractor under cover or in the shade if possible TM 5 2410 233 10 0006 00 5 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN DEEP MUD OR SALTWATER NOTE To ensure all salt residue has been removed all rock guards and belly pans must be removed and all sur rounding areas thoroughly flushed with fresh water 1 Clean tractor with fresh water if available 2 Notify Unit Maintenance OPERATE IN SANDY OR DUSTY CONDITIONS NOTE Refer to FM 90 3 Desert Operations 1 Check engine coolant temperature and engine oil pressure frequently 2 Keep radiator core free of obstructions to air circulation 3 Keep engine air precleaner free of debris Maintain air cleaner filters as clean as possible Notify Unit Maintenance to ser vice air cleaner if service indicator is showing RED 4 Ensure engine and transmission oil dipstick tubes are cleaned before dipsticks are removed to check fluid levels Clean accumulations of sand and dirt from around any fluid filler location before checking or adding fluids 5 Clean spouts of fuel containers and areas around filler caps on fuel tank before adding fuel Under extremely sandy or dusty conditions filter fuel when filling tank 6 When not in use cover engine compartment and operator station to prevent ent
35. and place blade control lever in FLOAT CAUTION DO NOT turn tractor while shanks are in the ground Twisting puts strain on shanks and tips that may cause failure Inspect scarifier tips frequently for damage b Back up machine in a straight line Do NOT turn machine c Raise bulldozer blade reposition machine for another pass and repeat steps a and b 3 Scarifier Stowage WARNING Scarifier is heavy Use caution and assistance when lifting scarifier to avoid injury NOTE Each scarifier weighs 84 lb 38 kg a Raise blade and support on suitable cribbing b Remove pin and lock rod from each side of housing c With assistance support scarifier and remove pin and scarifier from working lowered position d Reposition scarifier at stowed raised position Reinstall pin e Secure with lock rod and pin on each side of housing OPERATE WINCH WARNING Follow winch operating precautions and procedures carefully Failure to follow safe operating precautions and procedures could result in injury or death or damage to equipment Wear heavy gloves when handling wire rope to protect fingers and hands from injury Do NOT use winch to pull when there are fewer than three wraps of wire rope on drum A bare drum pull can cause wire rope to break away from drum causing injury or death Stand clear of reeled out wire rope that is loaded Stand clear a distance equal to 1 1 2 times the length of reel
36. and raise blade to sufficient height to allow blade to clear ramp of trailer used to transport tractor e Move blade control lever to HOLD ATTACH SHACKLE ON EACH END OF BLADE 386 710 TM 5 2410 233 10 0006 00 3 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 TRACTOR EVACUATION AND RECOVERY CONTINUED 2 Raise Ripper to Transport Height NOTE Assistance from Unit Maintenance is required a Ensure tractor is secure against movement with transmission in neutral N safety lock lever ON and brake lock lever engaged Shut down engine b Move ripper control lever to FLOAT c Remove cotter pin retainer and pin from each ripper shank and ripper beam WARNING All personnel must stand clear when ripper is being lifted Failure to do so could result in injury or death in the event lifting device slips or fails d Use any suitable lifting device lift truck crane winch etc to raise ripper beam to sufficient height to allow shanks to be removed e Move ripper control lever to HOLD f Remove ripper shanks clear of beam g Reinstall each ripper shank in ripper beam in inverted position with pin retainer and cotter pin OPERATE IN EXTREME COLD NOTE Tractors operating in arctic conditions are equipped with a winterized cab Refer to FM 9 207 Operations and Maintenance of Ordinances Materiel in Cold Weather FM 31 70 Basic Cold Weather Manual and FM 31 71 Northern Opera
37. engine It is attached to the bottom of the engine block 2 Oil Pump The pump is located just above the oil pan in the crankcase The pump draws oil from the oil pan and sends it through the oil cooler and then through the oil filter From the filter the oil enters the cylinder block to lubricate the engine and is then returned to the oil pan From the filter oil is also sent through the turbocharger and then returned to the oil pan 3 Engine Oil Cooler Oil is sent through the oil cooler to lower its temperature 4 Engine Oil Filter The oil filter removes particles from the oil which could cause damage to the internal parts of the engine 386 114 ENGINE OIL COOLER ENGINE OIL FILTER OIL PUMP OIL PAN TM 5 2410 233 10 0003 00 3 THEORY OF OPERATION CONTINUED 0003 00 FUEL SYSTEM 1 Fuel Tank The fuel tank provides containment for the fuel A fuel strainer and the fuel level gage are contained in the filler neck of the tank 2 Priming Pump Priming pump is used to prime the fuel system 3 Primary Fuel Filter The primary fuel filter removes larger particles from the fuel before it reaches the transfer pump 4 Transfer Pump The transfer pump pulls fuel from the fuel tank through the primary fuel filter and pushes it onto the sec ondary filter and the injection pump 5 Secondary Fuel Filter The secondary fuel filter removes smaller particles from the fuel before it reaches the injection pump 6
38. 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 GENERAL LUBRICATION PROCEDURES NOTE Lubrication instructions contained in this PMCS are MANDATORY Overall view of lubrication points is located at the end of this work package Localized views are located together with specific lubrication instructions in the PMCS Table in WP 0012 00 The tractor is no longer enrolled in the Army Oil Analysis Program AOAP Refer to FM 9 207 for lubrication in arctic operation 1 Included in this PMCS are lubrication services to be performed by the operator 2 Lubrication intervals are based on normal operation Lubricate more during constant use and less during inactive periods Use correct grade of lubricant for seasonal temperature expected Refer to the KEY at the end of this work package 3 For equipment under manufacturer s warranty hardtime intervals shall be followed Shorten intervals if lubricants are known to be contaminated or if operation is under adverse conditions e g longer than usual operating hours extended idling periods extreme dust etc 4 Keep all lubricants in a closed container and store in a clean dry place away from extreme heat Keep container covers clean and do not allow dust dirt or other foreign material to mix with lubricants Keep lubrication equipment clean and ready
39. for three circuits the charging circuit the starting circuit and the lighting low amperage circuit Two 12 volt batteries are connected in series to provide 24 volt 1200 CCA starting power 2 Alternator The 24 volt 50 amp alternator an integral part of the charging circuit provides current when the engine is running 3 Starting Motor Part of the starting circuit the starting motor is used to turn the engine flywheel in order to start the engine STEERING CLUTCH LEVERS STEERING STEERING BRAKE 386 471 CONTROL VALVE CLUTCH TM 5 2410 233 10 0003 00 6 THEORY OF OPERATION CONTINUED 0003 00 ELECTRICAL SYSTEM CONTINUED 4 Circuit Breaker A switch that opens the battery circuit if the current in the electrical system exceeds the switch rating When the circuit is open no current will flow through the electrical system 5 Battery Disconnect Switch A switch that is controlled by the operator When it is in the OFF position the battery circuit will be open so that no current is flowing through the electrical system 6 NATO Slave Receptacle Used by operator or maintenance personnel to slave start tractor MACHINE HYDRAULIC SYSTEM 1 Blade Control Valve This valve is connected mechanically to the blade control lever The valve directs the flow of pres surized oil in response to the movement of the control lever The valve is located inside the hydraulic tank 2 Tilt Cylinder This cylinder is
40. for use WARNING Solvent cleaning compound MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well venti lated areas Keep away from open flames and other sources of ignition 5 Clean area around lubrication points with solvent cleaning compound Item 2 WP 0019 00 or equivalent before lubricat ing equipment Keep all external parts of equipment not requiring lubrication free of lubricants After lubrication wipe off excess lubricant to prevent accumulation of foreign matter 6 Maintain a record of lubrication performed and report any problems noted during lubrication Refer to DA Pam 738 750 for forms and procedures to record and report any findings TM 5 2410 233 10 0011 00 4 NOTE Only lubricants authorized for use by the operator are listed in this KEY KEY LUBRICANT COMPONENT REFILL CAPACITY EXPECTED TEMPERATURES INTERVALS Above 15 F Above 9 C 40 F to 15 F 4 C to 26 C 40 F to 65 F 4 C to 54 C OE HDO Lubricating Oil ICE Tactical Service MIL PRF 2104 D Daily W Weekly OEA 30 Lubricating Oil ICE Arctic MIL PRF 46167 Engine Crankcase 29 qt 27 4 l OE HDO 15 40 or OE HDO 30 See Note OE HDO 15 40 or OE HDO 10 See Note OEA 30 Transmission Bevel Gear and Steering Clutch Com partments 148 qt 140 0 l Hydrauli
41. kinks are evident d Reel in wire rope WP 0005 00 Page 0005 00 11 386 459 GAA TM 5 2410 233 10 0012 00 32 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 END OF WORK PACKAGE Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 50 Monthly Winterized Cab If Equipped a Check window latch on working window for proper operation b Check door stop and securing bolt for proper operation c Check door handles and locks for proper operation 51 Monthly Decals and Data Plates Ensure all decals and data plates are present and legible WP 0007 00 TM 5 2410 233 10 0013 00 1 REFUELING AND FUEL SYSTEM PRIMING 0013 00 THIS WORK PACKAGE COVERS Refueling Fuel System Priming INITIAL SETUP Support Equipment Extinguisher fire Item 2 WP 0017 00 Materials Parts Fuel Item 4 5 or 6 WP 0019 00 Rag wiping Item 12 WP 0019 00 Equipment Condition Engine OFF WP 0004 00 Item 12 Battery disconnect switch in OFF position WP 0004 00 Item 27 TM 5 2410 233 10 0013 00 2 REFUELING AND FUEL SYSTEM PRIMING CONTINUED 0013 00 REFUELING WARNING DO NOT smoke or permit any open flame in area of tractor while you are servicing fuel system Be sure hose nozzle is grounded agains
42. lever to middle position to HOLD tilt posi tion d When hydraulic lift and tilt cylinders have reached the limit of their stroke return blade control lever to HOLD 25 386 006 TM 5 2410 233 10 0004 00 8 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 26 Ripper Control Lever If Equipped Three position lever controls position of rear mounted ripper Positions are Pull lever all the way toward operator to the left to RAISE Center HOLD position holds ripper in position Push lever all the way away from operator to the right to LOWER 26 386 720 TM 5 2410 233 10 0004 00 9 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 27 Battery Disconnect Switch Cuts off battery power from machine electrical systems From operator seat switch is OFF with pointer at 12 o clock Turn pointer toward rear of machine 2 o clock to turn switch ON 27 386 010 TM 5 2410 233 10 0004 00 10 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 28 Winch Selector Lever If Equipped Four position lever with three detents controls winch Pull lever toward operator and ho
43. local hazardous waste disposal center or safety office for local regulatory guidance If further information is needed please contact The Army Environmental Hotline at 1 800 872 3845 WARNING HEARING PROTECTION Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of 85 DB or greater Hearing protection is required when operating machine or when working on machine while it is operating Failure to wear hearing protection may result in hearing loss WARNING HYDRAULIC SYSTEM PRESSURE Do NOT remove hydraulic tank filler cap or disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved Hydraulic system pressure can be over 2500 psi 17 237 kPa even with engine and pump OFF To relieve pressure lower all hydraulic attachments to the ground and shut down engine Move control levers through all operating positions then SLOWLY loosen hydraulic tank filler cap After maintenance tighten all connections before applying pressure Escaping hydraulic fluid under pressure can penetrate the skin causing injury or death TM 5 2410 233 10 f WARNING MACHINE OPERATION Use caution and maintain three point contact at all times when mounting or dismounting machine to avoid injury or death BE ALERT for personnel in the area while operating machine Always check to ensure area is clear of personnel and obstructions before moving Failure to follow thi
44. loose d Check batteries for broken and corroded connections or frayed burned melted cables and clamps Broken and corroded connections or frayed burned melted cables and clamps are evident e Remove fill plugs and check electrolyte level in cells of both batteries Level should be 1 8 in 3 mm above tops of plates Add distilled water as needed to maintain correct level TM 5 2410 233 10 0012 00 29 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 44 Con t f Ensure batteries are clean and battery cables are secure Battery cables are not secure g Close access cover and secure with two latches 45 Weekly 0 3 Hours Track Roller Frame Inner Bearings Apply GAA grease Item 7 WP 0019 00 to two track roller frame inner bearings under rear of machine 386 082 CABLES HOLD DOWN ACCESS COVER WINGNUT CLAMP FILL PLUGS 386 069 GAA GAA TM 5 2410 233 10 0012 00 30 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF
45. three forward and three reverse speeds and a transmission safety lock c operator station with adjustable seat and seat belt d ROPS canopy e clutch operated steering brakes with dual brake pedals and a brake lock lever that serves as a parking brake f 24 volt electrical system with NATO slave receptacle g front mounted Semi U SU bulldozer blade h either rear mounted ripper or rear mounted reversible winch and i a winterized cab installed on tractors operating in arctic conditions 5 Tractors procured from 1971 1984 that have not gone through the Service Life Extension Program SLEP have the fol lowing features NOTE If a non SLEP tractor has had its original engine replaced it may be equipped with a later model 3306 engine a engine model D333 or early model 3306 with precombustion chambers b glow plugs for cold weather starting and c old style two prong NATO slave receptacle TM 5 2410 233 10 0002 00 2 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES CONTINUED 6 SLEP tractors have the following features a later model 3306 engine b direct injection fuel system c ether starting aid system d engine oil sampling valve e selected tractors may have a transmission oil sampling valve f backup alarm g new style single prong NATO slave receptacle and h rear protective screen on ROPS 7 To
46. to Operate or Operates Slowly 0010 00 3 END OF WORK PACKAGE TM 5 2410 233 10 0009 00 2 This Page Intentionally Left Blank TM 5 2410 233 10 0010 00 1 TROUBLESHOOTING PROCEDURES 0010 00 Table 1 Troubleshooting Procedures MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ENGINE 1 Engine Fails to Crank When Switch is Turned to Start 1 Check battery disconnect switch for ON position Turn battery disconnect switch ON 2 Check circuit breaker reset button on dash panel Push circuit breaker reset button on dash panel 3 Check circuit breaker reset button on left side of engine firewall Push circuit breaker reset button on left side of engine firewall 4 Check to see if electrolyte level in batteries is over plates WP 0012 00 Item 44 If electrolyte level is below top of plates add distilled water until level is 3 8 in 9 5 mm above tops of plates Notify Unit Maintenance to recharge batteries 5 Inspect for loose corroded or broken battery cables or terminals Notify Unit Maintenance 2 Engine Fails to Start When Engine Cranks 1 Check governor control lever for correct starting position WP 0004 00 Item 7 Move lever to correct starting position 2 Check for empty fuel tank Fill tank if empty or low WP 0013 00 3 Ensure fuel shutoff valve is all th
