Powering and Interfacing to Agricultural Implement Electronic Systems{1408, 6304, 6330, 6331, 7300, 7332, 7490} Caterpillar

Agricultural Tractors:

Challenger 35 (PIN: 8DN1-UP; 8RD1-UP; ADK1-UP)

Challenger 45 (PIN: 1DR1-UP; ABF1-UP; 3BK1-UP)

Challenger 55 (PIN: 7DM1-UP; 6NN1-UP; AEN1-UP)

Challenger 65 (PIN: 7YC1-1899)

Challenger 65B (PIN: 7YC1900-UP)

Challenger 65C (PIN: 2ZJ1-1964)

Challenger 65D (PIN: 2ZJ1965-UP)

Challenger 70C (PIN: 2YL1-UP)

Challenger 75 (PIN: 4CJ1-UP)

Challenger 75C (PIN: 4KK1-UP)

Challenger 75D (PIN: 5AR1-UP)

Challenger 85C (PIN: 9TK1-UP)

Challenger 85D (PIN: 4GR1-UP)

Challenger 65E (PIN: 6GS1-UP)

Challenger 75E (PIN: 6HS1-UP)

Challenger 85E (PIN: 6JS1-UP)

Challenger 95E (PIN: 6KS1-UP)

Introduction

This special instruction contains the general guidelines and the procedures that are necessary to interface aftermarket electronics to your machine. Your installation may vary.

This special instruction contains the information that is necessary to interface the implement electronics with the machine. This special instruction also provides the different methods of modifying and connecting the implement electronics.

Many agricultural implements are designed to use the electronic systems that are for the machine for power, ground speed signals, and lighting. Three electronic interfaces that are widely used by the agriculture industry are seven-pin connectors, four-pin connectors for the ground speed signal, and implement status switches.

The configurations of agricultural equipment will vary due to the differences between North American and European standards. Some of the differences are related to roading the machine and pulling a trailer.

Wiring Connections From Machine to Implement

Seven-Pin Trailer Connector

Illustration 1	g00684461
Seven-pin trailer connector

Table 1

Functions for Seven-Pin Connector
Pin Number	Challenger 35 (PIN: 8DN), Challenger 45 (PIN: 1DR), and Challenger 55 (PIN: 7DM)	Challenger 65 (PIN: 7YC), Challenger 65B (PIN: 7YC), and Challenger 75 (PIN: 4CJ)	Challenger 65C (PIN: 2ZJ1-1964), Challenger 65D (PIN: 2ZJ1965-UP), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK), Challenger 85C (PIN: 9TK), Challenger 75D (PIN: 5AR), and Challenger 85D (PIN: 4GR)	Challenger 35 (PIN: ABF; ADK), Challenger 45 (PIN: ABF; 3BK), Challenger 55 (PIN: 6NN; AEN), Challenger 65E (PIN: 6GS), Challenger 75E (PIN: 6HS), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)
1	Ground	Ground	Ground	Ground
2	Left parking lights	Auxiliary power	The pin is not used.	Flood lights
3	Left turn signal	Auxiliary power	The pin is not used.	Flood lights
4	Stop lights	Stop lights	Stop lights	Auxiliary 1
5	Right turn signal	Right turn signal	Right turn signal	Right turn signal
6	Right parking lights	Tail lights	Tail lights	Tail lights
7	Work lights	Auxiliary power	The pin is not used.	Auxiliary 2

The seven-pin connector is used primarily for the following three purposes:

• Power for implement lighting for operating a machine on public roads

• Power for marking systems for operating a machine on public roads

• Power for implement electrical devices during field operations

All Challenger Agricultural Tractors provide connections for use in lighting and marking of trailers on public roads. The turn signal lights are compatible between the models. However, some functions have changed between models. Pin (2), Pin (4), and Pin (7) can have different functions between Challenger models. Pin (2), Pin (4), and Pin (7) can also have different functions between manufacturers.

Some implements use these "auxiliary" circuits as switched power or unswitched power for the implements. Other implements may use the "auxiliary" circuits for brake lights or flood lamps. You may need to modify these circuits in order to provide the functions that are needed for the implement.

Challenger 35 (PIN: 8DN), Challenger 45 (PIN: 1DR), and Challenger 55 (PIN: 7DM)

Illustration 2	g00684527
Switched power and unswitched power for implement systems (earlier Row Crop Tractors) (D) Unswitched auxiliary power (8 amp) (E) Grommet below rear window

Note: See the section with the title ""Access to Cab for Wiring of OEM Electronics to the Implement" " for more information about grommet (E).

Table 2

Required Parts for Illustrations 2, 3, and 4
Item	Part Number	Description	Misc Information
8	121-6716	Auxiliary Power Connecting Kit	This kit Includes the harness. This kit includes Item (9) through Item (12).
9	126-8295	Plug Connector
10	126-8296	Connector Pin (12-16 AWG)	This pin is for 8 amp unswitched auxiliary power. Cavity 2
11	126-8297	Connector Pin (8-10 AWG)	This pin is for 30 amp switched power (ground pin). Cavity 1 and 3
12	038-7063	Cable Clamp (stress relief)	This part is not serviced.
13	9G-8887	Receptacle Connector (seven-pin connector for machine)	The pins are designed to be solid.
14	112-8870	Trailer Socket Assembly (seven-pin connector for machine)	The pins are designed to be split pin.
15	102-4090	Connector Plug (seven-pin connector for trailer)	The connector for the trailer is part of the trailer harness.
16	9R-7942	Plug (two wire)	This plug is for an 8 amp unswitched auxiliary power.
17	7N-7978	Terminal (10-12 AWG)	This terminal is for attaching the wire to the terminal screw.
A	122-4424	Receptacle Connector	This connector is located in the machine's right hand console.
B	122-4393	Terminal	8 amp unswitched power Cavity 2
C	122-4392	Terminal	30 amp switched power (ground pin) Cavity 1 and 3

The earlier models for Row Crop Tractors have the following functions for the pins:

• Pin (2) is for left parking lights.

