Caterpillar 139-5439, 145-3381 & 152-3910 Combination Hose Machines Tool Operating Manual - PDF

R

NEHS0746-02 June 2005

TOOL OPERATING MANUAL Assembling Reusable Couplings in the 139-5439, 145-3381, and 152-3910 Combination Hose Machines SMCS: 0684

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

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 specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

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.

The information, specifications, and illustrations in this publication are on the basis of 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.

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 operation, lubrication, maintenance, and repair information.

WARNING 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.

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.

Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

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.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

2

Safety

WARNING WARNING

Use proper tools which are in good, working condition and replace or repair any damaged equipment. Always use the correct collets for the hose and coupling size. Improper sizing and installation of the collets or improper use of the hose machine can cause the hose and/or fitting to be suddenly released and strike someone, causing personal injury.

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools.

Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

The combination hose machine has the capability of producing many tons of force. Bad parts or an improper setup can cause parts to be explosively thrown from the hose machine, resulting in serious injury or death.

To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools.

ALWAYS match and install the hose, stem assembly, and sleeve according to ∆, +, the size and designated markings (∆ ∆), UHP, or ∞). NEVER interchange XT-3 (∆ ∞) hose, stem XT-5 (+), XT-6 (UHP) or XT-6 ES (∞ assemblies, or sleeves.

To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

Mismatched couplings and hoses can cause the coupling to blow off the hose when placed under pressure, separating with sudden, extreme force which can result in property damage, personal injury, or death.

Clean up all leaked or spilled fluids immediately.

Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Never use any hose at a hydraulic pressure greater than what is recommended as its maximum working pressure.

Always resize the stem (lD) of used couplings and reform the fingers during the reconditioning process to make sure the stem of the coupling holds the hose correctly. Failure to resize the coupling can cause the coupling to blow off the hose when placed under pressure, separating with sudden, extreme force which can result in property damage, personal injury, or death.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes.

Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

Never install couplings on used hose or apply oil between the coupling and hose. Coupling retention is lower on a hose with an oily residue on its surface which could cause a sudden, explosive release of the coupling from the hose when under pressure, resulting in personal injury.

3

Contents

Introduction

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 References. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Additional Hose Assembly Material. . . . . . . 5 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4C-9902 XT-3 ES Hose Tool Group . . . . . . . 6 171-2528 XT-5 and XT-6 Hose Tool Group . . . 7 215-9673 Accessories Group . . . . . . . . . . . 8 Tooling Required For XT-6 ES -12 and -16 Non-Integral Hex Reusable Couplings . . . . . . . 11 188-2157 XT-6 ES -24 Accessory Group. . 11 265-5818 XT-6 ES -32 Accessory Group. . 12 226-7150 Hose Gauge Kit . . . . . . . . . . . . . 13 Miscellaneous Tooling Required . . . . . . . . 14 Beveled Horseshoe Collets . . . . . . . . . . . . . 16 XT Hose Coupling Features and Benefits . . 16 Hose and Couplings . . . . . . . . . . . . . . . . . . 17 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 XT Couplings . . . . . . . . . . . . . . . . . . . . . . . 18 Couplings with Brazed-On Nut . . . . . . . . . 19 Bar Knob Clamping System . . . . . . . . . . . 19 Hose Disassembly Procedure . . . . . . . . . . . 20 Coupling Recovery . . . . . . . . . . . . . . . . . . 20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 24 Reform Fingers and Resize Stem . . . . . . . 24 Reconditioning the Coupling . . . . . . . . . . . . 24 Hose Assembly Procedure . . . . . . . . . . . . . 28 Cleaning the Coupling . . . . . . . . . . . . . . . . 28 Cutting Hose . . . . . . . . . . . . . . . . . . . . . . . 28 Skiving and Cleaning the Hose . . . . . . . . . 28 Coupling Orientation . . . . . . . . . . . . . . . . . 28 Coupling Installation . . . . . . . . . . . . . . . . . 28 Sleeve Installation . . . . . . . . . . . . . . . . . . . 31

Illustration 1. Caterpillar Reusable Coupling And XT Hose.

This manual contains the tools and procedures needed to assemble Caterpillar reusable couplings onto Caterpillar XT hose using the Combination Hose Machine. The reusable coupling uses a two-piece design that allows the dealer to disassemble a damaged hose and reuse the coupling, which is a significant cost savings.

Reusable coupling hose assemblies require a hose machine to remove and install the coupling stem (C) and sleeve (A). Using any other method of assembly or disassembly can damage the couplings or cause the hose assembly to fail.

Illustration 2. Reusable Coupling Design.

(A) Coupling Sleeve. (B) Hose. (C) Coupling Stem.

4

The reusable coupling design uses a coupling stem (C) which is inserted into the hose. The coupling sleeve (A) is then pressed onto the stem, locking the hose in place. Before assembly, reusable coupling hoses must be skived. Refer to NEHS0768, General Information for Hose Assembly, for additional information on skiving hoses.

;;

References Additional Hose Assembly Material The following Reference Chart contains form numbers for general hose assembly reference material, such as books, posters, videos, and stickers. These references can be very useful in producing the highest quality hose assembly possible.

; ; ; ;;;;

The following illustration shows three commonly used types of couplings.

O-ring Flange Head 1

8

6

3

5

Description

NEEG2737

Hose, Die Group, and Spacer Ring Selection Chart

NEEG2828

Certified Clean Hose (Decal), 250/Roll

7

2

4

References

Form No.

