Procedure to Install the Groeneveld Auto Lubrication System on Certain 777G Off-Highway Trucks{1408, 7510, 7513, 7516, 7540} Caterpillar

Off-Highway Truck/Tractor:

777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP; GT71-UP)

Introduction

This special instruction will provide instructions for installation of the Groeneveld auto lubrication system. 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 or order parts 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

Required Parts

Table 1

Required Parts
Qty	Part Number	Description
1	438-6095	Bracket As
8	8T-6466	Bolt
99	8T-4121	Hard Washer
18	344-5675	Nut
1	418-6494	Lubrication Pump Gp
17	8T-4195	Bolt
4	148-8337	Connector As
2	417-2736	Lubrication Distribution Valve Gp
2	418-6460	Plate
14	8T-4191	Bolt
12	8T-4136	Bolt
2	150-5968	Tee As
4	179-1660	Plug
4	192-5987	Gasket
2	7X-5331	Elbow
1	417-2734	Lubrication Distribution Valve Gp
1	418-6511	Plate As
35	8T-4137	Bolt
2	8T-4186	Bolt
2	198-4777	Hard Washer
3	132-5789	Clip
1	381-9644	Plate As
1	347-4412	Adapter As
1	6V-9173	Bulkhead Nut
1	189-1858	Coupler
1	148-8387	Elbow As
1	9D-3127	Indicator Light Base As
1	9D-2867	Amber Lens
1	435-5391	Lighting Harness As
25	7K-1181	Cable Strap
1	163-1883	Lamp
2	8T-4183	Bolt
2	5P-1076	Hard Washer
1	360-1299	Tube As
2	8S-0023	Clip
2	8S-0024	Clip
1	381-9646	Plate
3	7X-7729	Washer
1	3V-4791	Grommet
1	360-4438	Tube As
1	360-4851	Hose As
1	440-1852	Tube As
3	8T-1889	Clip
3	8T-1890	Clip
1	433-2894	Hose As
1	228-7093	O-Ring Seal
1	228-7094	O-Ring Seal
1	030-8370	Pipe Adapter
1	208-0423	Connector As
1	440-1853	Hose As
1	426-2154	Plate
1	067-3045	Clip
1	443-0789	Bracket As
1	8T-4200	Bolt
1	8T-4224	Hard Washer
2	4P-7581	Clip
1	352-3964	Clip
1	420-8587	Switch Harness As
1	144-4613	Angle As
3	130-5300	Clip
2	8C-6867	Connector
2	418-6466	Hose As
15	9M-4995	Clip
1	6V-2235	Clip
1	6D-4246	Clip
1	6B-1032	Clip
1	200-6345	Mount
1	418-6469	Hose As
1	418-6470	Hose As
1	109-1633	Clip
1	109-1634	Clip
1	5P-7468	Clip
1	5P-7469	Clip
1	6V-0545	Grommet
2	418-6468	Hose As
2	118-6878	Bracket As
1	418-6432	Hose As
2	418-6431	Hose As
1	418-6433	Hose As
1	418-6434	Hose As
5	4D-7735	Clip
2	418-6442	Hose As
1	418-6436	Hose As
1	418-6437	Hose As
23	9M-8406	Clip
14	7D-2746	Elbow
22	5P-9085	Clip
5	6K-6967	Pipe Adapter
2	418-6441	Hose As
1	418-6439	Hose As
1	418-6443	Hose As
1	418-6435	Hose As
2	3S-2093	Cable Strap
2	418-6446	Hose As
2	418-6447	Hose As
2	418-6448	Hose As
2	418-6449	Hose As
3	204-8000	Cable Tie Mounting
3	272-1777	Hard Washer
3	8T-4185	Bolt
3	204-2281	Cable Strap
2	4M-8973	Elbow
2	8T-4896	Hard Washer
6	3B-6552	Pipe Elbow
2	4B-9233	Clip
2	8L-5008	Pipe Elbow
1	437-5046	Hose As
1	5M-3062	Bolt
1	418-6450	Hose As
1	418-6451	Hose As
1	418-6452	Hose As
1	418-6453	Hose As
1	7E-9992	Bracket
1	9X-8582	Clip
1	419-4118	Sensor Harness As
1	434-5692	Film
1	434-5693	Film
1	434-5694	Film
1	150-1258	Film

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. You must 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 not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that 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.

Show/hide table

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

Show/hide table

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.

Autolube System Installation

Install the Lubrication Pump Group

Required Parts

Table 2

Required Parts
Item	Qty	Part Number	Description
1	1	438-6095	Bracket As
2	8	8T-6466	Bolt
3	16	8T-4121	Hard Washer
4	8	344-5675	Nut
5	1	418-6494	Lubrication Pump Gp
6	8	8T-4195	Bolt

Installation Procedure

Show/hide table



Illustration 2	g03446216
View of the right-hand platform

1. Locate auto lube reservoir mounting bracket assembly (1). Align bracket assembly (1) with the mounting holes on the right-hand platform. Use bolts (2), hard washers (3), and nuts (4) to assemble the bracket to the platform. Orientate bracket assembly (1) as shown in Illustration 2.

Show/hide table



Illustration 3	g03446351
View of the right-hand platform showing installation location

2. Mount the auto lube pump and lubrication pump group (5) to the mounting bracket assembly (1) and align the mounting holes. Assemble the auto lube pump and lubrication pump group (5) to mounting bracket assembly (1) using eight bolts (6) and eight hard washers (3). Refer to Illustration 3.

   Note: Ensure that all hose connections face forwards.

Install the Grease Injector Assemblies

Required Parts

Table 3

Required Parts
Item	Qty	Part Number	Description
3	7	8T-4121	Hard Washer
7	4	148-8337	Connector As
8	2	417-2736	Lubrication Distribution Valve Gp
9	2	418-6460	Plate
10	2	8T-4191	Bolt
11	4	8T-4136	Bolt
12	2	150-5968	Tee As
13	4	179-1660	Plug
14	4	192-5987	Gasket
15	2	7X-5331	Elbow
16	1	417-2734	Lubrication Distribution Valve Gp
17	1	418-6511	Plate As
18	1	8T-4137	Bolt
19	2	8T-4186	Bolt
20	2	198-4777	Hard Washer
21	1	132-5789	Clip

Install the Front Grease Injector Assemblies

Show/hide table



Illustration 4	g03452436
View of the right-hand lubrication distribution valve group

1. Assemble the right-hand grease injector assembly by installing four connector assemblies (7) into the right-hand lubrication distribution valve group (8). Refer to Illustration 4.

2. Assemble mounting plate (9) to the right-hand lubrication distribution valve group (8) using one bolt (10) and one hard washer (3). Refer to Illustration 4.