47. 0 Item 13 Fill tank to correct level with proper grade of oil WP 0011 00 and WP 0012 00 Item 13 11 Ripper Fails to Raise or Lower 1 Check that ripper control lever moves freely in all directions 1 If lever does not move freely notify Unit Maintenance 2 If lever is OK go to Step 2 2 Check oil level in hydraulic tank WP 0012 00 Item 13 Fill tank to correct level with proper grade of oil WP 0011 00 and WP 0012 00 Item 13 TM 5 2410 233 10 CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS TM 5 2410 233 10 This Page Intentionally Left Blank TM 5 2410 233 10 0011 00 1 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION 0011 00 GENERAL 1 To ensure that the D7F Tractor 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 00 contains systematic instructions on inspections lubrications services adjustments and corrections to be performed by the operator to keep your equipment in good operating condition and ready for its primary mission EXPLANATION OF TABLE ENTRIES 1 Item Number 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 indicat ing a fault Item numbers also appea
48. 0 14 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 39 Transmission Oil Level Dipstick Accessible under seat Indicates level of oil in transmission With engine at low idle and transmission in neutral N and warm level should be at FULL mark on dipstick For cold check level must be above ADD mark on dipstick KEY CONTROL OR INDICATOR FUNCTION 40 Hydraulic Tank Oil Level Dipstick Indicates level of oil in hydraulic tank With all machine implements fully lowered level of oil should be at FULL mark on dipstick Add oil if level falls below ADD mark on dipstick 386 016 39 386 012 40 TM 5 2410 233 10 0004 00 15 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 41 Seat Back Adjustment Lever Two position lever adjusts height of seat back To raise seat back height place lever in downward horizontal position To lower seat back height pull lever up to vertical position 42 Seat Release Lever Pull out on lever to tip seat forward for access to transmission and other components under seat 43 Seat Adjustment Lever Two position lever To adjust seat pull up on lever and move seat forward and up or rearward and down Push down on lever to lock seat in desired position 386 023 43 42 41
49. 0 2 D Data Plates 0007 00 3 Data Equipment 0002 00 7 Decals 0007 00 2 Deep Mud or Salt Water Operate in 0006 00 5 Description and Use of Operator s Controls and Indicators 0004 00 1 Destruction of Army Materiel to Prevent Enemy Use 0001 00 2 E Electrical System Theory of Operation 0003 00 5 Engine Cooling System Theory of Operation 0003 00 4 Lubrication System Theory of Operation 0003 00 2 Start 0005 00 2 Equipment Characteristics Capabilities and Features
50. 0 3 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0019 00 Table 1 Expendable and Durable Items List Continued END OF WORK PACKAGE 1 ITEM NUMBER 2 LEVEL 3 NATIONAL STOCK NUMBER 4 DESCRIPTION CAGEC AND PART NUMBER 5 U M 8 C OIL Lubricating OEA 30 Arctic 9150 00 402 4478 81349 MIL L 46167 1 Quart Can QT 9150 00 402 2372 81349 MIL PRF 46167 5 Gallon Can GAL 9150 00 491 7197 81349 MIL PRF 46167 55 Gallon Drum GAL 9 C OIL Lubricating OE HDO 10 81349 M2104 1 10W 9150 00 189 6727 9150 00 186 6668 9150 00 191 2772 1 Quart Can 5 Gallon Can 55 Gallon Drum QT GAL GAL 10 C OIL Lubricating OE HDO 15 40 81349 M2104 4 15W40 9150 01 152 4117 9150 01 152 4118 9150 01 152 4119 1 Quart Can 5 Gallon Can 55 Gallon Drum QT GAL GAL 11 C OIL Lubricating OE HDO 30 81349 M2104 1 30W 9150 00 186 6681 1 Quart Can QT 9150 00 188 9858 5 Gallon Can GAL 12 C RAG Wiping 64067 M2104 1 3W 7920 00 205 1711 7290 00 205 1711 50 Pound Bale LB TM 5 2410 233 10 0019 00 4 This Page Intentionally Left Blank TM 5 2410 233 10 0020 00 1 WARRANTY INFORMATION 0020 00 TM 5 2410 233 10 0020 00 2 WARRANTY INFORMATION CONTINUED 0020 00 TM 5 2410 233 10 0020 00 3 WARRANTY INFORMATION CONTINUED 0020 00 TM 5 2410 233 10 0020 00 4 WARRANTY INFORMATION CONTINUED 0020 00 TM 5 2410 233 10 0020 00 5
51. 01 00 1 WP 0002 00 Equipment Description and Data 0002 00 1 WP 0003 00 Theory of Operation 0003 00 1 CHAPTER 2 OPERATING INSTRUCTIONS WP 0004 00 Description and Use of Operator s Controls and Indicators 0004 00 1 WP 0005 00 Operation Under Usual Conditions 0005 00 1 WP 0006 00 Operation Under Unusual Conditions 0006 00 1 WP 0007 00 Stowage Decal and Data Plate Guide 0007 00 1 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication If you find any mistakes or if you know of a way to improve the pro cedures please let us know Submit your DA Form 2028 Recommended Changes to Equipment Technical Publications through the Internet on the Army Electronic Product Support AEPS website The Internet address is http aeps ria army mil If you need a password scroll down and click on ACCESS REQUEST FORM The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS Fill out the form and click on SUBMIT Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 progr
52. 07 00 1 STOWAGE DECAL AND DATA PLATE GUIDE 0007 00 INTRODUCTION 1 This work package shows the location for stowage of equipment and material required to be carried on the D7F Tractor 2 This work package also includes illustrations showing the location of all decals and data plates on the machine 3 There may be instances when a data plate on your machine is not located where indicated in this work package STOWAGE GUIDE NOTE Items listed in Table 1 below are illustrated in WP 0017 00 Components of End Item COEI and Basic Issue Items Lists Table 1 Stowage Guide ITEM NOMENCLATURE QTY STOWAGE LOCATION 1 Case Maintenance and Operational Manuals 1 Inside operator station behind seat 2 Extinguisher Fire 1 Mounted to bracket inside operator station 3 Key Socket Head Screw 1 Inside toolbox 4 Lubricating Gun Hand 1 Inside toolbox 5 Wrench Adjustable 1 Inside toolbox TM 5 2410 233 10 0007 00 2 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DECALS 386 062 386 709 TRACTOR WITH WINCH TM 5 2410 233 10 0007 00 3 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES 386 057 386 721 TRACTOR WITH RIPPER TM 5 2410 233 10 0007 00 4 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES CONTINUED 386 058 TM 5 2410 233 10 0007 00 5 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES CONT
53. 4 Engine OFF WP 0005 00 Page 0005 00 14 Blade lowered to ground WP 0005 00 Page 0005 00 14 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE NOTE Review all WARNINGs CAUTIONs and NOTEs before performing Operator PMCS on the D7F Tractor Perform all weekly and before operation PMCS checks if a You are the assigned operator but have not operated the tractor since the last weekly checks b You are operating the tractor for the first time Unless otherwise indicated perform all lubrication and preventive maintenance with tractor parked on level ground transmission in N Neutral with transmission lock lever in locked position brake lock lever engaged implements lowered to the ground and engine shut down After one week of initial operation of a SLEP D7F Tractor notify Unit Maintenance to replace transmission bevel gear and steering clutch oil filter element and clean magnetic strainer After one month of initial operation of a SLEP D7F Tractor notify Unit Maintenance to check level of oil in final drives TM 5 2410 233 10 0012 00 2 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor ITEM NO INTERVAL MAN HOURS LOCATION
54. 4 Do NOT lift scraper off ground 5 When scraper cut is complete upshift tractor to help scraper accelerate out of cut area i Large Tree Removal WARNING When removing trees precautions must be taken to avoid injury and damage to equipment Machines should never work close together as one may push a tree over on the other Do NOT follow too closely when a tree starts to fall as rootball may catch under front of tractor which will then require assistance to back off Bottom of tractor may be damaged Be alert for any dead limbs that could fall while tree is being removed 1 Use bulldozer to cut roots of tree on side opposite direction of fall 2 Cut roots on sides parallel to direction of fall TM 5 2410 233 10 0005 00 9 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE BULLDOZER BLADE CONTINUED WARNING Do not allow machine to straddle tree trunk while tree is falling Back away immediately when tree starts to fall to avoid injury or damage to tractor 3 Ease into tree Push in direction of fall with blade high Build earth ramp if higher contact is needed j Large Brush and Medium Size Tree Removal 1 Make contact with tree 12 16 in 30 5 40 6 cm above ground 2 Move forward while lifting blade k Brush Clearing 1 Lower blade a few inches into the ground and move forward 2 Lift blade when brush is out to loosen earth from roots l Stump Removal 1
55. AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 12 Heat Start Switch Three position spring loaded switch is used to start engine and energize ether starting aid system or glow plugs if equipped Positions are START HEAT START on data plate OFF and HEAT a To start engine depress and turn switch to START Release switch when engine starts b If temperatures are below 32 F 0 C depress and turn switch to START while at the same time depressing ether starting aid switch for 2 3 seconds Release switch when engine starts c If temperatures are below 60 F 16 C for older engines with glow plugs depress and turn switch to HEAT After appropriate time interval WP 0005 00 Start Engine turn switch to START to start engine Release switch when engine starts 13 Front Flood Lights Switch Toggle switch controls front flood lights Flip switch right to ON left to OFF 14 Rear Flood Lights Switch Toggle switch controls rear flood lights Flip switch right to ON left to OFF 386 007 12 13 14 15 16 17 18 19 TM 5 2410 233 10 0004 00 5 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 15 Engine Coolant Temperature Warning Light Illuminates to warn operator that coolant temperature in engine is too high 16 Circuit
56. APABLE IF ITEM TO CHECK SERVICE 20 During Overall Machine a Be alert for evidence of fluid leaks such as oil coolant or fuel Class III leaks are evident b Be alert for proper operation of steering brakes and power train components c Be alert for proper operation of implement controls FRONT AND LEFT SIDE NOTE Ensure tractor is parked on level ground with transmission in neutral N transmission safety lock lever in locked position brake lock lever engaged and implements lowered to ground Leave engine running for transmission and engine HOT oil level checks and until track inspection has been performed 21 After 0 2 Hours Transmission Oil Level Check level of oil in transmission with engine running at low idle speed and transmission warm a Tilt operator seat forward to access transmission dipstick and filler tube under seat b Wipe area clean around dipstick and oil filler tube and cap c Remove dipstick wipe clean then reinstall Remove dipstick and check level on dipstick Maintain level at FULL line on dipstick d If level is low use square key Item 3 WP 0017 00 and adjustable wrench Item 5 WP 0017 00 to remove filler cap Add lubricating oil Item 8 9 10 or 11 WP 0019 00 until level indicated on dipstick is at FULL line Refer to KEY at end of WP 0011 00 for correct grade of oil for expected temperature range TM 5 2410 233 10 0012 00 13 OPERATOR PREVENT
57. Authorization List AAL Expendable and Durable Items List and Warranty Information FEATURES OF THIS MANUAL 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 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 Refuel tractor WP 0013 00 go to WP 0013 00 in this manual for instructions on refueling 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 0016 00 for complete information 4 Illustrations are placed after and as 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 386 001 386 002 etc are art control numbers and are used for tracking purposes only 6 Dashed leader lines used
58. Breaker Reset Switch Press switch to reset circuit breaker that protects dash panel circuits 17 Air Cleaner Service Indicator Indicates air cleaner airflow is adequate if yellow band is in green zone on gage If restricted yellow band will rise to red area on gage After air cleaner is serviced press reset button at bottom of gage before resuming operation 18 Dash Lights Switch Toggle switch controls both dash panel lights one light on each side of steering clutch control lever console Flip switch right to ON left to OFF 19 Center Flood Lights Switch Toggle switch controls center flood lights Flip switch right to ON left to OFF TM 5 2410 233 10 0004 00 6 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 20 Engine Oil Pressure Gage Indicates pressure in engine oil lubrication system when engine is running Normal range at low idle is 38 58 psi 262 400 kPa Minimum allowable pressure is 20 psi 138 kPa 21 Engine Water Temperature Gage Indicates temperature of engine coolant Normal operating range is in GREEN zone on gage If gage indicates in RED zone stop engine and troubleshoot 22 Torque Converter Temperature Gage Indicates temperature of torque converter oil Normal range is indicated by GREEN zone on gage 150 250 F 66 121 C If temperature exceeds normal range reduce load on machine If nee
59. Depending on size of stump cut roots as in Large Tree Removal 2 Contact stump near ground and lift blade while pushing m Side Hill Cutting 1 Start cut downgrade if possible 2 Slope to inside of cut 3 Doze cut wide enough for bulldozers that will follow n Rock or Boulder Removal 1 Tilt blade place corner of blade under rock and work it up and down while pushing on rock 2 Disengage steering clutch on side opposite point of blade contact with rock TM 5 2410 233 10 0005 00 10 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE SCARIFIER 1 Scarifier Mounting WARNING Scarifier is heavy Use caution and assistance when lifting scarifier to avoid injury NOTE Each scarifier weighs 84 lb 38 kg Install scarifiers in balanced pairs a Raise blade and support on suitable cribbing b Remove pin and lock rod from each side of housing c With assistance support scarifier and remove pin and scarifier from stowed raised position d Reposition scarifier at working lowered position with tooth angled toward rear of machine Reinstall pin e Secure with lock rod and pin on each side of housing HOUSING LOCK ROD PIN LOCK ROD SCARIFIER SCARIFIER PIN 386 697 TM 5 2410 233 10 0005 00 11 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE SCARIFIER CONTINUED 2 Scarifier Operation a Lower bulldozer blade to the ground
60. FORMATION TM 5 2410 233 10 This Page Intentionally Left Blank TM 5 2410 233 10 0016 00 1 REFERENCES 0016 00 SCOPE 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 D7F Tractor PUBLICATION INDEXES The following indexes should be consulted frequently for 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 Functional User s Manual for the Army Maintenance Management System DA Pam 738 750 FORMS NOTE Refer to DA Pam 738 750 The Army Maintenance Management System TAMMS for instructions on the use of maintenance forms Equipment Inspection and Maintenance Worksheet DA Form 2404 DA Form 5988 E Product Quality Deficiency Report SF Form 368 Recommended Changes to Publications and Blank Forms DA Form 2028 FIELD MANUALS Basic Cold Weather Manual
61. INUED 386 060 TM 5 2410 233 10 0007 00 6 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES CONTINUED 386 061 ON HYDRAULIC CYLINDER UNDER TRACK ROLLER FRAME GUARDS ON UNDERSIDE OF ACCESS COVER TM 5 2410 233 10 0007 00 7 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES CONTINUED 386 059 386 065 TM 5 2410 233 10 0007 00 8 STOWAGE DECAL AND DATA PLATE GUIDE CONTINUED 0007 00 DATA PLATES CONTINUED END OF WORK PACKAGE 386 066 ON DASH TM 5 2410 233 10 CHAPTER 3 OPERATOR TROUBLESHOOTING TM 5 2410 233 10 This Page Intentionally Left Blank TM 5 2410 233 10 0008 00 1 TROUBLESHOOTING INSTRUCTIONS 0008 00 GENERAL 1 This chapter provides information for identifying and correcting malfunctions which may develop while operating the D7F Tractor 2 The Troubleshooting Symptom Index in WP 0009 00 lists common malfunctions which may occur and refers you to the proper page in WP 0010 00 for a troubleshooting procedure 3 If you are unsure of the location of an item mentioned in troubleshooting refer to WP 0002 00 or WP 0004 00 4 Before performing troubleshooting read and follow all safety instructions found in the Warning Summary at the front of this manual 5 The Troubleshooting Symptom Index cannot list all malfunctions that may occur nor all tests or inspections and correc tive actions If a malfunction is not listed
