Installation Manual

Automatic TWIN Greasing system

Dumptruck
Caterpillar 777 D
EF1761

your efficiency is our challenge

All rights reserved. No part of this manual may be copied and/or published by means of printing, photocopying,
microfilm or by any other means without prior written permission from Groeneveld. This applies also to the
drawings and diagrams appended.

Groeneveld reserves the right to change parts at any time, without prior or direct notice to the customer. The
contents of this manual may also be changed without prior notice.

This manual applies to the standard version of the product. Groeneveld cannot accept liability for any damage
arising from the use of specifications other than that supplied.

You are requested to contact Groeneveld technical service for information concerning adjustment, maintenance
work or repairs that is not described in this manual.

Whilst this manual has been prepared with the greatest possible care Groeneveld cannot accept responsibility for
any errors of the concequences of such errors.
Dumptruck Caterpillar 777 D

TABLE OF CONTENTS
1 Preface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.1 General information - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.2 Use of symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.3 Safety precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.4 General fitting instructions - - - - - - - - - - - - - - - - - - - - - - - 7

2 System lay-out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1 F170325 Twin 14 port block, complete - - - - - - - - - - - - - - 12
2.2 F170326 Twin 4-port block, complete - - - - - - - - - - - - - - - 14
2.3 F170327 Twin 12-port block, complete - - - - - - - - - - - - - - 16

3 Grease point location - - - - - - - - - - - - - - - - - - - - - - 19

4 Welding and drilling activities - - - - - - - - - - - - - - - - 23

5 Grease pump installation - - - - - - - - - - - - - - - - - - - - 27

5.1 F170342 Twin pumpkit Caterpillar 777 D - - - - - - - - - - - - 28

6 Electrical components - - - - - - - - - - - - - - - - - - - - - - 31
6.1 F170341 Electronics installation kit Caterpillar 777 D - - - 32

7 Distribution blocks - - - - - - - - - - - - - - - - - - - - - - - - 35
7.1 F170343 Installation kit Twin 14-port block B1 - - - - - - - - 36
7.2 F170344 Installation kit Twin 4-port block B2 - - - - - - - - - 40
7.3 F170345 Installation kit Twin 12-port block B3 - - - - - - - - 42

8 Installation main line - - - - - - - - - - - - - - - - - - - - - - - 47

8.1 F170346 Twin Main line kit Caterpillar 777 D - - - - - - - - - 48

9 Parameter settings - - - - - - - - - - - - - - - - - - - - - - - - 51

10 Testing of the system - - - - - - - - - - - - - - - - - - - - - - - 53

EF1761 Table of contents 3

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4 Table of contents EF1761

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1.

1.
PREFACE
Date of issue: June 2002

your efficiency is our challenge

EF1761 Preface 5
 Dumptruck Caterpillar 777 D

1.1 General information

This installation manual describes the mounting of the Twin-system on the
Caterpillar Dumptruck type 777 D.

Automatic Twin Grease Lubrication System

Machine type Number of Groeneveld OEM order Manual

grease points order number number
number

Caterpillar
27 x F170340 - EF1761 P1
777 D

1.2 Use of symbols

Symbol Explanation
H High pressure hose 1/4” I/D or 3/8” I/D
1/4” S6-200-E6 1/4” = internal diameter
S6 = connector straight ø6 mm
200 = lenght (mm)
E6 = connector elbow ø6 mm
P Grease pump
PS Main line pressure switch

Distribution block

Position number on the parts list

Grease point position number

BK Black
BN Brown
BU Blue
RD Red
Date of issue: June 2002

GY Grey
YE Yellow
BR Brass
PA Polyamide
SST Stainless steel
ST-YG Yellow passivated steel
ST-G Galvanised steel

6 Preface EF1761
 Dumptruck Caterpillar 777 D

1.3 Safety precautions

For starting installation, carry out the following tasks:
• Remove ignition key to prevent engine from starting while you are working.
• Block all moving parts, like lifting frames, breaking points and mast parts.
• Block the wheels.
• Follow machine manufacturer’s guidelines for general safety and precautions.

During activities that require a lifting jack:

• The machine should not rest on the lifting jack solely. Use additional support.

General:
• Always keep your work area clean.

1.4 General fitting instructions

Before
• Check if all the parts of the Twin-system are present by using the parts list.
• Check if all the grease points are open and provided with grease. Lubricate
the grease points if there is not sufficient grease. This way damage due to
insufficient grease is prevented.

