Installation Procedure for Motorized Flow Control{5051} Caterpillar

Agricultural Tractors:

Challenger 35 (S/N: 8DN1-UP; 8RD1-UP; ADK1-UP; 9DF1-UP; 3HS1-UP; 1TJ1-UP)

Challenger 45 (S/N: 1DR1-UP; ABF1-UP; 3BK1-UP; 4DZ1-UP; 4KW1-UP; 4YL1-UP)

Challenger 55 (S/N: 7DM1-UP; 6NN1-UP; AEN1-UP; 5DK1-UP; 7TZ1-UP; 3SM1-UP)

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 85D (S/N: 4GR1-UP)

Challenger 65E (S/N: 6GS1-UP; 1GM1-UP)

Challenger 75E (S/N: 6HS1-UP; 1HM1-UP)

Challenger 85E (S/N: 6JS1-UP; 1NM1-UP)

Challenger 95E (S/N: 6KS1-UP; 1SM1-UP)

Introduction

This Special Instruction provides the required parts list and the suggested installation procedures that are needed to install the 189-4426 Implement Valve Conversion Gp (Motorized Flow Control). This implement valve conversion gp is serviced as a single part number. The group converts a remote implement valve from manual flow control to motorized flow control. The required parts are listed in Table 1 for Row Crop Tractors and Table 4 for Tillage Tractors. Some replacement parts in the group are serviced separately. These parts are listed in Table 2 for Row Crop Tractors and Table 5 for Tillage Tractors.

This Special Instruction includes the installation procedures for both Row Crop Tractors and Tillage Tractors. Use the appropriate installation procedure for your machine.

Installation Procedure for Row Crop Tractors

Required Parts

Service Replacement Parts

Installation Procedure

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Installation Procedure for Motorized Flow Control

Note: Remove the cable assembly for the implement control valve. The cable assembly should be the one that is part of the flow control circuit that is being retrofitted. This will give you more room to work when you install the motorized flow control.

1. Remove the manual flow control assembly from your machine. This should be the flow control that is being replaced with a motorized flow control. Refer to the appropriate Disassembly and Assembly, "Machine Systems" for your particular machine for the removal and installation procedures.

2. Remove the motorized flow control from the packaging arrangement. Make sure that you have the parts that are listed in Table 1 in order to complete the installation procedure.

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Illustration 1	g00701281
(1) DC motor assembly (A) Set screw (B) Drive gear

3. Loosen set screw (A) at the drive end of DC motor assembly (1). Remove drive gear (B) .

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Illustration 2	g00701284
(B) Drive gear

Note: The sleeve for the flow control was removed from the implement valve for illustration purposes.

4. Drive gear (B) will need to be installed with the metering window of the flow control sleeve in the UP position, as shown. If the metering window is turned downward, the flow control will not function properly. The flow control will be out-of-phase.

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Illustration 3	g00774556
(B) Drive gear (C) Drive shaft

5. Make sure that the 2M-9780 O-Ring Seal is installed on drive gear (B). Install the sleeve and drive gear (B) in the implement valve body.

6. Line up drive gear (B) so that the gear fits into the notch of the flow control sleeve. Hold drive shaft (C) in order to keep the drive shaft from turning. This will ensure that the metering window stays in the UP position.

7. Tighten drive gear (B) to a torque of 70 ± 7 N·m (52 ± 5 lb ft). Make sure that the stem is free to turn clockwise and counterclockwise inside of drive gear (B) .

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Illustration 4	g00774953
(D) Original alignment pin

8. Install original alignment pin (D) into the implement valve body. If original alignment pin (D) was damaged during removal, use a 2K-8467 Spring Pin for replacement.

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Illustration 5	g00701289
(1) DC motor assembly

9. Install DC motor assembly (1) on the gear drive. Tighten set screw (A) that is located on the side of DC motor assembly (1) .

   Note: Set screw (A) is not visible in Illustration 5.

