Hose Machine Group Set-Up and Operation (0599, 0684)

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Welcome: j065btl
Product: INDUSTRIAL ENGINE
Model: C13 INDUSTRIAL ENGINE RRA01544
Configuration: C13 Industrial Engine RRA00001-UP

Tool Operating Manual


358-4528 (380/480 V, 50/60 Hz, 3 Phase), 457-6040 (230V, 60 Hz, Single Phase) , 457-6039
(230V, 50 Hz, Single Phase) Hose Machine Group Set-Up and Operation{0599, 0684}
Media Number -NEHS1098-05 Publication Date -09.09.2014 Date Updated -09.09.2014

i05918214

358-4528 (380/480 V, 50/60 Hz, 3 Phase), 457-6040 (230V, 60 Hz, Single


Phase) , 457-6039 (230V, 50 Hz, Single Phase) Hose Machine Group Set-
Up and Operation{0599, 0684}
SMCS - 0599; 0684

Caterpillar Products: All

Introduction
Important Safety Information

Illustration 1 g02139237
Think Safety

European Union Compliant, CE marked

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.

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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 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.
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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 Section
Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2 g02166423
Personal Protection/Important Information
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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Warnings

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.
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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.

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.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool


Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.

Dispose of all fluids according to local regulations and mandates.

NOTICE
To prevent dirt and contaminants from entering the hydraulic system,
always plug or cap the lines, fittings, or hoses as they are disconnected.

This action also lessens the chance of oil spills.

General Information Section


Introduction

The Radial Hose Crimping Machines are high-performance and rugged units designed to crimp permanent hose
couplings only. The hose machine is operated and controlled through a user friendly LCD touch screen interface
display. The microprocessor (controller) contains memory, which shortens setup times and helps make correctly
sized couplings every time. An electronic measuring system ensures highly accurate crimps for each and every
coupling.

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Illustration 3 g02166433
358-4528 Radial Hose Crimping Machine .

NOTICE
The hose machine has been constructed using state-of-the-art
engineering and acknowledged safety standards. Nonetheless, dangers
can arise for the operator and other persons in the operating area.
Machine and/or property damage can also occur if all safety and
operating recommendations are not followed. These operating
instructions contain the most important information needed to operate
the hose machine safely. The safety information must be observed by
all persons operating the hose machine.

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

Safety Devices
Emergency Stop Button

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Illustration 4 g03657922
(6) Emergency Stop

(7) Hydraulic Motor OFF Button

(8) Hydraulic Motor ON Button

(9) Foot Control Switch ( Activates foot control for dies OPEN/CLOSE.)

(10) Master Dies Open Button

(11) Master Dies Close Button

The Emergency Stop button (6) is located on the control console. When the Emergency Stop button (6) is pressed,
the C3 will display that the Emergency Stop button has been pressed and the hydraulics will shut down.

Specifications
Table 1
Crimp Force (kN / Ton) 1800/180
Control Crimputer III (C3)

Opening without dies (mm) 147


Noise Level "dBa" 69
Motor 4kW

Tool L x W x H(mm) 1000 x 600 x 700


Fluid Capacity(l) 50

Fluid Change Schedule Annually


Weight (kg) 260
Die System 239

Electrical Power Requirements 230-460V Three Phase 50/60 Hz (4kW Motor)(20A/15A)


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230 V Single Phase 60 Hz (4kw Motor) (30 A)

230 V Single Phase 50 Hz

Nomenclature

Illustration 5 g02177007
(2) Controller

(3) Main Power Switch

(4) Electrical Control Panel

(5) Master Dies

Installation and Setup


Machine Setup

Unpacking and Table Mounting

1. Carefully unpack the machine and verify that all components are in place and undamaged.

2. Place lifting straps of the correct size under machine and lift taking care not to damage the machine.

3. Fasten the machine to a 358-4545 or other appropriately sized table, on a stable, level surface. The hose
machine should be placed so that all sides can be accessed for efficient crimping and maintenance.

4. Mount the C3 controller to the machine.

5. Attach Calipers with the Caliper Cable to the USB port at the back of the C3 controller (2) .

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6. Attach the single and double foot switches to the machine. The connections are located below the C3
controller on the left side of the machine near the main power switch (3) .

