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© 2010 Caterpillar
All Rights Reserved
SEBU8252-01
August 2007
Operation and
Maintenance
Manual
D7G and D7G Series II Track-Type
Tractors
7MB5000-Up (Machine)
X7C100-Up (Machine)
C7G1000-Up (Machine)
66 SEBU8252-01
Maintenance Section
Maintenance Interval Schedule
Note: Before each consecutive interval is performed, Every 250 Service Hours or 3 Months
all maintenance from the previous interval must be
Engine Oil and Filter - Change ............................. 81
performed.
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 76
• A battery supplier
• An authorized battery collection facility
• Recycling facility
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Illustration 82
i00760485
In order to test the alarm for proper functioning, turn Battery, Battery Cable or
engine start switch (1) to the ON position.
Battery Disconnect Switch -
Apply both brakes (2). Disengage parking brake (3). Replace
Move transmission control lever (4) to the REVERSE
position. SMCS Code: 1401-510; 1402-510; 1411-510
The backup alarm should sound immediately. The 1. Turn the engine start switch key to the OFF
alarm alerts the personnel behind the machine that position. Turn all of the switches to the OFF
the machine is backing up. The backup alarm will position.
continue to sound until transmission control lever
(4) is moved to the NEUTRAL position or to the 2. Turn the battery disconnect switch to the OFF
FORWARD position. position. Remove the key.
The backup alarm is at the rear of the machine. The 3. Disconnect the battery cable at the battery
nonadjustable backup alarm is set at the appropriate disconnect switch. The battery disconnect switch
sound level when the machine is shipped from the is connected to the machine frame.
factory.
4. Disconnect the negative battery cable at the
i02486605
battery.
SMCS Code: 1401-040 6. Connect the negative battery cable at the battery.
Tighten the battery retainers on all batteries at every 7. Connect the battery cable at the battery disconnect
1000 hour interval. switch.
Perform the following procedures at every 1000 hour 8. Install the key and turn the battery disconnect
interval. Check these areas more often, if necessary. switch to the ON position.
i02578326
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspect
1. Open the engine access doors on both sides of
the machine, as needed.
Illustration 83
g01291778 Note: Use the same procedure in order to replace
Alternator and fan drive
the belts.
1. Loosen bolts (1). Note: If new belts are installed, check the belt
adjustment again after 30 minutes of engine
2. Loosen adjusting nuts (2). To achieve the correct operation.
belt adjustment, move the alternator inward or
move the alternator outward, as required. Tighten i02564751
adjusting nuts (2).
Brakes, Indicators and Gauges
3. Tighten bolts (1).
- Test
SMCS Code: 4100-081; 7450-081
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Illustration 85
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Illustration 87
SEBU8252-01 71
Maintenance Section
Condenser (Refrigerant) - Clean
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Illustration 88
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Illustration 89
72 SEBU8252-01
Maintenance Section
Cooling System Coolant (ELC) - Change
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Illustration 90
Rear view of radiator
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Illustration 92
• Capacities (Refill)
Note: Caterpillar antifreeze contains additive. If
you are using Caterpillar antifreeze, do not add the
supplemental coolant additive at this time. Also,
do not change the supplemental coolant additive
g01290751 element at this time.
Illustration 91
Front view of radiator guard
SEBU8252-01 73
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
2. Start the engine. Run the engine without the filler i02578612
cap until the thermostat opens and the coolant
level stabilizes. Cooling System Coolant
Extender (ELC) - Add
3. Maintain the coolant level at 13 mm (0.5 inch)
from the bottom of the filler tube. Add coolant to SMCS Code: 1395-538
the filler tube, if necessary.
