Procedure to Install the Lincoln Auto Lubrication System on Certain 777G Off-Highway Trucks{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 Lincoln 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 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

Required Parts

Table 1

Required Parts
Item	Qty	Part Number	Description
1	1	438-6094	Bracket As
2	18	8T-6466	Bolt
3	103	8T-4121	Hard Washer
4	27	344-5675	Nut
5	1	455-6746	Lubrication Pump Gp
6	11	8T-4195	Bolt
7	1	426-2154	Plate
8	31	8T-4137	Bolt
9	1	433-2892	Hose As
10	1	8C-6875	Connector
11	1	5K-9090	O-Ring Seal
12	1	4D-7388	Clip
13	1	440-1852	Tube As
14	3	228-7093	O-Ring Seal
15	3	8T-1889	Clip
16	3	8T-1890	Clip
17	2	8S-0023	Clip
18	2	8S-0024	Clip
19	1	433-2894	Hose As
20	1	360-4438	Tube As
21	3	228-7094	O-Ring Seal
22	1	381-9644	Plate As
23	1	9D-3127	Indicator Light Base As
24	1	163-1883	Lamp
25	1	9D-2867	Amber Lens
26	1	6V-9173	Bulkhead Nut
27	1	347-4411	Adapter
28	1	189-1858	Coupler
29	1	3J-5389	Plug
30	1	6V-9855	Elbow
31	2	6V-8400	O-Ring Seal
32	1	150-1258	Film
33	1	381-9646	Plate
34	16	8T-4136	Bolt
35	9	7X-7729	Washer
36	1	360-1299	Tube As
37	2	8T-4183	Bolt
38	2	5P-1076	Hard Washer
39	1	360-4851	Hose As
40	2	130-5300	Clip
41	1	144-4613	Angle As
42	1	132-5789	Clip
43	1	420-8587	Switch Harness As
44	50	7K-1181	Cable Strap
45	4	2T-2396	Elbow
46	3	8C-6871	Connector
47	1	3J-5390	Plug
48	1	280-2076	Block
49	5	8T-4185	Bolt
50	1	441-1277	Hose As
51	13	6D-4636	Clip
52	7	6V-8398	O-Ring Seal
53	1	368-8603	Hose As
54	1	118-6878	Bracket As
55	1	223-3490	Clip
56	1	125-8534	Plate As
57	1	359-5006	Hose As
58	1	200-6345	Mount
59	1	433-2732	Hose As
60	1	8T-6466	Bolt
61	1	179-0469	Spacer
62	1	067-3045	Clip
63	1	6V-2235	Clip
64	3	269-5348	Lubrication Distribution Valve Gp
65	2	269-5352	Lubrication Distribution Valve Gp
66	4	004-6683	Fitting
67	2	3J-5390	Plug
68	33	3B-6552	Pipe Elbow
69	2	307-9209	Plate
70	10	365-3303	Hard Washer
71	1	418-6439	Hose As
72	1	436-5775	Hose As
73	1	418-6433	Hose As
74	2	436-5767	Hose As
75	1	436-5777	Hose As
76	1	418-6442	Hose As
77	1	436-5778	Hose As
78	5	4D-7735	Clip
79	23	9M-8406	Clip
80	17	5P-9085	Clip
81	6	6K-6967	Pipe Adapter
82	15	7D-2746	Elbow
83	16	420-0939	Spacer
84	6	420-0940	Spacer
85	1	418-6431	Hose As
86	1	436-5769	Hose As
87	1	418-6441	Hose As
88	1	418-6443	Hose As
89	1	418-6435	Hose As
90	1	418-6432	Hose As
91	1	359-4871	Tube As
92	1	228-7090	O-Ring Seal
93	1	5P-9299	Clip
94	2	3S-2093	Cable Strap
95	2	269-5353	Lubrication Distribution Valve Gp
96	1	9M-5501	Street Elbow
97	1	8C-4985	Adapter
98	1	221-3404	Pressure Sensor Gp
99	1	3J-1907	O-Ring Seal
100	1	346-1684	Plate As
101	2	352-3964	Clip
102	1	352-3968	Clip
103	2	8T-4186	Bolt
104	2	198-4777	Hard Washer
105	5	420-0942	Spacer
106	1	419-4118	Sensor Harness As
107	2	237-9960	Clip
108	3	204-8000	Cable Tie Mounting
109	3	272-1777	Hard Washer
110	2	436-5766	Hose As
111	1	436-5765	Hose As
112	1	418-6446	Hose As
113	3	204-2281	Cable Strap
114	12	8T-4191	Bolt
115	2	4B-9233	Clip
116	2	8L-5008	Pipe Elbow
117	1	437-5046	Hose As
118	1	436-5760	Hose As
119	1	418-6447	Hose As
120	2	436-5764	Hose As
121	2	5M-3062	Bolt
122	2	8T-4896	Hard Washer
123	2	4M-8973	Elbow
124	1	437-1151	Hose As
125	1	436-5759	Hose As
126	1	436-5758	Hose As
127	1	436-5761	Hose As
128	1	7E-9992	Bracket
129	2	9X-8582	Clip
130	1	435-5391	Lighting Harness As
131	2	3V-4791	Grommet
132	1	4P-7581	Clip
133	1	231-3923	Film
134	1	231-3922	Film
135	1	289-2067	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.

