- 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 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 Section
Safety Icon Nomenclature
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| Fire hazard |
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 |
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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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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
The Radial Hose Crimping Machines (423-4362) are high-performance and rugged units designed to crimp permanent hose couplings only. The hose machine is operated and controlled through a user friendly LCD touch screen interface display. The microprocessor (C3 controller) contains memory, which shortens setup times and helps make correctly sized couplings every time. An electronic measuring system ensures highly accurate crimps for each and every coupling.
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| Illustration 3 | g03382810 |
| 1 | Crimp Tool |
| 2 | C3 Controller |
| 3 | Main Power Switch |
| 4 | Electrical Panel |
| 5 | Die Storage Racks |
| 6 | Hydraulic Motor |
| NOTICE |
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Always keep a safe distance of at least 120 mm (4.7 inch) to the crimp tool if the machine is switched on. |
| NOTICE |
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The hose machine has been constructed using state-of-the-art engineering and acknowledged safety standards. Nonetheless, dangers can arise for the operator and other persons in the operating area. Machine and/or property damage can also occur if all safety and operating recommendations are not followed. These operating instructions contain the most important information needed to operate the hose machine safely. The safety information must be observed by all persons operating the hose machine. |
Additional Contact Information
For additional product support questions concerning this tool, contact Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Technical Details
Specifications
| Crimp Force (kN / Ton) | 2800/280 |
| Control | Crimputer III (C3) |
| XT-6ES (100R15) (1) | 2 in |
| Low Medium Pressure (LMP) (1) | 4 in |
| Industrial | 6 in |
| Maximum permissible Crimp Area (mm) | Ø-Dies (PB) + 20 |
| Maximum Ø Dies (mm) | 145 |
| Opening Path (mm) | + 70 |
| Opening without dies (mm) | 215 |
| Speed (mm/sec) |
Close: 23 |
| Crimp: 1 and 4 | |
| Open: 33 | |
| Noise Level dBa | 62 |
| Drive | 4 kW |
| Crimp Tool L x W x H(mm) | 1200 x 600 x 1700 |
| Oil (l) | 100 |
| Change of Oil | Annually |
| Weight (kg) | 750 |
| QDS 239.3 | Yes |
| Die System | 237 |
| Permissible voltage + frequency | 230 - 480 V 50/60 Hz 3ph |
| ( 1 ) | according to the fitting |
Unpacking/Setup
The machine was tested prior to delivery and is delivered ready for operation.
Unpacking Contents:
- Carefully unpack the machine without destroying the packaging. Retain packaging for future use. The machine should only be transported in the original packaging.
- Check the delivery for completeness using the delivery note.
- The machine should only be unloaded and transported with a forklift.
- Consider the center of gravity during loading and transportation. The center of gravity is approximately in the middle of the tool.
- Persons must stay clear of suspended loads.
- Make sure that the transportation paths from the place of unloading to the place of installation are wide enough.
- Mark footprints and routes of transportation.
- Eliminate dangers by keeping the place tidy and clear.
Constructional Requirements
| Permanent floor load | approx. 0.07 kg/mm2 |
| Floor bearing capacity | min. 2500 kg/m2 |
| Floor quality | B25 |
| Flatness | max. waviness of 5 mm/m |
| Slope | max. 5 mm/m |
Ambient Conditions
| Ambient temp. | 10° C (50° F) to 35° C (95° F) |
| Air humidity | 45% - 65% |
Initiation
Note: Pay attention to the correct balance.
Note: The machine should be placed so that it is accessible from all sides for maintenance work.
Attach the machine to the ground by the feet.
Filling with Hydraulic Oil
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| Illustration 4 | g03402534 |
Note: Use HLP 46, DIN51524 oil.
Capacity is approximately 22 gal. (Cat part number 339-3249)
Close the oil filler on the tank plate when the correct oil level has been reached.
Connect the Electric Supply
| NOTICE |
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This work should only be performed by a qualified electrician. The machine is shipped with a prewired electrical cord. Connect the cord to the electrical supply following local electrical code requirements applicable to installation location. |
| NOTICE |
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The following prerequisites must be met before start-up of the installation: The machine is powered by a 3-phase motor that is capable of operating at either high voltage or low voltage. Note: The machine is shipped from the factory configured for high voltage. High Voltage: 380/460 V (50/60 Hz) 9 amps (see motor nameplate) Low Voltage: 190/230 V (50/60 Hz) 18 amps (see motor nameplate) If the machine is to be operated at a low voltage, the following two steps need to be performed: Step 1: Open the electrical enclosure and turn the Voltage Selector Switch to the 230 V position. Step 2: Next to the voltage selector switch is the Adjustable Motor Overload. Adjust OL to appropriate amperage. |
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| Illustration 5 | g03402926 |
Start Machine and Check Rotation of the 3-Phase Motor
| NOTICE |
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Do not start machine without hydraulic oil. Check oil level before starting. |
- Switch on the main power switch (see Table 1, Item 3). Twist the Emergency Stop Button to release.