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Illustration 6	g00774955
(1) DC motor assembly (5) Grommet (6) Wire harness (E) Wire harness (F) Clip

10. Route wire harness (E) from DC motor assembly (1) through clip (F). Connect the socket connector (DT) that is on wire harness (6) to the receptacle connector (DT) on the wire harness that is on DC motor assembly (1). Install grommet (5) and route wire harness (6) through the rear of the cab.

Installation of Rocker Switches

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Illustration 7	g00774964
Right Hand Console (G) Knockout panel

1. Remove knockout panel (G) for switch (2). Switch (2) will operate the motorized flow control. Use the appropriate amount of knockout panels for your use.

   Note: Switch (2) is not shown.

   Use Steps 2 through 7 to install an additional rocker switch.

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Illustration 8	g00774559
Template (H) 140.0 mm (5.51 inch) (J) 66.0 mm (2.60 inch) (K) 54.0 mm (2.13 inch) (L) 66.0 mm (2.60 inch) (M) 45.0 mm (1.77 inch) (N) 48.0 mm (1.90 inch) (P) 25.0 mm (0.99 inch) (Q) 74.0 mm (2.91 inch) (R) 7.0 mm (0.28 inch) diameter (S) 3.0 mm (0.12 inch) diameter (T) Template

2. Use Illustration 8 as a template.

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Illustration 9	g00774585
Cover for Right Hand Console (U) Cover for right hand console (T) Template

3. Remove cover (U) for the right hand console.

4. Align template (T) with the holes in cover (U), as shown.

5. Cut out the rectangular hole on the right hand console.

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Illustration 10	g00774588
Cover (V) 27.0 mm (1.06 inch) (W) 74.0 mm (2.91 inch) (X) 66.0 mm (2.60 inch) (Y) 45.0 mm (1.77 inch) (Z) 17.0 mm (0.67 inch) (AA) 23.0 mm (0.91 inch) (AB) 66.0 mm (2.60 inch) (AC) 23.0 mm (0.91 inch) (AD) 8.0 mm (0.32 inch) (AE) 25.0 mm (0.98 inch) (AF) 2.0 mm (0.079 inch) (AG) 90 degrees (AH) 90 degrees (AJ) 1.5 mm (0.06 inch) (AK) 2.5 mm (0.10 inch) (AL) 7.0 mm (0.28 inch) diameter (AM) 5.0 mm (0.20 inch) (AN) Cover

6. Use Illustration 10 to fabricate a cover in order to hold the rocker switches. Use a steel sheet that is 2.5 mm (0.01 inch) thick to make the cover.

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Illustration 11	g00774672
Cover for Right Hand Console (31) One 138-4054 Flat Head Screw (32) Two 4I-4334 Tapping Screws (33) 9S-3263 Thread Lock Compound (U) Cover for the right hand console (AN) Cover for rocker switches

7. Position cover (AN) on cover (U) for the right hand console. Install screw (31) and two screws (32) to cover (AN). Apply 9S-3263 Thread Lock Compound (33) to two 4I-4334 Tapping Screws (32) .

Installation of Control Wiring

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Illustration 12	g00715612
Electrical Schematic

Note: The implement socket is located at the rear of the right hand console.

1. In order to connect power (keyswitch) to the motorized flow control, splice the red wire that is on connector harness (3) onto the CM248 BR-10 (12V, 30A) pin by using wire splice (9). CM248 BR-10 (12V, 30A) is No. 1 Pin on the implement socket (three pin auxiliary connector). Connect the black wire on connector harness (3) to a suitable ground in the cab with spade terminal (4) or wire splice (9), as required.

2. Use a 1U-5804 Crimp Tool in order to install connector pins (DT) (8) on wire harness (6). Then install receptacle kit (7) .

   Note: Match the green wires to the green wires and the white wires to the white wires when you make the connection (DT). This will ensure the proper operation of the switch for the motorized flow control.

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Illustration 13	g00755975
(10) 198-8989 Film (11) 198-8990 Film (12) 198-8991 Film (13) 198-8992 Film

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Illustration 14	g00755980
(2) 113-8744 Switch

3. Install the appropriate decal from Table 1 on switch (2). See Illustration 13. The decal should be oriented so that the + symbol is at the top of the switch.

