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794 AC Off-Highway Truck Field Assembly Caterpillar


Air Cleaner - Install

Usage:

794 AC HRT
Reference: Testing and Adjusting, UENR2267, "794 AC Off-Highway Truck Machine Systems", Air Inlet system - Test and Inspect

Parts and Specification Information

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Illustration 1g03814538
Overall view of the platform

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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

Personal injury or death can occur from heavy components falling during removal or installation.

Properly support the component with a suitable lifting device during removal or installation.

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Table 1
Required Parts 
Item  Part Number  Description  Qty  Specification  Approximate Weight 
1  277-0736  Air Cleaner Gp  2    200 kg (440 lb) 
442-2661 Mount As  1  Left  102 kg (225 lb) 
442-2662 Mount As  1  Right  102 kg (225 lb) 
2  7X-0346  Bolt  8     
3  7X-0515  Hard Washer  14     
4  7X-0343  Bolt  6     
5  2W-9069  Precleaner Cup Assembly  6     
6  5N-7834  Clamp As  6     
7  442-2670  Pipe  2    44 kg (97 lb) 
8  442-2666  Pipe  1  Right side  39 kg (85 lb) 
442-2667 Pipe  1  Left side  38 kg (83 lb) 
9  442-2669(1)  Pipe  1  Right side  46 kg (101 lb) 
442-2668(2) Pipe  1  Left side  46 kg (101 lb) 
9  502-7100(3)  Tube  1  Left side  48 kg (106 lb) 
507-6295(4) Tube  1  Right side  49 kg (108 lb) 
10  442-2673  Clamp  32  Install 180 degrees apart   
11  243-5606  Hose  10     
12  434-5654  Nut  14     
13  442-2672  Washer  14     
14  177-4937  Spacer  14     
15  2L-6324  Bolt  14     
16  442-2671  Support  14     
17  431-5834  Support  14     
18  8T-2501(5)  Bolt  28     
18  8T-6466(6)  Bolt  40     
19  3K-6060(7)  Locknut  28     
19  6V-7744(8)  Locknut  46     
20  442-2795  Flap  1  Right side   
442-2794 Flap  1  Left side   
21  431-5933  Clamp  2     
22  4L-9337  Bolt  22     
23  5P-1075  Hard Washer  22     
24  2K-4973  Locknut  22     
25  442-2797  Retainer  2     
26  442-2796  Hanger  1     
27  8T-4121  Hard Washer  28     
28  495-2533  Bracket  1     
29  493-0479  Bracket  1     
31  495-2534  Bracket  1     
32  493-0481  Bracket  1     
33  334-2545  Reducer Hose  4     
34  442-2664  Pipe As  1     
36  431-8539  Clamp  8     
37  431-8541  Clamp  8     
38  7W-0650  Elbow  4     
39  442-2665  Pipe As  2     
40  442-2663  Pipe As  1     
41  432-3697  Pipe Bushing  4     
42  7W-0629  Filter Adapter  4     
43  2N-1287  Flared Elbow  4     
44  445-9741  Hose As  2     
45  445-9742  Hose As  2     
46  5M-3062  Bolt  4     
47  8T-4896  Hard Washer  5     
48  9M-4995  Clip  9     
50  432-3700  Clamp  2     
51  4L-9337  Bolt  2     
52  5S-7383  Bolt  4     
53  507-6294  Strap  1     
54  502-7102  Strap  2     
55  502-7100  Tube  1     
56  504-7487  Tube As  2     
57  431-8540  Clamp  16     
58  502-7101  Rubber Elbow  4     
59  504-7488  Tube As  2     
60  507-6295  Tube  1     
61  504-7487  Tube As  2     
62  495-3937  Hose As  2     
63  495-3936  Hose As  2     
65  8T-4196  Bolt  4     
66  502-7105  Pipe Clamp  6     
67  502-7104  Pipe Clamp  6     
68  8T-6466  Bolt  12     
69  502-7103  Strap  2     
71  2Q-3691  Spacer  2     
72  6V-8819  Self-Locking Bolt  2     
73  8T-4195  Bolt  2     
74  177-4937  Spacer  2     
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(1) Part used on the 442-2540 Air Cleaner Gp
(2) Part used on the 442-2540 Air Cleaner Gp
(3) Part used on the 442-2608 Air Cleaner Gp
(4) Part used on the 442-2608 Air Cleaner Gp
(5) Part used on the 442-2540 Air Cleaner Gp
(6) Part used on the 442-2608 Air Cleaner Gp
(7) Part used on the 442-2540 Air Cleaner Gp
(8) Part used on the 442-2608 Air Cleaner Gp

Installation Procedure

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    Illustration 2g03814883
    Underside view of the right air cleaner
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    Illustration 3g03814971
    View of the right air cleaner

  1. Use a suitable lifting device to position air cleaner group with mount assembly (1). Secure the mount assembly to the platform by using four bolts (2) and four hard washers (3) on the side and three bolts (4) and three hard washers (3) on the front.