- The touch screen display panel will pass through several screens, stopping at the "Start up Screen."
- The hydraulic motor (table 1, Item 6) can be started from this screen. Push motor-on button (Illustration 6 Item 8) and quickly push motor-off (Illustration 6 Item 7) while observing the fan in the end of the motor. Rotation should match the arrow on the end bell of the motor. (Refer to Table 1, Item 6) If rotation is not correct, see "Change Rotation".
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| Illustration 6 | g03507104 |
(6) Emergency Stop (7) Hydraulic Motor OFF Button (8) Hydraulic Motor ON Button (9) Foot Control Switch ( Activates foot pedal for open/close) (10) Crimp Tool Open Button (11) Crimp Tool Close Button | |
| NOTICE |
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Allowing the motor to rotate in the wrong direction will cause damage to the motor. |
Change Rotation of Electric Motor
| NOTICE |
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This procedure should be performed by a qualified electrician. |
Changing the position of two of the three power supply wires will reverse rotation of the hydraulic motor. Wires can be changed in main electrical box or changed inside of the electrical panel of the machine.
Note: Start/Stop the motor again to verify correct rotation.
Purging Hydraulic System
Note: Push-buttons items 10 and 11, illustration 6, are used to open and close the dies. These push-buttons are illuminated to indicate they are active.
- The open button is illuminated anytime the hydraulic motor is on and will open the dies if they are not already open.
- The close button is only illuminated and active when the hydraulic motor is on and at specific operation screens of the C3 panel.
- Sensor Information Screen - diagnostic type screen
- Die Change Screen - appears in process of crimping a hose
- Crimp Screen - screen at which the coupling is crimped on the hose
- Switch on the main power. Release E-stop push button and allow machine controller (C3) to boot up to the "Start Up Screen".
- There are two functions available from the start-up screen:
- The soft key with "i" is the software information button. Press "i" to see the revision levels of three software packages in the machine. Press EXIT to return to the "Start Up Screen."
- The green soft key labeled "OK" accesses the log-on screen. For username and password, touch the blinking curser in the data field. A soft keypad appears to enter data. The default username and password is CAT.
Note: The controller must be logged onto, to access any functionality of the machine.
Show/hide table
Illustration 7 g03471696
- When logged on, the controller displays the Crimputer III Menu screen. There are four functions available from this screen:
- Setup
- Utility
- Log off
- Crimp
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| Illustration 8 | g02177414 |
- Press the "Setup" soft key to access the setup menu screens.
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| Illustration 9 | g03632921 |
- Press the right arrow soft key two times. You will now be at the "Sensor Information" screen.
- From this screen, start the hydraulic motor and push the Open and Close (Illustration 6, Item 10 and 11) 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.
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| Illustration 10 | g03507115 |
- When complete, push back arrow soft key to back out to the Crimputer III main menu screen.
Adapter Dies 237.2392L2- Installation/Removal of Adapter Dies and Crimping Dies 239L 67mm and Larger
The adapter dies reside in the Master Dies and accept the 239L series crimping dies up to and including 62 mm. When using 67mm, 71 mm, 84 mm, 96mm, 103 mm dies, the adapter dies are removed and the crimping dies reside directly in the master dies. The adapter dies and 67mm and larger dies, have to be installed/removed by hand using the red handled die change tool.
- Turn motor power off.
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| Illustration 11 | g03573656 |
Use the red handled die change tool to push in and hold the spring loaded retaining pin in hole A, located in the Master Die C. Remove or insert the adapter die or 67mm (or larger) crimping die by placing the pin into hole B located in the Master die C. Release pressure on the die change tool and the die is now secured into the master die. Repeat the process for remaining dies. (See illustration 12.)
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| Illustration 12 | g03573701 |
Note: After long service, the retaining pins in hole A of the master dies may be a bit hard to release. In this case, use a rubber hammer and gently tap on the end of the handle of the die release tool to free the pin. Replacement pins and springs are available in a kit. (Cat part number 452-7655) (1 kit required for each die segment.)
Installation and Adjustment of Die Retention Assemblies Located in Adapter Dies
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| Illustration 13 | g03573838 |
The 239 series crimping dies are held in the adapter dies by the spring loaded ball (as shown in above illustration 13). The screw assembly is removed/installed using a straight blade screwdriver through the access hole on the front of the die.
Adjust the position of the screw assembly by turning the screw CW until you can see the ball entering the hole. Insert a 239 die segment into the hole and push it into the adapter die. The die should snap firmly into the hole and be held against the adapter die. If the die can move or there are gaps between the dies, the screw needs to be turned CW.
