Hose Products Reference Guide {0374, 0599, 0684, 0738, 5057} Caterpillar

Caterpillar Products

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Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This guideline enables dealers and customers to benefit from cost reductions which were made possible through an established Contamination Control Program. Fluids used in Caterpillar machines are highly effective unless the fluid contains damaging amounts of contaminates. Therefore, every effort must be made to reduce the contamination level within Caterpillar fluid systems. Caterpillar makes ongoing changes and improvements to the Caterpillar products. This guideline must be used with the latest technical information that is available from Caterpillar. Updated technical information will ensure that such changes and improvements are incorporated when applicable.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

If a Contamination Control Guideline is required, but not available in SIS Web, submit a form for feedback in the Service Information System (SIS Web) Interface.

Important Safety Information

Illustration 1	g02139237

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 is dangerous. Improper methods could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand the operation, lubrication, maintenance, and repair information. 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.

Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.

Illustration 2	g01032906

The following is the meaning of this safety alert symbol:

• Pay attention!

• Become alert!

• Your safety is involved.

The message that appears under the warning explains the hazard. The message will be written or pictorially shown.

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. Therefore, the warnings in this publication and on the product are not all inclusive. When a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that the tool, procedure, or work method is safe for all personnel around the machine. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.

All the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following specifications could change at any time: specifications, torque, pressures, measurement, adjustments, illustrations, and other items. These changes can affect the service that is given to the product. Obtain the most current and complete information before starting any job. Caterpillar dealers have the most current information that is available.

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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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, "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.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

References

Additional Hose Assembly Material

The following Reference Chart contains form numbers for general hose assembly reference material. The Reference Chart consists of books, posters, videos, and stickers. These References can be useful in producing the highest-quality hose assembly possible.

Quick Reference Hose Assembly Procedure

1. Measure the failed hose assembly. Record the total hose assembly length (THAL), angle of orientation, coupling size and type, hose size and type.

   1. Measure and record the assembled THAL (centerline-to-centerline of sealing surfaces). Refer to the "Measuring Total Hose Assembly Length" procedure in this manual.

   2. Measure and record the angle of orientation. Refer to the "Finding Angle of Orientation on Assembled Hoses" procedure in this manual.

   3. Identify the coupling attached to the hose assembly, referring to the "Coupling Identification" section. Record the Cat part number or determine a Cat replacement for hose couplings not produced by Caterpillar. Refer to PECP5030, Hose Products Reference Guide and/or Hydraulic Information System (HIS) to aid in the identification of the coupling and a replacement part number.

   4. Determine the cutoff factor (COF) of the coupling. Refer to the "Determining Coupling cutoff Factor" procedure. The cutoff factor for Cat couplings can also be found in PECP5030, Hose Products Reference Guide and/or Hydraulic Information System (HIS).

   5. Calculate the hose cut length (HCL) using the coupling cutoff factors for the couplings being used.

2. Remove the coupling. This step is only for reusable couplings. Refer to Tool Operating Manual, NEHS0745, "Assembling Reusable Couplings in the 4C-9900, 150-2568, and 173-9805 Combination Hose Machine" Tool Operating Manual, NEHS0746, "Assembling Reusable Couplings in the 139-5439, 145-3381, and 152-3910 Combination Hose Machines", and/or Reusable Coupling Tool List, NEHS0750, "Comprehensive Tooling List for Assembling and Disassembling Reusable Couplings" for tools and procedures for removing and reconditioning reusable couplings.

3. Measure and mark the new hose cut length from the dimension calculated in Step 1.

4. Cut the hose. Make sure that both ends are cut square.

   1. Use an abrasive saw for all hose types except 1E1028, 1E2760, and 1E1543 hose.

   2. Use a hand held 177-4271 Hose Cutter for 1E1028, 1E2760 Thermoplastic, and 1E1543 Air Conditioning Hose.

5. Remeasure the hose cut length.

6. Clean inside hose from both ends using a 233-7191 Hose Cleaner Group, 233-7192 Hose Cleaner Group, 233-7193 Hose Cleaner Group, or 265-4959 Hose Cleaner Group or an equivalent method.

