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AT03081

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COMPONENT CODE D 5

REF NO. AT03081


DATE May. 7, 2003
Page 1 of 11

SUBJECT: INSTALLATION PROCEDURE OF ENGINE STARTABILITY IM-


PROVEMENT KIT AT LOW AMBIENT TEMPERATURE

PURPOSE: To introduce installation procedure for the newly developed parts kit to
improve the engine starting performance under low ambient
temperature environments for use on GD555-3 thru GD675-3 motor
graders

APPLICATION: GD555-3A Motor Graders,Serial Nos 10001 and up 

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 Installation of this
GD555-3C Motor Graders,Serial Nos 10001 and up

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 kit is for option
GD655-3A Motor Graders,Serial Nos 10001 and up  in case of the ma-

GD655-3C Motor Graders,Serial Nos 10001 and up 
chines equipped
with the Tier 1
GD675-3A Motor Graders,Serial Nos 10001 and up 
engines.

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GD675-3C Motor Graders,Serial Nos 10001 and up 

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FAILURE CODE: D521NA

DESCRIPTION: ar
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1. Introduction
This Service News will introduce a newly developed parts kit to temporarily stop the
charge to the braking accumulator in order to improve the engine starting
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performance under low ambient temperature environments for use on the GD555-3A
thru GD675-3C motor graders and the installation procedure thereof.
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Installation procedure for the engine starting performance improving switch


¥ When installing the engine starting performance improving switch, follow the inst-
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ructions given in this Service News.


¥ With this modification, the currently used harness is to be kept in use and necessary
modification is to be made by use of additional harnesses.
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In the meantime, be careful since the connector numbers of the connector of


the current harness and the connector of the additional harness are the same.
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Printed in Japan AT03081


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Page 2 of 11

2. List of parts

Part No. Part Name Q'ty Remarks

23B-06-41640 Wiring harness 1

23B-06-41650 Wiring harness 1

569-06-61970 Relay 1
(569-06-61960) (Relay) (1)

08192-28202 Body 1

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08191-00770 Pulg 8

42C-06-11320 Switch 1

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08018-01426 Sleeve 1

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08033-11440 Tube 1
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AT03081
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3. Modification procedure
1) Removing the steering wheel post cover (Refer to Fig. 1.)
Remove the cover for the steering wheel post on the operator's seat side.

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Remove this cover.

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Fig. 1
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2) Removing the RH console box cover (Refer to Fig. 2.)


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Remove the transmission controller cover being installed to the RH console box.
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Remove the transmission controller cover together


with the controller itself.
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RH console box

Fig. 2

AT03081
Page 4 of 11

3) Changing the neutral relay (Refer to Fig. 3.)


Disconnect the connector No. BR12 and replace the neutral relay with the new
relay. (The relay to be replaced is the one to which the connector No. BR12 is being
connected.)
Leave the disconnected connector as it is.
k Part No. of the new relay to install : 569-06-61970

Replace the neutral relay with the new


relay.
(Part No. 569-06-61970)
(Connector No. BR12)

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Fig. 3
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4) Disconnecting the harness (Refer to Fig. 4.)


Disconnect the connectors No. B4 and No. BR11 being positioned as per the
drawing below.
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(The connector No. BR12 has already been disconnected as per the above section 3).
Disconnecting connectors:
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No. BR11 and No. BR12


(Rear side)
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Disconnecting
connector: No. B4
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Fig. 4

AT03081
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5) Installing the additional harness (RH console box) (Refer to Fig. 5.)
First, pass the connectors No. BR12 and No. BR11 of the new harness into the RH
console box through the lower side of the operator's stand.
Connect these connectors (BR12 and BR11) of this new harness to the relay from
which these connectors have been disconnected as per the above section 4).
After that, connect the connector No. B4 of the new harness to the corresponding
connector (B4) which has been disconnected as per the above section 4) before
fastening to the connector bracket.

k Part No. of the installing additional harness : 23B-06-41640 (hatched section)

k Blind plug for the current connector No. B4

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k 08192-28202 BODY × 1 pc.

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k 08191-00770 PLUG × 8 pcs.

