Use of 7S1100 Hydraulic Press Arrangement{0738} Caterpillar

Introduction

This special instruction contains safety information, operating instructions, parts information and tool recommendations for use of the 7S1100 Hydraulic Press Arrangement. Use of the 7S1100 Hydraulic Press Arrangement and connected tools permits the maintenance of a minimum stock of XT-3, XT-5 and XT-6 hose and couplings.

Some illustrations in this publication show details or attachments that may be different from your particular press. Also, guards and covers may have been removed for illustrative purposes.

Continuing improvement and advancement of product design may have caused changes to your press that are not included in this publication.

NOTE: In some instances, illustrations used in this publication may show a hydraulic press other than the 7S1100 Hydraulic Press Arrangement. Although the press may look different, the procedure will be the same.

Whenever a question arises regarding your press or this publication, please consult Caterpillar Service Technology Group at the telephone numbers listed below. Regular business hours are from 8:00 AM to 4:30 PM (Central Time Zone).

Within the State of Illinois:

1-800-541-8665

Outside the State of Illinois:

1-800-542-8665

Canada:

1-800-523-8665

Customers may also contact the Caterpillar Service Technology Group through the TELEX. The TELEX number is 404435.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: SEBD2080, Hydraulic Hose and Reusable Couplings (paper) or SBFY0604 (microfiche).

Safety Information

General

Use the correct tools in good condition and replace or repair damaged equipment.

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

Always wear protective glasses when using a hammer or similar tool to avoid injury to your eyes. Chips or other debris can fly off objects when they are struck. Make sure no one can be injured by flying debris before striking any object.

The hose coupling press has the capability of producing 445 kN (50 Ton) of force. To avoid personal injury, use the established operating procedure in this Special Instruction.

Press Operation

When operating the press, always wear safety glasses.

Never stand directly in front, to the rear, or at either side of the press. Bad parts, or a wrong set-up, could cause parts to be thrown out of the press. Stand in areas marked with an "X".

Always use the correct collets for the hose and coupling size. Improper sizing and installation of the collets, or improper use of the press, can cause the hose and/or fitting to be suddenly released and strike someone, causing personal injury.

Knife And Anvil Cutting Method

1. Cut only (Delta ) XT-3 Hose with this press. Do not cut (+) XT-5 or (UHP) XT-6 Hose with this press. Do not use broken tools. Use only the tools made for the press. Make sure knife (1) is in alignment with the center of the flat surface of anvil (2).

Make sure guard (3) is used when operating the press. For earlier presses a 2P5571 Guard Kit is available. Never lean on the press while it is being operated. Shield the pump hoses from the operator. Check the hoses regularly for damage.

2. Always use clamp (4) to hold front collets (5) in place. Never open the clamp without releasing the hydraulic pressure in the cylinders.

3. Always install the press over an opening as shown at location (A).

4. When operating the press, use of the "JOG" or remote position allows instantaneous power shutoff.

5. A 5P7278 Switch (6) is available for installation and use on these pumps. This switch is also available as a replacement for a damaged 5P7278 Switch.

6. ALWAYS resize (recondition) the stem of used couplings during the reconditioning process. This is to make sure that the stem of the coupling holds the hose correctly. Failure to resize can permit coupling blowoff (separation by force) and cause personal injury.

Always install the couplings in the correct position in the tool collets and in line with the action of the press.

Never install couplings on used hose, or apply oil between the coupling and hose. Coupling retention (ability to hold) is lowered on hose that has been in contact with hydraulic fluid.

Hose And Coupling Selection

Always use correct coupling assemblies and sleeves that are in relation to the correct size of hose.

The XT-3, XT-5 and XT-6 Hydraulic Hose and couplings are similar in many ways, and care should be used when identifying the differences.

Use only those parts that have a:

* (Delta ) triangular marking with XT-3 hose.* (+) symbol with XT-5 hose.* (UHP) symbol with XT-6 hose.

Never use a hose at a greater hydraulic pressure than its recommended working pressure.

XT-3 (Delta ) Hydraulic Hose is made for working (usable) pressures of 17 225 to 27 560 kPa (2,500 to 4,000 psi), depending upon hose size.

All XT-5 (+) Hydraulic Hose is made for a maximum working pressure of 34 450 kPa (5,000 psi).

All XT-6 (UHP) Hydraulic Hose is made for a maximum working pressure Of 41 340 kPa (6,000 psi).

Always install the hose, coupling assemblies and sleeves according to the markings (Delta , + or UHP) and size. Any mismatching or interchanging of couplings and hoses can cause the coupling to blow off the hose under pressure (separation with sudden force) and cause personal injury.