7. Check the hose ends for squareness. Some hose types have specific squareness requirements. Refer to "Checking Hose Ends for Squareness" procedure for additional information.

8. Skive the hose ends (for XT and DIN hose types only). For the complete procedure, refer to "Skiving High-Pressure Hose" procedure in this manual. For skive length refer to Electronic Chart, NEEG2956, "Skive Length Chart (For Cat High-Pressure Hose Assembly with Skived Couplings)"

   1. Mark the skive length on the hose ends using the skive length chart, depth gauge, and a fine tipped marking pen. Refer to "Skiving High-Pressure Hose" in this manual for additional information on specific tools.

   2. Place the hose in a skive vise and lightly tighten the vise.

   3. Insert skiving or squareness arbor into the hose. Leave approximately a 25 mm (0.98425 inch) gap between the end of the hose and the shoulder of the squareness skiving arbor.

   4. Align the skiving guide with pen mark.

   5. Place the hose and skiving guide against the skive vise. The opposite end of the skiving guide and pen mark is to be precisely aligned. Clamp the hose into the skive vise.

   6. Make the first skive cut in a counter clockwise (CCW) direction with skive tool positioned against the skiving guide.

   7. Turn the skive tool around and finish skiving the remaining hose in a clockwise (CW) direction.

9. Install coupling A (first coupling) onto the hose.

   1. Reusable couplings:

      • 1) Place the sleeve over the hose.

      • 2) Insert coupling A into the hose by hand.

      • 3) If necessary, completely push the coupling into the hose using the hose machine.

      • 4) Push the sleeve onto the coupling.

   2. Permanent Couplings:

      • 1) Insert coupling A into the hose by hand.

      • 2) If necessary, completely push the coupling into the nose using the hose machine.

      • 3) Crimp the coupling onto the hose.

      • 4) Measure the crimp diameter. Ensure that the crimp diameter is within the required tolerance.

      • 5) Remove any burrs or sharp edges from the coupling.

10. Install coupling B (second coupling) onto the hose.

    1. Reusable Couplings:

       • 1) Place sleeve over the hose.

       • 2) Insert the coupling B into the hose by hand.

       • 3) If necessary, completely push the coupling into the hose using the hose machine.

       • 4) Set the angle of orientation for the second coupling, if needed. Refer to the "Assembly Angle of Orientation" section in this manual.

       • 5) Push the sleeve onto the coupling.

    2. Permanent Couplings:

       • 1) Insert coupling B into the hose by hand.

       • 2) If necessary, completely push the coupling into the hose using the hose machine.

       • 3) Set the angle of orientation for the second coupling, if needed. Refer to the "Assembly Angle of Orientation" section in this manual.

       • 4) Crimp the coupling onto the hose.

       • 5) Measure the crimp diameter. Ensure that the crimp diameter is within the required tolerance.

       • 6) Remove any burrs or sharp edges from the coupling.

11. Recheck the total hose assembly length.

12. Recheck the angle of orientation.

13. Clean inside assembled hose using a 233-7191 Hose Cleaner Group, 233-7192 Hose Cleaner Group, 233-7193 Hose Cleaner Group, or 265-4959 Hose Cleaner Group or an equivalent method.

14. Cap the hose assembly with protective caps or plugs, as necessary.

15. Install appropriate stickers onto the hose assembly.

Hose Replacement Factors

The following factors should be considered when determining if a hydraulic hose needs replacing.

