- Motor Grader:
- 16M (S/N: B9H1-UP; R9H1-UP)
- 24M (S/N: B9K1-UP)
Introduction
This special instruction provides the procedure to install an updated solenoid for the Autolube system for the Motor Graders that are listed above.
Safety
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Personal injury can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. |
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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death. |
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Burn Hazard: Engine components may be hot during and after machine operation. Hot components can cause serious personal injury. Do not contact hot components with bare skin. |
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| NOTICE |
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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death. |
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Required Parts
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Table 1
| Parts Required for the 16M (S/N: B9H1-148) |
| Qty |
Part Number |
Description |
| 1 |
2T-1922 |
Elbow |
| 3 |
3B-6553 |
Elbow |
| 1 |
4L-7412 |
Adapter |
| 1 |
8B-2664 |
Reducer Bushing |
| 2 |
8T-4224 |
Hard Washer |
| 2 |
8T-5391 |
Bolt |
| 1 |
8X-3316 |
Fitting |
| 1 |
189-4395 |
Hose As |
| 1 |
371-2272 |
Solenoid As |
| 1 |
328-9090 |
Permanent Coupling As |
| 1 |
154-0061 |
Permanent Coupling |
| 12 |
122-6887 |
Hose |
| 1 |
124-1891 |
Permanent Coupling |
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Table 2
| Parts Required for the 16M (S/N: B9H149-UP; R9H1-UP) |
| Qty |
Part Number |
Part Description |
| 3 |
3B-6553 |
Elbow |
| 1 |
4L-7412 |
Adapter |
| 1 |
8B-2664 |
Reducer Bushing |
| 2 |
8T-4224 |
Hard Washer |
| 2 |
8T-5391 |
Bolt |
| 1 |
8x-3316 |
Fitting |
| 1 |
189-4395 |
Hose As |
| 1 |
371-2272 |
Solenoid As |
| 1 |
328-9090 |
Permanent Coupling As |
| 1 |
154-0061 |
Permanent Coupling |
| 12 |
122-6887 |
Hose |
| 1 |
124-1891 |
Permanent Coupling |
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Table 3
| Parts Required for the 24M (S/N: B9K1-UP) |
| Qty |
Part Number |
Part Description |
| 1 |
4L-7412 |
Adapter |
| 4 |
4M-0061 |
Bolt |
| 4 |
6V-8189 |
Nut |
| 1 |
8B-2664 |
Reducer Bushing |
| 1 |
8X-3316 |
Fitting |
| 6 |
8T-4224 |
Hard Washer |
| 2 |
8T-5391 |
Bolt |
| 2 |
189-4409 |
Bracket |
| 1 |
371-2272 |
Solenoid As |
Autolube System Operation
The chassis ECM turns on the Autolube solenoid valve after the engine start switch is turned to the ON position. The chassis ECM keeps the Autolube solenoid valve on until the Autolube pressure sensor detects system pressure. Then, the Autolube solenoid valve is turned off. Periodically, the chassis ECM will turn on the Autolube solenoid valve which will stay on until the Autolube pressure sensor detects system pressure. Then, the Autolube solenoid valve is turned off. This cycle continues until the ignition key switch is turned to the OFF position.
The desired pressure is also configurable (Minimum Autolube Pressure). Cold environments will use the higher PSI ranges.
Note: An alarm will sound and Autolube solenoid will shut off if the Autolube pressure sensor does not detect the correct pressure. As the Autolube solenoid valve is turned on, the solenoid makes a click sound. This click sound can be heard or felt. If the solenoid click occurs at the correct time, the electrical system is working properly. Refer to Systems Operation, RENR8462, "Lubrication System" for more information regarding Autolube operation.
Installation Procedure for 16M (S/N: B9H1-148)
Remove Existing Solenoid and Hardware
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| Illustration 1 | g02672432 |
- Disconnect all fittings and hoses from 148-8444 Swivel Tee As (A), 2T-1922 Elbow (1), and 033-2177 Pipe Tee (B) and set aside to reuse.
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| Illustration 2 | g02672456 |
- Remove 304-4266 Hose As (C) and 152-0199 Adapter (D) and discard. Remove 9L-3560 Elbow (E) and retain for reuse.
- Remove 189-4393 Union Adapter (F) and discard.
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| Illustration 3 | g02672536 |
- If needed, remove 5N-4439 Pipe Cap (G). If the 8T-4136 Bolts are threaded into free spinning nuts, reach into reservoir with a back-up wrench and prevent nuts from falling as four 8T-4136 Bolts and four 5P-4116 Hard Washers are removed.
