Construction Attachments, Inc. Auxiliary Hydraulics D03 KIT WITHOUT HOSES FOR TRACTOR WITH LESS THAN 14GPM OPEN CENTER HYDRAULIC SYSTEM AND A FACTORY OR AFTERMARKET 2 FUNCTION LOADER VALVE
BEFORE INSTALLING A CAL ONE TOUCH KIT PLEASE READ AND UNDERSTAND THE FOLLOWING >Check the flow for auxiliary hydraulics for your tractor. CAL standard kits include D03 valves and will heat the oil to unacceptable levels if continuous flow exceeds 15 gpm. Power beyond flow runs through the kit manifold constantly in normal operation. Cal usually recommends a D05 valve kit for tractors with auxiliary flow in excess of 14gpm. >Standard kits are designed to run on tractors and other machines using an open center hydraulic system. Some tractors have a large relief valve positioned directly after the gear pump and call their system an open center, pressure compensated system, but most do not have this relief. Be certain that the kit is installed after a system relief in the power beyond circuit. It is a certainty that when the kits functions are stroked to a deadhead condition they will destroy an open center hydraulic system pump if there is no relief between the pump and the kit. Your CAL one touch hydraulic kit does not include any relief function. We write instructions and design custom kits for as many tractors as we possibly can, but tractors and hydraulics systems are constantly changing, so please be certain that your kit is installed with a pressure relief between the pump and the kit valve. It is always a safe bet to install the kit between the loader valve and the tank, because it is certain that the loader valve has to be relieved at either the valve or just in front of the pump. If you are downstream from the valve you are usually always safe. >Kit instructions may be effected by items such as factory or aftermarket backhoes and other hydraulic functions on the auxiliary system. Whether or not the tractor has a cab is often a factor in which valve mount is required for the kit. Anything unique to the tractor you are installing the kit on may be relevant and if you are unsure, call us to determine what parts you need to get the tractor kitted up properly. >Larger tractors pose several issues that rarely come in play on the smaller D03 kits. Some large tractors have truly pressure compensated piston pumps which need a closed center valve instead of our standard tandem center. Putting a tandem center valve on these tractors will cause all flow to dump and will cause all of the other auxiliary functions to starve for fluid unless the kit hydraulics are stroked to deadhead condition. This will obviously not work. It is very important to get precise information about the tractor being kitted, because often times this pressure comp system is a premium feature for a tractor with standard open center hydraulics. In these cases the primary tractor model may be the same as a tractor with open center hydraulics, but with the premium feature all hydraulic functions are now plumed in parallel on the pressure side instead of in series with the power beyond.
>Load sense is another feature typically found on large tractors that poses a problem for adding after market kits. A load sense system requires a small amount of flow from the work ports of all functions A and B ports to go back and close off a spring loaded dump feature to make the kit work. This can be accomplished with standard aftermarket components, but in most cases it is not a very neat assembly and may be a situation where buying the factory auxiliary kit is more advantageous, even at the higher cost. In most of these setups the factory kit will be a stacked modular type valve slice that has an electric operated spool, but the slice stacks into the factory modular valve system and is machined to support the load sense feature of the hydraulic system. As much as we want to provide a quality alternative to higher priced factory kits, in these cases it is difficult for us to be a better deal. The diagram below is for reference only and represents a typical safe auxiliary setup. Our instructions are aimed at adding kits that are put together in the way shown on this print; however, it is important to check that there are not inconsistencies between the kit ordered and the actual tractor on which it is to be installed. Also if ordering a partial kit with no hoses, this diagram is an excellent reference to show how to add a kit in series with open center hydraulics and ensure there is a relief up stream of the kit valve.
Installation Instructions 1) Locate the D03 manifold sub plate from the kit and mount in a protected location. Sub plate is included with a mounting plate that can be either bolted to the frame or welded. For partial kits we use the ROPS mount valve plate that can be used as a clamp type valve holder on many tractors. Give consideration to the routing of the hoses before mounting valve sub plate. You will need to locate the tractor power beyond line from the tractor loader valve that returns to the tank. *The return line from the valve also runs to tank, but is not the power beyond line. Placing kit valve in series with the return line instead of the power beyond line will pressurize the return side of your loader valve and likely cause leaks or more serious problems. Pressure IN Return to tank Power beyond Above valve shows a typical loader valve. Note that the pressure in and the power beyond are directly across from one another. This is typical. 2) Bolt the sub plate to the mount plate once the mount is attached. Mount the D03 valve to the sub plate using the socket head cap screws included in the valve box. Be sure to keep o-rings in place on the bottom of the D03 valve as you place it on the sub plate. Valve will only work mounted in one direction. D03 valves have a four bolt 2