1. Fitting slippage on the hose.

2. Damaged, abraded, or cut hose covering.

3. Heat cracked or charred hose.

4. Corroded, cracked, or damaged fittings.

5. Fitting or hose leakage.

6. Kinked, crushed, flattened, or twisted hose.

7. Blistered, degraded, or loose hose covering.

Measuring Total Hose Assembly Length (THAL)

The first step to making a replacement hose assembly is to measure the total hose assembly length (THAL) of the failed hose. Failure to measure the THAL of the failed hose may result in a new hose assembly that is too long or too short. Use the following methods to determine the exact THAL.

Note: To obtain the most accurate measurement, the hose should be laying straight.

Straight Flange -Type Sealing Surface

Illustration 3	g02393187
Dimension (A) is the Total Hose Assembly Length (THAL).

Simply measure from the outer edge of one sealing surface to the opposite sealing surface, refer to illustration3.

Angled Flange-Type Sealing Surface

Illustration 4	g02393416
Dimension (A) is the Total Hose Assembly Length (THAL).

Measure from the center point of one sealing surface to the center point of the opposite sealing surface, refer to illustration 4

Swivel Nut Sealing Surface

Illustration 5	g02393459
Dimension (A) is the Total Hose Assembly Length (THAL).

Measure from the outer edge of one sealing surface (inside the swivel nut) to the opposite sealing surface, as shown in illustration 5.

Finding Angle of Orientation on Assembled Hoses

Illustration 6	g02396296
Ensure that the hose is straight when checking the angle of orientation.

1. Put coupling (A) in a vise with sealing surface (1) pointing up and level with the vise, as shown in illustration 7. Set the dial (2) of the 7S-1125 or 266-7533 protractor (3) to zero. With the dial face of the protractor facing toward the vise, clamp the protractor onto the hose assembly near the sleeve of the coupling. Adjust the position of the protractor (not the dial) on the hose assembly until the bubble is level.
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   Illustration 7	g02396496

2. Remove the hose assembly form the vise, leaving the protractor clamped to the hose.

3. Clamp coupling (B) in the vise with the sealing surface up and level with the vise as shown in illustration 8.
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   Illustration 8	g02396565
   (A) Coupling (B) Coupling (1) Sealing Surface (2) Dial Face (3) 7S-1125 or 266-7533 Protractor

4. Turn dial face (2) until the bubble is level. Read the angle from the dial. Record and use this angle position for the new hose assembly.

Note: Hold the hose in a straight line with coupling (B), while performing Step 4.

Coupling Identification

Two reference publications are available to identify couplings. Refer to PEPG2007, Coupling Identification Guide, and PECP5030, Hose Products Reference Guide.

Record the following coupling identification factors:

1. Reusable or permanent.

2. Coupling type (SAE, NPTF, BSP, DIN, GAZ, JIS).

3. Coupling sealing method (metal to metal seal on threads, metal to metal seal on flare or cone seats, rubber to metal with O-ring seal).

4. Head diameter and thickness or thread diameter and pitch.

5. Coupling angle of orientation (degree of angle), if any.

6. Hose inside diameter.

7. Stem assembly length.

8. Drop length.

9. Cutoff factor.

Note: When replacing competitor couplings with Cat couplings, all coupling dimensions should match as close as possible.

Determining Coupling cutoff Factor

There are two methods to determine the coupling cutoff factor.

1. The cutoff factor for all Cat hose couplings can be found in PECP5030, Hose Products Reference Guide, and Hydraulic Information Systems.

2. To identify coupling cutoff factors, measure from the end of the hose location to the center of the sealing surface, as shown in 9.

Illustration 9	g02398269
Dimension (A) represents the cutoff factor.

Calculating Hose Cut Length (HCL)

When calculating hose cut length, (the length of the new hose) use the following formula.

The "Total Hose Assembly Length" minus "Coupling A cutoff Factor" minus "Coupling B cut off Factor".

Illustration 10	g02398617
(A) Coupling (A) cutoff Factor (B) Coupling (B) cutoff Factor (C) Total Hose Assembly Length

If the hose assembly has adapters on one or both ends, these measurements must also be calculated into the formula to determine the hose cut length.