Show/hide table



Illustration 5	g03452581
View of the right-hand lubrication distribution valve group installed to the frame

3. Mount the assembly to the mounting block on the right-hand side of the truck frame using two bolts (11) and two washers (3). Refer to Illustration 5.

Show/hide table



Illustration 6	g03452825
View of the left-hand lubrication distribution valve group

4. Assemble the left-hand grease injector valve assembly by installing two tee assemblies (12) into the two housing ports on lubrication distribution valve group (8). Refer to Illustration 6.

5. Install two plugs (13) with two gaskets (14) into the upper ports on lubrication distribution valve group (8). Refer to Illustration 6.

Show/hide table



Illustration 7	g03453639
Left-hand lubrication distribution valve group with mounting plate

6. Assemble mounting plate (9) to the left-hand lubrication distribution valve group (8) using one bolt (10) and one hard washer (3). Refer to Illustration 7.

Show/hide table



Illustration 8	g03453665
View of the left-hand lubrication distribution valve group installed to the frame

7. Mount the assembly to the mounting block on the left-hand side of the truck frame using two bolts (11) and two washers (3). Refer to Illustration 8.

Install the Rear Grease Injector Assemblies

Show/hide table



Illustration 9	g03453791
View of the rear lubrication distribution valve assembly

1. Install two elbows (15) into the two bottom ports of lubrication distribution valve group (16). Refer to Illustration 9.

2. Install two plugs (13) with two gaskets (14) into the upper ports on lubrication distribution valve group (16). Refer to Illustration 9.

Show/hide table



Illustration 10	g03453807
View of the rear lubrication distribution valve assembly with plate mounted

3. Assemble the plate assembly (17) to the rear lubrication distribution valve group (16) using one bolt (18) and one hard washer (3). Refer to Illustration 10.

Show/hide table



Illustration 11	g03453815
View of the rear lubrication distribution valve assembly installed to the rear of the truck chassis

4. Install the assembly to the rear of the truck chassis using two bolts (19) and two hard washers (20). Refer to Illustration 11.

Show/hide table



Illustration 12	g03453819
Close up view of the right corner of the plate assembly

5. Install clip (21) to the right hand mounting bolt as shown in Illustration 12.

Install the Lubrication Lines Group and Harness Assembly

Required Parts

Table 4

Required Parts
Item	Qty	Part Number	Description
3	1	8T-4121	Hard Washer
6	1	8T-4195	Bolt
11	3	8T-4136	Bolt
22	1	381-9644	Plate As
23	1	347-4412	Adapter As
24	1	6V-9173	Bulkhead Nut
25	1	189-1858	Coupler
26	1	148-8387	Elbow As
27	1	9D-3127	Indicator Light Base As
28	1	163-1883	Lamp
29	1	9D-2867	Amber Lens
30	1	435-5391	Lighting Harness As
31	17	7K-1181	Cable Strap
32	2	8T-4183	Bolt
33	2	5P-1076	Hard Washer
34	1	360-1299	Tube As
35	1	8S-0023	Clip
36	1	8S-0024	Clip
37	1	381-9646	Plate
38	3	7X-7729	Washer
39	1	3V-4791	Grommet

Installation Procedure

Show/hide table



Illustration 13	g03453888
View of the fast fill connection

1. Locate the auto lube fast fill connection mounting plate assembly (22), and assemble adapter assembly (23) to plate assembly (22) with bulkhead nut (24). Refer to Illustration 13.

2. Install coupler (25) to adapter assembly (23). Refer to Illustration 13.

   Note: Apply thread sealer to the threads.

3. Install elbow assembly (26) to the rear of adapter assembly (23). Refer to Illustration 13.

Show/hide table



Illustration 14	g03453894
Profile view of indication light assembly

4. Install indicator light base assembly (27) to plate assembly (22) by inserting indicator light base assembly (27) into the mounting hole from the rear, installing lamp (28), and attaching amber lens (29) to the front. Refer to Illustration 14.

5. Connect lighting harness assembly (30) to indicator light base assembly (27) and to the weld link on the rear of plate assembly (22) using cable strap (31). Refer to Illustration 14.

   Note: Tie up the remaining length of the harness as the harness will be fully installed in a later step.

Show/hide table



Illustration 15	g03453925
View of left-hand front bumper fast-fill location

6. Mount plate assembly (22) to the truck frame using two bolts (32) and two hard washers (33). Refer to Illustration 15.

Show/hide table



Illustration 16	g03454620
View of left-hand front bumper fast fill location

7. Install tube assembly (34) to elbow assembly (26). Refer to Illustration 16.

   Note: Do not fully tighten.

8. Connect tube assembly (34) to the truck frame using clip (35) and (36). Attach clip (35) and clip (36) to the boss on the truck frame using bolt (6) and hard washer (3). Refer to Illustration 16.

9. Tighten tube assembly (34) on elbow assembly (26) .

Show/hide table



Illustration 17	g03454787
View of left-hand front bumper fast fill location

10. Install plate (37) to plate assembly (22) using three bolts (11) and three washers (38). Route lighting harness assembly (30) up through the hole in plate (37) and install grommet (39) into plate (37) to protect lighting harness assembly (30). Refer to Illustration 17.

Show/hide table



Illustration 18	g03455037
View of left-hand front bumper fast fill location

11. Route lighting harness assembly (30) through the hole in the left-hand battery support plate above the auto lube fast fill bracket assembly. Install grommet (39) into the hole to protect the harness. Refer to Illustration 18.

Show/hide table



Illustration 19	g03455163
View of the underside of the left-hand access stairway

12. Route lighting harness assembly (30) up the underside of the left-hand platform access stairway. Attach lighting harness assembly (30) to the weld links on the stairway using cable straps (31). Refer to Illustration 19.

Show/hide table



Illustration 20	g03455337
View of the left-hand access stairway

13. Route lighting harness assembly (30) along the underside of the front panel below the cab and through the slot in the mudguard assembly. Refer to Illustration 20.

Show/hide table



Illustration 21	g03455437
View of the upper frame

14. Attach lighting harness assembly (30) to the main chassis harness and route lighting harness assembly (30) with the chassis harness across the upper frontal cross tube above the radiator fan, along the right hand main beam and follow the main harness leg up to the auto lube reservoir. Attach lighting harness assembly (30) to the main harness at regular intervals using cable straps (31). Refer to Illustration 21.

15. Tighten tube assembly (34) onto elbow assembly (26) .

16. Re-assemble the service port box top cover and route the keypad harness back-up through the panel work and re-connect to the electrical connector under the left-hand stairway.