    Note: Place the existing lift bracket on top of the mount assembly.

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    Illustration 4g03815402
    Underside view of the right air cleaner

  2. Install three precleaner cup assemblies (5) to the bottom of the air cleaner group using three clamps (6).

    Note: Orient the clamps so that the tension rod is towards the middle of the machine.

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    Illustration 5g03815470
    View of the right side air intake pipes
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    Illustration 6g03815496
    Close up view of one the supports used to secure the air intake pipes.

  3. Use a suitable lifting device to position pipe (7), pipe (8), and pipe (9). Connect pipe (7) and pipe (9) to the back of the air cleaner group. Connect pipe (8) to pipe (7). Use four clamps (10) and one hose (11) at each of three connections and at the end of pipe (8) and pipe (9). Secure pipe (7) and pipe (8) in two places and pipe (9) in three places. Secure the pipes by using one nut (12), one washer (13), one spacer (14), one bolt (15), one support (16), one support (17), two bolts (18), and two locknuts (19) at each location.

    Note: Install clamps (10) so that there are two clamps (10) on each side of hose (11) and so that the two clamps (10) are 180 degrees apart.

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    Illustration 7g03815636
    Underside view of the right air cleaner

  4. Install flap (20) to the air cleaner group. Secure the lower portion of flap (20) by using one clamp (21) and seven bolts (22), seven hard washers (23), and seven locknuts (24). On the right side of the machine only, install hanger (26) to the platform using the mounting hardware used in Step 1 and Illustration 3. Secure the upper portion of flap (20) using retainer (25) and four bolts (22), four hard washers (23), and four locknuts (24).

    Note: On the left side of the machine, the upper portion of flap (20) will remain unsecured until the platform extensions are installed. Refer to Disassembly and Assembly, "Handrail (Front) - Install".

  5. Repeat Steps 1 through 4 for the opposite side air cleaner group.

Hose and Pipe Assembly Instructions

  1. Check all the new pipes for the protective caps. Inspect the new pipes to ensure that the pipes are free of rust and debris. If debris and rust are found, clean inside the pipes until free of debris and rust.
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    Illustration 8g06242265
    Cleaning the inside the pipe

  2. Before assembly, clean inside all the pipes.

  3. Obtain a length of rope (4) long enough to extend through the entire length of the longest pipe (3). Obtain a stiff pillow (1) large enough fit tightly through the pipe. Tie the rope around the pillow. Cut a hole in a chunk of blanket (2) large enough to cover the pillow. Pass the rope through the hole in the blanket.

  4. Spray the blanket with window cleaner. Pull the blanket through the pipe several times to clean inside the pipe. Remove all debris from inside the pipe.

  5. Before installation, mark the hose overlap distance on all pipes.
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    Illustration 9g06242280
    Hose and pipe overlap
    (A) 60 ± 5 mm (2.4 ± 0.2 inch) (A)

  6. The overlap distance for the hose on the pipe to filter assembly connections, the pipe to pipe connections, and the pipe to elbow connection is 60 ± 5 mm (2.4 ± 0.2 inch) (A). The overlap is on both ends of the hose. Both units are the same diameter.
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    Illustration 10g06242311
    Reduced diameter hose overlaps
    (B) 67 ± 5 mm (2.6 ± 0.2 inch)

  7. The overlap distance for the hose on the pipe to reduced diameter pipe connection is 67 ± 5 mm (2.6 ± 0.2 inch) (B). The overlap is on both ends of the hose.

  8. During the pipe installation, leave the components loose to adjust the alignment of the pipes and hoses. Misalignment of the pipes should not exceed 3.0 mm (0.12 inch).

  9. Check the overlap distance marks. If the assembly is within the specifications, tighten the clamps.

    Note: Position the clamps 180 degrees apart.

  10. Pressure check the pipe assemblies. Refer to UENR2267, Air Inlet System - Test and Inspect

442-2540 Air Cleaner Gp

Installation Procedure

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    Illustration 11g06234319
    Front of the truck showing the two areas where work begins
    (A) Right side of the platform
    (B) Left side of the platform
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    Illustration 12g06234338
    View of area (A)
    ( 22) 4L-9337 Bolt
    (27) 8T-4121 Hard Washer
    (28) 454-4203 Bracket As

  1. Go to area (A) in Illustration 11. Use four bolts (22), and four hard washers (27) to install bracket assembly (28).
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    Illustration 13g06234349
    Position of the bracket and bracket assembly
    (22) 4L-9337 Bolt
    (27) 8T-4121 Hard Washer
    (28) 454-4203 Bracket As
    (29) 445-9813 Bracket
    (30) 445-9815 Bracket As

  2. Go right from bracket assembly (28). Use two bolts (22) and two hard washers (27) to install bracket (29), and bracket assembly (30) at each location.
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    Illustration 14g06234474
    View of area (B)
    ( 22) 4L-9337 Bolt
    (27) 8T-4121 Hard Washer
    (31) 454-4198 Bracket As