Illustration 11	g02398676
(A) Total Hose Assembly Length (THAL) (B) Adapter for Coupling (A) (C) Coupling (A) cutoff Factor (CACOF) (D) Hose Cut Length (HCL) (E) Coupling (B) cutoff Factor (CBCOF) (F) Adapter for Coupling (B)

Removing Reusable Couplings from Failed Hose Assembly

This procedure is only for reusable couplings. Refer to Special Instruction, NEHS0745, "Assembling Reusable Couplings in the 4C-9900, 150-2568, and 173-9805 Hydraulic Hose Machine", Special Instruction, NEHS0746, "Assembling Reusable Couplings in the 139-5439, 145-3381, and 152-3910 Combination Hose Machines", and Special Instruction, NEHS0750, "Comprehensive Tooling List for Assembling and Disassembling Reusable Couplings" for tools and procedures for removing and reconditioning reusable couplings.

Cutting Hose

Abrasive Saw

A 6V-6015 9U-7319 9U-7320 223-2105 Hose Cutting Machine Group can be used to cut a hose.

Note: An abrasive saw will generate more foreign material and more care is needed to clean the hose. A 6V-6017 Fume Exhauster Group can be added to the 6V-6015 Hose cutoff Machine Group to reduce dust and debris.

Illustration 12	g02398887
A 6V-6015 Hose Cutting Machine Group with a 202-8959 Hose Cutoff Support Group.

1. Place the hose in the 202-8959 Hose Cutoff Support Group. If the hose has a natural curvature, place the curvature upward to help make a straight cut.
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   Illustration 13	g02398957
   The natural curvature of the hose should be up.

2. Set the stop screw to stop the blade at 3 mm (0.118) below the "V-channel" and keep adjusting the stop screw as the blade wears.

3. Cut the hose to the appropriate length and ensure that the hose has a good, square cut.

Illustration 14	g02406456

Hand-Held Hose Cutter

The 177-4271 Hose Cutter is used to cut thermoplastic, air conditioning, and air hose up to 25.4 mm (1.00) inside diameter.

Illustration 15	g02407976
(1) 177-4271 Hose Cutter used to cut Thermoplastic and Air conditioning hose. (2) 177-4272 Hose Cutter blades.

Checking Hose Cut Length (HCL)

After the hose is cut, recheck the hose cut length to ensure that the length is correct.

Cleaning the Hose

1. Tap both ends of the hose to remove any large particles.

2. Use the appropriate Hose Cleaner Group to clean the inside diameter of the hose. A cleaning projectile should be sent through each end of the hydraulic hose.

Illustration 16	g02410180
233-7191 Hose Cleaner Group

Checking Hose Ends for Squareness

1. Insert the appropriate arbor, from table 3 , into the hydraulic hose until the setscrew contacts the end of the hydraulic hose.
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   Illustration 17	g02410256
   Insert Squareness Arbor into the Hose.

2. Rotate the arbor a full 360 degrees. Ensure that the setscrew of the arbor remains in contact with the end of the hose. The setscrew must maintain contact with the end of the hose for the entire rotation (360 degrees) of the arbor. Complete contact of the setscrew during rotation will ensure the tolerance for squareness of the hose cut.
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   Illustration 18	g02414518
   Rotate the arbor 360 degrees to check the hose for squareness.

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   Illustration 19	g02414561
   View of the setscrew on the squareness arbor.

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   NOTICE
   Do not move or tamper with the setscrew in the squareness arbor. This setscrew is factory set to the correct dimension, which determines the squareness of the cut. If the setscrew is moved or damaged, the squareness tolerance may not be checked accurately and the hose assembly may fail.

3. If the hose is not square, cut another hose to the right length and check for squareness again.

Illustration 20	g02414640
Cut a new length of hose if the end is not square.

