Use of 4C9900 Hydraulic Hose Service Press{0738, 5057} Caterpillar

Introduction

This Special Instruction contains safety information, operating instructions, parts information and tool recommendations for use of the 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Press. Use of the 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Presses and connected tooling permits the maintenance of a minimum stock of XT-3, XT-5, and XT-6 hose and couplings.

Some photographs or illustrations in this publication show details or attachments that may be different from your press. Also, guards and covers may have been removed for illustrative purposes.

Continuing improvement and advancement of product design may have caused changes to your press which are not included in this publication. Whenever a question arises regarding your press or this publication, please consult Caterpillar Service Technology Group at the telephone numbers listed below. Regular business hours are from 8:00 a.m. to 4:30 p.m. (Central Time Zone).

1-800-542-8665 (USA)

1-800-541-8665 (Illinois)

1-800-543-8665 (Canada)

32 (2) 254.42.71 (Belgium)

1-309-675-6618 (Fax)

32 (2) 252.56.06 (Belgium Fax)

Customers may also contact the Caterpillar Service Technology Group through the TELEX. Our number is 404435.

Reference: SEBD2080, Hydraulic Hose and Reusable Couplings (paper) or SBFY0604 (microfiche).

Safety Information

General

Use proper tools in good condition and replace or repair damaged equipment.

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

Always wear protective glasses when using a hammer or similar tool to avoid injury to your eyes. Chips or other debris can fly off objects when struck. Make sure no one can be injured by flying debris before striking any object.

The hose coupling press has the capability of producing 445 kN (50 Ton) of force. To avoid personal injury, use the established operating procedure in this Special Instruction.

Press Operation

When operating the press, always wear protective glasses.

Never stand directly in front, rear, or at sides of the press. Bad parts or a wrong set-up could cause parts to be thrown out of the press. Stand in areas marked with an "X".

Always use the correct collets for the hose and coupling size. Improper sizing and installation of the collets or improper use of the press can cause the hose and/or fitting to be suddenly released and strike someone, causing personal injury.

Knife And Anvil Cutting Method

Cut only (Delta ) XT-3 hose with this press. Do not cut (+) XT-5 hose or (UHP) XT-6 hose with this press. Do not use broken tools. Use only the tools made for the press. Make sure knife (1) is in alignment with the center of the flat surface of anvil (2).

Always use clamp assembly (3) to hold front collets (4) in position. Never open the clamp until the pressure in the hydraulic cylinder is released.

NOTE: In some photos, the clamp and shield on the hydraulic press are out of position for illustrative purposes. When the press is in use, the clamp and shield must be in their proper position.

Resizing

Always resize (recondition) the stem (I.D.) of used couplings during the reconditioning process to make sure that the stem of the coupling holds the hose correctly. Failure to resize can permit coupling blowoff (separation by force) and cause personal injury.

Always install the couplings in the correct position in the tool collets and in line with the action of the press.

Never install couplings on used hose, or apply oil between the coupling and hose. Coupling retention (ability to hold) is lowered on hose that has been in contact with hydraulic fluid.

Hose And Coupling Selection

Always use correct coupling assemblies and sleeves that are in relation to the correct size of hose.

The XT-3, XT-5 and XT-6 Hydraulic Hose and couplings are similar in many ways, and caution should be used when identifying the differences.

Use only parts that have a:

* (Delta ) triangular marking with XT-3 hose.* (+) symbol with XT-5 hose.* "UHP" mark with XT-6 hose.

Never use a hose at a greater hydraulic pressure than its recommended working pressure.

XT-3 (Delta ) Hydraulic Hose is made for working (usable) pressures of 17 225 to 27 560 kPa (2,500 to 4,000 psi), depending upon hose size.

All XT-5 (+) Hydraulic Hose is made for a maximum working pressure of 34 450 kPa (5,000 psi).

All XT-6 (UHP) Hydraulic Hose is made for a maximum working pressure of 41 340 kPa (6,000 psi).

Always install the hose, coupling assemblies and sleeves according to the marking (Delta , +, or UHP) and size. Any mismatching or interchanging of couplings and hoses can cause the coupling to blow off the hose under pressure (separation with sudden force) and cause personal injury.