Cutoff Saws

Improper use of saws and cutoff wheels can cause personal injury. Always use protective equipment and the recommended procedure for cutting each type of hose.

Cutting Tool Reconditioning

Knife and Anvil

(1) Cutting knife.

(2) Anvil.

Keep hose cutting knife (1) sharp and the surface of anvil (2) ground smooth to be sure of a straight, even cut. Do not permit too much heat on the surfaces when reconditioning the knife and the anvil.

Skiving Knife Blade Sharpening

Flat file.

Round file.

The blade of skiving knife (3) is softer than the wire used in the hydraulic hose. This prevents damage to the wire by the skiving knife. The edge of the blade will become less sharp on the inside of the cutter. Sharpen the cutter by removing only the metal that has bent over on the inside edge. Use a round file only in the corners.

Cutting Hose

Use one of three methods to cut Caterpillar XT-Hose. A cutting tolerance is also required to achieve the desired length of hose. Make reference to the charts and the instructions that follow for cutting method and tolerance recommendations.

Knife And Anvil

1. To cut XT-3 Hose with a knife and anvil, install anvil (5) and knife (6) in the press. Use clamp assembly (7) to tighten the anvil in position. Measure the hose and check the chart for the correct tolerances. Carefully put the hose in position and close the press to cut.

Note oval shape of hose after cut.

2. Make the cut end round by using 1S0258 Plastic Hammer (8). Put one point of the cut on a solid surface and hit the other point at an angle.

Friction Saw or Abrasive Saw

Friction saw.

When XT-3, XT-5 or XT-6 Hose is cut on either the 5P6540 or 5P6542 Friction Saw, the hose must be bent as shown. When cutting small diameter hose (1), put pins (2) in position toward the center of table (3). For larger diameter hose (4), move pins (2) toward the outer edge of the table.

Abrasive saw.

If an abrasive saw cutoff method is used, more care must be used to clean the hose, because this method causes more foreign material than the friction cutoff method.

Skiving Hose

1. Put the hose in position in hydraulic press (1). Clamp the hose in position and install coupling (2).

NOTE: Be sure to use the correct collets for the type and size of hose to be skived. Refer to the Necessary Tools Chart and select the correct Grip Collets.

OR

Put the hose in the clamp jaws of 6V6018 Hose Skiving Vise (1). Install coupling sleeve (2).

NOTE: The 6V6018 Hose Skiving Vise is no longer available. Prints to fabricate a similar vise are available at no charge from Caterpillar Service Technology Group. Please order print number FT2270.

2. Use 6V6022 Skiving Gauge and the coupling sleeve to set the skiving length. Use the correct scale on the gauge marked (Delta ) for XT-3 Hose, (+) for XT-5, or (UHP) for XT-6 Hose. Tighten the clamp.

NOTE: If a 6V6022 Skiving Gauge is not available, refer to the charts that follow for the correct skiving length.

(A) Inside diameter. (B) Skiving length.

NOTE: Do not permit wire to show beyond the end of the coupling fingers. See the charts that follow for the correct skiving length.

3. Put arbor (4) into the end of the hose.

4. Use sleeve (2) as a guide to make the first cut counterclockwise (CCW). The lay of the wire and the counterclockwise (CCW) cut will force the skiving tool to make a straight cut against the sleeve.

5. To prevent the pull up of wire ends, turn the tool clockwise (CW) to finish the skiving.

6. When the wires can be seen, the skiving is finished. Do not remove material from between the wires. A clean or shiny look is not necessary.

7. Remove arbor (4). Do the same procedure on the other end of the hose. Keep the skiving knife sharp.

Coupling Installation

NOTE: If Round Wire Armor Guard is to be installed, refer to the topic Round Wire Armor Guard For Hose Assemblies before installing the second coupling onto the hose. Round Wire Armor Guard can not be installed if both couplings have been installed.

1. Slide sleeve (1) onto the hose with the larger chamfer toward the end of the hose. Install coupling (2) in the new hose as far as possible. Do the same procedure for the other end of the hose.

2. To push the coupling into the hose, use the correct front grip collets and rear collets. Make the correct selections from the charts that follow.

NOTE: If either hose coupling has a straight stem, push the coupling into the hose using the following steps. If both couplings have angled stems, refer to the topic Coupling Position before pushing the coupling on the hose.

3. Install the grip collets at location (A).

4. Install the rear collets at location (B). Clamp the collets securely. Close the press to push the stem into the hose.

5. Use a hammer with plastic tips to put the fingers tight against the hose.

6. To install the sleeve that holds the coupling, select the correct collets from the charts. Where the front collet counterbore faces the rear, put the sleeve in the collet counterbore. The rear collet counterbore is generally toward the rear.