Skiving High-Pressure Hose

This procedure is for all 1E736 (XT-3 ES), 1E1036 (XT-5), 1E1136 (XT-6), 1E1956 (DIN), and 1E2836 (XT-6 ES) hoses with permanent or reusable couplings.

The proper preparation of the hose end is essential to producing a high-quality hose assembly. High-pressure hose 1E736 (XT-3 ES), 1E1036 (XT-5), 1E1136 (XT-6), 1E1956 (DIN), and 1E2836 (XT-6 ES) may need to be skived prior to installing permanent or reusable couplings. The basic procedure is the same for all the hose types listed. Different skive lengths are specified for each type and size of hose.

Skiving XT Hose

For a list of tools required to skive XT-3 ES, XT-5, XT-6, XT-6 ES, and DIN hoses, refer to Tool Operating Manual, NEHS0750, "Comprehensive Tooling List for Assembling and Disassembling Reusable Couplings".

1. Place the hose in a 127-1909 Skiving Tool Vise As with 127-1910 Block Group installed.
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   Illustration 21	g02415222
   127-1909 Skiving Tool Vise As with 127-1910 Block Group installed.

2. Determine the skive length using Electronic Chart, NEEG2956, "Skive Length Chart (For Cat High-Pressure Hose Assembly with Skived Couplings)".
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   Illustration 22	g02416176
   Mark skive length using 226-7149 Depth Gauge (4) and 202-6602 Pen Marking Kit (3).

3. Place the proper guide, refer to table 4 over the hose. Insert the appropriate skive arbor into the hose far enough to support the hose when clamped into the skive vise.
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   Table 4

   Skiving Guides and Arbors for DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES
   Hose Size	Guide	Arbor	Color
   9.53 mm (3/8 inch) (-6)	226-7141	209-3320	Yellow
   12.7 mm (1/2 inch) (-8)	226-7142	209-3322	Blue
   15.88 mm (5/8 inch) (-10)	226-7143	209-3324	Orange
   19.05 mm (3/4 inch) (-12)	226-7144	202-3277	Green
   25.4 mm (1 inch) (-16)	226-7145	202-3278	Black
   31.75 mm (1-1/4 inch) (-20)	266-7146	202-3279	White
   38.1 mm (1-1/2 inch) (-24)	226-7147	202-3280	Red
   50.8 mm (2 inch) (-32)	226-7148	202-3281	Green

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   Illustration 23	g02416197
   Place guide (5) onto hose and insert the arbor (6) into the hose leaving a 25.4 mm (1 inch) gap (A).

   Note: The arbor will keep the hose straight and prevent the hose from collapsing during the skiving process. Leave a gap, refer to (A) illustration 23 between the hose and the shoulder of the arbor (approximately 1 inch). The 1 inch gap will allow the skive blade to skive the end of the hose.

4. Position guide (5) against block group (2) refer to illustration 23. Ensure the radius of the skive tool will begin cutting on the pen mark.
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   Illustration 24	g02416279
   (1) 127-1909 Skiving Tool Vise As. Ensure guide (5) is positioned against 127-1910 Block Group

5. Place 7S-1126 Skiving Tool Group (7) next to the sleeve. Position the skive tool to rotate counter clockwise (as viewed from the end of the hose). Reposition the hose and guide, if necessary. Ensure the radius of the skive tool is cutting on the pen line.

   Note: Rotating the skive tool counter clockwise forces the skive tool to move toward the guide (5) due to the wrap of the wire.

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   Illustration 25	g02416376
   Place skiving tool (7) against guide (5).

6. Adjust the skiving tool to the proper cutting depth.
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   NOTICE
   After skive is completed, the wire should be exposed, but not shiny. Do not break or damage the wire while using the skiving tool to remove the hose covering.

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   Illustration 26	g02416517
   Initial skive.

7. Reposition the skive tool and rotate the skive tool clockwise to skive the remaining hose covering.
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   Illustration 27	g02416525
   Completed skiving procedure.

