Set up and Basic Operation of the 145-5161 Floor Model Hose Machine {0374, 0599, 0684, 0738, 5057} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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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	g02854238
145-5161 Floor Model Hose Machine

This manual covers the assembly and operation of the 145-5161 Floor Model Hose Machine . To put together a complete hose assembly machine, you must also order a 145-7042 or 146-5861 Crimputer Group and a 147-4437 Hydraulic Power Supply (110/220 VAC, 60 Hz, 1 phase) or 147-4438 Hydraulic Power Supply (220 VAC, 50 Hz, 1 phase).

References

Special Instruction, PECP5030, "CAT Hose and Couplings Reference Guide"

Special Instruction, NEHS0664, "Crimping Caterpillar 1E294, 1E716, and 1E844 Hose and Couplings"

Special Instruction, NEHS0748, "Crimping Permanent Couplings Using the 136-3642 Crimp Tool Group in Combination and XT Hose Machines"

Special Instruction, NEHS0749, "Crimping 1E-1028 Thermoplastic and 1E-1543 A/C Hose "

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

Additional Contact Information

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

Features

General

• Crimp all Caterpillar hose types up through 2.00 inch (-32) using Caterpillar Crimping Die Groups.

• No spacer rings or spacer plates are required when using the Crimputer.

• Die bowls are interchangeable and replaceable, if they wear out.

• Crimp diameters can easily be adjusted to allow for bowl or die wear.

• Positive die retraction feature prevents dies from sticking in the bowl and gives the operator precise control when positioning couplings in the crimping dies.

Crimputer

• The crimputer functions by measuring the position of the pusher relative to the bowl (DVDT) and sending a signal to an electronically controlled valve. When the pusher reaches the desired distance from the top of the bowl. The hose machine automatically stops crimping.

• Caterpillar hose types and sizes are selected from menus in the Crimputers memory.

• Crimputer shows which die groups to use by part number and color coding.

• Attached caliper measures the finished crimp and provides information for comparison to specifications which are stored in the Crimputer database. The Crimputer also calculates new DVDT values to compensate for dimensional variations and wear, if necessary.

• The crimputer is programmed to allow the hose machine to crimp only in the crimping cycle.

• Crimputers are available in both 110/220 VAC, 60 Hz or 220 VAC, 50 Hz. The 146-5861 Crimputer Group is CE-compliant for use in Europe.

Tooling Required

The following tooling is required to make the Hose Machine operational.

Assembly

The 145-5161 Floor Model Hose Machine is shipped partially disassembled.

The Hydraulic Power Supply is shipped with approximately 5 gal of SAE 10 or SAE 15 weight oil, such as 8T-9580 Hydraulic Oil.

1. Remove four Allen screws and remove the sheet metal guard from the top of the machine.

2. Remove two 1/2-13 bolts from the bottom of the bottom platen.

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Illustration 4	g02854256
Attach The Hose Assembly Machine To The Stand

3. Attach either the two 1U-8222 Straps to the top platten and lift the hose machine assembly.

4. Reinstall the two 1/2-13 bolts through the frame into the bottom platten.

   Note: Do not install the guard at this time.

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Illustration 5	g02854258
Attach The Power Supply

5. Attach 147-4437 Hydraulic Power Supply or 147-4438 Hydraulic Power Supply onto the back shelf of the frame.

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NOTICE
If installing the power supply with a strap and lifting device, wrap the strap around the base of the motor, being careful not to damage the covers over the capacitors or the switch.