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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.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's weights in order to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Note: The lifting devices that are shown in this publication are not Caterpillar parts.

Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a lifting operation.

Illustration 2	g00629745
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

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.

Autolube System Installation

Install the Lubrication Pump Group

Required Parts

Table 2

Required Parts
Item	Qty	Part Number	Description
1	1	438-6094	Bracket As
2	8	8T-6466	Bolt
3	22	8T-4121	Hard Washer
4	8	344-5675	Nut
5	1	455-6746	Lubrication Pump Gp
6	6	8T-4195	Bolt

Installation Procedure

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Illustration 3	g03638301
View of right-hand platform

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Illustration 4	g03638302
View of underside of the right-hand platform

1. Locate auto lube reservoir mounting bracket assembly (1). Align bracket assembly (1) with the existing mounting holes on the right-hand platform. Use eight bolts (2), 16 hard washers (3), and eight nuts (4) to assemble the bracket to the platform. Orientate bracket assembly (1) as shown in Illustration 3 and 4.

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Illustration 5	g03639601
View of right-hand platform

2. Install lubrication pump group (5) with six bolts (6) and six hard washers (3) .

   Note: lubrication pump group (5) weighs approximately 77 kg (170 lb). Use an appropriate lifting device when transporting, positioning, and installing lubrication pump group (5) .

Installation of the Fast Fill Lines Group

Required Parts

Table 3

Required Parts
Item	Qty	Part Number	Description
3	7	8T-4121	Hard Washer
4	3	344-5675	Nut
6	3	8T-4195	Bolt
7	1	426-2154	Plate
8	1	8T-4137	Bolt
9	1	433-2892	Hose As
10	1	8C-6875	Connector
11	1	5K-9090	O-Ring Seal
12	1	4D-7388	Clip
13	1	440-1852	Tube As
14	3	228-7093	O-Ring Seal
15	3	8T-1889	Clip
16	3	8T-1890	Clip
17	1	8S-0023	Clip
18	1	8S-0024	Clip
19	1	433-2894	Hose As
20	1	360-4438	Tube As
21	1	228-7094	O-Ring Seal

Installation Procedure

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Illustration 6	g03640160
View of right fore-aft beam

1. Install plate (7) to the frame with one bolt (8) and one hard washer (3) .

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Illustration 7	g03705217
Close up view of the bottom of lubrication pump group (5)

2. Install hose assembly (9) to the lubrication pump group (5) with O-Ring seal (14), connector (10) and O-Ring seal (11) .

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Illustration 8	g03640679
Close up view next to the hydraulic tank

3. Secure hose assembly (9) to plate (7) with a clip (12), bolt (6), two hard washers (3), and nut (4) .

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Illustration 9	g03641020
View of the inside of the right fore-aft beam

4. Install tube assembly (13) to hose assembly (9) with O-Ring seal (14) .

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Illustration 10	g03641865
Close up view next to the hydraulic tank

5. Attach clip (15) and clip (16) to tube assembly (13) with bolt (6), two hard washers (3) and nut (4) .

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Illustration 11	g03642184
Close up view of the right fore-aft beam next to the hydraulic tank

6. Secure tube assembly (13) to the frame with clip (15) and clip (16) using existing mounting hardware.

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Illustration 12	g03642293
View of the area under the right fore-aft beam

7. Secure tube assembly (13) to 317-7300 Tube As with clip (15), clip (16), bolt (6), two hard washers (3), nut (4), clip (17), and clip (18) .

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Illustration 13	g03642810
A top down view by the right front rail

8. Install hose assembly (19) to tube assembly (13) with one O-Ring seal (14) .

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Illustration 14	g03642838
A view of the front frame

9. Install tube assembly (20) to hose assembly (19) with one O-Ring seal (21). Route tube assembly (20) through the two blocks under the front of the engine.

Install the Service Box

Required Parts

Table 4

Required Parts
Item	Qty	Part Number	Description
3	1	8T-4121	Hard Washer
6	1	8T-4195	Bolt
17	1	8S-0023	Clip
18	1	8S-0024	Clip
21	2	228-7094	O-Ring Seal
22	1	381-9644	Plate As
23	1	9D-3127	Indicator Light Base As
24	1	163-1883	Lamp
25	1	9D-2867	Amber Lens
26	1	6V-9173	Bulkhead Nut
27	1	347-4411	Adapter
28	1	189-1858	Coupler
29	1	3J-5389	Plug
30	1	6V-9855	Elbow
31	2	6V-8400	O-Ring Seal
32	1	150-1258	Film
33	1	381-9646	Plate
34	3	8T-4136	Bolt
35	3	7X-7729	Washer
36	1	360-1299	Tube As
37	2	8T-4183	Bolt
38	2	5P-1076	Hard Washer
39	1	360-4851	Hose As

Installation Procedure

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Illustration 15	g03643097
Close up view of the access panel under the access stairway on the left side of the machine

1. Assemble the indicator light to plate assembly (22) as indicated in Illustration 15.

   1. Install indicator light base assembly (23) to plate assembly (22) .

   2. Install lamp (24) to indicator light base assembly (23) .

   3. Install amber lens (25) to indicator light base assembly (23) .

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Illustration 16	g03643403
Close up view of the access panel under the access stairway on the left side of the machine

2. Assemble the fill connector to plate assembly (22) as indicated in Illustration 16.

   1. Install bulkhead nut (26) and adapter (27) to plate assembly (22) .

   2. Install coupler (28) and plug (29) to adapter (27) .

   3. Install elbow (30) to adapter (27) with an O-Ring seal (31) .

   4. Install an O-Ring seal (31) into the open end of elbow (30) .

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Illustration 17	g03643547
A view of plate assembly (22)

3. Install film (32) to plate assembly (22) .

   Note: For proper quality, place the film perpendicular to the edge of the plate.