Install the Fast Fill Lines Group

Required Parts

Table 5

Required Parts
Item	Qty	Part Number	Description
3	4	8T-4121	Hard Washer
4	1	344-5675	Nut
6	2	8T-4195	Bolt
18	1	8T-4137	Bolt
35	1	8S-0023	Clip
36	1	8S-0024	Clip
40	1	360-4438	Tube As
41	1	360-4851	Hose As
42	1	440-1852	Tube As
43	2	8T-1889	Clip
44	2	8T-1890	Clip
45	1	433-2894	Hose As
46	1	228-7093	O-Ring Seal
47	1	228-7094	O-Ring Seal
48	1	030-8370	Pipe Adapter
49	1	208-0423	Connector As
50	1	440-1853	Hose As
51	1	426-2154	Plate
52	1	067-3045	Clip

Installation Procedure

Show/hide table



Illustration 22	g03459438
Bottom view from the underside of the engine bay

1. Loosen and remove the lower sections of the two hose retention blocks which are installed on the bottom of the engine cross member. Refer to Illustration 22.

Show/hide table



Illustration 23	g03459488
View of the underside of the engine bay

2. Install tube assembly (40) into the lower front tube cutouts in the tube retention block sections and re-install the block halves along with the associated hardware. Refer to Illustration 23.

   Note: Do not tighten.

3. Install hose assembly (41) to the left-hand side of tube assembly (40). Refer to Illustration 23.

4. Connect the other end of hose assembly (41) to the open end of tube assembly (34). Refer to Illustration 23.

5. Tighten tube retention block hardware and hose assembly (41) .

Show/hide table



Illustration 24	g03459676
View of the right-hand inside front truck frame

6. Install tube assembly (42) to the right hand inside front of the truck chassis as shown in Illustration 24.

Show/hide table



Illustration 25	g03459860
A close up view of the upper portion of tube assembly (42)

7. Attach tube assembly (42) to the chassis using clip (43) and clip (44). Clip (43) and clip (44) are mounted using the existing bolt and boss. Refer to Illustration 25.

Show/hide table



Illustration 26	g03459916
View of the lower portion of tube assembly (42)

8. Attach the lower portion of tube assembly (42) to the steering tank drain tube using clip (35), clip (36), clip (43), and clip (44). Install with bolt (6), two hard washers (3), and one nut (4). Refer to Illustration 26.

Show/hide table



Illustration 27	g03460356
A view of the right-hand frame behind the right front wheel.

9. Attach hose assembly (45) to the open ends of tube assembly (42) and tube assembly (40) with O-ring seal (46) and O-ring seal (47). The elbow end of hose assembly (45) connects to tube assembly (40). Tighten all connections. Refer to Illustration 27.

Show/hide table



Illustration 28	g03460737
A view of the lower portion of lubrication pump group (5)

10. Install pipe adapter (48) into the bottom fast fill port on the grease lubrication pump group (5). Refer to Illustration 28.

11. Install connector assembly (49) into pipe adapter (48). Refer to Illustration 28.

Show/hide table



Illustration 29	g03460817
A view of the right-hand platform in front of the steering hydraulic tank

12. Install the elbow end of hose assembly (50) to connector assembly (49) and the other end of hose assembly (50) to tube assembly (42). Route hose assembly (50) between the steering hydraulic tank and the edge of the hood assembly. Refer to Illustration 29.

Show/hide table



Illustration 30	g03460876
A close up view of the boss in front of the steering hydraulic tank

13. Attach plate (51) to the boss located on top of the right hand main beam located in front of the steering hydraulic tank. Use bolt (18) and hard washer (3) to attach plate (51). Refer to Illustration 30.

Show/hide table



Illustration 31	g03460999
A close up view of the boss in front of the steering hydraulic tank

14. Attach hose assembly (50) to plate (51) using clip (52). Attach clip (52) to bracket (51) with bolt (6) and hard washer (3). Refer to Illustration 31.

Install the Electrical Harness to the Lubrication Pump Group

Required Parts

Table 6

Required Parts
Item	Qty	Part Number	Description
3	5	8T-4121	Hard Washer
11	4	8T-4136	Bolt
18	1	8T-4137	Bolt
21	1	132-5789	Clip
31	3	7K-1181	Cable Strap
53	1	443-0789	Bracket As
54	1	8T-4200	Bolt
55	1	8T-4224	Hard Washer
56	2	4P-7581	Clip
57	1	352-3964	Clip
58	1	420-8587	Switch Harness As
59	1	144-4613	Angle As
60	2	130-5300	Clip

Installation Procedure

Show/hide table



Illustration 32	g03462016
A view of the backside of lubrication pump group (5)

1. Attach bracket assembly (53) to the rear of auto lube pump and lubrication pump group (5) using bolt (54) and hard washer (55). Refer to Illustration 32.

2. Attach clip (56) to bracket assembly (53) using bolt (11) and hard washer (3). Refer to Illustration 32.

3. Attach clip (57) to the mounting block on the left side of the auto lube pump and lubrication pump group (5) using bolt (18) and hard washer (3). Refer to Illustration 32.

Show/hide table



Illustration 33	g03462482
A view of the backside of lubrication pump group (5)

4. Install switch harness assembly (58) to lubrication pump group (5) by connecting the corresponding electrical connector into the socket in the rear of the upper motor housing. Refer to Illustration 33.

5. Connect the pump pigtail harness to the corresponding connector on the switch harness assembly (58). Refer to Illustration 33.

6. Secure switch harness assembly (58) and the pump pigtail harness to clip (56) and clip (57). Refer to Illustration 33.

Show/hide table



Illustration 34	g03462619
A top down view of the right-hand platform

7. Route the switch harness assembly (58) around the grease lubrication pump group (5) and attach to lighting harness assembly (30) and 421-1025 Chassis Harness As . Refer to Illustration 34.

8. Route switch harness assembly (58) between grease lubrication pump group (5) and the steering hydraulic tank. Refer to Illustration 34.

Show/hide table



Illustration 35	g03462997
View of the gap between the lubrication pump group and the steering hydraulic tank

9. Remove the front bolt from the torque converter breather mounting bracket and add clip (21). Refer to Illustration 35.

10. Attach switch harness assembly (58) to clip (21) using one cable strap (31). Refer to Illustration 35.

Show/hide table



Illustration 36	g03487985
View of the gap between the lubrication pump group and the steering hydraulic tank

11. Attach angle assembly (59) with bolt (11) and hard washer (3). Refer to Illustration 36.

12. Attach clip (60) to angle assembly (59) with bolt (11) and hard washer (3). Refer to Illustration 36.

Show/hide table



Illustration 37	g03489417
A view on the front side of the steering hydraulic tank

13. Install clip (60) and clip (56) with bolt (11) and hard washer (3). Secure lighting harness assembly (30) to clip (56) with cable strap (31). Secure lighting harness assembly (30) to switch harness assembly (58) with cable strap (31). Refer to Illustration 37.