NOTICE
4. If the gasket is damaged, replace the filler cap.
Care must be taken to ensure that fluids are contained
Install the filler cap.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
5. Stop the engine.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Table 6
RECOMMENDED AMOUNT OF EXTENDER BY
COOLING SYSTEM CAPACITY
g01117259
Illustration 93
Recommended Amount
Cooling System Capacity
of Extender
6. Clean the radiator cores with compressed air. You
may need to use water in order to remove debris. 22 to 30 L (6 to 8 US gal) 0.57 L (0.60 qt)
30 to 38 L (8 to 10 US gal) 0.71 L (0.75 qt)
7. Close the engine access door.
38 to 49 L (10 to 13 US gal) 0.95 L (1 qt)
For additional information about the cooling
49 to 64 L (13 to 17 US gal) 1.18 L (1.25 qt)
system coolant, see Operation and Maintenance
Manual, SEBU6250, “Caterpillar Machine Fluids 65 to 83 L (17 to 22 US gal) 1.60 L (54 oz)
Recommendations”, “Cat Extended Life Coolant
(ELC)” or consult your Caterpillar dealer.
When a Caterpillar Extended Life Coolant (ELC)
is used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
determined by the cooling system capacity.
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Illustration 94
SMCS Code: 1350-008; 1395-008; 7542 3. Obtain the coolant sample from radiator filler pipe
(2). Collect the sample into the proper sampling
Note: It is not necessary to obtain a Coolant bottle.
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling Note: Always discard drained fluids according to
systems that are filled with Cat ELC should have local regulations.
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the Obtain the sample of the coolant as close as possible
Maintenance Interval Schedule. to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
Note: Obtain a Coolant Sample (Level 1) if the must establish a consistent trend of data. In order
cooling system is filled with any other coolant to establish a pertinent history of data, perform
instead of Cat ELC. This includes the following consistent samplings that are evenly spaced.
types of coolants. Supplies for collecting samples can be obtained from
your Caterpillar dealer.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1 Use the following guidelines for proper sampling of
(Caterpillar “EC−1”) the coolant:
• Cat Diesel Engine Antifreeze/Coolant (DEAC) • Complete the information on the label for the
sampling bottle before you begin to take the
• Commercial heavy-duty antifreeze/coolant samples.
Note: Level 1 results may indicate a need for • Place the sample in the mailing tube immediately
Level 2 Analysis. after obtaining the sample in order to avoid
contamination.
i02576000
NOTICE
Cooling System Water Since Caterpillar engines incorporate a shunt design
Temperature Regulator - cooling system, it is mandatory to always operate the
engine with a thermostat.
Clean/Replace
Depending on load, failure to operate with a thermo-
SMCS Code: 1355-070; 1355-510 stat could result in either an overheating or an over-
cooling condition.
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
problems with the cooling system. NOTICE
If the thermostat is installed incorrectly, it will cause
A new thermostat should be installed after the cooling the engine to overheat.
system has been cleaned. Install the thermostat
while the cooling system is completely drained or
while the cooling system coolant is drained to a level 4. Install a new seal in the thermostat housing. Install
that is below the thermostat housing. a new thermostat and a new gasket. Install the
thermostat housing on the engine cylinder head.
NOTICE 5. Install the elbow and the hose. Tighten the hose
Failure to replace the engine’s thermostat on a regu- clamp.
larly scheduled basis could cause severe engine dam-
age. 6. Close the left engine access door (if equipped).
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Illustration 98
Rear view
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NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage can result.
2. Remove the air cleaner cover. 6. If the primary element is not damaged, clean the
primary element.
• Pressure air
SEBU8252-01 79
Maintenance Section
Engine Air Filter Secondary Element - Replace
NOTICE
The filter should be kept in service for no longer than
g00039203 one year.
Illustration 103
7. When you clean the inside pleats and the outside NOTICE
pleats, direct the air along the pleats or direct the Always leave the secondary filter element in place
water along the pleats. while you clean the air cleaner housing.
The element can be washed in a solution that
consists of warm water and of nonsudsing 1. Open the engine access door, if equipped.
household detergent. Fully rinse the pleats. Allow
the filter to air dry completely. 2. Remove the air cleaner housing cover.