8. Measure the skive length and compare that length to Electronic Chart, NEEG2956, "Skive Length Chart". If necessary, adjust the sleeve position for the next skive.

9. Repeat skiving procedure for the other end of the hose.

Coupling Installation

Refer to the Hose Machine Tool Operating Manual for the correct tooling and procedure.

Measure the length of the coupling shell and transfer this measurement, as a reference mark, to the end of the hose. Install coupling A (first coupling) onto the hose. Use the reference mark on the hose to make sure that the coupling has been inserted into the hose, prior to crimping.

Installing coupling A (first Coupling) onto the hose

1. Reusable couplings:

   1. Place sleeve over the hose.

   2. Insert the coupling A into the hose by hand.

   3. If necessary, completely push the coupling into the hose using the hose machine.

   4. Push the sleeve onto the coupling.

2. Permanent Couplings:

   1. Insert the coupling A into the hose by hand.

   2. If necessary, completely push the coupling into the hose using the hose machine.

   3. Crimp the coupling onto the hose.

   4. Measure the crimp diameter. Ensure that the crimp diameter is within required tolerance.

   5. Remove any burrs or sharp edges form the coupling.

Installing coupling B (Second Coupling) onto the hose

1. Reusable Couplings:

   1. Place sleeve over the hose.

   2. Insert the coupling B into the hose by hand.

   3. If necessary, completely push the coupling into the hose using the hose machine.

   4. Set the angle of orientation for the second coupling, if needed. Refer to the "Assembly Angle of Orientation" section in this manual.

   5. Push the sleeve onto the coupling.

2. Permanent Couplings:

   1. Insert coupling B into the hose by hand.

   2. If necessary, completely push the coupling into the hose using the hose machine.

   3. Set the angle of orientation for the second coupling, if needed. Refer to the "Assembly Angle of Orientation" section in this manual.

   4. Crimp the coupling onto the hose.

   5. Measure the crimp diameter. Ensure that the crimp diameter is within the required tolerance.

   6. Remove any burrs or sharp edges from the coupling.

Assembly Angle of Orientation

Note: Keep the hose straight when setting the angle of orientation.

Illustration 28	g02419718
Keep hose straight when checking/setting angle of orientation.

Refer to illustration 28 for steps 1 through 4.

1. Assemble coupling (A).

2. For reusable couplings, put the sleeve for coupling (B) onto the hose. Push coupling (B) far enough into the hose to hold the angle. The coupling must be able to rotate.

   Note: The ID chamfer on the sleeve should face toward the hose end.

3. Put assembled coupling (A) in a vise with sealing surface (1) pointing upward, as shown. Set dial (2) of 7S-1125 Protractor (3) to zero. The 266-7533 Protractor is used for -40 through -56 63.5 mm (2.5 inch) through 88.9 mm (3.5 inch) hose. With dial face (2) of the protractor facing toward the vise, clamp protractor onto the hose near the coupling. Adjust the protractor on the hose until the bubble is level.

4. Remove coupling (A) from the vise. Turn the hose end for end and clamp coupling (B) into the vise with sealing surface (1) pointing up.
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   Illustration 29	g02423396
   Put hose coupling (A) into vise. (1) Sealing Surface. (2) Dial Face. (3) 7S-1125 Protractor or 266-7533 Protractor. (A) Coupling A. (B) Coupling B.

5. Turn the dial to the angle of orientation (position) desired.
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   Illustration 30	g02423737
   Clamp Coupling (A) in Vise. (1) Sealing Surface. (2) Dial Face. (2) Dial Face. (3) 7S-1125 Protractor or 266-7533 Protractor. (A) Coupling A. (B) Coupling B.

