- Caterpillar Products: All
Introduction
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
European Union Compliant, CE marked
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator, and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.
Service Parts Section
The Service Parts Section is a reference for parts identification and available part numbers.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02140175 |
Personal Protection/Important Information | |
Prohibited Action
| Do Not Weld |
| No Smoking |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Introduction
All operators of the Crimputer III 358-4535 (C3) and 457-6030 (C3-290) should read and become familiar with this manual. The C3 and C3-290 are microprocessor-based controllers, which contain a database of hose and coupling types and sizes. The 457-6030 C3-290 is the new replacement kit used on the Cat Legacy Crimper (CLC290).Crimping specifications and tolerances are also included for comparison to the measured values, which can be measured at the completion of the crimp. The C3 and C3-290 will adjust the controlling numbers (DVDT) to compensate for wear or other discrepancies. The C3 and C3-290 is compatible and can be replaced with part numbers 358-4532, 457-6037, 457-6038, 423-4361. For more information on compatibility, contact Dealer Service Tools (DST).
Setup/Operation
The Illustration shows and explains the physical buttons on the Crimputer III panel. It is recommended that the operator gets familiarized with this control panel before using this machine.
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| Illustration 3 | g03864146 |
(1) Emergency Stop Button - When the emergency stop button is engaged, this machine will no longer allow the operator to turn on the C3 or C3-290 until this button has been released.
(2) Motor OFF - Shuts off any hydraulic pressure in the system.
(3) Motor ON - Engages the hydraulic system to begin the hose crimping process.
(4) Double Foot Switch - Overrides buttons (5) and (6) to allow the operator to use the foot pedals.
(5) Jaw Open - Expands die group back to its original position.
(6) Jaw Close - Die group is engaged to begin crimp.
Checking Software
Checking the software is recommended as a first step before the operator logs in.
- The "i" button shown in Illustration 2 will provide the user access to the current software revision of the C3 and C3-290. It is recommended that the operator check for updates on dealer.cat.com. It is important that the correct software is installed for most recent capabilities and availability crimps.
Note: https://dealer.cat.com/ is the direct URL to the website.
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| Illustration 4 | g03864427 |
- In order to ensure that your C3 and C3-290 has the most updated software, go to dealer.cat.com.
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| Illustration 5 | g03864493 |
- Once you have reached that point, click on service tool, which is listed under product support.
Note: Illustration 3 is only an example screenshot and does not reflect any current software versions.
Log in/User Management
- When the C3 and C3-290 is turned on, press the OK button shown in Illustration 4 to begin the process.
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| Illustration 6 | g03866422 |
- The default user ID and password is set to CAT.
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| Illustration 7 | g03866429 |
Additional Users
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| Illustration 8 | g03866430 |
Create a new user so the user can log on under the user designation in runtime. After the project has been transferred as an alternative, the users can be changed and created with the User View in runtime. Logon is only successful if the user designation entered during logon agrees with the user in runtime. In addition, the password entered at logon has to agree with the password of the user.
Note: The user designation must be unique within the project, or the input is not accepted.
Note: In order for a created user to have authorizations, the user has to be assigned to a user group, and allocate authorizations to the user group. Currently, user groups 9 and 1 are the only user groups available.
The following options are available for the range of changes that can be made:
- The administrator, or a user with user administration authorization, can change the data for all users on the C3 and C3-290 system in the user view: User Name, Group Assignment, Password, and Logoff Times.
- A user without user administration authorization can only change the user data: Password and Logoff time.
Note: An additional dialog will be displayed when you alter a password. The input of the password is concealed.
- Click on an empty line in the "Name" column on the "Users" table.
Note: Use only alphanumeric characters and space characters for user names.
- Enter "Foreman" for the user designation.
- Touch the "Password" column.
- Enter the password of the user.
- Specify that the "Log Off Time" (5 minutes) is preset as the "Log Off Time".
Note: If you enter the value "0" in the log-off time, there will be no automatic user log-off.
Setup
Note: Once the user has logged in, the next screen on the panel is referred to as the "Home" screen. This screen provides access to Crimp information, Setup, and Utility. Each of these buttons on this screen will be covered in detail.
- To begin selecting a language, press the Setup box that is outlined in red in the image above.
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| Illustration 9 | g03866720 |
- Push the flag to select the proper language. Use the arrows to advance to the next Setup function.
