SFN-20231221B Install DEF tank

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TICO Document #: SFN-20231221B (Formerly TES 263)

Description of Procedure: There is a shortage of components to produce replacement DEF tank heads. Install a new 11-gallon KUS DEF tank with associated hoses, tank bracket, and tank protection cover.

Units Affected: CUMMINS 2016 ISB-powered tractors that are equipped with a 5-gallon Shaw Development DEF tank (P/N 62433).

Parts Required: Note, DEF tank bracket, P/N 123371

Wheelbase: 116’’ = KIT -DEF SYSTEM REPLACEMENT, SHAW DEV (5 GAL) TO KUS (11 GAL), 2016 ISB, 116" WB (QTY) 1 970095

Wheelbase: 128 = KIT -DEF SYSTEM REPLACEMENT, SHAW DEV (5 GAL) TO KUS (11 GAL), 2016 ISB, 128" WB 970096

Planned Labor: 1 hour

  • Figure 1 shows a Shaw Development 5-gallon DEF tank, hold-down brackets, tank bracket, and tank cover.

  • This procedure will work for tractors equipped with a Shaw Development 5-gallon DEF tank, if equipped.

  • Caution: The installation procedure will require two people due to the weight of the components.

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. Start the truck and ensure that the vehicle is parked on a flat surface; apply parking brake, and chock wheels.

  3. Build air pressure until it reaches 90 psi. Raise the boom via the boom control, see Figure 2a, to allow for easier access to DEF tank bracket hardware inside the frame rail. Refer to Figure 2b.

  4. Turn the truck off.

  1. Grasp the cab lift handle located on the right-hand side of the tractor. Pull it towards the rear of the tractor. Refer to Figure 3a.

  2. Raise the cab using the cab lift switch. Refer to Figure 3b.

  3. Ensure that the cab is raised to its highest position to allow for access to the engine. Refer to Figure 3c.

  1. Use a thick steel bar to prevent the boom from lowering during the installation process. Ensure that the bar is placed behind the risers so that the boom is fully secured. Refer to Figure 4a.

  2. Remove the battery box cover and disconnect the ground battery cables (black cables). Remove batteries or insulate terminal ends with a non-conductive wrap to prevent inadvertent contact between battery terminals and cables. See Figure 4b.

  1. Using a 9/16” socket and 9/16” wrench, remove (2) bolts, (4) washers, and (2) lock nuts from the boom cover grating near the fifth wheel. Refer to Figure 5a.

  2. Remove the boom cover grating from the tractor. Refer to Figure 5b.

  3. Retain the hardware and boom cover grating. It will be reinstalled at the end of this procedure.

  1. Using a 1/2” socket and a 1/2” wrench, remove (4) bolts, (8) washers, and (4) lock nuts from the DEF tank cover and DEF tank hold-down brackets. Refer to Figures 6a and 6b.

  2. Remove and discard the DEF tank cover, DEF tank hold-down brackets, and all the associated hardware. Replacements for all these components are included in these service kits.

  1. The DEF tank and DEF tank bracket should now resemble Figure 7.

  1. The DEF tank design varies depending on the age of the tractor. Two examples shown below in Figure 8.

  2. However, each design has arrows or labels on the DEF tank head to indicate the direction of fluid flow for the coolant and DEF fluid. Refer to Figure 8.

  1. Label the black DEF hoses with a “S” for suction (outward flow). Identification for the return “R” (inward flow) hose is unnecessary, for this service kit will replace this hose with P/N 410376. Reference DEF head shown in Figure 9a.

  2. Label the blue coolant hoses with an “O” for outward flow and “I” for inward flow, as indicated on top of the referenced DEF head shown in Figure 9b.

  1. Disconnect the DEF harness from the DEF tank. Refer to Figure 10a.

  2. Disconnect the (2) black DEF hoses from the DEF tank.

  3. Save the suction (outward flow) hose.

  4. Discard the return (inward flow) hose and remove it from the vehicle, for this hose will be replaced in this service kit with P/N 420494. Refer to Figure 10b.

  5. To prevent the DEF fluid from leaking, raise the hoses and have rags or granular absorbent available to soak up any spilled fluid.

  1. Use (1) pair of hose clamp pliers to clamp each blue coolant hose. See Figure 11a.

  2. Alternatively, use (1) 9.6” long zip tie P/N: 420510, provided with this service kit, to fold each coolant hose over. Refer to Figure 11b.

    • Note: Either method, for preventing coolant from leaking, will suffice. However, ensure that the coolant hoses aren’t damaged if vise grips are used.

  3. Using a 5/16” socket, remove the (2) hose clamps to disconnect the blue coolant hoses from the DEF tank. These clamps can be discarded as replacements are provided with this service kit. Refer to Figure 11c.