Install the Lines Group from the Lubrication Pump Group to the Right Side Lubrication Distribution Valve Group

Required Parts

Table 7

Required Parts
Item	Qty	Part Number	Description
3	8	8T-4121	Hard Washer
4	4	344-5675	Nut
6	4	8T-4195	Bolt
31	2	7K-1181	Cable Strap
43	1	8T-1889	Clip
44	1	8T-1890	Clip
61	2	8C-6867	Connector
62	2	418-6466	Hose As
63	4	9M-4995	Clip
64	1	6V-2235	Clip
65	1	6D-4246	Clip
66	1	6B-1032	Clip
67	1	200-6345	Mount

Installation Procedure

Show/hide table



Illustration 38	g03463062
View of the top front side of lubrication pump group (5)

1. Install two connectors (61) into the outlet ports on the grease lubrication pump group (5). Refer to Illustration 38.

Show/hide table



Illustration 39	g03463117
Hose assemblies (62) with example marks (L) for "Left" and (R) for "Right"

2. Install two hose assemblies (62) to connectors (61). Refer to Illustration 39.

   Note: Mark hose assemblies (62) on both ends to indicate which position each hose is in.

Show/hide table



Illustration 40	g03464097
View in front of the hydraulic steering tank

3. Route hose assemblies (62) down between the steering tank and the hood assembly. Attach the hose assemblies to plate (51) with clip (63) using the existing mounting hardware from Step 13. Refer to Illustration 40.

Show/hide table



Illustration 41	g03464277
Close up view in front of hydraulic steering tank

4. Attach hose assemblies (62) to tube assembly (42) using clip (63), clip (43), and clip (44). Assemble the clips with bolt (6), two hard washers (3), and nut (4). Refer to Illustration 41.

Show/hide table



Illustration 42	g03464319
View of the right fore-aft beam

Show/hide table



Illustration 43	g03464356
Close up view of the steering pump suction tube along the right fore-aft beam

5. Route hose assemblies (62) down towards the rear of the truck and attach the hose assemblies (62) to the steering pump suction tube. Use clip (63) and clip (64) to attach the hose assemblies (62). Assemble the clips with bolt (6), two hard washers (3), and nut (4). Refer to Illustration 42 and 43.

Show/hide table



Illustration 44	g03464438
Close up view of the right rear pedestal area

6. Route hose assemblies (62) along and down the lower side of 358-1518 Tube As . Attach hose assemblies (62) to the tube assembly using clip (65), clip (63), bolt (6), two hard washers (3), and nut (4). Refer to Illustration 44.

Show/hide table



Illustration 45	g03465178
View of the right rear pedestal area

Show/hide table



Illustration 46	g03465216
Close up view of the right rear pedestal area

7. Route hose assemblies (62) down behind the front right-hand brake cooling tube mounting bracket and above the brake cooling tube assemblies. Attach hose assemblies (62) to the rear brake cooling tube using clip (66), clip (63), bolt (6), two hard washers (3), and nut (4). Refer to Illustration 45 and 46.

Show/hide table



Illustration 47	g03465404
View of the outside face of the frame below the right rear pedestal

Show/hide table



Illustration 48	g03465458
Close up view of the outside face of the frame below the right rear pedestal

8. Route hose assemblies (62) down behind 369-8217 Hose As and connect to the right-hand injector assembly (8). Fasten hose assemblies (62) to the 369-8217 Hose As using mount (67) and two cable straps (31). Refer to Illustrations 47 and 48.

   Note: Ensure hose assemblies (62) are connected to the correct port on lubrication distribution valve group (8). Refer to the marks placed in Step 8.

Install the Lines Group from the Right Side Lubrication Distribution Valve Group to the Left Side Lubrication Distribution Valve Group

Required Parts

Table 8

Required Parts
Item	Qty	Part Number	Description
3	4	8T-4121	Hard Washer
4	2	344-5675	Nut
6	2	8T-4195	Bolt
63	4	9M-4995	Clip
68	1	418-6469	Hose As
69	1	418-6470	Hose As
70	1	109-1633	Clip
71	1	109-1634	Clip
72	1	5P-7468	Clip
73	1	5P-7469	Clip
74	1	6V-0545	Grommet

Installation Procedure

Show/hide table



Illustration 49	g03465520
View of the outside face of the frame below the right rear pedestal

1. Orientate tee assemblies (12) so that the side ports are located towards the rear of the truck. Refer to Illustration 49.

2. Install hose assembly (68) by connecting the elbow end to tee assembly (12) closest to the truck chassis. Refer to Illustration 49.

Show/hide table



Illustration 50	g03465676
View of the back side of the torque converter

3. Route hose assembly (68) across to the opposite side of the truck, passing hose assembly (68) along the rear side of the torque convertor as shown in Illustration 50.

Show/hide table



Illustration 51	g03465703
View of the outside face of the frame below the right rear pedestal

4. Install hose assembly (69) to tee assembly (12) furthest from the truck chassis. Refer to Illustration 51.

Show/hide table



Illustration 52	g03467001
View of the back side of the torque converter

5. Route hose assembly (69) and hose assembly (68) across to the opposite side of the truck to the rear side of the torque convertor as shown in Illustration 52.

Show/hide table



Illustration 53	g03467017
View of the outside face of the frame below the left rear pedestal

6. Route hose assembly (68) and hose assembly (69) below torque convertor oil fill hose and connect to the left-hand lubrication distribution valve group (8). Connect hose assembly (68) to the port closest to the truck chassis. Connect hose assembly (69) to the outside port. Refer to Illustration 53.

Show/hide table



Illustration 54	g03467120
View of the underside of the frame below the left rear pedestal

7. Secure hose assembly (68) and hose assembly (69) in place with clip (63) on the inner mounting stud for the brake hydraulic group hose retention block on the left side of the machine. Use existing mounting hardware to secure clip (63) in place. Refer to Illustration 54.

Show/hide table



Illustration 55	g03467408
View from behind the torque converter

Show/hide table



Illustration 56	g03467416
A close up view of the mounting point behind the torque converter

8. Secure hose assembly (68) and hose assembly (69) to 352-1218 Tube As with clip (70), clip (71), clip (63), bolt (6), two hard washers (3), and nut (4). Refer to Illustration 55. and 56.

Show/hide table



Illustration 57	g03467421
View from behind the torque converter

9. Secure hose assembly (68) and hose assembly (69) with clip (63) to 113-9556 Baffle Tube on the rear of the torque convertor utilizing the existing upper right-hand flange mounting bolt. Refer to Illustration 57.

