SFN-20231011D_Replace the hydraulic line

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TICO Document #: SFN-20231011D (formerly TES-218)

Complication: The external hydraulic filter connection fails in certain applications due to possible over-pressurization of the line from the external hydraulic filter to hydraulic tank.

Description of Procedure: Replace the hydraulic line and associated fittings to increase the line size from ¾” to 1” from the hydraulic filter to hydraulic tank

Parts Required: See image below and order as follows:

Cummins QSB series engines (painted black) kIT - HYDRAULIC sySTEM EXTERNAL FILTER TO TANK UPFIT, QSB 970029 (QTY) 1

Or

Cummins B6.7 series engines (painted red) kit - HYDRAULIC SYSTEM EXTERNAL FILTER TO TANK UPFIT, B6.7 970030 (QTY) 1

Planned Labor: 1 hour

Identify which kit will be required by the engine model. The are painted black and the are painted red from the factory. See Figures #1 & #2.

Instructions:

  1. Park the vehicle on a 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.

  2. Using the proper collection reservoir, drain the hydraulic fluid from the hydraulic tank. The drain port is located on the bottom of the hydraulic tank. See Figure #3.

    Do not reuse the hydraulic fluid.

  1. Take notice of the hose routing from the filter to the hydraulic tank. The hydraulic tank configuration for the Cummins QSB Tier III & Tier IV Final engines is shown in Figure #4, and the Cummins B6.7 engine is shown in Figure #5.

Note: The hydraulic line size change is not impacted by the engine series hydraulic tank used, the procedure for both is identical.

  1. Remove the ¾” hydraulic line between the hydraulic filter and the side of the tank at the connections shown. See Figure #6.

    To avoid any environmental impact, be careful to capture any hydraulic fluid when the hose is disconnected.

  1. Remove the (4) u-bolt nuts that hold the filter assembly elbows to the hydraulic tank. Retain the hardware. See Figure #7.

  1. Remove the (2) bolts with associated washers and nuts that hold the filter assembly to the hydraulic tank. Retain the hardware. See Figure #8.

  1. Remove the outlet elbow fitting from the hydraulic filter head assembly; see Figure #9.

To avoid any environmental impact, be careful to capture any hydraulic fluid when the fitting is removed.

  1. Remove the inlet elbow fitting from the hydraulic tank. See Figure #10.

To avoid any environmental impact, be careful to capture any hydraulic fluid when the fitting is removed.

  1. Discard the removed parts (except for the retained filter head mounting hardware).

  1. Install fittings and shut-off valve on the hydraulic tank, as shown in Figure #11.

  1. Install a zip tie around the body of the valve and valve handle to keep the valve in the open position. This is to prevent accidental closure of the valve when the hydraulic system is in operation.

  1. The threaded pipe connections will require a sealant. Use a pipe sealant such as Loctite 565 or equivalent. See Figure #12.

  1. Install the outlet elbow fitting into the hydraulic filter head assembly. See Figure #13.

  1. The threaded pipe connection will require a sealant. Use a pipe sealant such as Loctite 565 or equivalent. See Figure #12.

  1. Install the (2) bolts with associated washers and nuts that hold the filter assembly to the hydraulic tank. See Figure #14.

  1. Install the (4) u-bolt bolts with associated washers and nuts that hold the filter assembly elbows to the hydraulic tank bracket. Do not over-tighten and cause the elbow to bend. See Figure #15.

  1. Install the 1” hydraulic line between the hydraulic filter and the side of the tank at the connections shown. See Figure #16.

Note: 1” hose length will vary based upon a Cummins QSB or B6.7 engine installation. See chart below:

  1. Refill the hydraulic tank to the appropriate level with Dextron III, Allison C4 or equivalent. The fluid level can be verified by the level gauge located on the side of the hydraulic tank. See Figure #14.

  1. Start the truck and inspect the new fittings and hose for any leaks at the connection points. If a leak is observed, turn off the truck and correct the leak.

  1. Re-inspect the fluid level and refill again to the appropriate level, if required.

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

  1. Return vehicle to service.