- Remove 304-4277 Solenoid (H) from the 304-4275 Plate . Remove the two 304-4273 Adapters , 033-2177 Pipe Tee , 114-3399 Pipe Nipple , and four 5C-9553 Bolts as an assembly.
Note: Release electrical connector from clip-on reservoir lid when removing Solenoid (H) .
- If 5N-4439 Pipe Cap (G) was removed in Step 4, then reinstall four 8T-4189 Bolts and four 5P-4116 Hard Washers along with nuts in order to seal the holes in the reservoir lid. Reinstall 5N-4439 Pipe Cap (G) .
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| Illustration 4 | g02672619 |
- Remove and retain the 9x-2474 Adapter , 8X-2321 Check Valve Gp , and 290-2688 Gasket as an assembly (J) .
Installation of Updated Hardware
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Table 4
| Required Parts for the 16M (S/N: B9H1-148) |
| Item |
Qty |
Part Number |
Description |
| 1 |
1 |
2T-1922 |
Elbow |
| 2 |
3 |
3B-6553 |
Elbow |
| 3 |
1 |
4L-7412 |
Adapter |
| 4 |
1 |
8B-2664 |
Reducer Bushing |
| 5 |
2 |
8T-4224 |
Hard Washer |
| 6 |
2 |
8T-5391 |
Bolt |
| 7 |
1 |
8X-3316 |
Fitting |
| 8 |
1 |
189-4395 |
Hose As |
| 9 |
1 |
371-2272 |
Solenoid As |
| 10 |
1 |
328-9090 |
Permanent Coupling As |
| 11 |
1 |
154-0061 |
Permanent Coupling |
| 12 |
12 |
122-6887 |
Hose |
| 13 |
1 |
124-1891 |
Permanent Coupling |
Note: All threads should be cleaned and prepped with thread sealant prior to assembly, and all connections adequately tightened to ensure a leak-free installation.
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| Illustration 5 | g02672776 |
- Install Elbow (2) into the pump outlet, oriented as shown in Illustration 5.
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| Illustration 6 | g02680337 |
- Install assembly group 9x-2474 Adapter , 8X-2321 Check Valve Gp , and 290-2688 Gasket (J) that was removed in Step 7 of ""Remove Existing Solenoid and Hardware"
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| Illustration 7 | g02672880 |
- Install Elbow (2) into assembly group (J) angled as shown in Illustration 7.
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| Illustration 8 | g02672911 |
Top View (J) 38 mm (1.500 inch)
(K) 34.3 mm (1.350 inch)
(L) 25.4 mm (1.000 inch)
(M) Hole with diameter of 9.53 mm (0.375 inch)
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- Drill two holes (M) through the reservoir lid in the locations shown in Illustration 8. The holes location is defined by the center point.
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| Illustration 9 | g02672960 |
- Mount 371-2272 Solenoid As (9) on the lid in the position shown in Illustration 9 using two 8T-5391 Bolts (6) and two 8T-4224 Hard Washers (5) .
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| Illustration 10 | g02672982 |
- Install 8B-2664 Reducer Bushing (4) into grease outlet of Solenoid As (9) .
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| Illustration 11 | g02672985 |
- Install 8X-3316 Fitting (7) into grease inlet of Solenoid As (9) .
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| Illustration 12 | g02672999 |
- Install 4L-7412 Adapter (3) into vent block on reservoir lid as shown in Illustration 12.
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| Illustration 13 | g02673017 |
- Install 9L-3560 Elbow (E) that was removed in Step 2 of ""Remove Existing Solenoid and Hardware"
" and position as indicated in Illustration 13.
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| Illustration 14 | g02673041 |
- Install 3B-6553 Elbow (2) into vent outlet of Solenoid As (9) .
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| Illustration 15 | g02673057 |
Hose (12) length (N) 305 mm (12 inch)
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| Illustration 16 | g02673058 |
- Create and install 122-6887 Hose (12) with a 154-0061 Permanent Coupling (11) and a 124-1891 Permanent Coupling (13) between Elbow (E) and Elbow (2)
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| Illustration 17 | g02673117 |
- Install 189-4395 Hose As (8) between Fitting (7) and Elbow (2) .
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| Illustration 18 | g02673137 |
- Reconnect 2T-1922 Elbow (1) from Step 1 to Reducer Bushing (4). Reconnect both Swivel Tee As (A) to Elbow (1) .
