SFN-20231109A_Replace the ignition solenoid with a relay horizontal/vertical

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TICO Document: SFN -20231109A (formerly TES -269)

Complication: Ignition solenoids in gasoline PDC boxes are failing.

Description of Procedure: Replace the ignition solenoid with a relay

Units Affected: All PSI-powered gasoline tractors

Parts Required: KIT –GASOLINE PDC, VERTICAL/HORIZONTAL SOLENOID MOUNT, RELAY REPLACEMENT 970106 (QTY) 1

Planned Labor: 45 mins

Instructions:

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

  1. Remove the battery box cover and disconnect the battery cables (red cables). Remove batteries or insulate terminal ends with non-conductive wrap to prevent inadvertent contact between battery terminals and cables. See Figure 3.

  1. Remove four (4) bolts and washers on the chassis PDC box lid with a 9/16” socket wrench. Retain hardware. See Figure 4.

  1. Remove the PDC box lid and inspect the solenoid in the gasoline PDC box and to determine if the the solenoid is vertical or horizontal.

  • If the solenoid in the gasoline PDC box contains a vertically oriented (up and down) as shown in figure 5a, go to step 5.

  • If the solenoid in the gasoline PDC box is horizontal, go to step 13.

Remove the vertical mount solenoid

  1. Use a 1/2” socket wrench to remove (2) nuts and (2) washers from the larger 5/16”-18 solenoid terminals. Refer to Figure 6a.

  2. Use a 3/8” wrench to remove (2) nuts and (2) washers on the smaller #10-32 solenoid terminals. Refer to Figure 6b.

  1. Remove all wire connections and, if applicable, the external diode from the solenoid.

  1. Use a 9/16” socket wrench to remove one (1) nut and one (1) washer from the circuit breaker. See Figure 7.

  1. Remove the solenoid using a 7/16” socket wrench and a 5/32 Allen key. Retain the hardware and discard the solenoid. See Figures 8a and 8b.

  2. Remove and discard the existing busbar (p/n: 122309) as shown in Figure 8b.

  1. Install wire, p/n: 910939 on the bottom stud of the circuit breaker with the 90-degree terminal on the circuit breaker stud. 

  2. Reinstall the nut and washer as shown in Figure 9.  

New components from the service kit are shown in Figures 10a and 10b.

Go to the next procedure steps, and please advance to step 20.

Remove the Horizontal mount solenoid

  1. To make the removal of the hardware less difficult, you can remove the hardware connected to the ignition wire and ignition bracket (p/n: 910980) with a 7/16” socket wrench and a 5/32” Allen key. See Figure 11c.

  1. Remove bracket p/n: 910890 and the yellow 12GA ignition wire from the 5/16” stud. (Both wires will be reinstalled on the junction box later.). See Figure 12.

  1. Remove the yellow 16GA wire and the two (2) white 16GA wires from the two (2) #10 studs with a 3/8” wrench as shown in Figure 13a. 

    The solenoid should have no connected wires as shown in Figure 13b. 

  1. Remove the hardware attaching the solenoid to bracket p/n: 910893as shown in Figure 14 with a 5/32” Allen key and 7/16” socket wrench. 

  1. Remove hardware attaching bracket (p/n: 910893) to the PDC box closest to the battery busbar (p/n: 910889) as shown in Figure 15. Use a 5/32” Allen key and a 7/16” socket wrench.

    Save this hardware, it will be used later in the procedure.

  1. Rotate the solenoid as shown in Figure 16, to reveal the other hardware attaching bracket p/n:910893 to the PDC box. 

  2. Repeat the 5-10, using the same socket wrench and Allen key to remove hardware. Retain the hardware for future use. 

  1. Remove the Deutsch connector inside the PDC box as shown in Figure 17 using a 5/64” Allen key and a 5/16” socket wrench. Save the Deutsch connector mounting hardware as it will be used later in the procedure. 

  1. Remove the two (2) 1/4” bolts connecting the ground busbar to the PDC box as shown in Figure 18a using a 5/32” Allen key and a 7/16” socket wrench (save the hardware). 

