Use Of 8T5120 and 8T5130 Crimp Tool Groups In Either the 7S1100 Press Arrangement or 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Press{0738, 5057} Caterpillar

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

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Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

The XT-3 Hydraulic Hose is similar in many ways to other types of hydraulic hose, and special care must be used when identification of the differences is made. XT-3 Hydraulic Hose is made for working pressures of 17 225 kPa (2500 psi) to 27 560 kPa (4000 psi), according to hose size. Use caution, and attach only Caterpillar Permanent Couplings to XT-3 Hose.

NOTE: Use 8T5120 Crimp Tool Group with the 7S1100 Press Arrangement and use the 8T5130 Crimp Tool Group with 4C9900, 1U9160, and 6V4880 Hydraulic Hose Service Press.

NOTE: In some illustrations, the clamp and protective shield are not shown in position of use. This is for illustrative purposes only. When the press is in use, always use the clamp and protective shield.

Introduction

Use of either the 8T5120 or 8T5130 Crimp Tooling Groups in the 7S1100 or 4C9900, 1U9160, and 6V4880 Hydraulic Hose Press, permits maintenance of a minimum stock of hose and couplings. It also reduces the need to stock many different hose assemblies. Use the procedures given in this instruction, and refer to the latest issue of Technical Partsgram SEBD2080 (paper) or SBFY0604 (Microfiche).

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The hose press has a capacity of 445 000 N (50 tons) of force, and if not used according to the following procedure, could result in personal injury or death. NEVER install couplings on used hose; NEVER lubricate the inside diameter of a hose before installing couplings; coupling retention (ability to hold) is lowered on hose that has been in contact with either hydraulic fluid, or lubrication compounds.

Components of 8T5120 and 8T5130 Crimp Tool Groups

NOTE: Except for size, the crimp tool groups look alike, therefore, only one illustration is used to show component parts.

* 8T5120 Crimp Tool Group: (1). 8T5121 Mounting Plate. (2). 8T5124 Bowl Assembly. (3). 8T5125 Press Ring. (4). 4C8735 Sleeve. (5). 8T5119 Pusher. (A). Die Set; see NOTE that follows.

* 8T5130 Crimp Tool Group: (1). 8T5123 Mounting Plate. (2). 8T5124 Bowl Assembly. (3) 8T5125 Press Ring. (4). 4C8735 Sleeve. (5). 8T5122 Pusher. (A). Die Set; see NOTE that follows.

NOTE: The die set (A) shown above is for illustrative purposes only. Each die set is available separately from the Parts Department and is not a part of either crimp tool group. Refer to the chart that follows for die set part number needed according to hose size. Use the normal ordering procedure to order the die sets from the Parts Department.

General Precautions

1. Wear protective glasses; never stand directly in front, rear or at sides of the press. (See areas (X) in the diagram). Bad parts or a wrong setup could cause parts to be thrown out of the press.

2. Cut only XT-3 Hose with this press. Do not cut +XT-5 or UHPXT-6 Hose with this press (see page 7). Do not use worn, broken or rebuilt 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).

3. Make certain that die segments (3) are correctly positioned in bowl assembly (4). Notice that in the illustration above, segment (A) of the die set is not in alignment with the other segments. Make sure all segments are in alignment. Failure to do so can result in die or bowl damage and an unacceptable crimp.

Cutting Tool Reconditioning

1. Keep hose cutting knife (1) sharp, and the surface of anvil (2) ground smooth, to be sure of a straight, even cut.

2. Do not let the surfaces of either knife (1) or anvil (2) get too hot during reconditioning.

3. The blade of skiving knife (3) is softer than the wire used in the hydraulic hose. This is to prevent damage to the wire by the skiving knife. With use, the inside edge of the cutter will become dull. To sharpen, use a flat file as shown, to remove any metal that has bent over on the inside edge.

4. Use a round file (5) in the corners only.

Cutting Hose

1. When XT Hose is cut on either the 5P6540 or 5P6542 Friction Saw, the hose must be bent as shown.

2. 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.

3. If a 6V6015 Hose Cutoff Machine (abrasive saw) (5) is used to cut the hose, more care must be used to clean the hose after it has been cut. This method of cutting the hose causes more foreign material to be left inside the hose than with other methods.

