Procedure To Retrofit A New Brake Valve{4250, 4258, 4266} Caterpillar

Procedure To Retrofit A New Brake Valve{4250, 4258, 4266}

Usage:

70C 2YL

Agricultural Tractors:: Challenger 65C (S/N: 2ZJ1-1964); Challenger 65D (S/N: 2ZJ1965-UP); Challenger 70C (S/N: 2YL1-UP); Challenger 75C (S/N: 4KK1-UP); Challenger 75D (S/N: 5AR1-UP); Challenger 85C (S/N: 9TK1-UP); Challenger 85D (S/N: 4GR1-UP)

Introduction

Reference: Special Instruction, REHS0288, "148-3573 Repair Kit For The 145-9560 Brake Valve".

Reference: Systems Operation/Testing and Adjusting, SENR5265, "Pump Compensator Tests"

Reference: Systems Operation/Testing and Adjusting, SENR1741, "Service Brake System Check"

This Special Instruction provides the information that is necessary in order to retrofit a new brake valve in place of the master cylinder. These instructions are for tractors with the following equipment:

104 L/min (27.5 US gpm) pumps
132 L/min (35 US gpm) pumps
Charge oil lines (earlier models)
Charge oil lines (later models)

Keep this Special Instruction with the tractor after the modifications are made. This information will not be available in any other publication.

Required Parts

Note: The parts that are listed in Table 1 are for all machines. Check all of the tables in order to determine the additional parts that are needed for your particular machine.

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Table 1
Parts List (All Machines)
Part Number	Description	Qty
2P-8421	Adapter	2
3D-2824	O-ring Seal	6
3E-2345	Tee	1
3E-7410	Tee	1
3E-7693	Switch Assembly	1
3J-1907	O-Ring Seal	9
3K-0360	O-Ring Seal	1
4C-4198	Paint (Black)	1
4L-6454	Bolt	7
4S-1936	Clip	2
5K-9090	O-Ring Seal	3
5M-3062	Bolt	2
5P-4272	Union	1
5P-7076	Bolt	3
5P-8167	Bolt	2
5S-7379	Bolt	8
6R-7605	Shuttle Valve	1
6V-0484	Adapter	1
6V-0852	Dust Cap	2
6V-3965	Nipple Assembly	2
6V-8397	O-Ring Seal	7
6V-8398	O-Ring Seal	2
6V-8724	Elbow	4
6V-8775	Tee	1
6V-8801	Nut	2
6V-9008	Elbow	1
6V-9343	Elbow	1
6V-9746	O-Ring Seal	3
6V-9830	Cap	1
7M-8485	O-Ring Seal	3
7X-0507	Washer	3
8T-2502	Bolt	2
8T-4896	Washer	17
8T-8901	Tee	1
9R-2807	Clip	1
9W-0844	Socket	2
102-8808	Kit (DT 3 pin)	1
104-3173	Clamp	2
122-6869	Order this hose by the inch.	1524 mm (60 inch)
124-2116	Fitting	1
124-2130	Fitting	1
131-5007 or 136-4398	Accumulator Assembly	1
145-9560	Brake Valve	1
145-9561	Lever Assembly	1
148-7010	Hose Assembly (Supply Oil)	1
148-7011	Hose Assembly (Signal Oil)	1
148-7012	Support Assembly	1
148-7015	Cover	1
148-7016	Pin	1
148-7017	Spacer	1
148-7018	Plate	1
148-7020	Hose Assembly	1
148-7021	Tube Assembly	1
179-8253	Hose Assembly	1
149-1501	Bracket	2
5P-5623	16 Gauge Wire	254 mm (180 inch)
4C-4774	Grease	1
2L-8076	Ring Terminal ⁽¹⁾	1
9T-9844	Screen	1

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^( 1 )

Package of 20

Order the parts in Table 2 if your machine is equipped with a three-point hitch.

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Table 2
Parts List Machines that are Equipped with a Three-Point Hitch
Part Number	Description	Qty
6V-8781	Face Seal Tee	1
3J-1907	O-Ring Seal	1
6V-8397	O-Ring Seal	2

Order the additional parts in Table 3 for machines that are equipped with a 104 L/min (27.5 US gpm) pump.

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Table 3
104 L/min (27.5 US gpm) Implement Pump
Part Number	Description	Qty	Location
3D-2824	O-Ring Seal	1	Tee
6V-8716	Connector	1	Supply oil line at the brake valve (No. 16 to No. 12)
6V-9746	O-Ring Seal	3	One for the cap and two for the supply line
6V-9832	Cap	1	Hydraulic valve
6V-9961	Fitting (straight)	2	Signal line
6V-9972	Fitting	1	Supply line
7D-7233	Clip	4
9S-0247	XT3 Hose (No. 12)		387 mm (15.25 inch)
2P-5943	XT3 Hose (No. 6)		686 mm (27 inch)
108-7005	Tee	1	Hydraulic valve
123-5240	Fitting	1	Supply oil line

Order the additional parts in Table 4 for machines that are equipped with a 132 L/min (35 US gpm) pump.

