- AVSpare Products: All
Introduction
Important Safety Information
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| 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.
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 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
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| 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. |
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| NOTICE |
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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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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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. |
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
E-mail: [email protected]
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.
The 161-5717 Power Supply (115 VAC, 60 Hz, 1 phase) is the recommended power supply for this hose machine.
A 163-5309 Hydraulic Power Supply (230 VAC, 50 Hz, 1 phase) CE-compliant unit is available for hose machines being used in Europe.
General Information Section
Introduction
Hose Machine
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| Illustration 3 | g02638438 |
243-0765 Bench Model Hose Machine Mounted On A 157-6125 Stand . | |
The 243-0765 Bench Model Hose Machine is used for crimping permanent couplings onto AVSpare hoses. It is designed to work with the 242-3567 Variable Crimp Die Group . It can crimp all current hoses in the AVSpare line up to and including (-20), except for the XT-5 (-20). It cannot be used to assemble reusable couplings. Refer to the Hose Machine Capabilities Chart on the next page for a complete listing of hose types and sizes.
The hose machine is capable of using up to 68950 kPa (10,000 psi) of pressure. The portable power supply used with this hose machine must be equipped with a three-way valve which is set up for a single acting cylinder. A pendant (remote) electrical switch is recommended to control the hose machine.
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| Illustration 4 | g02638459 |
Three-Way Pendent For Controlling Power Supply. | |
Power Supply
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| Illustration 5 | g02638464 |
161-5717 Power Supply And 162-1410 High-Pressure Hose Assembly . | |
A hydraulic power supply does not come with the bench model hose machine; one of the following three recommended power supplies can be used.
The 161-5717 Power Supply (115 VAC, 60 Hz, 1 phase) is the recommended power supply for this hose machine.
A 163-5309 Hydraulic Power Supply (230 VAC, 50 Hz, 1 phase) CE-compliant unit is available for hose machines being used in Europe.
High-Pressure Hose
A 162-1410 High-Pressure Hose Assembly is recommended for connecting the power supply to the hose machine. This 9.50 mm (.375 inch) ID hose is rated at 68950 kPa (10,000 psi) with a 4 to 1 safety factor.
The high-pressure hose is not part of the bench model hose machine and must be ordered separately.
Hose Machine Capability
Table provides the maximum size and type of hose that can be crimped with this hose machine using the variable crimp die bowl. Do not attempt to crimp hose couplings larger than recommended.
| Hose Machine Capabilities Chart | |
| Hose Type | Maximum Hose Size |
| 294 | -20 |
| 716 | -20 |
| 844 | -20 |
| 1956 | -20 |
| XT-3 ES | -20 |
| XT-5 | -16 |
| XT-6 | -12 |
| XT-6 ES | -16 |
| 1543 | -14 |
| 1028 | -12 |
| 2760 | -8 |
References
Special Instruction, NEEG2956, "Skive Length Chart"
Special Instruction, NEEG2955, "Hose Cleaner Projectile Sizing Chart for Hose and Hose Assemblies"
Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567"
Special Instruction, Using the 233-7191, 233-7192 and 233- 7193 Hose Cleaner Groups, NEHS0643
Special Instruction, NEHS0664, "Crimping AVSpare 1E294, E716, and 1E844 Hose and Couplings"
Special Instruction, NEHS0768, "General Information for Hose Assembly"
Special Instruction, NEHS0924, "242-3567 Variable Crimp Die Bowl"
Special Instruction, NENG7001, "Hydraulic Hose Assembly Tools"
Special Instruction, PECP5030, "AVS Hose and Couplings Reference Guide"
Specifications
| Description/Part No. | Specification |
| 243-0765 | Bench Model Hose Machine |
| Tie Rod Torque | 1632 N·m (1200 lbft) |
| 161-5717 | Hydraulic Power Supply |
| Power Requirements | 115 VAC 60 HZ one phase |
| Oil Capacity | 5.7 L (1.5 gal) |
| Oil | SAE 10 Hydraulic Oil SAE 15 oil may be used, but may extend the time to retract the cylinder after crimping. |
| Minimum Required Circuit | 15 Amp |
| 163-5309 | Hydraulic Power Supply |
| Power Requirements | 230 VAC 50 HZ one phase |
| Rating | CE Compliant |
| Minimum Required Circuit | 15 Amp |
Tooling and Equipment
| Part No. | Description |
| 243-0765 | Bench Model Hose Machine |
| 161-57171 | Hydraulic Power Supply (115 VAC) |
| 163-53091 | Hydraulic Power Supply (230 VAC) |
| 162-1410 | High-Pressure Hose Assembly (pump to cylinder) |
| 157-6125 | Stand (Optional) |
| 242-3567 | Variable Crimp Die Bowl (order separately) |
| Optional Measuring Equipment | |
| 136-0536 | Caliper |
| 136-0538 | Cable |
| 136-0539 | Foot Switch |
| 136-0544 | Processor |
| 136-4219 | AC Adapter |
| 9U-6690 | Replacement Ribbon |
| 136-0543 | Paper Rolls (10) |
1Requires one power supply. Refer to the Table 2 for additional information.