   Note: There is a separate decal for each flow control circuit.

4. Install switch (2) in position on the right hand console so that the clip is positioned at the rear of the console. (This is for the correct orientation for control of increased flow and decreased flow.) Connect wire harness (6) to switch (2) .

5. The switch for the motorized flow control should control the hydraulic flow in the following manner:
   • Press the + symbol at the top of the switch in order to increase the flow.

   • Press the - symbol at the bottom of the switch in order to decrease the flow.

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With the engine running, this machine spot turns when the steering wheel is turned, even with the transmission in NEUTRAL and the parking brake engaged. To avoid personal injury due to unexpected machine movement, make sure the area is free of personnel before starting the engine. Be prepared to apply the service brakes to counteract any steering that might occur when the engine starts.

6. Turn the engine start switch to the ON position in order to activate the machine's electrical system. Check the operation of the DC motor assembly. You should be able to hear the operation of the DC motor assembly.

7. Start the machine in order to activate the machine's hydraulic system. In order to verify that the motorized flow control is operating properly, connect a flow meter or a hydraulic motor to the hydraulic system.

   Note: Always refer to the Operation and Maintenance Manual for the proper operation of your machine.

Installation Procedure for Tillage Tractors

Required Parts

Service Replacement Parts

Installation Procedure

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Installation of Motorized Flow Control

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Illustration 15	g00702901

1. Remove the manual flow control assembly from your machine. This should be the flow control that is being replaced with a motorized flow control. Refer to the appropriate Disassembly and Assembly, "Machine Systems" for your particular machine for the removal and installation procedures.

2. Remove the motorized flow control from the packaging arrangement. Make sure that you have the parts that are listed in Table 4 in order to complete the installation procedure.

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Illustration 16	g00701281
(1) DC motor assembly (A) Set screw (B) Drive gear

3. Loosen set screw (A) at the drive end of DC motor assembly (1). Remove drive gear (B) .

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Illustration 17	g00701284
(B) Drive gear

Note: The sleeve for the flow control was removed from the implement valve for illustration purposes.

4. Drive gear (B) will need to be installed with the metering window of the flow control sleeve in the 3 o'clock position, as shown. If the metering window is not in the 3 o'clock position, the flow control will not function properly. The flow control will be out-of-phase.

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Illustration 18	g00774556
(B) Drive gear (C) Drive shaft

5. Make sure that the 2M-9780 O-Ring Seal is installed on drive gear (B). Install the sleeve and drive gear (B) in the implement valve body.

6. Line up drive gear (B) so that the gear fits into the notch of the flow control sleeve. Hold drive shaft (C) in order to keep the drive shaft from turning. This will ensure that the metering window stays in the 3 o'clock position.

7. Tighten drive gear (B) to a torque of 70 ± 7 N·m (52 ± 5 lb ft). Make sure that the stem is free to turn clockwise and counterclockwise inside of drive gear (B) .

Note: Steps 8, 9, and 10 do not show the components.

8. Install the original alignment pin on the implement valve body. If the original alignment pin was damaged during removal, use a 2K-8467 Spring Pin for replacement.

9. Position DC motor assembly (1) on the gear drive. Tighten the screw that is located on the side of DC motor assembly (1) .

10. Route the wire harness from DC motor assembly (1) to the inside of the cab. Install the wire harness through the hole that was used for the cable for the manual flow control.

Installation of Rocker Switches Without Three-Point Hitch on the Machine

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Illustration 19	g00755975
(10) 198-8989 Film (11) 198-8990 Film (12) 198-8991 Film (13) 198-8992 Film

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Illustration 20	g00755980
(2) 113-8744 Switch

1. Install the appropriate decal from Table 4 on switch (2). See Illustration 19. The decal should be oriented so that the + symbol is at the top of the switch.

   Note: There is a separate decal for each flow control circuit.

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Illustration 21	g00775010
Right Hand Console (D) Knockout panel

2. On the right hand console, remove knockout panel (D) for switch (2) that operates the motorized flow control. Use the appropriate amount of knockout panels (D) for your use.