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Table 4
132 L/min (35 US gpm) Implement Pump
Part Number	Description	Qty	Location
5K-9090	O-Ring Seal	2	Supply Oil Line
6V-8635	Connector	1	Brake valve (supply line)
148-7008	Hose Assembly	1	Supply Oil Line (No. 16)
148-7009	Hose Assembly	1	Signal Line (No. 6)

Order the additional parts in Table 5 for machines that are equipped with a 6E-4946 Steering Pump .

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Table 5
6E-4946 Steering Pump PIN numbers 2ZJ1-1788, 2YL1-1299, 4KK1-2036, and 9TK1-1553
Part Number	Description	Qty	Location
5K-9090	O-Ring Seal	2	Charge pump and filter
7D-7233	Clip	2	Charge pump (steering)
8T-6684	Elbow (90 degree)	1	Charge pump (steering)
5H-9394	Boss	1	Saddle
5P-2228	Bolt (1/2 inch)	1	Boss
8T-4223	Washer (1/2 inch)	1	Boss
124-2155	Fitting (90 degree)	1	Pump
124-2138	Fitting (45 degree)	1	Filter
122-6892	Hose ( 1981 mm (78 inch)) Order this hose by the inch.		Charge pump (steering)

Order the additional parts in Table 6 for machines that are equipped with a 127-4589 steering pump .

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Table 6
127-4589 Steering Pump PIN numbers 2ZJ1789-UP, 2YL1300-UP, 4KK2037-UP, 9TK1554-UP, 4GR1-UP, and 5AR1-UP
Part Number	Description	Qty	Location
5K-9090	O-Ring Seal	2	Union
6V-8734	Union	1	Steering Oil Cooler
6V-9746	O-Ring Seal	2	Charge pump
7D-7233	Clip	2	ROPS and engine mount
122-6891	Hose ( 1156 mm (45.5 inch)) Order this hose by the inch.		Charge pump to the oil cooler (steering)
124-2121	Fitting	1	Charge pump to the oil cooler (steering)
124-2122	Fitting	1	Charge pump to the oil cooler (steering )

Order the additional parts in Table 7 for the Challenger 65C and Challenger 70C.

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Table 7
Challenger 65C and Challenger 70C
Part Number	Description	Qty	Location
5P-8167	Bolt	1	Throttle cable
8T-4896	Washer	2	Throttle cable
6V-8801	Nut	1	Throttle cable
9L-1775	Bracket ⁽¹⁾	1	Throttle cable

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^( 1 )

This bracket may be removed from the steering control on the early "C" models. If the bracket is being utilized you will need to order the bracket from parts service.

Instructions

Remove the access covers on each side of the machine.
1. Steam clean the machine.
1. Drain the hydraulic tank into a suitable container.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Illustration 1	g00470959

Remove clamp (1) at the air cleaner inlet. Remove clamp (2) at the turbocharger.

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Illustration 2	g00470961

Attach an appropriate lifting device to air cleaner and muffler assembly (3) .

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Illustration 3	g00470965

Remove four bolts and four spacers (4). Remove the muffler and the air cleaner as a unit.

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Illustration 4	g00470971

Attach lifting eye (5) and an appropriate lifting device to right fender assembly (6) .

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Illustration 5	g00470975

Disconnect wiring harness (8) .

Remove four bolts and washers (7) from the rear bracket of the fender.

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Illustration 6	g00470980

Remove six bolts and washers (9) from the front bracket of the fender. Remove the shims (if equipped). Remove the right fender.
Note: The front bracket on the right fender may have four bolts and washers or it may have six bolts and washers. The number of bolts and washers will depend on the model and the age of the machine.

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Illustration 7	g00471008

Disconnect wiring harness (10). Attach an appropriate lifting device to the left fender assembly. Remove four bolts and washers (11). Remove the shims (if equipped).

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Illustration 8	g00471013

Remove four bolts and washers (12). Remove the left fender assembly.
Note: Take note of any shims that are removed in order to reinstall the shims in the proper position.

Install a New Charge Oil Line and Reroute the Steering Line

Remove The Brake Master Cylinder and the Booster

Note: The procedure to remove the master cylinder and the booster is for all machines. Any differences in machines will be noted in the text.

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Illustration 9	g00471033

Remove three bolts, washers (13), and cover (14). Move the throttle control and clip (15) aside for later installation with an additional bracket.
Note: Clip (15) is used on the Challenger 65 and Challenger 70 only.

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Illustration 10	g00471035

Loosen jam nut (16) on the housing for the brake cable (not shown) before removing bolts (17). Loosen the jam nut in order to facilitate adjustment of the brake cable when the new brake valve is installed.

