Using the 9U-5792, 4C-5052, 4C-5054, 4C-3670, and 4C-3680 Hydraulic Hose Machines{0374, 0599, 0684, 0738, 5057} Caterpillar

Introduction

Important Safety Information

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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.

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.

AVSpare 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 AVSpare 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 AVSpare recommends using AVSpare 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.

Operation and Maintenance Section

The Operation and Maintenance 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.

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

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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

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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. 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.

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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.

References

ReferenceTool Operating Manual, NEEG2736, "Hose, Die Group, and Spacer Ring Selection Chart (for 4C-3660, 4C-5052, 4C-5053, 9U-5792, and 9U-7261 Hose Assembly Machines)".

ReferenceTechnical Data & Information, NEEG2746, "Crimp Diameters Chart".

ReferenceTool Operating Manual, NEHS0664, "Crimping AVSpare 1E294, 1E716, and 1E844 Hose and Coupling".

ReferenceTool Operating Manual, NEHS0749, "Crimping 1E1028 Thermoplastic Hose and 1E1543 Air Conditioning Hose".

ReferenceTool Operating Manual, NEHS0768, "General Information for Hose Assembly".

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

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Typical Hydraulic Hose Machine

The 4C-3670, 4C-5054, and 4C-3680 Hydraulic Hose Presses can be used on 3/16 inch -3 through 2.0 inch -32 hose and couplings. The 9U-5792 and 4C-5052 Hydraulic Hose Presses can be used on many AVSpare XT Hoses with crimped fittings.

For information on cutting hose, orienting couplings, skiving, hose insertion depths, and other hose assembly information, refer to Tool Operating Manual, NEHS0768, "General Information Hose Assembly".

Hose and Coupling Selection

For the correct size coupling for each hose diameter refer to Technical Data & Information, PECP5030, "Cat Hose and Couplings Reference Guide".

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 also leave foreign material inside the hose. Use a 130-6061 Hose Cleaner Gp or 156-0058 Hose Cleaner Gp for cleaning the hoses. For additional information, refer to Tool Operating Manual, NEHS0643, "Using the 233-7191 Hose Cleaner Gp , 233-7192 Hose Cleaner Gp , 233-7193 Hose Cleaner Gp , and 265-4959 Hose Cleaning Groups", Using the 130-6061 Hose Cleaner Gp or 156-0058 Hose Cleaner Gp .

Parts

When a hose machine is ordered, the die rings and some other components are included.

4C-3680 Hose Machine

Includes a 4C-4359 Die Ring (Black), a 4C-4360 Die Ring (Silver), and a 4C-5079 Hose Assembly (connects the hand pump and hose machine).

4C-3670 and 4C-5054 Hose Machine

Includes a 4C-4362 Die Ring (Black) and a 4C-4361 Die Ring (Silver).

9U-5792 and 4C-5052 Hose Machine

Includes a 4C-4372 Die Ring (Black), a 4C-5483 Die Ring, and a 4C-4378 Adapter Bowl.

Hose Assembly Instructions

Hoses Up To 38.1 mm (1.5 inch)

1. Cut the hoses to length and slide the coupling onto the hose. Refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for a Hose Insertion Depth chart.

   Note: To install the coupling onto XT Hoses, refer to the Skiving section in Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for skiving instructions.

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(1) 4C-4378 Adapter Bowl (2) 133-7362 Seat

2. Install 4C-4378 Adapter Bowl (1) and 133-7362 Seat (2) into the hose machine. This adapter bowl is not required for hoses larger than 38.1 mm (1.5 inch).

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Install 4C-4378 Adapter Bowl for hose up to 38.1 mm (1.5 inch)

3. Select the proper die and spacer ring, if required. Refer to Tool Operating Manual, NEEG2736, "Hose, Die Group, and Spacer Ring Selection Chart (for 4C-3660, 4C-5052, 4C-5053, 9U-5792, and 9U-7261 Hose Assembly Machines)".

