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Procedure to Improve the Air Dryer System on Certain 785C Off-Highway Trucks {0679, 1408, 4257, 4264, 4265, 4269, 4280, 4285, 7050} Caterpillar


Procedure to Improve the Air Dryer System on Certain 785C Off-Highway Trucks {0679, 1408, 4257, 4264, 4265, 4269, 4280, 4285, 7050}

Usage:

785C 5AZ
Off-Highway Truck/Tractor
785C (S/N: APX1-UP; 5AZ1-UP)

Introduction

This Special Instruction has the procedure to install the improved air dryer. Read and understand the entire procedure before ordering parts or beginning the procedure.

Safety Section

Safety Section

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

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------ WARNING! ------

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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------ WARNING! ------

Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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------ WARNING! ------

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine can cause injury to persons on or near the machine.

To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools.

Work safely. 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 to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Prepare the Machine

Note: Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

  1. Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.

  2. Move the transmission control to the P position.

  3. Stop the engine.

  4. Place wheel chocks in front of the wheels and behind the wheels.

  5. When unable to use wheel chocks, ensure that the machine is unable to roll by turning the wheels into a suitable bank or placing with the wheels in a suitable ditch.

Required Parts

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Table 1
Qty.  Part Number  Part Name 
5  4E-1494  Boss 
1  8D-3508  Boss 
1  466-2859  Air Dryer Gp 
11  5S-7379  Bolt 
6  5P-1075  Hard Washer 
1  469-8170  Hose As 
2  2T-1922  Elbow 
2  228-7090  O-Ring Seal 
1  8T-6757  Pipe Plug 
1  466-8468  Hose As 
4  1S-1015  Clip 
1  4L-6454  Bolt 
20  8T-4896  Hard Washer 
3  5M-3062  Bolt 
6  6D-4244  Clip 
2  1S-0996  Clip 
3  9V-3418  Angle As 
4  4P-7581  Clip 
4  130-5300  Clip 
4  7K-1181  Cable Strap 
1  7T-0266  Bracket As 
2  8T-5409  Taperlock Stud 
6  6V-8801  Nut 
7  204-8000  Cable Tie Mounting 
2  1A-2029  Bolt 
1  091-9035  Spacer 
1  8T-1889  Clip 
1  8T-1890  Clip 
1  353-7953  Grommet 
1  4W-3161  Plate 
1  2A-4639  Bolt 
2  144-6302  Bracket 
2  3B-1915  Bolt 
1  0S-1594  Bolt 
1  7N-1277  Bracket As 
1  484-0370  Wiring Harness 
16  204-2281  Cable Strap 
3  166-4341  Wiring Harness 
1  8X-7415  Plate 
1  384-8821  Plate As 
2  8T-4223  Hard Washer 
2  8T-4192  Bolt 
1  267-5286  Air Lines Filter Gp 
2  8T-4224  Hard Washer 
2  8T-4908  Bolt 
1  2H-3940  Elbow 
1  2S-5100  Manual Valve 
1  2H-9091  Pipe Connector 
1  9D-5568  Boss 
6  1S-0994  Clip 
3  8S-0948  Clip 
1  133-6934  Spacer 
1  5S-7383  Bolt 
8462 mm (333.14894 inch)  5P-0722  Hose 
4  167-1237  Permanent Coupling 

Air Dryer Hydraulics Rework

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Table 2
Item  Qty.  Part Number  Part Name 
1  5  4E-1494  Boss 
2  1  8D-3508  Boss 
3  1  466-2859  Air Dryer Gp 
4  5  5S-7379  Bolt 
5  6  5P-1075  Hard Washer 
6  1  469-8170  Hose As 
7  2  2T-1922  Elbow 
8  2  228-7090  O-Ring Seal 
9  1  8T-6757  Pipe Plug 
10  1  466-8468  Hose As 
11  4  1S-1015  Clip 
12  1  4L-6454  Bolt 
13  1  8T-4896  Hard Washer 
14  1  5M-3062  Bolt 
15  6  6D-4244  Clip 
16  2  1S-0996  Clip 
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Illustration 1g06099488

Removal Procedure

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Illustration 2g06099560
Front view of compressor location
(A) Elbow
(B) Hose
(C) Clips
(D) Hose
(E) Elbow As

  1. Remove hose (B) and hose (D) from compressor.

    Note: Hose (B) and hose (D) will be discarded when fully removed.

