Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439} Caterpillar


Information for equipment:


BRAKING SYSTEM
TOOLS

Hose Inspection Form {0374, 0599, 5057, 5057} Hose Inspection Form {0374, 0599, 5057, 5057}

Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439} Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439}
Installing 457-6030 (C3-290 Controller) on Hose Crimping Machines 233-8048, 286-4354, 286-4355, 275-6199, 286-4353, and 233-8038{0374, 0599, 0684, 0700, 0738, 5057} Installing 457-6030 (C3-290 Controller) on Hose Crimping Machines 233-8048, 286-4354, 286-4355, 275-6199, 286-4353, and 233-8038{0374, 0599, 0684, 0700, 0738, 5057}
NEHS1214: 455-0126 Nitrogen Booster Pump Group {0374, 0599, 0647, 0756, 4263, 4331, 5077, 7200} NEHS1214: 455-0126 Nitrogen Booster Pump Group {0374, 0599, 0647, 0756, 4263, 4331, 5077, 7200}


Caterpillar Products: All

Introduction

European Union Compliant, CE Marked

Important Safety Information




Illustration 1g02139237

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




Illustration 2g00702020

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 the 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

------ WARNING! ------

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




Illustration 3g02166423

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.

General Information Section

Product Description




Illustration 4g03643122

The 453-3204 Pressure and Temperature Test Kit is a service tool for generating pressures up to 500 psi and temperatures from ambient to 350 C. The generated temperatures and pressures can be used to troubleshoot, calibrate, or validate pressure and temperature sensors and systems set points. The group contains a thermal well that generates precise temperatures, a pressure hand pump, connection hose, and adaptor fittings as well as some tools needed to remove or isolate some particular sensors. The group also contains some seals (o-rings) used for replacement when sensors are removed from an operating system for testing. See the parts list for detailed information.

Temperature

Temperature is generated using a Fluke Thermal Calibrator. The Thermal generator may be used as a portable instrument or bench top temperature calibrator for calibrating thermocouples and RTD temperature probes. It is small enough to use in the field, and accurate enough to use in the lab. The unit operates on 115 VAC or 230 VAC and cords are provided to work with most global power connections. The thermal generator contains an insert with test holes for 7 of the most common sizes of temperature probes.

The instrument features:

  • Rapid heating and cooling

  • Interchangeable multiple hole aluminum probe sleeves

  • Convenient hand strap

  • RS-232 interface capability

Built in programmable features include:

  • Temperature scan rate control

  • Temperature switch hold

  • Eight set point memory

  • Adjustable readout for °C or °F.

The temperature is accurately controlled by a hybrid analog/digital controller. The controller uses precision platinum RTD as a sensor and controls the well temperature with a solid-state relay (triac) driven heater. The LED front panel continuously shows the current well temperature. The temperature may be easily set with the control buttons to any desired temperature within the specified range. The multiple fault protection devices of the instrument, insure user and instrument safety and protection.

Pressure

Pressure is generated using a Fluke hand pump. Pressure can be generated to 34 bar (limited by gauge) as well as vacuum to -0.96 bar. The hand pump has a digital pressure gauge for precise pressure setting. A short 1 meter test hose and various adaptor fittings are provided to adapt to the most common pressure sensors used on Cat products. A longer test hose could be used but pressure generation would take more strokes of the hand pump.

Parts List

The 453-3204 pressure and temperature test group consists of:

Table 1
Item     Qty     Part No     Name    
1     1     4C9660     Case    
2     1     453-3205     Foam Assembly    
3     1     453-3208     Tool Group    
4     1     453-3210     Insert    
5     1     453-3209     Tool Group    
6     1     453-3207     Tool    
7     1         Short #2 Phillips Screwdriver    
8     1         Global Power Cord Set    
9     1     9U-6795     Hose    
10     5     8T-5114     Adapter    
11     1     335-3999     Adapter    
12     1     5P-9617     Adapter    
13     1     9X0261     Adapter    
14     1     331-1137     Adapter    
Consumables    
15     4     214-7568     Seal    
16     10     6V9028     Seal    
17     10     199-9267     Seal    
18     10     219-0669     Seal    
19     10     228-7100     Seal    
20     10     228-7101     Seal    
21     10     9T4057     Seal    
22     11     214-7566     Seal    
23     10     214-7567     Seal    
24     10     033-6028     Seal    
25     10     6V6609     Seal    
26     10     238-5058     Seal    