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| Illustration 19 | g02673157 |
- Reconnect 8W-3241 Hose As (P) to the top of the first Swivel Tee As (A) .
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| Illustration 20 | g02673176 |
- Reconnect 288-6908 Hose As (T) to the top of the second Swivel Tee As (A) .
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| Illustration 21 | g02673196 |
- Remove the existing 90 degree coupling from 288-6908 Hose As (R) and replace with 328-9090 Permanent Coupling As (10). Reconnect Hose As (R) to Swivel Tee As (A) .
Installation Procedure for 16M (S/N: B9H149-UP) (S/N: R9H1-UP)
Remove Existing Solenoid and Hardware
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| Illustration 22 | g02673298 |
- Disconnect all fittings and hoses from 033-2177 Pipe Tee (A) and set aside to reuse. Also disconnect and retain all fittings and hoses from 194-5336 Swivel (B) .
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| Illustration 23 | g02672456 |
- Remove 304-4266 Hose As (C) and 152-0199 Adapter (D) and discard. Remove 9L-3560 Elbow (E) and retain for reuse.
- Remove 189-4393 Union Adapter (F) and discard.
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| Illustration 24 | g02672536 |
- If needed, remove 5N-4439 Pipe Cap (G). If 8T-4136 Bolts are threaded into free spinning nuts, reach into reservoir with a back-up wrench, and prevent nuts from falling as four 8T-4136 Bolts and four 5P-4116 Hard Washers are removed.
- Remove 304-4277 Solenoid (H) from the 304-4275 Plate . Remove the two 304-4273 Adapters , 033-2177 Pipe Tee , 114-3399 Pipe Nipple , and four 5C-9553 Bolts as an assembly.
Note: Release electrical connector from clip-on reservoir lid when removing Solenoid (H) .
- If 5N-4439 Pipe Cap (G) was removed in Step 4, then reinstall four 8T-4189 Bolts and four 5P-4116 Hard Washers along with nuts in order to seal the holes in the reservoir lid. Reinstall 5N-4439 Pipe Cap (G) .
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| Illustration 25 | g02672619 |
- Remove and retain 9x-2474 Adapter , 8X-2321 Check Valve Gp and 290-2688 Gasket as an assembly (J) .
Installation of Updated Hardware
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Table 5
| Required Parts for the 16M (S/N: B9H149-UP) (S/N: R9H1-UP) |
| Item |
Qty |
Part Number |
Part Description |
| 1 |
3 |
3B-6553 |
Elbow |
| 2 |
1 |
4L-7412 |
Adapter |
| 3 |
1 |
8B-2664 |
Reducer Bushing |
| 4 |
2 |
8T-4224 |
Hard Washer |
| 5 |
2 |
8T-5391 |
Bolt |
| 6 |
1 |
8x-3316 |
Fitting |
| 7 |
1 |
189-4395 |
Hose As |
| 8 |
1 |
371-2272 |
Solenoid As |
| 9 |
1 |
328-9090 |
Permanent Coupling As |
| 10 |
1 |
154-0061 |
Permanent Coupling |
| 11 |
12 |
122-6887 |
Hose |
| 12 |
1 |
124-1891 |
Permanent Coupling |
Note: All threads should be cleaned and prepped with thread sealant prior to assembly, and all connections adequately tightened to ensure a leak-free installation.
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| Illustration 26 | g02673338 |
- Install Elbow (1) into the pump outlet, oriented as shown in Illustration 26.
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| Illustration 27 | g02680337 |
- Install assembly group 9x-2474 Adapter , 8X-2321 Check Valve Gp , and 290-2688 Gasket (J) that was removed in Step 7 of ""Remove Existing Solenoid and Hardware"
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| Illustration 28 | g02673342 |
- Install Elbow (1) into assembly group (J) angled as shown in Illustration 28.
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| Illustration 29 | g02672911 |
Top View (J) 38 mm (1.500 inch)
(K) 34.3 mm (1.350 inch)
(L) 25.4 mm (1.000 inch)
(M) Hole with diameter of 9.53 mm (0.375 inch)
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- Drill two holes (M) through the reservoir lid in the locations shown in Illustration 8. The holes location is defined by the center point.
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| Illustration 30 | g02673347 |
- Mount 371-2272 Solenoid As (8) on the lid in the position shown in Illustration 30 using two 8T-5391 Bolts (5) and two 8T-4224 Hard Washers (4) .
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| Illustration 31 | g02673349 |
- Install 8B-2664 Reducer Bushing (3) into grease outlet of Solenoid As (8) .