Remove two bolts and washers (17) that hold the housing for the brake cable to the support assembly.

Disconnect the brake cable from lever (18) .

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Illustration 11	g00471038

Disconnect hose assembly (19). This hose assembly is connected to the brake reservoir.
Note: Drain the fluid from the reservoir into a suitable container.

Disconnect tube assemblies (20), (21), and (22).

Remove four bolts and washers (23). Remove the master cylinder booster, the master cylinder and the support as a unit.

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Illustration 12	g00471045

Remove bolts, washers (24) and the clips. Remove brake reservoir (25) and the hose assembly. Discard the hose assembly, the clips, and the reservoir. Reinstall bolts and washers (24) in the front wall of the cab in order to maintain cab pressurization.

6E-4946 Steering Pump (2ZJ1-1788, 2YL1-1299, 4KK1-2036, and 9TK1-1553)

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Illustration 13	g00762730
Right side view (20) 102-1628 Hose (22) 8T-7970 Elbow (23) 102-1622 Hose (24) 102-1626 Tube (AA) Location for the hitch control line before moving (if equipped)

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Illustration 14	g00471070

Remove the bolts and the clips that hold tube assembly (24) and hose assembly (23) in place. Leave bolts, washers, and clips (A) in place on the frame. The bolts, washers, and clips will be used to install the new hose assemblies. Remove elbow (22) from the charge pump. Discard tube assembly (24), hose assembly (23), and elbow (22) .
See Illustrations 15 through 17 and see Steps 2 through 2.e for the information that is needed to connect the hitch control line on machines that are equipped with a three-point hitch.

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Illustration 15	g00763005
Earlier Machines (2ZJ1-334 and 4KK1-342) (AA) Location for the hitch control line before moving (if equipped) (AB) Supply line from makeup valve (AC) Tee (AK) Connection point between tee (AD) and tee (AC)

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Illustration 16	g00763014
Later Machines (2ZJ335-1788, 4KK343-2036, 2YL1-1299, and 9TK1-1553) (AA) Location for the hitch control line before moving (if equipped) (AB) Supply line from makeup valve (AC) Tee (AK) Connection point between tee (AD) and tee (AC)

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Illustration 17	g00764366
Earlier Machines and Later Machines (AD) 6V-8781 Face Seal Tee (AE) 3J-1907 O-Ring Seal (AF) Connection point for supply line from makeup valve (AG) 6V-8397 O-Ring Seal (AH) Connection point for hitch control line (AK) Connection point between tee (AD) and tee (AC)

For machines that are equipped with a three-point hitch, complete the following steps:
Note: See Illustration 15 and 17 for earlier machines. See Illustration 16 and 17 for later machines.
1. Disconnect the hitch control line at location (AA). This line will need to be lengthened.
1. Disconnect supply line (AB) (makeup valve) from tee (AC) .
1. Install tee (AD) to tee (AC) at connection point (AK). Use O-ring seal (AE) .
1. Connect supply line (AB) (makeup valve) to tee (AD) at location (AF). Use O-ring seal (AG) at location (AF) .
1. Connect the hitch control line at location (AH). Use O-ring seal (AG) at location (AH) .
  Note: The hitch control line will need to be lengthened in order to reach location (AH) .

Disconnect hose assembly (20) at the oil filter. Discard the hose assembly.

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Illustration 18	g00471073

Replace elbow (22) with an 8T-6684 Elbow (90 degree) and a 3D-2824 Seal .

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Illustration 19	g00465460
(1) 124-2155 O-Ring Face Seal Fitting (90 degree) (2) 122-6892 Hydraulic Hose (1981 mm (78 inch)) (3) 124-2138 Permanent Coupling (30 degree) (A) Fabricated hose assembly

Fabricate hose assembly (A). Orient coupling (3) 210 degrees counterclockwise from 90 degree fitting (1) .

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Illustration 20	g00471074
(24) 5K-9090 O-Ring Seal

Install O-Ring seal (24) and the 90 degree end of hose assembly (A) to the charge pump at the elbow that was installed in Step 4. Orient the hose to the left side of the machine. Orient the hose slightly forward under the pump. Locate the hose assembly along the frame rail. Fasten the hose assembly to the frame rail to an existing boss with a 7D-7233 Clip . Route the hose across the saddle. Then, route the hose downward over the makeup valve and up to the filter base.

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Illustration 21	g00471075
(B) Left rear engine mount

Install a 5K-9090 O-Ring Seal and connect the hose to the filter base.

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Illustration 22	g00471080
(26) 5H-9394 Boss (1/2 inch) (27) 5P-2228 Bolt (1/2 inch) (28) 8T-4223 Washer (29) 7D-7233 Clip (A) Fabricated hose assembly (B) Left rear engine mount

Weld boss (26) on top of the saddle close to the makeup valve. Use bolt (27), washer (28), and clip (29) to fasten the hose in place. Make sure that hose assembly (A) does not rub or touch any sharp edges.