References

Table 2
Media Number     Type    
NEHS1199     Tool Operating Manual    
NEEG3159     Decal    

Specifications

Pressure Generator

  • Pressure to 40 bar (600 psi)

  • Vacuum to -0.96 bar (-13.9 psi)

  • Wetted materials: aluminum, silicon, neoprene, stainless steel, Buna-N

  • Weight: 1.03 lb (467 g)

  • Dimensions: length 220 mm (8.7 in), width 122 mm (4.8 in), depth 89mm (3.5 in).

  • Display units: psi, bar, KPA

Adapter Fittings for:

  • 12mm JIC Male

  • 14mm JIC Male

  • 9/16 JIC Male

  • 7/16 JIC Male and Female

  • 16 mm sample port

Temperature Generator

Table 3
Temperature Generator    
Power     115 VAC (±10%), 2.2 A, switchable 500 W    
Ambient Temperature     5 - 50°C (41 - 122°F)    
Operating Range     35 - 350°C (95 - 662°F)    
Resolution     0.1°C or °F resolution    
Readout     Switchable °C or °F    
Accuracy     0.5°C (±0.9°F), in holes greater than 1/4" (6.35 mm) accuracy is ± 1°C (±1.8°F)    
Stability     0.03°C at 50°C, 0.05°C at 350°C    
Uniformity     ±0.4°C typical, ±0.1°C with similarly sized wells    
Controller     Digital controller with data retention    
Heater     500W    
Heating Time     12 minutes from ambient to 350°    
Cooling Time     15 minutes from 350°C to 100°C    
Cooling     2 speed internal fan    
Stabilization Time     7 minutes    
Immersion Depth     124 mm (4.88 in)    
Fault Protection     Sensor burnout and short protection, over temperature thermal cut-out electrical fuses    
Test Wells     31.8 mm dia x 123.7 mm deep (1.25 in x 4.87 in). Multi-hole inserts are available.    
Exterior Dimension     152.4 mm H x 85.7 mm W x 196.9 mm D (6 in x 3.375 in x 7.75 in)    
Weight     2.7 kg (6 lbs)    
Fuse Rating     115 V: 6 A (fast acting), 250 V 230 V: 3.15 A (fast acting), 250 V    
Safety     OVERVOLTAGE (Installation) CATEGORY II, Pollution Degree 2 per    

Although the instrument has been designed for optimum durability and trouble-free operation, it must be handled with care. The instrument should not be operated in an excessively dusty or dirty environment. Maintenance and cleaning recommendations can be found in the Maintenance Section of this manual.

The instrument operates safely under the following conditions:

  • Temperature Range: 5 - 50°C (41 - 122°F)

  • Ambient Relative Humidity: 15 - 50%

  • Pressure: 75 kPa - 106 kPa

  • Main voltage within ±10% of nominal

  • Vibrations in the calibration environment should be minimized

  • Altitude does not effect the performance of the unit

Operation Section

Using the Thermal Generator

Calibrator Set-Up

  1. Place the calibrator on a flat surface with at least 6 inches of free space around the instrument. Overhead clearance is required. DO NOT place under a cabinet or other structure. Plug the power cord into a grounded main outlet. Observe that the nominal voltage corresponds to that indicated on the back of the calibrator.

  1. Gently insert the probe sleeve into the well. The probe sleeve should be of the smallest hole size possible while allowing the probe to slide in and out easily. The well must be clear of any foreign objects, dirt, and grit before the sleeve is inserted.

