1999/11/01 Caterpillar

Challenger 65E (6GS),
Challenger 75E (6HS),
Challenger 85E (6JS),
Challenger 95E (6KS) Agricultural Tractors

Description of Change: A battery disconnect switch is available for E series Tillage Tractors. The battery disconnect switch helps minimize battery discharge when the machine is not operated for extended periods.

Adaptable To: The disconnect switch is adaptable to Challenger 65E (6GS), Challenger 75E (6HS), Challenger 85E (6JS), and Challenger 95E (6KS) Agricultural Tractors. The necessary parts and proper procedures to install the electrical disconnect switch are described below.

Show/hide table

Do not weld on machines that are equipped with an ECM when the battery is connected.

1. Fabricate bar (18) to the dimensions shown in Table 2. Make the bar from mild steel to thickness (C).

Illustration 1.
Fabricated Bar (18)

(A) 80.0 mm (3.15 in)

(B) 25.4 mm (1.00 in)

(C) 12.0 mm (.47 in)

(D) 9.0 mm (.35 in)

(E) 9.0 mm (.35 in)

(F) 12.7 mm (.50 in)

Show/hide table

Do not torch or weld on painted areas. The effect of gasses from burned paint is dangerous to the person doing the cutting or welding.

Illustration 2.
Location of Bosses (16), Stud (17), and Bar (18)

(G) 150 ± 5 mm (5.91 ± .20 in)

(H) 237 ± 3 mm (9.33 ± .12 in)

(J) 21 ± 3 mm (.83 ± .12 in)

(K) 515 mm (20.28 in)

(L) 135 ± 5 mm (5.31 ± .20 in)

Illustration 3.
Location of Boss (16), Stud (17), and Bar (18)

(M) 515 ± 3 mm (20.28 ± .12 in)

(N) 290 ± 3 mm (11.42 ± .12 in)

(P) 15 ± 3 mm (.59 ± .12 in)

(Q) 88 ± 3 mm (3.46 ± .12 in)

(R) 66 ± 3 mm (2.60 ± .12 in)

(S) 27.3 ± 2 mm (1.07 ± .08 in)

2. Position bar (18) on top of the right frame rail to the dimensions shown in Illustration 3.

3. Weld bar (18) to the top of the right frame rail using a 3.0 mm (.12 in) fillet weld.

4. Position two bosses (16) on the front right side of the battery box area on the frame to the dimensions shown in Illustration 2 and 3.

5. Weld bosses (16) to the frame.

6. Position third boss (16) on the inside right frame rail to the dimensions shown in Illustration 2.

7. Weld third boss (16) to the frame rail.

8. Position stud (17) on the inside right frame rail to the dimensions shown in Illustration 2 and 3.

9. Weld stud (17) to the frame rail.

10. Clean the areas surrounding the welds on bosses (16) and stud (17) and paint with an appropriate paint.

Illustration 4.
Top view of existing frame

11. Remove cable assembly (T) and nut (U).

Installation Procedure

Illustration 5.
Top view and right side view of frame

1. Install bracket assembly (11) to bar (18) on the frame with two screws (13) and two washers (14).

2. Install disconnect switch (12) to bracket assembly (11). Tighten the mounting nut to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

3. Install cable assembly (1) to stud (17) to the frame with nut (2). Connect the other end of cable assembly (1) to the rear disconnect switch terminal. Tighten the nut to a torque of 8 ± 2 N·m (6 ± 1.5 lb ft).

4. Connect cable assembly (3) to the front disconnect switch terminal. Tighten the nut to a torque of 8 ± 2 N·m (6 ± 1.5 lb ft).

5. Install clip (7) with bolt (9) to secure cable assembly (3) to the frame. (Location A) Install straps (10) to cable assembly (3), as shown.

6. Install clips (7) with bolts (6) and washers (8) on bosses (16) in order to secure cable assembly (3) to the frame. (Location B)

7. Turn the disconnect switch to the open "off" position.

8. Connect cable assembly (3) to the negative battery terminals with bolts (4) and nuts (5). Tighten bolts (4) to a torque of 7.2 ± 1.6 N·m (5.3 ± 1.2 lb ft).

9. Turn the disconnect switch to the closed "on" position and perform a functional check of the system. Refer to the Operation and Maintenance Manual specific to your machine for proper operation.