During installation
• Prevent dirt from entering the system during installation.
• Use clean tools.
• Clean the machine at points, where the pump and the distribution blocks
have to be installed. Even small pollution can cause failure of the system!
• Even if stud couplings or plugs are not provided with an O-ring sealing or
sealing ring, use teflon tape or a liquid sealing agent.
Date of issue: June 2002

EF1761 Preface 7
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Notes

Date of issue: June 2002

8 Preface EF1761
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2.

2.
SYSTEM LAY-OUT
Date of issue: June 2002

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EF1761 System lay-out 9

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Parts list

The Twin-system for the Caterpillar 777 D comprises the following parts:

Kit number Groeneveld order Description

number

F170342 Twin pompkit Caterpillar 777 D

F170341 Electronics installation kit Caterpillar 777 D

F170325 F170343 Installation kit Twin 14-port block B1

F170326 F170344 Installation kit Twin 4-port block B2

F170327 F170345 Installation kit Twin 12-port block B3

F170346 Twin Main line kit Caterpillar 777 D

810864 High pressure hose 3/8” E10-4000-S10 H1 2x

810184 High pressure hose 3/8” S10-2700-S10 H2 2x

810511 High pressure hose 3/8” S10-2500-S10 H3 2x

830141 High pressure hose 1/4” S6-1850-S6

830276 High pressure hose 1/4” S6-2200-S6 3x

830513 High pressure hose 1/4” S6-3250-S6

830533 High pressure hose 1/4” S6-3300-S6

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10 System lay-out EF1761

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Date of issue: June 2002

EF1761 System lay-out 11

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Parts list

2.1 F170325 Twin 14 port block, complete

Pos. Q’ty Groeneveld order Description

number

1 4 47402 Elbow stud coupling ø10 mm - 1/4"NPT ST-YG

2 2 70901 Metering unit no.2-0.100cc/M22/6mm/BR

3 8 71101 Metering unit no.4-0.200cc/M22/6mm/BR

4 4 71201 Metering unit no.8-0.400cc/M22/6mm/BR

5 1 88501 Twin 14-port block M10 BR

6 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

7 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

8 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

9 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

10 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

11 1.5m 77301 Grease pipe ø6 mm x 1.5 PA

12 2 72301 Grease pipe 2 x ø6 mm x 1.5 per 3m PA

13 4m 77401 Grease pipe 2 x ø6 mm x 1.5 PA

14 4m 77401 Grease pipe 2 x ø6 mm x 1.5 PA

15 6 02717 Protective cap ø6 mm

16 4 28401 Protective cap ø9.5 mm

Date of issue: June 2002

12 System lay-out EF1761

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EF1761 System lay-out 13

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Parts list

2.2 F170326 Twin 4-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 31801 Sealing ring

2 2 32901 Threaded plug G1/4 BR

3 2 50802 T-stud coupling ø10 mm - 1/4”NPT ST-YG

4 3 79601 Metering unit no.9-1.000cc/M22/6mm/BR

5 1 66501 Pressure switch 150 bar

6 1 66601 Pressure switch

7 1 70301 Twin 4-port block M10 BR

8 3 72201 Grease pipe ø6 mm x 1.5 per 3m PA

9 3 02717 Protective cap ø6 mm

Date of issue: June 2002

14 System lay-out EF1761

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EF1761 System lay-out 15

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Parts list

2.3 F170327 Twin 12-port block, complete

Pos. Q’ty Groeneveld order Description

number

1 2 31801 Sealing ring

2 2 32901 Threaded plug G1/4 BR

3 2 47402 Elbow stud coupling ø10 mm - 1/4"NPT ST-YG

4 4 72701 Metering unit no.6-0.300cc/M22/6mm/BR

5 4 79501 Metering unit no.8,5-0.700cc/M22/6mm/BR

6 2 70701 Shut-off plug M22 x 1 BR

7 1 70601 Twin 12-port block M10 BR

8 1 830141 High pressure hose 1/4” S6-1850-S6

9 3 830276 High pressure hose 1/4” S6-2200-S6

10 1 830513 High pressure hose 1/4” S6-3250-S6

11 1 830533 High pressure hose 1/4” S6-3300-S6

12 10 02717 Protective cap ø6 mm

14 2 79601 Metering unit no.9-1.000cc/M22/6mm/BR

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16 System lay-out EF1761

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Date of issue: June 2002

EF1761 System lay-out 17

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Notes

Date of issue: June 2002

18 System lay-out EF1761

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3.

3.
GREASE POINT LOCATION
Date of issue: June 2002

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EF1761 Grease point location 19

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Date of issue: June 2002

20 Grease point location EF1761

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EF1761 Grease point location 21

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Notes

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22 Grease point location EF1761

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4.

4.
WELDING AND DRILLING ACTIVITIES
Date of issue: June 2002

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EF1761 Welding and drilling activities 23

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Safety instructions for installation of attachment points:

In case of drilling:
• Wear safety goggles.
• Make sure there are no vital parts behind the hole to be drilled.