4. When cutting XT-3 Hose with an anvil and knife, install anvil (6) and knife (7) in the press. Use clamp (8) 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.

5. Use 1S258 Plastic Hammer (9) to make the cut end round. Put one point of the cut end on a solid surface and hit the opposite side at an angle as shown.

Skiving Hose

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

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

NOTE: Coupling sleeve (2) is a reusable coupling component. Refer to the chart below for coupling sleeve (2) part numbers according to hose size.

2. Adjust the hose in the vise. Use a length scale (3) and coupling sleeve (2) to set the skiving length. Tighten the clamp.

3. Adjust the hose in the clamp. Use 6V6022 Skiving Gauge (3) and coupling sleeve (2) to set the skiving length. Use the correct scale on the gauge. Tighten the clamp.

NOTE: If 6V6022 Skiving Gauge is not available, refer to the chart that follows 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 above chart for the correct skiving length.

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

5. Use sleeve (2) as a guide; make the first cut counterclockwise.

6. To prevent the pull up of wire ends, turn the skiving tool clockwise to finish the skiving procedure.

7. 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.

8. Remove arbor (4). Do the same procedure on the other end of the hose. Keep the skiving knife sharp; see page 4.

Tool Preparation (For use in horizontal position)

NOTE: Fabricate a support fixture for use in the procedure that follows. See SUPPORT FIXTURE FABRICATION DIMENSIONS at the back of this instruction.

1. Fasten the fabricated support fixture to a work bench so it is solid. Put mounting plate (1) on the support fixture.

2. Put 8T5124 Bowl Assembly (2) on mounting plate (1). Be sure that internal teeth (A) of the bowl are facing up as shown.

3. Use charts that follow to select the correct die set, (3) needed, then put the die set in position in bowl assembly (2) as shown. Make sure all die segments are installed correctly, as shown, and that none are out of alignment.

Location of the Color Coding on Dies.

Top View of A/C Die Set

NOTE: Put lubrication (oil or grease) on all contact surfaces of the die segments and bowl assembly. Correct lubrication will ensure minimum wear, and give the coupling the correct crimp configuration.

4. Put press ring (4) over the die segments. Make sure that mounting plate (1), bowl assembly (2), with die set (3), and press ring (4) are in alignment, then put sleeve (5) over the stacked components. Lock sleeve (5) in position by turning it far enough to engage the internal "L" shaped slots at the bottom, with pins (B) (not shown) in the sides of mounting plate (1).

Tool Preparation (For use in near vertical position)

1. Put mounting plate (1) on the support fixture.

2. Put 8T5124 Bowl Assembly (2) on mounting plate (1). Be sure that internal teeth (A) of the bowl are facing up as shown.

3. Use charts that follow to select the correct die set, (3) needed, then put the die set in position in bowl assembly (2) as shown. Make sure all die segments are installed correctly, as shown, and that none are out of alignment.

Location of the Color Coding on Dies.

Top View of A/C Die Set

NOTE: Put lubrication (oil or grease) on all contact surfaces of the die segments and bowl assembly. Correct lubrication will ensure minimum wear, and give the coupling the correct crimp configuration.

4. Insert bowl assembly (2), and sleeve (5) on to mounting plate (1). Lock sleeve (5) in position by turning it far enough to engage the internal "L" shaped slots at the bottom, with pins (B) in the sides of mounting plate (1).

Installation Of Couplings

1. Remove the sleeve from the hose. Install coupling (1) in the new hose as far as possible. Now do the same for the other end of the hose.

2. Use the correct front grip collets and rear backup collets to push the couplings on the hose. Use the chart that follows to find the correct tool part numbers.

NOTE: If either hose coupling has a straight stem, push the coupling into the hose using the procedure that follows. If both hoses have angled stems, see the topic INSTALLATION ANGLE (ORIENTATION) FOR COUPLINGS, before installation of a coupling.

