CATERPILLAR’ ae April 1997 Custom Product By Caterpillar Supplementary Product Support Literature For 777B, 777C And 777D Off-Highway Trucks Equipped With A Cluster Lubrication System 3Z4827 Factory And Field Installed Cluster Lubrication Group TT7B: 4YC 777C: 4XJ 7770: 3PR, AGC 777D HAA: AGY177 CLUSTER LUB INTRODUCTION INTRODUCTION The 324827 (Factory and Field Installed) Modification is made to the 777 Off-Highway Trucks to equip it with Cluster lub. ‘This Modification is designed to make servicing of the truck easier by clustering grease fittings in three locations on the vehicle. This modification will reduce maintenance time. This supplementary product support literature is to be used with the appropriate Service Manual and Parts Manual available for each standard machine. This supplement should be used first to determine the difference between the above modification and a standard machine. If the service information is not in this supplement, then use the Service Manual and Parts Manual that is available for the standard machine.277 CLUSTER LUB INDEX INDEX PAGE INTRODUCTION ... INSTALLATION PROCEDURE AND PARTS MANUAL INDEX 324827 PARTS LIST (FIELD INSTALLED) . WELDING INSTRUCTIONS (FIELD INSTALLED) INSTALLATION PROCEDURES FOR REAR CLUSTER LUB INSTALLATION PROCEDURES FOR L/H CLUSTER LUB 12 INSTALLATION PROCEDURES FOR R/H CLUSTER LUB 13 INSTALLATION PROCEDURES FOR FRONT STRUTS, STEERING, TIE RODS AND CENTER PIVOT HOSE ASSEMBLIES : 14207 CLUSTER LUB. PARTS MANUAL LUBRICATION SYSTEM PARTS LIST REF] PART INOTE|NO.| NUMBER | QTY PART NAME 1 5M3012 16 |LUG 2 |spe1cs |2. |noss 3 |opsess |11 |poss 4 5B1983 3 BOSS 5 |sveos1 |1 |ptock 6 |7ri099 |4 |zinK 7 |126-8205|1 | PLare 8 |7xo2e9 |2 |pour 9 |eraess |2 |wasneR ro |st7799_ |1_ |ptock 11 |3B8488 13 | FITTING-GREASE 22 Jeness7 |4 |connecror 23 Janize7 |17 |eteow 14 |5N5646 2 HOSE ASSEMBLY 15 |7w2539 |2 |Hose ASSEMBLY 16 |ste310 |2 |Hose assemBLY 17 ]307312 |1 [Hose assemBLY is |7vi037 |: |Hose ASSEMBLY 19 |350-390 |: [Hose ASSEMBLY 20 |195044 1 HOSE ASSEMBLY 21 |1Q6276 1 HOSE ASSEMBLY 22 |sta3ea |1 |Hose ASSEMBLY 23 |exess7 |4 |aDaPTER 24 Jotsi25 |6 |eteow 25 Japaiss |e |screw 26 |axeesa |17 |curP 27 |5M3062 18 |BOLT 28 |2R1939 5 CLIP 29 |382093 20 |STRAP 30 |6G9581 6 HOSE ASSEMBLY 31 |6D4859 2 HOSE ASSEMBLY 32 |sta377_|2 [Hose ASSEMBLY 33 |sta375 |2 |nose assEMBLY 34 Jawaa70 |: [HOSE ASSEMBLY 35 |st7798_|2 |Btock 36 Jaw3oes |2 |pLare 37 |et2s01 |4 |pour 38 |st7796 |2 |BRacKer 39 |ss7379 [1 [pour 40 Jeveeor |2 |Nor 41 |3g7314 [1 |Hose assenpty 42 japease |2 |curP 324827 LINES GROUP-GREASE CLUSTER 3277 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL WELDING INSTRUCTIONS FOR CLUSTER LUB 1. Weld two 5M3012 Lugs (1) to Banjo as shown below in sketch A. 2. Weld two 9D6168 Bosses (2) to Banjo as shown below in sketch B. 2 - SM-3012 ~ LUS SKETCH A TOP VIEW OF BANJO SKETCH B REAR VIEW OF BANUO 324827 LINES GROUP-GREASE CLUSTER 4777 CLUSTER LUB (FIELD INSTAL PARTS MANUAL 3. Weld eight 9D5659 Bosses (3) and one 5B1983 Boss (4) to L/H Frame Rail as shown below. (On «A ® Thy oi ce INSIDE VIEW OF LH FRAME RAIL Jerr ~ aos viey ce OUTSIDE VIEW OF LH FRAME RAIL 324827 LINES GROUP-GREASE CLUSTER 5q1 TER LUB (FIELD INSTALLED) PAR’ AL 4. Weld one 9V8051 Block (5) to Rear Frame as shown below on print. 1 = BLOCK & 11343 REAR VIEW OF FRAME 324827 LINES GROUP-GREASE CLUSTER 6277 CLUSTER LUB (FIELD INSTALLED) 'S_ MANUAL 5. Weld three 9D5659 Bosses (3) and two 5B1983 Bosses (4) to R/H Frame Rail as shown. 