SFN-20231007C_Convert an air intake system to the pre-cleaner design

TICO Document #: SFN-20231007C (formerly TES-205)

Description of Procedure: Convert an air intake system to the remote-mounted pre-cleaner design

Units Affected: TICO tractors that are equipped with a Cummins QSB Tier-IV Final or a QSB Tier-III low-mount turbo engine

Parts Required:

• FIELD KIT AIR INTAKE REMOTE PRE-CLEANER CONVERSION 2017 CAB 920450 (QTY 1)

OR

• FIELD KIT, AIR INTAKE, REMOTE PRE-CLEANER CONVERSION, OLD CAB 970012 (QTY 1)

Planned Labor: 8 hours

WARNING: Performing this conversion will inhibit the use of the right-hand cab window as an emergency exit (see Figure #1). Do not proceed if you wish to maintain the function of the emergency exit.

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.

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2. Raise the cab to expose the tractor’s air intake system (see Figure #2).

3. Remove all components and mounting brackets of the tractor’s air intake system from the air filter up to the 4” hump hose (see Figures #3 & #4). Discard all components except for the 4” U-bolt clamp and constant torque clamp. Set clamps aside.

4. Cover exposed air intake connection to prevent any contamination from getting into the engine.

5. Lower the cab.

6. Remove the cab latch handle from the tractor. The handle is secured to the tractor at two locations: bottom of the cab latch bar (see Figure #5) and the air bag support (see Figure #6).

7. Set all components aside.

8. Remove the quarter fender from behind the front right tire (see Figure #7). The fender can be removed by loosening the clamp hardware and sliding off the frame bracket (see Figure #8).

   Note: Do not remove the frame bracket. It will be used to mount the new tire fender.

   

9. Drain coolant from the tractor by first removing the cap from the surge tank (see Figure #9) and then the drain plug located in the lower right-hand corner of the radiator’s rear side (see Figure #10). Make sure a collection pan is underneath the drain port to collect the draining coolant. Dispose of the coolant properly.

10. 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.

11. Remove the mirror stanchion from the cab side fender (see Figure #11). Set the stanchion assembly, clamp plate, and mounting hardware to the side.

    Note: Prior to removing the stanchion, be sure to disconnect any electrical connectors. Remove cable ties and p-clamps securing wires on the chassis side of the harness (see Figure #12).

12. Disconnect all coolant hoses and electrical connections from the surge tank and pull through the pass-thru hole on the cab side fender (see Figure #13).

13. Remove the fender grommet from the pass-thru hole of the cab side fender and set aside.

14. If the tractor is equipped with the 2017 cab, remove the surge tank bracket from the cab side fender (Figure #14). Set the tank, bracket, and mounting hardware to the side.

Note: The surge tank bracket is welded to the cab floor structure on the old cab design and cannot be removed (See Figure #15).

15. Remove the cab side fender from the cab floor (See Figure #16). Discard the existing fender and retain the fender’s mounting hardware.

16. Using drawing #SK0310 (See Figure #17), drill a hole into the right-hand side of the cab bar (See Figure #17a) and a hole into the right-hand side of the chassis frame (See Figure #17b).

17. Using the hole previously drilled into the right-hand side of the frame (see Figure #17b above), mount the air filter bracket (p/n 122931) onto the frame rail (see Figure #18).

18. Mount the new Donaldson PCD100145 air filter (p/n 621056) to the air filter bracket (see Figure #19) such that the outlet is on the bottom side.

    Note: Air flows from the filter to the turbo (See Figure #20).

19. Install the filter outlet intake pipe (p/n 621059) onto the 4” hump hose (see Figure #21) using the constant torque clamp previously removed from the 4” hump hose.

20. Install the rubber elbow (p/n 920312) onto the filter’s outlet and filter outlet intake pipe (see Figure #22) using the constant torque clamps provided.

21. Install the pipe support bracket (p/n 122935) onto the air filter bracket (see Figure #23).

22. Position the previously removed 4” U-bolt clamp onto the support bracket and secure the filter outlet intake pipe (See Figure #24).

23. Using the hole previously drilled into the right-hand side of the cab bar (see Figure #17a above), mount the cab bar support bracket (p/n 122934) to the cab bar (see Figure #25).

24. Install the 5” hump hose (p/n 621060) onto the air filter inlet with the constant torque clamp (p/n 40190-1) provided (see Figure #26).

25. Install the filter inlet intake pipe (p/n 621058) onto the other side of the 5” hump hose using one of the constant torque clamps (p/n 40190-1) provided (see Figure #27).

26. Secure the filter inlet intake pipe to the cab bar support bracket using the 5” U-bolt clamp (p/n 420434) provided (see Figure #28).

27. Position the Donaldson TopSpin pre-cleaner (p/n 621057) onto the filter inlet intake pipe so that the slots on the base are fully covered (see Figure #29).

28. Rotate the pre-cleaner to position the outlet slot away from the operator (see Figure #30).

29. Tighten the clamp provided with the Donaldson pre-cleaner. Torque to 40 in-lbs.

30. Mount the new cab side fender onto the cab floor structure (see Figure #31) using the mounting hardware removed from the original cab side fender. Torque bolts to 80 ft-lbs.

31. Mount the surge tank bracket onto the new cab side fender (new cab design only). Torque bolts to 80 ft-lbs.

32. Install the fender grommet removed from the previous cab side fender onto the new cab side fender.

31. Pull all coolant hoses and electrical connectors up and through the pass-thru hole and reconnect to the surge tank (see Figure #32).

32. Mount the mirror stanchion onto the new cab side fender. Reconnect any electrical connections for the mirrors that were previously disconnected.

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33. Place a “CAUTION: NOT A STEP” decal (p/n 90554-1) onto the top surface of the cab side fender, 6” from rear edge and 1” from the outer edge (see Figure #33).

    

34. Mount the upper steer axle fender support (p/n 122939) to the air filter bracket (see Figure #34).

35. Install the lower steer axle fender support (p/n 122937) to the quarter fender frame bracket (see Figures #35 & #36).

36. Secure the half fender (p/n 122940) rough side up and the upper clamp plate (p/n 122942) to the upper fender support (see Figure #37).

Note: Install bolts with the threads facing upward to protect the tire from damage.

37. Secure the opposite end of the half fender and the lower clamp plate (p/n 122941) to the lower fender support (see Figure #38).

38. Install the mud flap (p/n 12409) and the mud flap bar (p/n 10963-2) to the lower fender support (see Figure #38).

39. Place a 2” plastic plug (p/n 91515) into the open end of the lower fender support (see Figure #38).

40. Reinstall the cab latch handle onto the cab latch bar (see Figure #39) and air bag support bracket (see Figure #40).

41. Fill the surge tank with coolant until the sight glass has been completely filled with fluid (See Figure #41). Reinstall the surge tank cap.

42. 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 (see Figure #42), add more coolant until the sight glass is completely filled.

43. Reinstall the surge tank cap.

44. Remove the emergency exit decal from the passenger window (see Figure #43).

Figure #44 shows a completed installation.

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

48. Return vehicle to service.