Drill

10mm
Drilling depth

M8x1.25
Tap

1 Drilling location

In case of welding:
• Ask the workshop manager whether welding is allowed in this room.
• Disconnect the earthing cable from the battery or remove the earthing key.
• Disconnect any computers present. In case of doubt, always refer to the
supplier of the machine.
• Wear welding goggles and overalls.

Welding

Grind

1
Date of issue: June 2002

Welding location

24 Welding and drilling activities EF1761

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EF1761 Welding and drilling activities 25

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26 Welding and drilling activities EF1761

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5.

5.
GREASE PUMP INSTALLATION
Date of issue: June 2002

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EF1761 Grease pump installation 27

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Parts list

5.1 F170342 Twin pumpkit Caterpillar 777 D

Pos. Q’ty Groeneveld order Description

number

2.1 1 F112126 Twin pump 12cc/24V/4L/250bar

2.2 4 38922 Grease Greenlube EP-2 / 1Kg

2.3 1 81522 Pump bracket

2.4 4 108050 Bolt M8 x 50 ST-G

2.5 4 200008 Nut M8 ST-G

2.6 8 300008 Washer M8 ST-G

2.7 4 330008 Spring washer M8 ST-G

2.8 4 101030 Bolt M10 x 30 ST-G

2.9 4 200010 Nut M10 ST-G

2.10 8 300010 Washer M10 ST-G

2.11 4 330010 Spring washer M10 ST-G

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28 Grease pump installation EF1761

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EF1761 Grease pump installation 29

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Notes

Date of issue: June 2002

30 Grease pump installation EF1761

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6.

6.
ELECTRICAL COMPONENTS
Date of issue: June 2002

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EF1761 Electrical components 31

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Parts list

6.1 F170341 Electronics installation kit Caterpillar 777 D

Pos. Q’ty Groeneveld order Description

number

1.1 1 13233 Quick-brake switch

1.2 1 15033 Wiring harness for 13233

1.3 1 82301 Cable wire 7m

1.4 1 86801 Lens for 13233

1.5 1 86901 Lens Twin

1.6 1 04812 Connector cable 8m

1.7 2 03203 Flat plug sleeve BU

1.8 1 61106 2-pins connector housing male

1.9 1 61006 2-pins connector housing female

1.10 3m 02808 Electrical wire 1.5 mm2 RD+YE+BU

1.11 1 19508 Fuse 10A

1.12 1 17408 Fuse holder single

1.13 1 17508 Foot plate fuse holder

1.14 1 17608 Cross-slotted screw

1.15 1 13103 4-pole connector male

1.16 1 67506 4-pole connector housing 901

1.17 6 61416 Flat plug 1.5 mm2

1.18 6 67806 Flat plug sleeve 1.5 mm2

1.19 2 68606 Flat plug cover 2.5mm2

1.20 2 68706 Flat plug 180409-2

1.21 2 800003 Connector eye 4-6mm2 M8

Date of issue: June 2002

32 Electrical components EF1761

 Dumptruck Caterpillar 777 D

with control lamp

Pressure sensor
Selectorswitch

in mainlines

Fusebox

Timeswitch inside
greasepump
Date of issue: June 2002

EF1761 Electrical components 33

 Dumptruck Caterpillar 777 D

1.21

1.14 1.13

1.12 1.11

1.21

1.16 1.15
Date of issue: June 2002

1.7

34 Electrical components EF1761

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7.

7.
DISTRIBUTION BLOCKS
Date of issue: June 2002

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EF1761 Distribution blocks 35