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| Illustration 10 | g03866745 |
- Press the ">>" twice to move on to editing user data and sensor information. If you press ">>" once, you will continue onto the Logfile screen.
LogFile to USB
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| Illustration 11 | g03866770 |
- Click LogFile to USB that is shown in Illustration 11.
- There is a standard USB port located on the back side of the C3 and C3-290 panels. The operator can insert a standard USB flash drive to download the data. Once the data is downloaded, the data will include the user ID, Hose Type, Coupling, Crimp Specs, Actual Crimp, Date/Time, Stamps,etc.
Sensor Information
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| Illustration 12 | g03866771 |
- From this screen, start the hydraulic motor and push the Open and Close buttons several times to purge hydraulics and verify machine operation.
Note: Hydraulic motor will automatically shut off after 20 seconds if there is no machine activity.
- When complete, push back arrow soft key to back out to the Crimputer III main menu screen.
Utility
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| Illustration 13 | g03866775 |
- When logged on, the controller displays the Crimputer III Menu screen. One of the options available is the Utility button, which will guide the user to Probe Calibration shown in Illustration 13.
- Select "Utility" from the Crimputer III menu screen.
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| Illustration 14 | g03866822 |
- The next step is to calibrate hose machine and the section below covers the details of the process.
Calibration Procedure
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| Illustration 15 | g03866833 |
- C3 and C3-290 will prompt you to install the 32mm Die Group. Refer to the section, Installation, and Removal of 239 Series Crimping Dies, and complete the steps for a die change. When the die change is completed, press the GO soft key. The screen will advance to Step 2 of 5.
Note: There may or may not be a set of 239 Series Dies in the Adapter Dies. Therefore, either remove and install the 32mm dies, or install the 32mm dies.
- Insert the small end of the 423-4364 Calibration Mandrel into the dies. Start motor and push and hold the Close button until dies stop. The screen will advance to step 3 of 5.
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| Illustration 16 | g03866848 |
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| Illustration 17 | g03866852 |
- Open die and remove mandrel. Press OK when ready. The screen will advance to step 4 of 5.
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| Illustration 18 | g03866875 |
- Insert the large end of the 423-4364 Calibration Mandrel into the dies. Start motor. Push and hold the Close button until the dies stop. The screen will advance to step 5 of 5.
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| Illustration 19 | g03866880 |
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| Illustration 20 | g03866889 |
- Screen will display "Calibration Complete". Open dies and remove mandrel.
- Check calibration number. It should have a value between 1.00 and 1.03. If the value is out of limits, perform calibration again.
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| Illustration 21 | g03866893 |
- If calibration value is within limits, press OK. Calibration is successful. Store calibration mandrel in a safe place.
Crimping Hose Coupling
Crimping a Coupling
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| Illustration 22 | g03866901 |
- To begin the first step of crimping a hose, you will need to select "Crimp" as shown in Illustration 22.
Note: For illustration purposes, a hose type 296 with a dash size 4 is used.
- Select the type of bulk hose being crimped. The "Select Coupling Type" screen will now be displayed. C3 and C3-290 will prompt for the proper coupling series type.
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| Illustration 23 | g03866904 |
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| Illustration 24 | g03866916 |
- Select the proper coupling type. The "Select Dash Size" screen will now be displayed.
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| Illustration 25 | g03866919 |
- Select the dash number (size of hose) being crimped.
- Install the correct die size as shown. Click GO after installation.
Note: Use the quick die change tool (QDC), CAT part number (233-8047). Use the same for the CSC6 machine to install the proper die size. Refer to NEHS 1098 or NEHS 1153 for using QDC.
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| Illustration 26 | g03867177 |
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| Illustration 27 | g03867187 |
This screen shows the crimp length and skive length for the assembly. Proper marking is recommended. Hit OK to continue.
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| Illustration 28 | g03867259 |
Illustration 28 shows Crimp Screen.
Note: It is recommended that the operator check all parameters before crimping.
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| Illustration 29 | g03867264 |
The above illustration shows where to properly set the hose into the C3 and C3-290 machine.
- Place the coupling into the die opening with the crimp length mark positioned at the edge of the die group. Press and hold the Close (6) push button, or press the right foot switch to crimp the hose coupling. The dies will automatically stop at the correct crimp diameter. If the foot switch is used, the foot switch (4) selector switch must be depressed and lit. The dies will return to full open automatically.