8. Inspect the filter elements after you clean the filter 3. Remove the primary filter element. Refer to
elements. Do not use a filter if the pleats, the Operation and Maintenance Manual, “Engine Air
gaskets or the seals are damaged. Filter Primary Element - Clean/Replace”.
9. Cover the clean filter elements. Store the elements 4. Clean the inside of the air cleaner housing.
in a clean, dry location.
i02575964
2. Loosen the wing nut on the top of the precleaner. Engine Oil Level - Check
Remove the cover and the cup. Empty and clean
the cup. Clean the cover. SMCS Code: 1302-535-FLV; 1326-535-FLV
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Illustration 108
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Illustration 107 1. Remove the crankcase drain valve access cover,
which is in the crankcase guard.
2. Check dipstick (2) while the engine is running at
LOW IDLE WITH WARM OIL. The oil should be
at operating temperature. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
This is the only accurate way to check the oil level.
3. Remove oil filler cap (1). If necessary, add oil. 2. Remove the drain plug. Then, open drain valve
(1). Allow the oil to drain into a suitable container.
4. Clean the oil filler cap and install the oil filler cap.
3. Close the drain valve after all of the oil has
5. Close the engine access door (if equipped). drained. Install the drain plug.
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g00679445 g01282952
Illustration 111 Illustration 113
3. Watch the top surface on each valve rotator. The 2. Inspect the rubber pads. Replace the rubber pads
rotator should turn slightly. if the rubber pad is cracked. Replace the rubber
pads if the rubber pad is starting to peel. Install
If a valve fails to rotate, consult your Caterpillar the guards.
dealer.
Consult your Caterpillar dealer for replacements.
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Illustration 112
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Illustration 114
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Illustration 115
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Illustration 117
2. Loosen the cylinder retaining clamp from the
support that is bolted to the cylinder block casting. Lubricate the fitting.
Unscrew and remove empty ether starting aid
cylinder (not shown). Close the right engine access door.
3. Remove the used gasket. Install the new gasket
that is provided with each new ether starting aid i02562747
cylinder.
Final Drive Oil - Change
4. Install the new ether starting aid cylinder. Tighten
the ether starting aid cylinder by hand. Tighten the SMCS Code: 4050-535-FLV
cylinder retaining clamps securely.
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g01280809
Illustration 118
Rear view
Some components are removed for clarity.
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Illustration 116
SEBU8252-01 85
Maintenance Section
Final Drive Oil Level - Check
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NOTICE
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Care must be taken to ensure that fluids are contained
Illustration 119 during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
2. Remove the drain plug. Drain the oil in a suitable collect the fluid with suitable containers before open-
container. ing any compartment or disassembling any compo-
nent containing fluids.
3. Install the drain plug.
Refer to Special Publication, NENG2500, “Caterpillar
4. Maintain the oil level to the bottom of the plug. Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
5. Clean the filler plug. Install the filler plug. products.
6. Repeat the procedure for the other final drive. Dispose of all fluids according to local regulations and
mandates.
i02558808
Final Drive Oil Level - Check Obtain the Sample and the Analysis
SMCS Code: 4050-535-FLV In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order
to monitor the condition and the maintenance
requirements of the final drives.
i02575683
1. Remove the oil filler plug and obtain the oil sample
with a proper suction device. Use a 1U-7683
Suction Gun or use an equivalent pump such as Fuel leaked or spilled onto hot surfaces or elec-
1U-5718 Vacuum Pump to take the oil sample. trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
2. Install the oil filler plug. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
3. Repeat Step 1 to Step 2 in order to sample the oil
in the other final drive.