Repeat adjusting the screw in small increments until the 239 die rests firmly in the adapter die. If the 239 die cannot be pushed into the hole, the assembly is too far into the hole. Turn the screw CCW.
Repeat for all 8 adapter die segments.
Installation and Removal of 239 Series Crimping Dies using the Quick Die Change Tool (QDC)
The 12mm though 54mm Die Groups can be changed using the Quick Die Change tool (Cat part number 233-8046).
The 57mm and the 62mm Die Groups must be installed and removed by hand, 1 die segment at a time. They are too thin to accommodate the holes necessary for the Quick Die Change Tool.
Note: The head should be open and the hydraulic motor turned off while installing or removing 57mm or 62mm dies.
| NOTICE |
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Failure to change the 57mm and the 62mm die segments by hand will cause damage to the 57mm and the 62 mm Die Groups. They are too thin to accommodate the holes necessary for the Quick Die Change Tool. |
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| Illustration 14 | g03403993 |
Installing 239 Series Dies
- Insert the eight pins of the quick die change tool in the front of the 239 Series Crimp Dies and turn toward the left. Take the tool and the dies out of the Die Storage Rack.
- Hold the QDC in the center of the crimp tool.
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| Illustration 15 | g03403997 |
- Use the close push button to close the machine on the die group until they snap into place.
Note: While closing make sure that the pins are aligned with the holes in the adapter dies. If not, they will be broken or severly damaged. This process requires some practice. Replacement pins for the 239 series dies are Cat Part Number 330-3951.
- When dies are in place, pull the QDC out of the dies and open the machine completely.
Removing 239 Series Dies
- Reverse the order of above procedure.
- Insert QDC Tool.
- Open machine.
Calibration
The machine will need to be calibrated before it is put into service.
- Select "Utility" from the "Crimputer III" menu screen.
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| Illustration 16 | g02177434 |
- Select "Probe Calibration" from the Utility screen.
- C3 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 just install the 32mm dies.
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| Illustration 17 | g03591147 |
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| Illustration 18 | g02178231 |
- 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 19 | g02336039 |
- Open die and remove mandrel. Press "OK" when ready. The screen will advance to step 4 of 5.
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| Illustration 20 | g02336040 |
- 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 21 | g02391759 |
- 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 22 | g02430977 |
- If calibration value is within limits, press "OK". Calibration is successful. Store calibration mandrel in a safe place.
Maintenance
Note: During the first four weeks after the initial operation, check all screws and hydraulic connections and fasten if necessary.
Daily Maintenance
- Open the crimp tool completely.
- Switch off the motor and switch off the machine by the main switch.
- Clean the crimp tool of crimping scales with some pressurized air.
- Check the emergency-off switch by operating it.
- Check the level of oil in the sight glass.
- Check visually for oil leakage.
- Check the machine for outer damages or dismounting of parts such as covers.
- Check the holding bolts of the crimping dies for damages.
Monthly Maintenance
- Check the hydraulic hose assemblies for porosity and leaks.
- Check the screwed joints and clamps of the hose assemblies for leaks.
Annual Maintenance: Change Oil and Filter
- Turn off the machine at the main switch.
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| Illustration 23 | g03404136 |
- Pump/Drain the hydraulic oil out of the machine.
- Unscrew the filter cartridge.
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| Illustration 24 | g03404142 |
- Catch the oil in a basin. Dispose of the oil according to local regulations.
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| Illustration 25 | g03404148 |
- Take off the case.
- Change the filter. Assemble again in reverse order.
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| Illustration 26 | g03404152 |
Filter | |
- Fill the machine with Cat 339-3249.
Note: There are two possible filter elements. The Cat part number will be labeled on the filter cover, attached to the panel. Part numbers for the filter elements are 458-2920 and 458-2921.
Checking Slide Bearings
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| Illustration 27 | g03642243 |
Slide bearings are designed to last for thousands of cycles. However, cleanliness and heavy loading of the machine may be the two most influential variables on the life expectancy of the slide bearings. In order to identify a "worn" bearing, typically visual inspection is the best tool, especially since there are no pre-determined time or number of cycles of operation that can predict the life of the slide bearings.
If 50% or more of the anti-friction coating surface area is worn away (from visual inspection), replace the slide bearings. See illustration 27.
Replacing the Slide Bearings
- Open the crimping tool completely.
- Use a 5mm Allen wrench to remove the 2-socket head cap screws shown in the rectangular white-framed box and remove the cover plate. There are 2 cover plates on the front of the machine and 2 cover plates on the back of the machine.
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| Illustration 28 | g03599540 |
- Use a 5mm Allen wrench to remove the 2 socket head cap screws shown in the white circles that secure the holding plates for the bearings. There are 4 holding plates on the front of the machine and 4 holding plates on the back of the machine for a total of 16 screws.