   Note: Switch (2) is not installed.

Installation of Rocker Switches With Three-Point Hitch on Machine

Note: Use Steps 1 through 10 to install two additional rocker switches.

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Illustration 22	g00775015
Dimensions for Template (This illustration is not drawn to scale.) (E) 2.0 mm (0.08 inch) (F) 45.0 mm (1.80 inch) (G) 45.0 mm (1.80 inch) (H) 23.0 mm (0.90 inch) (J) 15.0 mm (0.59 inch) (K) 33.0 mm (1.30 inch)

1. The dimensions that are shown in Illustration 22 can be used to construct a template.

   Note: Do not use Illustration 22 for a template. This illustration is not drawn to scale.

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Illustration 23	g00775017
(This illustration is drawn to 1 to 1 scale.) (L) Template

2. Use Illustration 23 for a template. Template (L) is drawn to a scale of 1 to 1. Cut out the template and cut out the rectangular holes in the template.

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Illustration 24	g00775019
Right Hand Console (L) Template

3. Remove the cover for the right hand console.

4. Position template (L) on the cover for the right hand console. Line up the top and left side of template (L). See Illustration 24.

5. Mark the required number of rectangular holes for your installation.

6. Cut out the rectangular holes for one or two rocker switches, as required.

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Illustration 25	g00775022
(M) Rectangular hole

7. Cut out rectangular hole (M) that is in the sheet metal underneath the cover for the right hand console, as shown.

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Illustration 26	g00755975
(10) 198-8989 Film (11) 198-8990 Film (12) 198-8991 Film (13) 198-8992 Film

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Illustration 27	g00755980
(2) 113-8744 Switch

8. Install the appropriate decal from Table 4 on switch (2). See Illustration 26. The decal should be oriented so that the + symbol is at the top of the switch.

   Note: There is a separate decal for each flow control circuit.

9. Install the rocker switches on the cover for the right hand console.

10. Install the cover on the right hand console.

Installation of Control Wiring

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Illustration 28	g00775023
(3) Pair 3 (N) Positive terminal (P) Negative terminal

1. In order to connect power (keyswitch) to the motorized flow control, connect the red wire from connector harness (3) to upper pair 3 connection 173-H36 YL-18 (12V, 10A) by using spade terminal (4). The upper pair 3 connection 173-H36 YL-18 (12V, 10A) is on the auxiliary power terminals. Connect the black wire on connector harness (3) to lower pair 3 connection 200-H16 BK-10. Refer to the appropriate Operation and Maintenance Manual, "Auxliary Power Terminals" for more detail about your machine.

2. Use a 1U-5804 Crimp Tool in order to install connector pins (DT) (8) on wire harness (6). Then install receptacle kit (7) .

   Note: Match the green wires to the green wires and the white wires to the white wires when you make the connection (DT). This will ensure the proper operation of the switch for the motorized flow control.

3. Install switch (2) in position on the right hand console so that the clip is positioned at the rear. (This is for the proper orientation for the control of increased flow or decreased flow.) Connect wire harness (6) to switch (2) .

   The switch for the motorized flow control should control the hydraulic flow in the following manner:

   • Press the + symbol at the top of the switch in order to increase the flow.

   • Press the - symbol at the bottom of the switch in order to decrease the flow.

Show/hide table

With the engine running, this machine spot turns when the steering wheel is turned, even with the transmission in NEUTRAL and the parking brake engaged. To avoid personal injury due to unexpected machine movement, make sure the area is free of personnel before starting the engine. Be prepared to apply the service brakes to counteract any steering that might occur when the engine starts.

4. Turn the engine start switch to the ON position in order to activate the machine's electrical system. Check the operation of the DC motor assembly. You should be able to hear the operation of the DC motor assembly.

5. Start the machine in order to activate the machine's hydraulic system. In order to verify that the motorized flow control is operating properly, connect a flow meter or a hydraulic motor to the hydraulic system.

   Note: Always refer to the Operation and Maintenance Manual for the proper operation of your machine.