  3. Go to Area (B) in Illustration 11. Use four bolts (22), and four hard washers (27) to install bracket assembly (31).
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    Illustration 15g06234489
    Center bracket in area (B)
    ( 22) 4L-9337 Bolt
    (27) 8T-4121 Hard Washer
    (31) 454-4198 Bracket As
    (32) 445-9813 Bracket

  4. Go to the right of bracket assembly (31). Use two bolts (22) and two hard washers (27) to install bracket (32).
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    Illustration 16g06234500
    Left bracket assembly in area (B)
    ( 22) 4L-9337 Bolt
    (27) 8T-4121 Hard Washer
    (32) 445-9813 Bracket
    (33) 445-9814 Bracket As

  5. Go left from bracket (32). Use two bolts (22) and two hard washers (27) to install bracket assembly (33).
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    Illustration 17g06233899
    Position of the first set of turbocharger lines looking forward from behind the left air cleaner
    (9) 442-2668 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (34) 442-2664 Pipe As
    (35) Position of the supports and fasteners for the pipe and pipe assembly
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    Illustration 18g06234551
    View of area (C)
    ( 9) 442-2668 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (34) 442-2664 Pipe As
    (35) Position of the supports and fasteners for the pipe and pipe assembly

  6. Before installation, install one hose (11), and four clamps (10) between pipe (9), and pipe assembly (34).

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  7. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of pipe (9) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  8. Use a suitable lifting device to position pipe (9), and pipe assembly (34). The approximate weight of the two parts is 70 kg (154 lb). Position pipe (9) on the outlet form the left air cleaner that is toward the center of the machine.
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    Illustration 19g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  9. Secure the pipe and pipe assembly to the machine by using the following parts at each of the four locations (35) shown in Illustration 17, and Illustration 18.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
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    Illustration 20g06234586
    Connection to turbocharger
    (34) 442-2664 Pipe As
    (36) 431-8539 Clamp
    (37) 431-8541 Clamp
    (38) 7W-0650 Elbow

  10. Go to the end of pipe assembly (34). Before installation, assemble two clamps (36) on the end of elbow (38) that will connect to pipe assembly (34). Assemble two clamps (37) on the end of the elbow that will connect to the turbocharger on the outside of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 21g06234669
    Position of the second set of turbocharger lines looking forward from behind the air cleaner
    (7) 442-2670 Pipe
    (8) 442-2667 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
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    Illustration 22g06234671
    View of area (D)
    ( 8) 442-2667 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
    (39) 442-2665 Pipe As

  11. Before installation, install one hose (11), and four clamps (10) between pipe (7), and pipe (8) on the straight section of the pipes.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  12. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of pipe (7) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  13. Refer to the view of area (D). Before installation, install one hose (11), and four clamps (10) between pipe assembly (39) and pipe (8) on the 90 degree bend end of pipe (8).

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  14. Use a suitable lifting device to position pipe (7), pipe (8), and pipe assembly (39). The approximate weight of the three parts is 96 kg (212 lb). Position pipe (7) on the outlet form the left air cleaner that is toward the outside of the machine.
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    Illustration 23g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  15. Secure the two pipes and the pipe assembly to the machine by using the following parts at each of the five locations (35) shown in Illustration 21, and Illustration 22.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
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    Illustration 24g06234852
    Second turbocharger air line installation
    (36) 431-8539 Clamp
    (37) 431-8541 Clamp
    (38) 7W-0650 Elbow
    (39) 442-2665 Pipe As

  16. Go to the end of pipe assembly (39). Before installation, assemble two clamps (36) on the end one elbow (38) that will connect to pipe assembly (39). Assemble two clamps (37) on the end of the elbow that will connect to the second turbocharger in from the outside of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 25g06234908
    Position of the third set of turbocharger lines looking forward from behind the right air cleaner
    (9) 442-2668 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
    (40) 442-2663 Pipe As
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    Illustration 26g06234923
    View of area (E)
    ( 9) 442-2668 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
    (40) 442-2663 Pipe As

  17. Go to the right side of the machine behind the right air cleaner. Before installation, install one hose (11), and four clamps (10) between pipe (9), and pipe assembly (40).

