Installation of the <NOBR>486-9932</NOBR> Auxiliary Control Ar (Medium Pressure) on Certain Hydraulic Excavators {1408, 5057, 5059, 5070, 5073, 7405, 7557} Caterpillar


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Installation of the <NOBR>486-9932</NOBR> Auxiliary Control Ar (Medium Pressure) on Certain Hydraulic Excavators {1408, 5057, 5059, 5070, 5073, 7405, 7557} [M0066436]
ELECTRICAL AND STARTING SYSTEM
WIRING GP
Installation of the <NOBR>486-9932</NOBR> Auxiliary Control Ar (Medium Pressure) on Certain Hydraulic Excavators {1408, 5057, 5059, 5070, 5073, 7405, 7557}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Tuning Section
5.2. Set the machine tool control system.
6.2. Calibrate the machine electronic control system.
7.2. Set tool flows and pressures.
Excavator
325F (S/N: XAA1-10000; YCA1-10000)
Work Tool
HYDRAULIC KIT (S/N: HKF1-UP)

Introduction

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, GEHS1181, "Tool Control Systems Supplemental Guide"

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

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

Reference: Torque Specifications, SENR3130, "Torque Specifications"

Safety Section



Illustration 1g00104545

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.

------ WARNING! ------

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.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

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.


------ WARNING! ------

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.


------ WARNING! ------

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.


------ WARNING! ------

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


Required Parts

Table 1
486-9932 Auxiliary Control Ar"Revision - 00" 
Qty  Part No.  Description  Media 
(1)  204-2747  Auxiliary Pump and Mounting Gp  REHS3941 
(1)  451-7514  Front Lines Gp  M0066438 
(1)  451-7525  Pilot Lines Gp  M0066440 
(1)  451-8356  Medium Pressure Wiring  M0066442 
(1)  444-9174  Film 
(1)  451-7490  Pump Lines Gp  M0066446 

Tuning Section

Set the machine tool control system.

Reference: Excavator Tool Control System, UENR6229, "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, UENR6229, "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, UENR6229, "Testing and Adjusting Section", "Medium Pressure: Hydraulic System"

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.

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