• Pin (4) is for stop lights.

• Pin (7) is for work lights.

See Illustration 1 and Table 1 for information about Pin (2), Pin (4), and Pin (7) .

If switched power is only needed for Pin (7), operate the machine while the work lights are turned on. This will give you switched power at Pin (7). Working with the work lights ON eliminates the need for an additional harness. Pin (7) has power when the work lights are switched ON. Running the machine with the work lights ON may be acceptable for customers that occasionally have the need for power for the implement on Pin (7) .

If both Pin (4) and Pin (7) require power, Illustration 2 shows a method for connecting the pins.

Note: Caterpillar recommends purchasing an additional seven-pin connector and constructing a harness assembly that is independent of the factory installed seven-pin connector. The additional harness assembly maintains the compatibility with the trailer systems that are used for roading. This harness also helps make connecting a trailer easier.

Challenger 35 (PIN: 8RD; ADK), Challenger 45 (PIN: ABF; 3BK), and Challenger 55 (PIN: 6NN; AEN)

The circuits for the seven-pin connector were made identical for all Challenger Agricultural Tractors. Pin (4) and Pin (7) were changed in order to be auxiliary circuits. Both of these circuits are powered when the engine start switch is in the ON position. Pin (2) was changed in order to be a floodlight circuit. This circuit is activated when the flood lights are switched to the ON position.

Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), and Challenger 75 (PIN: 4CJ)

Pin (2) and Pin (7) are connected to the auxiliary switches that are located in the upper dash. Pin (4) is used for the stop lights.

The auxiliary circuits can be switched to the ON position and OFF position, as required. This will provide power to the implement systems. The fuses for the auxiliary circuits are 10 amperes. The fuses are located in the fuse panel that is in the upper console.

Some implements require Pin (4) to be powered. If power is needed in Pin (4), the wire from either Pin (2) or Pin (7) could be moved to Pin (4). You can leave the existing wire in the original location. This configuration allows the operator to power the implement circuit by the auxiliary circuit. This will still allow the braking system for roading the machine to be maintained.

Challenger 65C (PIN: 2ZJ1-1964), Challenger 65D (PIN: 2ZJ1965-UP), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK), Challenger 75D (PIN: 5AR), Challenger 85C (PIN: 9TK), and Challenger 85D (PIN: 4GR)

Note: See Table 2 for information about Items (13), (14), (15), and (17).

Illustration 3	g00684600
Unswitched power connection for implement systems (F) No. 4 terminal (+) (G) No. 3 terminal (+) (H) Access plate (J) Fabricated harness assembly (#10 - 12 AWG) (K) Any screw (-) (M) Ground (-) (N) Power (+)

Note: Access plate (H) is located below the rear window. See the section with the title ""Access to Cab for Wiring of OEM Electronics to the Implement" " for more information.

Note: See Illustration 1 and Table 1 for information about Pin (2), Pin (4), and Pin (7) .

Pin (2) and Pin (7) are not connected. Pin (4) is used for stop lights. If power to Pin (4) and Pin (7) is required for implements, Illustration 3 shows the method to be used to connect implements to unswitched power (+ battery).

For only later machines, see Illustration 4 for the method that is used to connect to switched power (key).

Challenger 65C (PIN: 2ZJ566-UP), Challenger 70C (PIN: 2YL243-UP), Challenger 75C (PIN: 4KK586-UP), Challenger 85C (PIN: 9TK287-UP), Challenger 75D (PIN: 5AR), and Challenger 85D (PIN: 4GR)

Note: See Table 2 for information about Items (13), (14), and (15).

Illustration 4	g00684623
Switched power connection to implement systems (Q) Adapter for cigar lighter (R) Ground (-) (S) Power (+) (T) Fabricated harness assembly (#10 AWG) (U) Access plate (V) Cigar lighter (W) Splice the circuit at this location. (+)

Note: Access plate (U) is located below the rear window. See the section with the title ""Access to Cab for Wiring of OEM Electronics to the Implement" " for more information. Drill the appropriate sized hole in the plate. Seal the hole with a grommet. Cigar lighter (V) is located on the right hand console. See the section with the title ""Power Connections" " for more information about the power capacity and the location of the cigar lighter.

The cigar lighter was effective with the serial numbers that are listed above. Earlier machines will not be configured as shown in Illustration 4. All C Series machines can be configured for unswitched power as shown in Illustration 3.

Note: Caterpillar recommends purchasing an additional seven-pin connector and then constructing a harness assembly that is independent of the factory installed seven-pin connector. The additional harness maintains the compatibility with the trailer systems that are needed for roading the machine. This harness also helps make connecting a trailer easier.

Challenger 65E (PIN: 6GS), Challenger 75E (PIN: 6HS), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)

Note: See Illustration 1 and Table 1 for information about Pin (2), Pin (4), and Pin (7) .

