Procedure to Update a 777G Off-Highway Truck for a Groeneveld or Lincoln Auto Lubrication Installation {0679, 1408, 7253, 7516, 7540} Caterpillar

Off Highway Truck

777G (S/N: T5A1-117; TNM1-734; RDR1-281; T4Y1-187)

Introduction

This special instruction will provide instructions for updating the machines listed above with an auto lubrication system on the right-hand platform. This special instruction must be used with either Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks" or Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks". This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine. A complete listing of the required parts is listed in the Parts Manual, SEBP6011. Systems Operations and Testing and Adjusting information is available in the Systems Operation Testing and Adjusting Manual, KENR9937.

Note: Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Reference: Operation and Maintenance Manual, SEBU8095, "Parking"

Reference: Operation and Maintenance Manual, SEBU8227, "Parking"

Reference: Parts Manual, SEBP6011

Reference: Systems Operation Testing and Adjusting Manual, KENR9937

Reference: Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks"

Reference: Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks"

Reference: Special Instruction, REHS1841, "General Welding Procedures"

References to Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks"

This section provides additional information for the machines listed above to relocate the auto lubrication pump from the rear of the chassis to the right-hand platform.

Refer to Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks" for machines with the following service center arrangements to relocate the auto lubrication pump from the rear of the chassis to the right-hand platform:

• 360-2633 SERVICE CENTER AR

• 373-4027 SERVICE CENTER AR

• 340-9998 SERVICE CENTER AR

• 358-9141 SERVICE CENTER AR

In Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks", in Section "Installation of the Fast Fill Lines Group", the following parts from Table 3 are required. Reference Step 1 through Step 10, and Illustration 6 through Illustration 14 of Section "Installation of the Fast Fill Lines Group" for assembly of the parts. These parts will connect the existing 360-4438 Tube As on a machine to the auto lubrication pump on the right-hand platform.

In Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks", in Section "Install the Lubrication Block and Lines Group", the following parts from Table 6 are required. Reference Step 10 through Step 15, and Illustration 33 through Illustration 35 of Section "Install the Lubrication Block and Lines Group" for assembly of the parts. These parts route the 433-2732 Hose As from the distribution block from the inside right rear of frame to the auto lubrication pump on the right-hand platform.

In Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks", in Section "Install the Lubrication Block and Lines Group", the following parts from Table 6 are required. Reference Step 3 and Illustration 27 of Section "Install the Lubrication Block and Lines Group", and reference Illustration 90 of Section "Install the Lower Rear Lubrication Distribution Lines" for assembly of the parts. These parts route the 433-2732 Hose As from the distribution block from the inside right rear of frame to the auto lubrication pump on the right-hand platform.

Required Parts

Safety Information

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product, until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

Illustration 1	g00008666

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. Youmust not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method, or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Youshould also ensurethat the product will not be damaged or become unsafe by the operation, lubrication, maintenance, or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

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When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

General Information

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, do the procedure that follows before testing and adjusting the automatic lubrication system.

1. Move the machine to a smooth horizontal location. Move away from operating machines and move away from all personnel. Put blocks in front of the wheels and behind the wheels.

2. Put the transmission direction and speed control in the PARK position. The parking brake automatically activates when the vehicle shifts to "P". Stop the engine.

3. Permit only one operator on the machine. Keep all other personnel away from the machine. Also, all personnel should be visible to the operator.

4. Make sure that all hydraulic pressure is released before you perform any of the following procedures:

   • Loosen any fitting, any hose, or any component.

   • Tighten any fitting, any hose, or any component.

   • Remove any fitting, any hose, or any component.

   • Adjust any fitting, any hose, or any component.

For the locations of your individual system components, refer to the Systems Operation module for your machine.

For more information on the electrical system, refer to the Electrical Schematic for your machine.

Visual Inspection

When you are identifying a problem, visually inspect the automatic lubrication system. As follows, visually inspect the complete automatic lubrication system.

1. Inspect the injector banks, all of the lubrication lines, and all of the connections for lubrication leaks.

2. Inspect the electrical system for worn wiring or frayed wiring. Also, inspect the electrical system for damaged connectors or a bad fuse.

Welding Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 237-5181 Respirator for breathing protection.