127-4589 Steering Pump (2ZJ1789-UP, 2YL1300-UP, 4KK2037-UP, 9TK1554-UP, 4GR1-UP, and 5AR1-UP)

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Illustration 23	g00762733
(1) 111-3875 Hose (2) 102-1626 Tube (3) 107-9607 Hose (4) Clip (5) Fitting (AU) Location for the hitch control line before moving (if equipped)

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Illustration 24	g00471329

Disconnect hose assembly (1) at the pump. Remove any clips that hold the hose in place.

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Illustration 25	g00471331

Remove any clips that hold tube assembly (2) in place. Reinstall the clips to the bosses for later use. Remove hose assembly (1) and tube assembly (2). Discard the hose and tube assemblies.
If the machine is equipped with a three-point hitch, disconnect the hitch control line at location (AU). This line will be relocated in Step 7.

Loosen all of the bolts and clips (4) on hose assembly (3) between this end of the hose and the oil cooler.

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Illustration 26	g00471339

Loosen fitting (5) at the oil cooler.

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Illustration 27	g00471341
(6) Clip (7) 6V-8734 Union (8) 5K-9090 O-Ring Seal

Move hose assembly (3) to the left side of the machine. Rotate the hose in order to orient the elbow toward the rear of the machine. Use a 7D-7233 Clip to secure the hose. Mount clip (6) on the hose at the existing boss at the rear of the engine mount.

Use O-Ring seal (8) to install union (7) (not shown) onto hose assembly (3) .
See Illustrations 28 and 29 and Steps 7 through 7.d for the information that is needed to connect the hitch control line on machines that are equipped with a three-point hitch.

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Illustration 28	g00762768
(AU) Location for the hitch control line before moving (if equipped) (AL) Tee (AM) Supply line from makeup valve (AT) Connection point between tee (AN) and tee (AL)

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Illustration 29	g00764376
(AN) 6V-8781 Face Seal Tee (AP) 3J-1907 O-Ring Seal (AQ) Connection point for supply line from makeup valve (AR) 6V-8397 O-Ring Seal (AS) Connection point for hitch control line (AT) Connection point between tee (AN) and tee (AL)

For machines that are equipped with a three-point hitch, use the following steps:
1. Disconnect supply line (AM) (makeup valve) from tee (AL) .
1. Install tee (AN) to tee (AL) at connection point (AT). Use O-ring seal (AP) .
1. Install supply line (AM) (makeup valve) to tee (AN) at location (AQ). Use O-ring seal (AR) at location (AQ) .
1. Connect the hitch control line at location (AS). Use O-ring seal (AR) at location (AS). This line was disconnected in Step 2.
  Note: The hitch control line will need to be lengthened in order to reach location (AS) .

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Illustration 30	g00466500
(1) 124-2122 Permanent Coupling (1 7/16-16) (2) 122-6891 Hydraulic Hose (1155 mm (45.5 inch)) (3) 124-2121 Coupling (1 3/16-12) (B) Fabricated hose assembly (charge pump to the cooler line)

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Illustration 31	g00471393
(7) 6V-8734 Union (8) 5K-9090 O-Ring Seal

Install seal (8) and connect hose assembly (B) to union (7).

Install 6V-9746 O-Ring Seal (9) on the hose end at the charge pump. Connect hose assembly (B) to the charge pump.

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Illustration 32	g00471399

Install 7D-7233 Clip (10) in order to attach hose assembly (B) to the ROPS mounting support. The charge oil line is also clamped to the support at this location. Use the existing bolt and the washer.

Replace Existing Brake Line with a New Brake Line and Hose Assembly

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Illustration 33	g00466908
(1) 6V-8724 Elbow (2) 9U-1184 Tube (3) 7B-1597 Clip (4) 9U-1183 Tube

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Illustration 34	g00471413

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Illustration 35	g00471415
(A) Parking brake caliper (reference point)

Disconnect tube assemblies (2) and (4). Discard these tube assemblies. Keep elbow (1) and clip (3) for installing the new tube and hose assembly for the brake.

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Illustration 36	g00467027
(3) 7B-1597 Clip (5) 6V-8397 O-Ring Seal (6) 148-7021 Tube (7) Existing clip (8) 148-7020 Hose (9) Clip (if equipped)

Install seal (5) and connect tube assembly (6) to elbow (1). Reuse clip (3) at the ROPS post.

Install O-Ring seal (5) and connect hose assembly (8) to tube assembly (6). Install seal (5) into hose assembly (8) .

