Converting 137-7238 Hose Assembly Machines and 134-5640 Hose Assembly Machines (100 Ton) from Sony Control to Crimputer Control{0374, 0599, 0684, 5057} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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 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 Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Section

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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.

General Information

Introduction

Illustration 3	g02826098
100 Ton Hose Assembly Machine with Sony Control

Illustration 4	g02826101
100 Ton Hose Assembly Machine Upgraded with a Crimputer

This manual provides a procedure to remove the former Sony control and install the newer Crimputer from 100 Ton Hose Assembly Machines. This procedure is used on 137-7238 Hose Assembly Machine (110V, 60 Hz) and 134-5640 Hose Assembly Machine (220V, 50 Hz).

The Crimputer is a microprocessor-based controller with memory containing a database with hose types and sizes along with information to control the crimping operation of the hose machine. Crimping specifications and tolerances are also included for comparison to the measured values which can be measured with the integral caliper at the completion of the crimp. The Crimputer will adjust the controlling numbers (DVDT) to compensate for die wear or other discrepancies.

DVDT stands for Delta Vertical Die Travel and is simply the distance from the bottom of the pusher plates to the top of the bowl in millimeters at the completion of the crimp.

A 164-2691 Printer Group is also available for printing crimp measurement data as well as the databases.

Note: Before starting the conversion, make sure all parts required for the conversion are available. Verify that all of the parts from Tables 1, 2, and 3 in the ""Parts" " Section of this manual has been received and are available. DO NOT start the conversion if any items are missing and/or unavailable.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Electrical Disassembly

Note: All parts removed during this procedure must be returned to CSTG. Use the return label that is included with these instructions.

1. Turn the hose machine ON and check and record the rotation of the electric motor for future reference.

2. Disconnect all electrical power from the hose machine being modified

   1. Electric - Unplug the hose machine accessories and other possible add-ons such as hand tools, lights, or other related items.

   2. Hydraulic - If any accessories have been added to the hose machine, remove before continuing.

   3. Pneumatic - If any accessories have been added to the hose machine, remove before continuing.

3. Remove the power cable.

   1. Open the black enclosure on rear of hose machine.

   2. Locate motor starter. Identify where wires are attached at top.

   3. Make sure that wires are marked for future identification.
      • Wires should already be marked with either "L" and "N", "L1" and "L2", or "1" and "2". If not, mark them so they can be identified later.

      • Disregard the other wire on top of the starter. It is not relevant in the conversion.

   4. Loosen screws holding wire ends on top of motor starter.

   5. Remove screw holding green/yellow wire.

   6. Loosen cable grip, device protruding through wall of enclosure through which the cable passes, on bottom of black enclosure and pull power cable out of enclosure.

   7. Remove cable grip from enclosure for use in new starter.

   8. Save power cable for later use.

4. Remove the motor cable.

   1. Open the enclosure on the motor. Save the screws for assembly.

   2. If the wires from the cable are connected to the toggle switch:
      • Identify the wires for assembly.

      • Only remove the screws from the toggle switch that hold the wires leading from the black enclosure.

      • Save the screws for reassembly.

   3. If the wires from the cable are connected by wire nuts:
      • Identify the wires for assembly.

      • Only remove the wire nuts that hold the cable leading from the black enclosure.

      • Save the wire nuts for reassembly.

   4. Remove the ground screw. Save for reassembly.

   5. Loosen the cable grip to the motor enclosure. Do not remove the cable grip.

   6. Remove the cable from the motor enclosure.

   7. Loosen the screws holding the other end of the cable inside the black enclosure.

   8. Remove the screw holding the green/yellow wire. Save the screw for reassembly.

   9. Loosen cable grip in black enclosure and remove cable. Discard cable.

   10. Remove cable grip in black enclosure that holds the motor cable. Save for use with new starter.

5. Remove solenoid cable.

   1. Open enclosure on top of solenoid.

   2. Disconnect wires by removing wire nuts.

   3. Identification is not important for reassembly.

      Note: Save wire nuts for reassembly.

   4. Loosen cable grip and remove cable from the solenoid enclosure, leave attached to black enclosure.

   5. Remove entire cable grip from solenoid enclosure.

6. Remove Sony communications cable.

   1. Remove four screws around face of Sony unit, supporting gray enclosure behind sheet metal.

   2. Pull back gray enclosure.

   3. Loosen three screws holding wires from black enclosure to Sony unit.

   4. Unplug Sony transducer from back of unit.

   5. Loosen thumb screw on top and bottom of Sony unit enough to remove retaining brackets.

      Note: Save retaining brackets for shipment back to CSTG.

   6. Pull Sony unit out from the front of the sheet metal.

7. Remove Control box.

   1. Remove the four bolts holding three switch control box on front.

   2. Leave control box attached to black enclosure.

Mechanical Disassembly

1. Disconnect pressure line from pressure gauge.

2. Remove 1/8 x 1/4 inch female adapter from gauge. Save for new gauge.

3. Remove gauge from sheet metal.

4. Remove the sheet metal.

5. Disconnect the hydraulic return line from the tank.

Mechanical Reassembly

Illustration 5	g02826158
Install Filter Group (5) (16) Filter Gauge (17) Filter Fitting, 1/8 inch NPT, 90° Female (18) Filter Fitting, 1/8 inch NPT, Straight Male

1. Mount filter group (5) to the tank and reconnect the return line. Install filter gauge (16) using a 1/8 inch NPT 90° female fitting (17) and a 1/8 inch straight male fitting (18) .