62. ION Gear and directional shifts at full engine speed are permissible However for maximum service life of power train components decelerating and or braking are recommended a Decrease engine speed by depressing decelerator pedal or pushing in on governor control lever b Depress both brake pedals c Make direction and gear selection with transmission selector lever d Release brake pedals e Increase engine speed by releasing decelerator pedal or pulling out on governor control lever 12 When tractor is stopped with engine running move transmission selector lever to neutral N and transmission safety lock lever to ON position This will prevent accidental engagement of transmission TM 5 2410 233 10 0005 00 6 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE BULLDOZER BLADE 1 General Information a Ensure that machine is fully warmed up before operating bulldozer blade b To raise and lower bulldozer blade operate blade control lever as follows 1 Pull lever all the way back to RAISE blade 2 Push lever all the way forward to LOWER blade 3 Center HOLD position holds blade in position 4 To allow blade to float follow surface contour without applying pressure push lever all the way forward past LOWER to detented FLOAT position CAUTION When control lever is returned to HOLD position oil stops bypassing valves thereby reducing oil heat and valve wear Be sure to retu
63. ITEM TO CHECK SERVICE 46 Weekly 0 3 Hours Track Roller Frame Outer Bearings On each side completely fill retainer cavity with GAA grease Item 7 WP 0019 00 to lubricate track roller frame outer bearings Pump grease gun until you can hear grease being expelled 47 Weekly 0 5 Hours Ripper If Equipped Apply GAA grease Item 7 WP 0019 00 to 20 ripper linkage and cylinder bearing grease fittings 10 on each side 48 Weekly 0 2 Hours Fan Drive Apply GAA grease Item 7 WP 0019 00 to fan drive grease fitting 386 070 GAA TM 5 2410 233 10 0012 00 31 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 48 Con t 49 Monthly Winch Wire Rope If Equipped WARNING When handling winch wire rope wear a pair of heavy gloves Damaged or frayed wires can injure fingers and hands a Unreel full length of wire rope WP 0005 00 Page 0005 00 11 WARNING Wear eye protection when using wire brush to protect against injury b Clean entire length of wire rope with a wire brush c Inspect entire length of wire rope for flat spots fraying kinks and signs of rusting Wire rope has any flat spot more than 1 2 the diameter of the wire rope Any frays or
64. IVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 21 Con t 22 After 0 2 Hours Engine Crankcase With engine running warm and operating at low idle check level of oil in engine crankcase a Wipe area clean around dipstick and oil filler tube and cap b Remove dipstick wipe clean then reinsert fully into dipstick tube Remove dipstick and take reading c Level must be at FULL mark on side of dipstick labeled ENGINE RUNNING AT LOW IDLE WITH OIL WARM d If required add lubricating oil Item 8 9 10 or 11 WP 0019 00 Refer to KEY at end of WP 0011 00 for correct grade of oil for expected temperature range 386 016 DIPSTICK FILLER TUBE FILLER CAP TM 5 2410 233 10 0012 00 14 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 22 Con t 1 Turn filler cap to the left and remove 2 Add oil through filler tube opening until level is at FULL mark on ENGINE RUNNING AT LOW IDLE WITH OIL WARM side of dipstick 3 Reinst
65. KS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 4 Con t c Note color of coolant Coolant should not appear rusty or brownish Notify your supervisor if coolant is rusty or brownish NOTE If unsure of coolant type in your tractor notify your supervisor Use clean water that is low in scale forming minerals Do NOT use softened water d If level of coolant is low add a 50 50 mixture of antifreeze Item 1 WP 0019 00 and clean water to bring level up to correct level e Wipe pressure cap clean with a clean rag Item 12 WP 0019 00 f Inspect radiator cap for damage to cap or cap gasket foreign material and deposits Gasket is missing or damaged g Install radiator cap 5 Before 0 2 Hours Engine Oil Level NOTE To ensure an accurate COLD CHECK reading engine must be shut down and cold a Wipe area clean around dipstick and oil filler tube b Remove dipstick wipe clean then reinsert fully into dipstick tube Remove dipstick and take reading c Level must be within cross hatched area on side of dipstick labeled SAFE STARTING RANGE WITH ENGINE STOPPED AND OIL COLD d If required add lubricating oil Item 8 9 10 or 11 WP 0019 00 Refer to KEY at end of WP 0011 00 for
66. Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 44 Weekly 0 3 Hours Batteries 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 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 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 injury or death NOTE For complete information on servicing batteries refer to TM 9 6140 200 14 a Release two latches and open battery box access cover on left side of tractor One or both batteries are missing b Inspect batteries for obvious damage such as a cracked case and electrolyte leakage Any electrolyte leakage is evident c Check battery hold down for looseness and damage If loose tighten wingnuts Hold down is damaged or
67. R MATTER IS 30 AND TOTAL NUMBER OF WORK PACKAGES IS 20 CONSISTING OF THE FOLLOWING Page WP Change No No Cover Back Blank 0 a to g h Blank 0 A B Blank 0 i to iv 0 WP 0001 00 to 0020 00 0 Index 1 to Index 4 0 Zero in this column indicates an original page or work package TM 5 2410 233 10 B This Page Intentionally Left Blank TM 5 2410 233 10 i TECHNICAL MANUAL HEADQUARTERS TM 5 2410 233 10 DEPARTMENT OF THE ARMY Washington D C 15 March 2005 OPERATOR S MANUAL FOR TRACTOR FULL TRACKED LOW SPEED DED MEDIUM DRAWBAR PULL TRACTOR WITH RIPPER NSN 2410 00 185 9794 EIC EAW TRACTOR WITH RIPPER AND WINTERIZED CAB NSN 2410 00 300 6665 TRACTOR WITH WINCH NSN 2410 00 185 9792 EIC EA6 TRACTOR WITH WINCH AND WINTERIZED CAB NSN 2410 00 300 6664 SUPERSEDURE NOTICE This manual supersedes TM 5 2410 233 10 dated 28 November 1972 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited Table of Contents Page Number Warning Summary a How To Use This Manual iii CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION WP 0001 00 General Information 00
68. RNING BE ALERT for personnel in the area while moving tractor to perform inspection While operator moves tractor an assistant must look for damage to sprocket segments Ensure assistant is clear to the side of tracks and all other personnel are clear of the area Failure to follow this warning may cause injury or death f Check sprocket segments for missing or broken segments Any sprocket segment is missing or damaged g Check track tension as follows 1 Place a straight edge on top of grousers between idler and front carrier roller 2 Measure track sag between bottom edge of straight edge and top of grouser at midpoint between idler and front carrier roller 3 If sag distance A is 1 1 2 2 in 3 8 5 1 cm track tension is OK 4 Adjust track if too tight or too loose WP 0015 00 A STRAIGHT EDGE GROUSER GROUSER IDLER FRONT CARRIER ROLLER 386 715 TM 5 2410 233 10 0012 00 23 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 34 Con t NOTE Ensure tractor is parked on level ground with transmission in neutral N transmission safety lock lever in locked position brake lock lever engaged and implements lowered to the ground
69. RVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 29 After Grabhandles Check for presence and security of grabhandle mounting at left rear of cab REAR AND RIGHT SIDE 30 After Overall View a Check on ground under tractor for evidence of transmission and final drive oil leakage Class III leaks are evident b Check tractor for obvious damage that would impair operation Damage that would impair operation is evident 31 After Ripper If Equipped a Inspect ripper teeth and shanks for cracks breaks looseness or wear Teeth are worn if a hole has developed in tip Cracks breaks looseness or holes in teeth are evident b Inspect ripper lift cylinder and lines for damage or leakage Damage that would impair operation or Class III leaks are evident c Check for pitting or rust on exposed cylinder rods Pitting or rust are evident 32 After Grabhandles Check for presence and security of grabhandle mounting at right rear of cab TRANSMISSION AND FINAL DRIVES 386 002 CHECK ON GROUND FOR OIL LEAKS GRABHANDLE GRABHANDLE TM 5 2410 233 10 0012 00 21 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE
70. S CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 25 After Lift Cylinders Tilt Cylinder and Lines and Fittings a Check lift cylinders on both sides at front of machine for damage or leakage Also check tilt cylinder on left side Class III leaks are evident or damage that would impair operation b Check exposed tilt cylinder and lift cylinder lines for leaks or for damage or wear that could cause leaks Class III leaks are evident Lines show wear or damage that could cause leaks c Check for pitting or rust on exposed cylinder rods Pitting or rust are evident 26 After Radiator Guards Check upper and lower guards for damage and loose or missing bolts Guard is touching radiator Guard dents or damage prevent air circulation to radiator Loose or missing bolts are evident RADIATOR GUARDS HYDRAULIC LINES 386 677 TM 5 2410 233 10 0012 00 17 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 27 After 0 3 Hours Tracks a Inspect tracks on left side of machine
71. TM 5 2410 233 10 TECHNICAL MANUAL OPERATOR S MANUAL FOR TRACTOR FULL TRACKED LOW SPEED DED MEDIUM DRAWBAR PULL TRACTOR WITH RIPPER NSN 2410 00 185 9794 EIC EAW TRACTOR WITH RIPPER AND WINTERIZED CAB NSN 2410 00 300 6665 TRACTOR WITH WINCH NSN 2410 00 185 9792 EIC EA6 TRACTOR WITH WINCH AND WINTERIZED CAB NSN 2410 00 300 6664 CATERPILLAR MODEL D7F SUPERSEDURE NOTICE This manual supersedes TM 5 2410 233 10 dated 28 November 1972 DISTRIBUTION STATEMENT A Approved for public release distribution is unlimited HEADQUARTERS DEPARTMENT OF THE ARMY MARCH 2005 This page Intentionally Left Blank This page is blank TM 5 2410 233 10 a 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 Also included are explanations of safety and hazardous materials icons used within the technical manual BIOLOGICAL abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health CHEMICAL drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue EAR PROTECTION Headphones over ears show that noise level will harm ears ELECTRICAL electrical wire to arm with electricity symbol running
72. Use winch brake lever to control load 4 Move winch selector lever to NEUTRAL position to automatically apply brake TM 5 2410 233 10 0005 00 13 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE RIPPER CAUTION DO NOT turn or back tractor while shanks are in ground Twisting puts strain on shanks and tips that may cause failure Inspect ripper tips frequently for damage NOTE Rip downhill whenever possible 1 General Use a Operate transmission in 1st gear for most ripping operations It is better to use additional shanks where practical rather than to increase speed b Always use center shank when ripping with one shank only If material breaks up easily more shanks may be added NOTE It may be necessary to raise and lower ripper to keep tractor from stalling and to properly break up material c Move tractor straight into material to be ripped and lower ripper gradually to desired depth as tractor moves forward d When ripping in preparation for scraper loading rip in the same direction that scraper will load e Cross rip only when necessary f In most cases it is preferable to rip as deeply as possible Sometimes it is better to rip at partial depth and to remove the material in its natural layers WARNING Shanks are heavy Assistance from Unit Maintenance is required to adjust ripper shank depth of penetration Suitable lifting device must be used to ensure adjustment is perfor
73. aintenance on the machine 2 A Table of Contents located in the front of the manual lists all chapters and work packages in the publication a The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses for the submittal of corrections to this manual b 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 Chapter 1 Introductory Information with Theory of Information provides general information on the manual and the equipment 4 Chapter 2 Operating Instructions explains and illustrates all operator controls and indicators and contains a Stowage Decal and Data Plate Guide It also describes how to perform all operating procedures for the tractor Operation Under Usual Conditions and Operation Under Unusual Conditions 5 Chapter 3 covers all Operator Troubleshooting WP 0009 00 contains a Troubleshooting Symptom Index If the tractor malfunctions this index should always be consulted to locate the appropriate troubleshooting procedure TM 5 2410 233 10 iv CONTENTS OF THIS MANUAL CONTINUED 6 Chapter 4 deals with Operator Maintenance Major areas covered are Preventive Maintenance Checks and Services PMCS and operator level maintenance tasks 7 Chapter 5 includes Supporting Information References Components of End Item COEI and Basic Issue Items BII Lists Additional
74. all filler cap and turn to the right until filler cap is tight 386 013 OIL FILLER TUBE FILLER CAP DIPSTICK TM 5 2410 233 10 0012 00 15 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 23 After Overall View a Check on ground under tractor for evidence of fluid leakage such as oil coolant or fuel Class III leaks are evident b Check tractor for obvious damage that would impair operation Damage that would impair operation is evident c Check for evidence of fluid leakage at tractor belly pans Class III leaks are evident 24 After Bulldozer Blade Assembly a Check blade cutting edges and end bits for cracks wear or damage and missing or loose mounting bolts Edge is cracked damaged or worn to less than 3 4 in 19 mm from edge of moldboard End bits are worn damaged in the same manner Mounting bolts are missing or loose b Check that all four scarifiers are present securely mounted and in good condition Scarifier is missing or mounting is loose Teeth are missing or damaged if required for mission CHECK FOR LEAKS AT BELLY PANS 386 712 TM 5 2410 233 10 0012 00 16 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMC
75. am You may also mail fax or e mail your letter DA Form 2028 direct to AMSTA LC CI TECH PUBS TACOM RI 1 Rock Island Arsenal Rock Island IL 61299 7630 The e mail address is TACOM TECH PUBS ria army mil The fax number is DSN 793 0726 or Commercial 309 782 0726 TM 5 2410 233 10 ii Table of Contents Continued Page Number CHAPTER 3 OPERATOR TROUBLESHOOTING WP 0008 00 Troubleshooting Instructions 0008 00 1 WP 0009 00 Troubleshooting Symptom Index 0009 00 1 WP 0010 00 Troubleshooting Procedures 0010 00 1 CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS WP 0011 00 Operator Preventive Maintenance Checks and Services PMCS Introduction 0011 00 1 WP 0012 00 Operator Preventive Maintenance Checks and Services PMCS 0012 00 1 WP 0013 00 Refueling and Fuel System Priming 0013 00 1 WP 0014 00 Air Cleaner Service 0014 00 1 WP 0015 00 Track Adjustment 0015 00 1 CHAPTER 5 SUPPORTING INFORMATION WP 0016 00 References