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Illustration 6	g02854259
Install Breather/Oil Level Gauge

6. Remove the red filter plug and install the breather/oil level gauge. Remember the unit is shipped filled with oil.

7. Connect the hoses to the power supply and cylinder.

   1. The connections to the power supply are obvious.

   2. Attach the hose connected vertically to the valve to the bottom fitting on the cylinder.

   3. Attach the hose connected horizontally to the valve to the top fitting on the cylinder.

8. Adjust the springs and extractor assembly, if necessary. The top of the extractor plate should be 127 mm (5.0 inch) from the top of the bottom platten.
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   Illustration 7	g02854316
   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 8	g02854317
   Adjust Height Of Extractor Plate Using Two Nuts (lower end of rod)

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   Illustration 9	g02854319
   Check Measurement Of Extractor Assembly

   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 platten. Check the dimension on both sides to make sure that dimensions are the same. Lock the two nuts together and recheck the dimension.
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   Illustration 10	g02854320
   Tighten Nuts To Compress Spring

   3. To adjust the spring tension at the top of the rods, thread two nuts onto each rod with the ram (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.

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Illustration 11	g02854380
Attach Motor Switch Box To Left Frame Rail

9. Attach the motor switch box to the plate on the front of the machine (left side of the frame).

10. Make electrical connections according to local codes.

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NOTICE
To prevent possible machine damage, all electrical connections should be made by a qualified electrician.

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Illustration 12	g02854397
Attach Crimputer To Mounting Bracket

11. Attach the Crimputer to the mounting bracket.

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Illustration 13	g02854398
Attach Crimputer Cables

12. Attach the Crimputer cables. Refer to the decal on the rear of the Crimputer for the correct location.

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Illustration 14	g02854399
Solenoid Valve

13. Attach the connector to the solenoid valve and tighten the screw on the top of the connector. If the connector on the solenoid has a rubber protective plug over the terminals, remove the plug and discard it.

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Illustration 15	g02854417
Install Pusher Plate (1) And Probe (2)

14. Install the probe onto the pusher plate as shown. Make sure that the probe contacts the top surface of the bowl when the pusher is completely lowered.

15. Install the top guard on the machine using four Allen screws.

16. Carefully operate the pusher through the full travel and check for smooth operation. Make adjustments, if necessary.

Calibrating the Probe to the Crimputer

This procedure is for calibrating the probe to the crimputer. This should be done if the probe is a 147-2641 Potentiometer , the 8T-1002 Probe is replaced, or the software has been updated.

Note: This procedure should not be confused with the routine calibration done as part of the crimping process.

1. 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.

2. When the calibration screen appears, follow the instructions on the Crimputer screens.

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Illustration 16	g02854419
Install 152-8008 Calibration Plate

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

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Illustration 17	g02854420
Make Sure Probe Is Touching The Bowl And Not The 152-8008 Calibration Plate

4. 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.

Set Up Machine for Crimp Operation

Illustration 18	g02854421
Place 134-1256 Extractor Plate On Support

1. Place the 134-1256 Extractor Plate onto the support.

   Note: Make sure that extractor plate support is centered in the bowl cavity using two 136-7955 Tee Handles .

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Illustration 19	g02854436
Install 131-3035 Die Bowl

2. Place 131-3035 Die Bowl into the press bowl cavity using two 136-7955 Tee Handles .

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Illustration 20	g02854437
Tighten Die Bowl Holding Bolt

3. Tighten the bowl holding bolt, located on the front face of the platten.

4. Remove tee handles.

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Illustration 21	g02854438
Place 134-1257 Extractor Tube In The Bowl

5. Place the 134-1257 Extractor Tube into bowl.

6. Continue on with a specific hose crimping procedure, such as crimping straight couplings, 90 degree couplings, or 1E-1543 Hose Couplings or 1E-1028 Hose Couplings .

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. Skive high-pressure hoses prior to insertion in the coupling. Refer to Special Instruction, NEHS0768, "General Information for Hose Assembly" for skiving instructions.

3. Clean the inside of the hose to avoid contamination of the hydraulic system. The 156-0058 Hose Cleaner Group is recommended.