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Connect the connector No. BR12 to the
ar newly installed neutral relay and connect
the connector No. BR11 to the parking
brake relay, respectively. (Rear side)
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Fasten the harness at


appropriate positions by
use of the tie wrap.
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Replace the connector No. B4


of the current harness with this
connector.
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Install the blinding connector


to the current connector No.
B4.
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Fig. 5

AT03081
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6) Installation of the harness and the switch (inside the steering wheel post)
(Refer to Fig. 6.)
Removing the blinding cap, install the new switch.
(Although there are two mounting holes, use the steering wheel side hole.)

Installing the harness to the switch (by the connector No. FP19), fasten the harness
along the currently installed harness using the tie wrap.

k Part No. of the harness to install : 23B-06-41650 (hatched section)

Connect the harness to the connector No. FP20 of the harness which has been
installed as per the above section 5).

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Engine starting performance
improving switch

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Part No. : 42C-06-11320
Connector No. FP19

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Fasten the harness at
appropriate positions
by use of the tie wrap.
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Added connector B4
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Connector No. FP20


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Fig. 6

AT03081
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7) Connecting the power supply to the neutral relay (Refer to Fig. 7.)
Connect the single lead (red/white) harness coming out from the new harness (23B-
06-41640) to the No. 2 terminal of the connector No. T11 (red/white).
(The connecting position can be optional.)
Regarding the connecting method, adopt either soldering or caulking by use of
crimp sleeve. (Regarding the using method of the crimp sleeve, refer to the
Attached Sheet 1.)

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Position of the power supply
terminal (No. 2 : red/white)
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Connector No. T11


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Operator's stand
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When viewed from the RH side


of the machine

Fig. 7

AT03081
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8) Connecting the solenoid valve (Refer to Fig. 8.)


Install the new harness as it connects both ends of the existing connector (B20) at
the solenoid valve and the existing harness side.

Fasten the harness along the harness


being connected to the solenoid valve
at appropriate positions by use of the
tie wraps.

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Connect the connector No. B20A of

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the new harness to the existing
connector No. B20
and connect the connector No.
B20B of the new harness to the

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solenoid valve side.

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Engine starting
performance improving
solenoid valve
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Fig. 8
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9) Restoration of removed covers


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Restore the removed covers to their original positions in the reversed procedure to
the procedure per Section 1) and Section 2).

AT03081
Page 9 of 11

4. Operation checks
1) Check that the speed shift lever is being set to the parking position.
2) Turn the starting switch key to the ON position and press the engine starting
performance improving switch.
3) Check that the engine starting performance improving solenoid valve located at the
LH side of the bottom of the operator's stand operates when the engine starting
performance improving switch is pressed.
k For safety, the engine starting performance improving solenoid valve
does not operate when the speed shift lever is being set to any other
positions than the parking position.

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5. Operation method

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1) Check that the speed shift lever is being set to the parking position.
2) Set the fuel flow adjust lever to the half-open position.
3) While pressing the engine starting performance improving switch, turn the starting

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switch key to the "START" position to start the engine.
4) When the engine revolution rises to a degree of a half revolution rate, depress the

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accelerator pedal for several times.
At this time if the engine revolution follows the movement of the accelerator pedal,
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move your hand off the engine starting performance improving switch.
The switch will return to the "OFF" position automatically.
5) After carrying out warming up operation for about 5 minutes, set the fuel flow
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adjust lever to the "Lo-Idling" position.
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AT03081
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Attached Sheet 1: Using method of the crimp sleeve

1 Peel off the insulation cover of the wire with care not to damage the
internal lead. (For about 10 mm per side)
At the same time, cut the wire into two pieces.

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2 Peel off the insulation cover of the connecting wire and, aligning the
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uninsulated section of the lead and the uninsulated section of the lead
of the wire as per the above Section 1, set the crimp sleeve as shown
below.
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Crimp sleeve
08018-01426
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3 After swaging the crimp sleeve by use of the swaging tool, cover the
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caulked crimp sleeve by the heat shrink tube and heat the tube to let it
shrink as the water proofing treatment.
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Heat shrink tube


08033-11440

AT03081
Page 11 of 11

Circuit diagram

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Engine starting performance


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improving switch
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Engine starting
performance
improving
solenoid valve

AT03081

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