Use of the 9U5792, 4C5052, 4C5054, 4C3670 and 4C3680 Hydraulic Hose Presses{0618, 5057} Caterpillar

Introduction

The 4C3670, 4C5054 & 4C3680 Hydraulic Hose Presses can be used on any of the types of hose listed in the chart for each press. The 9U5792 and 4C5052 Hydraulic Hose Press can be used on all Caterpillar XT Hoses with crimped fittings, and on any of the types of hose listed in the chart for the 4C3670, 4C5054 & 4C3680 Hydraulic Hose Presses.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: PECP3301, Cat Hose & Couplings Reference Guide; SEBD2080, Hydraulic Hose & Reusable Coupling; SBFY0604 (microfiche), Cat Hydraulic Hose & Reusable Couplings.

Hose And Coupling Selection

For the correct size coupling for each hose diameter refer to PECP3301-02 Cat Hose & Couplings Reference Guide.

Always use correct coupling assemblies 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 and Couplings are 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 and Couplings are made for a maximum working pressure of 34 450 kPa (5,000 psi).

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

Show/hide table

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. Always install the hose and coupling assemblies according to the markings (Delta , +, or UHP) and size to avoid possible personal injury.

Cutting Hose

Use one of three methods to cut Caterpillar 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.

Coupling Installation

1. Install coupling (1) in the new hose as far as possible. Now do the same for the other end of the hose.

NOTE: The surfaces that contact each other, on both the coupling and the hose, must be free of oil.

NOTE: If either hose coupling has a straight stem, push the coupling into the hose using the procedure that follows. If both hoses have angled stems, see the topic COUPLINGS POSITION, before installation of a coupling.

2. Measure the depth of the coupling.

3. Measure the same distance on the outside of the hose and make a mark (A).

NOTE: Since it is not possible to see when the hose is bottomed in the coupling, it may be necessary to put a mark on the hose, to show the fully installed depth required.

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.

2. Adjust the position of the protractor on the hose until the bubble is level. Turn the dial to the angle position desired. (See the current Technical Partsgram.)

3. 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.

4. 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 the rear coupling (B) clockwise to the front coupling (A). In the chart, (D) is the length of the hose assembly and (E) is the degree of tolerance.

5. When the angle position is correct, crimp the coupling to the hose.

Determining Coupling Angle on Former Assembled Hoses

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.

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. 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. Watch for new cleaning tools and procedures from the Caterpillar Service Technology Group.

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 dimensions 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) Identifying symbol.

Plus (+) sign is the identification for an XT-5 hose assembly.

Delta is the identification for an XT-3 hose assembly.

UHP is the identification for an XT-6 hose assembly.

* (2) Provides the inside diameter of the hose.

B = 9.7 mm (0.38 in)

C = 12.7 mm (0.50 in) or = 15.88 mm (0.625 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) Provides the length of the hose (in centimeters).

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

* (5) Provides the coupling angle.

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

Necessary Parts

When a press is ordered, the die rings and other components are included.

The 4C3680 Press has a 4C4359 Die Ring (Black), a 4C4360 Die Ring (Silver) and a 4C5079 Hose Assembly (connects the hand pump and press) included.

The 4C3670 and 4C5054 Press has a 4C4362 Die Ring (Black) and a 4C4361 Die Ring (Silver) included.

The 9U5792 and 4C5052 Press has a 4C4372 Die Ring (Black), a 4C5483 Die Ring and a 4C4378 Adapter Bowl included.

Location of the Color Coding on Dies.

Top View of A/C die set.

Use of 4C3680 Hydraulic Hose Press Arrangement

For each hose type and size use the above chart to make the correct die and die ring selection prior to assembly.

4C3680 Hydraulic Hose Press Arrangement.

1. Slide the coupling onto the hose. See the chart entitled HOSE INSERTION DEPTH (located in the Crimp Inspection topic) to select the correct distance. The insertion depth in the chart is the coupling shell length.

2. Pull the retainer pin and swivel the cylinder out of the way.

3. Insert the die set in place.

4. Insert the hose and coupling from below in the die.

The die set will automatically position the coupling and hold it during crimping.

If an angled coupling is used, it may be necessary to remove part of the die set to install and remove the coupling and hose.

