Crimping XT-3 ES and XT-5 S4G, MCSH, and MCSX Couplings Using 4C-3660, 4C-5052, 4C-5053, 9U-5792, or 9U-7261 Hose Machines{0374, 0599, 0684, 0738, 5057} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

European Union Compliant, CE Marked

Illustration 1	g02139237
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.

General Information Section

Introduction

To crimp S4G couplings, use the 233-0346 Die Group (XT-3 ES [-20]), 233-0347 Die Group (XT-3 ES [-24]), or 233-0348 Die Group (XT-3 ES [-32]).

To crimp MCSH and MCSX couplings use the 233-0349 Die Group (XT-5 [-20]).

All of these dies are designed to be used only with 4C-3660, 4C-5052, 4C-5053, 9U-5792, or 9U-7261 Hose Machines.

These die groups do not have steps to locate the coupling in the die group during crimping. The crimp length is determined by visually aligning the coupling shell transition with the top surface of the die group. The 233-0350 Pusher Group assists in the alignment process and is provided for crimping when using the large bowl of the hose machine. The 134-9582 Pusher Plate can be used but is not recommended.

In all cases using these die groups, no spacer rings are required or available.

Illustration 3	g02625991
Typical Hose Machine.

Nomenclature

Illustration 4	g02626007
Die Groups For S4G, MCSH, And MCSX Couplings For Caterpillar XT-3 ES and XT-5 Hose. (1) 233-0348 Die Group (XT-3 ES [-32]). (2) 233-0346 Die Group (XT-3 ES [-20]). (3) 233-0349 Die Group (XT-5 [-20]). (4) 233-0347 Die Group (XT-3 ES [-24]). (5) 233-0350 Split Pusher Group.

Illustration 5	g02626011
Typical S4G, MCSH, And MCSX Couplings.

Illustration 6	g02626015
Coupling Identification. (1) Crimp-To-Shell-Transition. (2) Coupling Dash Number. (3) Coupling Style. (4) Caterpillar Part Number.

Note: On couplings with a radius instead of the sharp "Crimp-To-Shell-Transition", the "Crimp-To-Shell-Transition" is at the bottom of the radius (shown with dashed line in Illustration 6).

References

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

Special Instruction, NEHS0768, General Information for Hose Assembly

Special Instruction, NEEG2973, S4G, MCSH, and MCSX Coupling Crimp Chart

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.

General Information

For information on cutting hoses, orienting couplings, skiving, and other general hose assembly information, refer to Special Instruction, NEHS0768, "General Information for Hose Assembly".

Cleaning Hoses

Bulk hose that is not cleaned before installing the coupling can cause hydraulic system component damage. Foreign material inside the ends of the hose can cause grip failure and sudden release of the coupling from the hose. The use of a blade-type cutoff saw or a wire brush skiver can also leave foreign material inside the hose.

Use one of the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups for cleaning the bulk hose and hose assemblies. For additional information refer to Special Instruction NEHS0643 Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups.

Operation Section

General 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 bulk hose and or hose assembly to avoid contamination of the hydraulic system using a hose cleaning group.

3. DO NOT put oil or grease on the hose or couplings. Only water is permitted as a lubricant when pressing the coupling into hoses.

4. Insert the hose in the new coupling and make sure that it is oriented properly.

5. Carefully position and align the coupling's "Crimp-To-Shell-Transition" mark in the die group before crimping.

6. Remove any sharp edges or burrs on crimped couplings with 80 grit emery paper or other suitable means.

7. Measure the finished crimp diameter to make sure that it meets the correct crimp diameter specifications.

Crimp Procedure for XT-3 ES (-20) Hose

When crimping XT-3 ES (-20) hose assemblies, a 4C-4370 Die Bowl (small bowl) must be installed in the hose machine. Use the following setup and crimp procedure when crimping XT-3 ES (-20) hose assemblies.

1. Cut the hose to length. Refer toSpecial Instruction, NEHS0768, "General Information for Hose Assembly" for additional information.

2. Clean the bulk hose to remove any loose debris or foreign objects. Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups, for additional cleaning recommendations.

3. Install the 4C-4370 Die Bowl.

   1. Remove the 133-7363 Die Rest from the hose machine die bowl, if installed.
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   Illustration 7	g02626021
   Remove 133-7363 Die Rest.

   2. Insert the 133-7362 Die Rest into the 4C-4370 Die Bowl.
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   Illustration 8	g02626024
   Insert 133-7362 Die Rest.

   3. Insert the 4C-4370 Die Bowl into the hose machine die bowl.

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Illustration 9	g02626027
Insert 4C-4370 Die Bowl.