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Illustration 6	g02826159
Install Hose Guard

2. Weld hose shield plate (6) into position, as shown.

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Illustration 7	g02826160
Attach Motor Starter Plate

3. Hold new motor starter mounting plate (1) over the old plate and mark where the new screw holes will be. Relieve these areas so that the new screws will work.

4. Weld new motor starter plate (1) in place.

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Illustration 8	g02826161
Install Sheet Metal Cover (1)

5. Attach piece of sheet metal (3a) that contains the opening for the pressure gauge. Predrill holes for the screws, if necessary.

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Illustration 9	g02826162
Attach Monitoring Bracket And Pressure Line To Pressure Gauge

6. Install 147-4439 Pressure Gauge (7). May need to open up hole slightly. Slide gauge mounting bracket onto the back of the gauge and secure it to the cover.

7. Connect the pressure line to pressure filter gauge (7) .

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Illustration 10	g02826176
Install Sheet Metal Cover (3b)

8. Slide sheet metal (3b) over the handle and attach it to the first piece using sheet metal screws (4). Predrill holes if necessary.

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Illustration 11	g02826177
Mount 146-5861 Crimputer Group (19) (20) 0S-1614 Bolt (21) 9S-8750 Nut (22) 145-6949 Crimputer Mounting Bracket (23) 4C-6521 Stop Collar (24) Crimputer

9. Mount 146-5861 Crimputer Group (19) .

   1. Mount 4C-6521 Stop Collar (23) on front right tie-rod approximately 400.1 mm (15.75 inch) up from bottom platen.

   2. Mount crimputer bracket (22) on top of stop collar (23) .

   3. Mount crimputer (19) to mounting bracket (22) using 0S-1614 Bolts (20) and 6V-8185 Nuts (21) .

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Illustration 12	g02826178
Install Position Indicator (C1) 147-2641 Potentiometer (C2) 6D-3897 Potentiometer Indicator Bolts (C9) 147-2407 Potentiometer Mounting Plate

10. Mount 147-2407 Potentiometer Mounting Plate (C9) and 147-2641 Potentiometer (C1) to the hose machine.

    1. Attach potentiometer mounting plate (C9) to the back of the ram using potentiometer indicator bolts (C2) .

    2. Mount potentiometer (C1) to potentiometer mounting plate (C9) .

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Illustration 13	g02826179
Extractor Tube Assembly (8) (11) 145-6947 Rod (12) 145-6946 Spring (13) 8T-8890 Washer (14) 5S-0003 Nut

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Illustration 14	g02826180
Extractor Tube Assembly (8) (14) 5S-0003 Nut (15) 145-7047 Spacer

11. Install 133-9890 Extractor Tube Assembly (8) using items (11), (12), (13), (14), and (15) as shown.

12. Adjust the extractor tube assembly, as follows:
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    Illustration 15	g02826196
    Remove Two Nuts From Each Rod

    1. Remove the two nuts from each rod and allow the extractor assembly to drop down. It should be supported by the two nuts on the lower end of each rod.
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    Illustration 16	g02826197
    Adjust Height of Extractor Plate Using Two Nuts, Lower End of Rod

    2. Adjust the two nuts at the lower end of the rod so the extractor tube assembly is exactly 127 mm (5.0 inch) below the top of the platen. Check the dimension on both sides to make sure that it is the same. Lock the two nuts together and recheck the dimension.
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    Illustration 17	g02827200
    Check Measurement Of Extractor Assembly

    3. To adjust the spring tension at the top of the rods, thread two nuts onto each rod with the ram or pusher, all the way up. Tighten each nut until the spring becomes solid. Loosen one nut on each side two full turns and lock in place with a second nut.

       Note: This procedure is for calibrating the probe to the crimputer and should not be confused with the routine calibration done as part of the crimping process. This should be done if the probe is a 147-2641 Potentiometer , the 8T-1002 Probe is replaced, or the software has been updated.

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    Illustration 18	g02827217
    Tighten Nuts To Compress Spring

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    Illustration 19	g02827202
    Install 152-8008 Calibration Plate

    4. Turn the crimputer OFF. Press and hold the "4" key while turning the crimputer ON. Continue pressing the key until the calibration screen appears on the crimputer.
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    Illustration 20	g02827203
    Make Sure Probe Is Touching The Bowl And Not The 152-8008 Calibration Plate

    5. When the calibration screen appears, follow the instructions on the crimputer screens.

    6. When instructed to install the 19 mm (0.75 inch) plate, install the 152-8008 Calibration Plate as shown.

    7. When the calibration procedure is complete, the new number which appears should be in the range of 22000 to 27000. If not, repeat this procedure.

