Bypass Valve Installation for Improved Cold Start{1386, 1387, 1408, 3154, 5057} Caterpillar

Motor Grader:

120M (S/N: B9C1-UP; B9N1-UP; B9W1-UP; D9W1-UP)

12M (S/N: B9F1-UP; B9R1-UP)

140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)

160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

Introduction

M-Series Motor Graders require reduction of parasitic loads for improved starting in cold ambient conditions and in high altitude conditions.

Installation of a hydraulic bypass on the transmission pump and the fan and brake pump allows the engine to run at minimum speed by reducing parasitic loads during starting.

Do not perform any procedures until you read the information that is contained in this manual. Do not order any parts until you have read the information and you understand the information that is contained in this manual.

Safety Section

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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic system. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all work tools to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the work tool in the raised position, the work tool and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

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High voltage may be present. The power source must be disconnected before working on the equipment. Failure to disconnect the power source could result in injury or death. Verify that the equipment is not energized before performing any maintenance. This work must be performed by trained personnel with correct tools and procedures.

Required Parts

Installation Procedure

Bypass Procedure for the Transmission

ReferenceRefer to Table 1 for this procedure.

1. Drop the belly guard and remove the transmission filter.

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Illustration 1	g01698173

2. Assemble O-ring seal (3), elbow (4) and O-ring seal (5). Attach the assembly to the outlet port on the solenoid valve group (7). Assemble O-ring seal (3), O-ring seal (5) and elbow (6). Attach the assembly to the inlet port on the solenoid valve group (7) .

3. Attach the solenoid valve group (7) to the plate assembly. The solenoid must face the front of the machine. Use two bolts (8), four hard washers (9) and two nuts (10) .

4. Attach the plate assembly (1) to the right side of transmission. The assembly needs to be mounted on the transmission case on the guard plate below the electronic control module (ECM).

5. Use the same bolts on the transmission case to mount the plate assembly. Replace the bolts on the guard with three bolts (2) for mounting the plate assembly.

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Illustration 2	g01698780

6. Remove the hose from filter base and loosen filter base.

7. Replace the old elbow assembly on the inlet for the transmission filter with swivel tee (11), two O-ring seals (3) and a O-ring seal (5). Reconnect the inlet tube for the transmission pump to the tee.

8. Attach the tube assembly (12) to the tee on the transmission filter at one end and to the assembly in Step 2 on the inlet port on the solenoid valve group at the other end.

9. Assemble O-ring seal (3), O-ring seal (5) and elbow (6). Attach the assembly to the lube port on the right side of the transmission below the pressure tap.

10. Attach tube assembly (13) to the assembly in Step 9 on the lube port on the transmission at one end and to the assembly in Step 2 on the outlet port on the solenoid valve group at the other end.

11. Attach both tube assemblies to each other. Use two clips (14), a bolt (2), two hard washers (9) and a nut (10) .

Fan and Brake Bypass Procedure for 120M and 12M

ReferenceRefer to Table 2 for this procedure.

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Illustration 3	g01703682

1. Mount the bracket assembly (1) to the transmission case on the left side of the transmission. Use the same two transmission bolts.

2. Assemble O-ring seal (2), O-ring seal (3) and connector (4). Attach assembly to Port "C" on the solenoid valve group (8). Assemble O-ring seal (2), O-ring seal (3) and elbow (5). Attach assembly to Port "P" on the solenoid valve group (8). Assemble O-ring seal (2), O-ring seal (6) and elbow (7). Attach assembly to Port "T" on the solenoid valve group (8) .

3. Mount the solenoid valve group (8) to the assembly in Step 1. Use two washers (9), two bolts (10) and two hard washers (11) .

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Illustration 4	g01712473

4. Attach bracket (12) on the transmission guard on left side of the transmission. Use the existing bolts.

5. Assemble O-ring seal (3) and elbow (13). Attach assembly and nut (14) to bracket (12) at the bend.

6. Assemble O-ring seal (3) and elbow (15). Attach this assembly to the assembly in Step 5.

7. Disconnect the load sensing line (A) from the brake and fan drive pump. Connect the load sensing line (A) to the assembly in Step 5 on the bracket.

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Illustration 5	g01712475

8. Assemble O-ring seal (3), O-ring seal (15) and connector (16). Replace old elbow group (B) on the load sensing port of the fan pump with assembly.

9. Attach tube assembly (18) from the load sensing port on the brake and fan drive pump to the "C" port on the solenoid valve group.

10. Attach tube assembly (19) from the elbow on the bracket to the "P" port on the solenoid valve group.

11. Restrain both the tubes with four clips (20), four hard washers (21), two bolts (22) and two nuts (23) .

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Illustration 6	g01712477

12. Assemble O-ring seal (6), O-ring seal (24) and connector (25). Unplug the case drain port on the brake and fan drive pump and attach the assembly to that port.