  2. Remove and discard elbow (A), elbow assembly (E), and clips (C).
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    Illustration 3g06100054
    Side view of dryer group
    (B) Hose
    (F) Clips and Hardware
    (G) Air Dryer

  3. Remove and discard clips and hardware (F).

  4. Remove hose (B) from air dryer (G). Discard hose (B).
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    Illustration 4g06100151
    View of air dryer group
    (D) Hose
    (G) Air Dryer
    (H) Harness

  5. Remove hose (D) from air dryer (G). Discard hose (D).

  6. Remove harness (H) from air dryer (G). Tie back harness (H) to be reworked later in the procedure.
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    Illustration 5g06100169
    Side and bottom view of air dryer
    (G) Air Dryer
    (J) Hose
    (K) Hose

  7. Remove hose (J) and hose (K) from air dryer (G).

    Note: Hose (J) and hose (K) will be discarded when fully removed.

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    Illustration 6g06100180
    View of the bottom of hose K
    (K) Hose
    (M) Clip and Hardware
    (N) Coupler Assembly and Bracket

  8. Remove and discard clip and hardware (M).

  9. Remove and discard hose (K).

  10. Remove and discard coupler assembly and bracket (N). Discard associated hardware.
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    Illustration 7g06101545
    Side view of hose routing
    (J) Hose
    (P) Clip and Hardware
    (R) Clips
    (S) Clips

  11. Remove and discard clip and hardware (P)

  12. Remove and discard clips (R) and clips (S). Retain all hardware for installation procedure.
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    Illustration 8g06101644
    Top side view of hose routing
    (J) Hose
    (T) Clips
    (U) Clips
    (V) Elbow Assembly

  13. Remove and discard clips (T) and clips (U). Retain all hardware for installation procedure.

  14. Remove and discard hose (J). Retain elbow assembly (V) for installation procedure.
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    Illustration 9g06101862
    Side view of air dryer
    (G) Air Dryer
    (W) Hardware
    (Y) Plate

  15. Remove and discard air dryer (G) and hardware (W).
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    Illustration 10g06101871
    Side view of air dryer mounting plate
    (Y) Plate
    (Z) Hardware

  16. Remove and discard plate (Y) and hardware (Z).
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    Illustration 11g06128335
    Side view of frame preparation location
    (AA) Eye
    (AB) Boss

  17. Remove and discard eye (AA) and boss (AB).

Installation Procedure

Welding Procedure

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    Illustration 12g06105044
    Side view of boss (1) weld locations
    (AC) 80 mm (3.15 inch)
    (AD) 388.5 mm (15.3 inch)
    (AE) 625 mm (24.6 inch)
    (BB) 321.9 mm (12.67 inch)
    (BC) 142.4 mm (5.6 inch)
    (BD) 348.57 mm (13.72 inch)
    (BE) 249.6 mm (9.83 inch)
    (BF) 420 mm (16.54inch)
    (1) 4E-1494 Boss
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    Illustration 13g06105126
    Side view of boss (1) weld locations
    (1) 4E-1494 Boss

  1. Secure five bosses (1) with 5 mm (0.19 inch) fillet weld per illustrations 12 and 13.
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    Illustration 14g06105176
    View of boss (2) weld location
    (CC) 76.81 mm (3.02 inch)
    (DD) 174.05 mm (6.85 inch)
    (2) 8D-3508 Boss

  2. Secure boss (2) with 3 mm (0.12 inch) fillet weld per illustration 14.

Air Dryer Installation

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    Illustration 15g06105376
    Side view of air dryer
    (3) 466-2859 Air Dryer Gp
    (4) 5S-7379 Bolt
    (5) 5P-1075 Hard Washer

  1. Position air dryer group (3) per illustration 15. Secure with five bolts (4) and five hard washers (5).
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    Illustration 16g06105450
    Top front view of hose installation
    (3) 466-2859 Air Dryer Gp
    (6) 469-8170 Hose As
    (7) 2T-1922 Elbow
    (8) 228-7090 O-Ring Seal
    (9) 8T-6757 Pipe Plug

  2. Install elbow (7) and seal (8) to compressor.

  3. Install hose (6) to air dryer group (3) and elbow (7) per illustration 16.

  4. Install plug (9) into open port from removal procedure.
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    Illustration 17g06108897
    Top front view of hose installation
    (2) 8D-3508 Boss
    (3) 466-2859 Air Dryer Gp
    (5) 5P-1075 Hard Washer
    (7) 2T-1922 Elbow
    (8) 228-7090 O-Ring Seal
    (10) 466-8468 Hose As
    (11) 1S-1015 Clip
    (12) 4L-6454 Bolt

