Crimping Permanent Couplings Using the 136-3642 Crimp Tool Group in Combination and XT Hose Machines{0374, 0599, 0684, 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, 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 operation, lubrication, maintenance, and repair information.

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 Cat 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. This 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 tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

General Hazard

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Information

Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Obey all local regulations for the disposal of liquids.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Stay clear of all rotating and moving parts.

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.

Personal Protection/Important Information

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Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

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.

Introduction

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Illustration 1. 136-3642 Crimp Tool Group with Standard Spacer Rings and Die Group

The 136-3642 Crimp Tool Group can be used in former 4C-9900, 6V-4880 and 1U-9160 XT Hose Machines. It is also used in the current 150-2568 Hose Machine or the CE-compliant 173-9805 XT Hose Machine. It can be used in the 139-5439, 145-3381 and 152-3910 Combination Hose Machines without a Crimputer.

The crimp tool group will work on inside diameter hose sizes up to 1.25 inches. The crimp tool group uses standard spacer rings and dies. It can also be used with the 1E1543 Air Conditioning Dies and the 1E1028 Thermoplastic Dies.

Note: Refer to PECP5030, "Hose and Couplings Reference Guide," for a complete list of spacer rings and die sets.

References

Additional Tooling

General Guidelines

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

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

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

3. Do not allow oil or grease on the hose or couplings. Only water is permitted as a lubricant when placing couplings onto hoses.

4. Insert the hose in the new coupling until it is aligned with the coupling insertion mark. Refer to the Depth Chart in NEHS0768 Tool Operating Manual for additional information.

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

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

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

Die Bowl Assembly Procedure

The 136-3542 Crimp Tool Group (Illustration 5) must be used with a die bowl group (Illustration 6) assembled from the parts in Chart A. This crimp tool group can then be used with standard Cat dies as well as air conditioning and thermoplastic hose die groups. Prior to using the crimp tool group, follow the assembly procedure.

Illustration 5	g03562939

1. Assemble the die bowl group, as shown in Illustration 5. Make sure that the notches in the die separator are facing upward (toward the angled bowl).

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Illustration 6	g03562177
Illustration 3. Crimp Tool Group Die Bowl Assembly (1) 4C-4376 Snap Ring (2) 4C-4375 Spring (3) 135-4561 Die Separator (4) 140-9360 Ring (5) 141-9718 Die Bowl (6) 133-7362 Die Rest

2. Assemble the die group into the 136-3642 Crimp Tool Group .

Crimping Procedures

XT Hose Machine

1. Select the correct die group and spacer rings using NEEG2737, Hose, Die Group and Spacer Ring Selection Chart.

2. Tilt the XT Hose Machine into a vertical position and lock it into place.

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Illustration 7	g03563096
Tilt Hose Press into a Vertical Position

3. Thoroughly lubricate the die bowl with 129-1939 "Desert Gold" Grease.

4. To crimp hoses using Cat designed die groups, make sure the 133-7362 Die Rest is installed.

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Illustration 8	g03563159
Install 133-7362 Die Rest when Crimping Hoses with Cat Die Groups

Note: When crimping air conditioning and thermoplastic hose, remove the 133-7362 Die Rest . This allows the air conditioning and thermoplastic dies to be used in the crimp tool group. For specific crimping instructions, refer to NEHS0749, Crimping 1E543 Air conditioning Hose and 1E1028 Thermoplastic Hose.

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Illustration 9	g03563171
Remove Die Rest when Crimping 1E-1543 Air Conditioning and 1E1028 Thermoplastic Hose

5. Place the crimp tool group into the hose machine.

6. Place the correct spacer rings on top of the die bowl.

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Illustration 10	g03563179
Install the Correct Spacer Ring

7. Place the correct die group into the die bowl.

   Note: When using a Caterpillar two-piece split die, place the split from front to back. This helps keep the dies in place when installing the hose and coupling assembly.

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Illustration 11	g03563256
Install the correct Die Group

Note: Refer to Tool Operating Manual NEHS0768, "General Information for Hose Assembly,'
for additional information on cutting and skiving hoses, insertion depth, and general hose assembly information.

8. Place the hose and coupling assembly into the crimp tool group. Make sure that the coupling is squarely seated on the step in the die group.

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Illustration 12	g03563296
Place Hose Assembly into Die

9. Lower the pusher until the pusher plate firmly contacts the top of the spacer rings. Stop lowering the pusher and try to turn the spacer ring by hand. If the ring rotates, the crimp is not complete.

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Illustration 13	g03563505
Crimp the hose Assembly until Pusher Contacts Spacer Ring (see arrows)

10. If the crimp is complete, raise the pusher and remove the hose assembly from the machine.

11. Measure the crimp diameter and make sure the crimp meets the correct assembly specifications shown on the NEEG2746 Crimp Diameter Chart.

Combination Hose Machine

1. Select the correct die group and spacer rings using NEEG2737, Hose, Die Group and Spacer Ring Selection Chart.

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Illustration 14	g03563558
Combination Hose Machine

2. Thoroughly lubricate the bowl with 129-1939 "Desert Gold" Grease.

3. To crimp hose using Cat designed die groups, make sure the 133-7362 Die Rest is installed.

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Illustration 15	g03563598
Install 133-7362 Die Rest when Crimping Hoses with Cat Die Groups

Note: When crimping air conditioning and thermoplastic hose, remove the 133-7362 Die Rest . This allows the air conditioning and thermoplastic dies to be used in the crimp tool group. For specific crimping instructions, refer to NEHS0749, Crimping 1E1543 Air Conditioning Hose and 1E1028 Thermoplastic Hose.

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Illustration 16	g03563616
Remove Die Rest for Air Conditioning and Thermoplastic Hose

4. Place the crimp tool group into the hose machine.

5. Place the correct spacer rings on top of the die bowl.

6. Place the correct die group into the die bowl.

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Illustration 17	g03563625
Place Tooling into Hose Machine

Note: Refer to Tool Operating Manual NEHS0768, "General Information for Hose Assembly," for additional information on cutting and skiving hoses, insertion depth, and general hose assembly information.

7. Place the hose and coupling assembly into the crimp tool group. Make sure that the coupling is squarely seated on the step in the die group.

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Illustration 18	g03566056
Place Hose Assembly into Die

8. Lower the pusher until the pusher plate firmly contacts the top of the spacer rings. Stop lowering pusher and try to turn the spacer ring by hand. If the ring rotates, the crimp is not complete.

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Illustration 19	g03566063
Crimp the Hose Assembly

9. If the crimp is complete, raise the pusher and remove the hose assembly from the machine.

10. Measure the crimp diameter and make sure the crimp meets the correct assembly specifications shown on the NEEG2746 Crimp Diameter Chart.