Installation Procedure for the 448-1172 Coupler Control Ar {1408, 5057, 7301, 7405, 7557} Caterpillar

Installation Procedure for the 448-1172 Coupler Control Ar {1408, 5057, 7301, 7405, 7557}

Usage:

Excavator:: 336E (S/N: KED1-UP; YCE1-UP; TEG1-UP; FJH1-UP; GTJ1-UP; JRJ1-UP; YEP1-UP; BZY1-UP; TMZ1-UP)
Work Tool:: HYDRAULIC KIT (S/N: HKB1-UP)

Introduction

The following instructions explain the procedure to install the 448-1172 Quick Coupler Control Ar .

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.

ReferenceService Guide, SEBD0512, "Caterpillar Service Welding Guide"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

ReferenceTorque Specifications, SENR3130, "Torque Specifications"

ReferenceTraining 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.

Safety Section

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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 Caterpillar 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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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.

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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.

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NOTICE

Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

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 Caterpillar Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.

Remove any oil or grease with a Caterpillar approved solvent.

Note: After welding, allow all areas to cool to room temperature. After the areas have cooled, paint the area with primer. After the primer has dried, coat the area with Caterpillar 4C-4200 Yellow Paint .

Parts Section

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Table 1
448-1172 Quick Coupler Control Ar
Qty	Part Number	Description	Media
1	319-1197	Chassis Wiring Gp	GEHS0663
1	378-6948	Cab Wiring Gp	GEHS0664
1	443-4728	Front Lines Gp	GEHS0665
1	343-8342	Hydraulic Lines Kit	REHS3854
1	448-4756	Film Gp	-

Installation of the 448-4756 Film Gp

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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.

ReferenceExcavator Tool Control System, KENR7988, "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.

ReferenceExcavator Tool Control System, KENR9508, "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.

ReferenceExcavator Tool Control System, KENR7988, "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.