2 Bosses 3 BOSSES 27335 3 - 90-5659 - Boss 18325 47285 2 - 58-1983 - Boss 92845. VIEW 0-D 324827 LINES GROUP-GREASE CLUSTER 7LUSTER LUB (FIELD INSTALLED} 6. print below. Weld four 7T1099 Links (6) to Cross Tube as shown on —~ +— A t Ga | 35845 4 PLACES & OF TRUCK 30045 4 - 77-1099 — LINK t 35845 i 15245 # \ TOP VIEW OF he—114.645.0 CROSS TUBE 324827 LINES GROUP-GREASE CLUSTER 877 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL INSTALLATION PROCEDURES FOR REAR CLUSTER BLOCK 7. Preassemble to bottom of 517799 Block (10) thirteen 3B8488 Fittings (11). 8. Preassemble eleven 816557 Connectors (12) and two 2N1287 Elbows (13) to top of 517799 Block (10). Install both 2N1287 Elbows (13) to outside L/H and R/H ends on 5T7799 Block (10) with the 2N1287 Elbows (13) pointing horizontally to L/H and R/H sides of truck. 9. Preassemble thirteen Hose Assemblies to the eleven 8L6557 Connectors (12) and two 2N1287 Elbows (13) on top side of 517799 Block (10). Attach two 5N5646 Hose Assemblies (14), two 7N2539 Hose Assemblies (15), two 5T6310 Hose Assemblies (16), two 307312 Hose Assemblies (17), one 71037 Hose Assembly (18), one 350-0390 Hose Assembly (19), one 195044 Hose Assembly (20), one 106276 Hose Assembly (21) and one 514384 (22) Hose Assembly as shown in photo below. 10. Install preassembled 517799 Block (10) and 126-8205 Plate (7) to Banjo with two 7X0289 Bolts (8) and two 8T4896 Washers (9). NOTE: Photo below is a typical example. 11. Install identification plate not shown with four 4B4158 Screws (25) to 126-8205 Plate (7). 324827 LINES GROUP-GREASE CLUSTER 9777 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL 12. Attach both ends of 5N5646 Hose Assemblies (14) to L/H and R/H Rear Lower Struts with two 2N1287 Elbows (13) and two 6K6997 Adapters (23). Secure Hose Assemblies to Banjo with two 4K8864 Clips (42), two 5M3062 Bolts (27) and two 8T4896 Washers (9). 13. Attach both ends of 7N2539 Hose Assemblies (15) to L/H and R/H Rear Grease Blocks with two 816557 Connectors (12). Attach standard Hose Assemblies to Upper Struts. Note: Photo below is a typical example and does not show R/H and L/H Grease Blocks. 324827 LINES GROUP-GREASE CLUSTER 10777 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL 14. Attach both ends of 576310 Hose Assemblies (16) to L/H and R/H Grease Blocks on frame with two 8L6557 Connectors (12). NOTE: Grease Blocks, Body and Body Pivot Pins installation is not shown in photo. 15. Attach both ends of 337312 Hose Assemblies (17) to L/H and R/H Upper Hoist Cylinder not shown with two 915125 Elbows (24). 16. Attach end of 7V1037 Hose Assembly (18) to Inboard Sway Bar (inner) with one 2N1287 Elbow (13). 17. Attach end of 350-390 Hose Assembly (19) to Outboard Sway Bar (outer) with one 2N1287 Elbow (13). i a 324827 LINES GROUP-GREASE CLUSTER 1777 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL 18. 19. 20. 21. Attach end of 195044 Hose Assembly (20) to L/H Lower Hoist Cylinder with one 2N1287 Elbow (13) as show in photo below. NOTE: Photo below is a typical example. ae Attach end of 5174384 Hose Assembly (22) to R/H Lower Hoist Cylinder with one 2N1287 Elbow (13) not shown. Attach end of 106276 Hose Assembly (21) to A-Frame Bearing with one 2N1287 Elbow (13) not shown. Secure L/H Lower Hoist Cylinder Hose Assembly (20), R/H Lower Hoist Cylinder Hose Assembly (22) and A-Frame Bearing Hose Assembly (21) to inside L/H Frame using five 2R1939 Clips (28) (use existing fastening hardware) . NOTE: These Hoses are routed from R/H Hoist Cylinder across Hoist Hanger Tube to L/H side of inside frame to rear Cluster Block (10). 