Using the 209-3153 Portable Hose Machine {0374, 0599, 0684, 0738, 5057} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

European Union Compliant, CE Marked

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Think Safety

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, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

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 Caterpillar 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. The 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 the tools 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 Information

Safety Alert symbols

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Personal Protection

Prohibited Action

No liquid around electrical components

No smoking

Hazard Avoidance

Safety alert symbol

Electrocution hazard

Entanglement hazard

Explosion hazard

Fire hazard

Poisonous gas

Pressurized air

Slipping hazard

Tripping hazard

Ventilate

Safety Warnings

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause 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. Always use a board or cardboard when checking for a leak.

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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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills.

General Information Section

Introduction

This light-weight, yet durable 209-3153 Hose Machine has been designed for use in service trucks and in other similar field applications. The hose machine will crimp permanent couplings onto 294, 716, 844, 1956, XT-3 ES, XT-5, XT-6, XT-6 ES, 1543, 1028, and 2760 Hose .

The hose machine is capable of crimping -04 through -20 hose.

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209-3153 Portable Hose Machine .

An optional power supply is required to operate the portable hose machine. Caterpillar recommends using a 1U-7544 Hydraulic Hand Pump , 236-6600 Air-Over-Hydraulic Pump , or a 161-5717 Electric Pump .

Also required is a 700 bar (10,000 psi) 135-2532 Straight Adapter (3/8-18 NPT Male to 1/4-18 NPT Female) and 8F-0024 Hose Assembly with a 1P-2376 Quick Disconnect .

Using the 242-3567 Variable Crimp Die Bowl with the portable hose machine provides infinite crimp diameter adjustment when making hose assemblies.

The die bowl uses an internal thread to raise and lower the height or thickness of the die bowl. Micrometer-like markings on the bowl halves allow the user to quickly and accurately adjust the thickness of the bowl, which eliminates the need for conventional spacers.

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The variable die bowl is used with Caterpillar-style dies on all hose types except 1543. Refer to Special Instruction, NEHS0924, " 242-3567 Variable Crimp Die Bowl " for additional information on using the die bowl.

Note: 1543 hose couplings require special dies. Refer to the Die Groups and Tooling Parts List section or Figure 19 in this manual for a list of 1543 die part numbers.

The following chart provides the maximum size hose coupling that can be crimped with a specific hose machine using the variable crimp die bowl. Do not attempt to crimp hose couplings larger than recommended.

Table 1

Hose Machine Capabilities
Hose Type	Maximum Hose Size
294	-20
716	-20
844	-20
1956	-16
XT-3 ES	-16
XT-5	-12
XT-6	-8
XT-6 ES	-8
1543	-14
1028	-12
2760	-8

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

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

References

Special Instruction, NEHS0643, "Using the 233-7191, 233-7192, and 233-7193 Hose Cleaner Groups "

Special Instruction, NEHS0768, "General Information for Hose Assembly"

Special Instruction, NEHS0924, " 242-3567 Variable Crimp Die Bowl "

Special Instruction, NEEG2955, "Hose Cleaner Projectile Sizing Chart for Hose and Hose Assemblies"

Special Instruction, NEEG2956, "Skive Length Chart"

Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart"

Service Guide, PECP5030, "CAT Hose and Couplings Reference Guide"

Pump Specifications

Table 2

Description	Specification
1U-7544 Hydraulic Hand Pump
Maximum pressure	700 bar, 68948 kPa (10,000 psi)
236-6600 Air-Over-Hydraulic Pump
Minimum air supply	20 cfm at 100 psi
Maximum air pressure	965 kPa (140 psi)
Noise level	83 dB at rated capacity
Hydraulic reservoir	1.7 L (.45 gal)
Pump	Two stage
Overall size	356 x 203 x 218 mm (14.0 x 8.0 x 8.5 in)
161-5717 Electric Pump
Pump	Two stage
Motor	Voltage (115), HZ (60), 1/2 HP, 3450 rpm
Controller	Standard hand-type remote with 10 foot cord
Reservoir	7.6 L (2 gal)
Electrical circuit	15 amps
Internal relief valve	700 bar (10,000 psi)

