caterpillar d7g crawler parts manual - jensales...the caterpillar d7g crawler parts manual \(s/n...

Parts Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Parts

Man

ual

D7G S/n 92V11898 & Up

CT-P-D7G92V118

http://www.jensales.com/products/caterpillar-d7g-crawler-parts-manual-s-n-92v11898.html

ALPHABETICALINDEXOF dROUPS __ 3 CONVERSION EQUIVALENT

TABLES ' INSIDE BACK COVER ORDERING PARTS ___ -'-...:.. _______ ;... __ 2

QUIC.K REFERENCE CHART INSIDE FRONT "€OVER"

lJSING THE P'ARTS BOOK __________ ,2c

PARTS BOOK D.7G TRACTOR POWERED BY 3306 ENGINE SERIAL NUMBER 92Vl18a8-UP (VECHICLE) 8Z16129-UP (ENGINE) 2GA1-UP (TRANSMISSION) 30F1500-UP (7 A BULLDOZER) 72F17800-UP(7A BULLDOZER) 49K1800-UP (7S BULLDOZ~R) 60K8000-U P (7S BU LLDOZER) " 61 K1200-UP (7U BULLDOZER) 28A13000-UP (1738 HYDRAULIC qONTROL) 12G7500-U P(RI PPER) 83G1000-UP (RIPPER) 29U2884-UP(57 WINCH)

CA IERPI LLAR TE;tACTOR CO. PUBLICATIONS·[)IV . ...,-SERVICE G.O~. PEORIA, ILL. U.~.A. '


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REPLACEMENT ITEMS The following chart provides a convenient listing of those items which require occasional replacement during normal operation or maintenance.

QTY. PAGE PART NO. USED NO.

BATTERIES -12 Volt 9G4247 2 96

BREATHERS Crankcase - Breather Assem. 8S248 1 34 :"". Transmission 9G5127 1 153 Winch 8S5820 1 299A

COOLING SYSTEM Relief Valve Assem. 5S1218 1 36

FILTERS Air Cleaner I Element :~:~.~Ni 1 52 Element 1 52 Cab Pressurizer - Filter Assem. 6P6664 & 2 317

6P1319 1 316 Crankcase - Filter Assem, 2P4004 1 32 Fuel

Element Assem. 9M2341 1 86 Filter Assem. 1P2299 1 90

Hydraulic Tank - Element Assem. 9J5461 or 1 231

(Use with Fire Resistant Fluid) 3G3448 1 231 Transmission & Steering Clutch

Element Assem. 4J6064 or 1 156 (Use with Fire Resistant Fluid) 1 U2094 1 156

Screen 3S3875 1 156 Seal 5F149 1 156

Winch Element 2P5834 1 293

GASKETS Hydraulic Filler Cap 9H6454 1 231 Radiator Filler Cap 2P3230 1 37 Valve Cover 8S1605 1 18

HOSES - Fumes Disposal 8S780 1 35

LAMPS Front & Rear - Sealed Units 1M5898 4 134

i'· SEAT BELT 7G2998 1 327

VEE· BELTS Air Conditioner 4N7335 1 343 Alternator & Fan 7M471 0 (Includes 2 Belts) 23

.. WINDSHIELD WIPER BLADE (Front & Rear) 5P5345 3 352 .


308880

POWER TRAIN SCHEMATIC

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INDEX

Name Page Name Page

A Clutch & Refrigerant Compressor 345 Compressor Auxiliary Drive .................. 346

Accessory Drive-Rear Gear ................... 27 Condenser-Air Conditioner .................... 341 Air Cleaner ............................................ 52 Connecting Rod & Piston ....................... 13 Air Conditioner ..................................... 332 Cover-Cylinder Head .............................. 16 Air Conditioner Arrangement ..... 330 & 334 Cover-Front Engine Housing ................... 20 Air Conditioner Lines ............................ 337 Crankcase Guard ................................. 203 Air Lines-Engine ..................................... 50 Crankshaft ............................................. 11 Alarm-Battery & Wiring .......................... 95 Crankshaft Bearing Replacements .......... 12 Alternator ..................................... 104-113 Crankshaft Pull~y ... ;............................... 24 Ammeter-Battery & Wiring ...................... 94 Crankshaft Seals ...... ............................. 13 Ammeter-Cab Wiring ............................ 131 Cutting Edge & End Bit Arm & Brace-Bulldozer ......................... 286 Replacements .................................. 281