  5. Install elbow (7) and seal (8) to air dryer (3).

  6. Route hose (10) and position clip (11) per illustration 17. Secure clip (11) to boss (2) with one bolt (12) and one washer (5).
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    Illustration 18g06109031
    Top side view of hose routing
    (10) 466-8468 Hose As
    (11) 1S-1015 Clip
    (13) 8T-4896 Hard Washer
    (14) 5M-3062 Bolt
    (15) 6D-4244 Clip

  7. Route hose (10), position three clips (11), and one clip (15) per illustration 18.

  8. Secure forward most clip (11) with one washer (13) and one bolt (14). Secure remaining clips (11) and (15) with hardware retained from removal procedure.
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    Illustration 19g06109499
    Top view of hose routing
    (10) 466-8468 Hose As
    (15) 6D-4244 Clip
    (16) 1S-0996 Clip

  9. Route hose (10), position two clips (15), and two clips (16) per illustration 19.

  10. Secure clips (15) and (16) with hardware retained from removal procedure.
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    Illustration 20g06109551
    Top view of hose routing
    (10) 466-8468 Hose As
    (15) 6D-4244 Clip

  11. Route hose (10) and position three clips (15) per illustration 20.

  12. Secure clips (15) with hardware retained from removal procedure.
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    Illustration 21g06109558
    View of hose installed on elbow assembly
    (V) Elbow Assembly
    (10) 466-8468 Hose As

  13. Install hose (10) onto retained elbow assembly (V) from removal procedure.

    Note: Ensure that the arrow on valve points into air tank.

Air Dryer Electronics Rework

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Table 3
Item  Qty.  Part Number  Part Name 
1  3  9V-3418  Angle As 
2  4  4P-7581  Clip 
3  4  130-5300  Clip 
4  16  8T-4896  Hard Washer 
5  6  5S-7379  Bolt 
6  4  7K-1181  Cable Strap 
7  1  7T-0266  Bracket As 
8  2  8T-5409  Taperlock Stud 
9  6  6V-8801  Nut 
10  7  204-8000  Cable Tie Mounting 
11  2  1A-2029  Bolt 
12  1  091-9035  Spacer 
13  1  8T-1889  Clip 
14  1  8T-1890  Clip 
15  1  353-7953  Grommet 
16  1  4W-3161  Plate 
17  1  2A-4639  Bolt 
18  2  144-6302  Bracket 
19  2  3B-1915  Bolt 
20  1  0S-1594  Bolt 
21  1  7N-1277  Bracket As 
22  1  484-0370  Wiring Harness 
23  16  204-2281  Cable Strap 
24  3  166-4341  Wiring Harness 
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    Illustration 22g06111099
    Overview of new harness routing
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    Illustration 23g06111147
    Side view of mounting hardware
    (1) 9V-3418 Angle As

  1. Position angle assembly (1) on inner left-hand frame per illustration 23 and secure with existing hardware.
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    Illustration 24g06111173
    Bottom view of clips
    (1) 9V-3418 Angle As
    (2) 4P-7581 Clip
    (3) 130-5300 Clip
    (4) 8T-4896 Hard Washer
    (5) 5S-7379 Bolt

  2. Position clip (2) and clip (3) per illustration 24 . Secure to angle assembly (1) with one bolt (5) and one washer (4).
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    Illustration 25g06111231
    Side view of harness to be reworked
    (H) Harness
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    Illustration 26g06111255
    View of harness rework
    (H) Harness
    (2) 4P-7581 Clip
    (3) 130-5300 Clip
    (6) 7K-1181 Cable Strap

  3. Re- route retained harness (H) from step 6 of "Removal Procedure". Attach the connector end of harness (H) to clip (3).