Show/hide table



Illustration 58	g03467486
Close up view from behind the torque converter

10. Secure hose assembly (68) and hose assembly (69) to 355-6299 Hose As using clip (72), clip (73), grommet (74), clip (63), bolt (6), two hard washers (3), and nut (4). Refer to Illustration 58.

Install the Lines Group from the Right Side Lubrication Distribution Valve Group to the Rear Lubrication Distribution Valve Group

Required Parts

Table 9

Required Parts
Item	Qty	Part Number	Description
3	8	8T-4121	Hard Washer
11	1	8T-4136	Bolt
18	7	8T-4137	Bolt
63	7	9M-4995	Clip
75	2	418-6468	Hose As
76	2	118-6878	Bracket As

Installation Procedure

Show/hide table



Illustration 59	g03467539
View of the right side main frame rail

1. Install two hose assemblies (75) to the side ports of tee assemblies (12) on the bottom of the right-hand side lubrication distribution valve group (8). Refer to Illustration 59.

   Note: Mark hose assemblies (75) on both ends to indicate if the hose is connected in the position close to the chassis or away from the chassis.

2. Route hose assemblies (75) towards the rear of the truck, behind the fuel tank and over the top of the drop tube. Refer to Illustration 59.

3. Install two bracket assemblies (76) to the two bosses located on the lower edge of the right-hand frame rail behind and in front of the fuel tank with two bolts (18) and two hard washers (3). Refer to Illustration 59.

Show/hide table



Illustration 60	g03467612
View of the right side main frame rail

4. Attach hose assemblies (75) to both bracket assemblies (76) with two clips (63), bolt (11), bolt (18), and two hard washers (3). Refer to Illustration 60.

Show/hide table



Illustration 61	g03468057
View of the right rear frame rail above the drop tube

Show/hide table



Illustration 62	g03468156
Close up view of the right rear frame rail above the drop tube

5. Route hose assemblies (75) together and up along the inside of the right-hand frame rail. Secure hose assemblies (75) to three points using three clips (63), two bolts (18), and two hard washers (3). Refer to Illustration 61.

   Note: Use existing mounting hardware in the front clip location. Refer to Illustration 62.

Show/hide table



Illustration 63	g03468277
View of the rear cross member

6. Route hose assemblies (75) along the inside of the right-hand frame rail, above the rear axle lateral control rod and out below the rear cross member of the truck chassis. Attach hose assemblies (75) to the boss located on the inside rear of the right-hand frame rail using clip (63), bolt (18), and hard washer (3). Refer to Illustration 63.

7. Attach hose assemblies (75) to the boss located on the right-hand underside of the rear frame cross member using clip (63), bolt (18), and hard washer (3). Refer to Illustration 63.

Show/hide table



Illustration 64	g03468416
View from below of the rear support assembly

8. Connect hose assembly (75) that was marked for being close to the chassis to elbow (15) that is closest to the truck chassis on lubrication distribution valve group (16). Refer to Illustration 64.

9. Connect hose assembly (75) that was marked for being away from the chassis to elbow (15) that is away from the truck chassis on lubrication distribution valve group (16). Refer to Illustration 64.

Install the Right Side Injector Lines Group

Required Parts

Table 10

Required Parts
Item	Qty	Part Number	Description
3	5	8T-4121	Hard Washer
18	5	8T-4137	Bolt
77	1	418-6432	Hose As
78	1	418-6431	Hose As
79	1	418-6433	Hose As
80	1	418-6434	Hose As
81	3	4D-7735	Clip
82	1	418-6442	Hose As
83	1	418-6436	Hose As
84	1	418-6437	Hose As
85	6	9M-8406	Clip
86	6	7D-2746	Elbow
87	2	5P-9085	Clip
88	1	6K-6967	Pipe Adapter

Installation Procedure

Show/hide table



Illustration 65	g03468503
View of the outside face of the frame below the right rear pedestal

1. Install hose assembly (77), hose assembly (78), hose assembly (79), and hose assembly (80) onto right-hand lubrication distribution valve group (8). Refer to Illustration 65.

2. Route hose assembly (77), hose assembly (78), hose assembly (79), and hose assembly (80) up above the mounting boss on the frame rail in front of the injector assembly and install clip (81) with bolt (18) and hard washer (3). Refer to Illustration 65.

Show/hide table



Illustration 66	g03468556
View of the outside face of the frame below the right rear pedestal

3. Install hose assembly (82), hose assembly (83), and hose assembly (84) onto right-hand lubrication distribution valve group (8). Refer to Illustration 66.

4. Route hose assembly (82), hose assembly (83), and hose assembly (84) below the clip mounting boss on the right frame rail in front of the injector assembly and install clip (85) with the mounting hardware used in Step 2. Refer to Illustration 66.

Show/hide table



Illustration 67	g03469009
View of the right side of the frame behind the front wheel

5. Route the seven hose assemblies along the outside of the right-hand frame rail and behind the 341-2692 Protection Cover Gp . Attach the hoses to the two boss locations on the right-hand frame rail using two bolts (18), two hard washers (3), two clips (81), and two clips (85). Attach an additional clip (85) with existing hardware as indicated in Illustration 67.

Show/hide table



Illustration 68	g03469278
A view in front of the torque converter showing steering lubrication connections

Show/hide table



Illustration 69	g03469457
A top down view in front of the torque converter showing steering lubrication connections

6. Route hose assembly (82), hose assembly (83), and hose assembly (84) down towards the center of the front axle. Install three elbows (86) and connect the hose assemblies to grease joints as indicated in Illustrations 68 and 69.

7. Secure hose assembly (82), hose assembly (83), and hose assembly (84) with two clips (85) using existing mounting hardware. Refer to Illustrations 68 and 69.

8. Secure hose assembly (83) to the boss in the center of the front axle with clip (87), bolt (18), and hard washer (3). Refer to Illustrations 68 and 69.

Show/hide table



Illustration 70	g03469576
A view behind the right front wheel

9. Route hose assembly (77) and hose assembly (80) down to the steering arm assembly. Install an elbow (86) into each ball joint cap, and connect hose assembly (77) and hose assembly (80) to the two elbows (86) as shown in Illustration 70.

10. Install elbow (86) into the grease point on the rear of the right-hand suspension strut. Attach hose assembly (77) to elbow (86). Refer to Illustration 70.

Show/hide table



Illustration 71	g03469676
A view of the right front suspension strut

11. Route hose assembly (79) up the right-hand suspension strut mounting flange. Attach hose assembly (79) with pipe adapter (88) to the grease connection. Secure hose assembly (79) to the boss location on the rear edge of the suspension strut mounting flange using clip (87), bolt (18), and hard washer (3). Refer to Illustration 71.