The circuits of the seven-pin connector were made identical for all Challenger Agricultural Tractors. Pin (4) and Pin (7) were changed to auxiliary circuits. Pin (2) is connected to the flood lights. Pin (4) and Pin (7) are controlled by switches that are installed on the dash display. See Illustration 5.

Illustration 5	g00684663
Control switches for auxiliary circuits (18) Pin (4) (19) Pin (7)

Implement Status Switch

All Challenger Agricultural Tractors are equipped with an interface for the implement status switch. The connector for the implement status switch is located in the harness assembly near the seven-pin connector for the trailer.

When the machine is equipped with a electronic performance monitor, the implement status switch will send an input to the machine electronic system. This switch will indicate if the implement is in the RAISED position or the LOWERED position. This information is used to calculate the "Area Accumulation" functions.

An 8T-8652 Implement Status Switch Kit is available from your Caterpillar dealer. Refer to Special Instruction, SEHS8729, "Installation of 8T-8652 Implement Status Switch Kit " for more information about the correct installation procedure.

Challenger 35 (PIN: 8DN; 8RD; ADK), Challenger 45 (PIN: 1DR; ABF; 3BK), and Challenger 55 (PIN: 7DM; 6NN; AEN)

The models that are listed above are equipped with an interface for the implement status switch as well as an interface for the three-point hitch. This interface is used for actuating the "Area Accumulation" function. The position of the hitch on earlier machines will determine the source of the input that is used. The threshold value on later machines will determine the source of the input that is used.

Control of Status Switch by the Three-Point Hitch

The Electronic Monitoring Center (EMC) utilizes the signal from the hitch position potentiometer. This signal will cause the "Area Accumulation" function to be enabled or disabled. The functionality of this feature depends on the version of software that is installed on the machine.

The following software was used in earlier machines:

• EMC 6.21, 6.30, 6.37, 6.40, 6.44

• RHC 3.07

• ETC 5.13, 5.19, 5.20

• EDC 5.08, 6.00

Note: If your machine is using the software that is listed above, the following paragraphs will explain the operation of the implement status switch.

If the hitch is raised to a position that is greater than 85 percent of the allowable range of travel, the "Area Accumulation" will be disabled.

When the control knob is used to lower the maximum height of the hitch, the "Area Accumulation" will be disabled when the hitch is raised to a position that is 85 percent greater than the maximum allowable height.

When the hitch is lowered to less than 85 percent of the maximum allowable travel, the "Area Accumulation" will be enabled.

The following software is being used currently in later machines:

• EMC 6.80

• RHC 3.30

• ETC 5.50

• EDC 6.30

Note: If your machine is using the software that is listed above, the following paragraph will explain the operation of the implement status switch.

Note: Later machines will use later versions of the software that is listed above.

Note: This software can be flashed into earlier machines. See Service Magazine, SEPD0504 10 January, "Improved Software Includes New Features" for more information.

The software for later machines significantly improves the "Area Accumulation" functions. Previously, the three-point hitch would override the implement status switch. By using the new software, the operator can select a value for the threshold in Mode 1 by using the EMC. The "Area Accumulator" will collect information from one of three sources. The source depends on the threshold value that was set in Mode 1. The default factory setting is 98 percent.

The possible settings are listed in the Table 3.

Table 3

Operation of Implement Status Switch
Threshold Value	Source Of Input
0 percent	"START/STOP" switch
1 to 98 percent	Three-Point hitch position sensor (1)
99 percent	Implement status switch (2)

( 1 )	The source of the input is from the position sensor for the three-point hitch. The input will stop when the setting for the height limit is reached.
( 2 )	If the setting for the height limit on the hitch is lower than the value for the threshold, then the value for the threshold will default to the setting for the height limit. The hitch must also be enabled. Pushing the reset button in Mode 1 will reset the value to zero.

Note: You can press the "START/STOP" switch in order to override the default actions in any situation.

Control of Status Switch by Implement

A remotely mounted connection for the implement status switch is provided on the main cab harness. This harness is behind the seat and under the floormat. This spade-type connector (wire code CM40) can be connected as shown in Illustration 6.

The Electronic Monitoring Center (EMC) looks for a change of state in the wire. Therefore, either a normally open switch or a normally closed switch may be used. The enable function and the disable function for "Area Accumulation" could get "out of synch" with the remote status switch. If this happens, you can synchronize the state of "Area Accumulation" by manually changing the state on the dash keypad.

Illustration 6	g00684710
Remotely mounted implement status switch (Y) Grommet (Z) Implement status switch (AA) Fabricated harness (AB) Ground wire

Note: Grommet (Y) is located below the rear window. Ground wire (AB) should be connected to the screw that is on the side of the Chassis Control Module (CCM).

Table 4

Required Parts for Remotely Mounted Implement Status Switch Parts for Illustration 6
Item	Part Number	Description
20	7N-9738	Receptacle Housing
21	9X-6857	Socket
22	9X-6856	Connector Pin
23	7N-9737	Plug Housing
24	8T-7875	Wire (10 cm (3.94 inch) - 16 ga) (black wire)
25	122-4415	Plug Connector
26	5P-5694	Blade Connector
27	2L-8078	Connector (8.00 mm (0.315 inch) inside diameter)
28	3T-3048	Clip Assembly

Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), Challenger 75 (PIN: 4CJ), Challenger 65C (PIN: 2ZJ1-1964), Challenger 65D (PIN: 2ZJ1965-UP), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK), Challenger 75D (PIN: 5AR), Challenger 75E (PIN: 6HS), Challenger 85C (PIN: 9TK), Challenger 85D (PIN: 4GR), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)

The models that are listed above are equipped with a connector for the implement status switch that is located in the harness assembly. This harness is located near the seven-pin connector for the trailer.