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  18. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of pipe (9) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  19. Use a suitable lifting device to position pipe (9), and pipe assembly (40). The approximate weight of the two parts is 70 kg (154 lb). Position pipe (9) on the outlet form the left air cleaner that is toward the center of the machine.
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    Illustration 27g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  20. Secure the pipe and pipe assembly to the machine by using the following parts at each of the four locations (35) shown in Illustration 25, and Illustration 26.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
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    Illustration 28g06234938
    Connection to the turbocharger
    (36) 431-8539 Clamp
    (37) 431-8541 Clamp
    (38) 7W-0650 Elbow
    (40) 442-2663 Pipe As

  21. Go to the end of pipe assembly (40). Before installation, assemble two clamps (36) on the end of elbow (38) that will connect to pipe assembly (40). Assemble two clamps (37) on the end of the elbow that will connect to the turbocharger closest to the right side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 29g06234962
    Position of the fourth set of turbocharger lines looking forward from behind the right air cleaner
    (7) 442-2670 Pipe
    (8) 442-2666 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
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    Illustration 30g06234974
    View of area (F)
    ( 8) 442-2666 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
    (39) 442-2665 Pipe As

  22. Before installation, install one hose (11), and four clamps (10) between pipe (7), and pipe (8) on the straight section of the pipes.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  23. Before installation, install one hose (11), and four clamps (10) on the bent end of pipe (7) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  24. Refer to the view of area (F). Before installation, install one hose (11), and four clamps (10) between pipe assembly (39) and pipe (8) on the 90 degree bend end of pipe (8).

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  25. Use a suitable lifting device to position pipe (7), pipe (8), and pipe assembly (39). The approximate weight of the three parts is 97 kg (214 lb). Position pipe (7) on the outlet form the left air cleaner that is toward the outside of the machine.
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    Illustration 31g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the five locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  26. Secure the pipe and pipe assembly to the machine by using the following parts at each of the five locations (35) shown in Illustration 29, and Illustration 30.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
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    Illustration 32g06235000
    Connection to the turbocharger
    (36) 431-8539 Clamp
    (37) 431-8541 Clamp
    (38) 7W-0650 Elbow
    (39) 442-2665 Pipe As

  27. Go to the end of tube assembly (39). Before installation, assemble two clamps (36) on the end of elbow (38) that will connect to pipe assembly (39). Assemble two clamps (37) on the end of the elbow that will connect to the second turbocharger in from the right side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 33g06235270
    Position of the Fittings hardware on the pipe assemblies looking back from the front of the machine
    (34) 442-2664 Pipe As
    (39) 442-2665 Pipe As
    (40) 442-2663 Pipe As
    (41) 432-3697 Pipe Bushing
    (42) 7W-0629 Filter Adapter
    (43) 2N-1287 Flared Elbow
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    Illustration 34g06235302
    View of area (G)
    ( 39) 442-2665 Pipe As
    (41) 432-3697 Pipe Bushing
    (42) 7W-0629 Filter Adapter
    (43) 2N-1287 Flared Elbow

  28. Assemble one pipe bushing (41), one filter adapter (42), and one flared elbow (43) onto the four pipe assemblies in the positions shown.
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    Illustration 35g06235343
    Position of the hose assemblies on the pipe assemblies
    (44) 445-9742 Hose As
    (45) 445-9741 Hose As

  29. Assemble one hose assembly (44) onto the two flared elbows shown.

  30. Assemble one hose assembly (45) onto the two flared elbows shown.
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    Illustration 36g06235389
    Hose assembly routing
    (44) 445-9742 Hose As
    (46) 5M-3062 Bolt
    (47) 8T-4896 Hard Washer
    (48) 9M-4995 Clip

  31. Route the two hose assemblies (44) across the bottom of the platform. Use one bolt (46), one hard washer (47), and one clip (48) to secure the two hoses at the three positions shown.
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    Illustration 37g06240782
    Hose assembly routing
    (44) 445-9742 Hose As
    (45) 445-9741 Hose As
    (46) 5M-3062 Bolt
    (47) 8T-4896 Hard Washer
    (48) 9M-4995 Clip
    (49) Existing boss
    (50) 432-3700 Clamp
    (51) 4L-9337 Bolt
    (74) 177-4937 Spacer

  32. Route the two hose assemblies (44) farther across the bottom of the platform. Join the two hose assemblies (45) with the two hose assemblies (44). Assemble one clip (48) to the two hose assemblies (44) near boss (49). Position the clip with the flat side of the clip downward. Assemble one clip (48) to the two hose assemblies (45) near boss (49). Position the clip with the flat side of the clip upward. Use one bolt (46), one hard washer (47) to secure the two clips to the boss.

  33. Route the four hose assemblies toward the outside of the platform to the hole as shown. Assemble one clamp (50) to the platform as shown. Assemble one clip (48) around the two hose assemblies toward the front of the platform. Position the flat part of the clip toward the clamp. Assemble one clip (48) around the two hose assemblies toward the back of the platform. Position the flat part of the clip toward the clamp. Position one spacer (74) between the two clips. Use one bolt (51), one hard washer (47) to secure the two clips to the clamp.

  34. Route the four hose assemblies toward the front, right corner of the cab.
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    Illustration 38g06235887
    Front, right corner of the cab
    (E) 4S-4465 Screw

  35. Remove the nine screws (E) . Save the parts.
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    Illustration 39g06235892
    Front, right corner of the cab
    (F) 432-3639 Plate

  36. Remove plate (F). Save the part.
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    Illustration 40g06235894
    Area of hose assembly installations
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    Illustration 41g06235895
    View of area (H)
    ( A) The second end of one hose assembly (45) from the second pipe assembly in from the right side of the machine
    (B) The second end of one hose assembly (45) from right pipe assembly on the machine
    (C) The second end of one hose assembly (44) from the second pipe assembly in from the left side of the machine
    (D) The second end of one hose assembly (44) from the left pipe assembly on the machine.