Note: The cover is already removed on the right side of the machine.
- Remove the spacer washers between the holding plate and the master die. Be sure to reinstall the washers before remounting the holding plates.
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| Illustration 29 | g03599602 |
- Use the die removal tool to hold the dies in position while removing the old slide bearing.
- Replace the 4 slide bearings on the movable dies with new slide bearings.
- Use a 6mm Allen wrench to loosen the socket head cap screw in the 6 oclock master die and the 12 oclock master die.
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| Illustration 30 | g03599636 |
- Do not remove them.
- Use a flat blade screw driver to remove the slotted pan head screws shown in the white circles in the front and back of the machine. (4 screws each).
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| Illustration 31 | g03599940 |
- Replace the 4 slide bearings under the fixed dies with the new slide bearings.
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| Illustration 32 | g03600156 |
- Reinstall the slotted pan head screws.
- Use a small amount of grease to hold the spacer washers in place and reinstall the holding plates.
- If there are compensating plates, they must be inserted again at the same spot.
- After exchanging the bearing plates, re-calibrate the machine.
Spare Parts
Note: Illustration 33 and Table 5 shows the spare parts and corresponding part numbers associated with the machine. All of the parts listed in Table 5 are serviceable and can be ordered individually, if needed.
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| Illustration 33 | g03649284 |
| Position | Quantity | Cat Part No | Uniflex Part No | Description |
| 1 | 1 | 423-4364 | Calibration Mandrel | |
| 2 | 1 | 358-4537 | Caliper-Interface cable | |
| 3 | 1 | 423-4373 | Starrett caliper | |
| 4 | 1 | 358-4538 | Foot Switch Single | |
| 5 | 1 | 358-4544 | Foot Switch Double Close/Open | |
| 6 | 1 | 233-8046 | Quick Die Change Tool | |
| 7 | 1 | 233-8047 | Die Release Tool | |
| 8 | 1 | 807.410 (Uniflex) |
Potentiometer (Path Sensor) | |
| 9 | 1 | 358-4535 | Crimputer 3 Controller Only | |
| 1 | 233-8050 | 239L Series 12mm Die | ||
| 1 | 233-8051 | 239L Series 14mm Die | ||
| 1 | 233-8052 | 239L Series 17mm Die | ||
| 1 | 233-8053 | 239L Series 20mm Die | ||
| 1 | 392-3961 | 239L Series 22mm Die | ||
| 1 | 233-8054 | 239L Series 24mm Die | ||
| 1 | 392-3962 | 239L Series 26mm Die | ||
| 1 | 233-8055 | 239L Series 28mm Die | ||
| 1 | 233-8056 | 239L Series 32mm Die | ||
| 1 | 233-8057 | 239L Series 36mm Die | ||
| 1 | 233-8058 | 239L Series 40mm Die | ||
| 1 | 233-8059 | 239L Series 44mm Die | ||
| 1 | 233-8060 | 239L Series 47mm Die | ||
| 1 | 233-8061 | 239L Series 50mm Die | ||
| 1 | 233-8062 | 239L Series 54mm Die | ||
| 1 | 233-8063 | 239L Series 57mm Die | ||
| 1 | 233-8064 | 239L Series 62mm Die | ||
| 1 | 423-4365 | 237L Series 67mm Die | ||
| 1 | 423-4366 | 237L Series 71mm Die | ||
| 1 | 424-1400 | 237L Series 84mm Die | ||
| 1 | 424-1401 | 237L Series 96mm Die | ||
| 1 | 424-1402 | 237L Series 103mm Die | ||
| 1 | 457-6033 | Pressure Sensor | ||
| 1 | 458-2920 | Oil Filter Element 1 | ||
| 1 | 458-2921 | Oil Filter Element 2 | ||
| 1 | 416-6400 | Shim Kit |
Master Die and Adapter (Intermediate) Die Details and Parts
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| Illustration 34 | g03649308 |
| Position | Quantity | Cat Part No | Uniflex Part No | Description |
| 1 | 4/4 | 237.101.2/ 237.102.2 | Master (Primary) Dies/Secondary Dies | |
| 2,3,4,5 | 1 | 452-7655 (Kit includes 1 each) | Bolt, Spring, Threaded Pin M5 x 10, Threaded Pin M12 x 20 | |
| 6 | 8 | 421-2654 (8 pieces) | Detent Screw, Spring Loaded Ball Retainer | |
| 7 | 8 | 233-8077 (1 piece) | Steel Pins for 237 Series Dies | |
| 8 | 8 | 423-4367 (Kit, 8 dies) | Intermediate/Adapter Dies | |
| 9 | 8 | 330-3951 (Kit, 8 pins) | Steel Pins for 239 Series Dies |