Install the Left Side Injector Lines Group

Required Parts

Table 11

Required Parts
Item	Qty	Part Number	Description
3	6	8T-4121	Hard Washer
11	2	8T-4136	Bolt
18	4	8T-4137	Bolt
78	1	418-6431	Hose As
81	2	4D-7735	Clip
82	1	418-6442	Hose As
85	6	9M-8406	Clip
86	6	7D-2746	Elbow
87	3	5P-9085	Clip
89	2	418-6441	Hose As
90	1	418-6439	Hose As
91	1	418-6443	Hose As
92	1	418-6435	Hose As
93	1	3S-2093	Cable Strap

Installation Procedure

Show/hide table



Illustration 72	g03470665
View of the outside face of the frame below the left rear pedestal

1. Install two hose assemblies (89), hose assembly (90), and hose assembly (78) to the left-hand lubrication distribution valve group (8). Refer to Illustration 72.

   Note: Mark hose assembly (89) installed on the top position of lubrication distribution valve group (8) on both ends.

2. Route two hose assemblies (89), hose assembly (90), and hose assembly (78) above the clip mounting boss on the frame rail in front of lubrication distribution valve group (8) and install clip (81) with bolt (18) and hard washer (3). Refer to Illustration 72.

Show/hide table



Illustration 73	g03470705
View of the outside face of the frame below the left rear pedestal

3. Install hose assembly (82), hose assembly (91), and hose assembly (92) to the left-hand side lubrication distribution valve group (8). Refer to Illustration 73.

4. Route hose assembly (82), hose assembly (91), and hose assembly (92) below the clip mounting boss on the frame rail in front of lubrication distribution valve group (8) and install clip (85) using the mounting hardware from Step 2.

Show/hide table



Illustration 74	g03470917
A view of the left side frame behind the front wheel

5. Route the hose assemblies along the outside of the left-hand frame rail and behind the service and park brake accumulator assembly. Attach the hoses to the boss location on the right-hand frame rail using clip (81), clip (85), bolt (18) and hard washer (3). Refer to Illustration 74.

6. Route two hose assemblies (89) and hose assembly (78) up to the service brake hose clip point. Secure with clip (85) using the existing mounting hardware. Refer to Illustration 74.

7. Attach hose assembly (82), hose assembly (91), and hose assembly (92) to the two boss locations on the frame rail. Attach with a clip (85), bolt (11), and hard washer (3) at each location. Refer to Illustration 74.

8. Route hose assembly (82), hose assembly (91), and hose assembly (92) down towards the center of the front axle. Refer to Illustration 74.

Show/hide table



Illustration 75	g03471442
A view in front of the torque converter showing steering lubrication connections

9. Install elbows (86) into the three locations indicated in Illustration 75. Connect hose assembly (82), hose assembly (91), and hose assembly (92) into elbows (86) as indicated.

10. Secure hose assembly (82), hose assembly (91), and hose assembly (92) to the boss locations with clip (85) and clip (87) with existing mounting hardware. Refer to Illustration 75.

11. Secure hose assembly (91) to the boss in the center of the front axle location with clip (87) with existing mounting hardware from Step 8 in ""Install the Right Side Injector Lines Group" ". Refer to Illustration 75.

Show/hide table



Illustration 76	g03471581
A top down view in front of the torque converter showing the steering connections

12. Install cable strap (93) to hose assembly (83) and hose assembly (91). Refer to illustration 76.

Show/hide table



Illustration 77	g03471640
A view of the steering lubrication connections behind the left wheel

13. Route two hose assemblies (89) down the left-hand steering arm assembly. Install elbows (86) into each ball joint cap and connect to hose assemblies (89). Refer to Illustration 77.

    Note: Install hose assembly (89) marked as being in the top position to the joint on the steering linkage, indicated by an arrow.

14. Install elbow (86) into the grease point on the rear of the suspension strut. Connect hose assembly (78) to elbow (86). Refer to Illustration 77.

Show/hide table



Illustration 78	g03471657
A view of the left-hand suspension strut

15. Route hose assembly (90) up the left-hand suspension strut mounting flange and attach hose assembly (90) to the boss location on the rear edge of the suspension strut mounting flange. Attach with clip (87), bolt (18), and hard washer (3). Refer to Illustration 78.

16. Route hose assembly (90) behind the upper spindle section of the left-hand suspension strut and connect hose assembly (90) and elbow (86) to the grease port on the upper suspension bearing cap housing. Refer to Illustration 78.

17. Secure hose assembly (90) to the boss location on the underside of the left-hand beam assembly with clip (87), bolt (18), and hard washer (3). Refer to Illustration 78.

Install the Left Rear Injector Lines Group

Required Parts

Table 12

Required Parts
Item	Qty	Part Number	Description
3	12	8T-4121	Hard Washer
4	2	344-5675	Nut
10	6	8T-4191	Bolt
18	2	8T-4137	Bolt
85	2	9M-8406	Clip
86	1	7D-2746	Elbow
87	7	5P-9085	Clip
88	1	6K-6967	Pipe Adapter
94	1	418-6446	Hose As
95	1	418-6447	Hose As
96	1	418-6448	Hose As
97	1	418-6449	Hose As
98	2	204-8000	Cable Tie Mounting
99	2	272-1777	Hard Washer
100	2	8T-4185	Bolt
101	1	204-2281	Cable Strap
102	1	4M-8973	Elbow
103	1	8T-4896	Hard Washer
104	1	3B-6552	Pipe Elbow
105	1	4B-9233	Clip
106	1	8L-5008	Pipe Elbow

Installation Procedure

Show/hide table



Illustration 79	g03471718
View of the rear lubrication distribution valve group

1. Install hose assembly (94), hose assembly (95), hose assembly (96), and hose assembly (97) to lubrication distribution valve group (16). Refer to Illustration 79.

Show/hide table



Illustration 80	g03472497
View of the tail below the left tail light

2. Install two cable tie mountings (98), two hard washers (99), two bolts (100), four hard washers (3), and two nuts (4) to the left-hand rear tail light mount assembly. Refer to Illustration 80.

Show/hide table



Illustration 81	g03472556
View of the tail below the left tail light

3. Route hose assembly (94), hose assembly (95), and hose assembly (96) up to the upper cable tie mounting (98) and secure with cable strap (101). Refer to Illustration 81.

4. Route hose assembly (94), hose assembly (95), and hose assembly (96) across onto the left hand rear corner of the frame casting and mount to the boss location with clip (85), bolt (18), and hard washer (3). Refer to Illustration 81.