  37. Assemble the four hose assemblies to the cab. Assemble the second end of hose assemble (45) from pipe assembly (B), the second pipe assembly in from the right side of the machine, to the connection on the left.

  38. Assemble the second end of hose assemble (45) from pipe assembly (A), the right pipe assembly on the machine, to the second connection in from the left.

  39. Assemble the second end of hose assemble (44) from pipe assembly (C), the second pipe assembly in from the left side of the machine, to the second connection in from the right.

  40. Assemble the second end of hose assemble (44) from pipe assembly (D), the left pipe assembly on the machine, to the connection on the right side.
    Show/hide table
    Illustration 42g06236138
    Secure the hose assemblies
    (48) 9M-4995 Clip

  41. Use two clips (48) to secure the four hose assemblies to the existing steering hose assemblies under the platform.
    Show/hide table
    Illustration 43g06235892

  42. Install plate (F) that was removed in Step 39
    Show/hide table
    Illustration 44g06235887
    Front, right corner of the cab
    (E) 4S-4465 Screw

  43. Use the nine screws (E) saved in Step 38 to secure the plate installed in the previous step.

442-2608 Air Cleaner Gp

    Show/hide table
    Illustration 45g06236796
    Front of the truck showing the two areas where work begins
    (A) Right side of the platform
    (B) Left side of the platform
    Show/hide table
    Illustration 46g06236815
    View of area (A)
    ( 22) 4L-9337 Bolt
    (23) 5P-1075 Hard Washer
    (28) 495-2533 Bracket
    (47) 8T-4896 Hard Washer
    (52) 5S-7383 Bolt
    (53) 507-6294 Strap

  1. Go to area (A) in Illustration 45. Use two bolts (22), and two hard washers (23) to install bracket (28). Use two bolts (52), and two hard washers (47) to install strap (53) and bracket (28).
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    Illustration 47g06236830
    Position of the bracket
    (22) 4L-9337 Bolt
    (23) 5P-1075 Hard Washer
    (28) 454-4203 Bracket
    (29) 493-0479 Bracket

  2. Go right from bracket (28). Use four bolts (22) and four hard washers (23) to install bracket (29) at the two locations shown.
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    Illustration 48g06236839
    View of area (B)
    ( 22) 4L-9337 Bolt
    (23) 5P-1075 Hard Washer
    (31) 495-2534 Bracket
    (47) 8T-4896 Hard Washer
    (52) 5S-7383 Bolt
    (54) 502-7102 Strap

  3. Go to Area (B) in Illustration 45. Use two bolts (22), and two hard washers (23) to install bracket assembly (31). Use two bolts (52), and two hard washers (47) to install strap (54) and bracket (31).
    Show/hide table
    Illustration 49g06234489
    Center bracket in area (B)
    ( 22) 4L-9337 Bolt
    (23) 5P-1075 Hard Washer
    (31) 454-4198 Bracket As
    (32) 493-0481 Bracket

  4. Go to the right of bracket assembly (31). Use two bolts (22) and two hard washers (23) to install bracket (32).
    Show/hide table
    Illustration 50g06237729
    Position of the first set of turbocharger lines looking forward from behind the left air cleaner
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
    (55) 502-7100 Tube
    (56) 504-7487 Tube As
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    Illustration 51g06237740
    View of area (C)
    ( 10) 442-2673 Clamp
    (33) 334-2545 Reducer Hose
    (55) 502-7100 Tube
    (56) 504-7487 Tube As
    (57) 431-8540 Clamp

  5. Refer to Illustration 51. Before installation, install one reducer hose (33), two clamps (10), and two clamps (57) between tube (55), and tube assembly (56).

    Note: Position two clamps (10), and two clamps (57) on each side of hose (33) as shown. Position the clamps 180 degrees apart.

  6. Refer to Illustration 50. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of tube (55) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  7. Use a suitable lifting device to position tube (55), and tube assembly (56). The approximate weight of the two parts is 70 kg (154 lb). Position pipe (55) on the outlet form the left air cleaner that is toward the center of the machine.
    Show/hide table
    Illustration 52g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the three locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  8. Secure the tube and tube assembly to the machine by using the following parts at each of the three locations (35) shown in Illustration 50.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
    Show/hide table
    Illustration 53g06239055
    View of the supports for Tube assembly (56) from the front of the machine
    (19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (56) 504-7487 Tube As
    (64) Location of tube assembly supports
    (69) 502-7103 Strap
    (73) 8T-4195 Bolt used with strap (69)
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    Illustration 54g06239065
    Parts used to secure tube assembly (56) at the two locations (64)
    ( 19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (65) 8T-4196 Bolt
    (66) 502-7105 Pipe Clamp
    (67) 502-7104 Pipe Clamp
    (68) 8T-6466 Bolt

  9. Refer to Illustration 54. Secure the tube assembly to the machine by using strap (69) and the following parts at the two locations (64) shown in Illustration 53.

