SFN-20240118F Replace tubes to DPF & Decomposition

TICO Document #: SFN-20240118F (formerly TES 135)

Description of Procedure: A new tube with an additional section of flex tubing has been released, additional flex tubing increases the allowable movement between the “DPF and Decomposition Reactor”. The new tube requires additional clamps and brackets to maintain alignment and support while allowing for greater movement between exhaust components. A new clamp and bracket are now available to support the first tube in the exhaust system which attaches to the turbocharger outlet. Bracket reduces the load on the tube flange. An additional clamp between the “DPF” and the battery box has been added at the rear of the DPF. New clamp reduces the side load on the “DPF” frame mounting bracket.

Units Affected: Units built from January 2013 to September 2014

Parts Required:

• Tube-Turbo to Flex 62212 (QTY 1)

• Bracket- Tube Support 12689 (QTY 1)

• Clamp- 4” 40066 (QTY 1)

• Tube Flex DPF-Dozier Reactor 62151-1 (QTY 1)

• Bracket-Tube Support 12926 (QTY 1)

• Clamp-4 ” 40066 (QTY 1)

• Bolt-1/2-13NC x 5” Lg 2550 (QTY 2)

• Nut-1/2 Nylok 85027 (QTY 2)

• Bracket-DPF Support Upper 62409 (QTY 1)

• Bracket-DPF Support Lower 62416 (QTY 1)

• Clamp-Tank 40393-1 (QTY 2)

• Bolt-3/8-16NC x 5” Lg 82548 (QTY 1)

• Bolt-3/8-16NC x 1 ¼” Lg 82383 (QTY 6)

• Nut-3/8 Nylok 85025 (QTY 7)

Planned Labor: 3 hour

Procedure: Engine Turbocharger Outlet Tube Support

Instructions:

1. Park vehicle on flat surface, apply parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

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2. Raise the cab to its full upright position. Ensure the cab latch bracket is engaged and is supporting the cab.

3. Locate the RH side engine motor mount and remove the bolt that holds the engine side to the frame side. Retain this bolt and nut, it will be reinstalled later.

4. Remove the old exhaust tube from engine by removing clamps on both ends. Remove the NOx sensor. Take care in handling sensors, do not damage or clean with chemicals.

5. Install new tube (P/N 62212) and loosely tighten the exhaust clamps. Ensure that the exhaust gaskets are correctly in place between tube flange and turbocharger exhaust outlet and tube-to-tube flanges. If required, install new gaskets (P/N 61762). Install NOx sensor in new tube. Install sensor using (P/N 3824879) anti-seize and torque to 37 ft./lbs.

6. Position bracket (P/N 12689) over engine mount and install bolt-through bracket and engine mount.

7. Install exhaust tube clamp (P/N 40066) on tube where the insulation is removed. The “U” bolt legs should protrude through the bracket. Snug the exhaust clamp nuts; this will position bracket correctly over the engine mount.

8. When installing new exhaust tube, ensure that you have provided adequate clearance (1” min) between the tube and the top of the frame.

9. After you have positioned the tube with adequate frame clearance, then tighten the tube flange clamps on both ends. Check that the “V” of the clamp has captured both sides of the joint. If the clamp is not seated properly, you will have an exhaust gas leak at the joint. Lightly tapping around the circumference of the clamp with a small hammer will help seat the clamp.

10. Tighten the saddle clamp holding the tube to the bracket. Torque to 12 ft./lbs.

11. The tighten bracket mounting bolt on the rear engine mounts to 210 ft./lbs.

12. Lower cab, start engine, and test for leaks at the tube joints. If leaks are found, they must be corrected. Possible items to check are joints for proper clamp installation. Check gasket (P/N 61762), install a new gasket in the joint if required, and tighten “V” clamps.

13. Remove “Lock Out, Tag Out” plaque.

14. Return vehicle to service.

Procedure: REAR DPF SUPPORT BRACKET

15. Remove the middle battery box step and the lower heat shield

16. Install two tank clamps (P/N 40393-1) to lower DPF support bracket (P/N 62416) using two 3/8- 16NC x 1 ¼ Lg bolts and nylok nuts.

17. Install tank clamps around “DPF” just to the rear of existing tank clamp using 3/8-16NC x 5 Lg bolt.

18. Position the clamp so that bracket is over the “DPF”.

19. Install DPF upper bracket (P/N 62409) to the DPF lower bracket that you have clamped to DPF using two 3/8-16NC x 1 ¼ Lg bolts—snug bolts on the two brackets to where upper bracket is held in place but still maybe moved.

20. Position DPF upper bracket so it is flat against the bottom of the battery box. Mark the two holes in bracket on bottom of box. Check the location on the inside of battery box for interference with the step platform and with partition in battery box. If interference is found, rotate or slide upper bracket to eliminate interference. Drill two 7/16 diameter holes thru battery box bottom.

21. Install two 3/8-16NC x 1 ¼ Lg bolts in upper DPF bracket. Tighten all bolts to 35 ft./lbs. Torque.

22. Install battery box step and lower heat shield.

23. Unit maybe returned to service.

Procedure: DPF – REACTOR TUBE SUPPORT BRACKET

24. Remove the front and rear exhaust system heat shields

25. Remove tube “V” clamps from both ends of tube.

26. Install new exhaust tube (P/N 62151-1), which has an increased amount of flex tubing.

27. Install “V” clamps on both ends of tube. Ensure clamps are capturing both flanges.

28. Using the 4” clamp (P/N 40066), attach clamp and bracket (P/N 12926) to exhaust tube where bracket is snug against the cab bar. Clamp should be approx. 7” from end of tube. Your tube may have a section where the insulation is reduced. Install a clamp in that area. Ensure that you have clearance to the SCR connector table and all electrical connectors.

29. Mark holes in bracket on cab bar. Transfer hole locations from inside of cab bar tube to outside of cab bar tube. Drill two 9/16 diameters holes thru both walls of the tube.

30. Install two ½-13NC x 5 Lg bolts and nylok nuts. Torque to 65 ft.-lbs.

31. Tighten the clamp “U” bolt, using 3/8 nuts to secure the tube to the bracket.

32. Before installing rear heat shield, ensure there aren’t any hoses or electrical wires rubbing the new tube. Hoses should be secure so they will not rub against exhaust tube.

33. Start engine and test for leaks at the tube joints. If leaks are found, they must be corrected. Possible items to check are joints for proper clamp installation. If required, install new gasket (P/N 61761) in joints and tighten “V” clamps.

34. After a successful leak check, install front and rear heat shields.

35. Unit maybe returned to service.