Cutoff Saws

Improper use of saws and cutoff wheels can cause personal injury. Always use protective equipment and the recommended procedure for cutting each type of hose.

Coupling Identification

(1) XT-3 (Delta ) Coupling and Sleeve. (2) XT-5 (+) Coupling and Sleeve. (3) XT-6 (UHP) Coupling and Sleeve.

(A) Coupling. (B) Sleeve.

The hydraulic press is needed to remove and install couplings (A) and sleeves (B). Use the procedures in this instruction and make reference to SEBD2080.

Cutting Tool Reconditioning

Knife and Anvil

(1) Cutting knife.

(2) Anvil.

Cutting knife blades are replaceable. Keep hose cutting knife (1) sharp and the surface of anvil (2) ground smooth to be sure of a straight, even cut. Do not permit too much heat on the surfaces when reconditioning the knife and the anvil.

Skiving Knife Blade Sharpening

Flat file.

Round file.

The blade of skiving knife (3) is softer than the wire used in the hydraulic hose. This prevents damage to the wire by the skiving knife. The edge of the blade will become less sharp on the inside of the cutter. Sharpen the cutter by removing only the metal that has bent over on the inside edge. Use a round file only in the corners.

Cutting Hose

Use one of three methods to cut Caterpillar XT-Hose. A cutting tolerance is also required to achieve the desired length of hose. Make reference to the charts and the instructions that follow for cutting method and tolerance recommendations.

Knife And Anvil

1. To cut XT-3 Hose with an knife and anvil, install anvil (5) and knife (6) in the press. Use clamp assembly (7) to tighten the anvil in position. Measure the hose and check the chart for the correct tolerances. Carefully put the hose in position and close the press to cut.

Note oval shape of hose after cut.

2. Make the cut end round by using a 1S0258 Plastic Hammer (8). Put one point of the cut on a solid surface and hit the other point at an angle.

Friction Saw or Abrasive Saw

Friction saw.

1. When XT-3, XT-5, and XT-6 Hose are cut on either the 5P6540 or 5P6542 Friction Saw, the hose must be bent as shown. When cutting small diameter hose (1), put pins (2) in position toward the center of table (3). For larger diameter hose (4), move pins (2) toward the outer edge of the table.

Abrasive saw.

If an abrasive cutoff method is used, more care must be used to clean the hose because this method causes more foreign material than the friction cutoff method.

Skiving Hose

1. Place the hose into the hydraulic press (1), and clamp. Install coupling sleeve (2).

NOTE: Be sure to use the correct collets for the type and size of hose to be skived. Refer to the Necessary Tools Chart and select the correct Grip Collets.

OR

Put the hose in the clamp jaws of 6V6018 Hose Skiving Vise (1). Install coupling sleeve (2).

NOTE: 6V6018 Hose Skiving Vise is no longer available. Prints to fabricate a similar vise is available at no charge from Caterpillar Service Technology Group. Please order print no. FT2270.

2. Adjust the hose in the clamp. Use 6V6022 Skiving Gauge (3) and coupling sleeve (2) to set the skiving length. Use the correct scale on the gauge marked (Delta ) for XT-3, (+) for XT-5, and (UHP) for XT-6 Hose. Tighten the clamp.

NOTE: If 6V6022 Skiving Gauge is not available, refer to the charts that follow for the correct skiving length.

(A) Inside diameter. (B) Skiving length.

NOTE: Do not permit wire to show beyond the end of the coupling fingers. See the above chart for the correct skiving length.

3. Put arbor (4) into the end of the hose.

4. Use sleeve (2) as a guide, make the first cut counterclockwise. The lay of the wire and the counterclockwise cut will force the skiving tool to make a straight cut against the sleeve.

5. To prevent the pull up of wire ends, turn clockwise to finish the skiving.

6. When the wires can be seen, the skiving is finished. Do not remove material from between the wires. A clean or shiny look is not necessary.

7. Remove arbor (4). Do the same procedure on the other end of the hose. Keep the skiving knife sharp.

Coupling Installation

NOTE: If Round Wire Armor Guard is to be installed, refer to the topic Round Wire Armor Guard For Hose Assemblies before installing the second coupling onto the hose. Round Wire Armor Guard cannot be installed if both couplings have been installed.