  1. Turn on the power to the calibrator by toggling the switch at the rear of the instrument to the "I" (on) position. The fan will begin circulating air through the instrument. After a brief self test the controller should begin normal operation showing the well temperature. The block will heat or cool until it reaches the programmed set-point.

------ WARNING! ------

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

----------------------


NOTICE

When in operation, air may be blown from the front of the instrument. The front area of the instrument near the probe insert will become hot. Take care not to touch any of the metal areas around the probe insert or a burn may result


Switching to 230 V Operation

The thermal generator is switchable from 115 VAC to 230 VAC 50/60 Hz. Switching the voltage can change the calibration, so it is recommended to recalibrate the unit after changing the input voltage.




Illustration 5g03659673

To change from 115 VAC to 230 VAC:

  1. Unplug the unit.

  1. With a small straight slot screwdriver, remove the fuse holder located on the rear panel. Replace the two 6 amp fuses with 3 amp 250V fuses.

  1. Replace the fuse holder with the "230V" in the display window.

  1. Using the same straight slot screwdriver, move the heater switch to display "230V". Refer to the rear panel drawing in Illustration 5.

Note: If the heater switch and the fuse holder do not both read 230V when complete, the unit will either not heat, or only heat at a fraction of its capacity.


NOTICE

DO NOT plug the unit into 230 V if the heater switch and fuse holder read 115. This will cause the fuse to blow and may damage the instrument.


General Description

Controller Display

The digital display is an important part of the temperature controller because it not only displays set and actual temperatures, but also various calibrator functions, settings, and constants. The display shows temperatures in units according to the selected scale in °C or °F.

Controller Keypad




Illustration 6g03659739

The four button keypad allows easy setting of the set point temperature. The control buttons (SET, DOWN, UP, and EXIT) are used to set the calibrator temperature set point, access, and set other operating parameters, plus access and set calibration parameters.

The functions of the buttons are as follows:

SET - Used to display the next parameter in the menu and to store parameters to the displayed value.

DOWN - Used to decrement the displayed value of parameters.

UP - Used to increment the displayed value.

EXIT - Used to exit a function and to skip to the next function. Any changes made to the displayed value are ignored.

Changing Display Units

The thermal generator can display temperature in Celsius or Fahrenheit. The temperature units are shipped from the factory set to Celsius. To change to Fahrenheit or back to Celsius, there are two ways:

  1. Press the "Set" and "UP" simultaneously. This will change display units.

  1. Press the "SET" key three times from the temperature display to show Un=C. Press the "UP" or "DOWN" key to change units.

Setting the Temperature

Section 7.2 of the Fluke Manual, included in the documentation, explains in detail how to set the temperature set-point on the calibrator using the front panel keys. The procedure is summarized here.

  1. Press "SET" twice to access the set-point value.

  1. Press "UP" or "DOWN" to change the set-point value.

  1. Press "SET" to program in the new set-point.

  1. Press "EXIT" to return to the temperature display.

When the set-point temperature is changed the controller will switch the well heater on or off to raise or lower the temperature. The cycle indicator, a two color LED, will also indicate on (red and heating) or off (green and cooling).

The displayed well temperature will gradually change until it reaches the set-point temperature. The well may require 5 to 20 minutes to reach the set-point depending on the span. Another 5 to 10 minutes is required for the temperature to stabilize.

Removing the Thermal Insert

The probe insert has 6 probe holes on one end and one large hole on the other. It must be removed from the thermal generator and swapped end for end to use the opposite probe holes.

------ WARNING! ------

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

----------------------


NOTICE

Always unplug power from the thermal generator before removing the thermal insert.



NOTICE

Never remove or insert the probe insert when the Thermal generator is hot. Always allow to cool to room temperature before removing or inserting. Failure to do so may cause damage to the thermal generator or the insert and high temperatures can cause burns.