4. Water is permitted as a lubricant when placing couplings onto hoses. Never use oil or grease.

5. Insert the hose into the new coupling until it is firmly against the bulkhead inside the coupling.

6. Carefully seat the coupling against the step in the die group before crimping.

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

8. Measure finished crimp diameters to verify the accuracy of the crimp.

General Crimping Instructions

Follow the instructions for using the Crimputer.

1. Place the selected crimping die group into the bowl. Make sure to lubricate with 5P-0960 Grease or 129-1939 Grease or equivalent.

2. Assemble the coupling to the hose end, making sure that the hose is inserted properly into the coupling. Orient the coupling as noted in Special Instruction, NEHS0768, "General Information for Hose Assembly".

3. Place the coupling into the die group, being careful that the coupling is firmly seated against the step in the die group.

4. Lower the pusher against the top of the die group using the hand controlled valve until the Crimputer stops the downward movement.

5. Raise the pusher, retracting the die group from the bowl and releasing the hose assembly.

Crimping Straight Couplings

Illustration 22	g02854476
Small Bowl, Extractor Plate, And Extractor Tube

Illustration 23	g02854477
Small Bowl, Extractor Plate, And Extractor Tube

1. Select the proper bowl, extractor plate, and extractor tube for the coupling being crimped, as shown in Illustrations 22 and 23.

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Illustration 24	g02854478
Lubricate Die With Grease

2. Select the proper die set and lubricate with 129-1939 Desert Gold Grease or an equivalent grease.

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Illustration 25	g02854479
Place Die Group In Bowl Make Sure Front Pusher Plate Is In Place

3. Place the die set into the bowl. The 133-9887 Front Pusher Half should also be in place at this time.

4. Follow directions on Crimputer menus.

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Illustration 26	g02854536
Place Hose And Coupling In Die (The front pusher half has been removed to show a properly seated coupling.

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NOTICE
If the coupling is not properly seated or seated at an angle, the coupling may be improperly crimped. This could result in a faulty crimp that may fail under pressure.

5. Position the hose and coupling in the die set. Make sure that the bottom edge of the coupling is evenly seated on the counterbore inside the die.

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Illustration 27	g02854538
Lower Ram And Crimp The Coupling

6. Lower the ram and crimp the coupling. The Crimputer will automatically determine the travel of the ram in order to crimp the coupling to the proper size.

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Illustration 28	g02854539
Check Crimp Diameter

7. Remove the coupling from the die and check the crimp diameter. Make any adjustments by entering the crimp data into the Crimputer.

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Illustration 29	g02854556
Finished Hose Assembly

8. Deburr the outside of the coupling to remove any sharp edges and clean the inside of the hose using a hose cleaner group.

Crimping 90 Degree Couplings

1. Select the proper bowl, extractor plate, and extractor tube for the coupling being crimped.

2. Select the proper die set and lubricate with 129-1939 Desert Gold Grease or an equivalent grease.

3. Place the die set into the bowl. The 133-9887 Front Pusher Half should not be in place at this time.

4. Position the hose and coupling in the die set. Make sure that the bottom edge of the coupling is evenly seated on the counterbore inside the die.

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NOTICE
If the coupling is not properly seated or seated at an angle, the coupling may be improperly crimped. This could result in a faulty crimp that may fail under pressure.

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Illustration 30	g02855415
Carefully Lower Ram And Install 133-9887 Front Pusher Half

5. Carefully lower the ram until the 133-9887 Front Pusher Half can be installed.

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Illustration 31	g02855417
Lower Ram And Crimp The Coupling

6. Lower the ram and crimp the coupling. The Crimputer will automatically determine the travel of the ram in order to crimp the coupling to the proper size.

7. Remove the coupling from the die and check the crimp diameter. Make any adjustments by entering the crimp data into the Crimputer.

8. Deburr the outside of the coupling to remove any sharp edges and clean the inside of the hose using a hose cleaner group.

Crimping 1E-1028 and 1E-1543 Hose

Crimping 1E-1028 and 1E-1543 Hose Couplings requires different die sets, separator, and spacers. Refer to Special Instruction, NEHS0749, "Crimping 1E-1028 Thermoplastic and 1E-1543 A/C Hose " for additional information.

