SFN-20231012A_Replace rubber coolant hoses with silicone coolant hoses

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TICO Document #: SFN-20231012A (formerly TES-220)

Complication: The 3/8” surge tank coolant hoses are showing signs of environmental degradation, possibly due to ultraviolet damage to the hose.

Description of Procedure: Replace the 3/8” and 1” rubber coolant hoses with a silicone coolant hoses.

Units Affected: S/N 5639-5968

Parts Required: Kit – HOSE, SILICONE, RADIATOR SURGE TANK 970031 (QTY) 1

Planned Labor: 1 hour

Instructions:

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

  2. Locate the radiator surge tank above the right-hand fender, next to the cab. See Figure #1.

  1. Drain coolant from the tractor by first removing the cap from the surge tank (Figure #2) and then the drain plug located in the lower right-hand corner of the radiator’s rear side (Figure #3). Make sure a collection pan is underneath the drain port to collect the draining coolant. Dispose of the coolant properly.

  1. Once the system has been completely drained, reinstall the drain plug and set the surge tank cap aside. It will be installed later in the procedure.

Replace the 3/8” hose on the forward side of the radiator surge tank to the side of the engine.

  1. Remove all the cable ties securing the hose.

  2. Use the existing rubber hose to measure for the length of silicone hose required.

  3. Use the provided hose clamps to secure the hose to the connection ports. Torque clamp to 35 in-lbs. See Figures #4 & #5.


Replace the 3/8” hose from the rear side of the radiator surge tank to the top of the radiator.

  1. Remove all the cable ties securing the hose.

  2. Use the existing rubber hose to measure for the length of the silicone hose required.

  3. Use the provided hose clamps to secure the hose to the connection ports. Torque clamp to 35 in-lbs. See Figures #6 & #7.

Replace the 1” hose from the bottom radiator surge tank to the side of the right-hand frame rail.

  1. Remove all the cable ties securing the hose.

  2. Use the existing rubber hose to measure the length of the silicone hose required.

  3. Use the provided hose clamps to secure the hose to the connection ports. Torque clamp to 35 in-lbs. See Figures #8 & #9.

Replace the 1” hose from the inside of the right-hand frame rail to the engine.

  1. Remove all the cable ties securing the hose.

  2. Use the existing rubber hose to measure for the length of silicone hose required.

  3. Use the provided hose clamps to secure the hose the connection ports. Torque clamp to 35 in-lbs. See Figures #10 & #11.

As a preventative measure, replace the 1” hose from the air inlet pipe to the engine on the left-hand side of the truck.

  1. Remove all the cable ties securing the hose.

  2. Use the existing rubber hose to measure for the length of silicone hose required.

  3. Use the provided hose clamps to secure the hose the connection ports. Torque clamp to 35 in-lbs. See Figures #12 & #13.

  1. Fill the surge tank with coolant until the sight glass has been completely filled with fluid (Figure #14). Reinstall the surge tank cap.

  2. Run the truck at idle for several minutes. Loosen the surge tank cap to relieve the pressure and observe the fluid level in the tank through the sight glass. If the fluid level has dropped below the sight glass (Figure #15), add more coolant until the sight glass is completely filled.

  1. Reinstall the surge tank cap.

  1. Inspect the newly installed hoses for any leaks at the connection points. If a leak is observed, turn off the truck and correct the leak(s). See Figure #16.

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

  1. Return vehicle to service.