- Caterpillar Products: All
Introduction
Important Safety Information
European Union Compliant, CE Marked
Illustration 1 | g02139237 |
Think Safety |
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, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any 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.
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 Information
Safety Alert symbols
Illustration 2 | g02178794 |
Personal Protection |
Prohibited Action
No liquid around electrical components |
No smoking |
Hazard Avoidance
Safety alert symbol |
Electrocution hazard |
Entanglement hazard |
Explosion hazard |
Fire hazard |
Poisonous gas |
Pressurized air |
Slipping hazard |
Tripping hazard |
Ventilate |
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. 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 |
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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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar 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. |
General Information Section
Introduction
To crimp S4G couplings, use the 233-0346 Die Group (XT-3 ES [-20]), 233-0347 Die Group (XT-3 ES [-24]), or 233-0348 Die Group (XT-3 ES [-32]).
To crimp MCSH and MCSX couplings use the 233-0349 Die Group (XT-5 [-20]).
All of these dies are designed to be used only with 4C-3660, 4C-5052, 4C-5053, 9U-5792, or 9U-7261 Hose Machines.
These die groups do not have steps to locate the coupling in the die group during crimping. The crimp length is determined by visually aligning the coupling shell transition with the top surface of the die group. The 233-0350 Pusher Group assists in the alignment process and is provided for crimping when using the large bowl of the hose machine. The 134-9582 Pusher Plate can be used but is not recommended.
In all cases using these die groups, no spacer rings are required or available.
Illustration 3 | g02625991 |
Typical Hose Machine. |
NOTICE |
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Read and understand this manual before using the hose machine. If you do not understand any function of the machine, contact CSTG. These machines must only be operated by one operator at a time. |
Nomenclature
Illustration 4 | g02626007 |
Die Groups For S4G, MCSH, And MCSX Couplings For Caterpillar XT-3 ES and XT-5 Hose. (1) 233-0348 Die Group (XT-3 ES [-32]). (2) 233-0346 Die Group (XT-3 ES [-20]). (3) 233-0349 Die Group (XT-5 [-20]). (4) 233-0347 Die Group (XT-3 ES [-24]). (5) 233-0350 Split Pusher Group. |
Illustration 5 | g02626011 |
Typical S4G, MCSH, And MCSX Couplings. |
Illustration 6 | g02626015 |
Coupling Identification. (1) Crimp-To-Shell-Transition. (2) Coupling Dash Number. (3) Coupling Style. (4) Caterpillar Part Number. |
Note: On couplings with a radius instead of the sharp "Crimp-To-Shell-Transition", the "Crimp-To-Shell-Transition" is at the bottom of the radius (shown with dashed line in Illustration 6).
References
Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups
Special Instruction, NEHS0768, General Information for Hose Assembly
Special Instruction, NEEG2973, S4G, MCSH, and MCSX Coupling Crimp Chart
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
For information on cutting hoses, orienting couplings, skiving, and other general hose assembly information, refer to Special Instruction, NEHS0768, "General Information for Hose Assembly".
Cleaning Hoses
Bulk hose that is not cleaned before installing the coupling 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 one of the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups for cleaning the bulk hose and hose assemblies. For additional information refer to Special Instruction NEHS0643 Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups.
Operation Section
General 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 bulk hose and or hose assembly to avoid contamination of the hydraulic system using a hose cleaning group.
- DO NOT put oil or grease on the hose or couplings. Only water is permitted as a lubricant when pressing the coupling into hoses.
- Insert the hose in the new coupling and make sure that it is oriented properly.
- Carefully position and align the coupling's "Crimp-To-Shell-Transition" mark in the die group before crimping.
- Remove any sharp edges or burrs on crimped couplings with 80 grit emery paper or other suitable means.
- Measure the finished crimp diameter to make sure that it meets the correct crimp diameter specifications.
Crimp Procedure for XT-3 ES (-20) Hose
When crimping XT-3 ES (-20) hose assemblies, a 4C-4370 Die Bowl (small bowl) must be installed in the hose machine. Use the following setup and crimp procedure when crimping XT-3 ES (-20) hose assemblies.
- Cut the hose to length. Refer toSpecial Instruction, NEHS0768, "General Information for Hose Assembly" for additional information.
- Clean the bulk hose to remove any loose debris or foreign objects. Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups, for additional cleaning recommendations.
- Install the 4C-4370 Die Bowl.
- Remove the 133-7363 Die Rest from the hose machine die bowl, if installed.
- Lubricate the outside surface of the die group or the inside surface of the 4C-4370 Die Bowl with 129-1939 Desert Gold Grease and insert the die group into the die bowl.
Illustration 9 | g02626027 |
Insert 4C-4370 Die Bowl. |
- Place the coupling/hose assembly in the die group.
Illustration 10 | g02626030 |
Insert Die Group. |
- Install the front pusher half onto the hose machine.
Illustration 11 | g02626032 |
Insert Coupling/Hose. |
- Lower the ram enough to hold the coupling snugly within the die while still allowing enough movement to make slight up and down adjustments of the coupling and hose.
Illustration 12 | g02626034 |
Install Front Pusher Half. |
- Make sure the "Crimp-To-Shell-Transition" of the coupling, as shown in Illustration 6, is aligned with the top of the die.
