785G Off-Highway Truck Caterpillar

DEF Manifold Filters - Replace

Usage:

785G RTL

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NOTICE

Ensure that the engine is stopped before any servicing or repair is performed.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Note: Refer to Special Instruction, REHS8231, "Removal Procedures for Diesel Exhaust Fluid (DEF) Connectors" for the correct removal procedure of hose assemblies (2) and (5).

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Illustration 1	g06166701

Remove DEF manifold cover plates (1) and locate the 2 center DEF manifolds.
Note: Only the 2 center DEF manifolds require filter replacement. Replace one filter at a time.
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Illustration 2 g06080074
Clamp off hoses (2).
Disconnect harness assemblies (3) and (4). Remove hose assemblies (2) and (5).
Remove bolts (8) and plate (7). Remove manifold (6) and gasket (not shown).
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Illustration 3 g03665737
Unscrew the band clamp (9) and remove the band clamp from the filter base (10).
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Illustration 4 g03664911
Remove the filter (11) from the filter base.
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Illustration 5 g03666075
Remove the suction filter (12) at the bottom of the header coils by pulling tabs (13). Replace with a new suction filter.
Install new filter by pulling filter over the manifold coils up to the bottom of the assembled filter base.
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Illustration 6 g03665754
Tighten the band clamp to 4.5 ± 0.7 N·m (40 ± 6 lb in), ensuring that the band clamp is aligned, as shown in illustration 6, to the flat spot on the base. Ensure that the filter does not bunch when tightening the band clamp.
Install the tank manifold following steps 2 through 4 in reverse order with a new gasket.
Tighten bolts (8) in an alternating sequence to 5 ± 1 N·m (44 ± 9 lb in). Tighten bolts (8) a second time in an alternating sequence to 5 ± 1 N·m (44 ± 9 lb in). Apply rubber lubricant to the o-ring seal inside hose assemblies (2).
Perform procedure (steps 2 through 11) on 2 center DEF manifolds.