  4. Secure slack in harness (H) to clip (2) with one strap (6).
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    Illustration 27g06111324
    Side view of mounting location
    (A) Bolts
    (B) Washers

  5. Remove and discard bolts (A). Retain washers (B).
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    Illustration 28g06117213
    Side view of bracket
    (B) Washers
    (7) 7T-0266 Bracket As
    (8) 8T-5409 Taperlock Stud
    (9) 6V-8801 Nut

  6. Install two studs (8) in place of removed bolts (A).

  7. Position bracket assembly (7) onto lower stud (8) with weld-nut toward frame. Secure clips and bracket assembly (7) with two retained washers (B) and two nuts (9).
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    Illustration 29g06117242
    Side view of mount
    (4) 8T-4896 Hard Washer
    (7) 7T-0266 Bracket As
    (10) 204-8000 Cable Tie Mounting
    (11) 1A-2029 Bolt

  8. Position mount (10) on bracket (7). Secure with one bolt (11) and one washer (4).
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    Illustration 30g06117444
    View of harness mount
    (C) Existing Hardware
    (10) 204-8000 Cable Tie Mounting
    (12) 091-9035 Spacer

  9. Position spacer (12) and mount (10) onto existing bracket. Secure with existing hardware (C).
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    Illustration 31g06117502
    View of mounting bracket
    (4) 8T-4896 Hard Washer
    (9) 6V-8801 Nut
    (10) 204-8000 Cable Tie Mounting
    (13) 8T-1889 Clip
    (14) 8T-1890 Clip
    (15) 353-7953 Grommet
    (16) 4W-3161 Plate
    (17) 2A-4639 Bolt

  10. Position two piece clip (13) ( 14) and grommet (15) to air dryer tube.

  11. Position plate (16) and mount (10) to two piece clip (13) ( 14) per illustration 31. Secure with one bolt (17) two washers (4), and one nut (9).
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    Illustration 32g06117565
    View of clip mounting
    (2) 4P-7581 Clip
    (3) 130-5300 Clip
    (4) 8T-4896 Hard Washer
    (9) 6V-8801 Nut
    (11) 1A-2029 Bolt
    (16) 4W-3161 Plate

  12. Position clip (3) and clip (2) on to plate (16) per illustration 32. Secure with one bolt (11), two washers (4), and one nut (9).
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    Illustration 33g06117680
    Side view of air dryer
    (D) Bolt and Washer
    (18) 144-6302 Bracket
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    Illustration 34g06117694
    Top view of bracket position

  13. Install bracket (18) with existing hardware (D).

    Note: Position bracket (18) with end angled toward frame.

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    Illustration 35g06117738
    Side, rear, and top view of mount location
    (4) 8T-4896 Hard Washer
    (9) 6V-8801 Nut
    (10) 204-8000 Cable Tie Mounting
    (18) 144-6302 Bracket
    (19) 3B-1915 Bolt

  14. Position mount (10) onto bracket (18). Secure with one bolt (19), two washers (4), and one nut (9).

    Note: Orient mount (10) toward frame.

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    Illustration 36g06117758
    Side view of mounting hardware
    (E) Bolt and Washer
    (4) 8T-4896 Hard Washer
    (9) 6V-8801 Nut
    (10) 204-8000 Cable Tie Mounting
    (18) 144-6302 Bracket
    (19) 3B-1915 Bolt

  15. Position bracket (18) onto air dryer. Secure with existing bolt and washer (E).

  16. Position mount (10) onto bracket (18). Secure with one bolt (19), two washers (4), and one nut (9).

    Note: Mount (10) should face away from machine frame.

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    Illustration 37g06118073
    Side view of lower brackets
    (1) 9V-3418 Angle As
    (3) 130-5300 Clip
    (4) 8T-4896 Hard Washer
    (5) 5S-7379 Bolt

  17. Position two angle brackets (1) and one clip (3) onto air dryer. Ensure the forward most bracket (1) is slightly angled per illustration 37. Secure with two bolts (5) and two washers (4).
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    Illustration 38g06118101
    Side view of lower mounts
    (1) 9V-3418 Angle As
    (2) 4P-7581 Clip
    (4) 8T-4896 Hard Washer
    (5) 5S-7379 Bolt
    (10) 204-8000 Cable Tie Mounting
    (20) 0S-1594 Bolt

  18. Position one mount (10) onto forward angle bracket (1). Secure with one bolt (5) and one washer (4).

  19. Position one mount (10) and one clip (2) onto rear angle bracket (1). Secure with one bolt (20) and one washer (4).
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    Illustration 39g06118159
    (2) 4P-7581 Clip
    (3) 130-5300 Clip
    (4) 8T-4896 Hard Washer
    (5) 5S-7379 Bolt
    (21) 7N-1277 Bracket As

  20. Position bracket (21) onto air dryer. Secure with one bolt (5) and one washer (4).

  21. Position clip (2) and clip (3) onto bracket (21). Secure with one bolt (5) and one washer (4).
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    Illustration 40g06118200
    View of harness routing
    (3) 130-5300 Clip
    (22) 484-0370 Wiring Harness