  2. Remove the white 16GA ground wire that was connected to the #10 solenoid stud as shown in Figure 18b. 

The gasoline PDC box should now have everything disconnected as shown in Figure 19. 

  1. Install junction blocks p/n: 920705 onto junction bracket p/n: 920706 with four (4) #10-32 screws p/n: 80218 and four (4) #10 nylon nuts p/n: 800424 as shown in Figures 20a and 20b. 

    Install hardware using a 1/8” Allen key and a 3/8” socket wrench.

  1. Remove the screw shown in Figure 21a with a 7/16” socket wrench and a 5/32” Allen key and reinstall the screw in the location indicated in Figure21b.

  2. Align the holes of the assembled junction bracket where the two (2) holes in the PDC box are without hardware as shown in Figures 21b and 21c.

  1. Use the existing hardware from the previous bracket that was removed in pages 9 (for vertical mount) or pages 16 and 17 (for horizontal mount) to install the assembled junction bracket.

  2. Insert both screws into the bracket holes before tightening all the way to ensure proper fitment of the bracket as shown in Figure 22. 

  1. Remove the screw shown in Figure 23a with a 1/8” Allen key and 3/8” socket wrench.

  2. Use the hole in the metal relay bracket on harness p/n: 621548 to mount the relay onto the PDC box. 

  3. Rotate the relay so that the wires are pointed away from the fuse block as shown in Figure 23b.

  1. Take the Deutsch connector on harness p/n: 620548 and install it in the same orientation as the previous Deutsch connector that was removed as shown in Figure 24. 

  2. Use the existing hardware from the previous Deutsch connector from page 18 to install the new harness Deutsch connector using a 5/64” Allen key and 5/16” socket wrench. 

  1. Install harness p/n: 621548 ground wire (white 16GA with ring terminal) on ground busbar on the same stud as the previous solenoid ground wire. See Figure 25a.

  2. Reinstall left and right 1/4” screws on the ground busbar bracket, as shown in Figure 25b.

    Use a 5/32” Allen key and 7/16” socket wrench to install.  

  1. Take the yellow 12GA ignition wire along with busbar p/n: 910890 and install them onto the junction block as shown in Figure 26. 

    You will need a 9/16” wrench if you are using hardware included with the junction blocks. If you are using the existing solenoid hardware, use a 1/2” wrench.

  1. On harness p/n: 621548 Install the red 8GA ignition cable , with the 1/4” ring terminal, onto the other end of busbar p/n: 910890

  • Use the existing hardware to install the three (3) items together shown in Figure 27.

  • You will need a 5/32” Allen key and 7/16” socket wrench.

  • Hardware includes (1) 1/4”-20 screw p/n: 80219, (2) 1/4” washers p/n: 80311, and (1) 1/4”-20 lock nut p/n: 800419

  1. On harness p/n: 621548 Install the red 8GA battery cable, with the 5/16” ring terminal, onto the junction block with busbar p/n: 910889 as shown in Figure 28. 

    You will need a 9/16” wrench if you are using hardware included with the junction blocks. If you are using the existing solenoid hardware, use a 1/2” wrench.

  1. Double-zip tie the two (2) yellow ignition cables together as well as zip tying all the ground wires together as shown in Figure 29. 

  • Notice the orientation of the two (2) red 8-gauge cables coming from the ignition harness. 

  • This is how the gasoline PDCbox should look at this point in the procedure. 

  1. Zip-tie the two (2) red cables from the relay harness, as shown in Figure 30. 

  • Both cables should be double zip-tied to the battery cable and then double zip-tied to each other.

  • This is how the gasoline PDCbox should look at this point in the procedure. 

  1. Install the updated provided DECAL on the inside of the PDCbox lid over the existing DECAL. See Figure 31.

  • This DECAL shows the schematic of the retrofit of the newly installed relay harness. 

  1. Re-install (4) bolts and washersback onto the chassis PDC box lid using a 9/16” socket wrench. See Figure 32.

  1. Reconnect the battery cables in the battery box. See Figure 33.

  1. If a “lock out, tag out” procedure was employed, it can now be disengaged.  

  1. Start the vehicle to ensure proper function.

  1. Once tested, return vehicle to service.