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| Illustration 32 | g02674037 |
- Install 8X-3316 Fitting (6) into grease inlet of Solenoid As (8) .
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| Illustration 33 | g02674040 |
- Install 4L-7412 Adapter (2) into vent block on reservoir lid as shown in Illustration 12.
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| Illustration 34 | g02673017 |
- Install 9L-3560 Elbow (E) that was removed in Step 2 of ""Remove Existing Solenoid and Hardware"
" and position as indicated in Illustration 13.
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| Illustration 35 | g02674041 |
- Install 3B-6553 Elbow (1) into vent outlet of Solenoid As (9) .
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| Illustration 36 | g02673057 |
(N) 305 mm (12 inch)
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| Illustration 37 | g02674043 |
- Create and install 122-6887 Hose (11) with a 154-0061 Permanent Coupling (10) and a 124-1891 Permanent Coupling (12) between Elbow (E) and Elbow (1) .
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| Illustration 38 | g02674045 |
- Install 189-4395 Hose As (7) between Fitting (6) and Elbow (1) .
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| Illustration 39 | g02674057 |
- Install the 033-2177 Pipe Tee (A) that was retained from Step 1. Reconnect the fittings that were disconnected from Pipe Tee (A). Refer to Illustration 39.
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| Illustration 40 | g02674078 |
- Install the 194-5336 Swivel (B) that was retained from Step 1. Reconnect the fittings that were disconnected from Swivel (B). Refer to Illustration 40.
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| Illustration 41 | g02674085 |
- Reconnect 8W-4991 Hose As (P) to Swivel (B) .
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| Illustration 42 | g02674098 |
- Remove 90 degree coupling from 311-8413 Hose As (U) and replace with 328-9090 Permanent Coupling As (9) and install group to 287-7292 Tee As (R). Refer to Illustration 42.
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| Illustration 43 | g02674119 |
- Reconnect 8X-5561 Hose As (S) and lengthen hose 200 mm (7.9 inch) to provide proper fit. Reconnect to 197-6355 Elbow As (T) .
Installation Procedure for 24M (S/N: B9K1-UP)
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Table 6
| Required Parts for the 24M (S/N: B9K1-UP) |
| Item |
Qty |
Part Number |
Part Description |
| 1 |
1 |
4L-7412 |
Adapter |
| 2 |
4 |
4M-0061 |
Bolt |
| 3 |
4 |
6V-8189 |
Nut |
| 4 |
1 |
8B-2664 |
Reducer Bushing |
| 5 |
1 |
8X-3316 |
Fitting |
| 6 |
6 |
8T-4224 |
Hard Washer |
| 7 |
2 |
8T-5391 |
Bolt |
| 8 |
2 |
189-4409 |
Bracket |
| 9 |
1 |
371-2272 |
Solenoid As |
Note: All threads should be cleaned and prepped with thread sealant prior to assembly, and all connections adequately tightened to ensure a leak-free installation.
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| Illustration 44 | g02674180 |
Parts to remove |
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| Illustration 45 | g02674181 |
- Remove old solenoid, bracket, lines, and fittings as shown in Illustration 44 and 45. Retain 169-4279 Connector As (A) and 6V-9837 Swivel Tee (B) .
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| Illustration 46 | g02674302 |
- Install 8X-3316 Fitting (5) to 371-2272 Solenoid As (9) with sealant as shown in Illustration 46. The 12.7 mm (0.5 inch) female hole should be facing to the right side of the machine and the other 19 mm (0.75 inch) female hole would be facing to the rear of the machine. Install 8B-2664 Reducer Bushing (4) to the rear hole with sealant.
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| Illustration 47 | g02674416 |
- Install 371-2272 Solenoid As (9) with two 189-4409 Brackets (8), two 8T-5391 Bolts (7), four 4M-0061 Bolts (2), four 6V-8189 Nuts (3), and six 8T-4224 Hard Washers . Connect Fitting (5) to the outlet of the pump with sealant.
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| Illustration 48 | g02674496 |
- Reinstall 169-4279 Connector As (A) that was removed in Step 1. Then reattach 6V-9837 Swivel Tee (B) from the same Step.
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| Illustration 49 | g02674536 |
Former Hose route |
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| Illustration 50 | g02674537 |
Updated Hose route |
- Install 4L-7412 Adapter (1). Connect hoses and rotate fittings as show in Illustrations 49 and 50. Reverse the route of hoses (C) and (D) .