242-3567 Variable Crimp Die Bowl
The 209-3153 Portable Hose Machine uses a 242-3567 Variable Crimp Die Bowl to crimp hose assemblies. This die bowl is made from the parts listed below. Refer to Special Instruction, NEHS0924, "242-3567 Variable Crimp Die Bowl" for assembly instructions.
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| Illustration 6 | g02638469 |
| Item | Part No. | Description |
| (1) | 133-7362 | Die Rest |
| (2) | 242-3567 | Variable Die Bowl |
| (3) | 135-4561 | Die Separator |
| (4) | 140-9360 | Separator Ring |
| (5) | 4C-4375 | Spring |
| (6) | 4C-4376 | Snap Ring |
Die Groups
| All Die Groups (except 1543) | |
| Part No. | Die Inside Diameter |
| 241-9133 | 12 mm |
| 241-9134 | 14 mm |
| 241-9135 | 16 mm |
| 241-9136 | 18 mm |
| 241-9137 | 20 mm |
| 241-9138 | 22 mm |
| 241-9139 | 24mm |
| 241-9140 | 26 mm |
| 241-9140 | 28 mm |
| 241-9142 | 30 mm |
| 241-9143 | 33 mm |
| 241-9144 | 37 mm |
| 241-9145 | 40 mm |
| 241-9146 | 43mm |
| 220-8686 | 48 mm |
| 241-9147 | 50 mm |
| 1543 Die Groups | |
| Part No. | Die Dash Number |
| 4C-3675 | -6 |
| 4C-3676 | -8 |
| 214-5155 | -10 |
| 4C-3677 | -12 |
| 189-0990 | -14 |
Hose Machine Assembly with Optional Stand
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| Illustration 7 | g02638476 |
243-0765 Bench Model Hose Machine Mounted On A 157-6125 Stand . | |
The 243-0765 Bench Model Hose Machine is mounted on and overhang a heavy work bench. An optional 157-6125 Stand is also available and allows the bench model hose machine to be freestanding.
- Remove all the parts from the shipping crate.
- Assemble the optional stand as shown.
- Using an appropriate lifting device, carefully set the hose machine on the stand or work bench.
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| Illustration 8 | g02638479 |
- Use the supplied bolts to attach the hose machine to the stand or work bench surface.
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| Illustration 9 | g02638497 |
- Connect one end of the 162-1410 High-Pressure Hose Assembly to the power supply.
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| Illustration 10 | g02638500 |
- Connect the other end of the 162-1410 High-Pressure Hose Assembly to the hydraulic cylinder on the hose machine.
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| Illustration 11 | g02638505 |
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| Illustration 12 | g02638516 |
Note: Make sure that the hose connections are tight.
General Hose Assembly Guidelines
Producing high-quality hose assemblies requires observing the following general guidelines:
- Cut the ends of the hose as square as possible.
- Clean the inside of the hose to make sure that the coupling does not have dirt or other debris between the coupling and the inside of the hose. One of the 233-7191, 233-7192, or 233-7193, Hose Cleaning Groups is recommended for cleaning the hose.
Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233- 7193 Hose Cleaner Groups for more detailed instructions on cleaning hoses.
- Insert the hose in the new coupling until it is aligned with the coupling insertion mark. Refer to the Insertion Depth Chart in Special Instruction, NEHS0768, "General Information for Hose Assembly", for additional information. Do not allow oil or grease on the hose or couplings. Only water is permitted as a lubricant when placing couplings onto hoses.
- When crimping 1543 Air Conditioning Hose Couplings, carefully seat the coupling against the locating tab in the die group before crimping.
- Sharp edges and burrs on crimped couplings can be removed with 80 grit emery paper or other suitable means.
- To maintain the quality of each hose assembly, measure the finished crimp diameter to make sure that it meets the correct assembly specifications. Crimp diameters can be measured using a micrometer, calipers, or caliper measurement system.
Note: Use Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567" (laminated chart) for crimp diameter specifications. Refer to Special Instruction, NEHS0768, "General Information for Hose Assembly" for additional information on measuring hose coupling crimp diameters. The parts in the following chart can be ordered individually and used to check the crimp diameter.
Show/hide tableTable 6 Crimp Measurement Tooling 136-0536 Caliper 136-0538 Cable (attaches to caliper) 136-0539 Foot Switch 136-0544 Mini Processor 136-4219 AC Adapter 9U-6690 Replacement Ribbon 136-0543 Paper Rolls (10)
- Clean each hose after assembly.
- Tap both ends of the hose to remove any large particles.
- Use one of the 233-7191, 233-7192, or 233-7193, Hose Cleaning Groups to clean the inside diameter of the hose assembly. A cleaning projectile should be sent through each end of the hydraulic hose.
Note: Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233- 7193 Hose Cleaner Groups for more detailed instructions on cleaning hoses.
| NOTICE |
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Hoses that are not clean can cause hydraulic system component damage. |
Operation
Crimping Hose Couplings Using AVSpare Dies
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| Illustration 13 | g02638520 |
- Select the appropriate die from the Die Groups Table 1 of this manual.
- Set the variable die bowl to the correct "Bowl Setting" reference number found in Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567" or in this manual.
- Find the crimp length on Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567" and mark that length on the hose coupling.
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| Illustration 14 | g02638537 |
- Insert the variable die bowl into the hose machine.
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| Illustration 15 | g02638586 |
- Align the crimp length mark on the coupling with the top of the die.
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| Illustration 16 | g02638596 |
- Install the front pusher plate.
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| Illustration 17 | g02638606 |
- Lower the pusher plate until it touches the top of the variable crimp die bowl.
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| Illustration 18 | g02638600 |
- Raise the pusher plate. Remove the hose assembly, and check the crimp diameter. Refer to Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567" for crimp diameter specifications.
- If necessary, adjust the variable crimp die bowl to make the crimp diameter of the next hose assembly as close as possible to the specified crimp diameter. Write this new Bowl Setting number in the "Actual Setting" column of Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567". Using this new number should provide a more accurate crimp diameter the next time the die is used to crimp a hose coupling.
Crimping 1543 Air Conditioning Couplings
1543 Air Conditioning Couplings can be crimped using the variable die bowl by removing the 133-7362 Die Rest and using the appropriate die group. Refer to Special Instruction, NEEG3000, "Crimp Diameter Chart for 242-3567" for the "Bowl Setting" and die group part number for the coupling being assembled.
For additional information, refer to Special Instruction, NEHS0749, "Crimping 1E-1543 Air Conditioning Hose and 1E-1028 Thermoplastic Hose ".
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| Illustration 19 | g02638610 |
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| Illustration 20 | g02638613 |
Maintenance
- Clean all dirt and debris off the hose machine and counterbore of the die bowl.
- Lubricate the variable crimp die bowl with 129-1939 Grease or equivalent.
Inspection
- Inspect the variable crimp die bowl parts daily for damage or abnormal wear. Replace all worn or damaged parts immediately.
- Inspect the hydraulic power supply and high-pressure hose. Make sure that the hose connections are tight and not leaking.
- Make sure that the hydraulic cylinder is not leaking. A seal kit is available to repair the cylinder.