Filling Hydraulic Reservoir

1. Remove Fill cap. Fill tank to full line on the dip stick. Machine holds approximately 50 L (52.8 qt) of
hydraulic fluid.

NOTICE
The hose machine must be filled with either CAT BIO HYDO, HLP 46,
DIN51524, or equivalent ISO 46 hydraulic oil.

Note: CAT BIO HYDO is available in 20 L containers ( 341-2442 ) or 5 US gal containers ( 339-3249 ).

Illustration 6 g02177017

2. Fill the tank until the oil level reaches the safe operating zone (1) on the dip stick.

Connect the Electric Supply

The CSC6 Cat Crimp Machine is powered with either a 3-phase motor or a 1 (single) phase motor.

A 3-phase motor will rotate in either direction determined by the order in which the 3 power wires are connected.
A further consideration of this machine is that the motor is located in the hydraulic tank, therefore the rotation
cannot be visually observed. There is no way to predetermine the correct rotation of the motor, therefore the
machine has to be powered up and machine operation checked to determine the correct motor rotation.

A single phase motor does not have a rotation consideration as it is not reversible.

Connecting 3 Phase Machine

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NOTICE
This work should only be performed by a qualified electrician. The
machine is shipped with a pre-wired electrical cord. Connect the cord
to the electrical supply following local electrical code requirements
applicable to the installation site.

The 3 phase machine is capable of being operated at either: High Voltage: 380/480 V, 50/60 HZ, 15A or Low
Voltage: 230/280 V, 50/60 HZ, 25A.

Note: The machine is shipped from the factory configured for high voltage.

If the machine is to be operated at high voltage, no changes are necessary.

If the machine is to be operated at low voltage, the following steps need to be performed:

1. Remove the 3mm Allen head screws from the electrical panel cover and remove it.

2. Locate the Voltage Selector Switch, S56, and turn it to the 230 V setting.

3. Locate the adjustable overload adjustment screw and turn it to 25 Amps.

4. High voltage to low voltage conversion is complete.

Illustration 7 g03657883

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Illustration 8 g03657893

Connecting 1 (Single) Phase Machine

NOTICE
This work should only be performed by a qualified electrician. The
machine is shipped with a pre-wired electrical cord. Connect the cord
to the electrical supply following local electrical code requirements
applicable to the installation site.

The motor rotation of the single phase machine is not reversible, therefore it is ready for service when wired to the
electrical supply.

Start Machine and Check Motor Rotation of 3 Phase Machine

NOTICE
Do not start machine without hydraulic oil. Check oil level before
starting.

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Illustration 9 g03507104
(6) Emergency Stop

(7) Hydraulic Motor OFF Button

(8) Hydraulic Motor ON Button

(9) Foot Control Switch ( Activates foot pedal for open/close)

(10) Crimp Tool Open Button

(11) Crimp Tool Close Button

The motor on a CSC 6 machine is located in the hydraulic tank, therefore it cannot be visually checked for proper
rotation. The machine has to be powered up and an attempt made to close and open the dies to verify correct motor
rotation. If the rotation is correct, the dies will close and open. If the rotation is not correct, the hydraulic pump
will not supply oil. Therefore the dies will not move.

Note: Push-buttons items 10 and 11, illustration 9, are used to open and close the dies. These push-buttons are
illuminated to indicate they are active.

1. The open button is illuminated anytime the hydraulic motor is on and will open the dies if they are not
already open.

2. The close button is only illuminated and active when the hydraulic motor is on and at specific operation
screens of the C3 panel. Those screens are:

a. Sensor Information Screen - diagnostic type screen

b. Die Change Screen - appears in process of crimping a hose

c. Crimp Screen - screen at which the coupling is crimped on the hose

1. Switch on the main power. Release E-stop push button and allow machine controller (C3) to boot up to the
"Start Up Screen".

2. There are two functions available from the start-up screen:

a. The soft key with "i" is the software information button. Press "i" to see the revision levels of three
software packages in the machine. Press EXIT to return to the "Start Up Screen."
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Illustration 10 g03471696

b. The green soft key labeled "OK" accesses the log-on screen. For username and password, touch the
blinking curser in the data field. A soft keypad appears to enter data. The default username and
password is CAT.