13. Attach hose assembly (26) from the case drain port on the brake and fan drive pump to "T" port on the solenoid valve group.

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Illustration 7	g01712479

14. Restrain assembly in Step 13 with the engine oil drain line with clip (27), clip (28), bolt (29), two hard washers (21) and nut (23) .

15. Restrain the assembly in Step 10 with clip (30) and clip (20). Refer to Illustration 7 for the correct routing of the assembly.

Fan and Brake Bypass Procedure for 140M and 160M

ReferenceRefer to Table 3 for this procedure.

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Illustration 8	g01703682
Left side view of transmission

1. Assemble O-ring seal (2), O-ring seal (3) and connector (4). Attach assembly to port "C" on the solenoid valve group (8). Assemble O-ring seal (2), O-ring seal (3) and elbow (5). Attach assembly to port "P" on the solenoid valve group (8). Assemble O-ring seal (2), O-ring seal (6) and elbow (7). Attach assembly to port "T" on the solenoid valve group (8) .

2. Mount the solenoid valve group (8) to the assembly in Step 3 with two washers (9), two bolts (10) and two hard washers (11) .

3. Attach bracket assembly (1) to the transmission case on the left side of the transmission with the same two transmission bolts.

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Illustration 9	g01705196
Left side view of transmission

4. Use the existing bolts to attach bracket (12) to the transmission guard on the left side of the transmission.

5. Assemble O-ring seal (3) and elbow (13). Attach assembly and nut (14) to bracket (12) at the bend.

6. Disconnect the load sensing line (A) from the brake and fan drive pump. Connect the load sensing line to the assembly in Step 5 on the bracket.

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Illustration 10	g01705796
Left side view of transmission

7. Assemble O-ring seal (3), O-ring seal (15) and connector (16). Replace old elbow group (B) on the load sensing port on the fan pump with assembly.

8. Attach tube assembly (17) from the load sensing port on the brake and fan drive pump to the "C" port on the solenoid valve group.

9. Attach tube assembly (18) from the elbow on the bracket to the "P" port on the solenoid valve group.

10. Restrain both the tubes with four clips (19), four washers (20), two bolts (21) and two nuts (22) .

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Illustration 11	g01705934
Left side view of transmission

11. Assemble O-ring seal (6), O-ring seal (23) and connector (24). Unplug the case drain port on the brake and fan drive pump and attach the assembly to the port.

12. Attach hose assembly (25) from the case drain port on the brake and fan drive pump to "T" port on the solenoid valve group.

13. Restrain assembly in Step 12 with the suction tube on the brake and fan drive pump with clip (26),clip (27), bolt (28), two hard washers (20) and nut (22) .

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Illustration 12	g01706413
Left side view of transmission

14. Restrain the engine oil drain line to the suction tube on the brake and fan drive pump with clip (26), clip (29), two hard washers (20), nut (22) and bolt (28) .

15. Restrain the differential lock line to the assembly in Step 12 with clip (30), clip (27), two hard washers (20), bolt (21) and nut (22). Refer to Illustration 12 for the correct routing of the differential lock line.

Transmission Bypass Rework and Fan Bypass Wiring Rework

ReferenceRefer to Table 4 for this procedure.

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Illustration 13	g01703358
Top left side of transmission

1. Assemble O-ring adapter (1) and O-ring seal (2). Install the assembly into the transmission case.

2. Install pressure sensor group (3) into the above assembly with O-ring (4) .

3. Secure sensor wire with two cable straps (5), clip (6), and clip (7) .

4. Receptacle kit (8) will mate to the plug for the sensor. Use three connector pins (9) at the receptacle.

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Illustration 14	g01708104
Top left side of transmission

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Illustration 15	g01712273
View of rear of pressure sensor connector for the transmission

5. Use one socket (11) in order to fabricate Wire (C458-BR) (10). Run the wire (C458-BR) to the transmission ECM J2 (A) to pin 26. Use a connector pin (9) in order to attach the other end of the wire to receptacle kit (8) at pin "C".

6. Splice the wires into the relay circuit for the air conditioning clutch (B). These wires are located on the back bumper of the machine. Run Wire (124-GN) (12) to the pin "A" on the pressure sensor connector on the transmission pump. Run Wire (200-BK) (13) to pin "B" on the pressure sensor connector on the transmission pump.

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Illustration 16	g01708162
Bottom right side of transmission

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Illustration 17	g01712313
Rear view of plug for solenoids

7. Wire (X961-GY) (14) will run from transmission ECM J1 pin 65 to Pin "1" of the solenoid valve group for the transmission.