  4. When disconnecting the hoses, raise them and have rags or granular absorbent available to soak up any spilled fluid.

  1. Remove and discard the existing DEF tank as a replacement DEF tank is provided with this service kit.

  2. Gently pull the DEF tank harness through the hole in the bracket. Refer to Figure 12.

  1. Using a 3/4” socket and a 3/4” wrench, remove (2) bolts, (4) washers, and (2) lock nuts from the DEF tank bracket.

  2. Discard existing hardware. It will not be used in this installation as replacement hardware is included in this service kit. Refer to Figure 13.

  1. Use a hydraulic cart or jack to support the DEF tank bracket from underneath. Refer to Figure 14.

    • Note: Def tank bracket P/N 123371

    • Note: The images that contain the hydraulic cart are used for representational purposes only. A 10-gallon DEF tank and associated tank bracket are displayed in these images. However, the installation procedure is identical for the removal of the 5-gallon Shaw Development DEF tank.

  1. Using a 3/4” socket and a 3/4” wrench, remove the remaining mounting hardware, (1) bolt, (2) washers, and (1) lock nut, to disconnect the DEF tank bracket from the frame rail.

  2. Discard existing hardware. It will not be used in this installation as replacement hardware is included in this service kit. Refer to Figure 15.

  1. Remove the DEF tank bracket from the tractor. Refer to Figure 16.

  2. This DEF tank bracket can be discarded as a replacement bracket is provided with this service kit.

  1. Loosen the hose clamp on the engine connection for the coolant hose. This hose clamp can be discarded. Refer to Figure 17a.

  2. Cut the double-loop zip ties to remove the entire section of the coolant hose that routes from the DEF tank head to the engine.

  3. Remove this coolant hose from the tractor. Refer to Figure 17b.

    • 40A To prevent coolant from leaking, raise the hoses and have rags or granular absorbent available to soak up any spilled fluid.

  1. The coolant hose and heater control valve can be discarded as the new heater control valve is integrated into the KUS tank DEF head assembly. Figure 18.

  1. Install the new 150” length 5/8” coolant hose onto the engine connection using a 5/16” socket for (1) #10 hose clamp P/N: 420454. Refer to Figure 19a.

  2. Re-route the new coolant hose through the P-clamps that were used to secure the old coolant hose. Take care in preventing dirt and contamination from entering the hose end by taping the opening closed. Refer to Figures 19b and 19c.

  3. If the new coolant hose is too long, cut it to the proper final length.

  1. Route the new coolant hoses through the P-clamp(s) on the L-bracket(s).

    • 45A For 116” wheelbase tractors, refer to Figure 20a.

    • 45A For 128” wheelbase tractors, refer to Figures 20b and 20c.

  1. Install grommet P/N: 20032-2 in the harness pass-through hole of the new DEF tank bracket. Refer to Figure 21.

  1. While supporting the DEF tank bracket and DEF tank stiffener with the cart, use a 3/4” socket and a 3/4” wrench to install (2) 1/2”-13 X 2-1/4" bolts P/N: 82429, (4) 1/2” washers P/N: 85093, and (2) lock nuts P/N: 85027 into the top two slots. Refer to Figure 22.

  1. Using a 3/4” socket and a 3/4” wrench, install (1) 1/2”-13 X 2" bolt P/N: 82418 into the bottom slot, (2) 1/2” washers P/N: 85093, and (1) lock nut P/N: 85027 into the bottom slot. Refer to Figure 23.

  2. Remove the cart from under the DEF tank bracket. The cart will no longer be needed for this installation.

  1. Install DEF tank pad P/N: 420508 into the bottom of the DEF tank bracket with the notch facing the rear of the bracket. • Ensure that the pad is oriented correctly. Refer to Figure 24.

  1. Route the DEF harness back through the hole in the bracket. Refer to Figure 25.

  1. Install the new DEF tank P/N: 621451 into the DEF tank bracket. Refer to Figure 26a.

  2. The sump portion will protrude through the bottom of the mounting bracket. Refer to Figure 26b.

  1. Install (1) #10 hose clamp P/N: 420454 onto each coolant hose. Refer to Figure 27a.

  2. Reconnect the (2) coolant and (2) DEF hoses, taking note of the flow. Refer to Figure 27b.

    • Note: Be sure to match the “S”, “O”, and “I” labels on the coolant and DEF hoses with the correct inward or outward flow connections, so that the fluids flow in the proper directions. For reference, see Figure 27c for the directions of fluid flow on the 11-gallon KUS DEF tank. The return DEF hose “R” is the new hose installed.

    • Be sure to have rags or granular absorbent available to soak up any spilled fluid.

  1. Install the hose and clamp assembly onto the correct coolant hose fitting inlet/outlet. Tighten the hose clamp on each coolant hose using a 5/16” socket. Refer to Figure 28.

    • Note: The hose clamps should be torqued to 35 in. – lbs. maximum. Do not over tighten.

  1. Reconnect the end of the DEF tank head harness to the DEF harness that was routed through the tank bracket. The connector will be behind the DEF tank. Refer to Figure 29.