. Auxiliary Drive-Refrigerant Cylinder Block ......................................... 8 Compressor ..................................... 346 Cylinder Block Covers ........... ....... ......... 11

Cylinder Head ........................................ 15 Cylinder Head Cover .............................. 16

B Cylinder Head Fasteners ........................ 16 Cylinder Mounting-Hydraulic-Bulldozer ... 261

Battery & Wiring .................................... 94 Cylinder-Hydraulic Tilt ............... 260 & 285 Battery .................................................. 96 Cylinder-Ripper .................................... 267 Battery Box ......................................... 215 Bearings-Camshaft ................................... 8 Blade-Bulldozer .................................... 278 D Brace-Safety-ROPS ............................. 203 Brake Band & Lining ............................ 167 Damper ................................................. 24 Brake Hydraulic Mechanism ................. 174 Dash ................................................... 184 Breather-Engine ..................................... 34 Decelerator Control ............................... 62 Breather-Towing Winch ........................ 299 Drain Lines-Fuel ..................................... 85 Breather-Transmission Oil.................... 153 Drawbar-Fixed ..................................... 209 Brush Guard ......................................... 206 Drawbar-Swinging ................................ 209 Bulldozer Arrangements ....................... 274 Drive Shaft-Transmission ...................... 139 Bulldozer Lift & Tilt Control Valve ......... 227 Drum-Steering Brake ............................ 161 Bulldozer Lines .................................... 248 Dust Ejector .......................................... 53

c E C-F rame-Bulldozer 287 Element-Air Cleaner 52 Cab Accessories ................................. 329 Emergency Starting Receptacle ........... 130 Cab Heater .......................................... 347 End Bit Replacements .......................... 281 Cab Liner-Sound Suppression ......... :.... 314 Engine Arrangements .~............................. 4 Cab Pressurizer .. .................................. 316 Engine Enclosure ................................. 210 Cab Sliding Window.·............................ 313 Engine Mounting Hardware ..................... 23 Cab Wiring ........................................... 131 Engine Support ...................................... 22 Cable Guide & Case ............................ 304 Equalizer Bar & Track Roller Camshaft ........... :; ........... : .................... ;. 14 Camshaft-Fuel Injectin Pump.......... .... 69

Frame Arrangement ......................... 188 Equalizer Bar ....................................... 192

Cartridge-Hydraulic Pump ........ ; ............. 243 Ether Starting Aid ................................ 114 Case-Cab Pressurizer ........ ;.................. 319 Exhaust Extension ................................. 57 Circuit Breaker~Cab Wiring .... : .. ;;.......... 131


Name Page Name Page

Exhaust Manifold ................................... 58 G . Exhaust Manifold Fastener ...................... 58

Gasket Kit ........................................... 363 Gasket-Cylinder Head ............................ 15

F Gasket-Valve Cover ............................... 18 Gauge-Air Filter ................................... 355

Fan Drive ............................................... 18 Gauge-Engine Oil Level .......................... 33 Fan Drive Pulley .................................... 23 Gauge-Transmission Oil ........................ 152 Fan-Blower .......................................... 39B Gauges ................................................ 354 Fah~Reversible ....................................... 41 Gauges-Sound Suppression .................. 358 Fan-Supplemental Cooling ...................... 42 Gears-Front Timing-Engine ..................... 21 Fender ................................................. 186 Governor & Decelerator Control ............. 62 Filler-Transmission Oil .......................... 153 Governor & Fuel Injection Pump ............. 66 Filter & Tank-Hydraulic ......................... 230 Governor ............................................... 72 Filter-Air Cleaner .................................... 52 Governor Control ................................... 60 Filter-Cab Pressurizer .......................... 316 Grab Iron-Hood .................................... 210 Filter-Engine Oil .................................... ,._.,:,~2 Grease Gun ......................................... 362 Filter-Fuel .............................................. . 90 Guard-Brush ....................•................... 206 Fi',ter-Hydraulic Tank ............................ :~ 231 Guard-Crankcase ................................. 203 Filter-Primary Fuel .................................. 86 Guard-Fan ............................... ............. 39B Filter-Transmission & Steering Clutch ... 156 Fiiter-Winch ............................ : ........... : 293

Guard-Final Drive ................................. 207 Guard-Radiator .................................... 200