Illustration 13 | g02626035 |
Lower Ram To Secure Coupling. |
NOTICE |
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Be careful to avoid gripping the coupling too tightly. Gripping the coupling too tightly could allow the hose to be partially pulled out of the coupling when aligning the "Crimp-To-Shell-Transition" with the top of the die. |
- Crimp the coupling to the hose by lowering the ram until the pusher plate contacts the die bowl.
Illustration 14 | g02626037 |
Align "Crimp-To-Shell-Transition". |
- Check the crimp diameter to make sure that it is within the proper crimp diameter specifications. Refer to Special Instruction NEEG2973, S4G, MCSH, and MCSX Coupling Crimp Chart, or the specifications in the Table 1 in this manual.
Illustration 15 | g02626038 |
Lower Ram To Crimp Coupling. |
Crimp Procedure for XT-3 ES (-24 and -32) or XT-5 (-20)
When crimping XT-3 ES (-24 and -32) and XT-5 (-20) hose assemblies, use the following setup and crimp procedure.
- Cut the hose to length. Refer to Special Instruction NEHS0768, General Information for Hose Assembly for additional information.
- Clean the bulk hose to remove any loose debris or foreign objects. Refer to Special Instruction, NEHS0643, Using the 233-7191, 233-7192, and 233-7193 Hose Cleaning Groups, for additional cleaning recommendations.
- Insert the 133-7363 Die Rest into the hose machine die bowl.
- Attach the 233-0352 Rear Pusher Half to the hose machine pusher plate by tightening the thumb screws.
Illustration 16 | g02626039 |
Insert 133-7363 Die Rest. |
- Lubricate the outside surface of the die group or the inside surface of the die bowl with 129-1939 Desert Gold Grease and insert the die group into the die bowl.
Illustration 17 | g02626041 |
Attach 233-0352 Rear Pusher Half. |
Note: To help retain the rear pusher half on the machine pusher half, a small groove can be ground into the side of the pusher, as shown in Illustration 18. To locate the groove correctly, apply bluing to the surface of the machine pusher plate and install the 233-0352 Rear Pusher Half. Remove the pusher half and grind approximately a 4.50 mm (.188 inch) wide x 4.50 mm (.188 inch) deep groove. This will help hold the 233-0352 Rear Pusher Half onto the pusher plate.
Illustration 18 | g02626042 |
Groove To Help Retain Rear Pusher Half. |
- Place the coupling/hose assembly in the die.
Illustration 19 | g02626043 |
Insert Die Group. |
- Install the front pusher half on the hose machine.
- Assemble the 233-0351 Front Pusher Half, onto the machine front pusher half.
- Attach the front pusher halves onto the hose machine.
Show/hide tableIllustration 21 g02626047
Assemble Front Pusher Halves.
Illustration 20 | g02626044 |
Insert Coupling/Hose. |
- Lower the ram just enough to hold the coupling snugly within the die while still allowing enough movement to make slight up and down adjustments of the coupling and hose.
Illustration 22 | g02626048 |
Attach Front Pusher Halves. |
- Make sure the "Crimp-To-Shell-Transition" of the coupling, as shown in Illustration 6, is aligned with the top of the die.
Illustration 23 | g02626049 |
Lower Ram To Secure Coupling. |
NOTICE |
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Be careful to avoid gripping the coupling too tightly. Gripping the coupling too tightly could allow the hose to be partially pulled out of the coupling when aligning the "Crimp-To-Shell-Transition" with the top of the die. |
- Crimp the coupling to the hose by lowering the ram until the pusher plate contacts the die bowl.
Illustration 24 | g02626050 |
Align "Crimp-To-Shell-Transition". |
- Check the crimp diameter to make sure that it is within the proper crimp diameter specifications. Refer to Special Instruction, NEEG2973 S4G, MCSH, and MCSX Coupling Crimp Chart, or the specifications in the Table 1 in this manual.
Illustration 25 | g02626052 |
Lower Ram To Crimp Coupling. |
Hose Crimp Specifications Chart
Hose Crimp Specification Chart for S4G, MCSH, and MCSX Couplings     | ||||||||
Hose Type     |
Dash No.     |
Anchor Coupling Style     |
Die Group Part No.     |
Inner Color     |
Outer Color     |
Bowl Size     |
Skive Length +/- 1.0 mm (.04 in)     |
Crimp Diameter +/- 0.13 mm (.005 in)     |
XT-3 ES     | -20     | S4G     | 233-0346     | Tan     | White     | Small     | 44.5 (1.75)     |
48.51 (1.910)     |
XT-3 ES     | -24     | S4G     | 233-0347     | Tan     | Red     | Large     | 57.0 (2.24)     |
55.63 (2.190)     |
XT-3 ES     | -32     | S4G     | 233-0348     | Tan     | Green     | Large     | 62.0 (2.44)     |
68.83 (2.710)     |
XT-5     | -20     | MCSH, MCSX     | 233-0349     | Brown     | White     | Large     | 70.0 (2.76)     |
52.45 (2.065)     |
Serviceable Parts
Illustration 26 | g02626054 |
233-0351 Front Split Pusher . (1) 233-0351 Pusher Front-Half . (2) 233-0353 Plate . (3) 233-0354 Block . |