Show/hide table



Illustration 82	g03472998
Close up view of the left lower rear suspension mount

Show/hide table



Illustration 83	g03473037
View of the left lower rear suspension mount

5. Route hose assembly (97) down to the left-hand suspension strut lower mounting pin grease port and install with elbow (102). Secure hose assembly (97) with clip (87) to the boss location on the rear axle housing inboard of the left-hand suspension cylinder using the existing mounting hardware for the axle oil level sensor. Replace the existing washer with hard washer (103). Refer to Illustration 82 and 83.

6. If the rear axle filtration system is present, secure hose assembly (97) to the filtration system with clip (87) using existing mounting hardware. Refer to Illustration 82 and 83.

Show/hide table



Illustration 84	g03473218
View of the rear left side body pivot point

7. Route hose assembly (94), hose assembly (95), and hose assembly (96) up towards the left-hand body mounting pin and attach to the boss location on the left hand rear frame below the body pin mounting pin. Secure hose assembly (94), hose assembly (95), and hose assembly (96) to the boss with clip (85). Refer to Illustration 84.

8. Insert pipe elbow (104) into the left-hand body mounting pin and attach hose assembly (95) to the body mounting pin grease location. Refer to Illustration 84.

9. Insert elbow (86) into pipe adapter (88) into the left-hand suspension cylinder. Connect hose assembly (96) to elbow (86). Refer to Illustration 84.

10. Secure hose assembly (94) to the boss on the truck body with clip (87), bolt (10), and hard washer (3). Refer to Illustration 84.

Show/hide table



Illustration 85	g03473299
View of the left side body frame rail

11. Route hose assembly (94) around the rear of the pivot area and forward to the left-hand hoist cylinder upper bearing joint. Secure hose assembly (94) in place with one clip (105), and five clips (87) with a five bolts (10) and five hard washers (3). Refer to Illustration 85.

Show/hide table



Illustration 86	g03474516
Close up view of the top of the left side hoist cylinder

12. Route hose assembly (94) around the front side of the hoist cylinder and connect to the hoist cylinder with pipe elbow (106). Refer to Illustration 86.

Install the Right Rear Lubrication Lines Group

Required Parts

Table 13

Required Parts
Item	Qty	Part Number	Description
3	10	8T-4121	Hard Washer
4	1	344-5675	Nut
10	6	8T-4191	Bolt
18	2	8T-4137	Bolt
85	2	9M-8406	Clip
86	1	7D-2746	Elbow
87	7	5P-9085	Clip
88	2	6K-6967	Pipe Adapter
94	1	418-6446	Hose As
95	1	418-6447	Hose As
96	1	418-6448	Hose As
97	1	418-6449	Hose As
98	1	204-8000	Cable Tie Mounting
99	1	272-1777	Hard Washer
100	1	8T-4185	Bolt
101	1	204-2281	Cable Strap
102	1	4M-8973	Elbow
103	1	8T-4896	Hard Washer
104	2	3B-6552	Pipe Elbow
105	1	4B-9233	Clip
106	1	8L-5008	Pipe Elbow
107	1	437-5046	Hose As
108	1	5M-3062	Bolt

Installation Procedure

Show/hide table



Illustration 87	g03474977
View of the rear lubrication distribution valve group

1. Install hose assembly (94), hose assembly (95), hose assembly (96), and hose assembly (97) to lubrication distribution valve group (16). Refer to Illustration 87.

Show/hide table



Illustration 88	g03475024
View of the tail section under the right side tail light

2. Install cable tie mounting (98), hard washer (99), bolt (100), two hard washers (3), and nut (4) to the right hand rear tail light mount assembly. Refer to Illustration 88.

Show/hide table



Illustration 89	g03476385
View of the tail section under the right side tail light

3. Install hose assembly (107) to lubrication distribution valve group (16). Refer to Illustration 89.

Show/hide table



Illustration 90	g03475296
View of the tail section under the right side tail light

4. Route hose assembly (94), hose assembly (95), hose assembly (96), and hose assembly (107) up to the cable tie mounting (98) on the right rear tail light mount assembly and secure with cable strap (101). Refer to Illustration 90.

Show/hide table



Illustration 91	g03475358
View of the right side tail casting

5. Route hose assembly (94), hose assembly (95), and hose assembly (96) across onto the right hand rear corner of the frame casing and mount to two boss locations with two clips (85), two bolts (18) and two hard washers (3). Refer to Illustration 91.

Show/hide table



Illustration 92	g03476107
View of the right rear lower suspension mount

6. Route hose assembly (97) down to the right-hand suspension strut lower mounting pin grease port. Secure the hose to the boss location on the rear axle housing inboard of the right-hand suspension cylinder. Attach using clip (87), bolt (108), and hard washer (103). Refer to Illustration 92.

7. Connect elbow (102) into the lower grease port of the suspension cylinder. Connect hose assembly (97) to elbow (102). Refer to Illustration 92.

Show/hide table



Illustration 93	g03476203
View of the right rear body pivot point

8. Connect hose assembly (95) to pipe elbow (104). Connect pipe elbow (104) to pipe adapter (88). Connect pipe adapter (88) to the right-hand body mounting pin grease location. Refer to Illustration 93.

9. Connect hose assembly (96) to elbow (86). Connect elbow (86) to pipe adapter (88). Connect pipe adapter (88) to the grease fitting on the right hand rear suspension cylinder upper pin grease joint. Refer to Illustration 93.

10. Route hose assembly (94) up to the truck body assembly, and secure hose assembly to the body assembly with clip (87), bolt (10), and hard washer (3). Refer to Illustration 93.

Show/hide table



Illustration 94	g03476246
View of the right rear body pivot point

11. Continue routing hose assembly (94) around the rear of the pivot area and forward to the right-hand hoist cylinder upper bearing joint. Secure hose assembly (94) in place with one clip (105), and five clips (87) with a five bolts (10) and five hard washers (3). Refer to Illustration 94.

Show/hide table



Illustration 95	g03476314
Close up view of the top of the right hoist cylinder

12. Insert pipe elbow (106) into the grease port of the upper end of the hoist cylinder assembly. Route hose assembly (94) into pipe elbow (106). Refer to Illustration 95.

Show/hide table



Illustration 96	g03476413
A view of the tail section below the right tail light

Show/hide table



Illustration 97	g03476428
A close of up view of the right tail section at the lateral control rod mount point

13. Route hose assembly (107) around to the outboard grease port of the rear axle lateral control rod. Install hose assembly (107) to the grease port with pipe elbow (104). Refer to Illustrations 96 and 97.