Qualifications

Welders must be qualified for the appropriate type of weld that is being performed. Welders must be qualified for the appropriate position of weld that is being performed. Welders must be qualified for the welding process that is being utilized: Shielded Metal Arc Welding (SMAW) and Flux Cored Arc Welding (FCAW). Refer to Specification ANSI/AWS D1.1 for information that regards qualification requirements. The welders must have used the process at some time within the last 6 months. The welders must complete the process of certification if the welders have not used the welding processes for 6 months.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Attach the clamp for the ground cable as close as possible to the area that is being welded. This process will reduce the likelihood of damage from the welding current to the following components: bearings, hydraulic components, and electrical components. DO NOT weld plates to the frame for grounding/clamping purposes. Use existing blocks, brackets, bosses, and so on, to attach the clamp.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

4. Protect the wiring harnesses and machine surfaces from sparks and welding spatter.

Area Preparation

The area to be welded shall be clean, dry, and free of the following contaminants:

• Oil

• Grease

• Paint

• Dirt

• Rust

• Any fluids or moisture

All welding shall be conducted on base material heated and maintained at a minimum temperature of 15.6° C (60° F).

Note: Heating instructions (preheat, interpass, and postheat) for any specific repair shall override the minimum 15.6° C (60° F) requirement.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Welding Electrodes and Parameters

Flux Cored Welding Electrode for the FCAW Process

Use the Flux Cored Arc Welding (FCAW) with E71T-1 H8 (ANSI/A5.20) welding electrode and the manufacturer's shielding gases that are specified (typically 75% argon and 25% carbon dioxide). The H8 implies that the electrode is designed to provide less than 8 ml/100 g of diffusible hydrogen in the weld deposit. The weld that is deposited by the flux cored welding electrode will have the following minimum mechanical properties:

The tables that follow show the recommended parameter ranges for out of position welding in the field for two different flux cored welding electrode diameters.

Note: The settings listed above are recommendations-based on experience from welding in the horizontal, vertical-up, and overhead positions. Slight changes in the voltage and amperage may be necessary due to welding position and various formulations by different electrode manufacturers. The use of higher parameters than specified for welding in the flat position is acceptable.

Use a polarity setting of DC reverse polarity. Remove the slag after each welding pass. The fast freezing characteristics of flux cored welding electrode increases the possibility of evolving gas that is trapped in the weld. Control the size of the weld in order to reduce the possibility of evolving gas that is trapped in the weld. The maximum size weld per pass should be equivalent to that of a 8.0 mm (.32 inch) fillet weld.

Low Hydrogen Electrodes for the SMAW Process

As an alternative process or when wind conditions are a factor, use SMAW and low hydrogen electrodes that meet the following requirements.

Low hydrogen electrodes must be stored in an electrode oven at 120 °C (250 °F) when not in use. If low hydrogen electrodes get damp, scrap the low hydrogen electrodes or recondition the low hydrogen electrodes to the manufacturer's specifications.

The table that follows shows the settings for the welding current based on electrode diameter.

Use a polarity setting of DC reverse polarity. Remove the slag after each pass of the welding electrode. The width of the weld should not exceed two times the electrode diameter.

Weld Inspection and Acceptance Criteria

Auto Lubrication Update Procedure

Modify the Right-Hand Platform

Required Parts

Modification Procedure

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Illustration 2	g03660047
View of the left rear of the right-hand platform (A) 171 mm (6.732 inch) (B) 581 mm (22.874 inch) (C) 183.3 mm (7.217 inch) (D) 347.7 mm (13.689 inch) (E) 536 mm (21.102 inch)

1. Mark the location of the four mounting holes on the left rear of the right-hand platform deck plate. Refer to Illustration 2.
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   Illustration 3	g03660800
   View of the left rear of the right-hand platform

2. Position bracket assembly (1) at the left rear of the right-hand platform and align with the four marked locations. Using bracket assembly (1) as a template, mark the eight mounting holes on the right-hand platform deck plate.

3. Drill the eight mounting hole locations using a 13.5 mm (0.532 inch) bit.

   Note: Grind smooth any tread protrusions on the right-hand platform plate that will interfere with the mounting locations of bracket assembly (1).