    • Three nuts (19)

    • Six or eight washers (27)

    • One bolt (65)

    • One support (66)

    • One support (67)

    • Two bolts (68)
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    Illustration 55g06237755
    Connection to turbocharger
    (36) 431-8539 Clamp
    (56) 504-7487 Tube As
    (57) 431-8540 Clamp
    (58) 502-7101 Rubber Elbow

  10. Go to the end of tube assembly (56). Before installation, assemble two clamps (57) on the end of rubber elbow (58) that will connect to tube assembly (56). Assemble two clamps (36) on the end of the elbow that will connect to the turbocharger on the left side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 56g06237764
    Position of the second set of turbocharger lines looking forward from behind the air cleaner
    (7) 442-2670 Pipe
    (8) 442-2667 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the pipe and pipe assembly
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    Illustration 57g06237768
    View of area (D)
    ( 8) 442-2667 Pipe
    (10) 442-2673 Clamp
    (33) 334-2545 Reducer Hose
    (59) 504-7488 Tube As
    (70) Position of the supports and fasteners for the tube assembly

  11. Refer to Illustration 56. Before installation, install one hose (11) and four clamps (10) between pipe (7), and pipe (8) on the straight sections of the pipes.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  12. Refer to Illustration 56. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of pipe (7) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  13. Refer to Illustration 57. Before installation, install one hose (33), two clamps (10), and two clamps (57) between tube assembly (59) and pipe (8) on the 90 degree bend end of pipe (8).

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  14. Use a suitable lifting device to position pipe (7), pipe (8), and tube assembly (59). The approximate weight of the three parts is 96 kg (212 lb). Position pipe (7) on the outlet form the left air cleaner that is toward the outside of the machine.
    Show/hide table
    Illustration 58g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  15. Secure the two pipes to the machine by using the following parts at each of the four locations (35) shown in Illustration 56 .

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
    Show/hide table
    Illustration 59g06239487
    View of the supports and fasteners used to secure the tube assembly at locations (70)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (47) 8T-4896 Hard Washer
    (66) 502-7105 Pipe Clamp
    (67) 502-7104 Pipe Clamp
    (68) 8T-6466 Bolt
    (71) 2Q-3691 Spacer
    (72) 6V-8819 Self-Locking Bolt

  16. Refer to Illustration 57. Use the following parts to secure tube assembly (59) to the machine at position (70).

    • One nut (12)

    • One washer (13)

    • Two locknuts (19)

    • Four hard washers (27)

    • One hard washer (47)

    • One support (66)

    • One support (67)

    • Two bolts (68)

    • One spacer (71)

    • One self locking bolt (72)
    Show/hide table
    Illustration 60g06237774
    Second turbocharger air line installation
    (36) 431-8539 Clamp
    (57) 431-8540 Clamp
    (58) 502-7101 Rubber Elbow

  17. Go to the end of tube assembly (59). Before installation, assemble two clamps (57) on the end one rubber elbow (58) that will connect to tube assembly (59). Assemble two clamps (36) on the end of the elbow that will connect to the second turbocharger in from the left side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
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    Illustration 61g06237785
    Position of the third set of turbocharger lines looking forward from behind the right air cleaner
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the tube
    (60) 507-6295 Tube
    (61) 504-7487 Tube As
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    Illustration 62g06237796
    View of area (E)
    ( 10) 442-2673 Clamp
    (33) 334-2545 Reducer Hose
    (57) 431-8540 Clamp
    (60) 507-6295 Tube
    (61) 504-7487 Tube As
    (64) Position of the supports and fasteners for the tube assembly

  18. Before installation, install one hose (11), and four clamps (10) on the 90 degree bend end of tube (60) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  19. Before installation, install one hose (33), two clamps (10), and two clamps (57) between tube (60), and tube assembly (61).

    Note: Position two clamps (10) on the end of reducer hose (33) that will assemble to tube (60). Position the two clamps (57) on the end of the reducer hose that will assemble to tube assembly (61). Position the clamps 180 degrees apart.

  20. Use a suitable lifting device to position tube (60), and tube assembly (61). The approximate weight of the two parts is 70 kg (154 lb). Position tube (60) on the outlet from the air cleaner that is toward the center of the machine.
    Show/hide table
    Illustration 63g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  21. Secure the pipe and pipe assembly to the machine by using the following parts at each of the three locations (35) shown in Illustration .

