Usage:
120G, 130G, 140G, 12G, 14G, 16G Motor Graders
The Electronic Monitoring System (EMS) on the above motor graders constantly checks coolant temperature, engine oil pressure, brake air pressure, hydraulic oil temperature, alternator output and fuel level. If problems are found, the EMS gives the operator a warning.
Some customers want a coolant flow circuit added to the EMS. A coolant flow circuit can be added to the EMS if the procedure which follows is used.
1. Remove the two S1617 Bolts, the two 9M1974 Washers, the 4N3840 Cover and the 4N3841 Gasket from the transmission oil cooler bonnet. See Illustration 1.
Illustration 1. Location of parts.
2. Check the condition of the 4N3841 Gasket. If necessary, get a new gasket. Install the 4N3841 Gasket and a 6N6960 Coolant Flow Switch Assembly in the transmission oil cooler bonnet. See Illustration 2 for the correct orientation of the switch to the direction of the coolant flow.
Use two 2B2695 Bolts and the washers removed in Step 1 to fasten the switch to the transmission oil cooler bonnet.
3. Remove the tape from the wires at the 3T345 Endbell Assembly (right-angle connector). Cut the black/white stripe wire that goes to the No. 12 socket. Remove approximately 12.7 mm (.50") of insulation from both of the cut ends.
Illustration 2. 6N6960 Coolant Flow Switch Assembly.
NOTE: If desired, this wire can be cut at a location nearer to the 6N6960 Coolant Flow Switch Assembly.
4. Cut two necessary lengths of 5P5623 Wire (16 gauge) to connect the contacts on the flow switch to the ends of the cut black/white wire.
5. Install a crimp-type ring terminal on one end of each of the lengths of wire.
6. Fasten the terminal end of one of the new wires to the input contact on the flow switch. See Illustration 2. Use an 8S4626 Splice to connect the other end of the wire to the end of the black/white wire that goes to the right-angle connector. See Illustration 3.
Illustration 3. Location of the black/white wire that must be cut and the connections that must be made.
7. Fasten the terminal end of the other new wire to the ground contact on the flow switch. See Illustration 2. Use an 8S4626 Splice to connect the other end of the wire to the end of the black/white wire which goes into the wiring harness. See Illustration 3.
NOTE: Connect the ground wire to the harness. Do not connect the wire to the frame for a ground.
8. Put electrical tape around the splices. Put tape around all of the wires at the right-angle connector, and use plastic ties to fasten the new wires to the harness.
9. Put the identification "Coolant Flow" by the lightemitting diode (LED) on the EMS front cover, below "Coolant Temperature" and above "Engine Oil Pressure."
To check the operation of the EMS, use the "EMS Functional Test" procedure given on page 2 of the "Operation Supplement, G Series Motor Graders, Electronic Monitoring System (EMS) Panel," Form No. SEBU5873.
The coolant flow circuit gives a "Level Three" warning. The fault light, the panel light and the warning horn will be activated by the EMS if the coolant flow stops.
If a "Level Three" warning is activated, immediately stop the machine and shut off the engine. Have the necessary repairs made before the engine is started.