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   Illustration 4	g03660856
   (F) 342.3 ± 3 mm (13.47 ± 0.12 inch) (G) 486.5 ± 2 mm (19.15 ± 0.08 inch) (H) 411.4 ± 3 mm (16.18 ± 0.12 inch) (J) 56 ± 2 mm (2.2 ± 0.08 inch) (K) 12.7 mm (0.5 inch) (entire perimeter)

4. Modify the steering hydraulic tank to accept clipping points for the auto lube system wiring harness. Install plate (2) to the steering hydraulic tank with a 6 mm (0.25 inch) all around filet weld. Install weld boss (3) to the side of the steering tank with a 6 mm (0.25 inch) all around filet weld. Refer to Illustration 4 for positioning. Refer to Special Instruction, REHS1841, "General Welding Procedures".

5. Begin installation of the auto lubrication system.

   1. For Groeneveld systems, refer to Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks". Proceed through the installation steps, but stop before completing the "Install Sensor Harness Assembly" section.

   2. For Lincoln systems, refer to Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks". Proceed through the installation steps, but stop before installing the rear sensor harness assembly in the "Install the Rear Lubrication Valve Group" section.

Install the Supplemental Wiring Harness

Required Parts

Installation Procedure

Note: 437-5500 Sensor Harness As is not re-used on machines with the Lincoln System with updated harness assembly. Refer to Service Magazine, SEPD1664, "A New Harness Assembly is Available for Certain 777G Off-Highway Trucks".

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Illustration 5	g03661125
View of the front facing side of the steering tank

1. Install wiring harness (4) to the auto lube switch harness assembly installed with either the Groeneveld or Lincoln auto lubrication system.

   Note: Refer to item (58) in Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks" or item (43) in Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks"

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   Illustration 6	g03661756
   View of the right platform and steering tank

2. Route wiring harness (4) down the steering tank, and route the longest leg of the harness towards the rear of the machine, and the shorter leg along the right side of the engine compartment towards the front of the machine. Secure wiring harness (4) to the steering tank wiring harness with two cable straps (5). Secure the long leg of wiring harness (4) to the auto lube supply hose(s) with two straps (6).
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   Illustration 7	g03685376

3. Assemble clip (7) onto the tube assembly as shown in Illustration 7. Insert bolt (8) through one hard washer (9), clip (10), clip (7), and one hard washer (9). Assemble nut (11) on to bolt (8) and tighten nut (11). Secure wiring harness (4) to clip (10) with one cable strap (5).
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   Illustration 8	g03685894

4. Assemble one mount (12) to hose assembly that connects to the steering pump using one cable strap (5) as shown in Illustration 8.
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   Illustration 9	g03686047

5. Assemble clip (13) on the hose assembly as shown in Illustration 9. Insert bolt (14) through one hard washer (9), clip (13), clip (15) and one hard washer (9). Assemble nut (11) on to bolt (14) and tighten nut (11). Secure wiring harness (4) to clip (15) using one cable strap (5).
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   Illustration 10	g03686110

6. Assemble clip (16) on to the hose assembly using the existing bolt and washer as shown in Illustration 10. Secure wiring harness (4) to clip (16) using one cable strap (5).
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   Illustration 11	g03686233

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   Illustration 12	g03686607

7. Continue routing wiring harness (4) along the inside right frame rail as shown in Illustration 11 and 12. Secure wiring harness (4) to chassis wiring harness using one cable strap (5).
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   Illustration 13	g03686684

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   Illustration 14	g03686644

8. Continue routing wiring harness (4) along the right inside frame rail as shown in Illustration 13 and 14. Secure wiring harness (4) to four frame weld links using four cable straps (5). Secure any excess length with an additional cable strap (5).
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   Illustration 15	g03662509

9. Connect the three wiring connectors on wiring harness (4) to the three corresponding receptacles on the chassis wiring harness as shown in Illustration 15. Assemble one clip (17) as shown in Illustration 15. Secure wiring harness (4) to clip (17) using one cable strap (5). Secure wiring harness (4) to existing clip using one cable strap (5).

   Note: For Lincoln system Step 10 and Step 11 are not required. Skip to Step 12. The remaining length of wiring harness (4) may be coiled up and secured back to the harness on the inside right frame rail using one cable strap (5).

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   Illustration 16	g03662812

10. Continue routing wiring harness (4) along the inside right frame rail and over the rear support assembly as shown in Illustration 16. Assemble wiring harness (4) to chassis wiring harness using four cable straps (5).
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    Illustration 17	g03686790

11. Continue routing wiring harness (4) down the left-hand side of the right side rear tail lamps mounting plate. Secure wiring harness (4) using the existing mounting plate hardware with two clips (18) and two cable straps (5). The lower clip (18) requires one bolt (14), two washers (19), and one nut (11). Secure wiring harness (4) to the existing ladder clip using one cable strap (5). Connect wiring harness (4) to pressure sensor and secure any excess length using one cable strap (5). Refer to Illustration 17.