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Parts list

7.1 F170343 Installation kit Twin 14-port block B1

Pos. Q’ty Groeneveld order Description

number

3.1 1 02512 Mounting bracket

3.2 2 15001 Coupling elbow 1/8"- 1/8" ST-YG

3.3 4 07908 Coupling straight 1/8"- ø6 mm BR

3.4 10 08008 Stud coupling elbow 1/8"- ø6 mm BR

3.5 4m 02008 Protection spiral ø8 mm

3.6 1 F170325 Twin 14-port block, complete

Date of issue: June 2002

36 Distribution blocks EF1761

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Date of issue: June 2002

EF1761 Distribution blocks 37

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4 3 1
2

5 6

8
Date of issue: June 2002

38 Distribution blocks EF1761

 Dumptruck Caterpillar 777 D

11

10
12

13

14
Date of issue: June 2002

EF1761 Distribution blocks 39

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Parts list

7.2 F170344 Installation kit Twin 4-port block B2

Pos. Q’ty Groeneveld order Description

number

4.1 1 12712 Mounting bracket

4.2 3 08008 Stud coupling elbow 1/8"- ø6 mm BR

4.3 1 08508 Adaptor, screw thread G1/8 - R1/8 BR

4.4 1 F170326 Twin 4-port block, complete

15

16
Date of issue: June 2002

17

40 Distribution blocks EF1761

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Date of issue: June 2002

EF1761 Distribution blocks 41

 Dumptruck Caterpillar 777 D

Parts list

7.3 F170345 Installation kit Twin 12-port block B3

Pos. Q’ty Groeneveld order Description

number

5.1 6 08508 Adaptor, screw thread G1/8 - R1/8 BR

5.2 10 39008 Bracket ø14 mm, for 10 mm bolt

5.3 4 43402 Stud connector straight ø6 mm - R1/8 ST-YG

5.4 6 43802 Stud connector elbow ø6 mm - R1/8 ST-YG

5.5 3 81802 Tube clamp, single ø12 mm

5.6 3 82002 Welding plate, tube clamp single

5.7 3 16012 Cover plate, tube clamp single

5.8 1 78222 Mounting bracket

5.9 6 126030 Allen bolt M6 x 30 ST-G

5.10 10 101016 Bolt M10 x 16 ST-G

5.11 10 300010 Washer M10 ST-G

5.12 1 F170327 Twin 12-port block, complete

5.13 4 15001 Coupling elbow 1/8"- 1/8" ST-YG

5.14 10m 00817 High pressure hose 1/4”

5.15 8 00917 Hose coupling sleeve

5.16 8 05217 Straight hose coupling pin ø6 mm

Date of issue: June 2002

42 Distribution blocks EF1761

 Dumptruck Caterpillar 777 D
Date of issue: June 2002

EF1761 Distribution blocks 43

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20

19

18

27

20

21
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22

44 Distribution blocks EF1761

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25

24
26
23

26

25
Date of issue: June 2002

EF1761 Distribution blocks 45

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Notes

Date of issue: June 2002

46 Distribution blocks EF1761

 Dumptruck Caterpillar 777 D

8.

8.
INSTALLATION MAIN LINE
Date of issue: June 2002

your efficiency is our challenge

EF1761 Installation main line 47

 Dumptruck Caterpillar 777 D

Parts list

8.1 F170346 Twin Main line kit Caterpillar 777 D

Pos. Q’ty Groeneveld order Description

number

6.1 2 810864 High pressure hose 3/8” E10-4000-S10

6.2 2 810184 High pressure hose 3/8” S10-2700-S10

6.3 2 810511 High pressure hose 3/8” S10-2500-S10

6.4 100 00208 Cable tie, black 186mm

6.5 50 11107 Cable tie, black 338 mm

6.1 6.2
3.6

2.1

6.3
Date of issue: June 2002

5.12

4.4

6.3

48 Installation main line EF1761

 Dumptruck Caterpillar 777 D
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EF1761 Installation main line 49

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Notes

Date of issue: June 2002

50 Installation main line EF1761

 Dumptruck Caterpillar 777 D

9.

9.
PARAMETER SETTINGS
Date of issue: June 2002

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EF1761 Parameter settings 51

 Dumptruck Caterpillar 777 D

Parameter settings

Code Description Setting

HDCY Heavy duty cycle 20 minutes

NDCY Normal duty cycle 25 minutes

LDCY Low duty cycle 30 minutes

CMS Cycle mode select 2

MPT Maximum pumping time 10 minutes

VMF Venting multiply factor 5 (/10) x

Number of attempts before pump

NOA 10 x
holds

BCDC Blink code duty cycle 4x

CSI Command signal 'inverted' 0 (GINA)/NO(PC)

Consumption metering units each cycle : 12,4 cc

Date of issue: June 2002

52 Parameter settings EF1761

 Dumptruck Caterpillar 777 D

10.

10.
TESTING OF THE SYSTEM
Date of issue: June 2002

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EF1761 Testing of the system 53

 Dumptruck Caterpillar 777 D

Testing of the system

Warning

Only operate machine when fully familiar with the controls and permission
of the person in charge at the working place.

• Remove the end-plugs out of the distributions blocks.

De-aerate pipe A
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (A) is
completely clear of air and dirt.
• Stop the pump.
• Remove main pipe A.

De-aerate pipe B
• Mount main pipe (B) on exit A of the pump.
• Start the pump manually with the Gina; leave the 5/2 magnet valve non-
excited (exit A).
• Close the distribution blocks with an end-plug as soon as main pipe (B) is
completely clear of air and dirt.
• Stop the pump.
• Connect main pipe (B) to exit B and main pipe (A) to exit A.

Accelerated test
• Start an accelerated test by means of the test button on the pump or with the
GINA.
• Check the main pipe for leakage.
• Check if all the grease points are provided with grease.
• Terminate the accelerated test by switching off the ignition.

• Switch the machine back on.

• Operate the machine in all positions and check if all the parts of the Twin-
lubrication have enough tolerance and do not jam or scrape.
• Check the timer settings by means of the GINA (if available).
• Shut the machine down.
Date of issue: June 2002

54 Testing of the system EF1761

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