76. ar right TM 5 2410 233 10 0005 00 7 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE BULLDOZER BLADE CONTINUED d After adjustment lock tilt brace by inserting end of adjusting bar in locking loop 3 Dozing Techniques a General Precautions WARNING Use caution when crossing side hills ridges logs and ditches Ensure that safety belt is fastened Tractor could tip and roll over causing injury or death 1 When running over an obstruction such as a log or ditch bank both steering clutches may be released slightly until tractor balances on top of obstruction One clutch may be engaged gradually so that tractor moves forward at an angle over and down If tractor is operating without a load it may be necessary to use brakes CAUTION Lift cylinder rods may be damaged if dirt spills over top of blade 2 DO NOT allow load to spill over top of blade b Straight Dozing 1 If blade digs in and rear of tractor rises raise blade to continue with an even cut 2 Moving a heavy load will cause engine speed to drop Shift to a lower gear and or raise blade slowly 3 When doing finishing or leveling work a full blade works better than a partially loaded blade SHORTEN LENGTHEN ADJUSTING BAR TILT BRACE 386 696 LOCKING LOOP LOCKING LOOP TM 5 2410 233 10 0005 00 8 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE BULLDOZER BLADE CONTINUED c Slot Dozing
77. at if necessary WARNING Use of seat belt while operating machine is mandatory Fasten belt BEFORE operating machine Trying to fasten seat belt during operation creates a hazardous condition Failure to follow this warning may result in injury or death 4 Fasten seat belt Adjust as needed so that belt is snug across lap with buckle in the center TM 5 2410 233 10 0005 00 2 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 START ENGINE WARNING DO NOT start tractor engine in enclosed areas without adequate ventilation Failure to follow this warning may result in permanent brain damage or death due to carbon monoxide poisoning Your hearing can be permanently damaged if you are exposed to constant high noise levels of 85 DB or greater Hearing protection is required when operating machine or when working on machine while it is operating Failure to wear hearing protection may result in hearing loss NOTE Follow this procedure to start engine at any temperature Tractors with ether starting aid system use ether to start engines at temperatures below 32 F 0 C If your tractor is equipped with glow plugs use glow plugs to preheat precombustion chambers at temperatures from 60 F 16 C to 0 F 18 C Before attempting to start engine in extreme cold refer to instructions in WP 0006 00 to prepare tractor for operation in extreme cold 1 Ensure brake lock lever is engaged 2 Ensur
78. c Tank 88 qt 83 2 l OE HDO 15 40 or OE HDO 10 See Note OEA 30 Hydraulic System 112 qt 106 0 l GAA Grease Automotive and Artillery Track Roller Frame Inner and Outer Bearings As Reqd All Temperatures Blade Lift Cylinder Support and Upper and Lower Trun nion Bearings As Reqd All Temperatures Blade Tilt Brace and Tilt Cylinder Ball and Socket As Reqd All Temperatures Blade Tilt Brace Screw Threads As Reqd All Temperatures Blade Adjustable Brace As Reqd All Temperatures Ripper Linkage and Cylin der Bearings As Reqd All Temperatures Fan Drive Pulley Bearing As Reqd All Temperatures ANTIFREEZE Permanent Ethylene Gly col Inhibited MILA46153 Cooling System 48 qt 45 4 l Refer to PMCS Table For arctic operation refer to FM 9 207 Note Grade 15W 40 OE HDO 15 40 is the preferred lubricant but should only be used when temperatures are above 0 F 18 C TM 5 2410 233 10 0011 00 5 LUBRICANT INTERVAL INTERVAL LUBRICANT D D D D D W D D D W D D W D GAA GAA GAA GAA GAA GAA OE HDO or OEA 30 GAA GAA OE HDO or OEA 30 OE HDO or OEA 30 GAA OE HDO or OEA 30 Blade Adjust able Brace 2 Fit tings Each Side Blade Tilt Brace Ball and Socket 2 Fittings Fan Drive Pulley Bearing 1 Fitting Blade Tilt Brace Screw Threads 1 Fitting Lift Cylinder Sup port and Upper Trunn
79. 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 glove and skin protection when handling coolants Failure to do so may cause injury WARNING SLAVE STARTING When slave starting tractor use NATO slave cable that DOES NOT have loose or missing insulation DO NOT proceed if suitable cable is not available WARNING SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL PRF 680 Type III is an environmentally compliant and low toxic 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 WARNING WINCH OPERATION Follow winch operating precautions and procedures carefully Failure to follow safe operating precautions and procedures could result in injury or death or damage to equipment Wear heavy gloves when handling wire rope to protect hands against injury Stand clear of a reeled out wire rope that is loaded Stand clear a distance equal to 1 1 2 times the length of reeled out wire rope TM 5 2410 233 10 h This Page Intentionally Left Blank TM 5 2410 233 10 A LIST OF EFFECTIVE PAGES WORK PACKAGES Date of issue for original manual is Original 15 March 2005 TOTAL NUMBER OF PAGES FOR FRONT AND REA
80. conds at a time After 30 seconds allow starter motor to cool for at least two minutes before attempting to start engine again Excessive heating of starter motor may result in damage or early starter failure Engine MUST have adequate oil pressure within 15 seconds after starting DO NOT leave engine on if oil pressure is not indicated on gage after 15 seconds Damage to engine will result 10 Crank engine as follows a Push in and turn heat start switch to START and crank engine b Press manual override switch to by pass automatic disconnect system if temperature is below 32 F 0 C NOTE If temperature is below 60 F 16 C and your engine is equipped with glow plugs return heat start switch to HEAT until engine runs smoothly As soon as engine is running smoothly release heat start switch c Release heat start switch and manual override switch as soon as engine starts d Run engine at low idle after initial start to allow lubrication to reach turbocharger 11 If engine fails to start perform the following a If engine is equipped with glow plugs and does not start return heat start switch to HEAT for 30 seconds then attempt to start engine again b If engine is equipped with ether starting aid system and does not start push ether starting aid switch for 2 3 seconds then release for 2 3 seconds at the same time engine is cranked Continue to use ether at 2 3 second intervals during cranking until engi
81. correct grade of oil for expected temperature range TM 5 2410 233 10 0012 00 5 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 5 Con t 1 Turn filler cap to the left and remove 2 Add oil through filler tube opening until level is within cross hatched area on SAFE STARTING RANGE WITH ENGINE STOPPED AND OIL COLD side of dipstick 3 Reinstall filler cap and turn to the right until tight 386 013 OIL FILLER TUBE FILLER CAP DIPSTICK TM 5 2410 233 10 0012 00 6 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 6 Before ROPS Inspect for loose mounting bolts and cracks bends or broken welds in ROPS and pads ROPS and pads have loose or missing bolts or cracks bends or broken welds REAR AND RIGHT SIDE NOTE Notify Unit Maintenance to check final drive oil level if Class III leaks are noted from final drive 7 Before Overall View a Check on ground under tractor for evidence of transmission and fina
82. determine if you have a SLEP tractor do the following a On tractors equipped with a winch look for the suffix R stamped after the serial number on the data plate at the left rear of the machine ETHER STARTING AID SYSTEM LATER MODEL 3306 ENGINE ENGINE OIL SAMPLING OIL DESIGNATES SLEP TRACTOR TRACTOR WITH WINCH TM 5 2410 233 10 0002 00 3 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES CONTINUED b On tractors equipped with a ripper look for the suffix R stamped after the serial number on the data plate inside the operator station DESIGNATES SLEP TRACTOR TRACTOR WITH RIPPER TM 5 2410 233 10 0002 00 4 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS KEY COMPONENT DESCRIPTION 1 Front Flood Lights Illuminate work area to front of machine 2 Lift Cylinders Raise or lower bulldozer blade Located on both sides of machine 3 Engine Air Precleaner Prevents debris from entering engine air intake system 4 Center Flood Lights Illuminate track and rear of blade 5 Grabhandles Provide a handhold for personnel climbing on machine 6 Fuel Tank Stores fuel supply for engine operation 7 Toolbox Provides stowage for tools or other items required by operator 8 Battery Box Enclosure protects batteries from damage Two batteries inside are easily accessible for servicin
83. dle stays in elevated RED zone on gage stop engine and notify Unit Maintenance 23 Ammeter Indicates rate of battery charge or discharge in volts Pointer in GREEN zone on gage shows normal battery condition Pointer in upper RED zone indicates overcharge condition Pointer in lower RED zone indicates undercharge condition When ammeter shows either an undercharged or overcharged condition for extended period notify Unit Maintenance 24 Transmission Oil Pressure Gage Normal range is indicated by GREEN zone on gage If needle is in RED zone on gage shut down engine and notify Unit Maintenance 20 21 22 23 24 386 026 TM 5 2410 233 10 0004 00 7 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 25 Blade Control Lever a Lever controls bulldozer blade raising lowering and tilting b Raising and lowering functions Pull lever all the way back to RAISE blade Center HOLD position holds blade in position Push lever all the way forward to LOWER To allow blade to float follow surface contour without using pressure push lever all the way for ward past LOWER position to detented FLOAT position c Tilting functions Move lever all the way left to lower left side of blade Move lever all the way right to lower right side of blade Move
84. e pump is driven directly off the engine and is responsible for the circulation of the oil The pump is located under the floor plates in the operator station on the right side 3 Magnetic Strainer Oil is pulled from the reservoir and goes through the strainer before it enters the lubrication system and the hydraulic control system The strainer removes harmful large metallic particles from the oil which could cause damage to the systems 4 Filter Removes smaller harmful particles from the oil before the oil returns to the reservoir 5 Control Valve This valve responds to the winch selector lever When you move the lever the valve sends pressurized oil to engage or disengage directional clutches which permit the drum to turn 6 Drum The gears which turn the drum are powered by the transmission The direction the drum turns is controlled by moving the winch selector lever END OF WORK PACKAGE TM 5 2410 233 10 CHAPTER 2 OPERATING INSTRUCTIONS TM 5 2410 233 10 This Page Intentionally Left Blank TM 5 2410 233 10 0004 00 1 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS 0004 00 GENERAL Before operating the D7F Tractor read and become familiar with the location and function of all operator controls and indicators as described in this work package CONTROLS AND INDICATORS KEY CONTROL OR INDICATOR FUNCTION 1 Transmission Safety Lock Lever Prevents accidental engagement of transmission Lock
85. e that wires are in good condition g Hoses and Fluid Lines Look for wear damage and signs of leaks Check for loose clamps and fittings Wet spots indicate leaks but a stain around a fitting or connector can also mean a leak If a leak comes from a loose fitting or connector notify your supervisor If something is broken or worn out report it to your supervisor 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 classes of leakage you need to know to be able to determine the status of your machine Learn and be familiar with them and remember when in doubt notify your supervisor CAUTION Operation is allowable with Class I and Class II leakage EXCEPT for fuel where NO leaks are allowed WHEN IN DOUBT NOTIFY YOUR SUPERVISOR When operating with Class I or Class II leaks check fluid levels more frequently Class III leaks must be reported immediately to your supervisor Failure to do this will result in damage to vehicle and or components TM 5 2410 233 10 0011 00 3 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED NOTE Notify your supervisor of any leaks you cannot fix 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
86. e transmission is in neutral N with safety lock lever in ON position 3 Ensure all implements are lowered and control levers are in HOLD 4 Ensure all accessories are off 5 Turn battery disconnect switch to ON 6 Pull governor control lever all the way back past detent position then push forward to 1 3 throttle position NOTE Perform steps 7 and 8 if machine is equipped with a D333 or early model 3306 engine that has glow plugs 7 If temperature is below 60 F 16 C push in and turn heat start switch to HEAT for time specified below a From 32 60 F 0 16 C place heat start switch to HEAT for one 1 minute b From 0 32 F 18 16 C place heat start switch to HEAT for two 2 minutes c Below 0 F 18 C place heat start switch to HEAT for three 3 minutes 8 Release heat start switch when preheat time has elapsed NOTE Perform step 9 if machine is equipped with a later model 3306 engine with an ether starting aid system 9 If temperature is 32 F 0 C or below push in and turn heat start switch to START HEAT START on data plate Hold switch in START position while at the same time injecting ether with ether starting aid switch Push ether starting aid switch for 2 3 seconds then release Proceed to step 10 TM 5 2410 233 10 0005 00 3 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 START ENGINE CONTINUED CAUTION DO NOT operate starter motor for more than 30 se
87. e way ON Turn fuel shutoff valve all the way ON 3 Engine Hard to Start or Stalls Frequently 1 Check air cleaner service indicator reading If red band is showing service air cleaner primary elements Remember to reset air cleaner service indicator WP 0014 00 2 Check for clogged fuel filter Check fuel pressure gage reading Notify Unit Maintenance for filter servicing if gage needle is in RED zone 3 Check for low fuel supply Fill tank with proper grade of fuel WP 0013 00 TM 5 2410 233 10 0010 00 2 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION 4 Engine Overheats 1 With engine shut down and cool check radiator for obstructions dirt leaves etc Remove obstructions dirt leaves etc 2 Check fan belt for wear and tension Notify Unit Maintenance for replacement or adjustment WARNING 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 burns 3 Allow engine to cool then remove radiator fill cap and check coolant level WP 0012 00 Item 4 Add coolant as needed WP 0011 00 and WP 0012 00 Item 41 4 Check level of engine oil WP 0012 00 Item 5 Fill crankcase with proper grade of oil to FULL mark on dipstic
88. ed Low Speed DED Medium Drawbar Pull D7F TM 5 2410 233 10 15 March 2005 Operator s Manual for Tractor Full Tracked Low Speed DED Medium Drawbar Pull D7F TM 5 2410 233 10 15 March 2005 Operator s Manual for Tractor Full Tracked Low Speed DED Medium Drawbar Pull D7F THE METRIC SYSTEM AND EQUIVALENTS APPROXIMATE CONVERSION FACTORS Linear 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 Weights 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 Liquid Measure 1 Milliliter 0 001 Liters 0 0338 Fluid Ounces 1 Liter 1000 Milliliters 33 82 Fluid Ounces Square Measure 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 Cubic Measure 1 Cu Centimeter 1 000 Cu Millimeters 0 06 Cu Inches 1 Cu Meter 1 000 000 Cu Centimeters 35 31 Cu Feet Temperature 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 To Change To Multiply By Inches Centimeters 2 540 Feet Meters 0 305 Yards Meters 0 914 Miles Kilometers 1 609
89. ed out wire rope 1 Introduction a Engine must be running when operating winch Winch line speed is controlled by engine RPM b Ensure engine is at idle when moving winch selector lever from NEUTRAL to any other gear c Use a pair of heavy gloves when handling winch wire rope d Do not use winch to pull when there are fewer than three wraps of wire rope on drum e Keep personnel clear of wire rope when it is loaded TM 5 2410 233 10 0005 00 12 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE WINCH CONTINUED f Exercise care with suspended loads Maintain engine speed at a high enough RPM If engine speed is too low weight of load may cause it to drop even with winch selector lever in REEL IN position CAUTION Damage to wire rope may result if load is winched at an angle greater than five 5 degrees to either side of longitudinal axis of tractor g Always winch with wire rope in as straight a line as possible behind tractor Do not winch a load at an angle greater than five 5 degrees to either side of longitudinal axis of tractor h Assistance is needed when reeling in wire rope without a load onto drum to ensure wire rope windings are properly wound i Always lock winch selector lever in NEUTRAL position with safety lever when not operating winch 2 Winch Operation a To lock wire rope so that it will not move move winch selector lever to NEUTRAL position When towing