242-3567 Variable Die Bowl

The 209-3153 Portable Hose Machine uses a 242-3567 Variable Crimp Die Bowl to crimp hose assemblies. This die bowl is made from the parts listed below. Refer to Special Instruction, NEHS0924, "NEHS0924 242-3567 Variable Crimp Die Bowl" for assembly instructions

Table 3

Item	Part No.	Description
(1)	133-7362	Die Rest
(2)	242-3567	Variable Die Bowl
(3)	135-4561	Die Separator
(4)	140-9360	Separator Ring
(5)	4C-4375	Spring
(6)	4C-4376	Snap Ring

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Hose Machine Assembly Instructions

1. Bolt the portable hose machine to a work surface in the service truck. It is not necessary to bolt the hose machine to a work surface, but it is recommended.

2. Obtain a 162-1410 Hose Assembly .

3. Using the 162-1410 Hose Assembly , connect a power supply to the portable hose machine. Use a 1U-7544 Hydraulic Hand Pump , 236-6600 Air-Over-Hydraulic Pump , or a 161-5717 Electric Pump .

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4. Connect the hydraulic power supply to either an electrical or air pressure power source, unless using the hand pump. See Table 2 for the specific pump requirements.

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236-6600 Air-Over-Hydraulic Pump . (A) Air Inlet. (B) Pump Outlet.

5. The portable hose machine is now ready to assemble hoses. The hose machine can be swiveled to make hose assembly easier or for storage.

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(A) Air Inlet. (B) Pump Outlet.

Note: The portable hose machine can be swiveled on the base for easier, more compact storage in a tool compartment of the service truck.

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General Hose Assembly Guidelines

Producing high-quality hose assemblies requires observing the following general guidelines:

1. Cut the ends of the hose as square as possible.

2. Clean the inside of the hose to make sure that the coupling does not have dirt or other debris between the coupling and the inside of the hose. One of the 233-7191, 233-7192, and 233-7193 Hose Cleaner Groups is recommended for cleaning the hose. Refer to Special Instruction, NEHS0643, "Using the 233-7191, 233-7192, and 233-7193 Hose Cleaner Groups " for more detailed instructions on cleaning hoses.

3. Insert the hose in the new coupling until it is aligned with the coupling insertion mark. Refer to the Special Instruction, NEHS0768, "General Information for Hose Assembly", for additional information. Do not allow oil or grease on the hose or couplings. Only water is permitted as a lubricant when placing couplings onto hoses.

4. When crimping 1543 Air Conditioning Hose Couplings , carefully seat the coupling against the locating tab in the die group before crimping.

5. Sharp edges and burrs on crimped couplings can be removed with 80 grit emery paper or other suitable means.

6. To maintain the quality of each hose assembly, measure the finished crimp diameter to make sure that it meets the correct assembly specifications. Crimp diameters can be measured using a micrometer, calipers, or caliper measurement system.

   Note: Use Figure 19, for crimp diameter specifications. Refer to Special Instruction, NEHS0768, "General Information for Hose Assembly", for additional information on measuring hose coupling crimp diameters. The parts in Table 5 can be ordered individually and used to check the crimp diameter.

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   Table 4

   Crimp Measurement Tooling
   136-0536	Caliper
   136-0538	Cable (attaches to caliper)
   136-0539	Foot Switch
   136-0544	Mini Processor
   136-4219	AC Adapter
   9U-6690	Replacement Ribbon
   136-0543	Paper Rolls (10)

7. Clean each hose after assembly.

   1. Tap both ends of the hose to remove any large particles.

   2. Use one of the 233-7191, 233-7192, or 233-7193 Hose Cleaner Group to clean the inside diameter of the hose assembly. A cleaning projectile should be sent through each end of the hydraulic hose.

Note: Refer to Special Instruction, NEHS0643, "Using the 233-7191, 233-7192, and 233-7193 Hose Cleaner Groups " for more detailed instructions on cleaning hoses.

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NOTICE
Hoses that are not clean can cause hydraulic system component damage.

