SFN-20231219B - Install the crankcase breather heater

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TICO Document #: SFN-20231219B (formerly TES 276)

Description of Procedure: Field installation of Cummins Crankcase Breather Heater kit.

Units Affected: SERIAL NUMBERS: 11429, 11430, 11431

Parts Required: KIT, CRANKCASE BREATHER HEATER, CUMMINS B6.7/QSB. 970111 (QTY 1)

Planned Labor: 45 minutes

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, you should employ it during this procedure.

  2. Remove the battery box cover and disconnect the black, ground battery cables. Remove batteries or insulate terminal ends with a non-conductive wrap to prevent inadvertent contact between battery terminals and cables. See Figure 2.

  1. Lock the cab in the upward position by utilizing the cab lift switch and the orange pull handle found on the right-hand side of the unit as seen in Figure 3.

  1. Remove the driver-side panel from the front exterior of the cab and locate the electrical center P/N: 620639, as shown if Figure 4

  1. Locate the “F9” fuse as shown in figure 5a and replace the 20amp fuse with a 30amp provided in the kit as shown in Figure 5b.

  1. Once done replacing fuse, re-install the front driver-side panel with a torque of 15-20 lbs. (Figure 6).

  1. Remove (4) bolts, nuts and (8) washers on the cab step grate with a 9/16” socket wrench and 9/16” wrench. The wrench is used to hold the nuts below the grate in place. Retain hardware, see Figure 7a.

  2. Remove (4) bolts and (4) fender washers on the transmission grate with a 9/16” socket wrench. Retain hardware, see Figure 7b.

  1. Locate the fuel filter on the driver side of the engine. See Figures 8a & 8b.

  1. Locate the L-bracket that is attached to the fuel filter as shown in Figure 9a. Remove this bolt and the washers with a 13mm socket. Discard the hardware. New hardware will be supplied in the kit.

  2. Remove the L-bracket and set to the side to be used again later.

    11A Fuel filter should now appear as seen in Figure 9b.

  1. Install the support plate from the installation kit, ensuring that the triangle is pointed toward the engine. See Figure 10a.

  2. Re-install the previously removed L-bracket back to the fuel filter head, placing it on top of the new plate as seen in Figure 10b.

  1. Secure the mounting plate and L-bracket using the provided M8 hardware. One lock washer and one flat washer will be used for each bolt to a torque specification of 84 in-lbs. The installation order can be seen in Figure 11.

  1. Install the crankcase breather heater relay harness (Figure 12a). Ensure that the wires are pointed to the rear of the truck.

  2. Using the provided 5/16” hardware (2 bolts, 2 washers, 2 nuts), secure the crankcase breather heater relay harness bracket in place, to a torque specification of 18 ft-lbs. The installation order can be seen in Figure 12b

  1. Locate the crankcase breather tube on the driver’s side of the truck.

    17A The tube should be located behind the front wheel as shown in Figure 13.

  1. Clean off the crankcase breather tube with a methyl alcohol-based cleaner to thoroughly remove any dirt and oils that may be on the surface. See Figure 14.

  1. Locate the crankcase breather cylindrical heater from kit, as shown in Figure 15.

  1. Wrap cylindrical heater onto crankcase breather tube with wiring tab pointed upward as shown in Figure 16.

  1. Route cylindrical heater wire along the side of the crankcase breather tube, as shown in Figure 17a.

    21A Ensure that the cylindrical heater wire is not tangled in any other wires or tubing while routing (Figure 17b).

  1. Once you can see the cylindrical heater wire from the top of the frame, lightly pull it up as shown in Figure 18.

  1. Locate the (2) hose clamps and apply them to the top and bottom of the crankcase breather heater, as shown in Figures 19a and 19b.

  2. Use a flathead screwdriver to loosen and tighten the hose clamps

  1. Locate both of the two-way Deutsch connector branches from the crankcase breather heater relay harness. See Figures 20a and 20b.

    25A Only one of these branches is needed for this outfit. Choose either one as they both have the same function.

  1. Unplug the cap from the connector branch that was chosen and plug in the cylindrical breather heater wire as shown in Figure 21.

  1. Neatly and securely zip-tie both two-way Deutsch connector branches. The example is shown in Figure 22.

  1. Place the zip-tied harness inside the frame with the other cables.

  2. Butterfly zip ties the harness onto one of the cables, making sure it is secure, as shown in Figure 23.

  1. Locate the 4-way Deutsch connector end of the crankcase relay harness. See Figure 24.

  1. Feed the 4-way Deutsch end between the side of the frame and the bracket below the PDC box as indicated in Figures 25a and 25b.

  1. Once the 4-way connector is through the passing, locate the tail end of this jumper harness as shown in Figure 26.

  1. Connect the 4-way Deutsch end of the relay harness to the 4-way Deutsch tail end of the T-shaped jumper harness as shown in Figure 27.

  1. Locate the 4-way Deutsch connector on the bottom driver side of the PDC box and remove the Deutsch connector. See Figures 28a and 28b.

  1. Insert the removed Deutsch connector from the PDC box into the Plug end of the T- shape harness.

  2. Insert the Deutsch socket end of the T-shape into the PDC box where you removed the previous Deutsch socket, as shown in Figures 29a and 29b.

  1. Neatly and securely zip-tie any extra length of the crankcase heater relay with the other harnesses that are under the PDC box, as shown in Figure 30.

    Warning: Ensure that no harnesses are touching the steel braided hose in the figure as it gets extremely hot.

  1. Re-install (4) bolts and washers for the transmission grate using a 9/16” socket wrench, see Figure 31a.

  2. Re-install (4) bolts, nuts and (8) washers for the cab step grate using a 9/16” socket wrench and 9/16” wrench to hold the nuts in place below the grate, see Figure 31b.

  1. Reconnect the black ground battery cables (Figure 32)

  2. Apply dielectric grease to all battery terminals in the battery box if none is present.

  1. Unlock the cab from its upward position by utilizing the cab lift switch and lowering the cab.

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

  1. Return vehicle to service.