Reusable Couplings For Caterpillar XT-3, XT-5, and XT-6 Hose Caterpillar


Reusable Couplings For Caterpillar XT-3, XT-5, and XT-6 Hose

Usage:



Reusable Couplings For Caterpillar XT-3, XT-5, and XT-6 Hose

SEBF8176-01
September 2000
SMCS Code: 5057

GUIDELINE FOR
REUSABLE PARTS
AND SALVAGE OPERATIONS

Reusable Couplings For Caterpillar XT-3, XT-5, and XT-6 Hose

Summary of Revisions

Page

Description

All

Revised format.

Contents

Introduction

1

Summary

2

Nomenclature for Hose Coupling

2

Coupling Identification

3

Reconditioning Procedures

3

General Information

3

Reconditioning the Flange Head

4

Reconditioning Specifications

4

Flange Head Couplings

4

Face Seal Couplings

5

Visual Inspection

5

Head

7

Outside Stem

8

Inside Stem

9

Collet

10

Sleeve

10

 

Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information available from Caterpillar to ensure such changes and improvements are incorporated where applicable.

For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer Support (309) 675-5156.

Summary

XT-3, XT-5, and XT-6 reusable hose couplings can be reused many times as long as they are not damaged in certain areas. The only repair method that applies to hose couplings are light deburring. This guideline presents reconditioning procedures, specifications, and visual examples of various "Use again" and "Do not use again" conditions.

For the proper assembly procedures for reusable hose couplings, refer to Special Instructions, SEHS7957, "Use of 6V-4900 Hydraulic Hose Service Press Arrangement".

Nomenclature for Hose Couplings

Illustration 1

Coupling Nomenclature. See Chart A.

 

Chart A
Coupling Nomenclature

Item

Description

1

Flange Head

2

Ring Groove Land

3

Outside Stem

4

Collet

5

Fingers

6

Inside Stem ?

7

Stem Taper

8

Grip Grooves

9

Swivel Nut

10

Seal Face

Coupling Identification

Illustration 2

Coupling identification.

(11) XT-3 () Coupling and Sleeve
(12) XT-5 (+) Coupling and Sleeve
(13) XT-6 (UHP) Coupling and Sleeve

 

Identification

Symbol

Hose

Type

Hose

ID

Maximum

Working

Pressure

Head

Flange

Thickness

XT-3

9.5
(.38)

28,000
(4,000)

6.73
(.265)

XT-3

12.7
(.50)

28,000 (4,000)

6.73
(.265)

XT-3

19.1
(.75)

28,000 (4,000)

6.73-8.00
(.265-.315)

XT-3

25.4
(1.00)

28,000 (4,000)

8.00-9.50 (.315-.375)

XT-3

31.8
(1.25)

21,000 (3,000)

8.00-9.50 (.315-.375)

XT-3

38.1
(1.50)

17,500 (2,500)

8.00-9.50 (.315-.375)

XT-3

50.8
(2.00)

17,500 (2,500)

9.50
(.375)

+

XT-5

All

35,000 (5,000)

14.22 (.560)

UHP

XT-6

All

42,000 (6,000)

14.22 (.560)

Note: All dimensions are in mm (in) and all pressure is in kPa (psi).

Reconditioning Procedures
General Information

The reconditioning procedure can be used on a coupling. After reconditioning, the coupling may meet "Use again" specifications and thus be re-used. Since a coupling is part of a pressure containment system, all that can be done to recondition the coupling is to remove burrs or raised metal. These flaws can prevent a seal connection from being leak-free or can cause damage to the hose-to-coupling joint.

Reconditioning the Flange Head

Illustration 3

Flange face has minor surface damage with "high" spots.

Use again---

after removing the high spots.

  1. Obtain a clean, ground surface plate
    (7B-0337 Plate) or other flat surface.
  2. Place a medium-to-fine grit emery paper onto the surface plate.
  3. Note: Some sandpapers may also be suitable for this procedure. The emery cloth can also be "wet" with clean petroleum solvent in order to reduce friction.

  4. Hold the flange face against the emerycloth.
  5. Illustration 4

    Removing burrs and raised metal from the flange face using medium grit emery paper.

  6. Move the coupling laterally back and forth across the emery cloth. Use care to keep the flange face flat on the emery paper. It is not necessary to move the part in a figure eight "8" pattern as is done with piston pump slippers.
  7. Most burrs or high spots can be removed in two to six strokes. Once the surface has been sanded, look for areas that do not shine. These areas mean that the raised metal around a burr or dent has not been removed. If the face has not cleaned up, repeat the reconditioning procedure.

    Illustration 5

    Flange head minimum thickness.

    Do not remove more than 0.08 mm (0.003 inch) from the face of the flange. It is not necessary to polish the face to a fine finish since an O-ring, rather than the face, makes the seal.

    Illustration 6

    Flange face after refinishing. Minor dents remain, but "high" spots have been removed.

    Use again

  8. Wash the coupling in clean solvent. Protect the flange face from damage until the coupling is used.

Reconditioning Specifications
Flange Head Couplings

Do not remove too much metal from either the face or the back of the coupling flange. If the flange is too thin, the split clamps will contact the mating part without clamping the coupling head or compressing the O-ring. This can result in a leaking connection.