Final Drive ....... ~................................... 160 Guard-Radiator Bottom ........................ 201 Final Drive Case .................................. 207 Guard-Recoil Mechanism ...................... 189 Fihal Drive Wear Guard ....................... 207 Guard-Track Guiding ............................ 193 Fire Extinguisher .................................. 360 Guard-Track Roller ............................... 193 Floormat-Cab Liner .............................. 314 'Floorplate ............................................ 181 Flywheel ................................................ 25 H

. Flywheel Housing ............... :................... 26 Frame & Case ..................................... 182 Handle-Steering Clutch Control ............. 168

'. Front Housing Fastener .......................... 20 Harness-Battery & Wiring ...... ,............... 100 • IIf6nt Housing-Engine ............................. 19 Harness-Cab Pressurizer ..................... 320 '., " Idler ............................................ 190 Harness-Cab Wiring ............................. 132

r'"JTing. Gears-Engine ..................... 21 Fuel Dram Lmes ..................................... 85

Heater-Cab .......................................... 348 Hood & Dash ....................................... 184

Fuel Heater Changeover ........................ 89 Horn ...................................................... 95 Fuel Injection Lines ......... : ...................... 81 Hose-Upper & Lower Radiator ............... 37 Fuel Injection Pump ................................ 68 Housing-Front-Engine ............................. 19 Fuel Lines .............................................. 91 Hydraulic Control Arrangements ........... 217 Fuel Priming Pump & Primary Filter ........ 87 Hydraulic Lines-Bulldozer Push Arm ..... 255 Fuel Pump Housing ................................ 70 Hydraulic Pump Lines ............... 244 & 246 Fuel Pump-Boost .................................... 85 Hydraulic Tank & Valve ........................ 226 Foel Ratio Control .................................. 78 Hydraulic Tank Mounting ...................... 223

;. '. Fuel Tank .............................................. 92 . "FOel Transfer Pump & Mounting ............. 65

. . Disposal ..................................... 35 I usE~-Batt49rv & Wiring ............................ 94

i=tise~Cab Wiring .................................. 131 Idler ..................................................... 191 Implement Linkage-Dozer & Blade

Tilt ................................................... 268


Name Page Name Page

Implement Linkage-Ripper .................... 270 Mirror .................................................. 328 Indicator-Air Filter ................................ 355 Mounting-Hydraulic Tank ...................... 223 Instrument Panel Protection .................. 359 Muffler ................................................... 57

J N

Jacket Water Heater ............................. 42 Name Plate & Films ............................. 364 Nozzle-Fuel Injection .............................. 82

K o

Key-RaPS Cab .................................... 312 Kit-Alternator repair ............................. 105 Oil Cooler-Engine ................................... 46 Kit-Turbocharger Repair ......................... 55 Oil Cooler-Transmission .......................... 47 Kit-Water Pump Repair .......................... 45 Oil Filler-Engine ...................................... 32

Oil Filter-Engine ...................................... 32 Oil Filter-Towing Winch ........................ 293

L Oil Level Gauge Protection-Engine ,......... 33 Oil Level Gauge-Engine ........................ o. 33

Lamp-Flood ......................................... 134 Oil Lines-Engine ..................................... 29 Lamp-Indicator-Cab Wiring ... ~............... 133 Oil Pan ................................................. : 28 Lever Housing-Bulldozer Lift & Oil Pan Fastener .................................... 28

Tilt Control ....................................... 232 Oil Pump-Engine ..................................... 30 Lift Cylinder & Valve ............................ 262 Lifter-Valve Mechanism .......................... 17 Lifting-Engine ............................... .......... 17 p Lighting ................................................ 133 Liner-Cylinder Block ............. ;.................... 9 Padlock-Fuel Tank Cap .......................... 93 Lines-Air Conditioner ............................ 337 Padlock-Hydraulic Tank Cap ................ 225 Lines-Bulldozer ..................................... 248 Padlock-Instrument Panel ..................... 359 Lines-Hydraulic Pump ................ 244 & 246 Padlock-Oil Level Gauge ........................ 33 Lines-Hydraulic-Bulldozer Push Arm ...... 255 Padlock-Radiator Cap ............................ 39 Lines-Ripper ......................... 0............... 251 Panel-Engine Sound Suppression ............ 21 Lines-Tilt Cylinder ................................ 256 Pedal-Steering Brake ........................... 165 Lines-Torque Converter Cooler ............... 48 Piston-Cylinder Block ............................. 13 Lines-Turbocharger Oil ........................... 53 Planetary Transmission ........................ 150 Lines-Winch ......................................... 250 Power Shift Schematic ........................... 2B Linkage-Governor Control ............ :.......... 60 Powershift Transmission Linkage-Implement-Dozer & Blade Arrangement .................................... 140