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Illustration 18	g03643596
Close up view of the access panel under the access stairway on the left side of the machine

4. Install plate (33) to plate assembly (22) with three bolts (34) and three washers (35) .

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Illustration 19	g03643706
Close up view of the access panel under the access stairway on the left side of the machine

5. Install tube assembly (36) to elbow (30) using O-Ring seal (31) installed in Step 2.d.

6. Secure tube assembly (36) in place with clip (17), clip (18), bolt (6), and hard washer (3) .

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Illustration 20	g03643765
Close up view of the access panel under the access stairway on the left side of the machine

7. Install plate assembly (22) to the front fender with two bolts (37) and two hard washers (38) .

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Illustration 21	g03643855
View of the left side frame rail at the front pedestal

8. Install hose assembly (39) between tube assembly (20) and tube assembly (36) with an O-Ring seal (21) at each end.

Install the Lubrication Pump Wiring Group

Required Parts

Table 5

Required Parts
Item	Qty	Part Number	Description
3	3	8T-4121	Hard Washer
34	3	8T-4136	Bolt
40	1	130-5300	Clip
41	1	144-4613	Angle As
42	1	132-5789	Clip
43	1	420-8587	Switch Harness As
44	2	7K-1181	Cable Strap

Installation Procedure

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Illustration 22	g03644267
View of the hydraulic tank on the right side of the machine

1. Install clip (40) with bolt (34) and hard washer (3) as indicated in Illustration 22.

2. Install angle assembly (41) with bolt (34) and hard washer (3) as indicated in Illustration 22.

3. Install clip (40) and clip (42) with bolt (34) and hard washer (3) to angle assembly (41) as indicated in Illustration 22.

4. Install clip (42) with existing mounting hardware as indicated in Illustration 22.

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Illustration 23	g03644370
View of the hydraulic tank on the right side of the machine

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Illustration 24	g03644391
View of the auto lube tank on the right side of the machine

5. Install switch harness assembly (43) with two cable straps (44) as shown in Illustrations 23 and 24.

Install the Lubrication Block and Lines Group

Required Parts

Table 6

Required Parts
Item	Qty	Part Number	Description
3	14	8T-4121	Hard Washer
4	2	344-5675	Nut
6	1	8T-4195	Bolt
8	6	8T-4137	Bolt
34	2	8T-4136	Bolt
44	2	7K-1181	Cable Strap
45	2	2T-2396	Elbow
46	2	8C-6871	Connector
47	1	3J-5390	Plug
48	1	280-2076	Block
49	2	8T-4185	Bolt
50	1	441-1277	Hose As
51	13	6D-4636	Clip
52	4	6V-8398	O-Ring Seal
53	1	368-8603	Hose As
54	1	118-6878	Bracket As
55	1	223-3490	Clip
56	1	125-8534	Plate As
57	1	359-5006	Hose As
58	1	200-6345	Mount
59	1	433-2732	Hose As
60	1	8T-6466	Bolt
61	1	179-0469	Spacer
62	1	067-3045	Clip
63	1	6V-2235	Clip

Installation Procedure

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Illustration 25	g03644497
A close up view of the auto lube distribution block (48)

1. Assemble two elbows (45), two connectors (46), and plug (47) to block (48) .

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Illustration 26	g03644500
View of the right side frame main beam

2. Install block (48) to the inside of the right frame rail with two bolts (49) and two hard washers (3) .

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Illustration 27	g03644514
View of the right side frame main beam

3. Install hose assembly (50) with three clips (51), three bolts (8), and three hard washers (3). Connect hose assembly (50) to connector (46) with O-Ring seal (52) .

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Illustration 28	g03644846
Close up view of the right side frame main beam near the center tube and hoist tube.

4. Install hose assembly (53) to elbow (45) with O-Ring seal (52). Secure in place with clip (51) using existing hardware.

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Illustration 29	g03644861
View of the outside of the right side main beam

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Illustration 30	g03644902
Close up view of the outside of the right side main beam

5. Install bracket assembly (54) to the boss on the frame with one bolt (8) and one hard washer (3). Secure hose assembly (53) to bracket assembly (54) with clip (55) using one bolt (8) and one hard washer (3) .

6. Install plate assembly (56) to the boss on the frame with one bolt (8) and one hard washer (3). Secure hose assembly (53) to plate assembly (56) with clip (51) using one bolt (34) and one hard washer (3) .

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Illustration 31	g03644950
View of the center tube

7. Install hose assembly (57) to connector (46) with O-Ring seal (52).

8. Secure hose assembly (57) to 424-6335 Hose As with one mount (58) and two cable straps (44). Secure hose assembly (57) to the center tube assembly with two clips (51) and existing mounting hardware.

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Illustration 32	g03645186
View of the center tube

9. Secure hose assembly (57) to the center tube assembly with clip (51) and existing mounting hardware.

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Illustration 33	g03645557
A close up view of the right side main beam near the center tube

10. Install hose assembly (59) to elbow (45) with O-Ring seal (52). Secure in place with one clip (51), one bolt (60), one hard washer (3), and one spacer (61) .