Remove Existing Lines to the Implement Valve (Supply Oil and Signal Oil)

Machines That are Equipped with Tees for the Hydraulic Power Beyond Circuit

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Illustration 37	g00467138

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Illustration 38	g00471440

Disconnect hose assembly (1). Remove tee fitting (2) in order to gain access to the fitting on supply oil line (3). Hose (1) and fitting (2) will be reinstalled later in the procedure. Disconnect supply oil line (3) at the implement valve.

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Illustration 39	g00467137

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Illustration 40	g00471442

Disconnect signal line (4) from the implement valve. Leave elbow (5) in place for use with the new signal line.

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Illustration 41	g00471446

Disconnect supply oil line (3) and signal line (4) at the implement pump. Discard the lines.

Machines without Tees for the Hydraulic Power Beyond Circuit

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Illustration 42	g00471474

Remove elbow (1) in order to gain access to the elbow for the supply line.

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Illustration 43	g00471513

Remove supply line (3) and the elbow.

Perform Step 2 and Step 3 from ""Machines That are Equipped with Tees for the Hydraulic Power Beyond Circuit" ".

Install New Supply Lines (Implement)

104 L/min (27.5 US gpm) Pump

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Illustration 44	g00471573
(1) 6V-9832 Cap (2) 108-7005 O-Ring Tee (3) 6V-9746 O-Ring Seal (4) 3D-2824 O-Ring Seal

Install cap (1) and O-Ring seal (3) to O-Ring tee (2) .

Install O-Ring tee (2) and O-Ring seal (4) into the port for the supply line. This port is located in the end cover on the implement valve.

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Illustration 45	g00467535
Orient fitting (1) 180 degrees counterclockwise from fitting (3) . (1) 123-5240 Permanent Coupling (No. 12) (30 degree) (2) 9S-0247 Hose (No. 12) (387 mm (15.25 inch)) (3) 6V-9972 Coupling Assembly (No. 12) (long drop 90 degree) (C) Fabricated hose (supply line from the pump to the brake)

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Illustration 46	g00467587
(4) 6V-9961 Fitting (No. 6) (straight) (5) 2P-5943 Hose (No. 6) (686 mm (27 inch)) (D) Fabricated hose (signal line from the pump to the brake)

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Illustration 47	g00471575
(C) Supply line from the pump to the brake valve (D) Signal line from the pump to the brake valve

Install a 6V-9746 O-Ring Seal and connect hose (C) to the implement pump.

Install a 6V-8397 O-Ring Seal and connect hose (D) to the implement pump.

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Illustration 48	g00467771
(6) 5K-9090 O-Ring Seal (7) 148-7010 Hose (8) Existing clips.

Install seal (6) and hose (7) to the implement valve. Use existing clips (8) to keep the hose in place. It may be necessary to reposition the pressure line to the steering motor in order to install the new hose assembly.

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Illustration 49	g00467773
(9) 6V-8397 O-Ring Seal (10) 148-7011 Hose (signal oil) (11) Existing clips

Install O-ring seal (9) and hose assembly (10) to the elbow at the implement valve. Use existing clips (11) to secure the hose.

132 L/min (35 US gpm) Pump

Reference Illustration 48. Install seal (6) and hose (7) to the implement valve. Use existing clips (8) to keep the hose in place. It may be necessary to reposition the pressure line to the steering motor in order to install the new hose assembly.

Reference Illustration 49. Install O-ring seal (9) and hose assembly (10) to the elbow at the implement valve. Use existing clips (11) to secure the hose in place.

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Illustration 50	g00471625
(12) 148-7008 Hose Assembly (supply oil) (13) 148-7009 Hose Assembly (signal oil)

Install a 5K-9090 O-Ring Seal and connect hose assembly (12) to the implement pump.

Install a 6V-8397 O-Ring Seal and connect hose assembly (13) to the implement pump.

Install the Drain Line for the Brake Valve

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Illustration 51	g00468057
(1) 124-2116 Coupling (straight fitting) (2) 122-6869 Hydraulic Hose (approximate measurement 1524 mm (60 inch)) (3) 124-2130 Coupling (45 degree) (E) Fabricated hose assembly

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Illustration 52	g00468229
(4) Plug (5) Screen housing (6) 9T-9844 Screen

Remove plug (4) from screen housing (5). Remove screen (6) from housing (5).
Note: This screen is seldom changed. Install a new screen while the oil is drained from the system. You should install a new screen whenever the oil is changed, as recommended.
Note: Machines that are equipped with the three-point hitch will have a hose assembly instead of a plug. Disconnect the hose assembly. It may be necessary to reposition the suction line for the steering in order to remove the plug. It may also be necessary to reposition the line in order to disconnect the hose assembly.

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Illustration 53	g00471633
(7) 6V-8775 Face Seal Tee (8) 3K-0360 O-Ring Seal

Install seal (8) and tee (7) into the screen housing. Position the tee, as shown. See Illustration 53.
Note: The tee may be positioned differently on early machines ("C" models). Position the tee so that there is clearance with existing hoses.

