[bulletpruf]

Ok, so today was a GREAT day!

Got on the road at 6:15. Picked up sidekick at 6:30. Got to dozer at 8:45. Owner was there waiting for us; he's a really good dude, 5th generation on their 550 acre cattle ranch. His dad bought the D7 10 or so years ago from a neighbor who lived a few miles away. They were going to use it to clear some of the land, and when you have a 550 acre ranch, I think you can justify a D7 to clear land.

Dozer was easy to get to. Didn't need to break out the chainsaw or weed-whacker. Just like you see in the pics.

The owner had 4 big freaking batteries in the back of his truck. I think the smaller ones were 4D's, but they were dead. The larger ones had 11.5 volts each, and look like they've been sitting in a shed for a decade or two.

We got unloaded and got the generator fired up (sidekick has a Honda generator) and got two chargers going on the big batteries.

Then we checked fluids and such - good on antifreeze, good on fuel, good on engine oil, milkshake in the transmission...gonna have to pretend we didn't see that...

Checked for air filter and it had been deleted at some point. Ruh-roh. Mice had made it into the turbo on the cold side, but not a worst case scenario. Just had to clean it out a bit.

Then started on fuel system, and that's where we ran into a problem. Injector rack seems to be immobile. But wasn't able to get it moving and the parts between the rack and the fuel filter are throwing me for a loop. Will have to wait for me to download pics and video, but we didn't want to force the issue, so we buttoned it back up for the time being.

Fuel filters (3) all had fuel in them; they were all full. And tank is gravity feeding the first fuel filter (small wire screen), so we don't have an obstruction between the tank and the first fuel filter. Fuel filters look almost new; we saw old filters laying in box that must have been changed out the last time someone tried to start it.

At that point, we figured we wouldn't be able to start it, but we could at least try to turn it over.

Starter was already wired with a pushbutton and we ohm'ed all the wires and everything checked out, including working pushbutton. We then built some quick 2/0 cables to connect the 12v batteries in series for a 24v system. Used the positive wire that was already in place because it ohm'ed fine and it was in good shape.

I was worried about a stuck rack and WOT/runaway engine if it started, but I really didn't think there was much chance of it lighting off immediately. I also had a thick denim shirt sitting right next to the intake; I could have smothered it if it caught.

Verified all controls were in neutral and then hit the starter. Almost forgot - no real way that I could see to turn it over manually, at least not at the front of the engine. Anyway, the sumbitch spun over quickly! No funny noises, just nice and smooth! I was turning it over with the compression release in the "start" position, so it wasn't building much compression. No smoke, so it wasn't getting any fuel that I could tell. Second time I turned it over, it spun for a second and then I switched the compression release to "run" position and it definitely has compression; really slowed it down.

Seller was there watching and he was certainly happy to see the engine turn over. He did mention that the winch was turning as I was cranking the engine, so that's a problem that we need to address; can't be using battery/starter power to turn the winch. The problem is the two controls for the winch -- one is "bluetooth" (i.e., cable is busted) and the other is frozen in position. Anyone have any ideas on how to disengage a Hyster D7 winch that has MIA and frozen control levers?

Anyway, at this point, we called it a day. Seller was leaving to go out of town for work for a few weeks and sidekick had to be back to for parental duties, so we packed up and headed home. Batteries also weren't happy from having to turn the engine and the winch.

I have pics and video. I'll post pics here when I get a chance, and I'll work on editing the video to put up on the YouTube channel.

Next step - figure out the fuel system, source an air filter, figure out how to disengage the winch, and plan the next trip!

Thanks for all the input!!!

Scott

[Nobuddy]

Originally Posted by bulletpruf

Anyone have any ideas on how to disengage a Hyster D7 winch that has MIA and frozen control levers?

Has been a long time, but I believe you remove the cover on the top right side of the winch to access where the push/pull cables attach and are adjusted. I'm sure there is a manual for a D7D winch online somewhere that has information for where neutral point is. Controls look like brake (long lever) is released and shorter lever is engaged to forward or cable in.

Epic project.

Barry

[bulletpruf]

Originally Posted by Nobuddy

Has been a long time, but I believe you remove the cover on the top right side of the winch to access where the push/pull cables attach and are adjusted. I'm sure there is a manual for a D7D winch online somewhere that has information for where neutral point is. Controls look like brake (long lever) is released and shorter lever is engaged to forward or cable in.

Epic project.

Barry

Thanks, Barry!

Scott