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Illustration 34	g03645690
A view of the right rear pedestal

11. Secure hose assembly (59) with clip (51) and existing mounting hardware to the 309-1341 Hoist Lines Gp . Secure hose assembly (59), to the 324-0765 Hose As with one clip (51), one clip (62), one bolt (34), two hard washers (3), and one nut (4) .

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Illustration 35	g03645723
A view of the right hand fore-aft beam

12. Secure hose assembly (59) to the 335-6444 Tube As on the 309-1347 Steering Lines Gp with one clip (51), one clip (63), one bolt (6), two hard washers (3), and one nut (4) .

13. Secure hose assembly (59) to tube assembly (13) with one clip (51) and existing mounting hardware from Step 5 in the ""Installation of the Fast Fill Lines Group" " section.

14. Secure hose assembly (59) to hose assembly (9) with one clip (51) and existing mounting hardware from Step 3 in the ""Installation of the Fast Fill Lines Group" " section.

15. Connect hose assembly (59) to lubrication pump group (5) .

Install the Right Side Lubrication Distribution Valve Group

Required Parts

Table 7

Required Parts
Item	Qty	Part Number	Description
2	2	8T-6466	Bolt
3	6	8T-4121	Hard Washer
4	2	344-5675	Nut
8	4	8T-4137	Bolt
34	2	8T-4136	Bolt
35	2	7X-7729	Washer
45	1	2T-2396	Elbow
52	1	6V-8398	O-Ring Seal
64	1	269-5348	Lubrication Distribution Valve Gp
65	1	269-5352	Lubrication Distribution Valve Gp
66	1	004-6683	Fitting
67	1	3J-5390	Plug
68	7	3B-6552	Pipe Elbow
69	1	307-9209	Plate
70	2	365-3303	Hard Washer
71	1	418-6439	Hose As
72	1	436-5775	Hose As
73	1	418-6433	Hose As
74	1	436-5767	Hose As
75	1	436-5777	Hose As
76	1	418-6442	Hose As
77	1	436-5778	Hose As
78	3	4D-7735	Clip
79	5	9M-8406	Clip
80	1	5P-9085	Clip
81	1	6K-6967	Pipe Adapter
82	3	7D-2746	Elbow
83	6	420-0939	Spacer
84	1	420-0940	Spacer

Installation Procedure

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Illustration 36	g03646308
A view of the right side lubrication distribution valve group

1. Assemble the right side lubrication distribution valve group by connecting lubrication distribution valve group (64) to lubrication distribution valve group (65) with one fitting (66). Install plug (67) to lubrication distribution valve group (64) .

2. Install seven pipe elbows (68) to the lubrication distribution valve group as shown in Illustration 36.

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Illustration 37	g03646418
A view of the right side lubrication distribution valve group and mounting hardware

3. Secure the lubrication distribution valve group to plate (69) with two bolts (2), two hard washers (70), two hard washers (3), and two nuts (4) .

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Illustration 38	g03646451
A view of the right side main beam

4. Install the lubrication distribution valve group with plate to the right had frame with two bolts (34) and two washers (35) .

5. Connect hose assembly (53) to the lubrication distribution valve group with one elbow (45) and one O-Ring seal (52) .

6. Install hose assembly (71), hose assembly (72), hose assembly (73), hose assembly (74), hose assembly (75), hose assembly (76), and hose assembly (77) to the lubrication distribution valve group.

7. Secure hose assembly (71), hose assembly (72), hose assembly (73), and hose assembly (74) in place with two clips (78). Secure hose assembly (75), hose assembly (76), and hose assembly (77) with two clips (79). Install each set of clips, with one bolt (8) and one hard washer (3) .

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Illustration 39	g03652372
A view of the right side main beam and strut mount

8. Secure hose assembly (71), hose assembly (72), hose assembly (73), and hose assembly (74) in place with clip (78). Route hose assembly (72), hose assembly (73), and hose assembly (74) up towards the suspension mount and secure with clip (79) and existing mounting hardware.

9. Secure hose assembly (75), hose assembly (76), and hose assembly (77) with clip (79) .

10. Secure clip (78) and clip (79) with one bolt (8) and one hard washer (3) .

11. Secure hose assembly (71) with clip (80), one bolt (8), and one hard washer (3) .

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Illustration 40	g03652967
A view of the top of the right side suspension

12. Route hose assembly (71) to the top of the suspension and connect to the grease port with pipe adapter (81) .

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Illustration 41	g03653063
A view of the right side lower suspension and steering mounts

13. Route hose assembly (72) to the lower grease port on the suspension and connect with elbow (82) .

14. Route hose assembly (73) and hose assembly (74) to the two steering mount grease ports and install with one elbow (82) each.

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Illustration 42	g03653088
A view of the right side main beam and support

15. Route hose assembly (75), hose assembly (76), and hose assembly (77) down under the frame towards the center of the truck along the steering box. Secure the hose assemblies in place with clip (79) and existing mounting hardware.