If the hose from the three-point hitch was disconnected from the screen housing in order to install the tee, connect the hose to the rearward end of the tee.

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Illustration 54	g00471635
(7) 6V-8775 Face Seal Tee (9) 6V-8398 O-Ring Seal (10) 6V-9830 Cap (11) Cable Strap (E) Fabricated hose assembly

If no hose was disconnected from the screen housing, install a 6V-9830 Cap and 6V-8398 O-Ring Seal on the forward end of the tee.

Install a 6V-8398 O-Ring Seal onto the straight fitting of hose assembly (E) .

Connect hose assembly (E) to the tee on the screen housing.

Install cable strap (11), as shown. See Illustration 54.

Route hose assembly (E) across the back of the transmission. Use two 4S-1936 Clips in the same location as the clips for the charge oil line for the steering.

Note: Hose assembly (E) may need to be routed differently on older tractors. If necessary, strap the hose assembly to an existing hose assembly. It may be possible to secure the hose to the ROPS mounting support. Route the hose so that moving parts and points of interference are avoided. Secure the hose in place with clips or cable straps.

Assemble the Brake Valve to the Support Assembly

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Illustration 55	g00471675
(1) 148-7012 Support (2) 5P-7076 Bolt (2) 7X-0507 Hard Washer (3) 145-9560 Brake Valve

Use three bolts and three washers (2) to install brake valve (3) to support (1) .

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Illustration 56	g00471730
(4) 148-7016 Pin (5) 148-7017 Spacer (6) 145-9561 Lever (7) 9R-2807 Clip

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Illustration 57	g00471731

Use pin (4), spacer (5) and clip (7) to install lever assembly (6) to support (1). Lubricate pin (4) with 4C-4774 Water and Temperature Resistant Grease before installation.

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Illustration 58	g00472137
(8) 6V-8716 Seal Connector (104 L/min (27.5 US gpm) pump) (8) 6V-8635 Seal Connector (132 L/min (35 US gpm) pump) (9) 7M-8485 O-Ring Seal (10) 6V-9008 Elbow (11) 7M-8485 O-Ring Seal

Note: Install all of the fittings. Do not tighten the fittings. Tighten a fitting only when the instructions say to tighten the fitting.

On machines that are equipped with the 104 L/min (27.5 US gpm) pump, install the following parts to the brake valve:
- 6V-8716 Seal Connector (8)
- 7M-8485 O-Ring Seal (9)

On machines that are equipped with the 132 L/min (35 US gpm) pump, install the following parts to the brake valve:
- 6V-8635 Seal Connector (8)
- 7M-8485 O-Ring Seal (9)

Install 6V-9008 Elbow (10) and O-ring seal (11) to the brake valve.

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Illustration 59	g00471733
(12) 2P-8421 O-Ring Adapter (13) 3D-2824 O-Ring Seal (14) 3J-1907 O-Ring Seal (15) 3E-7410 O-Ring Tee (16) 7M-8485 O-Ring Seal (17) 6V-8724 Elbow (18) 3J-1907 O-Ring Seal (19) 6V-0484 O-Ring Adapter (20) 3J-1907 O-Ring Seal (21) 6V-3965 Nipple Assembly (22) 6V-0852 Dust Cap

Install O-ring seal (13) and adapter (12) to the brake valve.

Install O-ring seal (14) and O-ring tee (15) into adapter (12) .

Install O-ring seal (16) and elbow (17) into O-ring tee (15) .

Install O-ring seal (18) and adapter (19) into O-ring tee (15) .

Install O-ring seal (20) and nipple assembly (21) into adapter (19).

Install dust cap (22) onto nipple assembly (21) .

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Illustration 60	g00471735
View from the right side of the machine The arrow points toward the front of the machine. (23) 3J-1907 O-Ring Seal (24) 6V-8724 Elbow (two) (25) 3J-1907 O-Ring Seal (26) 6R-7605 Shuttle Valve (27) 3J-1907 O-Ring Seal (28) 5P-4272 Union (29) 3D-2824 O-Ring Seal (30) 6V-9343 Elbow (31) 3D-2824 O-Ring Seal (32) 3E-2345 O-Ring Tee (33) 3J-1907 O-Ring Seal (34) 3E-7693 Pressure Switch

Install O-ring seal (27) and union (28) into the brake valve.

Install O-ring seal (25) and shuttle valve (26) into union (28) .

Install two O-ring seals (23) and two elbows (24) into shuttle valve (26). Orient the elbows toward the inside of the machine.

Install O-ring seal (29) and elbow (30) into the brake valve. Tighten the elbow in the position, as shown. See Illustration 60. This elbow will be difficult to tighten after the brake valve is bolted into position.