When the switch is closed, the "Area Accumulation" will function. When the implement is raised and the switch is open, the "Area Accumulation" will stop.

If an implement is not equipped with a status switch, a shorting plug must be installed in the machine connector in order for the "AREA PER HOUR" and the "TOTAL AREA" functions to work by using the controls in the dash. Refer to the following publications for additional information:

• Special Instruction, SEHS8729, "Installation of the 8T-8652 Implement Status Switch Kit "

• The Operation and Maintenance Manual for your machine

The Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), and Challenger 75 (PIN: 4CJ) connects to an implement status switch by using a Sure-Seal Cannon connector.

The Challenger C Series, D Series, and E Series machines are equipped with a Deutsch DT connector.

The 8T-8652 Implement Status Switch Kit has a Sure-Seal Cannon connector. Therefore, this kit can be directly used on Challenger 65, Challenger 65B, and Challenger 75 machines.

The implement status switch is mounted on the implement. The switch sends an input to the performance monitor. This switch input will indicate whether the implement is engaged in tillage applications.

Modifications must be made in order to use the switch on C Series, D Series, or E Series machines.

Note: In order to modify the 8T-8652 Implement Status Switch Kit , follow the instructions for your machine that are listed below.

Illustration 7	g00684748
Adapter harness for the implement status switch

Table 5

Adapter Harness for Implement Status Switch Required Parts for Illustration 7
Item	Part Number	Description	Qty
29	3E-3361	Connector Plug	1
30	3E-3362	Plug Lock Wedge	1
31	8T-8730	Connector Socket	2
32	7N-9737	Plug Housing	1
33	9X-6856	Connector Pin	1
34	9G-3695	Seal Plug	2
35	7N-9738	Receptacle Housing	1
36	3T-3048	Clip Assembly	2
37	5P-5677	Wire (1)
38	9X-6857	Connection Socket	1

( 1 )

Two 150 mm (5.9 inch) lengths of wire are required.

Option 1

An adapter harness assembly is necessary if the customer owns more than one series of machines. If an owner has a combination of a pre-C Series machine with a C Series, D Series, or E Series machine, it will be necessary to construct an adapter harness assembly. This adapter harness assembly will provide the method that is needed in order to use the implement status switch with any Tillage Tractor.

The dealer should fabricate the harness assembly. See Illustration 7 and Table 5. The adapter harness assembly allows the switch that has the Sure-Seal Cannon connector to plug directly into C Series, D Series, or E Series wiring.

Option 2

If the customer owns only C Series, D Series, or E Series machines, the Sure-Seal Cannon connector can be removed from the harness in the 8T-8652 Implement Status Switch Kit .

The Sure-Seal Cannon connector can be replaced with a Deutsch DT connector. See Table 5 for the part numbers of the substitute connectors. Use only Items (29), (30), and (31) .

Note: The implement status switch will not function unless the machine is equipped with a Machine Performance Panel (MPP).

Connections Between the OEM Electronics and the Machine

Many different electronic devices are used in Challenger Agricultural Tractors such as Cell phones, OEM monitors, and FM radios. Some of these units need a source of power from the machine in order to function. Some of these units also need some inputs from the machine such as ground speed signals (radar).

The information in this section describes these types of connections for each model of Challenger Agricultural Tractors.

General Guidelines for Installation of OEM Electronic Systems

Due to the potential for interference between the machine's electronic system and other OEM electronic systems (especially FM two-way radios), use the following installation and mounting recommendations:

• Do not install the cables for the radio and the antenna near the electronic modules or the wiring harnesses in the cab. The modules are located in the following areas for Row Crop Tractors: side console, front console and located beneath the floormat that is behind the seat. The modules are located in the following areas for Tillage Tractors: dash and side console.

• Mount the radio on the left side of the cab. Make sure that the radio is not near the electronic systems.

• Check the coaxial cable in order to verify that the cable is in good condition.

• Check the system in order to verify that the cable is the correct length for the system.

• Unless the radio is connected to an antenna outside the cab, do not use hand-held radios inside the cab.

Signal Interface for Ground Speed Sensor (Radar)

Many implement electronic systems can make use of the true ground speed signal that originates from the radar unit that is installed on the machine (if equipped). There are various connectors that are available from the manufacturer. The most common OEM connector that is available for interfacing with the ground speed signal is a circular plastic connector. This connector is a locking connector that has four pins.

Illustration 8 shows the way that you can convert the wiring that is for the speed signal to the circular plastic connector for each Challenger model.

Note: See Illustration 1 and Table 1 for information about Pin (1), Pin (2), Pin (3), and Pin (4) .

Note: Some monitors only require Pin (1) and Pin (2) to be connected. You may need to disconnect Pin (3) and Pin (4) in order for these monitors to function properly. The ground speed sensor for the machine is powered through the machine. The ground speed sensor is not powered by the OEM supplied monitor. Consequently, Pin (3) from the OEM supplied monitor is not needed. However, some OEM supplied monitors expect there to be a radar enable signal in Pin (4). Therefore, Pin (3) is connected to Pin (4) so that the ground speed sensor appears to be functioning. Harness assembly (54) can be used as an extension harness, if you desire.

Note: See Illustration 7 and Table 5 for information about Item (54) .