    Note: 419-4118 Sensor Harness As is not required. Refer to "Install Sensor Harness Assembly" section in Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks".

    Note: For Groeneveld system Step12 through Step 16 are not required. Skip to the "Route the Forward Section of the Wiring Harness on Groeneveld Systems" section.

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    Illustration 18	g03687056

12. Connect wiring harness (20) to the pressure sensor as shown in Illustration 18. Secure wiring harness (20) to existing ladder clips using two cable straps (5).

    Note: 419-4118 Sensor Harness As is not required. Refer to "Install the Rear Lubrication Valve Group" section in Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks".

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    Illustration 19	g03687114

13. Continue routing wiring harness (20) up the left-hand side of the right side rear tail lamp mounting plate. Secure wiring harness (20) using the existing mounting plate hardware with two clips (18) and two cable straps (5) as shown in Illustration 19. The lower clip (18) requires one bolt (14), two washers (19), and one nut (11). Secure wiring harness (18) to existing chassis wiring using one cable strap (5).
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    Illustration 20	g03687133

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    Illustration 21	g03687134

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    Illustration 22	g03687135

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    Illustration 23	g03687137

14. Continue routing wiring harness (20) along existing chassis wiring along the rear support assembly and left inside frame rail using 12 cable straps (5) as shown in Illustrations 20,21,22, and 23.
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    Illustration 24	g03687226

15. Continue routing wiring harness (20) along existing chassis wiring and over the left frame rail using two cable straps (5) as shown in Illustration 24
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    Illustration 25	g03687323

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    Illustration 26	g03687331

16. Locate the lubrication distribution valve group on the left outer frame rail. Disconnect and remove the grease system pressure sensor (L) from the lubrication distribution valve group as shown in Illustration 25. Remove plug (M) from the rear lubrication distribution valve group and install into the left side lubrication distribution valve group as shown in Illustration 24. Relocate the pressure sensor (L) to the rear lubrication distribution valve group assembly using street elbow (21) , adapter (22), and one cable strap (5) as shown in Illustration 26. Connect wiring harness (20) to the chassis wiring harness connection for grease system pressure sensor and secure connection in existing clip (N).

    Note: For Lincoln system, no additional modification is needed. Secure the short leg of wiring harness (4) Continue with the procedure from Special Instruction, REHS9324, "Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks". For Groeneveld, proceed with the remaining steps.

Route the Forward Section of the Wiring Harness on Groeneveld Systems

Required Parts

Installation Procedure

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Illustration 27	g03663136
View of the right fore-aft beam

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Illustration 28	g03663383
View of the right fore-aft beam near the front pedestal

1. Route the shorter leg of wiring harness (4) along the existing wiring harness under the right-hand fore-aft beam to the front of the truck. Secure wiring harness (4) with 13 cable straps (5).
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   Illustration 29	g03663600
   View of the right front pedestal area

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   Illustration 30	g03663665
   View of location of 341-9542 Guard

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   Illustration 31	g03663672
   View of the back side of connector C-C25

2. Route wiring harness (4) down alongside the existing harness to connector C-C25 located behind the front right-hand grill side cowl panel. Secure wiring harness (4) with three cable straps (5).

   Note: Remove the guard if needed to access the rear of the 31 pin C-C25 connector.

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   Illustration 32	g03663690
   A view of the connector C-C25

3. Remove the two wires from position 22 and 23 on the rear of connector C-C25. Install the yellow wire of wiring harness (4) into pin position 23. Install the green wire of wiring harness (4) into pin position 22. Connect the two removed wires from the original connector into the two pin connector located on wiring harness (4).

4. Finish the remaining procedure for the Groeneveld system. Refer to Special Instruction, REHS8629, "Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks".

Register the Retrofit

1. When performing a retrofit installation, record the vital information in Table 15.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 15

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number(1)
   Removed Component Serial Number(1)
   Installed Component Part Number(2)
   Installed Component Serial Number(3)

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   (1)	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   (2)	Record the highest level retrofit kit, arrangement, or group part number.
   (3)	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 15 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".