Install O-ring seal (31) and O-ring tee (32) into the brake valve. Tighten the tee in the position, as shown. See Illustration 60. This tee will be difficult to tighten after the brake valve is bolted into position.

Install O-ring seal (33) and pressure switch (34) into O-ring tee (32) .

Install the New Brake Valve and Support Assembly

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Illustration 61	g00469005
(1) 10.5 mm (0.4 inch) hole size (A) Dimension 273 mm (10.7 inch) (B) Dimension 170 mm (6.7 inch) (C) Dimension 15 mm (0.59 inch) (D) Dimension 125 mm (4.9 inch)

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Illustration 62	g00472201

Locate four new holes in the mounting support. Drill four 10.5 mm (0.4 inch) holes (1) .

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Illustration 63	g00472202
(2) 4L-6454 Bolt (3) 8T-4896 Hard Washer

Use four bolts (2) and four washers (3). Mount the support assembly and the brake valve as a unit.

The housing (cone) for the brake cable will need to be adjusted. Turn the housing clockwise by approximately three turns. This will allow the eye on the brake cable to line up with the lever assembly.

Use two 8T-2502 Bolts and two 8T-4896 Hard Washers to bolt the housing for the brake cable to the support assembly.

Adjust the brake cable so that the roller in lever assembly (4) is just touching the plunger in the top of the brake valve.

Use a 4L-6454 Bolt and a 8T-4896 Hard Washer to connect the brake cable to lever assembly (4) .

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Illustration 64	g00472203
(5) 148-7015 Cover (6) 5S-7379 Bolt (7) 8T-4896 Hard Washer

Use bolts (6) and washers (7) to install cover (5) .

Use the appropriate O-ring seals and connect all of the lines to the brake valve. Tighten all of the fittings after the lines are properly routed and secured in place.

Tighten all of the fittings on the brake valve that were not previously tightened.

Note: The transmission cooler lines on the engine may need to be repositioned in order to allow clearance for the support assembly on the Challenger 65C and Challenger 70C. Loosen the transmission cooler lines at the flange end on the engine and reposition the lines, if necessary. Tighten the lines after repositioning.

Note: The wiring harness assembly may need to be relocated also in order to provide clearance for the installation of the new support assembly.

Install the Supports for the Accumulator Assembly

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Illustration 65	g00469613
(1) 149-1501 Support (A) Dimension 300 mm (11.8 inch) (B) Dimension 3 mm (0.19 inch) (C) Dimension for weld 5 mm (0.2 inch) (D) Rear engine support (right side) (E) Right side view (F) Top view (A-A) Front view

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Illustration 66	g00472347
(1) 149-1501 Supports

Locate the supports for the accumulator, as shown. See Illustration 65. Line up the front support with the front of the engine mount, as shown. See Illustration 66. Make sure that the brackets are mounted at the specified distance from the edge of the frame, as shown. See View (A-A) of Illustration 65.

Weld the supports in place with 5 mm (0.2 inch) fillets.

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Illustration 67	g00472348
(1) 149-1501 Supports

Paint the supports and the welded area around the supports with 4C-4198 Black Paint .

Install the Accumulator Assembly

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Illustration 68	g00472363
(1) 104-3173 Clip (2) 5P-8167 Bolt (3) 8T-4896 Hard Washer (4) 6V-9746 O-Ring Seal (5) 179-8253 Hose Assembly (6) 3D-2824 O-Ring Seal (7) 8T-8901 O-Ring Port Tee (8) 3D-2824 O-Ring Seal (9) 2P-8421 O-Ring Adapter (10) 3J-1907 O-Ring Seal (11) 6V-3965 Nipple Assembly (12) 6V-0852 Dust Cap (13) 131-5007 Accumulator Assembly or 136-4398 Accumulator Assembly

If the accumulator is not charged, charge the accumulator with nitrogen before installation. Charge the accumulator to 5515 kPa (800 psi).
Note: The charging valve for the accumulator cannot be accessed after the accumulator is installed. Refer to Systems Operation/Testing and Adjusting, SENR1741, "Service Brake System Check" for the correct procedure to charge the accumulator.

Install seal (6) and O-Ring port tee (7) into accumulator (13) .

Install O-ring seal (8) and O-ring adapter (9) into O-ring port tee (7) .

Install O-ring seal (10) and nipple assembly (11) into O-ring adapter (9). Install dust cap (12) onto nipple assembly (11) .

Use two clips (1), two bolts (2), and two washers (3) to install the accumulator to the supports.

Use two O-ring seals (4) to connect hose assembly (5) to the accumulator and to the brake valve.

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Illustration 69	g00472391
(14) 5S-7379 Bolt (15) 8T-4896 Hard Washer (16) 148-7015 Cover

Use four bolts (14) and four washers (15) to install cover (16) .