Use the insert removal tool and insert the two prongs into the removal holes. Pull the insert straight out. Exchange ends and insert. Do not allow dirt, liquid, or other contaminant to enter the thermal generator or get on the insert. Clean off any contaminant before installing probe insert into thermal generator, or the probe insert may become permanently lodged in the thermal generator. Do not force the insert into the thermal generator. It should install easily.




Illustration 7g03702614



Illustration 8g03702624

Once the insert has been reinstalled, reconnect power and apply a new temperature set point.

Calibrating a Sensor

Insert the sensor probe to be calibrated into the well of the thermal generator. The probe should fit snugly into the probe sleeve yet should not be so tight that it cannot be easily removed. Avoid any dirt or grit that may cause the probe to jam into the sleeve. Best results are obtained with the probe inserted to the full depth. Once the probe is inserted, allow adequate time to allow the test probe temperature to stabilize. Once the probe reading has stabilized, it may be compared to the calibrator display temperature. The display temperature should be stable to within 0.1oC for best results.




Illustration 9g03702643


NOTICE

Never introduce any foreign material into the probe hole of the insert. Fluids, etc. can leak into the calibrator causing damage to the insert or cause binding and damage to the temperature probe.


Turning off the Thermal Generator

The thermal generator should always be cooled by lowering the set point to the ambient temperature before unplugging or turning off. Failure to do so can cause damage to the unit. Before turning off, lower the set point to below the surrounding ambient temperature and wait for the display to indicate that the thermal generator temperature has reduced to near the ambient room temperature. This may take up to 15 minutes depending on the previous temperature.


NOTICE

Do not place a hot thermal generator back into the carrying case. Doing so will cause damage to the foam in the case.


Additional Information about Advanced Features

For advanced features of the Fluke Thermal Generator, refer to the Fluke operating instructions included in the documentation pouch in the Group.

Using the Pressure Calibrator

Setup

Testing pressure sensors requires connecting the hand pump, test hose, and pressure sensor adaptors. Connect the test hose to the back of the hand pump. Ensure that the fitting is completely engaged. A slight resistance will be felt when the hose passes through the seal.




Illustration 10g03702706

Select the appropriate adaptor for the sensor to be tested. The available adaptors are listed below.

  • 12 mm JIC Male

  • 14 mm JIC Male

  • 9/16 JIC Male

  • 7/16 JIC Male and Female

  • 16 mm sample port

Tread the adaptor fitting onto the sensor hand tight. Resistance will be felt once the seal starts to make contact. Keep turning until the seal is covered and the adaptor is firmly seated.




Illustration 11g03702732

Thread the other end of the hose onto the adaptor in the same way it was done on the pump, making sure that it is firmly seated.




Illustration 12g03702790

Operation

  1. Loosen the pressure release on the pump (A) .

  1. Turn on the pressure gauge by pressing the ON/OFF button.

  1. If necessary, zero the gauge by pressing the Zero/Clear button.

    Note: To change the units displayed, press the Units button repeatedly until the desired units are displayed.

  1. Close the pressure release on the pump.

  1. Select to generate pressure or vacuum by pressing the plunger (C) in the sides of the pump. Press to the right for pressure and to the left for vacuum. Ensure that the plunger is completely pressed to the selected direction, or the pump will not generate any pressure or vacuum.

  1. Squeeze the handles of the pump (D) until the desired pressure is reached. As you get near the desired pressure, it may be necessary to use the fine adjustment knob (B) to make minute adjustments in the pressure. Rotate the fine adjustment knob clockwise to increase the pressure and counterclockwise to decrease the pressure.

    Note: If you need to lower the pressure more than the fine adjustment knob will allow, then open the pressure release slightly to bleed off some of the pressure and then tighten it back again.

  1. When the test is complete, slowly open the pressure release knob to release the pressure from the system. Only after the pressure gauge indicates zero pressure should you disconnect any connections. Disconnect the hose and fittings in the reverse order of connection.

