Installation of the 486-0608 Coupler Control Ar on Certain Hydraulic Excavators {6129, 7332, 7405, 7557} Caterpillar

Introduction

The following instructions explain the procedure to install the 486-0608 Coupler Control Ar.

Reference: Training Bulletin, GEGT0001, "Cat Pin Grabber Coupler". This guide contains an interactive 3D model in .pdf format that is available for free download at https://cmic.cat.com. Download the file. Open with Adobe Acrobat. Enable Content. Click on the image to activate. This guide is to be used as an installation and training aid. Refer to the Special Instructions for the latest parts information.

Note: Drain the hydraulic fluid from the hydraulic tank before opening the hydraulic system. Remember to fill the hydraulic tank with hydraulic fluid once the installation is complete.

Reference: Service Guide, SEBD0512, "AVSpare Service Welding Guide"

Reference: Special Instruction, REHS1841, "General Welding Procedures"

Reference: Torque Specifications, SENR3130, "Torque Specifications"

Safety Section

Illustration 1	g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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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 work tools have been lowered to the ground, and the 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.

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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

Welding Requirements

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to the next section. Refer to the illustrations in this special instruction for welding symbols and specifications.

All electrodes must be dried completely. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics may vary greatly depending on the following conditions:

• Electrode diameter

• Shielding gas

• Welding current

• Plate thickness

The following items also affect the welds:

• Geometry of welded joints

• Surface conditions

• Composition of the base metal and of the electrode

A root pass should be applied before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

For more welding information, consult the AVSpare Service Welding Guide, SEBD0512.

Parts Section

Installation of the 448-4756 Film Gp

Illustration 2	g02454257
Left side view of the cab (1) 268-4531 Film (2) 268-8872 Film (For U.S) (2) 269-0121 Film (For INTL)

Tuning Section

Set the machine tool control system.

Reference: Excavator Tool Control System, KENR6778, "Testing and Adjusting Section", "Process for setting Up the Work Tool"

Program the machine ECM to recognize the components that have been installed

Calibrate the machine electronic control system.

Reference: Excavator Tool Control System, KENR6778, "Testing and Adjusting Section", "Calibration"

Calibrate the different components that have been installed. These components may include: Foot Pedal, Thumb wheels, Attachment valve, Flow Limit valve, Variable Relief valves, and Pilot Pressure Limit valves.

Set tool flows and pressures.

Reference: Excavator Tool Control System, KENR6778, "Testing and Adjusting Section", "Process for Setting Up the Work Tool"

Set the proper operating and/or relief pressures and the proper flows for the tool that is attached to the machine. Refer to the Operation and Maintenance Manual of the specific work tool installed.