4. Lubricate the outside surface of the die group or the inside surface of the 4C-4370 Die Bowl with 129-1939 Desert Gold Grease and insert the die group into the die bowl.

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Illustration 10	g02626030
Insert Die Group.

5. Place the coupling/hose assembly in the die group.

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Illustration 11	g02626032
Insert Coupling/Hose.

6. Install the front pusher half onto the hose machine.

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Illustration 12	g02626034
Install Front Pusher Half.

7. Lower the ram enough to hold the coupling snugly within the die while still allowing enough movement to make slight up and down adjustments of the coupling and hose.

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Illustration 13	g02626035
Lower Ram To Secure Coupling.

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NOTICE
Be careful to avoid gripping the coupling too tightly. Gripping the coupling too tightly could allow the hose to be partially pulled out of the coupling when aligning the "Crimp-To-Shell-Transition" with the top of the die.

8. Make sure the "Crimp-To-Shell-Transition" of the coupling, as shown in Illustration 6, is aligned with the top of the die.

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Illustration 14	g02626037
Align "Crimp-To-Shell-Transition".

9. Crimp the coupling to the hose by lowering the ram until the pusher plate contacts the die bowl.

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Illustration 15	g02626038
Lower Ram To Crimp Coupling.

10. Check the crimp diameter to make sure that it is within the proper crimp diameter specifications. Refer to Special Instruction NEEG2973, S4G, MCSH, and MCSX Coupling Crimp Chart, or the specifications in the Table 1 in this manual.

Crimp Procedure for XT-3 ES (-24 and -32) or XT-5 (-20)

When crimping XT-3 ES (-24 and -32) and XT-5 (-20) hose assemblies, use the following setup and crimp procedure.

1. Cut the hose to length. Refer to Special Instruction NEHS0768, General Information for Hose Assembly for additional information.

2. Clean the bulk hose to remove any loose debris or foreign objects. Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups, for additional cleaning recommendations.

3. Insert the 133-7363 Die Rest into the hose machine die bowl.

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Illustration 16	g02626039
Insert 133-7363 Die Rest.

4. Attach the 233-0352 Rear Pusher Half to the hose machine pusher plate by tightening the thumb screws.

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Illustration 17	g02626041
Attach 233-0352 Rear Pusher Half.

Note: To help retain the rear pusher half on the machine pusher half, a small groove can be ground into the side of the pusher, as shown in Illustration 18. To locate the groove correctly, apply bluing to the surface of the machine pusher plate and install the 233-0352 Rear Pusher Half. Remove the pusher half and grind approximately a 4.50 mm (.188 inch) wide x 4.50 mm (.188 inch) deep groove. This will help hold the 233-0352 Rear Pusher Half onto the pusher plate.

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Illustration 18	g02626042
Groove To Help Retain Rear Pusher Half.

5. Lubricate the outside surface of the die group or the inside surface of the die bowl with 129-1939 Desert Gold Grease and insert the die group into the die bowl.

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Illustration 19	g02626043
Insert Die Group.

6. Place the coupling/hose assembly in the die.

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Illustration 20	g02626044
Insert Coupling/Hose.

7. Install the front pusher half on the hose machine.

   1. Assemble the 233-0351 Front Pusher Half, onto the machine front pusher half.
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   Illustration 21	g02626047
   Assemble Front Pusher Halves.

   2. Attach the front pusher halves onto the hose machine.

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Illustration 22	g02626048
Attach Front Pusher Halves.

8. Lower the ram just enough to hold the coupling snugly within the die while still allowing enough movement to make slight up and down adjustments of the coupling and hose.

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Illustration 23	g02626049
Lower Ram To Secure Coupling.

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NOTICE
Be careful to avoid gripping the coupling too tightly. Gripping the coupling too tightly could allow the hose to be partially pulled out of the coupling when aligning the "Crimp-To-Shell-Transition" with the top of the die.

9. Make sure the "Crimp-To-Shell-Transition" of the coupling, as shown in Illustration 6, is aligned with the top of the die.

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Illustration 24	g02626050
Align "Crimp-To-Shell-Transition".

10. Crimp the coupling to the hose by lowering the ram until the pusher plate contacts the die bowl.

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Illustration 25	g02626052
Lower Ram To Crimp Coupling.

11. Check the crimp diameter to make sure that it is within the proper crimp diameter specifications. Refer to Special Instruction, NEEG2973 S4G, MCSH, and MCSX Coupling Crimp Chart, or the specifications in the Table 1 in this manual.

Hose Crimp Specifications Chart

Serviceable Parts

Illustration 26	g02626054
233-0351 Front Split Pusher . (1) 233-0351 Pusher Front-Half . (2) 233-0353 Plate . (3) 233-0354 Block .