Troubleshooting

The following troubleshooting in formation should help find solutions or answer questions to some of the more commonly asked questions.

1. Machine consistently over crimps (crimp diameter too small).

   PROBABLE CAUSE: Solenoid valve has debris in it.

   SOLUTION: Disassemble and clean spool. Remove connector and black cover from solenoid end. Remove plug from the other end. Push spool out to clean.

2. Dies stick in the bowl.

   PROBABLE CAUSE: Wrong grease, no grease, or bad finish on the bowl.

   SOLUTION: Use 129-1939 Desert Gold Grease . Contact Caterpillar Service Technology if proper grease does not solve problem.

3. Crimputer skips steps.

   PROBABLE CAUSE: Connections not correct. Malfunctioning pickup. Pick up not calibrated (zeroed). Pick up not calibrated for linearity with 152-8008 Calibration Plate.

   SOLUTION: Check connections. Replace pickup. Calibrate pickup during normal crimping (zero). Do basic calibration of pickup to Crimputer using 152-8008 Calibration Plate. .

4. Cannot calibrate pickup.

   PROBABLE CAUSE: 8T-1002 Pickup or 147-2641 Pickup or pickup connector defective.

   SOLUTION: Probe can be checked by turning on the Crimputer while holding down the "3" key. Screen "AV" should show when the probe is all the way out. Pushing the probe all the way in should produce screen "AW". Numbers may vary slightly. If these screens do not show, pickup should be replaced. Pickup may have a bad connection at connector which can be repaired.

5. Oil leaks around cylinder rod.

   PROBABLE CAUSE: Defective seals.

   SOLUTION: Replace seals using 172-7095 Seal Kit .

6. Oil leaks from relief valve at top of hydraulic cylinder.

   PROBABLE CAUSE: Defective valve.

   SOLUTION: Replace with a new 173-3226 Valve .

7. Crimputer turns off and on when power supply pump is turned on.

   PROBABLE CAUSE: Line Voltage drops below 90 VAC when pump is turned on.

   SOLUTION: Improve power source or connect Crimputer to different circuit than pump.

8. Spring in hand control breaks.

   PROBABLE CAUSE: Defective spring and no pilot on retainer.

   SOLUTION: Replace 173-3227 Spring and 173-3228 Retainer . Grease spring.

Maintenance

Disassembly of Solenoid Valve

Illustration 32	g02854557
Solenoid Valve

1. Loosen screw and disconnect connector on Crimputer cable.

2. Remove black plastic nut and O-ring which holds solenoid coil on the stem. Remove coil.

3. Use a 1/2 inch wrench to loosen stem. Remove stem.

4. Remove spring and small plate (inside valve body).

5. Use a 7/8 inch wrench to loosen plug on other end. Remove plug and O-ring.

6. Remove spring and small plate.

7. Push the spool out either end.

8. Clean all parts with a suitable solvent and blow dry.

9. Reassemble in reverse order.

Add Lock Washers To Spring Stops

Illustration 33	g02854559
Add A Lock Washer To Location (2) (1) Spring Retainer.

If the spring ends slip past spring retainer (1), lock washers can be installed between the stops and the valve body (2) to extend the stops. This will add about 3.18 mm (0.125 inch) to the stop length. Replacing the spring retainer with a new 173-3228 Retainer will also help solve this problem.

Applying grease to the 173-3227 Spring will prolong spring life and improve the feel of the lever.

Service Parts

145-5161 Machine Hose Assembly

Illustration 34	g02854560
145-5161 Machine Hose Assembly

145-6944 Cylinder Group

Illustration 35	g02854562
145-6944 Cylinder Group

147-4438 and 147-4437 Power Supply Groups

Illustration 36	g02854563
147-4438 and 147-4437 Power Supply Groups