  1. Reconnect the heater control valve electrical connection. Refer to Figure 30a.

  2. Route the heater control valve connection towards the rear of the bracket and underneath the tractor. Refer to Figure 30b.

  1. Install hose protector shield P/N: 420408 onto the (2) blue coolant hoses where they route underneath the frame rail to prevent chaffing. Refer to Figure 31a.

    • 60A Using (2) 17” zip ties P/N: 420445, secure the hose protector shield onto the coolant hose as shown in Figure 31b.

  2. Cut off excess length of all zip ties installed.

  1. Assemble (2) adjustable retainer brackets using (1) bracket P/N: 123543 and (1) bracket P/N: 123544 per assembly. Ensure the orientation matches Figure 32.

  2. Use a 7/16” socket and 7/16” wrench to install (2) 1/4”-20 X 3/4” LG bolts P/N: 82359, (2) 1/4” lock washers P/N: 85133, and (2) 1/4” flat washers P/N: 85089 for each assembly.

    • Note: Leave an 1/8” gap between the flat washers and the retainer bracket to allow for adjustability when installing the retainer bracket assembly onto the DEF tank bracket.

  1. Prep the underside of both retainer brackets with an alcohol wipe to remove any dirt or grime. Refer to Figure 33a.

  2. Install (1) 6” EPDM extrusion P/N: 920551 onto the underside of each retainer bracket P/N: 123543. Refer to Figure 33b.

  1. Place the (2) retainer brackets onto the DEF tank bracket.

  2. To mount each retainer bracket assembly, use a 1/2” socket and a 1/2” wrench to install (2) 5/16”-18 X 1” bolts P/N: 82371, (4) 5/16” flat washers P/N: 85090, and (2) 5/16”-18 lock nuts P/N: 85024. Refer to Figure 34.

  1. Adjust the top retainer bracket on each retainer bracket assembly to ensure the DEF tank is secure. Refer to Figure 35a.

    • 68A The entire assembly should now resemble Figure 35b.

  1. Install the adjustable DEF tank guard P/N: 200472 onto the outer right-hand side of the retainer bracket. Refer to Figure 36a.

  2. Tighten all hardware used for mounting the retainer brackets and adjustable DEF tank guard.

  3. Ensure there is at least a 1/2” gap between the DEF tank head and the adjustable DEF tank guard. Refer to Figure 36b.

  1. Install (1) 8” edge trim P/N: 920577 onto the front edge of the DEF tank bracket. Refer to Figure 37.

  1. Along the length of the new coolant hose, use (7) 15.5” double loop zip ties P/N: 420446 to secure it to the existing coolant hose. Refer to Figures 38a, 38b, and 38c.

  2. Cut off excess length of all zip ties installed.

    • Note: Not all zip ties are shown in the images. Install the zip ties in locations that will ensure a secure connection.

  1. Use (5) 15.5” double loop zip ties P/N: 420446 to secure the DEF hoses, coolant hoses, and coolant heater control valve electrical connection near the DEF tank.

    • 75A Refer to Figures 39a (116” wheelbase) and 39b (128” wheelbase).

  2. Cut off excess length of all zip ties installed.

    • Note: Not all zip ties are shown in the images. Install the zip ties in locations that will ensure a secure connection.

  1. Prep the top surface of the adjustable DEF tank guard with an alcohol wipe to remove any dirt or grime. Refer to Figure 40a.

  2. Install the no-step decal P/N: 500402 onto the top of the adjustable DEF tank guard. The decal should be installed in the location specified by Figure 40b.

  1. Using a 9/16” socket, install the previously removed (2) bolts, (2) lock washers, and (2) flat washers to mount the boom cover grating. Refer to Figure 41.

  1. Reconnect the ground battery cables. Add dielectric grease to all battery terminals in the battery box if none is present. See Figure 42a.

  2. Fill the new DEF tank with DEF fluid. Refer to Figure 42b.

  1. Grasp the cab lift handle located on the right-hand side of the tractor. Pull it towards the rear of the tractor Refer to Figure 43a.

  2. Lower the cab using the cab lift switch. Refer to Figure 43b.

  3. Ensure that the cab is completely lowered. Refer to Figure 43c.

  1. Start the vehicle to ensure proper function.

  2. Raise boom to remove the steel safety bar. Refer to Figure 44a.

  3. Build air pressure to 90 psi and lower the boom via the boom control. Refer to Figures 44b and 44c.

  4. Dispose of rags or granular absorbent that were used to soak up spilled fluids in the designated locations for hazardous chemicals.

  1. Turn vehicle off.

  1. Check the engine coolant level via the sight glass on the surge tank. If needed, add the specified coolant until the sight glass is filled. Refer to Figure 45. Caution will need to be taken if adding coolant to system.

  1. Remove the wheel chocks.

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

  1. Return vehicle to service.