16. Adjust the lubrication distribution valve group using the following steps:
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    Illustration 43	g03653258
    Cross section of lubrication distribution valve (A) Adjustment screw (B) Locknut

    1. Remove the adjustment screw and locknut, then discard the locknut.
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    Illustration 44	g03653203
    View indicating the proper spacer placement

    2. Install a spacer (83) into six of the vales and a spacer (84) into the seventh valve.

    3. Reassemble the adjustment screw with the correct spacer into the lubrication injector.

    4. Turn the adjustment screw counterclockwise to the specified torque.

    5. Re-assemble the cap that covers the adjustment screw.

       Note: Only hand tighten the cap.

    6. Repeat for all seven lubrication injectors.

Install the Left Side Lubrication Distribution Valve Group

Required Parts

Table 8

Required Parts
Item	Qty	Part Number	Description
2	2	8T-6466	Bolt
3	8	8T-4121	Hard Washer
4	2	344-5675	Nut
8	4	8T-4137	Bolt
34	4	8T-4136	Bolt
35	2	7X-7729	Washer
46	1	8C-6871	Connector
52	1	6V-8398	O-Ring Seal
64	1	269-5348	Lubrication Distribution Valve Gp
65	1	269-5352	Lubrication Distribution Valve Gp
66	1	004-6683	Fitting
67	1	3J-5390	Plug
68	7	3B-6552	Pipe Elbow
69	1	307-9209	Plate
70	2	365-3303	Hard Washer
74	1	436-5767	Hose As
78	2	4D-7735	Clip
79	5	9M-8406	Clip
80	2	5P-9085	Clip
82	4	7D-2746	Elbow
83	6	420-0939	Spacer
84	1	420-0940	Spacer
85	1	418-6431	Hose As
86	1	436-5769	Hose As
87	1	418-6441	Hose As
88	1	418-6443	Hose As
89	1	418-6435	Hose As
90	1	418-6432	Hose As
91	1	359-4871	Tube As
92	1	228-7090	O-Ring Seal
93	1	5P-9299	Clip

Installation Procedure

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Illustration 45	g03653630
View of the left side lubrication distribution valve group

1. Assemble the left side lubrication distribution valve group by connecting lubrication distribution valve group (64) to lubrication distribution valve group (65) with one fitting (66). Install plug (67) to lubrication distribution valve group (65) .

2. Install seven pipe elbows (68) to the lubrication distribution valve group as shown in Illustration 45.

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Illustration 46	g03653697
A view of the left side lubrication distribution valve group and mounting hardware

3. Secure the lubrication distribution valve group to plate (69) with two bolts (2), two hard washers (70), two hard washers (3), and two nuts (4) .

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Illustration 47	g03653757
A view of the left side main beam

4. Install the lubrication distribution valve group with plate to the left had frame with two bolts (34) and two washers (35) .

5. Install hose assembly (74), hose assembly (85), hose assembly (86), and hose assembly (87) to the lubrication distribution valve group. Secure the four hose assemblies with two clips (78) .

6. Install hose assembly (88), hose assembly (89), and hose assembly (90) to the lubrication distribution valve group. Secure the three hose assemblies with two clips (79) .

7. Secure all seven hose assemblies with two clips (78) and two clips (79) with a bolt (8) and a hard washer (3) at the two mounting points.

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Illustration 48	g03653863
A view of the left side upper suspension mount

8. Route hose assembly (74) to the top front side of the suspension. Secure hose assembly (74) with two clips (80). Secure the two clips (80) with a bolt (8) and a hard washer (3) for each clip.

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Illustration 49	g03654173
A close up view of the left side upper suspension grease port

9. Connect hose assembly (74) to the top front side of the suspension grease port with elbow (82) .

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Illustration 50	g03654212
A view of the left side lower suspension mount

10. Route hose assembly (85), hose assembly (86), and hose assembly (87) and secure in place with clip (79) and existing mounting hardware.

11. Connect hose assembly (85) to the lower suspension grease port with elbow (82) .

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Illustration 51	g03654221
A view of the left side steering mounts

12. Connect hose assembly (86) and hose assembly (87) to the two steering arm grease ports with an elbow (82) each.

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Illustration 52	g03654238
A view of the left side main beam and support

13. Route hose assembly (88), hose assembly (89), and hose assembly (90) down under the frame towards the center of the truck along the steering box. Secure the hose assemblies in place with two clips (79), two bolts (34), and two hard washers (3) .

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Illustration 53	g03654314
A bottom view of the left side main beam

14. Install tube assembly (91) to hose assembly (56) with O-Ring seal (92) .

15. Secure tube assembly (91) with clip (93) and existing mounting hardware.

16. Install tube assembly (91) to the lubrication distribution valve group with connector (46) and O-Ring seal (52) .

17. Adjust the lubrication distribution valve group using the following steps:
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    Illustration 54	g03653258
    A cross section of a lubrication distribution valve (A) Adjustment screw (B) Locknut

    1. Remove the adjustment screw and locknut, then discard the locknut.
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    Illustration 55	g03654320
    A view indicating proper spacer placement

    2. Install a spacer (83) into six of the vales and a spacer (84) into the seventh valve.

    3. Reassemble the adjustment screw with the correct spacer into the lubrication injector.

    4. Turn the adjustment screw counterclockwise to the specified torque.

    5. Re-assemble the cap that covers the adjustment screw.

       Note: Only hand tighten the cap.