Challenger 35 (PIN: 8DN), Challenger 45 (PIN: 1DR), and Challenger 55 (PIN: 7DM)

Illustration 8	g00684837
Interface for ground speed signal (Challenger 35 and Challenger 45) (AH) This cable comes from the chassis harness. (AJ) Ground speed sensor (AK) Pin 1 (ground) (circuit ID - 201) (AL) Pin 3 (+battery) (circuit ID - 123) (AM) Pin 4 (circuit ID - 460) (AN) Pin 2 (signal for the radar) (circuit ID - 457) (AQ) Insert the plug at this location.

Note: Pin (AL) and Pin (AM) are spliced together. Pin (AM) is used to enable the radar.

Table 6

Required Parts for Illustrations 8, 9, and 10
Item	Part Number	Description	Misc Information
39	C45640-3030 (1)	Harness Assembly	Complete "T" harness The harness includes Items (40), (41), (42), (43), (45), (46), (47), and (48).
40	7N-8205	Plug Housing
41	7N-7780	Connector Pin
42	7N-8204	Receptacle Housing
43	7N-7779	Socket
44	128-4098	Connector Kit	The kit includes Items (45), (46), (47), and (48). Use only listed parts. Discard the extra parts.
45	110-7649	Connector Plug	This plug is a four pin female circular plastic connector (free hanging).
46	9G-6791	Pin	#4 - 18 wire The pin is not serviced separately.
47		Bushing	The bushing is not serviced separately. Sealing rubber bushing
48		Clamp	The clamp is not serviced separately.
49	C45640-4360	Harness Assembly	The harness assembly includes Items (45), (46), (47), (48), (50), (51), (52), and (53). Complete "T" harness
50	102-8808	Connecting Plug Kit	The kit includes a plug, a wedge, and a seal.
51	8T-8760	Socket	The socket is for wire that is 16 - 18 ga.
52	102-8804	Receptacle Kit	The kit includes a receptacle, a wedge, and a seal.
53	8T-8729	Connector Pin	The pin is for wire that is 15 - 18 ga.
54	C43940-0024 (1)	Harness Assembly (four pin) 3.05 m (10 ft) long	Extension harness This harness assembly Includes a female circular plastic connector (plug). This harness assembly includes a male circular plastic connector (receptacle with four sockets).
55	119-9705	Harness (jumper for radar)	Adapter harness assembly This harness must be installed.
56	8T-8737	Seal Plug	Insert the plug in location (AQ) when the plug is not connected.
57	128-4094	Receptacle Connector Kit	This kit includes Item (58) through Item (61). Use only the parts that are listed. Discard the extra parts.
58		Receptacle	The receptacle is not serviced separately. This receptacle is a male circular plastic connector that has four sockets (free hanging).
59		Socket	This socket is not serviced separately. 14 -18 AWG wire
60		Bushing	This bushing is not serviced separately. Sealing rubber bushing
61		Clamp	The clamp is not serviced separately. Stress relief
62	129-3540	Harness	Complete harness This harness includes Item (63) through Item (65) and Item (45) through Item (48).
63	102-8808	Connecting Plug Kit	This kit includes a plug, a wedge, and a seal.
64	8T-8730	Connector Socket	This socket is for wire that is 16 - 18 ga.
65	8T-8729	Connector Pin	This pin is for wire that is 16 - 18 ga.

( 1 )

See the note below the table.

Note: In North America consult Dickey-john Sales for the nearest dealer/distributor.

(800) 637-2952 (U.S. and Canada)

Note: For worldwide distributors, consult www.dickey-john.com for a list of international distributors.

Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), and Challenger 75 (PIN: 4CJ)

The ground speed signal can be detected by use of a "T" harness. See Illustration 8 for more information.

Note: See Table 6 for information about Item (39) through Item (57).

Illustration 9	g00684983
Interface for ground speed signal (AR) Coming from the chassis harness (AS) Ground speed sensor (AT) 760 mm (30 inch) (AU) 4625 mm (182 inch) (AV) Pin 1 (ground) (AW) Pin 3 (+battery) (circuit ID - 123) (AX) Pin 4 (AY) Pin 2 (signal from radar) (Circuit ID - 457)

Note: Pin (AX) is not installed.

Challenger 65C (PIN: 2ZJ1-1964), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK), and Challenger 85C (PIN: 9TK)

The ground speed signal can be used by OEM supplied monitors by using a "T" harness. See Illustration 10 for more information.

Note: See Table 6 for information about Item (47) through Item (57).

Illustration 10	g00684993
Interface for the ground speed signal (BA) Coming from the chassis harness (BB) Ground speed sensor (BC) 760 mm (30 inch) (BD) Pin 1 (ground) (circuit ID - 201) (BE) Pin 3 (+battery) (circuit ID - 123) (BF) Pin 4 (circuit ID - 450) (BG) Pin 2 (signal for radar) (circuit ID - 457) (BH) 4700 mm (185 inch)

Note: Pin (BF) is used to enable the radar.

Challenger 75D (PIN: 5AR), Challenger 75E (PIN: 6HS), Challenger 85C (PIN: 9TK393-UP), Challenger 85D (PIN: 4GR), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)

The ground speed signal can be used by OEM supplied monitors by plugging into an existing connector that is in the cab. See Illustration 11 for more information.

Note: See Table 6 for information about Item (44).

Illustration 11	g00685000
Interface for ground speed signal (BK) Pin 1 (ground) (circuit ID - 201) (BL) Pin 3 (+battery) (circuit ID - 141) (BM) Pin 4 (circuit ID - 141) (BN) Pin 2 (signal for radar) (circuit ID - 457)

Note: Pin (BM) and Pin (BL) are connected together.

