Installation of New Operator Control Joysticks{4122} Caterpillar


Installation of New Operator Control Joysticks{4122}

Usage:

D3G CFC
Track-Type Tractor:
D3G (S/N: CFC1-UP; CFF1-UP)
D4G (S/N: FDC1-UP; CFN1-UP)
D5G (S/N: FDH1-UP; FDW1-UP)

Introduction

The following procedure describes the steps involved in changing from the existing 220-1135 Operator Control Gp to the new 230-1025 Steering and Transmission Control Gp .

The existing 220-1135 Operator Control Gp to the new 230-1025 Steering and Transmission Control Gp have similar mounting configurations. Both joysticks also have identical 8-pin connectors. The following parts are unique to each joystick:

  • Cover

  • Boot

  • Mounting bracket

  • Base

  • FNR sensor connectors

  • Steering sensor connectors

Parts Required

Table 1
Parts Required    
Part Number     Description     Quantity    
155-2274     Connecting Plug Kit     1    
111-7899     Gasket     1    
230-1024     Electronic Control Gp (Steering)     1    
186-3735     Connector Pin     7    
8T-8737     Seal Plug     1    
235-6351     Boot     1    
235-6352     Cover     1    
235-6354     Spacer     4    
244-6822     Bolt     4    
235-6355     Plate     1    
235-6356     Bracket As     1    
237-4040     Grommet     1    
240-8149     Modular Handle Gp     1    
117-8683     Spring Pin     1    
156-6175     Ladder Clip     1    
9X-2042     Screw     4    
245-7483     Grommet     1    
7K-1181     Cable Strap     3    

Remove Old Joystick

In this procedure, the existing machine harness will be converted from the existing two 4-pin connectors to a single 6-pin connector. Although you will be changing two 4-pin connectors, there will only be six wires involved. Each 4-pin connector uses only three wires in the harness. In this procedure, you will remove the wires from the present 4-pin connectors ( 173-3047 Connector Plug ) and insert them into a single 6-pin DT connector ( 155-2274 Connecting Plug Kit ). You will not need to re-terminate the six wires.

  1. Turn OFF battery disconnect.

  1. Remove the 177-2278 Boot from the 230-7338 Control Group - Mounting .

  1. Remove the 177-2274 Cover from the 220-1135 Operator Control Gp .

  1. Unplug the connector that is attached to the 190-8478 Rocker Switch (PARKING BRAKE). The 190-8478 Rocker Switch (PARKING BRAKE) is part of the 220-1135 Operator Control Gp .



    Illustration 1g01060859

    (1) Bolts

  1. In order to remove the old joystick from the 220-1135 Operator Control Gp , remove the three bolts (1) that secure the joystick to the machine's left-hand console.

    Note: Access to these three bolts is gained through the left-side door (Illustration 1). The bolts are located just forward of the ECM. Upon removal of these bolts, the joystick will be loose and attached only to the machine via the electrical harness.

  1. Unplug the three joystick connectors from the machine wiring harness:

    • Two 4-pin connectors that connect directly to the joystick sensors

    • One 8-pin connector that connects to a short pigtail emanating from the joystick

    Note: The joystick will now be mechanically and electrically isolated from the machine.

  1. Remove the wires from each of the two 4-pin machine harness connectors ( 173-3047 Connector Plug ) that were attached to the joystick sensors.

    Note: It is not necessary to remove the sockets from the individual wires.

  1. Using the pinout information shown in Table 2, install the six wires (removed in Step 7) into a single 155-2273 Connector Plug and 155-2263 Plug Lock Wedge (from the 155-2274 Connecting Plug Kit ).

    Table 2
    155-2274 Connecting Plug Kit Pinout    
    155-2274 Connecting Plug Kit Location     Harness Wire Number     Description    
    1     709 - OR     V+    
    2     750 - YL     GND    
    3     853 - BR     FNR Signal    
    4     709 - OR     V+    
    5     750 - YL     GND    
    6     703 - BR     Steering Signal    

Install New Joystick




Illustration 2g01065966

230-1025 Steering and Transmission Control Gp

(2) 240-8149 Modular Handle Gp

(3) Joystick handle cable

(4) 245-7483 Grommet

(5) 237-4040 Grommet

(6) 235-6354 Spacer (4)

(7) 235-6356 Bracket As

(8) 244-6822 Bolt

(9) 156-6175 Clip (ladder)

(10) 7K-1181 Cable Strap

(11) Bolts/Nuts (3)

(12) Base connector (6 pin)

(13) Handle connector (8 pin)

(14) 230-1024 Electronic Control Gp




Illustration 3g01066120

(2) 240-8149 Modular Handle Gp

(3) Joystick handle cable

(4) 245-7483 Grommet

(5) 237-4040 Grommet

(7) 235-6356 Bracket As

(9) 156-6175 Clip (ladder)

(10) 7K-1181 Cable Strap

(12) Base connector (6 pin)

(13) Handle connector (8 pin)

(14) 230-1024 Electronic Control Gp

(15) 117-8683 Spring Pin




Illustration 4g01066145

(7) 235-6356 Bracket As

(9) 156-6175 Clip (ladder)