    6. Repeat for all seven lubrication injectors.

Install the Front Lower Lubrication lines

Required Parts

Table 9

Required Parts
Item	Qty	Part Number	Description
3	1	8T-4121	Hard Washer
8	1	8T-4137	Bolt
79	2	9M-8406	Clip
80	2	5P-9085	Clip
82	6	7D-2746	Elbow
94	1	3S-2093	Cable Strap

Installation Procedure

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Illustration 56	g03654323
A view of the left side support and steering box

1. Route the left side hose assembly (90) to the interior steering grease port. Secure hose assembly (90) with clip (79) and existing mounting hardware. Connect hose assembly (90) to the grease port with elbow (82) .

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Illustration 57	g03654326
A view of the right side support and steering box

2. Route the right side hose assembly (77) to the interior steering grease port. Secure hose assembly (77) with clip (79) and existing mounting hardware. Connect hose assembly (77) to the grease port with elbow (82) .

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Illustration 58	g03654344
A top down view of the steering box and steering arm

3. Route hose assembly (89) and hose assembly (76) to the two center steering cylinder grease ports. Connect the two hose assemblies with two elbows (82) .

4. Route hose assembly (88) and hose assembly (75) to the two interior steering rod end grease ports. Secure the two hose assemblies with two clips (80), one bolt (8), and one hard washer (3). Secure the two hose assemblies together with cable strap (94) .

5. Connect hose assembly (88) and hose assembly (75) to the two interior steering rod end grease ports with two elbows (82) .

Install the Rear Lubrication Valve Group

Required Parts

Table 10

Required Parts
Item	Qty	Part Number	Description
2	6	8T-6466	Bolt
3	28	8T-4121	Hard Washer
4	9	344-5675	Nut
8	4	8T-4137	Bolt
34	1	8T-4136	Bolt
35	2	7X-7729	Washer
40	1	130-5300	Clip
44	8	7K-1181	Cable Strap
49	3	8T-4185	Bolt
64	1	269-5348	Lubrication Distribution Valve Gp
66	2	004-6683	Fitting
68	16	3B-6552	Pipe Elbow
70	6	365-3303	Hard Washer
79	4	9M-8406	Clip
80	12	5P-9085	Clip
81	4	6K-6967	Pipe Adapter
82	2	7D-2746	Elbow
83	4	420-0939	Spacer
84	4	420-0940	Spacer
95	2	269-5353	Lubrication Distribution Valve Gp
96	1	9M-5501	Street Elbow
97	1	8C-4985	Adapter
98	1	221-3404	Pressure Sensor Gp
99	1	3J-1907	O-Ring Seal
100	1	346-1684	Plate As
101	2	352-3964	Clip
102	1	352-3968	Clip
103	2	8T-4186	Bolt
104	2	198-4777	Hard Washer
105	5	420-0942	Spacer
106	1	419-4118	Sensor Harness As
107	2	237-9960	Clip
108	3	204-8000	Cable Tie Mounting
109	3	272-1777	Hard Washer
110	2	436-5766	Hose As
111	1	436-5765	Hose As
112	1	418-6446	Hose As
113	2	204-2281	Cable Strap
114	12	8T-4191	Bolt
115	2	4B-9233	Clip
116	2	8L-5008	Pipe Elbow
117	1	437-5046	Hose As
118	1	436-5760	Hose As
119	1	418-6447	Hose As

Installation Procedure

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Illustration 59	g03654748
A view of the rear lubrication distribution valve group

1. Connect lubrication distribution valve group (64) to two lubrication distribution valve groups (95) with two fittings (66) .

2. Install 13 pipe elbows (68) to the lubrication distribution valve groups.

3. Install street elbow (96) to lubrication distribution valve group (95), and install adapter (97) to street elbow (96) .

4. Install pressure sensor group (98) to adapter (97) with one O-Ring seal (99) .

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Illustration 60	g03654866
A view of the rear lubrication distribution valve group and mounting hardware

5. Assemble the lubrication distribution valve group to plate assembly (100) with six bolts (2), six hard washers (70), six hard washers (3), six nuts (4), two clips (101), and one clip (102) .

6. Secure the cable for pressure sensor group (98) to clip (101) with a cable strap (44). Secure any excess cable length with an additional cable strap (44) .

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Illustration 61	g03654900
A view of the rear lubrication distribution valve group on the rear support assembly

7. Install the lubrication distribution valve group and plate assembly (100) to the rear of the machine with two bolts (103) and two hard washers (104) .

8. Adjust the lubrication distribution valve group using the following steps:
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   Illustration 62	g03653258
   A cross section of a lubrication distribution valve (A) Adjustment screw (B) Locknut

   1. Remove the adjustment screw and locknut, then discard the locknut.
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   Illustration 63	g03654916
   A view indicating the proper placement of spacers in the lubrication distribution valve group

   2. Install four spacers (83), four spacers (84), and five spacers (105) into the 13 vales.

   3. Reassemble the adjustment screw with the correct spacer into the lubrication injector.

   4. Turn the adjustment screw counterclockwise to the specified torque.

   5. Re-assemble the cap that covers the adjustment screw.

      Note: Only hand tighten the cap.

   6. Repeat for all 13 lubrication injectors.

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Illustration 64	g03654984
A view of the rear support assembly near the right side tail

9. Install sensor harness assembly (106) to the 421-1023 Sensor Harness As on the rear of the truck with clip (40) and existing mounting hardware. Secure sensor harness assembly (106) with cable strap (44) .

