Form No. 3396-283 Rev A Cold Start Kit RT1200 Traction Unit Model No. 131-2859 Installation Instructions WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Installation 1 Preparing to Install the Cold Start Kit No Parts Required Preparing the Machine 1. Move the machine to a level surface, shut off the engine, and remove the key from the key switch. 2.
Figure 2 1. Latch Figure 4 2. Side panel 3. Repeat steps 1 and 2 for the side panel at the other side of the machine. 4. Rotate the BATTERY DISCONNECT switch counterclockwise to the OFF position (Figure 3). 1. Flange-head bolts (5/16 x 1 inch) 3. 6-pin connector (traction-pedal sensor) 2. Traction-pedal assembly 4. 6-socket connector (machine harness) 2. Remove the cable tie securing the traction-pedal harness. 3.
Removing the Transmission Shield 2 1. Remove the 4 flanged locknuts (1/2 inch) from 4 carriage bolts (1/2 x 1-1/2 inch) that secure the transmission shield to the frame of the machine (Figure 6). Assembling the 2-Way Solenoid Valve Parts needed for this procedure: 1 2-way solenoid valve 2 O-ring 2 90º hydraulic fittings 1 Valve-mount plate 2 Carriage bolt (1/4 x 1-3/4 inch) 2 Locknut (1/4 inch) 2 Hose (1/4 x 16-1/4 inch) Procedure 1.
Figure 8 1. 90º hydraulic fitting (port 2) 5. 2-way solenoid valve 2. Hoses (1/4 x 16-1/4 inch) 6. Locknut (1/4 inch) 3. Carriage bolt (1/4 x 1-3/4 inch) 7. 90º hydraulic fitting (port 1) Figure 9 4. Valve-mount plate 1. Front of the machine 2. Hydraulic hose (signal port 6. HIC-fan valve X to LS hydraulic pump) 3. Assemble the straight fittings of the hoses (1/4 x 16-1/4 inch) onto the 90º hydraulic fittings and tighten the fittings by hand (Figure 8). 3 3.
Figure 10 1. Front of the machine 2. LS-pump port 3. Orifice insert 4. 90º hydraulic adapter—long (LS-pump port) 6. Thread the 90º hydraulic adapter into the LS-pump port of the HIC-fan valve (Figure 10). Note: You will tighten the jam nut for the 90º hydraulic adapter, install straight-hydraulic fitting, and install the fan-motor tube in later steps. Figure 11 4 3. 90° hydraulic fitting (T-port) 2.
Installing the Signal Port-X Hose 4. Align the holes in the valve-mount plate for the 2-way solenoid valve, the flow-divider valve, and the left frame channel (Figure 13). 1. Assemble the T-fitting onto the 90º hydraulic adapter at the LS-pump port of the HIC-fan valve (Figure 14). Figure 13 1. Flange locknuts (8 mm) 4. Left frame channel 2. Valve-mount plate (2-way solenoid valve) 5. Washer 3. Flow-divider valve 6. Bolt (8 x 100 mm) 5.
Figure 15 1. Swivel fitting (hydraulic hose—signal port X) Figure 16 2. LS hydraulic pump 1. Front of the machine 2. Hoses (1/4 x 16-1/4 inch)—Port 1 of the 2-way solenoid valve Installing the LS-Pump Hose 3. HIC-fan valve 4. T-fitting 2. Torque the hydraulic fittings (Figure 16) as specified in the following table below: 1. Install the hose that is connected to the 90º hydraulic fitting in port 1 of the 2-way valve to the T fitting at LS-pump port of the HIC-fan valve (Figure 16).
Connecting the Fan-Motor Tube Connecting the Hydraulic Return Hose 1. Install the straight-hydraulic fitting that you removed in step 2 of 3 Installing the Orifice Insert into the HIC-Fan Valve (page 4) and torque the fitting to 47 to 58 N-m (35 to 43 ft-lb). 1. Assemble a T-fitting onto the 90° hydraulic fitting in port T of the flow-divider valve (Figure 19). Figure 17 1. Front of the machine 3. Straight-hydraulic fitting 2. LS-pump port 4. Fan-motor tube Figure 19 2.
Removing the Dash Panel 5 1. Disconnect the 23-pin connector of the dash wiring harness from the 23-socket connector for the machine wiring harness (Figure 21) Installing the Wiring Harness Parts needed for this procedure: 1 Timer relay and mounting tab 1 Self-adhesive cover 1 Wiring harness (cold-start kit) 2 Flange head bolt (#10–32 x 3./4 inch) 2 Flange locknut (#10–32) Preparing the Timer Relay 1.
3. Remove the dash from the console (Figure 22). Connecting the Wiring Harness of the Cold-Start Kit to the Dash Panel 1. At the back of the dash, remove the 6-socket connector of the dash harness from the blade terminal of the starter switch (Figure 23). 2. At the auxiliary-power port, remove the socket terminal for the black (ground) wire of the dash harness (Figure 23). Figure 24 1. Blue wire (dash harness) 3. Piggyback terminal (wiring harness for the cold-start kit) 2.
Routing the Wiring Harness and Installing the Dash Panel 4. Route the leg of the wiring harness with the 2-socket connector down through the grommet of the floor plate (Figure 27). 1. Route the legs of the wiring harness with the 2-socket connector and 5-socket connector down through the console and long the main wiring harness of the machine (Figure 26). Figure 27 G030030 1. Front of the machine 3. Hydraulic pump 2. Wiring harness (cold-start kit) 5.
Drilling the Mounting Holes for the 5-socket Connector and Timer Relay 1. At the left, rear side of the firewall, measure from the floor plate vertically 197 mm (7-3/4 inches) and mark the firewall (Figure 30). Figure 28 1. Wiring harness (cold-start kit) 3. Front of the machine 2. 2-way valve 7. Connect the 2-socket connector of the wiring harness for the cold-start kit onto the 2-pin connector of the 2-way valve. Figure 30 1. Inner side of console to center of hole 103 mm (4-1/16 inches) 6.
4. At the center punch mark, drill a 5 mm (3/16 inch) hole through the firewall (Figure 30). 8. Remove the timer relay from the 5-socket connector, remove the 5-socket connector from the firewall, and centerpunch the mark that you made in step 7. Important: Cover the fuse block to prevent metal shavings from touching the block. 5. Assemble the 5-socket connector to the firewall (Figure 30) with a flange-head bolt (#10-32 x 3/4 inch). 6. Assemble the timer relay to the 5-socket connector (Figure 31). 9.
Installing the Side Panels 1. Rotate the battery disconnect switch to the On position; refer to Figure 3 in Removing the Side Panels and Disconnecting the Battery (page 1). 2. Align the side panel with the machine frame. 3. Align the mounting bolt at the top of the side panel with the hole in the support flange of the hood panel (Figure 35). Figure 34 1. Flange-head bolt (#10-32 x 3/4 inch) 2. Mounting tab (timer relay) 3.
Servicing the Hydraulic System 2. Ensure that the fan for the cooling system starts running 5 seconds after the engine starts. WARNING • If the fan starts earlier that 5 seconds after the engine starts, rotate the slot of the timer clockwise to increase the timer delay (Figure 36). Hydraulic fluid escaping under pressure can penetrate skin and cause injury. If hydraulic fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this type of injury.