It is necessary to put both the front and rear collets in reverse position for head clearance of smaller 90° couplings.

7. Install the assembly and collets in the press. Put a small amount of oil on the outside of stem assembly fingers (C). Do Not put oil between the stem assembly fingers and the hose.

Show/hide table

To avoid serious injury from flying objects, make sure the hose is free to slide in the front collets. Check the alignment of the parts, then close the press until the sleeve is even with the coupling shoulder.

8. Do this procedure for the other coupling if either coupling has a straight stem, otherwise, see the following topic.

Coupling Position

7S1125 Protractor

1. Put assembled coupling (1) in a vise with flange (2) UP as shown. Adjust the dial of 7S1125 Protractor (3) to zero. With the dial face of protractor (3) toward the vise, fasten the protractor near the sleeve of the coupling.

Adjust the position of the protractor on the hose until the bubble is level. Turn the dial to the angle position desired. Refer to SEBD2080 or SBFY0604.

2. Remove assembled coupling (1) from the vise, turn the hose end-for-end, and fasten loose coupling (4) in the vise with the flange UP. It is important that the flange direction on loose coupling (4) is the same as the flange direction on the assembled coupling.

3. Use assembled coupling (1) to turn the hose until the bubble is level. Remove the protractor.

NOTE: Coupling angle (C) is measured from the position of coupling (B) clockwise to coupling (A). In the chart, (D) is the length of the hose assembly and (E) is the degree of tolerance.

4. When the angle position is correct, install sleeve (5). See Coupling Installation.

1U9124 Protractor

The same procedure that was used for the 7S1125 Protractor can be used for the 1U9124 Protractor. The 1U9124 Protractor scale is broken up into 90° divisions.

When reading an angle greater than 90° use the angle reading in the quadrant as indicated by the dial and add 90° to this reading.

NOTE: When installing or removing the protractor group, we recommend that two hands be used.

Determining Coupling Angle On Former Assembled Hoses

NOTE: This method is the same for the 7S1125 and the 1U9124 Protractors.

1. Put one coupling in a vise with the flange up as shown. Adjust the dial of protractor (1) to zero. With the dial face of protractor (1) toward the vise, fasten the protractor near the sleeve of the coupling.

Adjust the position of the protractor on the hose unit until the bubble is level for the 7S1125 Protractor, or the arrow is aligned for the 1U9124 Protractor.

2. Remove the hose and protractor from the vise and install the other coupling in the vise as shown.

3. Turn the dial until the bubble is level, or the arrow is aligned. Read the angle position from the dial. Use this angle position for the new hose.

Cleaning Hoses

Hoses that are not clean 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 leave foreign material in the hose.

Show/hide table

Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

After the hose has been cut, hit both ends of the hose to remove any large particles. Use compressed air to push out any rubber dust that may have been caused when cutting. Finally, use a clean dry cloth to clean out both ends of the hose.

After a hose has been assembled, put caps (1) over both ends during storage. The caps give the O-ring grooves in the flange protection from damage. They also keep foreign materials out of the hose. Caps (1) are available from the following suppliers:

Round Wire Armor Guard For Hose Assemblies

NOTE: The round armor guard is installed after one coupling has been installed, and before installing the second coupling.

1. Select the correct size armor guard for the hose size being used from the chart that follows.

2. Cut the armor guard to the required length to protect the exposed portion of the hose. The correct armor guard length is the length of the hose less the sleeve length of each coupling.

3. Install the armor guard onto the hose. Install the sleeve on the hose with the larger chamfer toward the end of the hose. Install coupling (2) in the new hose as far as possible.

4. Refer to the topic Coupling Installation for instructions to complete the installation.

Reconditioning Used Couplings

An important feature of Caterpillar XT-3, XT-5 and XT-6 Hydraulic Hose Assemblies is the ability to reuse the couplings. When these couplings are reused, care must be taken to be sure the reconditioning has been done correctly and completely. Do not use damaged couplings, or those with defects.

The following pages give in detail the procedure for reconditioning used couplings. If this procedure is not followed, the result can be a sudden release of the coupling off the hose under pressure. Used couplings without reconditioning, should be put in separate storage with identification of condition.

1. Each time, be sure the correct collets are installed so that the best possible alignment is kept.

2. Use finger expander tool (1) to open the coupling fingers each time.

3. Use stem expander (2) for reconditioning the inside diameter of the stem. See the pages that follow.

Sleeve Removal

1. Cut the used hose 76.2 mm (3.00") from the couplings.

NOTE: Cut the hose as close as possible to the dimension given. Cutting the hose too long or too short can cause misalignment when expanding the fingers.