Install the Lower Rear Lubrication Lines Group

Required Parts

Table 14

Required Parts
Item	Qty	Part Number	Description
3	12	8T-4121	Hard Washer
11	1	8T-4136	Bolt
18	11	8T-4137	Bolt
85	7	9M-8406	Clip
87	3	5P-9085	Clip
88	1	6K-6967	Pipe Adapter
93	1	3S-2093	Cable Strap
104	3	3B-6552	Pipe Elbow
109	1	418-6450	Hose As
110	1	418-6451	Hose As
111	1	418-6452	Hose As
112	1	418-6453	Hose As
113	1	7E-9992	Bracket
114	2	9X-8582	Clip

Installation Procedure

Show/hide table



Illustration 98	g03476459
View of lubrication distribution valve group (16) on the tail section

1. Install hose assembly (109), hose assembly (110), hose assembly (111), and hose assembly (112) to lubrication distribution valve group (16). Refer to Illustration 98.

Show/hide table



Illustration 99	g03476519
A view of the left underside of the rear support assembly

2. Attach bracket (113) to the boss location on the left-hand underside of the rear frame cross member using bolt (11), bolt (18), and two hard washers (3). Secure hose assembly (109), hose assembly (110), and hose assembly (111) with two clips (85). Refer to Illustration 99.

Show/hide table



Illustration 100	g03477256
View of the inside of the left-hand frame rail

3. Route hose assembly (109), hose assembly (110), and hose assembly (111) on the inside lower edge of the left-hand frame rail. Secure in place on four bosses with four clips (85), four bolts (18), and four hard washers (3). Refer to Illustration 100.

Show/hide table



Illustration 101	g03477436
View of the left side drop tube

4. Route hose assembly (109), hose assembly (110), and hose assembly (111) down from the left-hand frame rail onto the top of the drop tube assembly. Secure hose assembly (109), hose assembly (110), and hose assembly (111) to boss location mounted on the frame rail above the left-hand drop tube casting. Secure in place with clip (85), bolt (18), and hard washer (3), and secure with cable strap (93). Refer to Illustration 101.

5. Route hose assembly (109) towards the grease port on the left-hand hoist cylinder joint. Secure in place with clip (87), bolt (18), and hard washer (3). Refer to Illustration 101.

6. Continue routing hose assembly (110) and hose assembly (111) along the top of the drop tube and secure in place with two clips (114), two bolts (18), and two hard washers (3). Refer to Illustration 101.

Show/hide table



Illustration 102	g03477737
View of the bottom of the left side hoist cylinder

7. Connect hose assembly (109) to the grease port of the left-hand hoist cylinder joint with pipe elbow (104). Refer to Illustration 102.

Show/hide table



Illustration 103	g03477957
A view of the A-frame pivot joint and drop tube

8. Connect hose assembly (111) to the grease port on the A-frame pivot joint in the center of the truck with pipe elbow (104). Refer to Illustration 103.

Show/hide table



Illustration 104	g03478038
A view of the bottom of the right side hoist cylinder

9. Route hose assembly (110) to the grease port on the right-hand hoist cylinder joint and install with pipe elbow (104). Secure hose assembly in place with two clips (87), two bolts (18), and two hard washers (3). Refer to Illustration 104.

Show/hide table



Illustration 105	g03478336
A view of the tail assembly and left side rear axle lateral control rod mount

10. Route hose assembly (112) around the rear of the grease injector valve assembly and down to the inboard pivot joint of the rear axle lateral control rod. Install pipe adapter (88) into the grease port, and install hose assembly (112) into pipe adapter (88). Refer to Illustration 105.

Install Sensor Harness Assembly

Required Parts

Table 15

Required Parts
Item	Qty	Part Number	Description
3	1	8T-4121	Hard Washer
18	1	8T-4137	Bolt
21	1	132-5789	Clip
31	3	7K-1181	Cable Strap
60	1	130-5300	Clip
115	1	419-4118	Sensor Harness As

Installation Procedure

Show/hide table



Illustration 106	g03489780
View of the top of the rear support assembly

1. Connect sensor harness assembly (115) to 421-1023 Sensor Harness As , and mount in place with clip (60), bolt (18), and hard washer (3). Refer to Illustration 106.

2. Secure sensor harness assembly (115) to 251-4169 Communication Cable As with two cable straps (31). Refer to Illustration 106.

Show/hide table



Illustration 107	g03490176
View of the tail and right tail light area

3. Secure sensor harness assembly (115) with clip (21) and cable strap (31) and the existing mounting hardware on the right rear brake light mount. Refer to Illustration 107.

4. Install sensor harness assembly (115) to lubrication distribution valve group (16). Refer to Illustration 107.

Install the Film Group

Required Parts

Table 16

Required Parts
Item	Qty	Part Number	Description
116	1	434-5692	Film
117	1	434-5693	Film
118	1	434-5694	Film
119	1	150-1258	Film

Installation Procedure

1. Install the film group.
   Show/hide table
   
   

   Illustration 108	g03478402
   View of the left side frame rail below the rear pedestal

   1. Install film (116) to the left-hand truck frame, behind the left-hand lubrication distribution valve group (8). Refer to Illustration 108.
   Show/hide table
   
   

   Illustration 109	g03478420
   View of the right side frame rail below the rear pedestal

   2. Install film (117) to the right-hand truck frame, behind the right-hand lubrication distribution valve group (8). Refer to Illustration 109.
   Show/hide table
   
   

   Illustration 110	g03478529
   View of the tail section

   3. Install film (118) to the rear grease injector valve plate assembly (17). Refer to Illustration 110.
   Show/hide table
   
   

   Illustration 111	g03478557
   View of the fast fill location at the left side of the front bumper area

   4. Install film (119) to the grease fast fill port location. Refer to Illustration 37.

Software Configuration

Note: The most recent version of the "CHASSIS" software must be flashed on to the truck to allow the Groeneveld Auto Lube system to function correctly.

Perform the following steps to configure the software:

1. Connect to the machine with Caterpillar Electronic Technician.

2. Select "Chassis ECM" and access the configuration menu.

3. Locate "Auto Lube System Installation Status" and configured this parameter to "Enabled"

4. Locate "Auto Lube System Configuration Code" and configure this parameter to "2".

Note: With the Groeneveld Auto Lube system installed, the "Auto Lube Interval" and "Auto Lube Duration" parameters will be "Unavailable". The two parameters are only utilized with the Lincoln Auto Lube system.

Table 17

Auto Lube System Installation Status	Installed
Auto Lube System Configuration Code	2
Auto Lube Interval	Unavailable
Auto Lube Duration	Unavailable

Register the Retrofit

1. When performing a retrofit installation, record the vital information in Table 18.

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

   Show/hide table

   Table 18

   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)

   Show/hide table

   ( 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 18 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".