1. Slide sleeve (1) on the hose with the larger chamfer toward the end of the hose. Install coupling (2) in the new hose as far as possible. Do the same procedure for the other end of the hose.

2. To push the coupling on the hose, use the correct front grip collets and rear collets. Make the correct selections from the charts that follow.

NOTE: If either hose coupling has a straight stem, push the couplings into the hose using the following steps. If both couplings have angled stems, refer to the topic Coupling Position before pushing the coupling on.

3. Install the grip collets at location (A). Install the rear collets at location (B).

4. Fasten the grip collets tightly. Close the press to push the stem into the hose.

5. Use a hammer with plastic tips to put the fingers tight against the hose.

6. To install the sleeve which holds the coupling, make a selection of the correct collets from the charts above. Where the front collet counterbore faces the rear, put the sleeve in the collet counterbore. The rear collet counterbore is generally toward the rear.

It is necessary to put both the front and rear collets in reverse position for head clearance of smaller 90° couplings.

7. Install the assembly and collets in the press. Put a small amount of oil on the outside of stem assembly fingers (B). Do Not put any oil between stem assembly fingers and the hose.

Show/hide table

To avoid serious injury from flying objects, make sure the hose is free to slide in the front collets. Check the alignment of the parts, then close the press until the sleeve is even with the coupling shoulder.

8. Do this procedure for the other coupling if either coupling has a straight stem, otherwise, see the following topic.

Coupling Position

7S1125 Protractor

1. Put assembled coupling (1) in a vise with flange (2) up as shown. Adjust the dial of 7S1125 Protractor (3) to zero. With the dial face of protractor (3) toward the vise, fasten the protractor near the sleeve of the coupling. Adjust the position of the protractor on the hose until the bubble is level. Turn the dial to the angle position desired. Refer to SEBD2080 or SBFY0604.

2. Remove assembled coupling (1) from the vise, turn the hose end-for-end, and fasten the loose coupling in the vise with the flange up. It is important that the flange direction on the loose coupling is the same as the flange direction on the assembled coupling.

3. Use assembled coupling (1) to turn the hose until the bubble is level. Remove the protractor.

NOTE: Coupling angle (C) is measured from the position of coupling (B) clockwise to coupling (A). In the chart, (D) is the length of the hose assembly and (E) is the degree of tolerance.

4. When the angle position is correct, install sleeve (5). See Coupling Installation.

1U9124 Protractor

The same procedure that was used for the 7S1125 Protractor can be used for the 1U9124 Protractor. The 1U9124 Protractor scale is broken up into 90° divisions.

When reading an angle greater than 90° use the angle reading in the quadrant as indicated by the dial and add 90° to this reading.

NOTE: When installing or removing the protractor group, we recommend that two hands be used.

Determining Coupling Angle On Former Assembled Hoses

NOTE: This method is the same for the 7S1125 and the 1U9124 Protractors.

1. Put one coupling in a vise with the flange up as shown. Adjust the dial of protractor (1) to zero. With the dial face of protractor (1) toward the vise, fasten the protractor near the sleeve of the coupling. Adjust the position of the protractor on the hose unit until the bubble is level for the 7S1125, or the arrow is aligned for the 1U9124.

2. Remove the hose and protractor from the vise and install the other coupling in the vise as shown.

3. Turn the dial until the bubble is level, or the arrow is aligned. Read the angle position from the dial. Use this angle position for the new hose.

Cleaning Hoses

Hoses that are not clean can cause hydraulic system component damage. Foreign material inside the ends of the hose can cause grip failure and sudden release of the coupling from the hose. The use of a blade type cutoff saw or a wire brush skiver can leave foreign material in the hose.

Show/hide table

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

After the hose has been cut, hit both ends of the hose to remove any large particles. Use compressed air to push out any rubber dust that may have been caused when cutting. Finally, use a clean dry cloth to clean out both ends of the hose.

After a hose has been assembled, put caps (1) over both ends during storage. The caps give the O-ring grooves in the flange protection from damage. They also keep foreign materials out of the hose. Caps (1) are available from the following suppliers:

Hose Assembly Identification

If a hose has been assembled according to dimension given in SEBD2080 or SBFY0604 and is not going to be used immediately, identification should be put on the hose for future reference.