Power Connections

There are many sources that are available for electrical power for OEM supplied monitors and other electrical devices in the cab.

These sources for power include the following connections:

• Auxiliary terminals

• Single pin connector

• Three pin connectors

This section (""Power Connections" ") provides the following information for each of the Challenger models:

• Locations of power sources

• Repair parts

• Capacities of the electrical power connections

Illustration 12	g00689331

Table 7 lists the power capacity for the three pin connectors (if equipped).

Table 7

Pins for the Three-Pin Connector
Pin	Circuit
66	12 Volt and 30 Ampere (1)
67	12 Volt and 10 Ampere (2)
68	Ground

( 1 )	Pin (66) is controlled by the engine start switch.
( 2 )	Pin (67) is powered continuously.

Table 8 lists the parts that are needed to construct a mating connector for the three-pin connector. This information is the same information for every model that is listed.

A 121-6716 Auxiliary Power Connecting Kit is also available from any Caterpillar dealer. This kit will work with any machine that is equipped with a three-pin connector. The kit includes all of the parts that are listed in Table 8. The parts are already assembled on a harness.

Table 8

Components for Mating Connector
Part Number	Description	Quantity
126-8295	Housing	1
126-8296	Terminal (10 Ampere)	1
126-8297	Terminal (30 Ampere)	2

Challenger 35 (PIN: 8DN), Challenger 45 (PIN: 1DR), and Challenger 55 (PIN: 7DM)

Single Pin Connector

Illustration 13	g00689338

One pin connector (69) is located at the rear of the cab on the right side.

The one pin connector is a 12 volt connector. The one pin connector can be used to power equipment that is rated for 8 amperes. The one pin connector is activated by the engine start switch.

A 9R-7942 Plug is available from any Caterpillar dealer. The 9R-7942 Plug mates with the one pin connector.

Three Pin Connector

Illustration 14	g00689342

A three pin connector (70) is located at the rear of the cab on the right side.

The three pin connector is a 12 volt connector. See Tables 7 and 8 for capacities, power source, and mating connectors.

Challenger 35 (PIN: 8RD; ADK), Challenger 45 (PIN: ABF; 3BK), and Challenger 55 (PIN: 6NN; AEN)

Three Pin Connector

Two three pin connectors (71) are located at the base of the right hand console, next to the main fuse panel. These connectors are available in addition to the single pin connector and the three pin connector. These connectors were listed for earlier machines. The three pin connector is a 12 volt connector. The outputs, power switching, and current ratings of the pins are identical to the other three pin connectors.

See Tables 7 and 8 for capacities, power source, and mating connectors. Each circuit in each of the two connectors is fused separately. The fuses are located at the base of the rear of the right hand console.

Illustration 15	g00689387
Three pin connectors

Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), and Challenger 75 (PIN: 4CJ)

Auxiliary Terminal Strip

Two different locations are provided for power connections. One set of terminals are located on the right hand side of the headliner.

The terminal screws are protected by a 10 amp fuse that is located in the terminal block. The screws are in the bottom row. This row is the third row from the left side of the terminal strip.

Another auxiliary terminal strip is located on the left hand side of the dash and underneath a removable cover. The terminal screws are protected by a 30 amp fuse in the adjacent fuse panel. The fuse is in the second row that is farthest from the right side.

See Tables 7 and 8 for the parts that are needed to adapt the connections for the terminal screws to the industry standard three pin connectors.

Challenger 65C (PIN: 2ZJ1-1964), Challenger 65D (PIN: 2ZJ1965-UP), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK), Challenger 75D (PIN: 5AR), Challenger 85C (PIN: 9TK), and Challenger 85D (PIN: 4GR)

Auxiliary Terminal Strip

Illustration 16	g00685064
Auxiliary terminals screws for C Series and D Series machines

The upper terminal strip is connected to ground.

The operator's station is equipped with eight unswitched terminal screws for use with monitors, telephones, or any accessory that requires power with the keyswitch in the OFF position. The total load in these terminals cannot exceed 50 amperes.

Table 9 shows the amperes of each terminal.

Table 9

Auxiliary Terminals
Terminal	Amperes
72	20 amp
73	20 amp
74	20 amp
75	20 amp
76	10 amp
77	10 amp
78	10 amp
79	10 amp

The upper strip is connected to ground. The auxiliary terminal screws are located on the left side of the dash behind the removable cover plate that is above the floormat.

See Tables 7 and 8 for the parts that are needed to adapt the connections at the terminal screws to the industry standard three pin connectors.

Challenger 65C (PIN: 2ZJ1-1964), Challenger 65D (PIN: 2ZJ1965-UP), Challenger 75C (PIN: 4KK), Challenger 75D (PIN: 5AR), Challenger 85C (PIN: 9TK), and Challenger 85D (PIN: 4GR)

Three Pin Connector and Cigar Lighter

Illustration 17	g00685077
Three pin connector for later C Series and D Series machines

A three pin connector is provided for powering monitors and OEM systems among other devices. The three pin connector is located on the right side of the front console.

Three pin connectors can be constantly powered or the three pin connectors can be switched from the engine start switch key. The three pin connector is a 12 volt connector.

See Tables 7 and 8 for capacities, power source, and mating connectors.

Note: The location of this three pin connector was changed in the Challenger E Series machines. This location is now for use with Caterpillar Service Tools. This connector is not used for a power connector in E Series machines.