90. egments for missing or broken segments Any sprocket segment is missing or damaged ROLLERS IDLER ROCK GUARDS RECOIL MECHANISM ACCESS COVER SPROCKET SEGMENT 386 678 RIGHT SIDE IS SHOWN LEFT SIDE IS THE SAME TM 5 2410 233 10 0012 00 19 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 27 Con t g Check track tension as follows 1 Place a straight edge on top of grousers between idler and front carrier roller 2 Measure track sag between bottom edge of straight edge and top of grouser at midpoint between idler and front carrier roller 3 If sag distance A is 1 1 2 2 in 3 8 5 1 cm track tension is OK 4 Adjust track if too tight or too loose WP 0015 00 28 After Belly Pans Look under tractor and check for damage to belly pans Check for loose or missing mounting bolts Belly pan is missing severely bent or loose A STRAIGHT EDGE GROUSER GROUSER IDLER FRONT CARRIER ROLLER 386 715 TM 5 2410 233 10 0012 00 20 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTE
91. entrated under conditions of inadequate ventilation The following precautions must be observed to ensure safety of personnel when engine of tractor is operated 1 DO NOT operate tractor engine in enclosed areas without adequate ventilation 2 DO NOT idle tractor engine without adequate ventilation 3 DO NOT drive tractor with inspection plates or cover plates removed 4 BE ALERT for exhaust poisoning symptoms They are Headache Dizziness Sleepiness Loss of muscular control 5 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 6 BE AWARE The field protective mask for nuclear biological chemical NBC protection will not protect you from carbon monoxide poisoning The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation TM 5 2410 233 10 d 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 w
92. er passages and cools the oil going through the oil passages of the cooler 5 Fan The fan is powered by the engine It helps lower the temperature of the coolant as it passes through the radiator RADIATOR FAN WATER PUMP ENGINE OIL COOLER TRANSMISSION OIL COOLER 386 676 TM 5 2410 233 10 0003 00 5 THEORY OF OPERATION CONTINUED 0003 00 STEERING AND BRAKE SYSTEM 1 Steering Clutch Levers Levers serve as mechanical linkage to the steering control valve 2 Steering Control Valve The valve is connected mechanically to the steering clutch levers The valve directs the flow of pressurized oil in response to the movement of the levers 3 Steering Clutch There is one steering clutch for each track They control the steering of the tractor Mechanically oper ated each steering clutch is controlled by the steering clutch lever in the operator s station When turning left the left clutch is released which causes the left track to stop moving and act as a pivot for the tractor to turn on The same thing happens when turning right 4 Brakes The tractor has two band type brakes one on each steering clutch drum which are used to stop the movement of the tractor and to assist with the steering of the tractor When the steering clutch levers are pulled completely out or the brake pedals are depressed the bands tighten around the steering clutch drums ELECTRICAL SYSTEM 1 Batteries The batteries provide power
93. erate engine to idle speed 2 Apply brakes and pull brake lock lever to engage brake lock 3 Move transmission selector lever to neutral N 4 Move transmission safety lock lever to ON 5 Lower all implements to the ground 6 Turn off all accessories CAUTION Shutting down engine immediately after operating under a load can result in overheating accelerated wear of engine components and damage to turbocharger DO NOT shut down without idling engine for appropriate time period 7 Move governor control lever to idle and idle engine for five 5 minutes 8 Move governor control lever all the way forward to shut down engine 9 Place battery disconnect switch in OFF position 10 Remove all rocks mud dirt or debris clear of tracks 11 Perform After operation PMCS WP 0012 00 CLEAN CLEAN 386 708 TM 5 2410 233 10 0005 00 15 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE PORTABLE FIRE EXTINGUISHER WARNING Discharging large quantities of dry chemical fire extinguisher inside an enclosed winterized cab may result in temporary breathing difficulty during and immediately after the discharge event Discharge fire extinguisher from outside the cab Ventilate cab thoroughly prior to reentry 1 Remove fire extinguisher from mounting bracket inside cab 2 Hold fire extinguisher upright Stand back 8 ft 2 4 m from fire point nozzle toward base of fire break seal and pull safe
94. for damaged shoes and missing or loose bolts Check master link for missing or loose bolts Any bolts are missing or loose b Check recoil mechanism access cover for damage and loose or missing bolt Access cover is damaged and cannot be securely closed c Check all rock guards for damage and loose or missing bolts Guard is missing or loose d Check idler and rollers for wear leaks damage and loose or missing hardware Notify your supervisor if any leaks are evident Damaged or worn idlers or rollers are evident Loose or missing hardware is noted e Inspect track pins for evidence of leaking oil Any wetness in area of track pin bushings indicates a problem Notify your supervisor 386 714 MASTER LINK TRACK PIN BOLTS TM 5 2410 233 10 0012 00 18 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 27 Con t WARNING BE ALERT for personnel in the area while moving tractor to perform inspection While operator moves tractor an assistant must look for damage to sprocket segments Ensure assistant is clear to the side of tracks and all other personnel are clear of the area Failure to follow this warning may cause injury or death f Check sprocket s
95. g 9 Tilt Cylinder Used in conjunction with brace on right side to adjust angle of bulldozer blade 10 SU Blade Assembly Used for earthmoving operations or as a push block Consists of moldboard removable cutting edges and end bits and blade pusharms that connect blade to the tractor Reinforced plate in center of blade is used to push assist scrapers Back rip scarifiers are attached to the back of the blade and can be lowered and locked in place with pins for scarifying Blade assembly controls are operated from operator seat 1 2 3 4 5 7 8 9 10 386 001 6 5 TM 5 2410 233 10 0002 00 5 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002 00 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED KEY COMPONENT DESCRIPTION 11 Rear Flood Lights Illuminate work area at rear of machine 12 ROPS Provides rollover protection for operator 13 Hydraulic Tank Stores hydraulic oil used in machine hydraulic systems Filler cap contains dipstick for oil level check 14 Blade Tilt Brace Allows for additional adjustment of blade tilt 15 Tracks Propel the tractor 16 Final Drive Provides power to the tracks 17 Backup Alarm If Equipped Alarm sounds when transmission is placed in reverse Switch on back of alarm adjusts volume Non SLEP machines have no backup alarm 386 002 11 17 12 13 14 15 16 TM 5 2410 233 10 0002 00 6 EQUIPMENT DESCRIPTION AND DATA CONTINUED 0002
96. holding a load or when winch in not in use selector lever should be in NEUTRAL position b To reel out wire rope by moving tractor away from a heavy load or to lower a load by its own weight 1 Move winch brake lever to APPLIED position CAUTION DO NOT leave winch selector lever in FREE SPOOL position for extended periods of time When moving away from a load operate tractor in low gear to prevent overspeeding of winch components 2 Move winch selector lever to FREE SPOOL position 3 Slowly lower load using winch brake lever 4 Move winch selector lever to NEUTRAL position to automatically apply brake c To lower a light load with power or when moving away from a load in 1st gear 1 Move winch selector lever to REEL OUT position 2 Control speed by varying engine RPM 3 Move winch selector lever to NEUTRAL position to automatically apply brake d To pull a load toward tractor 1 Move and hold winch selector lever in REEL IN position CAUTION To ensure maximum service life of wire rope engage winch at lowest practical engine speed 2 Engage winch at lowest possible speed Heavy line loads will require higher engine RPM than lighter loads 3 Move winch selector lever to NEUTRAL position to automatically apply brake e To inch out a load fine control operation 1 Move winch brake lever to APPLIED position 2 Move winch selector lever to FREE SPOOL or REEL OUT position 3
97. ill 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 injury or death a Eyes Flush with cold water for no less than 15 minutes and seek medical attention immediately b Skin Flush with large amounts of cold water until all acid is removed Seek medical attention as required c 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 d Clothing Equipment Wash area with large amounts of cold water Neutralize acid with baking soda or household ammonia WARNING COMPRESSED AIR Particles blown by compressed air are hazardous DO NOT exceed 15 psi 103 kPa nozzle pressure when drying parts with compressed air Use a maximum of 30 psi 207 kPa when cleaning components DO NOT direct compressed air against human skin Failure to follow this warning may result in injury or death Make sure air stream is directed away from user and other personnel in the area To prevent injury user must wear protective goggles or face shield WARNING ETHER STARTING AID SYSTEM Ether fuel is extremely flammable and toxic DO NOT smo
98. in the Lubrication Chart WP 0011 00 and in the PMCS Table WP 0012 00 indicate that called out lubrication points are located on both sides of the machine 7 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 TM 5 2410 233 10 CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION TM 5 2410 233 10 This Page Intentionally Left Blank TM 5 2410 233 10 0001 00 1 GENERAL INFORMATION 0001 00 SCOPE NOTE A Service Life Extension Program SLEP has been implemented on selected D7F Tractors This revised manual is designed to help you operate both configurations of D7F Tractors The major differences for the operator between a non SLEP and SLEP tractor are as follows a A non SLEP tractor is equipped with either a model D333 or early model 3306 engine These engines use glow plugs for cold weather starting In addition there is no oil sampling valve for engine oil sampling b A SLEP tractor is equipped with a later model 3306 engine with an ether starting aid system and an engine oil sampling valve Some SLEP tractors may be equipped with a transmission oil sampling valve Refer to WP 0002 00 Equipment Description and Data for further information on how to verify which tractor you have 1 Type of Manual This manual is for use in operating and performing operator troubleshooting a
99. ion Bear ings 4 Fittings Each Side Track Roller Frame Outer Bearings 1 Fitting Each Side Hydraulic Tank Check Level Add Blade Tilt Cylinder Ball and Socket 2 Fittings Blade Lift Cylinder Lower Trunnion Bearings 1 Fitting Each Side Radiator Check Level Add Engine Crankcase Check Level Add Transmission Assembly Check Level Add Track Roller Frame Inner Bearings 1 Fitting Each Side Winch Check Level Add 386 064 TM 5 2410 233 10 0011 00 6 END OF WORK PACKAGE LUBRICANT INTERVAL INTERVAL LUBRICANT D D D GAA GAA GAA Ripper Link Pivot Pins 4 Fittings Each Link Ripper Beam Pivot Pins 4 Fittings Each Beam Ripper Cylinder Pins 2 Fittings Each Cylinder RIPPER 386 085 TM 5 2410 233 10 0012 00 1 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS 0012 00 PMCS INITIAL SETUP Tools and Test Equipment Basic issue items WP 0017 00 Materials Parts Antifreeze Item 1 WP 0019 00 Detergent Item 3 WP 0019 00 Grease GAA Item 7 WP 0019 00 Oil lubricating OE HDO 10 Item 9 WP 0019 00 Oil lubricating OE HDO 15 40 Item 10 WP 0019 00 Oil lubricating OEA 30 Item 8 WP 0019 00 Materials Parts Continued Oil lubricating OE HDO 30 Item 11 WP 0019 00 Rags Item 12 WP 0019 00 Personnel Required Driver operator Equipment Condition Tractor parked on level ground WP 0005 00 Page 0005 00 1
100. ired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in search engines lt A HREF http www liberatedmanuals com gt Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
101. k WP 0011 00 and WP 0012 00 Item 5 5 Engine Runs Erratically and Vibrates 1 Check operation of governor control lever by moving it back and forth 1 If control lever does not operate linkage notify Unit Maintenance 2 If control lever and linkage are OK go to Step 2 2 Check for clogged fuel filter by observing fuel pressure gage reading Notify Unit Maintenance for filter servicing if gage needle is in RED zone 6 Low Engine Power 1 Ensure fuel shutoff valve is all the way ON Turn fuel shutoff valve all the way ON 2 Check air cleaner service indicator reading If red band is showing service air cleaner primary element Remember to reset air cleaner service indicator WP 0014 00 3 Check for clogged fuel filter by observing fuel pressure gage reading Notify Unit Maintenance for filter servicing if gage needle is in RED zone 4 Check operation of governor control lever 1 If control lever does not operate linkage notify Unit Maintenance 2 If control lever and linkage is OK go to Step 5 5 Check exhaust for excessive smoke Notify Unit Maintenance for turbocharger inspection TM 5 2410 233 10 0010 00 3 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION ELECTRICAL SYSTEM WARNING DO NOT check V belts with engine running Injury could result 7 Alternator Output Low Unsteady o
102. ke 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 injury or death WARNING FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher inside an enclosed winterized cab may result in temporary breathing difficulty during and immediately after the discharge event Discharge fire extinguisher from outside the cab Ventilate cab thoroughly prior to reentry TM 5 2410 233 10 e WARNING FUEL HANDLING DO NOT smoke or permit any open flame in area of tractor 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 result in injury to personnel or equipment damage DO NOT perform fuel system checks inspections or maintenance while smoking or near fire flames or sparks Fuel may ignite causing injury or death or damage to vehicle WARNING HAZARDOUS WASTE DISPOSAL When servicing this machine performing maintenance or disposing of materials such as engine coolant transmission fluid lubricants battery acids or batteries consult your unit
103. l drive oil leakage Be alert for leaks from final drive check level fill and drain plugs Class III leaks are evident b Check tractor for obvious damage that would impair operation Damage that would impair operation is evident ROPS PAD 386 711 TM 5 2410 233 10 0012 00 7 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 8 Before Ripper If Equipped Inspect ripper lift cylinder and lines for leakage Class III leaks are evident 9 Before Winch If Equipped a Inspect for structural damage or leakage Class III leaks are evident b Ensure hook and clevis are present and securely installed on end of wire rope Hook and clevis are miss ing if required for mission c Ensure safety latch is present on hook Safety latch is missing 10 Before Drawbar Ensure pin and safety latch are present Pin and safety latch are miss ing if required for mission TRANSMISSION AND FINAL DRIVES 386 002 CHECK ON GROUND FOR OIL LEAKS RIPPER LIFT CYLINDER TM 5 2410 233 10 0012 00 8 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Conti