5. Place the die ring on top of the die set.

6. Reposition the cylinder and insert the retainer pin.

7. Pump the hand pump until the die ring contacts the base plate.

8. Release the pressure and remove the finished assembly.

9. Repeat this procedure for the other end of the hose assembly.

10. Check the diameter of the coupling to make sure that the crimp was done correctly. Refer to the Crimp Inspection topic.

Use of 4C3670 and 4C5054 Hydraulic Hose Press Arrangement

For each hose type and size use the above chart to make the correct die and die ring selection prior to assembly.

4C3670, 4C5054 Hydraulic Hose Press Arrangement.

1. Slide the coupling onto the hose. See the chart entitled HOSE INSERTION DEPTH (located in the Crimp Inspection topic) to select the correct distance. The insertion depth in the chart is the coupling shell length.

2. Insert the die into the base plate.

3. Insert the hose and coupling from below into the die.

The die will automatically position the coupling and hold it during crimping.

NOTE: If an angled coupling is used it may be necessary to move part of the die to insert and remove the coupling and hose.

4. Place the die ring on the top of die.

5. Activate the pump by pulling the control handle forward. When the die ring contacts the base plate, the crimp is complete.

NOTE: Do not adjust factory relief valve setting or damage may result.

6. Push the control handle to open the die. Remove the finished assembly.

7. Repeat this procedure for the other end of the hose assembly.

8. Check the diameter of the coupling to make sure that the crimp was done correctly. Refer to the Crimp Inspection topic.

Use of 9U5792 and 4C5052 Hydraulic Hose Press Arrangement

NOTE: For 31.8 mm (1.25") diameter hose see both of the sections in this topic to determine which section is required according to the type of hose and coupling used.

9U5792, 4C5052 Hydraulic Hose Press Arrangement. 1/4

For Hoses Through 1 " I.D.

NOTE: Use the above charts to make the correct hose and die selection prior to assembly.

* For XT Hoses: Start at Step 1 and perform all the steps.

* For other than XT Hoses: Proceed to Step 8 and perform the remaining steps.

1. Put the hose in clamp jaws of the hose skiing vise (1). Install coupling sleeve (2).

NOTE: Hose skiving vise is no longer available. Prints to fabricate a similar vise are available at no charge from Caterpillar Service Technology Group. Please order print No. FT2270.

NOTE: Standard bench vise can be used, or Caterpillar Hose Press (4C9900). See Special Instruction, SEHS7957, For operating instructions.

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 with symbol Delta for XT3 Hose. Tighten the clamp.

NOTE: If 6V6022 Skiving Gauge is not available, refer to the chart that follows 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. Using 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 skiving.

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

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

8. For XT Hoses refer to the Coupling Installation topic of this Instruction to install the coupling.

For other hoses slide the coupling onto the hose. See the chart called HOSE INSERTION DEPTH (located in the topic entitled Crimp Inspection) to select the correct distance. The insertion depth is the coupling shell length.

9. With the pusher in the full up position, lift the back half of the split die ring. Lock it in the up position by pushing the slide pin in (the slide pin is located inside the pusher in the back).

10. Carefully insert the 4C4378 Adapter Bowl (5) into the base bowl. The adapter bowl must be tilted toward the back of the hose press during insertion.

11. Insert the die into the adapter bowl. See the note in Step 15 about angled couplings.

12. Place the die ring on the die. The ring should fit on the locating step of the adapter bowl. This step is not necessary if a die ring is not required (see chart for appropriate hoses).

13. Lower the back half of the split die ring onto the die by pulling the slide pin forward.

14. Inser the front half of the split die ring aligning the pin in the back half with the hole in the front half.

15. Insert the hose and coupling from below into the die.

The die will automatically position the coupling and hold it during crimping.

NOTE: For angled couplings it may be necessary to insert hose and coupling into die prior to installing split die ring. The die may require partial removal to insert and remove angled coupling.

16. Turn on the pump by pushing the green button at the left hand side of the machine. Lower the pusher by pulling the lever towards you. When the die ring contacts the adapter bowl, the crimp is complete.

17. Push the lever away from you to open die and remove the finished assembly.

18. Repeat this procedure for the opposite end of the hose assembly.

19. Check the diameter of the coupling to make sure that the crimp was done correctly. Refer to the Crimp Inspection topic.

For Hoses With 1 " I.D. and Up

For each hose type and size use the above chart to make the correct die and/or die ring selection prior to assembly.