3. Install the front grip collets in the front jaw and the backup collets in the rear jaw.

4. Fasten the grip collets tightly into position. Activate the press to push the stem into the hose.

NOTE: Since it is not possible to see when the hose is bottomed in the coupling, it may be necessary to put a mark on the hose, to show the fully installed depth required. Measure the depth of the coupling (shown above). Measure the same distance on the outside of the hose and make a mark (A).

5. To crimp the coupling to the hose, put the correct die set in the bowl assembly. See TOOL PREPARATION in this instruction.

NOTE: If the coupling has a bent stem, large diameter O-ring head, or a hex nut, see the topic ASSEMBLY OF COUPLINGS WITH BENT STEM OR LARGE O-RING HEAD in this instruction, before continuing with this procedure.

6. Install the die set and put mounting plate (2) in the front jaw of the press as shown. Install pusher (3) in the rear jaw of the press. Refer to the chart that follows for the list of tools needed according to the hose press arrangement that is being used.

4C4625 must be purchased separately.

The following die sets can be used with the 4C4625 die ring, for 2 wire 294 hose:

4C3657 for 6.3 mm (.25 in) hose9U5216 for 7.9 mm (.31 in) hose4C3659 for 9.7 mm (.38 in) hose4C3661 for 12.7 mm (.50 in) hose4C3662 for 15.7 mm (.62 in) hose4C3663 for 19.0 mm (.75 in) hose4C3664 for 25.4 mm (1.00 in) hose4C3665 for 31.7 mm (1.25 in) hose

For 844 suction hose:

4C3663 for 19.0 mm (.75 in) hose4C3664 for 25.4 mm (1.00 in) hose4C3665 for 31.7 mm (1.25 in) hose

The following sets can be used with the die ring that is included in the 8T5120 and 8T5130 Tool Groups,

(8T5125), for 1 wire 716 hose:4C3657 for 6.3 mm (.25 in) hose4C3659 for 9.7 mm (.38 in) hose4C3661 for 12.7 mm (.50 in) hose4C3662 for 15.7 mm (.62 in) hose4C3663 for 19.0 mm (.75 in) hose4C3664 for 25.4 mm (1.00 in) hose4C3665 for 31.7 mm (1.25 in) hose

For thermoplastic hose:

4C3668 for 4.6 mm (.18 in) hose4C3669 for 6.3 mm (.25 in) hose4C3671 for 7.9 mm (.31 in) hose4C3672 for 9.7 mm (.38 in) hose4C3673 for 12.7 mm (.50 in) hose4C3674 for 19.0 mm (.75 in) hose

7. Put uncrimped hose and coupling assembly (3) through mounting plate (2) in the front jaw and into the die set. Pull back on the hose until the end of the coupling is against the stop, location (B), in the die set.

8. While the hose and coupling are held in the position indicated in Step 7, close the shield and activate the press to crimp the coupling. Stop the press operation when press ring (4) comes into contact with bowl (5).

NOTE: The coupling will receive the correct amount of crimp when press ring (4) comes into contact with bowl assembly (5). Continued operation of the press after the press ring comes into contact with the bowl assembly, will not cause any additional crimp of the coupling on the hose, and may cause damage to the tools.

9. Release the pressure of the press and remove the hose and coupling. Do the same procedure, Steps 2-8, for the other end of the hose.

Assembly of Couplings with Bent Stem or Large O-ring Head - (For use in horizontal position only)
(For use in horizontal position only)

NOTE: Bent stem couplings, or couplings that have large diameter O-ring, or hex heads, will not fit through the die set after the die set is positioned in the bowl. For these couplings, use the procedure that follows.

1. Put mounting plate (1) on a flat surface, or over a plate with a "U" shaped cutout as shown. Put bowl assembly (2) on mounting plate (1) as shown.

2. Put hose and coupling (3) through the mounting plate and bowl assembly, from the bottom. Put the correct die set (4) around hose and coupling (3), then put press ring (5) over the die set, as shown.

3. With all tools in alignment, put sleeve (6) over the stacked components. Lock sleeve (6) in position by turning it far enough to engage the internal "L" shaped slots with the pins in the side of mounting plate (1).