Note: The operator must be logged onto the controller to access any functionality of the machine.

Illustration 11 g02177414

3. When logged on, the controller displays the Crimputer III Menu screen. Refer to Illustration 12. There are
four functions available from this screen:

a. Setup

b. Utility

c. Log off

d. Crimp

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Illustration 12 g03632921

4. Press the "Setup" soft key to access the setup menu screens.

5. Press the right arrow soft key two times. You will now be at the "Sensor Information" screen. Refer to
Illustration 13.

Illustration 13 g03507115

6. From this screen, start the hydraulic motor by pushing Item 8 (see Illustration 9). Items 10 and 11 will
illuminate. Push Item 11 (close button) and the dies should close. If they do not close, the motor is rotating
the wrong direction. See "Change Rotation," then repeat this step to verify dies close and open.

Note: Hydraulic motor will automatically shut off after 20 seconds if there is no machine activity.

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7. Close and open the dies a few times to purge air from the hydraulic system.

8. Push the back arrow softkey to back out of the Crimputer III menu screen. (Illustration 12).

Change Rotation

NOTICE
This procedure should be performed by a qualified electrician.

Change the position of any two of the three power supply wires to change the rotation of the hydraulic pump.
Repeat step 6 above to verify proper rotation.

Changing a Die Group

Adapter Dies 266-239L - Installation/Removal of Adapter Dies and Crimping Dies 266L 67mm and Larger

The adapter dies reside in the Master Dies and accept the 239-100 series crimping dies up to and including 62mm.
When using 67mm, 71mm, 84mm, 92mm, the adapter dies are removed and crimping dies reside directly in the
master dies. The adapter dies and 67mm and larger dies have to be installed/removed by hand using the red
handled die change tool.

Illustration 14 g03678494

1. Turn motor power off.

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Illustration 15 g03678495

2. Use the red handled die change tool to push in and hold the spring loaded retaining pin in hole A located in
the Master Die C. Remove or insert the adapter die or 67mm (or larger) crimping die by placing the pin into
hole B located in the Master die C. Release pressure on the die change tool and the die is now secured into
the master die. Repeat the process for remaining dies. Refer to illustration above.

Note: After long service, the retaining pins in hole A of the master dies may be a bit hard to release. In this case,
use a rubber hammer and gently tap on the end of the handle of the die release tool to free the pin. Replacement
pins and springs are available in a kit. (Cat part number 416-6396) (1 kit required for each master die segment)

Installation and Adjustment of Die Retention Assemblies Located in Adapter Dies

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Illustration 16 g03678505

The 239 series crimping dies are held in the adapter dies by the spring loaded ball/screw assembly. The assembly
is removed/installed using a straight blade screwdriver through the access hole on the front of the die. Adjust the
position of the assembly by turning the screw CW until you can see the ball entering the pin hole. Insert a 239 die
segment in the hole and push it into the adapter die. The die should snap firmly into the hole and be held against
the adapter die. If the die can move or there are gaps between the dies, the screw needs to be turned CW. Repeat,
adjusting the screw in small increments until the 239 die rests firmly in the adapter die. If the 239 die cannot be
pushed into the hole, the assembly is too far into the hole. Turn the screw CCW. Repeat for all 8 adapter die
segments.

Installation and Removal of 239 Series Crimping Dies using the Quick Die Change Tool
(QDC)

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The 12mm though 54mm Die Groups can be changed using the Quick Die Change tool (Cat part number 233-
8046).

The 57mm and the 62mm Die Groups must be installed and removed by hand, 1 die segment at a time. They are
too thin to accommodate the holes necessary for the Quick Die Change Tool.

Note: The head should be open and the hydraulic motor turned off while installing or removing 57mm or
62mm dies.

NOTICE
Failure to change the 57mm and the 62mm die segments by hand will
cause damage to the 57mm and the 62 mm Die Groups. They are too
thin to accommodate the holes necessary for the Quick Die Change
Tool.