  22. Secure the long end of harness (22) to previously installed clip (3).
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    Illustration 41g06118218
    View of harness routing
    (3) 130-5300 Clip
    (10) 204-8000 Cable Tie Mounting
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  23. Secure short end of harness (22) to previously installed clip (3). Route harness (22) along previously installed mounts (10) and secure with two straps (23).
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    Illustration 42g06118274
    Side view of harness routing
    (10) 204-8000 Cable Tie Mounting
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  24. Route harness (22) along previously installed mounts (10) and secure with two straps (23).
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    Illustration 43g06118287
    View of harness routing
    (3) 130-5300 Clip
    (22) 484-0370 Wiring Harness

  25. Secure end of harness (22) to previously installed clip (3).
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    Illustration 44g06118295
    Side view of harness routing
    (10) 204-8000 Cable Tie Mounting
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  26. Route harness (22) along previously installed mounts (10) and secure with two straps (23).
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    Illustration 45g06118641
    Side view of harness routing up left-hand pedestal
    (F) Harness
    (10) 204-8000 Cable Tie Mounting
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  27. Route harness (22) along previously installed mount (10) and up left-hand pedestal next to existing harness (F). Secure with two straps (23).
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    Illustration 46g06118657
    Side view of harness routing up left-hand pedestal
    (F) Harness
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  28. Route harness (22) up left-hand pedestal next to existing harness (F). Secure harness (22) to harness (F) with three straps (23).
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    Illustration 47g06118680
    Side view of harness connection
    (H) Harness
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  29. Connect the end of harness (22) to the reworked harness (H). Secure harness (22) to existing harnesses with two straps (23).
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    Illustration 48g06118703
    (F) Harness
    (22) 484-0370 Wiring Harness
    (23) 204-2281 Cable Strap

  30. Tie up slack in harness (22). Secure to existing harnesses with three straps (23).
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    Illustration 49g06118997
    Side view of air dryer
    (6) 7K-1181 Cable Strap
    (24) 166-4341 Wiring Harness

  31. Connect three harnesses (24) onto the air dryer in position shown. Secure with three straps (6).

Filter Group Rework

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Table 4
Item  Qty.  Part Number  Part Name 
1  1  8X-7415  Plate 
2  1  384-8821  Plate As 
3  2  8T-4223  Hard Washer 
4  2  8T-4192  Bolt 
5  1  267-5286  Air Lines Filter Gp 
6  2  8T-4224  Hard Washer 
7  2  8T-4908  Bolt 
8  1  2H-3940  Elbow 
9  1  2S-5100  Manual Valve 
10  1  2H-9091  Pipe Connector 
11  1  9D-5568  Boss 
12  6  1S-0994  Clip 
13  3  8T-4896  Hard Washer 
14  2  5M-3062  Bolt 
15  3  8S-0948  Clip 
16  1  133-6934  Spacer 
17  1  5S-7383  Bolt 
18  1  455-5888(1)  Hose As 
19  1  455-5885(1)  Hose As 
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(1) This part number must be made. Refer to hose information table for required parts to create this hose.

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Table 5
Hose Information 
Finished Part Number  Bulk Hose Length / Qty  Part Number  Part Name  Overall Hose Length 
455-5888  5330 mm  371-1254 Hose  Bulk Hose  5400 mm 
2 124-1900 Permanent Coupling  Permanent Coupling 
455-5885  3130 mm  371-1254 Hose  Bulk Hose  3200 mm 
2 124-1900 Permanent Coupling  Permanent Coupling 
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    Illustration 50g06119470
    Location of new filter group

  1. Use hose information table 5 to make 455-5888 Hose As and 455-5885 Hose As (19).
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    Illustration 51g06119366
    Top view of hose
    (A) Hose

  2. Remove and discard hose (A). Retain hardware and clips for installation of new hose.
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    Illustration 52g06119571
    Side view of weld location
    (AA) 321.6 mm (12.6 inch)
    (AB) 38.2 mm (1.5 inch)
    (BB) 139.7 mm (5.5 inch)
    (BC) 32.5 mm (1.3inch)
    (1) 8X-7415 Plate

  3. Filet weld plate (1) in location shown in illustration 52.
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    Illustration 53g06119588
    Inside view of left-hand rear pedestal
    (CC) 114 mm (4.5 inch)
    (CD) 88 mm (3.46 inch)
    (11) 9D-5568 Boss