4. Put the assembled tools, with hose and coupling, in the front jaw of the hose press.

5. Pull back on hose (3) until the end of the coupling is against the stop, location (A), in the die set.

6. While the hose and coupling are held in the position indicated in Step 5, close the hose press shield and activate the press to crimp the coupling. Stop the press operation when press ring (5) comes into contact with bowl assembly (2).

NOTE: The coupling will receive the correct amount of crimp when the press ring comes into contact with the bowl assembly (5). Continued operation of the press after the press ring comes into contact with the bowl assembly will not cause any additional crimp of the coupling on the hose, and may cause damage to the tools.

7. Release the pressure of the press and remove the hose and coupling. Do the same procedure, Steps 1-6, for the other end of the hose.

Crimp Inspection

* In Step 1 the (A) dimension in the illustration is for XT hoses ONLY.

* For other than XT hoses, dimension (A) is the Hose Insertion Depth (full length of the shell).

Crimped couplings should be inspected both visually and dimensionally to be sure of configuration to design specifications. Refer to the above charts for hose crimp length (A) and diameter specifications.

NOTE: For crimp diameter, make two measurements (B) and (C), 90° apart, and average these two measurements. Crimp diameter measurements are to be taken at the middle of the crimp length and at the center of the crimp segment.

Air Conditioning Hose Crimping

The crimping procedure for air conditioning hose assemblies is relatively the same for other assemblies with permanent couplings. Refer to SEHS9052. The differences will be identified below. Hose insertion depth for the air conditioning couplings is 40.4 mm (1.59 in).

1. Insert hose into coupling to proper depth.

2. Position the coupling in the die set such that the coupling shell contact is maintained with the "U-shaped crimp locator" on the die set during the crimping process.

It is a good crimp if:

* hose cover extrudes some from the hole at the top of coupling. (This ensures that the hose is seated in the coupling).

* the hose should not bulge at bottom/skirt of shell.

* crimp measurements should be within range in chart below.

NOTE: Do not cut hose with an abrasive saw or other types of rotating blade saws. Use a sharp knife so that the hose is not pinched and a square cut can be attained for proper seating with the coupling.

1. Coupling Tube. 2. Bottom/Skirt of shell. 3. Hose. 4. Coupling Shell View Hole.

Installation Angle (Orientation) of Couplings

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. (See the current Technical Partsgram.)

2. Remove assembled coupling (1) from the vise, turn the hose end-for-end, and fasten the loose coupling in the vise with the flange up. It is important that the flange direction on the loose coupling 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 coupling angle is correct, crimp the coupling to the hose.

Finding the Coupling Angle on Former Assembled Hoses

1. Put one coupling in a vise with the flange up as shown. Adjust the dial of 7S1125 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 until the bubble is level.

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

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

Cleaning Hoses

1. 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.

2. 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 the inside at both ends of the hose.

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When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

3. 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 supplier list:

Hose Identification

1. If a hose has been assembled according to dimensions given in the Hose Assembly Fabrication Guide and is not going to be used immediately, some type of identification should be put on the hose for future reference.

2. Aluminum tags, like the ones used by Caterpillar are available from the suppliers below. Use metal stamps to add the identification.

3. Metal tags, made by Dymo Metal Tape, can be fastened with wire to a hose assembly. The tape and marking equipment are available from the suppliers below:

4. If hose assemblies are made for applications other than Caterpillar, the technical information for the part can be put on the tag through code type identification. This would make it easier for future replacement of hoses used in a non-Caterpillar application.

5. An example of a code system is as follows:

8S4055

Delta - C - 45 - 8S4055 - O - A

(1) (2) (3) (4) (5) (6)

(1) Triangle (Delta ) is the identification for an XT-3 hose assembly.

(2) Gives the inside diameter of the hose: B-9.5 (0.38 in), C-1212.7 (0.50 in), D-15.9 (0.62 in), E-19.1 (0.75 in), F-25.4 (1.00 in).

(3) Gives the length of the hose.

(4) Gives the Caterpillar part number of stem assemblies (two are necessary for each hose assembly).

(5) Gives the coupling angle.

(6) Shows if armor is necessary. If armor is not necessary, "A" will not be present.

Bulk Armor Guard for A/C (1543) Hose.

Support Fixture Fabrication Dimensions