1. Slide the coupling onto the hose. See the chart called HOSE INSERTION DEPTH (located in the topic entitled Crimp Inspection) to select the correct distance. The insertion depth is the coupling shell length.

2. With the pusher in the full up position, lift the back half of the split die ring. Lock it in the up position by pushing the slide pin in (the slide pin is located inside the pusher at the back).

3. Place the die ring (1) on the base bowl. Locate the die ring by inserting the two roll pins in the holes on the base plate. Step 3 is not necessary if a die ring is not required (see chart for appropriate hose and coupling).

Two Piece Die Set

Installed Die Set in Base Plate

4. Insert the die into the base bowl. All of the dies come in two pieces.

5. Insert the hose and coupling from below into the die.

The die will automatically position the coupling and hold it during crimping.

NOTE: For angled couplings it may be necessary to insert hose and coupling into die prior to installing split die ring. The die may require partial removal to insert and remove angled coupling.

6. Lower the back half of the split die ring onto the die by pulling the slide pin forward.

7. Insert the front half of the split die ring aligning the pin in the back half with the hole in the front half.

8. Turn on the pump by pushing the green button at the left hand side of the machine. Lower the pusher by pulling the lever towards you. When the die ring contacts the adapter bowl, the crimp is complete.

9. Push the lever away from you to open die and remove the finished assembly.

NOTE: You do not have to remove any tooling to remove or insert straight couplings. The front half of the split die ring may have to be removed to insert and remove bent couplings.

10. Repeat this procedure for the opposite end of the hose assembly.

11. Check the diameter of the coupling to make sure that the crimp was done correctly. Refer to the Crimp Inspection topic.

Crimp Inspection

* In Step 1 the (A) dimension in the illustration is for XT hoses ONLY.

* For other than XT hoses, dimension (A) is the Hose Insertion Depth (full length of the shell).

Crimped couplings should be inspected both visually and dimensionally to be sure of configuration to design specifications. Refer to the above charts for hose crimp length (A) and diameter specifications.

NOTE: For crimp diameter, make two measurements (B) and (C), 90° apart, and average these two measurements. Crimp diameter measurements are to be taken at the middle of the crimp length and at the center of the crimp segment.

Air Conditioning Hose Crimping

The Hose crimping procedure for air conditioning hose assemblies is relatively the same as other assemblies with permanent couplings. Using the information in this Special Instruction, the differences will be identified below. Hose insertion depth for air conditioning couplings is 40.4 mm (1.59 in).

1. Insert hose into coupling to proper depth.

2. Position the coupling in the die set such that the coupling shell contact is maintained with the "U-shaped crimp locator" on the die set during the crimping process.

It is a good crimp if:

* hose cover extrudes some from the hole at the top of coupling. (This ensures that the hose is seated in the coupling).

* the hose should not bulge at bottom/skirt of shell.

* crimp measurements should be within range in the following chart.

NOTE: Do not cut hoses with an abrasive saw or other types of rotating blade saws. Use a sharp knife so that the hose is not pinched and a square cut can be attained for proper seating with the coupling.

1. Coupling Tube. 2. Bottom/Skirt of shell. 3. Hose. 4. Coupling Shell View Hole.

Bulk Armor Guard for A/C (1543) Hose.

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 following chart.

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.

Replacement Parts

Replacement parts are available for each hose press arrangement. Each arrangement is listed separately along with the available part numbers and part description.

4C3680 Hydraulic Hose Press Arrangement

4C4360 Die Ring (silver)

4C4359 Die Ring (black)

4C4355 Pin

4C4356 Die Separator

4C4358 Pusher

4C4357 Spring

4C5079 Hose Assembly

4C3670 and 4C5054 Hydraulic Hose Press

4C4361 Die Ring (silver)

4C4362 Die Ring (black)

4C4363 Die Separator

4C4364 Bearing Follower

4C4365 Left Ramp

4C4366 Right Ramp

4C4367 Pusher

4C4368 Pump Assembly

4C4371 Tank Assembly

4C4370 Valve

4C4369 Handle

4C3058 Guard

4C4461 Motor Assembly

9U5792 and 4C5052 Hydraulic Hose Press

4C4378 Adapter Bowl

4C4373 Split Die Ring

4C4372 Die Ring (black)

4C4374 Die Separator

4C4375 Conical Spring

4C4376 Snap Ring

4C3059 Guard

4C5483 Die Ring