Illustration 17 g03403993

Installing 239 Series Dies


1. Insert the eight pins of the quick die change tool in the front of the 239 Series Crimp Dies and turn toward
the left. Take the tool and the dies out of the Die Storage Rack.

Illustration 18 g03403997

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2. Hold the QDC in the center of the crimp tool.

3. Use the close push button to close the machine on the die group until they snap into place.

Note: While closing make sure that the pins are aligned with the holes in the adapter dies. If not, they will be
broken or severely damaged. This process requires some practice. Replacement pins for the 239 series dies
are Cat Part Number 330-3951.

4. When dies are in place, pull the QDC out of the dies and open the machine completely.

Removing 239 Series Dies


1. Reverse the order of above procedure.

2. Insert QDC Tool.

3. Open machine.

Calibration Procedure

The machine will need to be calibrated before it is put into service.

Once calibrated, the machine will not have to be calibrated again unless there is a failure of one of the electronic
controllers, or the machine develops operational problems. The machine can be calibrated just to verify that the
calibration has not become corrupted or as many times as necessary for training or demonstration.

Illustration 19 g02177434

1. Select "Utility" from the "Crimputer III" menu screen.

2. Select "Probe Calibration" from the Utility screen.

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Illustration 20 g03591147

Illustration 21 g02178231

3. C3 will prompt you to install the 32mm Die Group. Refer to the section, Installation and Removal of 239
Series Crimping Dies, and complete the steps for a die change. When the die change is completed, press the
"GO" soft key. The screen will advance to Step 2 of 5.

Note: There may or may not be a set of 239 Series Dies in the Adapter Dies. Therefore, either remove and
install the 32mm dies, or just install the 32mm dies.

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Illustration 22 g02336039

4. Insert the small end of the 233-8045 Calibration Mandrel into the dies. Start motor and push and hold the
close button until dies stop. The screen will advance to step 3 of 5.

Illustration 23 g02336040
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5. Open die and remove mandrel. Press "OK" when ready. The screen will advance to step 4 of 5.

Illustration 24 g02391759

6. Insert the large end of the 233-8045 Calibration Mandrel into the dies. Start motor. Push and hold the close
button until the dies stop. The screen will advance to step 5 of 5.

7. Screen will display "Calibration Complete". Open dies and remove mandrel.

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Illustration 25 g02430977

8. Check calibration number. It should have a value between .98 and 1.03. If the value is out of limits, perform
calibration again.

9. If calibration value is within limits, press "OK". Calibration is successful. Store calibration mandrel in a safe
place.

Maintenance
Scheduled Maintenance

Daily Maintenance

NOTICE
The master dies and any associated parts should never be lubricated.

Open the crimp tool completely.

Turn the Crimputer power switch to the OFF "0" position. Turn the main power switch to the OFF "0"
position.

Clean the master dies of metal, dirt, and debris with compressed air.

Check the operation of the emergency stop switch.

Check oil level using the dip stick.

Visually check the machine for oil leaks.

Check the machine for loose part covers or any visible damage.

Monthly Maintenance
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Check the hydraulic hose assemblies for porosity and leaks.

Check the screwed joints and clamps of the hose assemblies for leaks.

Biannual Maintenance

Check the bearing plates for wear.

Annual Maintenance

Hydraulic oil change

NOTICE
The hose machine must be filled with either CAT BIO HYDO, HLP 46,
DIN51524, or an equivalent ISO 46 hydraulic oil.

NOTICE
The operator assumes responsibility to change hydraulic hoses at an
acceptable interval.

Check Slide Bearings

Illustration 26 g03718980

Slide bearings are designed to last for thousands of cycles. However, cleanliness and heavy loading of the machine
may be the two most influential variables on the life expectancy of the slide bearings. In order to identify a "worn"

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bearing, typically, visual inspection is the best tool, especially since there are no pre-determined time or number of
cycles of operation that can predict the life of the slide bearings.

If 50% or more of the anti-friction coating surface area is worn away(from visual inspection), replace the slide
bearings. See illustration 26.

Replace Rear Slide Bearings Cat Part No. 416-6391

Illustration 27 g03698756

1. Open the crimp tool completely.

Illustration 28 g03698758

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2. Remove the 8 screws that secure the clamp ring.