104. ld lever to REEL IN cable To automatically apply brake push lever away from operator to first detent NEUTRAL position fully verti cal In NEUTRAL winch selector lever can be locked by safety lever 30 Push lever away from operator to third detent FREE SPOOL position to release cable as required Vary cable speed by throttling engine 29 Winch Brake Lever If Equipped Operate lever to winch a load Pull lever toward operator to APPLIED position Push lever away from operator to RELEASED position 30 Safety Lever If Equipped Locks winch selector lever when winch selector lever is in NEUTRAL Pull lever back to unlock winch selector lever Push lever forward to lock winch selector lever 29 386 011 30 28 TM 5 2410 233 10 0004 00 11 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 31 Fuel Priming Pump Plunger Located on right side of engine Allows fuel system priming in the event engine fails to start Rotate to the left to open pump Operate plunger until a strong pressure is felt Tighten securely all the way to the right after use 32 Fuel Pressure Gage Normal range is in GREEN zone on gage When gage needle is in RED zone fuel filter service is required 33 Hourmeter Used by maintenance personnel to schedule maintenance services based on hours of operation 31 386 009
105. left steering clutch lever back to disengage left steering clutch b Sharp LEFT turn pull left steering clutch lever all the way back to disengage left steering clutch Depress left brake pedal c Gradual RIGHT turn pull right steering clutch lever back to disengage right steering clutch d Sharp RIGHT turn pull right steering clutch lever all the way back to disengage right steering clutch Depress right brake pedal TM 5 2410 233 10 0005 00 5 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE TRACTOR CONTINUED WARNING DO NOT turn on a steep downgrade Machine could roll over causing injury or death 8 To steer on a moderate downgrade when load is pushing tractor a Gradual LEFT turn pull right steering clutch lever back to disengage right steering clutch b Sharp LEFT turn pull left steering clutch lever all the way back while simultaneously depressing left brake pedal c Gradual RIGHT turn pull left steering clutch lever back to disengage left steering clutch d Sharp RIGHT turn pull right steering clutch lever all the way back while simultaneously depressing right brake pedal e If engine starts to overspeed when going downhill depress both brake pedals 9 To slow down use decelerator pedal to reduce engine speed without disturbing governor control lever setting 10 To stop tractor decelerate and depress both brake pedals 11 To make gear and directional shifts CAUT
106. locate the item The entry for each item ends with the Commercial and Government Entity Code CAGEC in parentheses followed by the part number 4 Column 4 Usable on Code Indicates a code if the item needed is not the same for different models of equipment Usable on Codes for the D7F Tractor are Usable On Code Used On BSX D7F With Ripper BSW D7F With Winch 5 Column 5 Unit of Measure U M Indicates how the item is issued for the National Stock Number shown in Column 2 6 Column 6 Quantity Required Qty Rqd Indicates the quantity of the item required TM 5 2410 233 10 0017 00 2 COMPONENTS OF END ITEM COEI AND BASIC ISSUE ITEMS BII LISTS CONTINUED 0017 00 Table 1 Components of End Item List NOTE There are no COEI items assigned to the D7F Tractor Table 2 1 Basic Issue Items List END OF WORK PACKAGE 1 Illus Number 2 National Stock Number 3 Description CAGEC and Part Number 4 Usable on Code 5 U M 6 Qty Rqd 1 7520 00 559 9618 CASE MAINTENANCE AND OPERATIONAL MANUALS 83421 7520 00 559 9618 EA 1 2 4210 00 889 2221 EXTINGUISHER FIRE 58536 A A 393 EA 1 3 5120 01 275 2128 KEY SOCKET HEAD SCREW Drain Plug Tool 11083 5R6278 EA 1 4 4930 00 223 3391 LUBRICATING GUN HAND 19207 5644803 EA 1 5 5315 00 426 5074 PIN DRAWBAR 11083 7F9541 EA 1 6 5120 01 473 9274 WRENCH ADJUSTABLE 12 Inche
107. med in a safe manner Failure to follow this warning may cause injury or death NOTE Each shank weighs 328 lb 149 kg g Depth of penetration can be adjusted by removing cotter pin retainer and pin and placing each shank in one of two positions Higher shank mounting position provides penetration of 15 in 38 1 cm h Keep several inches of material on top of unripped formation to cushion machine and provide traction i When final material size must be relatively small close spacing of passes is recommended 2 Ripping Hard Materials a Solid Rock or Granite Use one shank in tough to rip material solid rock or material that tends to break off in large slabs or pieces granite b Asphalt Road Surfaces On asphalt raise shanks to lift out and break material c Concrete Road Surfaces On concrete a single shank is effective in severing reinforcement rods or mesh d Packed Soil Hard Pan Clay Shale or Cemented Gravel Three shanks work well in these materials Use as many shanks as possible to break up material without stalling or hanging up tractor TM 5 2410 233 10 0005 00 14 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE RIPPER CONTINUED e Rock With Fractures Faults and Planes of Weakness Use two shanks where rock breaks out in small pieces If tractor begins to stall or tracks spin use only the center shank SHUT DOWN TRACTOR 1 Position machine on level surface and decel
108. ment procedures WARRANTY INFORMATION SLEP machines are warranted by Caterpillar Inc IAW Warranty Information WP 0020 00 Record deficiencies on DA Form 2404 or DA Form 5988 E Report all defects in material or workmanship to your supervisor NOMENCLATURE CROSS REFERENCE LIST COMMON NAME OFFICIAL NOMENCLATURE Belly Pan Crankcase or Transmission Guard Dipstick Oil Level Gage Engine Coolant Antifreeze Ethylene Glycol Mixture Rock Guard Track Roller Frame Guard Track Roller Guard LIST OF ABBREVIATIONS NOTE Refer to ASME Y14 38 1999 Abbreviations and Acronyms for standard abbreviations ABBREVIATION DEFINITION AAL Additional Authorization List BII
109. nd live machines NOTE NATO slave receptacle is located inside operator s station 2 Connect NATO slave cable to receptacle on dead machine 3 Connect other end of NATO slave cable to receptacle on live machine 4 Start engine of live machine and run at high idle 5 Place battery disconnect switch and engine start switch on dead machine to ON position 6 Allow live machine to run for 2 3 minutes to charge batteries on dead machine 7 Start engine of dead machine WP 0005 00 8 Disconnect NATO slave cable from both machines TM 5 2410 233 10 0006 00 2 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 TRACTOR EVACUATION AND RECOVERY NOTE If tractor becomes inoperative during a work cycle the following procedure will allow bulldozer blade and ripper to be raised to allow tractor evacuation and recovery 1 Raise Bulldozer Blade to Transport Height a Ensure tractor is secure against movement with transmission in neutral N safety lock lever ON and brake lock lever engaged Shut down engine b Move blade control lever to FLOAT c Install shackle to lift point on each side of blade WARNING All personnel must stand clear when bulldozer blade is being lifted Failure to do so could result in injury or death in the event lifting device slips or fails d Attach any suitable lifting device lift truck crane winch etc to shackles
110. nd maintenance on the Caterpillar Model D7F Tractor 2 Equipment Name and Model Number a Tractor Full Tracked Low Speed DED Medium Drawbar Pull Caterpillar Model D7F b The D7F Tractor is available in the following configurations 1 Tractor with Ripper NSN 2410 00 185 9794 EIC EAW 2 Tractor with Ripper and Winterized Cab NSN 2410 00 300 6665 3 Tractor with Winch NSN 2410 00 185 9792 EIC EA6 4 Tractor with Winch and Winterized Cab NSN 2410 00 300 6664 3 Purpose of Equipment a The D7F Tractor is designed for dozing soil and rocks and for clearing land of trees and brush b Tractors equipped with ripper are designed for dozing and also for ripping soil rocks asphalt and concrete c Tractors equipped with winch are designed for dozing and also for winching operations MAINTENANCE FORMS RECORDS AND REPORTS Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738 750 Functional User s Manual for the Army Maintenance Management System TAMMS as contained in the Maintenance Management Update REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS EIRs If your tractor needs improvement let us know Send us an EIR You the user are the only one who can tell us what you don t like about your equipment Let us know why you don t like the design or performance Put it on an SF Form 368 Product Quality Deficiency Report Mail it to u
111. ne starts and is running smoothly CAUTION DO NOT operate starter motor for more than 30 seconds at a time After 30 seconds allow starter motor to cool for at least two minutes before attempting to start engine again Excessive heating of starter motor may result in damage or early starter failure 12 If engine still does not start continue to crank engine at the following intervals a Wait for two 2 minutes b Repeat 30 second starting cycles with 2 minute waits in between cycles for a total of six 6 more times c If engine still fails to start wait for 30 minutes d Repeat 30 second starting cycles with 2 minute waits four 4 more times e If needed wait another 30 minutes then repeat four 4 additional 30 second starting cycles CAUTION Limit idling time Excessive idling can cause carbon buildup and damage to engine 13 Before applying load warm up engine for at least five 5 minutes with governor control lever at 1 4 to 1 2 speed posi tion 14 Check gages and instruments to ensure they register in normal operating range TM 5 2410 233 10 0005 00 4 OPERATION UNDER USUAL CONDITIONS CONTINUED 0005 00 OPERATE TRACTOR WARNING BE ALERT for personnel in area while operating machine Always check to ensure area is clear of personnel and obstructions before moving out Failure to follow this warning may result in injury or death DO NOT allow riders on machine Failure to foll
112. nents of End Item List This listing is for informational purposes only and is not authority to requisition replacements These items are part of the end item but are removed and separately packaged for transportation or ship ment As part of the end item these items must be with the end item whenever it is issued or transferred between property accounts Illustrations are furnished to assist you in identifying the items 2 Table 2 Basic Issue Items List These are the minimum essential items required to place the tractor in operation to oper ate it and to perform emergency repairs Although shipped separately packaged BII must be with the tractor during oper ation and whenever it is transferred between property accounts This manual is your authority to request requisition replacement BII based on TOE MTOE authorization of end item Illustrations are furnished to assist you in identifying the items EXPLANATION OF COLUMNS Below is an explanation of columns found in the tabular listings 1 Column 1 Illustration Number Illus Number This column indicates the number of the illustration that shows the item 2 Column 2 National Stock Number Indicates the National Stock Number NSN assigned to the item and will be used for requisitioning purposes 3 Column 3 Description CAGEC and Part Number Indicates the Federal item name in all capital letters and if required a minimum description in parentheses to identify and
113. nued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 11 Before V belts Check fan and alternator V belts Check for loose torn frayed missing excessively worn or unevenly worn belts Belt deflection should be no more than 1 2 in 13 mm checked at midpoint between pulleys V belts are loose torn frayed missing or exces sively unevenly worn 12 Before Belly Pans Check for evidence of fluid leaks at tractor belly pans Class III leaks are evident 13 Before 0 2 Hours Hydraulic System Oil Level Check level of oil in hydraulic tank a Wipe area clean around filler cap b Slowly turn filler cap to the left and allow any pressure to release then remove cap V BELTS CHECK FOR DEFLECTION AT MIDPOINT BETWEEN PULLEYS 386 713 TM 5 2410 233 10 0012 00 9 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 13 Con t c Remove dipstick from filler opening wipe clean reinstall then remove to check reading on dipstick Oil must be between ADD and FULL lines on dipstick d If level is low first ensure that strainer is clean and free of debris Remove and clean if necessary a
114. on the left side of the machine It is controlled by the blade control lever When the lever is moved to the right pressurized oil from the hydraulic tank causes the cylinder to extend Moving the lever to the left causes the cylinder to retract 3 Lift Cylinders These are two cylinders which are controlled by the blade control lever When the lever is pushed for ward pressurized oil causes the cylinders to extend and lower the blade When the lever is pulled back the cylinders retract and raise the blade 4 Hydraulic Tank Oil reservoir contains the oil used in machine hydraulic operations RIPPER HYDRAULIC SYSTEM 1 Ripper Control Valve This valve is located inside the hydraulic tank and is connected mechanically to the ripper control lever This valve directs the flow of pressurized oil to the cylinders in response to the movement of the ripper control lever 2 Lift Cylinders These are two cylinders which are controlled by the ripper control lever When the lever is moved to the left pressurized oil causes the cylinders to extend and lift the ripper When the lever is moved to the right the cylinders retract and lower the ripper 3 Hydraulic Tank Oil to control ripper movement is stored in the same hydraulic tank as the machine s hydraulic system WINCH HYDRAULIC SYSTEM 1 Reservoir The reservoir is integral to the winch It contains oil which is used for winch lubrication and hydraulic control system 2 Pump Th
115. ose of drained fluid IAW local policy and ordinances Ensure all spills are cleaned up a Drain water or sediment from fuel tank as follows 1 Place a suitable container under drain hose at left rear of fuel tank Open drain valve and allow all water or sediment to drain 2 Close drain valve 3 Dispose of drained water and sediment IAW local policy and ordinances TM 5 2410 233 10 0012 00 25 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 38 Con t b Check level of fuel in tank and refuel as needed WP 0013 00 39 After 0 2 Hours Blade Tilt Cylinder Ball and Socket Apply GAA grease Item 7 WP 0019 00 to two grease fittings on blade tilt cylinder ball and sockets on left side of machine 386 067 DRAIN VALVE DRAIN HOSE HIDDEN GAA 386 083 TM 5 2410 233 10 0012 00 26 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 40 After 0 3 Hours Lift Cylinder Lower Trunnion Bearings Apply GAA g
116. ow this warning may result in injury or death CAUTION If at any time an abnormal gage reading is noted or engine coolant temperature warning light comes on adjust load on machine until reading on gage has returned to safe operating range If gage does not return to a safe operating range shut down and investigate cause 1 Move governor control lever to position that will provide desired engine speed 2 Disengage brake lock lever by depressing both brake pedals 3 Use appropriate control lever s to raise implement s off ground 4 Move transmission safety lock lever to OFF WARNING Keep tractor under control at all times DO NOT put transmission selector lever in neutral N and allow tractor to coast downhill Select gear range necessary BEFORE starting downgrade DO NOT change gears while going downhill Failure to follow this warning may result in loss of machine control resulting in injury or death 5 Move transmission selector lever to desired direction and speed NOTE DO NOT use brake pedals as foot rests 6 Slowly release both brake pedals and move tractor NOTE Steering operation depends on whether tractor is pushing a load or a load is pushing tractor Perform step 7 to steer on level ground or downhill when tractor is pushing load Perform step 8 to steer on a moderate downgrade when load is pushing tractor 7 To steer when tractor is pushing load a Gradual LEFT turn pull