Tilt ................................................... 268 Prescreener-Air Cleaner ......................... 52 Linkage-Steering Brake ........................ 163 Primary Fuel Filter ................................. 86 Linkage-Transmission Control............... 142 Protection Cap-Fuel Tank ....................... 93 Logging Sweep .................................... 322 Protection Cover-Hydraulic Tank Cap ... 225

Protection Cover-Radiator Cap ............... 39 Protection Screen-RaPS ...................... 321

M Pulley-Crankshaft ................................ ,.. 24 Pulley-Fan Drive ..................................... 23

Magnetic Screen-Towing Winch ............ 293 Pump-Fuel Injection ................................ 68 Magnetic Screen-Transmission

Oil Lines .......................................... 156


Name Page

Pump-Fuel Priming ................................. 87 Pump-Fuel Transfer ................................ 65 Pump-Gear-Transmission Oil Lines ....... 158 Pump-Gear-Winch ................... .............. 241 Pump-Scavenge-Transmission .............. 159 Pump-Vane-Hydraulic Control ............... 242 Push Arm-Bulldozer .............................. 283 Push Cup ............................................. 288

R

Radiator ............ ,................................... 36 Radiator Guard .................................... 200 Radiator Hinged Grill ............................ 202 Radiator Sand Blast Grid ....................... 39 Rear Gear-Accessory Drive ................... 27 Recoil Mechanism Guard ..•.................. 189

.~, .. :.:::::~::.:~:::::::::::

s,

190

343

Sand Blast Grid ..................................... 39 " Screen-Protection-ROPS ...................... 321

Seat-Fuel Injection Pump Housing ........... 81 Seat ..• ,;................................................ 326

" Seat Belt ............................................. 325 Seat-Adjustable .................................... 325

,: Secondary Fuel Filter ........ ~.................... 90 0'. Meter ....•............. ..................... 354

'slirlinln'7Window-Cab .............................. 313 SolerlOid"'Sijirting Motor........................ 122 Sound Suppression Cab Liner .............. 314 Sound Suppression panel-Engine ............. 21

'?66 ~.,.r"T1."'nt.c.rI··:;, •...•....... , .... 0· ....... ;.... ., 'l62

Name Page

Starting Motor-Electric .................. 115-129 Steering Brake .......................... 163 & 176 Steering Clutch ;................................... 170 Steering Clutch Control............. 168 &. 173 Suction Bell-Oil Lines ............................. 29 Supplemental Cooling .... ,........................ 42 Support-Engine .......... ............................. 22 Support-Equalizer Bar .......................... 192 Sweep : ................................................ 323 Switch-Disconnect ............................... 103 Switch-Heat-Start ................................. 131 Switch-Horn ........................................... 94 Switch-Light ....................... ,................... 94 Switch-Light-Cab Wiring ....................... 131 Switch-Starter .................................. ,... 103

T

Tank-Hydraulic ........... , ............ ............. 230 Thermostat-Water Temperature ............. 43 Tilt Cylinder Lines ................................ 256 Tool Box .............................................. 214 Tools-Hand .......................................... 361 Tooth-Ripper ........................................ 290 Torque Chart .....................................•. 365 Torque Control ....................... .................. 71 Torque Converter ............................... o. 135 Torque Converter Cooler Lines ......... ..... 48 Towing Winch ......... ................... ..... ..... 294 Towing Winch Arrangement ................. 291 Towing Winch Control .......................... 301 Track ............................................ :........ 198 Track Carrier Roller ............................. 195 Track Guiding Guard ............................ 193 Track Roller ......................................... 196 Track Roller Frame .............................. 194 Track Roller Guard ............ ;":~,; ... : .......... 193 Track Seals & Bushings ...................... .200 Transfer Gear ............................. '......... '149 Transmission Case & Covers ............... 148 Transmission Control ..... : .............. ,........ 142 Transmission ,,:!ydraulic Control ............ 141 Transmission Oil Lines ......................... 152 Trunnion-Bulldozer ................................ 277 Trunnion-Engine ...................................... 19 Turbocharger ......................................... 54 Turbocharger Oil Lines ........................... 53

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