Illustration 29 g03698760

3. Remove the clamp ring. Cat Part 416-6401

Illustration 30 g03698761

4. Remove the old slide bearing and insert a new one. Replace one bearing at a time. Don't remove all
bearings at one time.

Note: One or more bearings may have a piece of shim stock underneath it. Leave in place or replace with a
new shim of same thickness if it is damaged.

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Illustration 31 g03698762

5. Insert the new slide bearing. Continue replacing 8 slide bearings, 1 at a time.

Illustration 32 g03698763

6. Install clamp ring. Cat Part 416-6401 (includes 8 screws)

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Illustration 33 g03698764

7. Insert 8 screws to secure the clamp ring.

Spare Parts

Illustration 34 g03703342

Table 2
Position Quantity Cat Part Uniflex Part
Description
Number Number
1 1 233-8045 Calibration Mandrel

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2 1 358-4537 Caliper-Interface cable

3 1 358-4536 Starrett or Sylvac caliper

4 1 358-4538 Foot Switch Single

5 1 358-4544 Foot Switch Double Close/Open

6 1 233-8046 Quick Die Change Tool

7 1 233-8047 Die Release Tool


8 1 807.410 (Uniflex) Potentiometer (Path Sensor)

9 1 358-4535 Crimputer 3 Controller Only

1 358-4550 PB 239 100 12mm Die

1 358-4551 PB 239 100 14mm Die

1 358-4552 PB 239 100 17mm Die

1 358-4553 PB 239 100 20mm Die

1 392-3963 PB 239 100 22mm Die


1 358-4554 PB 239 100 24mm Die

1 392-3964 PB 239 100 26mm Die

1 358-4555 PB 239 100 28mm Die

1 358-4556 PB 239 100 32mm Die

1 358-4557 PB 239 100 36mm Die

1 358-4558 PB 239 100 40mm Die

1 358-4559 PB 239 100 44mm Die


1 358-4560 PB 239 100 47mm Die

1 358-4561 PB 239 100 50mm Die

1 358-4562 PB 239 100 54mm Die

1 358-4563 PB 239 100 57mm Die

1 358-4564 PB 239 100 62mm Die

1 358-4565 PB 266L 67mm Die


1 358-4566 PB 266L 71mm Die

1 358-4567 PB 266L 84mm Die

1 358-4568 PB 266L 92mm Die

1 421-2653 266.239L Die Adapter Set

1 457-6033 Pressure Sensor

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1 416-6391 Rear Slide Bearings (8 pcs)

Rear Retainer Ring for Slide Bearings (8


1 416-6401
Screws)

T-Nuts and Screws for Master Dies (8 pcs)


416-6402

Master Die Details and Parts

Illustration 35 g03703365

Table 3
Position Quantity Uniflex Part
Cat Part Number Description
Number

416-6403 (1 complete
1 8 Master Die Complete with items 2, 3, 4, 5
die)

2,3,4,5 416-6396 (Kit includes Bolt, Spring, Threaded Pin M5 x 10,


1
1 each) Threaded Pin M12 x 16
Detent Screw, Spring Loaded Ball Retainer
6 8 421-2654 (8 pieces)

7 8 233-8077 (1 piece) Steel Pins for 266.239L Adapter Dies

8 8 421-2653 (Kit, 8 dies) 266.239L Adapter Dies

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330-3951 (Kit, 8 pins)


9 8 Steel Pins for 239 Series Dies

Illustration 36 g03710493

Maintenance
Cleaning

Clean the machine with compressed air and a clean, dry cloth.

Storage

Store tooling indoors in a clean, dry location to prevent rust or corrosion. Lay flat or hang from suitable hooks to
prevent from falling.

Tool Disposal

At the end of the operational life of the tool, destroy the tool and dispose of as scrap. All fluids should be recycled
in an appropriate manner.

Copyright 1993 - 2017 Caterpillar Inc. Wed Dec 20 2017 12:36:24 GMT+0600 (Bangladesh Standard Time)
All Rights Reserved.
j065btl
Private Network For SIS Licensees.

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