NOTICE
Refer to Special Publication, PEHP6001 for more Care must be taken to ensure that fluids are contained
information on obtaining a good oil sample. Consult during performance of inspection, maintenance, test-
your Caterpillar dealer for complete information and ing, adjusting and repair of the product. Be prepared to
assistance in establishing an S·O·S program for your collect the fluid with suitable containers before open-
machine. ing any compartment or disassembling any compo-
nent containing fluids.
i02575650
Refer to Special Publication, NENG2500, “Caterpillar
Fuel System - Prime Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
SMCS Code: 1258 products.
The priming pump is located inside the right engine Dispose of all fluids according to local regulations and
access door. mandates.
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Illustration 122
SEBU8252-01 87
Maintenance Section
Fuel System Primary Filter - Clean/Replace
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g01290577
Illustration 123
Personal injury or death can result from engine
overspeed.
1. Open the engine access door on the right side of
the machine.
If the engine overspeeds, it can cause injury or
parts damage.
Illustration 124
g01290578 Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
2. Extend drain hose (2) into a suitable container.
Drain (1) is located under the primary fuel Turn the disconnect switch OFF or disconnect the
filter/water separator. battery when changing fuel filters.
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g01290579
Illustration 126
g01290608
Illustration 128
i02573812
g01289342
Illustration 131
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
i02574929
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
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Illustration 132 NOTICE
If it is necessary to replace fuses frequently, an elec-
1. Open the access cover on the rear of the machine. trical problem may exist.
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Illustration 133
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Illustration 134
Circuit Breaker
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Illustration 135
Fuses
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Illustration 137
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Horn - Test
g01290001 SMCS Code: 7402-081
Illustration 136
Fuse panel block Test the horn on a daily basis. Press downward on
the horn button in order to sound the horn. If the horn
Ignition Key (1) – 10 Amp does not sound, make the necessary repairs before
you operate the machine.
Flood Lights (Front) (2) – 15 Amp
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Illustration 139
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Illustration 138
i02575638
The hydraulic oil filter is located behind the right side 2. Open the oil drain valve under the hydraulic oil
access door. tank and drain in a suitable container.
The hydraulic oil tank is located on the right side of 3. Close the valve.
the rear of the machine.
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Illustration 141
SEBU8252-01 93
Maintenance Section
Hydraulic System Oil Filter - Replace
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Illustration 142
11. Close the right side access door. 1. To relieve the tank pressure, slowly remove
hydraulic oil filler cap (1).
i02575598
g01290502
Illustration 145
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Hot oil and components can cause personal in- Illustration 148
g01290349
jury. Do not allow hot oil or components to contact
skin. 1. Remove hydraulic tank filler cap (1) slowly in order
to relieve any pressure.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to 2. Remove the filler strainer (not shown). Use a
touch with your bare hand. Remove the filler cap 1U-5718 Vacuum Pump or an equivalent pump.
slowly in order to relieve pressure. Insert the suction tube into the filler tube and draw
a sample of the hydraulic system oil.
NOTICE
Always use a designated pump for oil sampling, and 3. Replace the filler strainer and the hydraulic tank
use a separate designated pump for coolant sampling. filler cap.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This The recommended interval for oil samples is every
contaminate may cause a false analysis and an incor- 500 hours. The recommended hydraulic oil change
rect interpretation that could lead to concerns by both interval is 2000 hours.
dealers and customers.
Reference: Refer to “Lubricant Viscosities” in the
Maintenance Section of this publication for the
Obtain a sample of the hydraulic oil from the hydraulic correct fluid for your machine.
tank. The hydraulic tank is located on the right side of
the rear of the machine. Reference: Refer to the Operation and Maintenance
Manual, “S·O·S Oil Analysis”.
i02106227 i00057294
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Illustration 150
i02575177
If equipped:
Tips
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Illustration 151
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Illustration 152
D7G ripper
Shank
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Illustration 155
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Illustration 154 Typical example
When the ripper shank is worn or damaged, replace Check the seat belt mounting hardware (1) for wear
the ripper shank. or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
1. Raise the ripper. Place blocking under the ripper. bolts are tight.
Lower the ripper onto the blocking. The ripper
should be high enough so that the ripper shank Check buckle (2) for wear or for damage. If the buckle
can be removed. Do not place the ripper too high. is worn or damaged, replace the seat belt.