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
    Show/hide table
    Illustration 64g06239603
    View of the supports for tube assembly (61) from the front of the machine
    (19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (61) 504-7487 Tube As
    (64) Location of the tube assembly supports
    (69) 502-7103 Strap
    (73) 8T-4195 Bolt
    Show/hide table
    Illustration 65g06239065
    Parts used to secure tube assembly (61) at locations (64)
    ( 19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (65) 8T-4196 Bolt
    (66) 502-7105 Pipe Clamp
    (67) 502-7104 Pipe Clamp
    (68) 8T-6466 Bolt
    (73) 8T-4195 Bolt used with strap (69)

  22. Refer to Illustration 64. Secure tube assembly (61) to the machine by using the following parts at location (64).

    • Three nuts (19)

    • Six or eight washers (27)

    • One bolt (65)

    • One support (66)

    • One support (67)

    • Two bolts (68)

    • One strap (69)

    • One bolt (73)
    Show/hide table
    Illustration 66g06237811
    Connection to the turbocharger
    (36) 431-8539 Clamp
    (57) 431-8540 Clamp
    (58) 502-7101 Rubber Elbow
    (61) 504-7487 Tube As

  23. Go to the end of tube assembly (61). Before installation, assemble two clamps (57) on the end of rubber elbow (58) that will connect to tube assembly (61). Assemble two clamps (36) on the end of the elbow that will connect to the turbocharger closest to the right side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
    Show/hide table
    Illustration 67g06237825
    Position of the fourth set of turbocharger lines looking forward from behind the right air cleaner
    (7) 442-2670 Pipe
    (8) 442-2666 Pipe
    (10) 442-2673 Clamp
    (11) 243-5606 Hose
    (35) Position of the supports and fasteners for the two pipes
    Show/hide table
    Illustration 68g06237827
    View of area (F)
    ( 8) 442-2666 Pipe
    (10) 442-2673 Clamp
    (33) 334-2545 Reducer Hose
    (57) 431-8540 Clamp
    (59) 504-7488 Tube As
    (70) Position of the supports and fasteners for the tube assembly

  24. Before installation, install one hose (11), and four clamps (10) between pipe (7), and pipe (8) on the straight section of the pipes.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  25. Before installation, install one hose (11), and four clamps (10) on the bent end of pipe (7) that is toward the air cleaner.

    Note: Position two clamps (10) on each side of hose (11). Position the clamps 180 degrees apart.

  26. Refer to the view of area (F). Before installation, install one hose (33), two clamps (10), and two clamps (57) between pipe assembly (59) and pipe (8) on the 90 degree bend end of pipe (8).

    Note: Position the clamps 180 degrees apart.

  27. Use a suitable lifting device to position pipe (7), pipe (8), and tube assembly (59). The approximate weight of the three parts is 97 kg (214 lb). Position pipe (7) on the outlet from the left air cleaner that is toward the outside of the machine.
    Show/hide table
    Illustration 69g06233839
    View of the supports and fasteners used to secure the pipe and pipe assembly at the four locations (35)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (14) 177-4937 Spacer
    (15) 2L-6324 Bolt
    (16) 442-2671 Support
    (17) 431-5834 Support
    (18) 8T-2501 Bolt
    (19) 3K-6060 Locknut

  28. Secure the pipe and pipe assembly to the machine by using the following parts at each of the four locations (35) shown in Illustration 67.

    • One nut (12)

    • One washer (13)

    • One spacer (14)

    • One bolt (15)

    • One support (16)

    • One support (17)

    • Two bolts (18)

    • Two locknuts (19)
    Show/hide table
    Illustration 70g06239487
    View of the supports and fasteners used to secure the tube assembly at locations (70)
    ( 12) 434-5654 Nut
    (13) 442-2672 Washer
    (19) 6V-7744 Locknut
    (27) 8T-4121 Hard Washer
    (47) 8T-4896 Hard Washer
    (66) 502-7105 Pipe Clamp
    (67) 502-7104 Pipe Clamp
    (68) 8T-6466 Bolt
    (71) 2Q-3691 Spacer
    (72) 6V-8819 Self-Locking Bolt

  29. Refer to Illustration 68. Use the following parts to secure tube assembly (59) to the machine at position (70).

    • One nut (12)

    • One washer (13)

    • Two locknuts (19)

    • Four hard washers (27)

    • One hard washer (47)

    • One support (66)

    • One support (67)

    • Two bolts (68)

    • One spacer (71)

    • One self locking bolt (72)
    Show/hide table
    Illustration 71g06238025
    Connection to the turbocharger
    (36) 431-8539 Clamp
    (57) 431-8540 Clamp
    (58) 502-7101 Rubber Elbow
    (59) 504-7488 Tube As

  30. Go to the end of tube assembly (59). Before installation, assemble two clamps (57) on the end of elbow (58) that will connect to pipe assembly (59). Assemble two clamps (36) on the end of the elbow that will connect to the second turbocharger in from the right side of the engine. Assemble the elbow to the pipe assembly and the turbocharger.
    Show/hide table
    Illustration 72g06238110
    Position of the fittings hardware on the tube assemblies looking forward from the front of the engine
    (41) 432-3697 Pipe Bushing
    (42) 7W-0629 Filter Adapter
    (43) 2N-1287 Flared Elbow
    (56) 504-7487 Tube As
    (59) 504-7488 Tube As
    (61) 504-7487 Tube As
    Show/hide table
    Illustration 73g06238122
    View of area (G)
    ( 41) 432-3697 Pipe Bushing
    (42) 7W-0629 Filter Adapter
    (43) 2N-1287 Flared Elbow
    (56) 504-7487 Tube As