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Illustration 65	g03655247
A view of the right tail light on the rear support assembly

10. Secure sensor harness assembly (106) in place with two clips (107) and three cable straps (44). Install one clip with existing mounting hardware, and the second clip with one bolt (34), two hard washers (35), and one nut (4) .

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Illustration 66	g03655253
A view of the backside of the rear lubrication distribution valve group

11. Secure sensor harness assembly (106) in place with two cable straps (44), and connect sensor harness assembly (106) to pressure sensor group (98) .

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Illustration 67	g03655283
A view of the left side tail light bracket

12. Install two bolts (49) with two hard washers (3), two cable tie mountings (108), two hard washers (109), two hard washers (3), and two nuts (4) .

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Illustration 68	g03655399
A view of the left side of the rear lubrication distribution valve group

13. Install hose assembly (110), hose assembly (111), and hose assembly (112) to the lubrication distribution valve group. Secure the hose assemblies to cable tie mounting (108) with cable strap (113) .

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Illustration 69	g03655497
A view of the rear left-hand suspension group mount

14. Secure hose assembly (110), hose assembly (111), and hose assembly (112) with two clips (79) and two bolts (8), and two hard washers (3) .

15. Connect hose assembly (110) to the grease port on the upper portion of the rear suspension with elbow (82) and adapter (81) .

16. Connect hose assembly (111) to the grease port on the body pivot pin with pipe elbow (68) and pipe adapter (81) .

17. Route hose assembly (112) around to the outside rail of the body with clip (80), bolt (114), and hard washer (3) .

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Illustration 70	g03655573
A view of the left side body frame

18. Secure hose assembly (112) along the frame of the body with one clip (115), and five clips (80) with five bolts (114) and five hard washers (3) .

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Illustration 71	g03655631
A view of the top of the left side hoist

19. Connect hose assembly (112) to the upper hoist cylinder grease port with pipe elbow (116) .

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Illustration 72	g03655900
A view of the right tail light bracket

20. Install bolt (49) with one hard washer (3), a cable tie mounting (108), a hard washer (109), a hard washer (3), and nut (4) .

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Illustration 73	g03655946
A view of the right side of the rear support

21. Install hose assembly (117), hose assembly (118), hose assembly (119), and hose assembly (110) to the lubrication distribution valve group. Secure the hose assemblies to cable tie mounting (108) with cable strap (113) .

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Illustration 74	g03656053
A view of the right lateral control rod mount

22. Route hose assembly (117) around to the lateral control rod grease port and connect with one pipe elbow (68).

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Illustration 75	g03656104
A view of the right side body pivot point

23. Secure hose assembly (118), hose assembly (119), and hose assembly (110) in place with two clips (79), two bolts (8), and two hard washers (3) .

24. Connect hose assembly (110) to the upper suspension grease port with elbow (82) and pipe adapter (81) .

25. Connect hose assembly (119) to the grease port on the body pivot pin with elbow (68) and pipe adapter (81) .

26. Route hose assembly (118) around to the outside rail of the body with clip (80), bolt (114), and hard washer (3) .

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Illustration 76	g03656212
A view of the right side body frame

27. Secure hose assembly (118) along the frame of the body with one clip (115), and five clips (80) with five bolts (114) and five hard washers (3) .

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Illustration 77	g03656235
A view of the top of the right side hoist

28. Connect hose assembly (118) to the upper hoist cylinder grease port with pipe elbow (116) .

Install the Lower Rear Lubrication Distribution Lines

Required Parts

Table 11

Required Parts
Item	Qty	Part Number	Description
3	13	8T-4121	Hard Washer
4	1	344-5675	Nut
8	11	8T-4137	Bolt
34	1	8T-4136	Bolt
45	1	2T-2396	Elbow
52	1	6V-8398	O-Ring Seal
68	3	3B-6552	Pipe Elbow
79	7	9M-8406	Clip
81	1	6K-6967	Pipe Adapter
94	1	3S-2093	Cable Strap
113	1	204-2281	Cable Strap
120	2	436-5764	Hose As
121	2	5M-3062	Bolt
122	2	8T-4896	Hard Washer
123	2	4M-8973	Elbow
124	1	437-1151	Hose As
125	1	436-5759	Hose As
126	1	436-5758	Hose As
127	1	436-5761	Hose As
128	1	7E-9992	Bracket
129	2	9X-8582	Clip

Installation Procedure

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Illustration 78	g03656262
A view of the right rear suspension

1. Install hose assembly (120) to the lubrication distribution valve group, and route down to the right lower suspension grease port. Secure hose assembly (120) with one clip (80), one bolt (121), and one hard washer (122) .

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Illustration 79	g03656540
A view of the right lower suspension mount

2. Connect hose assembly (120) to the lower suspension grease port with elbow (123) .

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Illustration 80	g03656586
A view of the left side rear suspension

3. Install hose assembly (120) to the lubrication distribution valve group, and route down to the left lower suspension grease port. Secure hose assembly (120) with clip (80) and existing hardware. Secure hose assembly (120) with one clip (80), one bolt (121), and one hard washer (122)

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Illustration 81	g03656611
A view of the left lower suspension mount

4. Connect hose assembly (120) to the lower suspension grease port with elbow (123) .

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Illustration 82	g03656656
A view of the rear lubrication distribution valve group

5. Install hose assembly (124), hose assembly (125), hose assembly (126), and hose assembly (127) to the lubrication distribution valve group. Secure the hose assemblies to cable tie mounting (108) with cable strap (113) .