2. If the shank is worn or damaged, remove cotter Inspect the seat belt (3) for webbing that is worn or
pin (3). Then drive out pin (4). Remove shank (5). frayed. Replace the seat belt if the seat belt is worn
or frayed.
3. Install the new shank and pin (4).
Consult your Caterpillar dealer for the replacement of
4. Install cotter pin (3). the seat belt and the mounting hardware.
5. Raise the ripper and remove the blocking. Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
6. Lower the ripper to the ground. the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
i02429589
buckle, and the seat belt retractor.
Seat Belt - Inspect
If your machine is equipped with a seat belt
SMCS Code: 7327-040; 7520 extension, also perform this inspection procedure for
the seat belt extension.
Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before i02429594
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine. Seat Belt - Replace
SMCS Code: 7327-510
i02560021
g01152685
Illustration 156
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
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Illustration 157
Check
Check the track adjustment. Check the track for wear
and for excessive dirt buildup.
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Illustration 160
Left track roller frame
SEBU8252-01 101
Maintenance Section
Track - Check/Adjust
Adjust
2. Remove the cover for the track adjusting 9. Repeat the procedure on adjusting of the other
mechanism. track for the other side.
3. Add grease (MPGM) through adjusting valve (4) Bolt Torque for Track Shoes
in order to move the idler forward until the track
is fully tight.
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Illustration 164
102 SEBU8252-01
Maintenance Section
Track Pins - Inspect
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Illustration 165
3. Do not hit the ends of the track pins with a sledge 2. Lubricate the two outer bearings. The bearings
hammer in order to loosen the track joints. are located on each side of the machine.
SEBU8252-01 103
Maintenance Section
Transmission Magnetic Screen - Clean
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Illustration 168 Illustration 170
Right view
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Illustration 171
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Illustration 169
(1) Cover
(2) Screen
(3) Magnet assembly
12. Install the oil filler cap and close the door.
i02578230
Operate the engine in order to warm the oil. Park the g01291710
machine on level ground. Lower all attachments to Illustration 174
the ground. Apply slight downward pressure.
2. Remove the access cover in the bottom guard
Engage the parking brake switch. Stop the engine. assembly. Remove the oil drain plug from the
torque converter housing.
Drain Oil 3. Allow the oil to drain in a suitable container.
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Illustration 173
Rear view
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Illustration 175
1. Remove the transmission oil drain plug from the
bevel gear case. Drain the oil into a suitable 5. Remove cover (1) and screen (2) from the torque
container. converter housing.
Fill Oil
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Illustration 178
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Illustration 176
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Illustration 179
Front view
i02578003 2. Remove housing drain plug (2) and allow the oil
to drain in a suitable container.
Transmission Oil Filter -
Replace 3. Remove housing cover (1).
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and 4. Remove the used filter element from the housing.
mandates.
5. Clean the inside of the housing with a clean cloth.
1. Open the left engine access door.
6. Clean the cover. Replace the damaged seal with
a new seal.
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g01291542
Illustration 181
Section view of transmission oil filter
SEBU8252-01 107
Maintenance Section
Transmission Oil Sample - Obtain
i02578159
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
Illustration 185
g01282066 rect interpretation that could lead to concerns by both
(A) Cold engine
dealers and customers.
(B) Warm engine
108 SEBU8252-01
Maintenance Section
Window Washer Reservoir - Fill
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NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
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Illustration 186
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Illustration 188
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Illustration 187
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Window Wipers -
Inspect/Replace
(If Equipped)
SMCS Code: 7305-040; 7305-510
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Illustration 190
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Illustration 189
i02578689
Windows - Clean
SMCS Code: 7310-070; 7340-070