  31. Assemble one pipe bushing (41), one filter adapter (42), and one flared elbow (43) onto the four pipe assemblies in the positions shown.
    Show/hide table
    Illustration 74g06238167
    Position of the hose assemblies on the pipe assemblies
    (62) 495-3937 Hose As
    (63) 495-3936 Hose As
    (A) First tube assembly in from the left side of the machine
    (B) Second tube assembly in from the left side of the machine
    (C) Third tube assembly in from the left side of the machine
    (D) Fourth tube assembly in from the left side of the machine

  32. Assemble one hose assembly (62) onto the two flared elbows shown. Route the two hose assemblies as shown.

  33. Assemble one hose assembly (63) onto the two flared elbows shown. Route the two hose assemblies as shown.
    Show/hide table
    Illustration 75g06238175
    Hose assembly routing
    (46) 5M-3062 Bolt
    (47) 8T-4896 Hard Washer
    (48) 9M-4995 Clip
    (63) 495-3937 Hose As

  34. Route the two hose assemblies (63) across the bottom of the platform. Use one bolt (46), one hard washer (47), and one clip (48) to secure the two hoses at the three positions shown.
    Show/hide table
    Illustration 76g06235417
    Hose assembly routing
    (E) 493-0481 Bracket
    (47) 8T-4896 Hard Washer
    (48) 9M-4995 Clip
    (50) 432-3700 Clamp
    (51) 4L-9337 Bolt
    (62) 495-3937 Hose As
    (63) 495-3936 Hose As
    (74) 177-4937 Spacer

  35. Route the two hose assemblies (63) farther across the bottom of the platform. Join the two hose assemblies (62) with the two hose assemblies (63). Assemble one clip (48) to the two hose assemblies near bracket (A). Position the clip with the flat side of the clip away from the bracket. Assemble one clip (48) to the other two hose assemblies near bracket (E). Position the clip with the flat side of the clip toward the bracket. Assemble one clamp (50) to the bracket as shown. Assemble one spacer (74) between the two clips (48) and clamp (50). Use one bolt (51), one hard washer (47) to secure the two clips to the clamp.

  36. Route the four hose assemblies toward the outside of the platform to the hole as shown. Assemble one clamp (50) to the platform as shown. Assemble one clip (48) around the two hose assemblies toward the front of the platform. Position the flat part of the clip away from the clamp. Assemble one clip (48) around the two hose assemblies toward the back of the platform. Position the flat part of the clip toward the clamp. Position one spacer (74) between the clamp and the two clips. Use one bolt (51), one hard washer (47) to secure the two clips to the clamp.

  37. Route the four hose assemblies toward the front, right corner of the cab.
    Show/hide table
    Illustration 77g06240725
    Front, right corner of the cab
    (F) 4S-4465 Screw

  38. Remove the nine screws (F) . Save the parts.
    Show/hide table
    Illustration 78g06240735
    Front, right corner of the cab
    (G) 432-3639 Plate

  39. Remove plate (G). Save the part.
    Show/hide table
    Illustration 79g06235894
    Area of hose assembly installations
    Show/hide table
    Illustration 80g06240755
    View of area (H)
    ( A) The second end of one hose assembly (62) from the first tube assembly in from the left side of the machine
    (B) The second end of one hose assembly (62) from the second tube assembly in from the left side of the machine
    (C) The second end of one hose assembly (63) from the third tube assembly in from the left side of the machine
    (D) The second end of one hose assembly (63) from the fourth tube assembly in from the left side of the machine

  40. Assemble the four hose assemblies to the cab. Assemble the second end of one hose assemble (62) from pipe assembly (A) to the connection on the left.

  41. Assemble the second end of hose assemble (62) from pipe assembly (B) to the second connection in from the left.

  42. Assemble the second end of hose assemble (63) from pipe assembly (C) to the third connection in from the left.

  43. Assemble the second end of hose assemble (63) from pipe assembly (D) to the connection on the right side.
    Show/hide table
    Illustration 81g06240763
    Secure the hose assemblies
    (48) 9M-4995 Clip

  44. Use two clips (48) to secure the four hose assemblies to the existing steering hose assemblies under the platform.
    Show/hide table
    Illustration 82g06240735
    Front, right corner of the cab
    (G) 432-3639 Plate

  45. Install plate (G) that was removed in Step 39
    Show/hide table
    Illustration 83g06240725
    Front, right corner of the cab
    (F) 4S-4465 Screw

  46. Use the nine screws (F) saved in Step 38 to secure the plate installed in the previous step.

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