6. Rotate assembled hose and coupling (A) until the bubble is level. Remove the protractor. Ensure that the angle is within the specified tolerance, shown in Table 5.
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   Table 5

   Hose Coupling Rotation Tolerance
   Hose Assembly Length	Tolerance (E)
   0 to 90 cm (0 to 35 in)	± 3 degrees
   90 to 150 cm (35 to 59 in)	± 4 degrees
   150 to 200 cm (59 to 83 in)	± 5 degrees
   210 to 270 cm (83 to 106 in)	± 6 degrees
   270 cm (106 inch) and up	± 8 degrees

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   Illustration 31	g02424137
   Rotate Assembled Coupling (A).

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   Illustration 32	g02424276
   Angle of Orientation (C) is measured from the position of coupling (B) clockwise to coupling (A). (THAL) Total Hose Assembly Length. (E) Tolerance.

7. When the coupling angle is correct, finish pushing coupling (B) into the hose.

8. Install the sleeve.

Measuring Permanent Coupling Crimp Diameters

Quality control of finished crimped hose assemblies is maintained by measuring the crimp diameter. Crimp diameters can be measured using a micrometer, calipers, caliper measurement system, or a Crimputer. If available, using the crimputer is the most efficient way to make these measurements. The crimputer automatically averages the four measurements and adjusts the crimp diameter.

Illustration 33	g02424362
(1) 1E1028 and 1E2760 Thermoplastic Hose. (2) 1E294, 1E716, 1E844, 1E736, 1E1036, 1E1136, 1E1956, and 1E2836 Hydraulic Hose. (3) 1E1543 Air Conditioning Hose.

Note: When measuring the crimp diameter, do not take measurements across the ridges of the coupling. To ensure accuracy, each measurement must be taken in the areas between the ridges.

Note: Use Crimp Chart, NEEG2746, "Crimp Diameters Chart" (laminated chart) for crimp diameter specifications.

Illustration 34 shows a crimp diameter measurement system which will take four crimp diameter measurements and calculate the average.

Illustration 34	g02438956
(1) 136-0536 Digital Caliper (2) 279-7315 Mini Processor (3) 136-0538 Cable to Attach Caliper (4) 136-0539 Foot Switch, also available 9U-6690 Replacement Ribbon, and 279-7316 Paper.

1E1028 and 1E2760 Thermoplastic Hose

The crimp diameter of 1E1028 and 1E2760 Thermoplastic Hose is measured in the center of the crimp length at four locations.

1. Measure the crimp diameter at the halfway point of the coupling. Refer to Illustration 35.
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   Illustration 35	g02440240
   Measure the Coupling at the Halfway Point.

2. Measure the crimp diameter at four locations around the coupling. Average the four measurements and compare with the Crimp Chart, NEEG2746, "Crimp Diameters Chart". Refer to illustration 36.

Illustration 36	g02440360
Measure the Crimp Diameter in Four Locations.

1E294, 1E716, 1E844, 1E736 (XT-3 ES), 1E1036 (XT-5 ES), 1E1956 (DIN), and 1E2836 (XT-6 ES) Hoses

The crimp diameter of these types of hoses is measured at the center of the crimp length in four locations.

1. Measure the crimp diameter at the halfway point on the coupling. Refer to illustration 37.
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   Illustration 37	g02440598
   Measure the Coupling at the Halfway Point.

2. Measure the crimp diameter in four locations around the coupling. Average these four measurements and compare with the Crimp Chart, NEEG2746, "Crimp Diameters Chart". Refer to illustration 38.

Illustration 38	g02440324
Measure the Crimp Diameter in Four Locations.

1E1543 Air Conditioning Hose

1. Measure the crimp diameter of 1E1543 Air conditioning Hose couplings at the crimp groove farthest from the hose. Refer to Illustration 39.
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   Illustration 39	g02440699
   Measure the Crimp Diameter in the First Groove (shown with arrow).

2. Measure the crimp diameter in four locations around the coupling. Average these four measurements and compare with the Crimp Chart, NEEG2746, "Crimp Diameters Chart". Refer to illustration 40.

Illustration 40	g02440716
Measure the Crimp Diameter in Four Locations.