- C3 and C3-290 will display the proper crimp length and the proper skive length. Mark the length of crimp on coupling and skive if necessary. Press OK when ready.
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| Illustration 30 | g03867270 |
Measuring Crimp
- The C3 and C3-290 will now display the "Measure Crimp Diameter" screen.
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| Illustration 31 | g03867272 |
Measuring Crimp Diameter
Measuring with Foot Switch and Calipers
The "Measure Crimp Diameter" procedure can be done using the digital caliper.
Caliper - This button begins the process for measuring the crimp diameter with the Caliper attached to the C3 and C3-290 with the Cable. Caliper part number for CPC325 - (423-4373). For CSC6 caliper part number - (358-4536).
If the Caliper button is selected, use the following steps:
Note: Make sure that the caliper is plugged into the machine.
- Press the Caliper button on the touch screen. The "Caliper Measurement Step 1 of 6" will now appear.
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| Illustration 32 | g03867749 |
- Zero the calipers and mark the center of the crimp length on the coupling. When you are ready to take the first measurement, press on the foot switch to record the data. The "Caliper Measurement Step 2 of 6" screen will now appear.
Note: In order to enter the measurement into C3 and C3-290 with calipers, take a diameter measurement and press the single foot pedal once. The measurement should be taken at the center of the crimp. The procedure will be performed on all four sides of the crimp.
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| Illustration 33 | g03867771 |
- Take the first measurement and press the foot switch. The "Caliper Measurement Step 3 of 6" screen will now appear.
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| Illustration 34 | g03867774 |
- Take the second measurement and push the foot switch. The "Caliper Measurement Step 4 of 6" screen will now appear.
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| Illustration 35 | g03867782 |
- Take the third measurement and push the foot switch. The "Caliper Measurement Step 5 of 6" screen will now appear.
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| Illustration 36 | g03867897 |
- Take the fourth measurement and push the foot switch. The "Caliper Measurement Step 6 of 6" screen will now appear.
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| Illustration 37 | g03867922 |
- The C3 and C3-290 will display the average of the four measurements as "Actual".
Note: If these measurements are accepted, press the OK button. The "Final Crimp Menu" screen will appear. If the measurements are to be retaken or seem to be wrong, press the back button "<<" and repeat 2 through 7. After retaking measurements, press the OK button and the "Final Crimp Menu" screen will appear. To print your results, press the printer icon.
Note: If the actual measurement reads out of tolerance or 0.00, the caliper may have a low battery. If there is a battery symbol in the lower left corner of the caliper display, the battery must be replaced. If the C3 and C3-290 display reads -8.00, then calipers are not connected properly.
Note: If after repeating 1, the measurements are accepted and the crimp diameter is not within tolerance, the hose must be discarded.
- When the measurement has been accepted by pressing the OK button on the touch screen, a "Final Crimp Menu" appears.
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| Illustration 38 | g03867925 |
Make Same Type Hose - Allows the operator to skip many of the preliminary hose and coupling identification setup screens.
Make Different Hose Type - Returns the operator to the home screen.
Adjust Crimp - Button will adjust crimp diameter of the last hose type and coupling crimped by up to .49 mm diameter.
Making a Special Hose
- At the "Crimputer III Menu" screen, press the Utility button that is outlined in the image above.
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| Illustration 39 | g03867979 |
- At the "Utility" screen, select the "Make Special Hose" function.
- Enter crimp diameter using key screen and press OK.
- The "Make Special Hose" screen will appear. Enter tolerance for crimp diameter that is outlined in the image above and press OK.
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| Illustration 40 | g03867982 |
- The "Make Special Hose" screen will appear. Enter DVDT Value in the box that is outlined in the image above and press OK.
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| Illustration 41 | g03867983 |
- Install the Correct Die Group. When the correct dies are installed, press GO when ready.
Note: The C3 and C3-290 will not prompt correct die size in special hose function.
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| Illustration 42 | g03867992 |
- Mark coupling at the desired crimp length and press OK when ready.
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| Illustration 43 | g03868004 |
- Position coupling in machine and apply pressure when ready.
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| Illustration 44 | g03868006 |
- Crimp is now complete. Refer to "Measuring Crimp".
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| Illustration 45 | g03868009 |
Maintenance
For product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1International: 1-309-578-7372