2. Put oil on the inside surface of the hose.

3. Install pusher (1) into the hose.

4. Install plate (2), collets (3) and the coupling in the press.

Use collets stamped with the hose size that is being worked. The counterbores should face toward the rear of the press.

NOTE: Use a 5S2846 Pusher marked Delta and + for XT-5 Hose with an inside diameter of 38.1 mm (1.50"). Earlier 5S2846 Pushers can be used if approximately 1.5 mm (.06") in length is removed.

5. Install the top collet and clamp in position.

6. Seat the coupling in the front counterbore, parallel to the action of the press. Clamp snugly.

7. Close the press to force the sleeve free.

Coupling Removal

1. Install the pusher into the end of the hose.

2. Install the assembly in the press with the counterbore of the rear collets facing the rear, and the counterbore of the front collets facing forward. On some 90° couplings, the front collets must be turned toward the rear for clearance.

Install the pusher plate into the press.

3. Install the top collets. Tighten the front collets to hold the coupling shoulder solidly in the counterbore.

Show/hide table

Failure to use the proper collets with the counterbore facing in the specified direction could result in improper clamping. Personal injury can result from couplings being propelled by the press force when not properly clamped.

Show/hide table

Do Not push too far. Couplings could be propelled and cause personal injury.

NOTE: Use only those collets listed in the charts. Collet sizes given permit the best possible alignment.

4. Close the press enough to expand the coupling fingers.

5. Release the press and remove the coupling. Sometimes the hose and coupling can be separated by hand. This will work on many of the smaller XT-3 sizes.

6. For larger sizes and any of the problem smaller sizes, except 19.0 mm (0.75") XT-5 hose, install the coupling assembly in the press using front grip collets (5) and plate (4).

7. Close the press and push the coupling out of the hose.

8. Use 1U8760 Chain Wrench (6), or a 1U8760 Chain Wrench, to remove the coupling from the XT-5, 19.0 mm (0.75") hose with a twisting movement as shown.

Reconditioning Stems

1. Slide expander (1) over the end of the stem.

2. Insert the front collets and the stem assembly in the press. Clamp securely and close the press.

3. Push the expander beyond bend (A) in the fingers, but do not push the expander against the base of the stem.

4. Using a plastic tipped hammer as shown, move the fingers tight against the expander.

5. Start stem expander (2) into the stem. Insert plate (3) and the assembly in the press and tighten the clamp.

Push the expander into the stem to the location shown in the specific chart that follows.

6. To remove the expander, reposition the stem assembly with the stem fingers ahead of the collets and clamp loosely. Reverse the press.

Remove any burrs, nicks or scratches that may be on the stem.

Fabricating Battery Cables

(1) 9S6331 Crimping Die Assembly.

It will be necessary to have either a 9S6331 Crimping Die Assembly (1), or an 8T3046 Crimping Die Assembly for use in the fabrication of battery cables.

1. Use knife (2) and anvil (3) to cut the battery cable to the correct length. Strip the insulation from the area to be crimped.

2. To install the terminals, install the anvil and die in the press. Position the cable and terminal as shown, then close the press to crimp the terminal.

3. Use the correct opening (A), according to the crimping die assembly being used, to crimp lug-style terminals on the cable.

Refer to the charts that follow for the part number of bulk cable according to cable size, and for the part number of the different types of terminals.

Straight type terminal.

Flag type terminal.

Lug type terminal.

Service Replacement Parts

5S2801 Hydraulic Hose Press Group

Hydraulic Pumps

The electric pumps given in the chart use alternating current and run on one specific voltage. A hand operated 1U5230 Pump can also be used if desired. Refer to the Caterpillar Tool Guide for pumps and service replacement parts. When using the hose press, read the 50 TON (red) scale (ram out) on the 9S2240 Pressure Gauge.

Necessary Tools

Other Tools

(1) 7S5376 Holder and 5S5173 Knife. (2) 7S5375 Anvil. (3) 5S2864 Plate. (4) 1S0258 Plastic Hammer. (5) 1U9124 Protractor. (6) 1U9159 Skiving Tool. (7) 5P3277 Tape. (8) 6V6022 Gauge Assembly (Skiving). (9) 5P6223 Blade. (10) 1U8760 Chain Wrench.

NOTE: Items 4, 7, 9 and 10 are NOT part of 7S1100 Hydraulic Press Arrangement.