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Lock Pusher Half in place with Slide Pin (3)

4. With the pusher in the full up position, lift the back half of the split die ring and lock it in place with pin (3) .

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Place Die Ring onto Adapter Bowl

5. Place the appropriate spacer ring (if required) on the adapter bowl. The ring should fit on the locating step of the adapter bowl.

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Lubricate Die and Adapter Bowl

6. Thoroughly lubricate the adapter bowl and die with 129-1939 High Temperature Grease .

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Insert Back Portion of Split Die

7. Insert the back portion of the split die into the adapter bowl.

   Note: The hose assembly is placed in the hose machine before inserting the front die half, if an angled coupling is being crimped onto the hose.

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Insert Front Portion of Split Die

8. Insert the front portion of the split die into the adapter bowl.

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Lower Back Pusher Half

9. Lower the back half of the split die ring onto the die by pulling the slide pin forward.

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Insert Front Pusher Half

10. Insert the front half of the split die ring, aligning the pin in the back half with the hole in the front half.

11. Insert the hose and coupling into the die (if not already done in Step 7). The die will automatically position the coupling and hold it during crimping.

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Illustration 13	g02377020
Crimp Coupling onto Hose

12. Turn the hose machine ON and lower the pusher. When the pusher plate contacts the spacer ring, the crimp is complete.

13. Raise the pusher and remove the finished hose assembly.

14. Repeat this procedure for the opposite end of the hose assembly.

15. Measure the crimp diameter and make sure the crimp meets the correct assembly specifications shown on Technical Data & Information, NEEG2746, "Crimp Diameters Chart".

Hoses Larger Than 38.1 mm (1.5 inch)

1. Cut the hoses to length and slide the coupling onto the hose. Refer to Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for a Hose Insertion Depth.

   Note: To install the coupling onto XT Hoses, refer to the Skiving section in Tool Operating Manual, NEHS0768, "General Information for Hose Assembly" for skiving instructions.

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Install 133-7363 Die Rest

2. Install the 133-7363 Die Rest into the hose machine.

3. Select the proper die and spacer plate, if required. Refer to Tool Operating Manual, NEEG2736, "Hose, Die Group, and Spacer Ring Selection Chart (for 4C-3660, 4C-5052, 4C-5053, 9U-5792, and 9U-7261 Hose Assembly Machines)".

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Illustration 15	g02377022
Lock Pusher Half in place with Slide Pin (3)

4. With the pusher in the full up position, lift the back half of the split die ring and lock it in place with slide pin (3) .

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Place Spacer Plate onto Hose Machine

5. Place the appropriate spacer plate (if required) onto the hose machine.

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Lubricate Die and Die Bowl

6. Thoroughly lubricate the adapter bowl and die with 129-1939 High Temperature Grease .

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Illustration 18	g02377025
Insert Back portion of Split Die and 134-9582 Press Plate

7. Insert the back portion of the split die and the 134-9582 Press Plate into the hose machine.

   Note: The hose assembly is placed in the hose machine before inserting the front die half, if an angled coupling is being crimped onto the hose.

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Insert Coupling through Press Plate

8. If an angled coupling is being crimped, insert the hose/coupling assembly through the press plate.

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Insert Front Portion of the Split Die

9. Insert the front portion of the split die.

10. Lower the back half of the split die ring onto the press plate by pulling the slide pin forward.

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Illustration 21	g02377028
Insert Front Pusher Half

11. Insert the front half of the split die ring aligning the pin in the back half with the hole in the front half.

12. Insert the hose and coupling into the die (if not already done in Step 7). The die will automatically position the coupling and hold it during crimping.

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Illustration 22	g02377029
Crimp coupling onto Hose

13. Turn the hose machine ON and lower the pusher. When the press plate contacts the spacer plate, the crimp is complete.

14. Raise the pusher remove the finished hose assembly.

15. Repeat this procedure for the opposite end of the hose assembly.

16. Measure the crimp diameter and make sure the crimp meets the correct assembly specifications shown on Technical Data & Information, NEEG2746, "Crimp Diameter Chart".

Replacement Parts

Replacement parts are available for each hose press arrangement. Each arrangement is listed separately along with the available part numbers and part description.