Aluminum tags, like the ones used by Caterpillar are available from the suppliers below. Use metal stamps to add the identification.

Metal tags, made by Dymo Metal Tape, can be fastened with wire to a hose assembly. The tape and marking equipment are available from the supplier below.

If hose assemblies are made for applications other than Caterpillar, the technical information for the part can be put on the tag through code type identification. This would make it easier for future replacement of hoses used in non-Caterpillar applications.

An example of a code system is as follows:

(1) Plus (+) sign is the identification for an XT-5 hose assembly, (Delta ) is the identification for an XT-3 hose assembly, and UHP is the identification for an XT-6 hose assembly.

(2) Gives the inside diameter of the hose.

B = 9.7 mm (0.38 in)

C = 12.7 mm (0.50 in)

D = 19.1 mm (0.75 in)

E = 25.4 mm (1.00 in)

F = 31.8 mm (1.25 in)

G = 38.1 mm (1.50 in)

H = 50.8 mm (2.00 in)

(3) Gives the length of the hose (in centimeters).

(4) Gives the Caterpillar part number of stem assemblies (two are necessary for each hose assembly).

(5) Gives the coupling angle.

(6) Shows if armor is necessary. If armor is not necessary, "A" will not be present.

Reconditioning Used Couplings

An important feature of Caterpillar XT-3, XT-5, and XT-6 Hydraulic Hose Assemblies is the ability to use the couplings again. When these couplings are used again, care must be taken to be sure the reconditioning has been done correctly and completely. Do not use damaged couplings, or those with defects.

The following pages give in detail the procedure for reconditioning used couplings. If this procedure is not followed, the result can be a sudden release of the coupling off the hose under pressure. Used couplings without reconditioning, should be put in separate storage with identification of condition.

1. Each time, be sure the correct collets are installed so that the best possible alignment is kept.

2. Use finger expander tool (1) to open the coupling fingers each time.

3. Use stem expander (2) for reconditioning the inside diameter of the stem. See the pages that follow.

Sleeve Removal

1. Cut the used hose 76.2 mm (3.00 in) from the couplings.

NOTE: Cut the hose as close as possible to the dimension given. Cutting the hose too long or too short can cause misalignment when expanding the fingers.

2. Put oil on the inside surface of the hose.

3. Install pusher (1) into the hose.

4. Install plate (2), collets (3) and the coupling in the press.

Use the collets shown in the chart below for the size of hose and couplings to be disassembled.

NOTE: The counterbores should be toward the rear of the press.

5. Install the top collet and slide clamp (4) into position.

6. Be sure the coupling is in position in the front counterbore parallel to the action of the press. Tighten clamp (4), close the press and remove the sleeve.

Coupling Removal

1. Install pusher into end of hose.

2. Install the assembly in the press. Install the pusher plate into the press.

3. Install the top collets. Tighten the front collets to hold the coupling shoulder solidly in the counterbore.

Show/hide table

Failure to use the proper collets with the counterbore facing in the specified direction could result in improper clamping. Personal injury can result from couplings being propelled by the press force when not properly clamped.

Show/hide table

Do Not push too far. Couplings could be propelled and cause personal injury.

4. Close the press enough for expansion of the coupling fingers. Release the press and remove the coupling.

5. Put the coupling in a vise and use a screwdriver to further expand the fingers. Sometimes the hose can be removed from the coupling by hand. This usually works on many of the smaller XT-3 sizes.

6. For larger size hoses and any of the problem smaller sizes, except 19.0 mm (0.75 in) and 25.4 mm (1.00 in) XT-5, put the coupling assembly in the press using front grip collets (4) and plate (5).

7. Slide clamp (6) in position and tighten it to hold the hose.

8. Push the coupling out of the hose. Use 1U8760 Chain Wrench (7) to twist the coupling in the hose during removal.

19.0 mm (0.75 in) through 38.1 mm (1.50 in) XT-5 Hose

For 19.0 mm (0.75 in) through 38.1 (1.50 in) XT-5 Hose, use the tools shown in the following chart to remove the coupling from the hose.

Install the coupling pusher into the hose and against the coupling. Slide the hose mandrel over the pusher and into the hose. Put the coupling assembly in the press with the correct tooling. Tighten the clamp and push the coupling out of the hose. Use a 1U8760 Chain Wrench to twist the coupling in the hose during removal.