324827 LINES GROUP-GREASE CLUSTER 12277 CLUSTER LUB (FIELD INSTALLE! PARTS MANUAL INSTALLATION PROCEDURES FOR L/H CLUSTER BLOCK 22. Preassemble to right side of 517798 Block (35) seven 3B8488 Fittings (11). 23. Preassemble to left side of 517798 Block (35) seven 8L6557 Connectors (12). 24, Preassemble seven Hose Assemblies to the seven 816557 Connectors (12) on left side of 5T7798 Block (35). Attach one 3J7314 Hose Assembly (41), three 6G958i Hose Assemblies (30), one 6D4859 Hose Assembly (31), one 5T4377 Hose Assembly (32) and one 5T4375 Hose Assembly (33) as shown in photo. 25. Attach 8W3085 Plate (36) and preassembled 517798 Block (35) to 9D5659 Bosses (3) welded to outside L/H Frame. Use two 8T2501 Bolts (37) and two 8T4896 Washers (9) as shown in photo. NOTE: Bosses were welded on outside L/H and R/H Frame earlier in steps three and five. 26. Attach end of 3J7314 Hose Assembly (41) to L/H standard Block located on L/H Front Strut. 324827 LINES GROUP-GREASE CLUSTER 13207. 27. 28. 29. 30. 31. CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL INSTALLATION PROCEDURES FOR R/H CLUSTER BLOCK Preassemble to left side of 517798 Block (35) seven 3B8488 Fittings (11). Preassemble to right side of 517798 Block (35) seven 8L6557 Connectors (12). Preassemble seven Hose Assemblies to the seven 8L6557 Connectors (12) on right side of 5T7798 Block (35). Attach one 8W4470 Hose Assembly (34), three 6G9581 Hose Assemblies (30), one 6D4859 Hose Assembly (31), one 574377 Hose Assembly (32) and one 5T4375 Hose Assembly (33) as shown in photo. Attach 8W3085 Plate (36) and preassembled 517798 Block (35) to 9D5659 Bosses (3) welded to outside R/H Frame. Use two 872501 Bolts (37) and two 8T4896 Washers (9) as shown in photo. NOTE: Bosses were welded on outside L/H and R/H Frame earlier in steps three and five. Attach end of 8W4470 Hose Assembly (34) to R/H standard Block located on R/H Front Strut. 324827 LINES GROUP-GREASE CLUSTER 14277 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL 32. Attach ends 6G9581 Hose Assemblies (30) to L/H and R/H Center Struts with two 9L5125 Elbows (24) not shown. 33. Secure Hose Assemblies from L/H and R/H 5T7798 Cluster Blocks (35) to Frame with two 517796 Brackets (38), two 5M3062 Bolts (27) and two 8T4896 Washers (9) as shown in photos below. 324827 LINES GROUP-GREASE CLUSTER 15777 CLUSTER LUB (FIELD INSTALLED) PARTS MANUAL 34. Attach ends of two 6D4859 Hose Assemblies (31) to L/H and R/H Outer Tie Rods with two 2N1287 Elbows (13). 35. Attach ends of two 6G9581 Hose Assemblies (30) to L/H and R/H Outer Steering Cylinders with two 2N1287 Elbows (3). NOTE: Photos below show L/H and R/H sides of outer Tie Rods and Outer Steering Cylinders Hose Assemblies installation. 324827 LINES GROUP-GREASE CLUSTER 16211 TER LUB (FIELD INST) PARTS MANUAL 36. Attach ends of two 574377 Hose Assemblies (32) to L/H and R/H Inner Tie Rods with two 2N1287 Elbows (13). 37. Attach L/H and R/H ends of two 5T4375 Hose Assemblies (33) to Center Steering Pivots with two 9L5125 Elbows (24). 38. Attach ends of two 6G9581 Hose Assemblies (30) to L/# and R/H Inner Steering Cylinders with two 2N1287 Elbows (13). 324827 LINES GROUP-GREASE CLUSTER a7277 CLUSTER LUB (FIELD INSTALLED: PARTS MANUAL 39. Secure L/H and R/H Hose Assemblies to Frame Assembly 40. with 4K8864 Clips (26), 4D6466 Clips (42) and 3$2093 Straps (29) as needed. Install two 5T7797 Plates (English) to L/H and R/H 577798 Cluster Blocks (35) with four 4B4158 Screws (25). 324827 LINES GROUP-GREASE CLUSTER 18Form No SEBC1141 Printed in U.S.A. (04/97)