  4. Filet weld boss (11) to pedestal in location shown in illustration 53.
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    Illustration 54g06119650
    Side view of plate location
    (1) 8X-7415 Plate
    (2) 384-8821 Plate As
    (3) 8T-4223 Hard Washer
    (4) 8T-4192 Bolt

  5. Position plate assembly (2) onto plate (1). Secure with two washers (3) and two bolts (4).
    Show/hide table
    Illustration 55g06119656
    Side view of filter group
    (2) 384-8821 Plate As
    (5) 267-5286 Air Lines Filter Gp
    (6) 8T-4224 Hard Washer
    (7) 8T-4908 Bolt

  6. Position filter group (5) onto plate assembly (2). Secure with two washers (6) and two bolts (7).
    Show/hide table
    Illustration 56g06120042
    Side view of filter group
    (5) 267-5286 Air Lines Filter Gp
    (8) 2H-3940 Elbow
    (19) 455-5885 Hose As

  7. Install elbow (8) to filter group (5). Install hose assembly (19) to elbow (8).
    Show/hide table
    Illustration 57g06120077
    Overview of hose routing
    (19) 455-5885 Hose As
    Show/hide table
    Illustration 58g06120099
    Rear view of hose routing
    (B) Hardware
    (12) 1S-0994 Clip
    (13) 8T-4896 Hard Washer
    (14) 5M-3062 Bolt
    (19) 455-5885 Hose As

  8. Route hose assembly (19) around base of left-hand rear pedestal. Position two clips (12) and secure with existing hardware (B), one washer (13), and one bolt (14).
    Show/hide table
    Illustration 59g06120199
    Side view of hose routing
    (C) Clip and Hardware
    (12) 1S-0994 Clip
    (15) 8S-0948 Clip
    (19) 455-5885 Hose As

  9. Route hose assembly (19) up left-hand rear pedestal. Install to cab in place of discarded hose (A) from step 2 of this procedure.

  10. Position clip (C), one clip (15), and two clips (12). Secure with existing hardware.

    Note: Clip (12) at detail (DD) needs to be flipped 180 degrees to prevent possible hose rub.

    Show/hide table
    Illustration 60g06120233
    Side view of filter group
    (5) 267-5286 Air Lines Filter Gp
    (9) 2S-5100 Manual Valve
    (10) 2H-9091 Pipe Connector
    (18) 455-5888 Hose As

  11. Install valve (9) and connector (10) to filter group (5). Install hose assembly (18) to connector (10).
    Show/hide table
    Illustration 61g06120220
    Overview of hose routing
    (18) 455-5888 Hose As
    Show/hide table
    Illustration 62g06120582
    Bottom view of hose routing
    (5) 267-5286 Air Lines Filter Gp
    (13) 8T-4896 Hard Washer
    (15) 8S-0948 Clip
    (16) 133-6934 Spacer
    (17) 5S-7383 Bolt
    (18) 455-5888 Hose As

  12. Route hose assembly (18) under frame and up left-hand inner frame rail. Position one clip (15) and secure one spacer (16), one washer (13), and one bolt (17).
    Show/hide table
    Illustration 63g06120657
    Side view of hose routing
    (D) Clip
    (12) 1S-0994 Clip
    (13) 8T-4896 Hard Washer
    (14) 5M-3062 Bolt
    (15) 8S-0948 Clip
    (18) 455-5888 Hose As

  13. Route hose assembly (18) up left-hand rear pedestal. Position clip (D), one clip (15), and uppermost clip (12). Secure with existing hardware.

    Note: Clip (15) at detail (EE) needs to be flipped 180 degrees to prevent possible hose rub.

  14. Position lower clip (12) and secure with one washer (13) and one bolt (14).
    Show/hide table
    Illustration 64g06120689
    Bottom view of hose routing
    (E) clipping points
    (18) 455-5888 Hose As

  15. Route hose assembly (18) along main beam up to air tank. Secure using retained clipping points and hardware (E) from removal of hose (A) in step 2 earlier in the procedure.
    Show/hide table
    Illustration 65g06120712
    Rear-Side view of hose routing
    (F) clipping points
    (18) 455-5888 Hose As

  16. Install hose assembly (18) to air tank. Secure using retained clipping points and hardware (F) from removal of hose (A) in step 2 earlier in the procedure.

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