Coupling Reconditioning

1. Start stem expander (1) into the coupling. Install plate (2) and the assembly into the press and tighten the clamp.

2. When reconditioning XT Hose Couplings, push stem expander (1) into the stem to the location shown in the chart below.

3. Do not push 5P5232 Stem Expander (1) to the full depth when used on 19.7 mm (0.75 in) 45° 3S8360 or 6V4664 Coupling (3). Look through the end of the coupling at location (F) to make sure that the end of the stem expander (1) does not damage the elbow at location (G).

4. To remove the expander, move the coupling assembly so the fingers are ahead of the collets and fasten the clamp loosely. Reverse the press.

5. Slide finger expander (4) over the end of the stem of the coupling.

6. Install the front collets and the coupling in the press.

7. Tighten the clamp and push the expander beyond bend (A) in the fingers, but do not push the finger expander against the base of the coupling.

8. Use a hammer with plastic tips to move the fingers tight against the expander.

9. Remove any rough places or scratches on the coupling.

Cleaning Couplings After Reconditioning

Reconditioning procedures generally cause oil to be left on the outside diameter of the stem of the coupling and on the inside of the fingers. In order to get the maximum grip from the fingers and the serrations (teeth) of the stem, follow these procedures to clean the couplings:

1. Clean each used coupling in a solvent that completely removes all oil.

2. Use a brush to remove any particles of hose inner liner.

Show/hide table

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

3. Use compressed air to dry the coupling.

4. Do Not install the coupling in a hose until the coupling feels dry.

5. Do Not use any cleaning process (chemical or particle blast) that removes the chromate (gold color) coating from the coupling.

JIC Coupling

The above photo shows the difference between the old and new JIC couplings.

Correct position.

1. Put coupling (1) in position so that the face of the coupling is against the face of the collet (2).

Incorrect position.

Do not permit nut (3) to be against the face of collet (2).

2. Use the following charts to find the correct collets for the hose size desired.

Press Replacement Parts

1U9160 Hydraulic Hose Service Press

4C9900 & 6V4880 Hydraulic Hose Service Press

Press Gauge

Typical installation of a 9S2240 Bottom Connection Gauge

Hydraulic Pumps

The 1U5555 or 1U5565 Hydraulic Pumps are recommended for use with either the 1U9160, 4C9900 or 6V4880 Hose Press. Each pump is equipped electrically to run on one specific voltage. However, if a different voltage is required, each pump can be changed electrically according to instructions with the pump.

Each of the other hydraulic pumps, 2P5550, 2P5500, 3S6224, and 8S8033, can run on the voltages shown in the chart. They are not limited to 50 or 60 Hertz operation.

The 1U5230 Pump (hand operated) can be used if electric power is not available.

When the hose press is used, read the 50 TON (red) scale (ram out) on the 9S2240 Pressure Gauge.

Round Wire Armor Guard For Hose Assemblies

NOTE: The round armor guard is installed after one coupling has been installed, and before installing the second coupling.

1. Select the correct size armor guard for the hose size being used from the chart that follows.

2. Cut the armor guard to the required length to protect the exposed portion of the hose. The correct armor guard length is the length of the hose less the sleeve length of each coupling.

3. Install the armor guard onto the hose and install the sleeve on the hose with the larger chamfer toward the end of the hose. Install coupling (2) in the new hose as far as possible.

4. Refer to the topic Coupling Installation for instructions to complete the installation.

Necessary Tools

Other Tools

1. 6V4931 Holder and 5S5173 Knife. 2. 6V4929 Anvil. 3. 6V4913 Plate. 4. 1S0258 Plastic Hammer. 5. 7S1125 Protractor. 6. 1U9159 Skiving Tool. 7. 5P3277 Tape. 8. 6V6022 Gauge Assembly (Skiving). 9. 5P6223 Blade. 10. 1U8760 Strap Wrench. 11. 6V7061 Crimping Die. 12. 6V4912 Plate. 13. 6V6016 Blade.

NOTE: Items 1, 2, 3, 4, 7, 9, 10, 11, and 13 are not part of 4C9901 Basic Accessory Group.