Chart D.
XT-3, XT-5, and XT-6 O-ring Face Seal Head
Specifications

Hose
Type

Head
Diameter

Nominal
Flange
Thickness

"Do Not
Exceed"
Minimum
Flange
Thickness

XT-3

30.2 (1.19)

6.73 (0.265)

6.65 (0.262)

XT-3

38.1 (1.50)

6.73 (0.265)

6.65 (0.262)

XT-3

44.5 (1.75)

8.00 (0.315)

7.92 (0.312)

XT-3

50.8 (2.00)

8.00 (0.315)

7.92 (0.312)

XT-3

60.3 (2.38)

8.00 (0.315)

7.92 (0.312)

XT-3

71.4 (2.81)

9.50 (0.374)

9.42 (0.371)

XT-3

84.1 (3.31)

9.50 (0.374)

9.42 (0.371)

XT-5

All Sizes

14.22 (0.560)

14.15 (0.557)

XT-6

All Sizes

14.22 (0.560)

14.15 (0.557)

Note: All dimensions are mm (in).

Face Seal Couplings

Although not retained by clamps, O-ring face seal heads are similar to O-ring flange heads and the flange thickness should not be reduced beyond the dimensions shown in Chart D.

Chart D.
XT-3 and XT-5 O-ring Face Seal Head

Hose
Type

Head
Diameter

Nominal
Flange
Thickness

"Do Not
Exceed"
Minimum
Flange
Thickness

XT-3

9.5 (0.380)

4.50 (0.177)

4.42 (0.174)

XT-3

12.70 (0.500)

5.00 (0.197)

4.93 (0.194)

XT-3

19.10 (0.750)

6.50 (0.256)

6.43 (0.253)

XT-3

25.40 (1.00)

7.00 (0.276)

6.93 (0.273)

XT-5

19.10 (0.750)

6.50 (0.256)

6.43 (0.253)

XT-5

25.40 (1.00)

7.00 (0.276)

6.93 (0.273)

Note: All dimensions are mm (in).

Visual Inspection
Head

Illustration 7

O-ring flange head has minor surface damage on sealing lands.

Use again---

after ensuring no burrs protrude above flange face. See "Reconditioning Procedure".

Illustration 8

O-ring flange head has heavy damage across inner sealing land only.

Use again---

after ensuring no burrs protrude above flange face. See "Reconditioning Procedure".

 

Illustration 9

Back side of flange has raised burr.

Use again---

after deburring.

Illustration 10

O-ring flange head has heavy damage across the outer or both sealing lands.

Do not use again

Illustration 11

Flange face is distorted and not flat.

Do not use again

 

Illustration 12

Do not reuse or attempt to salvage any coupling that has a crack in the indicated area.

Do not use again

Illustration 13

JIC (Joint Industry Council) sealing seat with heavy damage.

Do not use again

Illustration 14

JIC swivel nut is cracked.

Do not use again

 

 

Illustration 15

ORFS sealing face has minor surface damage.

Use again---

after ensuring no burrs protrude above sealing face. See "Reconditioning Procedure".

Illustration 16

ORFS (O-ring face seal) sealing face has heavy damage.

Do not use again

Illustration 17

Male pipe threads have heavy damage.

Do not use again

Outside Stem

Illustration 18

Stem has been stretched, resulting in reduced stem OD.

Do not use again

Illustration 19

Stem has heavy exterior damage.

Do not use again

 

Illustration 20

Stem has failed due to excessive system pressure.

Do not use again

Illustration 21

Stem has been bent due to external forces.

Do not use again

 

Inside Stem

Illustration 22

Grip grooves have rubber fragments.

Use again---

after cleaning.

Illustration 23

Stem taper has a raised burr which will tear hose's inner liner.

Use again---

after deburring.

Do not reuse an XT coupling unless it is first resized. XT couplings that are not resized can separate (blow-off) from the hose assembly and possibly cause personal injury.

 

 

Illustration 24

Resizing tool will not fit in end of coupling. Stem has not been resized.

Use again---

after resizing.

Illustration 25

Stem is not straight after resizing.

Do not use again

Illustration 26

The end of the stem has mushroomed.

Do not use again

Coupling

Illustration 27

Coupling has normal wear, minor dents, scratches, nicks, etc.

Use again

after reconditioning by filing or sanding.

It is permissible to use couplings that have had the zinc-chromate coating removed by bead blasting or exposure to non-caustic chemicals. Such couplings should be painted after they are assembled onto hoses to prevent corrosion damage.

Illustration 28

Coupling has been repaired by welding.

Do not use again

NOTE: Caterpillar does not recommend welding on hose couplings. Welding could cause localized stresses which can lead to reduced fatigue strength and performance life.

 

Illustration 29

Coupling has been exposed to fire.

Do not use again

Collet

Illustration 30

Fingers have surface cracks in zinc-chromate coating.

Use again

Illustration 31

Finger has a raised burr(s).

Use again---

after deburring.

Illustration 32

Collet has a cracked or missing finger.

Do not use again

Sleeve

Illustration 33

Sleeve is cracked.

Do not use again

Illustration 34

Sleeve does not have a straight, cylindrical shape.

Do not use again

Illustration 35

Sleeve does not have a circular shape.

Do not use again

 

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