  1. Turn gauge off using On/Off button when finished testing to conserve battery.

------ WARNING! ------

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 by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

----------------------


NOTICE

Pressures up to 600 psi can be generated by the hand pump. Do not disconnect sensor or hose until pressure is released using the pressure release knob. Do not cut, pinch, kink, or otherwise damage the test hose. If test hose is damaged, discard and replace. Do not use a damaged test hose. Do not place any part of your body over the test hose or hand pump outlet and attempt to generate a pressure. Doing so could cause serious injury.





Illustration 13g03703093



Illustration 14g03703092



Illustration 15g03703090

Pressure Gauge Settings

For additional functions of the digital pressure gauge, refer to the gauge manual included in the information packet.

Maintenance

Thermal Generator

The calibration instrument has been designed with the utmost care. Ease of operation and simplicity of maintenance have been a central theme in the product development. Therefore, with proper care, the instrument should require very little maintenance. Avoid operating the instrument in an oily, wet, dirty, or dusty environment.

  • If the outside of the instrument becomes soiled, it may be wiped clean with a damp cloth and mild detergent. Do not use harsh chemicals on the surface which may damage the paint.

  • It is important to keep the well of the calibrator clean and clear of any foreign matter. Do not use fluid to clean out the well.

  • The dry-well calibrator should be handled with care. Avoid knocking or dropping the calibrator.

  • For dry-wells with removable probe sleeves, the sleeves can become covered with dust and carbon material. If the buildup becomes too thick, it could cause the sleeves to become jammed in the wells. Avoid this build up by periodically buffing the sleeves clean.

  • If a sleeve should be dropped, examine the sleeve for deformities before inserting it in the well. If there is any chance of jamming the sleeve in the well, file or grind off the protuberance.

  • Do not drop the probe stems into the well. This type of action can cause a shock to the sensor.

  • If a hazardous material is spilt on or inside the equipment, the user is responsible for taking the appropriate decontamination steps as outlined by the national safety council with respect to the material.

  • If the main supply cord becomes damaged, replace it with a cord with the appropriate gauge wire for the current of the instrument. If there are any questions, call Caterpillar Customer Service for more information.

  • If the instrument is used in a manner not in accordance with the equipment design, the operation of the dry-well may be impaired or safety hazards may arise.

Pressure Generator

Occasionally, the 700PTP-1 may not work properly due to contamination of the internal valve assembly. Use the following procedure to clean the valve assembly.

  1. Using a small screwdriver, remove the 2 valve retention caps located on opposite sides of the pump below the pressure/vacuum switch.

  1. Gently remove the spring and o-ring assembly. Take care when removing check valve as it contains several small components. See the figure below.



    Illustration 16g03703116

  1. Set aside the valve assemblies and clean out the valve body using a cotton swab soaked in isopropyl alcohol.

  1. Repeat the process several times using a new swab until clean.

  1. Operate the pump handles several times and recheck for contamination.

  1. Clean the o-ring assembly and the o-ring on the retention caps with isopropyl alcohol and inspect the o-rings closely for any damage or excessive wear. Replacements are included in the repair kit.

  1. Inspect the springs for wear or loss of tension. They should be approximately 8.6 mm long in the relaxed state. If shorter, they may provide insufficient sealing force. Replace if needed.

  1. Once all parts have been cleaned and inspected, reinstall the o-ring and spring assembly into the valve body.

  1. Reinstall the retention caps and gently tighten each cap.

  1. Seal the output port and operate the pump to at least 50% of capacity.

  1. Release the pressure and repeat several times to ensure that the o-rings seat properly.

Routinely inspect the test hose and adaptor fittings for damage. Replace any damaged components. Do not use a damaged hose or fitting.

Occasionally the batteries in the pressure gauge may need replacing. When the pressure gauge indicates a low battery, remove the back cover and replace with the same type AA Alkaline battery.

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