Install the Clip for the Throttle Cable

Challenger 65C, Challenger 65D and Challlenger 70C (2ZJ1-UP and 2YL1-UP)

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Illustration 70	g00472395
(1) 9L-1775 Bracket (2) 5P-8167 Bolt (3) 8T-4896 Hard Washer (4) 6V-8801 Nut

Install bracket (1) to the cover on the support assembly, as shown. See Illustration 70.
Note: You may remove the bracket from the steering control unit. Some of the early "C" models used the bracket. If the bracket is being used on the steering control unit it will be necessary to order another bracket.

Use the existing clip, bolt (2), washer (3), and nut (4) in order to secure the throttle cable to the support assembly.

Install the Guard for the Accumulator (Rework)

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Illustration 71	g00470145
(1) Crosshatched area (2) Bolt holes (3) Crosshatched area (4) 148-7018 Plate (A) Dimension 114 mm (4.5 inch) (B) Dimension 12 mm (0.47 inch) (C) Dimension 70 mm (2.75 inch)

Trim crosshatched areas (1) and (3) from the plate.

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Illustration 72	g00472600
(4) 148-7018 Plate (5) 5M-3062 Bolt (6) 8T-4896 Hard Washer (7) 4L-6454 Bolt (8) 8T-4896 Washer (9) 6V-8801 Nut

Use two bolts (5) and two washers (6) to bolt plate (4) to the supports.

Drill two 3/8 inch holes in the ROPS support assembly and plate (4) in the approximate locations, as shown. See Illustrations 71 and 72.

Install two bolts (7), four washers (8), and two nuts (9).

Fabricate the Wire Harness and Install the Wire Harness

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Illustration 73	g00470243
(1) 2L-8076 Ring Terminals (No. 10) (2) 5P-5623 16 Gauge wire (2286 mm (90 inch)) (3) Black tape or 5P-6039 Spiral Wrap (4) 102-8808 Connecting Plug Kit (5) 5P-5623 16 Gauge wire (2286 mm (90 inch)) (6) 9W-0844 Connection Socket (not shown)

Fabricate the wire harness, as shown. See Illustration 73. Install the wires into socket (A) and socket (C). Install a plug in socket (B) .

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Illustration 74	g00472657

Connect plug (4) of the wiring harness assembly to the receptacle for the pressure switch.

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Illustration 75	g00472658
(5) Screw (6) Washer (7) Access cover

Remove six screws (5) and washers (6). Remove access cover (7) .

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Illustration 76	g00472659
(8) cable straps

Use cable straps (8) to secure the harness.

Route the wire harness through existing openings into the cab. Connect the two 2L-8076 Ring Terminals to the park brake switch. Connect the wire harness parallel with the two wires on the park brake switch.

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Illustration 77	g00472661
(9) Metal plug

You may need to remove metal plug (9) in order to gain access to the cab on some tractors. Drill a hole in a 5P-9212 Plug for the wire harness. Install this plug in place of the metal plug.

Set the Compensator on the Implement Pump (Challenger 65C (S/N: 2ZJ1-1964), Challenger 70C (S/N: 2YL1-UP), Challenger 75C (S/N: 4KK1-2229), and Challenger 85C (S/N: 9TK1-1764))

Set the compensator in the implement pump to 18960 ± 345 kPa (2750 ± 50 psi).
Refer to Systems Operation/Testing and Adjusting, SENR5265, "Pump Compensator Tests" for the proper procedure for the size of the implement pump on the machine (104 L/min (27.5 US gpm) or 132 L/min (35 US gpm)).

Purge Air From the Brake System

Fill the hydraulic tank.

Attach a line to the test port for the signal line on the implement pump for bleeding the air from the system. Place the other end of the line into the filler pipe for the hydraulic tank.

Actuate the implement lever in order to purge the air from the system. Run oil into the hydraulic tank until the oil is clear of air. Refer to the Testing and Adjusting, SENR1741, "Procedure to Purge Air From the Service Brake Hydraulic System" for more information.

Remove the brake bleeder from the top of the differential case. Install a test port.

Attach a hose to the test port. Place the other end of the hose into the filler pipe for the hydraulic tank.

Run the engine and actuate the brake pedal. Shut the machine off at least two times and pump the brakes in order to allow the accumulator to completely bleed off. Continue this process until the oil is clear of air.

Test the Pressure and the Operation of the Brake System

Refer to Systems Operation/Testing and Adjusting, SENR1741, "Service Brake System Check" for the proper procedure.

Check the pressure at the accumulator. The accumulator should start charging at 12065 ± 345 kPa (1750 ± 50 psi). The accumulator should complete charging at 16892 ± 345 kPa (2450 ± 50 psi).

Check the brake pressure with a hard application of the brake pedal. The pressure should be approximately 7584 ± 345 kPa (1100 ± 50 psi) at the test port out of the modulating valve.