A cigar lighter is provided on the right side console. This power source is for monitors and cell phones among other devices. The power is connected to the engine start switch. The key must be in the ON position in order for power to be available to the cigar lighter.

The lighter should only be used for electrical loads up a maximum of 15 amperes.

Challenger 65E (PIN: 6GS), Challenger 75E (PIN: 6HS), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)

Cigar Lighter and Power Port

Illustration 18	g00689390

Cigar lighter (80) and power port (81) are provided on the right side console.

Use the cigar lighter and the power port as a constant source of power for the following auxiliary equipment:

• Monitors

• Phones

• Laptop computers

The power port is an identical configuration to the cigar lighter and the same types of equipment will plug into either one.

The rated amperes for the auxiliary equipment must be less than 15 amperes.

Auxiliary Terminal Strips

The E Series machines are equipped with four pairs of screw terminals for powering auxiliary equipment.

Use the terminal strips as a constant source of power for the following auxiliary equipment:

• Monitors

• Phones

• Laptop computers

Illustration 19	g00685088
(86) Ground terminal strip

Table 10

Connections for the Terminal Strips
Terminal	Connection
82	12 Volt and 10 Ampere (1)
83	12 Volt and 20 Ampere (1)
84	12 Volt and 10 Ampere (2)
85	12 Volt and 20 Ampere (2)

( 1 )	The pair is controlled by the engine start switch and the auxiliary switch.
( 2 )	The pair is controlled by the engine start switch.

See Tables 7 and 8 for the parts that are needed to adapt the connections at the terminal screws to the industry standard three pin connectors.

Illustration 20	g00689393

Terminal (82) is controlled by rocker switch (87). While the engine start switch key is in the ON position, press the top of the rocker switch in order to activate terminal (83). Press the bottom of the rocker switch in order to deactivate the terminals.

Terminal (83) is controlled by rocker switch (88). While the engine start switch key is in the ON position, press the top of the rocker switch in order to activate terminal (83). Press the bottom of the rocker switch in order to deactivate the terminals.

Note: Terminal strip (86) is for ground.

Three Pin Connector

The machine is equipped with three three pin connectors for powering auxiliary equipment.

Use the three pin connectors as a constant source of power for the following auxiliary equipment:

• Monitors

• Phones

• Laptop computers

Illustration 21	g00393806

Two three pin connectors are located behind the access cover for the fuse panel in the right side console. See Illustration 21.

Illustration 22	g00393807

One three pin connector is located on top of the right side console. See Illustration 22.

The three pin connectors can be constantly powered or the three pin connectors can be switched from the engine start switch key. The three pin connector is a 12 volt connector.

See Table 7 and 8 for more information about connections and capacities.

A 121-6716 Auxiliary Power Connecting Kit is available from any Caterpillar dealer. The kit includes a connector that has been preassembled and a harness that has been preassembled.

See Table 8 for the components that are needed in order to assemble only the mating connector.

Access to Cab for Wiring of OEM Electronics to the Implement

Challenger 35 (PIN: 1DR; 8RD; ADK), Challenger 45 (PIN: 1DR; ABF; 3BK), and Challenger 55 (PIN: 7DM; 6NN; AEN)

Illustration 23	g00343014

A rubber grommet is provided at the bottom of the frame for the rear window. The rubber grommet allows you to route cables from the implement into the cab.

In order to use the rubber grommet, perform the following procedure:

1. Remove the grommet from the window frame.

2. Cut a slit into the grommet from the bottom of the grommet into the hollow center.

3. Insert the cables from the implement into the grommet.

4. Install the grommet into the window frame.

Challenger 65 (PIN: 7YC1-1899), Challenger 65B (PIN: 7YC1900-UP), and Challenger 75 (PIN: 4CJ)

The rear panel for the cab is equipped with a removable door from the inside as well as the outside of the cab. Wires can be installed by using grommets in order to keep the sealing of the cab tight.

Note: This area must be well sealed during operation in order to avoid the loss of pressurization of the cab. Poor performance of the air conditioner will result if excessive outside air is needed to maintain pressure in the cab. Loss of pressure causes the system to draw in excessive supplemental air.

Challenger 65C (PIN: 2ZJ1-1964), Challenger 70C (PIN: 2YL), Challenger 75C (PIN: 4KK1-2229), and Challenger 85C (PIN: 9TK1-1764)

Illustration 24	g00685331

The inner access panels and the outer access panels were standard equipment in the machines that are listed above. Item (89), Item (90), and Item (91) in Table 13 were standard equipment in the machines that are listed above. These items are part of the 136-4506 Panel Kit . See Table 13.

This panel can be used to route wiring to the implements. A hole can be drilled in this panel. A bulkhead fitting can be installed in the hole. You could also use a grommet to protect the wiring as the wiring goes through the plate. A 25.4 mm (1.00 inch) plug is provided for temporary routing of the wire.

Note: This area must be well sealed during operation in order to avoid the loss of pressurization of the cab. Poor performance of the air conditioner will result if excessive outside air is needed to maintain pressure in the cab. Loss of pressure causes the system to draw in excessive supplemental air.

Challenger 65D (PIN: 2ZJ1965-UP), Challenger 75C (PIN: 4KK2230-UP), Challenger 75D (PIN: 5AR), Challenger 85C (PIN: 9TK1765-UP), and Challenger 85D (PIN: 4GR)

The inner access panel was not installed on the machines that are listed above. The 136-4506 Panel Kit is adaptable to the machines that are listed above. Item (89), Item (92), and Item (93) are recommended for use in retrofitting machines that were not originally equipped with the access panel.