117. pport WARNING Wear eye protection and keep face clear when venting grease from relief valve during track adjustment NEVER visually inspect relief valve to see if grease is escaping Always observe track to verify it has loos ened Failure to follow this warning could cause eye injury or blindness 9 Open relief valve no more than one turn and allow grease to escape and idler to move back COVER RELIEF VALVE FILL VALVE 386 717 TM 5 2410 233 10 0015 00 3 TRACK ADJUSTMENT CONTINUED 0015 00 ADJUSTMENT CONTINUED 10 Put a drawbar pin or a length of steel pipe between top of track sprocket teeth near track link 11 Start engine and move machine in reverse until rear face of idler bearing support moves past mark made on track roller frame WP 0005 00 12 Move machine forward until pin is free of sprocket Shut down engine and remove pin WP 0005 00 13 Connect grease gun to fill valve Close relief valve 14 Pump grease into fill valve until rear face of idler bearing support lines up with mark made on track roller frame 15 Close recoil mechanism access cover and tighten bolt 16 Operate machine and check track for proper operation WP 0005 00 END OF WORK PACKAGE 386 716 1 2 IN 12 7 MM TRACK IDLER TRACK ROLLER FRAME IDLER BEARING SUPPORT 386 251 PIN SPROCKET TM 5 2410 233 10 0015 00 4 This Page Intentionally Left Blank TM 5 2410 233 10 CHAPTER 5 SUPPORTING IN
118. r Not Charging 1 Visually check for loose or broken V belts Notify Unit Maintenance for adjustment or replacement of V belts 2 Check to see that alternator mounting and wiring is secure Notify Unit Maintenance for repair TRANSMISSION 8 Tractor Will Not Move 1 Check transmission oil pressure gage for normal reading GREEN zone on gage Notify Unit Maintenance if reading is not in green zone 2 Check transmission oil level Fill with proper grade of oil to FULL mark on dipstick WP 0011 00 and WP 0012 00 Item 21 3 Check shifting levers and linkages Notify Unit Maintenance for linkage and lever adjustments 4 In cold weather ensure tractor is not frozen in mud Refer to WP 0006 00 before trying to move tractor WINCH 9 Winch Fails to Operate or Operates Slowly 1 Oil level in winch may be low Notify Unit Maintenance 2 Check adjustment of levers Notify Unit Maintenance for lever adjustment TM 5 2410 233 10 0010 00 4 TROUBLESHOOTING PROCEDURES CONTINUED 0010 00 Table 1 Troubleshooting Procedures Continued END OF WORK PACKAGE MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION EARTH MOVING EQUIPMENT COMPONENTS 10 Bulldozer Blade Fails to Raise or Lower 1 Check that blade control lever moves freely in all directions 1 If lever does not move freely notify Unit Maintenance 2 If lever is OK go to Step 2 2 Check oil level in hydraulic tank WP 0012 0
119. r 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 tractor b During procedures must be done while you are operating the tractor c After procedures must be done immediately after you have operated the tractor d Weekly procedures must be done once each week e Monthly procedures must be done once each month 3 Man Hours Column This column indicates man hours required to complete prescribed lubrication 4 Location Item to Check Service Column This column provides the location and 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 seri ous injury to yourself and others and CAUTIONs to prevent your equipment from being damaged 5 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 pro cedure at the time stated in the interval column 6 Not Fully Mission Capable If Column Information in this column tells you what faults will keep your equipment from being capable of pe
120. re clean to ensure an unobstructed view e Start engine and allow to warm up WP 0005 00 f Ensure all indicators and gages are functioning properly Be sure to check fuel pressure gage on right side of engine compartment WP 0004 00 Items 20 through 24 Needle is in RED zone on gage WARNING Use of seat belt while operating machine is mandatory Fas ten belt BEFORE operating machine Trying to fasten seat belt during operation creates a hazardous condition Failure to follow this warning may result in injury or death g Fasten seat belt WP 0005 00 page 0005 00 1 Adjust as needed so that belt is snug across lap with buckle in the middle Seat belt is missing or will not buckle or adjust h Check operation of flood lights and dash lights TM 5 2410 233 10 0012 00 11 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 15 Before Winterized Cab If Equipped a Check defroster fans for proper operation b Check windshield wipers for proper operation c Check heater for proper operation 16 Before Steering Brake and Steering Clutch Controls a Move tractor ahead slowly Depress both brake pedals and ensure tractor stops b Test right and left s
121. rease Item 7 WP 0019 00 to grease fitting at each lift cylinder lower trunnion bearing 41 After 0 5 Hours Blade Lift Cylinder Upper Trunnion Bearings and Lift Cylinder Support a Apply GAA grease Item 7 WP 0019 00 to four grease fittings two each side on lift cylinder upper trunnion bearings b Apply GAA grease Item 7 WP 0019 00 to four grease fittings two each side on lift cylinder support GAA 386 068 386 071 GAA GAA TM 5 2410 233 10 0012 00 27 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 42 After 0 3 Hours Blade Tilt Brace Ball and Socket and Screw Threads a Apply GAA grease Item 7 WP 0019 00 to two blade tilt brace ball and socket grease fittings on right side of machine b Apply GAA grease Item 7 WP 0019 00 to blade tilt brace screw threads grease fitting 43 After 0 4 Hours Blade Adjustable Diagonal Brace Apply GAA grease Item 7 WP 0019 00 to two grease fittings on blade adjustable diagonal brace ball and sockets on each side of machine GAA 386 081 GAA 386 084 GAA TM 5 2410 233 10 0012 00 28 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1
122. rforming 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 GENERAL PMCS PROCEDURES 1 Always perform PMCS in the same order so it gets to be a habit Once you ve had some practice you ll spot anything wrong in a hurry If the machine does not perform as required refer to the appropriate troubleshooting procedure in Chap ter 3 2 If anything looks wrong and you can t fix it write it on your DA Form 2404 or DA Form 5988 E If you find something seriously wrong IMMEDIATELY report it to your supervisor 3 Before performing preventive maintenance read all the checks required for the applicable interval and prepare all that is needed to make all the checks You ll always need a rag Item 12 WP 0019 00 or two TM 5 2410 233 10 0011 00 2 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS INTRODUCTION CONTINUED 0011 00 GENERAL PMCS PROCEDURES CONTINUED WARNING Solvent cleaning compound MIL PRF 680 Type III is an environmentally compliant and low toxic mate rial However it may be irritating to the eyes and skin Use protective gloves and goggles Use in well venti lated areas Keep away from open flames and other sources of ignition a Keep It Clean Dirt grease oil and debris get in the way and may cover up a serious problem
123. right steering clutch To make a sharp turn to the right pull lever back while applying right brake pedal 5 9 8 7 6 4 3 10 386 005 TM 5 2410 233 10 0004 00 3 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 7 Governor Control Lever Lever controls engine RPM Pull lever toward you to increase RPM and push away to decrease RPM When starting engine pull lever all the way back then push forward to 1 3 throttle position To stop engine push lever all the way forward past detent 8 Decelerator Pedal Depress pedal to reduce engine speed without changing governor control lever setting Release pedal to allow engine speed to return to governor control lever setting 9 Brake Pedals Depress both pedals to apply brakes Release both pedals to release brakes When used in conjunction with left or right steering clutch lever pressing left or right brake pedal turns machine sharply left or right 10 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start tractor KEY CONTROL OR INDICATOR FUNCTION 11 Brake Lock Lever Serves as parking brake To engage depress both brake pedals push down on lever and hold then release both brake pedals To disengage depress both brake pedals 11 386 006 TM 5 2410 233 10 0004 00 4 DESCRIPTION AND USE OF OPERATOR S CONTROLS
124. rn lever to HOLD when lift cylinders have reached limit of their stroke to prevent damage to control valve 5 When lift cylinders have reached limit of their stroke either raised or lowered return lever to HOLD position c To tilt bulldozer blade operate blade control lever as follows 1 Move lever all the way left to lower left side of blade 2 Move lever all the way right to lower right side of blade 3 Move lever to middle position to HOLD tilt position CAUTION When control lever is returned to HOLD position oil stops bypassing valves thereby reducing oil heat and valve wear Be sure to return lever to HOLD position when tilt cylinder has reached limit of its stroke to prevent damage to control valve 4 When tilt cylinder has reached limit of its stroke return lever to HOLD position 5 If additional tilt in blade is needed perform Bulldozer Blade Adjustment as described below 2 Bulldozer Blade Adjustment NOTE Bulldozer blade should never be operated with more than 1 2 in 13 mm of threads of tilt brace screw exposed Unit Maintenance assistance is required to adjust length of diagonal braces a Digging angle of dozer blade can be changed by adjusting length of tilt brace and diagonal braces and by using tilt cylinder b To shorten tilt brace unstow adjusting bar from locking loop and turn bar left c To lengthen tilt brace unstow adjusting bar from locking loop and turn b
125. ry of windblown sand or dust OPERATE AT HIGH ALTITUDE CAUTION If engine is operated at an altitude higher than marked on warning plate on dash damage to equipment may result from turbocharger overspeeding NOTE High altitude operation concerns are NOT an issue with Service Life Extension Program SLEP machines due to the new engines installed in these machines 1 Fuel rack and high idle speed settings for maximum turbocharger speed have been adjusted to permit engine operation at altitude marked on warning plate on dash 2 Engine can be operated at lower altitudes without changing the adjustment but with less than maximum performance FORDING 1 Test depth of water and ensure firmness and consistency of the bottom Do NOT attempt to ford if depth exceeds 30 in 76 2 cm to top of final drive cover 2 Ensure all gages are indicating normal operating pressure and temperature 3 Shift transmission into 1st gear and increase engine speed to minimize stalling 4 Enter water slowly to reduce surges of backwash into engine compartment Fording speed should not exceed 3 4 mph 4 9 6 4 kph 5 After fording wash tractor with fresh water if available TM 5 2410 233 10 0006 00 6 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 FORDING CONTINUED 6 Perform Operator PMCS as soon as possible WP 0011 00 and WP 0012 00 7 Notify Unit Maintenance END OF WORK PACKAGE TM 5 2410 233 10 00
126. s 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 injury or death a If required for cold weather starting check to ensure ether canister is present and securely installed Ether canister is missing or loose if required for cold weather starting b If canister is not installed loosen thumbscrew open cover and ensure cap is installed on solenoid valve 4 Before 0 3 Hours Radiator 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 any pressure out of cooling system then remove cap Failure to follow this warning may cause serious burns Wear effective eye glove and skin protection when handling coolants Failure to do so may cause injury a Check for coolant leaks worn or damaged hoses and debris buildup Remove buildup of debris Class III leaks are evident b With engine off and cool remove radiator cap and check coolant level Coolant level should be within 1 2 in 13 mm of bottom of fill pipe TM 5 2410 233 10 0012 00 4 OPERATOR PREVENTIVE MAINTENANCE CHEC
127. s follows WARNING Wear eye protection to avoid injury 1 Compress and remove retaining ring 2 Remove dipstick and strainer Clean strainer 3 Reinstall dipstick and strainer Secure strainer with retaining ring 386 012 FILLER CAP DIPSTICK STRAINER RETAINING RING TM 5 2410 233 10 0012 00 10 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION CAPABLE IF ITEM TO CHECK SERVICE 13 Con t e Add oil Item 8 9 or 10 WP 0019 00 through filler opening until level on dipstick is between ADD and FULL lines on dipstick Refer to KEY at end of WP 0011 00 for correct grade of oil for expected temperature range f Reinstall dipstick g Reinstall filler cap and turn to the right until tight OPERATOR STATION 14 Before Seat Seat Belt Gages and Indicators a Occupy and adjust seat WP 0004 00 Items 41 through 43 b Check all gages and indicators for damage Damage is evident that would impair operation c Check for damage to governor and steering clutch levers brake pedals and decelerator pedal There should be free movement Damage is evident that would impair operation d If equipped with winterized cab check for broken or damaged windows Ensure windows a
128. s transmission in neutral N when in ON forward position When in OFF rearward position transmission selector lever can be moved out of neutral N 2 Transmission Selector Lever Selects neutral N and three forward 1 2 and 3 and three 1 2 and 3 reverse transmission gear ranges Backup alarm located behind fuel tank sounds when transmission is placed in reverse 2 1 386 004 TM 5 2410 233 10 0004 00 2 DESCRIPTION AND USE OF OPERATOR S CONTROLS AND INDICATORS CONTINUED 0004 00 CONTROLS AND INDICATORS CONTINUED KEY CONTROL OR INDICATOR FUNCTION 3 Manual Override Switch NOTE Automatic disconnect system cuts off current to starter to prevent inadvertent re engagement of starter after engine has started and oil pressure is building up Press switch to by pass automatic disconnect system during engine cranking in temperatures below 32 F 0 C 4 Ether Starting Aid Switch Push down on switch and hold for 2 3 seconds When switch is released ether is injected into intake manifold If engine does not start wait 2 3 seconds before pressing switch again 5 Left Steering Clutch Lever Pull lever back to disengage left steering clutch and turn left Release lever to engage left steering clutch To make a sharp turn to the left pull lever back while applying left brake pedal 6 Right Steering Clutch Lever Pull lever back to disengage right steering clutch and turn right Release lever to engage
129. s Long 96508 AT112BK EA 1 1 3 4 6 2 5 386 063 TM 5 2410 233 10 0018 00 1 ADDITIONAL AUTHORIZATION LIST AAL 0018 00 NOTE There are no AAL items assigned to the D7F Tractor END OF WORK PACKAGE TM 5 2410 233 10 0018 00 2 This Page Intentionally Left Blank TM 5 2410 233 10 0019 00 1 EXPENDABLE AND DURABLE ITEMS LIST 0019 00 SCOPE This work package lists expendable supplies and materials you will need to maintain the D7F Tractor This listing is for information 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 and Class V Repair Parts Heraldic Items or CTA 8 100 Army Medical Depart ment Expendable Durable Items EXPLANATION OF COLUMNS 1 Column 1 Item Number This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item e g Use antifreeze Item 1 WP 0019 00 2 Column 2 Level This column identifies the lowest level of maintenance that requires the listed item C Operator Crew 3 Column 3 National Stock Number This is the NSN assigned to the item which you can use to requisition it 4 Column 4 Description CAGEC and Part Number This provides the other information you need to identify the item 5 Column 5 Unit of Measure U M This code shows the physical measurement or count of an item s