pattern that looks the same either way and for that reason there is an alignment dimple on the valve bottom and on the sub plate. Be certain that you have aligned this dimple on both pieces before attaching. 3) Your valve should be equipped with an external ground wire from the conduit box. Attach this wire to the mount plate or tractor chassis. 4) Remove the power beyond line from your tractor loader valve that returns to the tractor reservoir. *If there are no down-stream functions the power beyond runs to the tank, but if there are any more valves on the system they will be down stream in series with the power beyond. Proceed exactly the same way in this case. If you have purchased a one touch kit sized for the correct amount of auxiliary flow on your tractor then you can insert the one touch valve in series on this line whether it runs to tank or to another function. 5) Make and attach an appropriately sized line from the loader valve power beyond port to the P port on the kit manifold sub plate. 6) Make and attach a line from the T port on the kit manifold sub plate to the now empty return port left by removing the power beyond line. 7) Mount the universal bulkhead mount to the lowest crossbar on the loader or the nearest logical point to the actual attachment where the bulkhead can be mounted. The universal mount includes a double tube clamp and can be mounted to the crossbar tubes using the clamp. The clamp can be removed and you may use the bolt hole to mount the bulkhead bracket where possible. If neither of these options can be done, you may weld the bulkhead bracket to the crossbar on the loader. 8) The kit includes (2) female and (2) male 3/8 AG couplers. (1) male and (1) female need to be attached to the A and B ports of the kit manifold. Depending on the position of the valve you may want to attach adaptors directly to the manifold that allow mounting these couplers or you may want to make hoses and then mount these couplers in a different location. The important thing to remember is that these couplers will remain on the tractor when the loader is removed and they need to be positioned so that they are supported or fixed when the loader is removed to keep them from falling loosely into harms way when the loader is removed from the tractor. 9) Next make a set of 3/8 lines with JIC female fittings on one end and SAE 06 straight boss o-ring fittings on the other. The remaining small, 3/8 AG couplers will attach to the SAE fittings and the JIC end will attach to the bulkhead fittings at the front crossbar. Be careful to choose correctly straight or bent JIC fittings for the front according to how you have mounted the front bulkhead bracket. Size these hoses so that you can route them along the boom and attach the JIC fittings to the bulkhead fittings in the front bulkhead mount and you can 3
couple the end with 3/8 AG couplers to the fixed couplers you already mounted from the work ports of the kit manifold. At the front bulkhead you have 3/8-1/2 NPT adaptors on the bulkhead fitting and 8010 style AG couplers. Be sure to consider the hose loop size and location so that these hoses do not bind or pinch when lifting or lowering the loader. Any time the loader is removed from the tractor, the kit may be disconnected at the small AG couplers coming from the kit manifold. 3/8 AG COUPLER 6807-LL-06-06 10) Kit includes wire ties that may be used to attach the hoses to the loader arm to keep them out of harm s way. 4
11) Remove the stock handle from the loader control lever. Next remove the bushing from the new handle and drill it to fit the control lever. Be sure to back the set screws out of the bushing before drilling to avoid damaging the set screws. 13) Once drilled reinstall the bushing into new handle and install the new handle onto the loader lever. Secure bushing to loader handle using the set screws in the bushing. Route the wire harness down lever and through the rubber boot. Secure the harness with the zip ties provided by the kit. 14) Route the Green wire from the control handle wiring harness to the A coil in the valve conduit box on the D03 valve. The A coil in the conduit box will be marked at CAL with a short piece of black wire that may be discarded after this step. 15) Route the Blue wire from the control handle wiring harness to the B coil in the valve conduit box on the D05 valve. The B coil in the conduit box will be marked at CAL with a short piece of black wire that may be discarded after this step. 16) Locate the fusible link wire in your kit. The wire is in a loop. Cut the loop and check to see that there is a fuse in the holder. Attach the fuse holder wire to the white and brown wire from the control handle wiring harness. 17) Next you need to carefully find a wire coming from the tractor fuse box or other source on the tractor that has 12V preferably only when the tractor switch is ON. Using the side by side splice connector from the kit attach the fusible link to this wire. (You may have to add wire from the fusible link to conduct power to the brown and white wires in the handle harness.) 5
18) Test your electrical connections by turning the switch on and operating the kit buttons on the control handle. Each button should pull in one valve coil and should energize one of the LED lights on the valve conduit box when operated. Once this test confirms the electrical installation is correct follow these steps to seal valve conduit box. Your kit includes a plastic romex connector in the valve conduit box. Your wires should be routed through this connector as the other end of the conduit box is sealed. After all wires are routed carefully tighten the outer nut on the romex connector until the inner connector body has sealed around the wires. This will seal you valve box from water and dust and help ensure long lasting electrical 6
connections. Your kit should be fully installed and ready to test. Be sure to tighten all fittings, even if they were installed at CAL. None of the fittings installed at CAL are tightened, because they are put together to aid in system layout only. It is very possible that they may have to be removed and replaced during installation and for that reason they have been left loose for shipping. Qty-Description Parts List for Partial D03 kit 1 Scorpion control handle 1 Bushing for control handle 2 Bulkhead mounting bracket universal with hose clamp 2 Bulkhead fittings JIC/NPT (2706 6-6) 2 Bulkhead 3/8 JIC jam nuts 2 Adaptors 5405 8-6 1 Quick couplers male NV12-NPT-M same as 8010 1 Quick couplers female NV12-NPT-F same as 8010 2 Quick coupler male 3/8 SAE (NV14-38SAE-M) 2 Quick coupler female 3/8 SAE (NV14-38SAE-F) 1 Valve mount plate D03 ROPS mount 1 D03 sub plate 1 D03 valve with ground wire and lug installed and sealed romex 2 SHCS ¼-20x1-1/2 p 4 M8 flat washers 1 Hex bolt ¼-20X1 z 3 ¼ Hex nut 1 Fusible link with spring and fuse 1 Side by side splice connector 10-12 1 Side by side splice connector 14-16 4 Butt connectors 8 Wire ties Contact us: Construction Attachments, Inc., 1160 Cal Court, Lenoir, NC 28645 Tel: (828) 758-2674 Fax: 828-754-1887 E-mail: info@calmfg.comweb: www.calmfg.com 7