Electrical Reassembly

Motor Starter

1. Remove the cover from the new 149-5477 Motor Starter .

2. Knock out both metal hole plugs on the bottom of the starter.

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Illustration 21	g02827240
Install Cable Grips For Motor Cable (2) And Power Cable (1)

3. Insert a cable grip (1) for the power cable in bottom left and and tighten locknut. Insert a cable grip (2) for the motor cable in bottom right and tighten locknut.

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Illustration 22	g02827242

4. Mount motor starter on motor starter mounting plate using three screws provided.

5. Remove six overload mounting screws, two each above T1, T2, T3.

   Note: Use the proper overload for the power supply, 110 Volts, or 120 V, to the hose assembly machine. Use W56 overloads on a 137-7238 Hose Assembly Machine , 110V, 60 Hz, and W49 overloads on a 134-5640 Hose Assembly Machine , 220V, 50 Hz.

6. Place one overload in position T1 and replace the two mounting screws.

7. Press the "STOP/RESET" button.

8. Place one overload in position T2 and replace the two mounting screws.

   Note: Even though position T2 is not used, this overload MUST be inserted for proper operation.

9. Press the "STOP/RESET" button.

10. Place one overload in position T3 and replace the two mounting screws.

11. Press the "STOP/RESET" button.

Power Cable

Illustration 23	g02827251
Attach Power Cable To Motor Starter

(1) Ground Wire Attached To Mounting Screw (2) Wire Attached to "L1" (3) Wire Attached to "L3"

1. Test fit the wires into their new positions. Make sure that the ground wire (green/yellow) can reach one of the three mounting screws securing the starter to the machine.

2. Loosen terminal screws "L1" and "L3" in the starter.

3. Insert the power cable through the bottom left cable grip.

4. Place two power wires (not green/yellow) under "L1" and "L3".

   Note: If wires are marked "L" and "N", "L" goes to "L1" and "N" goes to "L3". If the wires are marked "L1" and "L2", "L1" goes to "L1" and "L2" goes to "L3".

5. Tighten the screws to secure the wires.

6. Place the ground wire with terminal (green/yellow) under one of the three starter mounting screws.

7. Tighten the cable grip.

Motor Cable

Starter End of Cable

Illustration 24	g02827254
Attach Motor Cable To Motor Starter (1) Black Wire "T1" (2) White Wire "T3" (3) Green/Yellow Wire (Ground)

1. Strip off 152 mm (6.0 inch) of the outer insulation and cable support strands from both ends of the motor cable.

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NOTICE
DO NOT nick any of the inner wires while stripping off the outer insulation. If a wire is cut or nicked, cut off another 152 mm (6.0 inch) and start over.

2. If a four conductor cable is used, cut off one wire. Keep the black, white, and green/yellow wire. Only three wires are required for the motor cable.

3. Strip off 12.7 mm (0.50 inch) of wire insulation on wires (1), (2), and the green/yellow wire (3) .

4. Crimp a terminal lug onto the green/yellow ground wire.

5. Route the cable through the cable grip in the bottom of the starter.

6. Loosen terminal screws "T1" and "T3".

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Illustration 25	g02827256

7. Place black wire (1) under terminal screw "T1" and tighten the screw.

8. Place white wire (3) under terminal screw "T3" and tighten the screw.

9. Connect the ground wire with terminal (green/yellow) to one of the three starter mounting screws.

10. Replace motor starter cover.

Motor End of Cable

Illustration 26	g02827296

Illustration 27	g02827297

1. If a four conductor cable is used, cut off one wire. Keep the black, white, and green/yellow wire. Only three wires are required for the motor cable.

2. Strip off 12.7 mm (0.50 inch) of wire insulation on wires (1), (2), and the green/yellow wire.

3. Crimp a terminal lug onto the green/yellow ground wire.

4. Place end of cable through the cable grip in the motor enclosure.

5. If the motor enclosure wires have crimp on terminals, crimp terminals onto all three wires and connect wires (1) and (3) to the switch.

6. If the motor enclosure uses wire nuts, crimp a terminal onto the green/yellow wire and connect wires (1) and (3) to the respective wire with wire nuts.

7. Connect the green/yellow ground wire to the ground post.

8. Replace motor enclosure cover.

Solenoid

Illustration 28	g02827317
Install Hirschman Connector

1. Screw the Hirschman Connector into the solenoid in the end where the old cable grip was located.

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Illustration 29	g02827318

2. Connect Hirschman Connector wires to the solenoid wires with the old wire nuts. Polarity is not important.

3. Plug the cable provided, into the Hirschman Connector and tighten screw to hold it in place.

4. The other end of this cable is plugged onto the Crimputer.

Crimputer Connections

Illustration 30	g02827320

Connect the cables to the back of the Crimputer, as shown.

Electrical Test

1. Connect the machine and Crimputer to the power supply.

2. While another person observes the motor rotation direction, push the "Start" button and then immediately press the "Stop/Reset" button.

3. If the motor does not rotate:

   1. Make sure that the toggle switch on the motor enclosure is "ON".

   2. Make sure that the hose machine is plugged into the power supply.

   3. Make sure that the outlet device has power.

   4. Make sure that the overloads were installed in the starter.

Parts