SFN-20240105A Solenoid valves replacement

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TICO Document #: SFN-20240105A (formerly TES 180)

Description of Procedure: This procedure is for the removal and replacement of the existing solenoid valves with upgraded improved solenoid valves.

Units Affected: N/A

Planned Labor: 1 hour

Parts Required: Solenoid valves for Cab Door - 970006

Parts included in Kit:

  • Jumper Harness – 12 Inches long. 420424 (QTY 2)

  • Solenoid Valves 420423 (QTY 2)

  • Screw #4-40 x 1-1/2” Philips Pan Head Machine 800475 (QTY 8)

  • Washers, Flat #4 Stainless Steel 800476 (QTY 8)

  • Washer, Flat #10 Stainless Steel 80232 (QTY 4)

  • Nylock Nut #4-40 Stainless Steel 800477 (QTY 4)

Solenoid valves replacement REAR AXLE DIFFERENTIAL, REAR INTER-AXLE 970007

  • (1) 420424 Jumper Harness – 12 Inches long.

  • (1) 420423 Solenoid Valves

  • (2) 800475 Screw #4-40 x 1-1/2” Philips Pan Head Machine

  • (4) 800476 Washers, Flat #4 Stainless Steel

  • (2) 80232 Washer, Flat #10 Stainless Steel

  • (2) 800477 Nylock Nut #4-40 Stainless Steel

SOLENOID VALVES REPLACEMENT DOLLY MASTER / MAGNETIC SWEEPER 970008

  • (1) 420426 Jumper Harness – 12 Inches long.

  • (1) 420423 Solenoid Valves

  • (2) 800475 Screw #4-40 x 1-1/2” Philips Pan Head Machine

  • (4) 800476 Washers, Flat #4 Stainless Steel

  • (2) 80232 Washer, Flat #10 Stainless Steel

  • (2) 800477 Nylock Nut #4-40 Stainless Steel

Removal Procedure:

Note: This procedure illustrates how to remove and replace the solenoid valves for the CABIN DOORS, DOLLY MASTER, MAGNETIC SWEEPER, and AXLE DIFFERENTIAL, REAR INTER - AXLE locations. These procedure steps shown are for the replacement of CABIN DOORS but are similar in removal and replacement for all locations.

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 existing (TICO P/N 620531) solenoid valve and harness located under the driver’s left side on the underside of the cab floor by removing all valves attached hardware screws, and plastic tie straps to release airlines and harness attached to the floor cab. See figure 1

  1. Remove all screws and washer hardware on valves to remove existing valves.

  2. Remove all plastic tie straps to release the harness and airlines.

  1. Remove existing air valve elbow connections with airlines from existing valves with an ½ inch wrench, as shown in FIGURE 2

Note: It is not required to remove existing air tubes from elbow connections to remove them from valves.

  1. Installation of valves for CAB DOORS requires installation Kit P/N 970006 for hardware requirements. SEE P/N KIT 970006 (Sheet 1) for detailed parts

  2. Prepare to install up-grade valves (TICO P/N 420423) by installing existing elbow air valve connections with existing air tubes to ports similar to removed valves. See figure 3.

  1. Install new solenoid valves utilizing the provided hardware pertain in each kit. Ensure valves are installed in same locations and all tubing is reconnected as the existing valves are removed. Connect the jumper harness to the new solenoid valve and the other end to the existing cab door harness. SEE FIGURE 4.

Note:

  1. Upgrade valves utilize the same mounting hole as the existing valve, however, an additional hole must be drilled to install additional screws and hardware. Use a ¼ inch drill bit.

  2. Washer, Flat #10 is used to compensate for large existing hole mount.

  1. After all connections are made and the harness is rerouted in the wheel well floor area of the cab, ensure all harnesses and valve air tubing are secured and tie strapped in place.

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

  1. Return vehicle to service.

The following Figures 6, 7, and 8 show the different locations of the valves and harnesses for field installations for CABIN DOORS, DOLLY MASTER, AXLE DIFFERENTIAL LOCK, and MAGNETIC SWEEPER.

Note: This shows the location of valves and harnesses for CABIN DOORS, DOLLY MASTER, AXLE DIFFERENTIAL LOCK, and MAGNETIC SWEEPER.

Note: This shows the valve location under the cabin floor for AXLE DIFFERENTIAL LOCK, REAR INTER AXLE, Driver side forward underside.

Note: This figure shows the valves and air routing for CAB DOORS, DOLLY MASTER, MAGNETIC SWEEPER, and AXLE DIFFERENTIAL LOCK.