8. Wire (K927-BU) (15) will run from transmission ECM J1 pin 55 to Pin "2" of the solenoid valve group for the transmission.

   Note: The Wire (K927-BU) (15) is common between the solenoid valve group for the transmission and the solenoid valve group for the brake and fan drive pump so this wire will need to be spliced in order to supply both components.

9. Connect plug kit (16) to the solenoid.

   Note: Use four connector sockets (11) for the solenoid and ECM connections.

10. Secure new harness with clips (6) and cable straps (5) along bracket (D) .

11. Secure the wires to the main harness that runs to the transmission with cable straps (17) .

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Illustration 18	g01708280
Left side of transmission

12. Wire (989-YL) (18) will run from transmission ECM J1 pin 66 to Pin "1" of the solenoid valve group for the brake and fan drive pump.

13. Wire (K927-BU) (15) will run from transmission ECM J1 pin 55 to Pin "2" of the solenoid valve group for the brake and fan drive pump.

    Note: The Wire (K927-BU) (15) is common between the solenoid valve group for the transmission and the solenoid valve group for the brake and fan drive pump so this wire will need to be spliced in order to supply both components.

14. Connect plug kit (16) to the solenoid valve group for the brake and fan drive pump.

    Note: Use four connector sockets (11) for the solenoid and ECM connections.

15. Secure new wiring to the existing harnesses and secure the wires with cable straps (17) .

Procedure to Enable Cold Starting Aid

1. Open Caterpillar Electronic Technician (ET) and select the Transmission/Chassis ECM.

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Illustration 19	g01741893

2. Under the "Service" tab, select the "Configuration" screen.

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Illustration 20	g01741934

3. Select the "Cold Start Aid Configuration".

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Illustration 21	g01741953

4. Double click on the "Cold Engine Parasitic Load Reduction Installation" and set the new value to INSTALLED.

5. When Cat ET displays "ARE SURE YOU WANT TO PROGRAM THIS PARAMETER" click "YES".

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Illustration 22	g01741974

6. The "Cold Start Aid Configuration" screen should now show the "Cold Engine Parasitic Load Reduction Installation" to "INSTALLED".

Procedure to Modify the Existing Guard Group on 12M and 120M Motor Graders

For machines that are equipped with the 299-8000 Engine Compartment Shield Gp , the shields will need to be modified. Follow the instructions below in order to fit the shield group onto the machine after the cold start group has been installed.

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Illustration 23	g01951638
Rear of machine (1) 299-8003 Guard (2) 299-8005 Guard (3) Hose for cold start group

1. Add a notch to the 299-8003 Guard (1) and add a notch to the 299-8005 Guard (2). Refer to Illustration 23 in order to find the correct shape.

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Illustration 24	g01951640
(3) Hose for cold start group (4) 299-8008 Plate As

2. Add a notch on the 299-8008 Plate As (4). Refer to Illustration 24 in order to find the correct shape.

3. Check in order to ensure that a notch exists for the hose on the left hand side of the rear frame. No modification should be necessary.

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Illustration 25	g01951645
View from rear of machine (5) 299-8003 Guard (6) 300-3587 Cover (7) Transmission oil filter

4. Add a notch to the 299-8003 Guard (5) and add a notch to the 300-3587 Cover (6). Refer to Illustration 25 in order to find the correct shape.

Procedure to Modify the Existing Guard Group on 140M and 160M Motor Graders

For machines that are equipped with the 270-6989 Engine Compartment Shield Gp , the shields will need to be modified. Follow the instructions below in order to fit the shield group onto the machine after the cold start group has been installed.

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Illustration 26	g01951638
Rear of machine (1) 297-5876 Guard (2) 297-5878 Guard (3) Hose for cold start group

1. Add a notch to the 297-5876 Guard (1) and add a notch to the 297-5878 Guard (2). Refer to Illustration 26 in order to find the correct shape.

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Illustration 27	g01951640
(3) Hose for cold start group (4) 297-8035 Plate As

2. Add a notch on the 297-8035 Plate As (4). Refer to Illustration 27 in order to find the correct shape.

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Illustration 28	g01951644
View from front left of rear frame (3) Hose for cold start group (5) 297-5875 Guard

3. Add a notch to the 297-5875 Guard (5). Refer to Illustration 28 in order to find the correct shape.

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Illustration 29	g01951645
View from rear of machine (6) 297-5876 Guard (7) 286-9715 Cover (8) Transmission oil filter

4. Add a notch to the 297-5876 Guard (6) and add a notch to the 286-9715 Cover (7). Refer to Illustration 29 in order to find the correct shape.