These items are part of the panel kit. See Table 13 and Illustration 25 for the information that is needed to install the bolt anchors.

Note: No bonding is required.

Installation of Bolt Anchor on Machines That Are Not Equipped with Inner Access Panel

Table 11

Required Tools
Description	Qty
Utility knife	1
12.0 mm (0.47 inch) diameter (drill bit)	1
25.4 mm (1.00 inch) diameter (drill bit)	1

Table 12

Dimensions for Reworking 124-4665 Trim Panel
Item	Dimension
BQ	12.0 mm (0.47 inch) diameter (C) (four holes)
BR	155.0 mm (6.10 inch)
BS	85.0 mm (3.35 inch)
BT	35.0 mm (1.38 inch)
BU	298.0 mm (11.73 inch)
BV	32.5 mm (1.28 inch)
BW	110.0 mm (4.33 inch)
BX	196.90 mm (7.752 inch)
BY	175.0 mm (6.89 inch)
BZ	6.35 mm (0.250 inch) (1)

( 1 )

Approximate dimension

Illustration 25	g00685340
124-4665 Trim Panel This view is shown from the inside of the cab and the view is looking rearward. (CA) Use 8T-9021 Adhesive to bond these areas. (CB) Carpet on the inside of the trim panel

Note: Section CC-CC in Illustration 25 shows the replacement of the original tee nut. Section CD-CD shows the bolt anchor for C Series and D Series machines.

Table 13

Required Parts for 136-4506 Panel Kit
Item	Part Number	Description	Qty
89	3W-6208	Cover (1) (2)	1
90	6V-5645	Screw (3)	6
91		Tee nut (1) (4) (10-32 THD) Bonded into the assembly	6
92		Bolt anchor (5)	6
93	2N-3162	Screw (6) (10-24 THD) (The screw has a slotted head.)

( 1 )	The cover is not serviced separately.
( 2 )	See the details in the installation procedure.
( 3 )	Screw (90) should be used with tee nut (91) .
( 4 )	Use 8T-9021 Adhesive to bond areas (CA). Make sure that you keep the adhesive out of the threads.
( 5 )	The bolt anchor is used only for the field installation of the panel. The bolt anchor is not serviced separately.
( 6 )	Screw (93) should be used with bolt anchor (92) .

Note: Items (89) and (90) in Table 13 are not shown in Illustration 25.

Note: The following steps are for the installation of the bolt anchor.

1. Use a 12.0 mm (0.47 inch) diameter of drill bit to produce holes (BQ) in the 124-4665 Trim Panel . Make sure that you turn the drill bit by hand in order to produce the holes. See Illustration 25 and Table 13 for the location of the holes and the size of the holes.

   Note: If an electric drill is used, the drill bit may catch the carpet and/or the drill bit may wrap the carpet around the drill bit. This could produce an oversize hole.

2. Use the utility knife to cut the rectangular hole in the panel.

   Note: If a finished look is desired, remove the fiberglass material from the back side of the panel at the rectangular hole location. Then cut the carpet so the carpet can be wrapped and bonded in place. Wrap the carpet and bond the carpet at the top of the opening. Wrap the carpet and bond the carpet at the bottom of the opening.

3. Mark the panel and cut a recess in the panel for the anchor. This should be done on the back of the 124-4665 Trim Panel at each hole (BQ). Use the nut end of the anchor bolt as a pattern. The recess should be approximately 50 x 10 x 8 mm (2 x .4 x .3 inch).

4. Push bolt anchor (92) through the holes that were previously drilled in the panel. Allow the nut to rotate. Lock the nut in place in the recess that is on the back of the panel.

   Note: When the 124-4665 Trim Panel is recessed properly screw (93) will start in the threads of the nut. This will also leave dimension (BZ) above the front surface of the panel. See Section CD-CD in Illustration 25.

5. Slide the front lock of bolt anchor (92) downward so that the anchor is tight against the panel.

6. Trim the handles, that are used for installation purposes, from bolt anchor (92) .

7. Repeat Steps 4 and 5 for the remaining three holes. The remaining bolt anchors (92) and screws (93) are provided as spares.
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   Table 14

   Rework for 3W-6208 Cover
   Item	Dimension
   CE	82.5 mm (3.25 inch)
   CF	97.5 mm (3.84 inch)
   CG	195.0 mm (7.68 inch)
   CH	7.0 mm (0.28 inch)
   CJ	25.4 mm (1.00 inch)

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Illustration 26	g00685392
(89) 3W-6208 Cover

8. Trim off one end of cover (89). See Illustration 26 and Table 14 for the dimensions.

   Note: Hole (CJ) is optional. Hole (CJ) may be drilled and filled with a 9D-3767 Button Plug .

Challenger 65E (PIN: 6GS), Challenger 75E (PIN: 6HS), Challenger 85E (PIN: 6JS), and Challenger 95E (PIN: 6KS)

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Illustration 27	g00391147

Note: A rubber grommet is provided at the bottom of the frame for the rear window. The rubber grommet allows you to route cables from the implement into the cab. In order to use the rubber grommet, perform Steps 2 through 4.

1. Remove the grommet from the window frame.

2. Cut a slit into the grommet from the bottom of the grommet into the hollow center.

3. Insert the cables from the implement into the grommet.

4. Install the grommet into the window frame.