130. s at Commander U S Army Tank automotive and Armaments Command ATTN AMSTA AC NML Rock Island Illinois 61299 7630 We ll send you a reply TM 5 2410 233 10 0001 00 2 GENERAL INFORMATION CONTINUED 0001 00 CORROSION PREVENTION AND CONTROL CPC 1 Corrosion Prevention and Control 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 2 While corrosion is typically associated with rusting of metals it can also include deterioration of other materials such as rubber and plastic Unusual cracking softening swelling or breaking of these materials may be a corrosion problem 3 If a corrosion problem is identified it can be reported using SF Form 368 Product Quality Deficiency Report Use of key words such as corrosion rust deterioration or cracking will ensure that the information is identified as a CPC problem The form should be submitted to the address specified in DA Pam 738 750 OZONE DEPLETING SUBSTANCES There are no ozone depleting substances cited in this manual or used on the D7F Tractor DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use refer to TM 750 244 3 PREPARATION FOR STORAGE OR SHIPMENT Notify Unit Maintenance to perform preparation for storage or ship
131. s warning may result in injury or death Use of seat belt while operating machine is mandatory Fasten belt BEFORE operating machine Trying to fasten belt during operation creates a hazardous condition Failure to follow this warning may result in injury or death DO NOT allow riders on machine Failure to follow this warning may result in injury or death WARNING NBC EXPOSURE If NBC exposure is suspected personnel wearing protective equipment must handle all air cleaner media Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures Refer to FM 3 3 Chemical and Biological Contamination Avoidance FM 3 5 NMC Decontamination FM 9 204 Nuclear Contamination Avoidance NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel To order this NBC decal use National Stock Number NSN 7690 01 114 3702 Part Number PN 12296626 Commercial and Government Entity Code CAGEC 19207 WARNING IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PER SONNEL WEARING FULL NBC PROTEC TIVE EQUIPMENT SEE OPERATOR MAINTENANCE MANUAL 7690 01 114 3702 TM 5 2410 233 10 g WARNING PRESSURIZED COOLING SYSTEM 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
132. sampling valve 3 Refer to WP 0002 00 Equipment Description and Data for further information on how to verify which tractor you have 4 This revised manual is designed to help you operate both configurations of Caterpillar D7F Tractors and perform operator troubleshooting and maintenance on the equipment 5 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 Operating Instructions Operator Troubleshooting Operator Maintenance Instructions and Supporting Information b Each Chapter is divided into work packages which are identified by a 6 digit number e g 0001 00 0002 00 etc located on the upper right hand corner of each page The work package page number e g 0001 00 1 0001 00 2 etc is located centered at the bottom of each page c If a Change Package is issued to this manual added work packages use the 5th and 6th digits of their number to indicate new material For instance work packages inserted between WP 0001 00 and WP 0002 00 are numbered WP 0001 01 WP 0001 02 etc 6 Read through this manual to become familiar with its organization and contents before attempting to operate or maintain the equipment CONTENTS OF THIS MANUAL 1 A Warning Summary is located at the beginning of this manual Become familiar with these warnings before operating or performing operator troubleshooting or m
133. t filler tube during refueling to prevent static electricity Failure to follow this warning may result in injury to personnel or equipment damage If equipped with a winterized cab turn heater off during refueling NOTE Ensure portable fire extinguisher is within reach prior to refueling DO NOT overfill fuel tank If fuel starts foaming from fuel tank stop IMMEDIATELY to avoid fuel spillage 1 Wipe off dirt from around filler cap 2 Turn filler cap to the left and remove cap 3 If strainer is filled with debris remove strainer and dipstick Remove debris and reinstall strainer and dipstick 4 Fill tank with fuel to FULL line on dipstick Use correct grade of fuel IAW expected temperature range of operation 5 Install filler cap by turning cap to the right DIPSTICK STRAINER FILLER CAP 386 014 TM 5 2410 233 10 0013 00 3 REFUELING AND FUEL SYSTEM PRIMING CONTINUED 0013 00 FUEL SYSTEM PRIMING NOTE If engine fails to start because tractor ran out of fuel it may be necessary to prime fuel system Fuel priming pump is located on right side of engine 1 Rotate fuel priming pump plunger to the left to open pump 2 Pull out and then push in pump plunger by hand Continue to pump until a strong pressure is felt and fuel pressure gage indicates in GREEN zone 3 After use push down on plunger then turn plunger all the way to the right until closed END OF WORK PACKAGE
134. teering clutch levers while moving ahead slowly Brakes do not function Either lever fails to turn trac tor 17 Before Implement Controls Check controls of bulldozer blade and winch if equipped or ripper if equipped for proper operation Controls do not function properly NOTE Non SLEP machines do not have a backup alarm 18 Before Backup Alarm If Equipped a Place transmission in reverse and listen for backup alarm to sound b Return transmission to neutral N and lock 19 During Indicators Gages and Dash Panel Lights a Check oil pressure gage for proper operating pressure Needle is in RED zone on gage b Check engine water temperature gage for proper operating temperature Needle is in RED zone on gage c Check transmission oil pressure gage and torque converter temperature gage for proper pressure and operating temperature Needle is in RED zone on gages d Check air cleaner indicator for proper operation If red band is visible service air cleaner WP 0014 00 e Check ammeter for proper operation Needle is in RED zone on gage f Check operation of dash lights TM 5 2410 233 10 0012 00 12 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES PMCS CONTINUED 0012 00 Table 1 Operator Preventive Maintenance Checks and Services PMCS for D7F Tractor Continued ITEM NO INTERVAL MAN HOURS LOCATION PROCEDURE NOT FULLY MISSION C
135. through human body shows that shock hazard is present EYE PROTECTION person with goggles shows that the material will injure the eyes FIRE flame shows that a material may ignite and cause burns FLYING PARTICLES arrows bouncing off face with face shield shows that particles flying through the air will harm face TM 5 2410 233 10 b 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 HYDRAULIC FLUID PRESSURE hydraulic fluid spraying human figure 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 TM 5 2410 233 10 c FOR INFORMATION ON FIRST AID REFER TO FM 4 25 11 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 exhaust fumes of internal combustion engines Carbon monoxide can become dangerously conc
136. tions for additional information on cold weather operation and maintenance 1 Introduction Extreme cold causes many problems a Lubricants thicken or congeal b Batteries may freeze or lose their electrical efficiency c Fuel may not readily atomize for combustion d Various materials become hard brittle and easily damaged e Cooling system requires adequate protection from extreme cold f Fuels lubricants and antifreeze require special storage handling and use TM 5 2410 233 10 0006 00 4 OPERATION UNDER UNUSUAL CONDITIONS CONTINUED 0006 00 OPERATE IN EXTREME COLD CONTINUED 2 Operation CAUTION Low idling speeds during extremely cold temperatures can result in incomplete combustion and heavy deposit formations on valves These deposits can cause burned valves bent pushrods or other damage to valve components a Carefully follow engine start and warmup procedures in WP 0005 00 Allow engine time to thoroughly warm up so that it idles smoothly However do NOT allow to idle excessively or at speeds that are too low Run engine at reduced speed ONLY long enough to circulate oil through engine then increase speed b To avoid water condensation in fuel tank completely fill fuel tank after each operating period Also drain water from fuel tank c Remove snow ice and mud from engine compartment hydraulic cylinders track components and implements before operation d Ensure tractor
137. tive Structure SLEP Service Life Extension Program SU Bulldozer Blade Semi U Bulldozer Blade END OF WORK PACKAGE TM 5 2410 233 10 0001 00 4 This Page Intentionally Left Blank TM 5 2410 233 10 0002 00 1 EQUIPMENT DESCRIPTION AND DATA 0002 00 EQUIPMENT CHARACTERISTICS CAPABILITIES AND FEATURES NOTE Refer to Equipment Data at the end of this work package for machine dimensions weights fluid capacities and other miscellaneous equipment data 1 The D7F Tractor is a full tracked low speed medium drawbar pull machine designed for earthmoving and construction operations 2 The three major assemblies of the tractor are a center section and two side sections a The center section contains the power source the operator s controls and the rollover protective structure ROPS b The two side sections consist of track frames extending approximately the full length of the tractor 3 The tractor can operate in mud or water as deep as the top of the final drive cover 30 in 76 2 cm 4 Features of the D7F tractor include a Caterpillar 6 cylinder turbocharged diesel engine b Caterpillar powershift manual transmission with Neutral N and
138. ty pin 3 Squeeze lever discharging chemical at base of fire Use a side to side motion to spread chemical 4 After using fire extinguisher notify Unit Maintenance to have fire extinguisher recharged END OF WORK PACKAGE TM 5 2410 233 10 0005 00 16 This Page Intentionally Left Blank TM 5 2410 233 10 0006 00 1 OPERATION UNDER UNUSUAL CONDITIONS 0006 00 GENERAL This work package contains instructions for safely operating the D7F Tractor under unusual conditions In addition to normal preventive maintenance special care must be taken to keep tractor operational in extreme temperatures and other environmental conditions SLAVE START TRACTOR WARNING To avoid possible electric shock when slave starting tractor use NATO slave cable that DOES NOT have loose or missing insulation DO NOT proceed with slave starting if suitable slave cable is not available CAUTION DO NOT allow live and dead machines to come in contact with each other during slave starting Failure to follow this caution may cause electrical system damage Under no circumstances can the tractor be started by being towed or pushed Failure to follow this caution will damage transmission NOTE If machine other than another D7F is used to slave start tractor refer to Operator s Manual for that machine for any special slave starting procedures 1 Ensure battery disconnect switch is in OFF position on dead a
139. uch as gallon dozen gross etc TM 5 2410 233 10 0019 00 2 EXPENDABLE AND DURABLE ITEMS LIST CONTINUED 0019 00 Table 1 Expendable and Durable Items List 1 ITEM NUMBER 2 LEVEL 3 NATIONAL STOCK NUMBER 4 DESCRIPTION CAGEC AND PART NUMBER 5 U M 1 C ANTIFREEZE Permanent Ethylene Glycol Inhibited 58536 AA52624 1 A 6850 01 441 3218 6850 01 441 3223 1 Gallon Bottle 55 Gallon Drum GAL GAL 2 C CLEANING COMPOUND Solvent Type III 81349 MIL PRF 680 6850 01 474 2318 6850 01 474 2320 6850 01 474 2321 1 Gallon Can 5 Gallon Can 55 Gallon Drum GAL GAL GAL 3 C DETERGENT General Purpose Liquid 83421 7930 00 282 9699 7930 00 282 9699 1 Gallon Can GAL 4 C FUEL Diesel DF 1 Grade Winter 81346 ASTM D 975 9140 00 286 5286 9140 00 286 5287 9140 00 286 5288 Bulk 5 Gallon Can 55 Gallon Drum GAL GAL GAL 5 C FUEL Diesel DF 2 Grade 81346 ASTM D 975 9140 00 286 5294 9140 00 286 5295 9140 00 286 5296 Bulk 5 Gallon Can 55 Gallon Drum GAL GAL GAL 6 C 9130 01 031 5816 FUEL TURBINE Aviation 81349 MILT83133 GR JP8 GAL 7 C GREASE Automotive and Artillery GAA 9150 01 197 7688 81349 M 10924 A 2 1 4 Ounce Tube OZ 9150 01 197 7693 81349 M 10924 B 14 Ounce Cartridge OZ 9150 01 197 7690 81349 M 10924 C 1 3 4 Pound Can LB 9150 01 197 7692 81349 M 10924 E 35 Pound Can LB TM 5 2410 233 10 0019 0
140. ughly wipe clean inside of air cleaner housing with rag 5 Check sealing surfaces on primary filter element for dirt on the clean side If this is evident problem may be a damaged filter element incorrect element fit or the need for cleaning sealing surfaces WARNING Particles blown by compressed air are hazardous DO NOT exceed 15 psi 103 kPa nozzle pressure when drying parts with compressed air Use a maximum of 30 psi 207 kPa when cleaning components DO NOT direct compressed air against human skin Failure to follow this warning may cause injury or death Make sure air stream is directed away from user and other personnel in the area To prevent injury user must wear protective goggles or face shield CAUTION To prevent damage do NOT clean primary filter element by bumping or tapping NOTE Use a light inside primary filter element to inspect filter for tears holes or other damage before and after each cleaning process Discard primary filter element if any damage is evident 386 297 FILTER ELEMENT AIR CLEANER HOUSING GASKET COVER PRIMARY TM 5 2410 233 10 0014 00 3 AIR CLEANER SERVICE CONTINUED 0014 00 SERVICE CONTINUED 6 Direct compressed air inside primary filter element along length of filter pleats 7 Direct compressed air outside along length of filter pleats 8 Repeat step 6 CAUTION To prevent primary filter element damage use a maximum of 40 psi 276 kPa
141. ulic System 0003 00 6 TM 5 2410 233 10 Index 4 INDEX Continued Subject Work Package Page T Continued Theory of Operation Continued Power Train 0003 00 1 Ripper Hydraulic System 0003 00 6 Steering and Brake System 0003 00 5 Winch Hydraulic System 0003 00 6 Track Adjustment 0015 00 1 Tractor Evacuation and Recovery 0006 00 2 Operation 0005 00 4 Shut Down 0005 00 14 Slave Start
142. water pressure 9 Direct water inside primary filter element along length of filter pleats 10 Direct water outside along length of pleats Rinse and air dry primary filter element thoroughly 11 Wash primary filter element in warm water and detergent 12 Rinse with clean water and air dry thoroughly NOTE Primary filter element should be replaced once each year or after being cleaned a maximum of 6 times If indicator shows RED shortly after installation of primary filter element which has been cleaned approximately 6 times replace primary filter element If indicator still shows RED shortly after installation of clean primary filter element notify Unit Maintenance to replace secondary filter element 13 Install primary filter element in air cleaner housing 14 Position cover on air cleaner housing and secure with two eye bolts 15 Reset air filter indicator by pushing button on bottom of indicator WP 0004 00 Item 17 16 Run engine and check for proper operation END OF WORK PACKAGE EYE BOLT COVER AIR CLEANER EYE BOLT 386 296 HOUSING TM 5 2410 233 10 0014 00 4 This Page Intentionally Left Blank TM 5 2410 233 10 0015 00 1 TRACK ADJUSTMENT 0015 00 THIS WORK PACKAGE COVERS Adjustment INITIAL SETUP Tools Drawbar pin Item 5 WP 0017 00 Lubricating gun hand Item 4 WP 0017 00 Wrench adjustable Item 6 WP 0017 00 Materials Parts Grease GAA Item
143. ystem dozer hydraulic system ripper hydraulic system and winch hydraulic system POWER TRAIN 1 Diesel Engine The tractor is powered by an in line six cylinder diesel engine SLEP engines have a direct injection fuel system Non SLEP engines use precombustion chambers glow plugs 2 Torque Divider The torque divider connects the engine to the transmission The torque divider will increase or decrease the torque from the engine depending on the load at which the tractor is working 3 U Joint The U joint transfers power from the torque divider to the transmission 4 Transmission The transmission controls the speed and direction of the tractor At this point in the power train the opera tor can control the power by moving the transmission selector lever to neutral N or one of the three speeds in forward or reverse 5 Bevel Gear The bevel gear connects transmission to the final drives 6 Final Drive The final drive delivers the power of the power train to the sprocket on each side of the machine which turns the track 7 Track The D7F has a steel roller type track that is sealed and lubricated Track tension may be adjusted by the operator 386 467 DIESEL ENGINE TORQUE DIVIDER U JOINT TRANSMISSION BEVEL GEAR FINAL DRIVE TRACK TM 5 2410 233 10 0003 00 2 THEORY OF OPERATION CONTINUED 0003 00 ENGINE LUBRICATION SYSTEM 1 Oil Pan The oil pan contains the oil that lubricates moving parts in the

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