(10) 7K-1181 Cable Strap

(12) Base connector (6 pin)

(13) Handle connector (8 pin)

(14) 230-1024 Electronic Control Gp

(16) 235-6351 Boot

(17) 9X-2042 Screw (4)

(18) 235-6355 Plate

(19) 190-8478 Rocker Switch

(20) 235-6352 Cover




Illustration 5g01066181

230-1025 Steering and Transmission Control Gp - Top view

(2) 240-8149 Modular Handle Gp

(5) 237-4040 Grommet

(7) 235-6356 Bracket As

  1. Use the three bolts (removed in Step 5) to secure the 235-6356 Bracket As to the machine's left-hand console.

  1. Install the 237-4040 Grommet (5) in the 235-6356 Bracket As (7). Refer to Illustration 5.

  1. Perform the following steps on the 240-8149 Modular Handle Gp .

    1. Install one 8T-8729 Connector Pin on the end of each of the joystick handle cable's seven wire ends.

    1. Install the 190-8478 Rocker Switch (PARKING BRAKE) (19) and the 111-7899 Gasket into the cover (20). Connect the 190-8478 Rocker Switch (PARKING BRAKE) to the machine wiring harness.



      Illustration 6g01069173

      Stacked components

      (2) 240-8149 Modular Handle Gp

      (3) Joystick handle cable

      (16) 235-6351 Boot

      (18) 235-6355 Plate

      (19) 190-8478 Rocker Switch (PARKING BRAKE)

      (20) 235-6352 Cover

    1. Insert the joystick handle cable (3) through the following components (in the order given, starting with the boot):




      Illustration 7g01069090

      3E-3388 Receptacle As .

      (22) Pin 4, WH-20, Horn Common, Sw 3

      (23) Pin 3, BR-20, Horn N/O, Sw 3

      (24) Pin 2, GN-20, Accelerate N/C, Sw 2

      (25) Pin 1, BK-20, Accelerate/Decelerate Common, Sw 1 and Sw 2

      (26) Pin 5, YL-20, Decelerate N/C, Sw1

      (27) Pin 6, BU-20, Decelerate N/O, Sw 1

      (28) Pin 7, RD-20, Accelerate N/O, Sw 2

      (29) Pin 8, Plugged ( 8T-8737 Seal Plug )

      (30) 3E-3389 Receptacle Lock Wedge

      (31) 3E-3388 Receptacle As

    1. Install the seven wire ends into the 3E-3388 Receptacle As . Refer to Illustration 7.

  1. Insert the four 235-6354 Spacers (6) between the 230-1024 Electronic Control Gp (14) and the 235-6356 Bracket As (7). Refer to Illustration 2.

  1. Use four 244-6822 Bolts (8) to attach the 230-1024 Electronic Control Gp (14) to the 235-6356 Bracket As (7) .

    Note: One of the four 244-6822 Bolts (8) also attaches the 156-6175 Clip (9) to the 235-6356 Bracket As (7). Refer to Illustration 2 for location and orientation.

  1. Install the 245-7483 Grommet (4) over the joystick adapter. Refer to Illustration 3.



    Illustration 8g01061830

    Joystick handle, cable, adapter, and adapter pin hole. Boot, plate, and cover not shown in order to display cable routing.

    (2) 240-8149 Modular Handle Gp

    (3) Joystick handle cable

    (14) Joystick adapter

    (22) Pin hole

  1. Place the joystick handle (2) over the adapter (14). Route the joystick handle cable (3) as shown in Illustration 3. When routing the cable, ensure that the cable is routed without pinch or abrasion points.

    Note: Ensure that there is 150 ± 10 mm (5.90 ± 0.40 inch) of harness cable between the joystick handle and the grommet. Refer to Illustration 2 and Illustration 3.

  1. Insert the 117-8683 Spring Pin into the hole at the bottom of the handle and into the hole in the shaft. Refer to Illustration 9.



    Illustration 9g01062334

    (2) 240-8149 Modular Handle Gp

    (22) 117-8683 Spring Pin

  1. Use a 7K-1181 Cable Strap (10) to secure the joystick handle cable to the 156-6175 Clip (9). Refer to Illustration 4.



    Illustration 10g01062330

    (12) 6-pin connector - base

    (13) 8-pin connector - handle

    (21) Machine harness

  1. Connect the 6-pin connector (12) and the 8-pin connector (13) to the machine harness (21) .

  1. Use four 9X-2042 Screws and the 235-6355 Plate to secure the 235-6351 Boot and the 235-6352 Cover to the 235-6356 Bracket As .



    Illustration 11g01061798

    (10) 7K-1181 Cable Straps

    (23) Harness

  1. Use 7K-1181 Cable Straps (10) to reattach the wiring harness to the machine (Illustration 11).

  1. Using Caterpillar ET, perform the joystick portion of the calibration procedure that appears in Troubleshooting, Testing and Adjusting, RENR5539, "D3G, D4G, and D5G HYSTAT Track-Type Tractors Electrohydraulic Power Train Systems".

  1. Ensure proper operation of the new joystick.

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