Operation

Crimping Hose Assemblies

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1. Select the appropriate die from the Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart" or Table 5 in this manual.

2. Set the variable die bowl to the correct "Bowl Setting" reference number found in Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart".

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3. Find the crimp length on Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart" and mark that length on the hose coupling.

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4. Insert the variable die bowl into the hose machine.

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5. Align the crimp length mark on the coupling with the top of the die.

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6. Install the front pusher plate.

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7. Lower the pusher plate until it touches the top of the variable crimp die bowl.

8. Raise the pusher plate, remove hose assembly, and check the crimp diameter. Refer to Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart" for crimp diameter specifications.

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9. If necessary, adjust the variable crimp die bowl to make the crimp diameter of the next hose assembly as close as possible to the specified crimp diameter. Write this new Bowl Setting number in the "Actual Setting" column of Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart". Using this new number should provide a more accurate crimp diameter the next time the die is used to crimp a hose coupling.

Crimping 1543 Air Conditioning Couplings

1543 Air Conditioning Couplings can be crimped using the portable hose machine with the variable crimp die bowl by removing the 133-7362 Die Rest and using the appropriate die. Refer to Special Instruction, NEEG3000, "Variable Die Bowl Crimp Diameter Chart" for the "Bowl Setting" and die group part number specification for the coupling being assembled.

For additional information, refer to Special Instruction, NEHS0749, "Crimping 1E-1543 Air Conditioning Hose and 1E-1028 Thermoplastic Hose ".

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Maintenance

1. Clean all dirt and debris off the hose machine, the outside and inside diameter, and the tapered surface of the variable crimp die bowl.

2. Lubricate the die bowl with 129-1939 Grease or equivalent.

Inspection

Inspect the hose machine, power supply, and die bowl parts daily for damage or abnormal wear. Replace all worn or damaged parts immediately. Check the high-pressure hose for any damage or abnormal wear.

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Die Groups and Tooling Parts List

Table 5

Die Bowl
Part No.	Description
133-7362	Die Rest
242-3567	Die Bowl
135-4561	Die Separator
140-9360	Separator Ring
4C-4375	Spring
4C-4376	Snap Ring
All Die Groups (except 1543)
Part No.	Die Inside Diameter
241-9133	12 mm
241-9134	14 mm
241-9135	16 mm
241-9136	18 mm
241-9137	20 mm
241-9138	22 mm
241-9139	24 mm
241-9140	26 mm
241-9141	28 mm
241-9142	30 mm
241-9143	33 mm
241-9144	37 mm
241-9145	40 mm
241-9146	43 mm
220-8686	48 mm
241-9147	50 mm
1543 Die Groups
Part No.	Die Dash Number
4C-3675	-6
4C-3676	-8
214-5155	-10
4C-3677	-12
189-0990	-14
Crimp Measurement Tooling
Part No.	Description
136-0536	Caliper
136-0538	Cable (attaches to caliper)
136-0539	Foot Switch
136-0544	Mini Processor
136-4219	AC Adapter
9U-6690	Replacement Ribbon
136-0543	Paper Rolls (10)

Hose Machine Parts List

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Table 6

209-3153 Portable Hose Machine
Item	Part No.	Description
(1)	209-3158	Assembly Stand
(2)	0S-1588	Bolt
(3)	209-3159	Threaded Rod
(4)	3S-1356	Nut
(5)	209-3154	Top Plate Assembly
(6)	209-3161	Assembly Tube
(7)	209-3160	Mtg Plate
(8)	209-3165	As. Knob
(9)	1J-6655	Lockwasher
(10)	4D-3120	Bolt
(11)	6L-5897	Bolt
(12)	139-5446	Half Pusher
(13)	139-5445	Half Pusher Assembly
(14)	6V-4792	Machine Screw
(15)	209-3157	Hydraulic Cylinder Group
(16)	139-5444	Pusher Tube
(17)	209-3156	Bottom Plate
(18)	-	Decal
(19)	Nehs0869	Manual
(20)	Neeg3000	Crimp Diameter Chart