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Illustration 83	g03656668
A view of the left underside of the rear support

6. Install bracket (128) to the rear support assembly with bolt (8) and hard washer (3) .

   Note: Do not tighten hardware until clip (79) is added to bracket (128) .

7. Secure hose assembly (124), hose assembly (125), hose assembly (126), and hose assembly (127) to bracket (128) with clip (79), bolt (34), two hard washers (3) and nut (4) .

8. Secure hose assembly (125), hose assembly (126), and hose assembly (127) to bracket (128) with clip (79) and the mounting hardware from Step 6.

9. Connect hose assembly (124) to the grease port on the lateral control rod with pipe adapter (81) .

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Illustration 84	g03656749
A view of the underside of the rear support, left tail section and left main rail

10. Route hose assembly (125), hose assembly (126), and hose assembly (127) around to the inside of the left frame. Secure the hose assemblies with two clips (79), two bolts (8), and two hard washers (3) .

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Illustration 85	g03656756
A view of the inside of the left main rail

11. Secure hose assembly (125), hose assembly (126), and hose assembly (127) to the left side frame with two clips (79), two bolts (8), and two hard washers (3). Secure hose assemblies together with cable strap (94) .

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Illustration 86	g03656809
A view of the left drop tube

12. Secure hose assembly (125), hose assembly (126), and hose assembly (127) to the left drop tube with clip (79), bolt (8), and hard washer (3) .

13. Route hose assembly (127) over to the lower hoist grease port. Secure hose assembly (127) in place with clip (80), bolt (8), and hard washer (3). Install hose assembly (127) to the grease port with pipe elbow (68) .

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Illustration 87	g03657062
A view of the hoist tube

14. Route hose assembly (125) and hose assembly (126) across the drop tube. Secure hose assembly (125) and hose assembly (126) with two clips (129) two bolts (8), and two hard washers (3) .

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Illustration 88	g03657096
A view of the center tube pivot

15. Route hose assembly (126) up to the center tube pivot grease port and install with pipe elbow (68).

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Illustration 89	g03657267
A view of the right side drop tube and lower hoist mount

16. Route hose assembly (125) to the right side lower hoist grease port. Secure hose assembly (125) in place with two clips (80), two bolts (8), and two hard washers (3) .

17. Connect hose assembly (126) to the right side lower hoist grease port with pipe elbow (68) .

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Illustration 90	g03659009
A view of the right side of the rear lubrication distribution valve group

18. Connect hose assembly (50) from Step 3 from the ""Install the Lubrication Block and Lines Group" " Section to the right side of the rear lubrication distribution valve group using one elbow (45) and one O-Ring seal (52) .

Install the Wiring Group

Required Parts

Table 12

Required Parts
Item	Qty	Part Number	Description
44	38	7K-1181	Cable Strap
130	1	435-5391	Lighting Harness As
131	2	3V-4791	Grommet
132	1	4P-7581	Clip

Installation Procedure

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Illustration 91	g03657313
A view of the auto lube indicator light from below

1. Install lighting harness assembly (130) to the auto lube indicator light. Secure lighting harness assembly (130) in place with two cable straps (44) .

2. Route lighting harness assembly (130) up under the stairway with two grommets (131) .

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Illustration 92	g03657518
A view of the left access stairway

3. Route lighting harness assembly (130) up the underside of the stairway with six cable straps (44) .

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Illustration 93	g03657539
A view of the left access stairway and underside of the left platform

4. Route lighting harness assembly (130) across and through an opening in the 342-6551 Guard . Secure lighting harness assembly (130) in place with two additional cable straps (44) .

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Illustration 94	g03657564
A view at the top of the left front pedestal

5. Route lighting harness assembly (130) up next to the air to air aftercooler and secure in place with five cable straps (44) .

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Illustration 95	g03657661
A top down view of the top of the left pedestal and front cross tube

6. Route lighting harness assembly (130) between the air to air aftercooler and the cab. Secure in place with four cable straps (44) .

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Illustration 96	g03657683
A view of the front cross tube

7. Route lighting harness assembly (130) along the front cross tube with seven cable straps (44) .

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Illustration 97	g03657794
A view of the right fore-aft beam

8. Route lighting harness assembly (130) along the right fore aft beam and secure in place with ten cable straps (44) .

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Illustration 98	g03709216
A view of the hydraulic tank on the right platform

9. Connect lighting harness assembly (130) to switch harness assembly (43). Install clip (132) in place with existing mounting hardware. Secure lighting harness assembly (130) in place with two cable straps (44) .

Install Film Group

Required Parts

Table 13

Required Parts
Item	Qty	Part Number	Description
133	1	231-3923	Film
134	1	231-3922	Film
135	1	289-2067	Film

Installation Procedure

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Illustration 99	g03657891
A view of the left side lubrication distribution valve group

1. Install film (133) next to the left side lubrication distribution valve group.

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Illustration 100	g03658138
A view of the right side lubrication distribution valve group

2. Install film (134) next to the right side lubrication distribution valve group.

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Illustration 101	g03658140
A view of the rear lubrication distribution valve group

3. Install film (135) to plate assembly (100) above the rear lubrication distribution valve group.

Register the Retrofit

1. When performing a retrofit installation, record the vital information in Table 14.

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

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   Table 14

   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 14 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".