Skive Length Chart

NEHS0643

Using the 233-7191, 233-7192, 233-7193, and 265-4959 Hose Cleaner Groups

NEHS0727

Using the 166-5853 Banding Tool

NEHS0745

Assembling Reusable Couplings in the 4C-9900, 150-2568, and 173-9805 Combination Hose Machine

;

NEEG2950

ORFS

10

9

JIC

10

0746-29

Illustration 3. Reusable Coupling Nomenclature.

(1) Flange Head. (2) Ring Groove Land. (3) Outside Stem. (4) Coupling. (5) Fingers. (6) Inside Stem.

(7) Stem Taper. (8) Grip Grooves. (9) Swivel Nut. (10) Sealing Surface.

5

NEHS0746

Assembling Reusable Couplings in the 139-5439, 145-3381, and 152-3910 Combination Hose Machine

NEHS0747

202-6601 Hose Cutting Guide

NEHS0748

Crimping Permanent Couplings Using the 136-3642 Crimp Tool Group in Combination and XT Hose Machines

NEHS0749

Crimping 1E1028 Thermoplastic and 1E1543 Air Conditioning Hose

NEHS0750

Comprehensive Tooling List for Assembling and Disassembling Reusable Couplings

NEHS0768

General Information for Hose Assembly

NEHS0860

Using the 223-2105 Hose Cutting Machine

NENG7001

Hydraulic Hose Assembly Tools

PECP5030

Hose and Coupling Reference Guide

PEEP3214

XT Hose Reuse Sticker, Small, 250/Roll

PEEP7210

XT Hose Reuse Sticker, 250/Roll

PEHP6033

Reusable Couplings for XT Hose

PEVN5041

XT Hose Reusable Coupling Recovery and Assembly (Video)

PEWP3013

XT Hose Assembly and Hose Coupling Poster

SBFY0604

Hydraulic Hose and Reusable Couplings (Microfiche)

SEBD2080

Hydraulic Hose and Reusable Couplings (Paper)

SEBF8176

Reusable Couplings for Caterpillar XT-3 ES, XT-5, and XT-6 Hose

SMHS8316

Preparation and Use of 6V-6015 Hose Cutoff Machine

Tooling Tooling for the 4C-9900, 150-2568, and 173-9805 Hose Machines Part No.

Description

4C-9902

XT-3 ES Hose Tool Group

171-2528

XT-5 and XT-6 Hose Tool Group

215-9673

Accessory Group (Replaces 171-2531 Accessory Group)

—

Required Tooling For XT-6 ES -12 and -16 Non-Integral Hex Couplings

188-2157

XT-6 ES -24 (1.50”) Accessory Group

265-5818

XT-6 ES -32 (2.00”) Accessory Group

226-7150

Hose Gauge Kit

131-3961

XT Hose Reclamation Collets

4C-9902 XT-3 ES Hose Tool Group Check Box

Part Number

Identification Color

6V-4886

Green

Top Collet

-6 XT-3 ES Sleeve and

6V-4887

Green

Bottom Collet

-12 XT-3 ES Stem

9U-6743

Red

Top Collet

-8 XT-3 ES Sleeve and

9U6744

Red

Bottom Collet

-16 XT-3 ES Stem -16 XT-3 ES Sleeve, -24 XT-3 ES Stem, and -12 XT-6 Sleeve

Description

Used On

6V-4893

Silver

Top Collet

6V-4894

Silver

Bottom Collet

6V-4891

Blue

Top Collet

6V-4892

Blue

Bottom Collet

-12 XT-3 ES Sleeve, -16 XT-6 Stem, and -20 XT-3 ES Stem

6V-4899

White

Top Collet

-32 XT-3 ES Sleeve

6V-4901

White

Bottom Collet

6V-4897

Orange

Top Collet

6V-4898

Orange

Bottom Collet

6V-4902

Green

Top Collet

-6 and -8 XT-3 ES Stem and

6V-4903

Green

Bottom Collet

-6 and -8 XT-6 Stem

6V-9069

Yellow

Top Collet

-20 XT-3 ES Sleeve and

6V-9070

Yellow

Bottom Collet

-32 XT-3 ES Stem

ToolList-01

Typical Stem Collet

-24 XT-3 ES Sleeve

ToolList-02

Typical Sleeve Collet

6

171-2528 XT-5 and XT-6 Hose Tool Group Check Box

Part Number

Identification Color

Description

Used On

Collets 4C-9422

—

Top Collet

-20 XT-6 Stem

4C-9423

—

Bottom Collet

4C-9433

—

Top Collet

-20 XT-5 and

4C-9474

—

Bottom Collet

-20 XT-6 Sleeve

6V-4915

—

Top Collet

-12 XT-5 Stem

6V-4916

—

Bottom Collet

6V-4917

—

Top Collet

-12 XT-6 Stem and

6V-4918

—

Bottom Collet

-16 XT-5 Stem

6V-4919

—

Top Collet

-12 XT-5 Sleeve

6V-4921

—

Bottom Collet

6V-4922

—

Top Collet

6V-4923

—

Bottom Collet

6V-4924

—

Top Collet

-24 XT-5 Sleeve and

6V-4925

—

Bottom Collet

-32 XT-5 Stem

6V-4926

—

Top Collet

-32 XT-5 Sleeve

6V-4927

—

Bottom Collet

8T-0815

—

Top Collet

-16 XT-5 Sleeve and

8T-0816

—

Bottom Collet

-24 XT-5 Stem

122-7321

—

Top Collet

-20 XT-5 Stem

122-7322

—

Bottom Collet

ToolList-04

Typical Stem Collet

-16 XT-6 Sleeve

ToolList-02

Typical Sleeve Collet

Stem Pusher 126-1023

—

Stem Pusher

-32 Hose XT-3 ES and XT-5

Stem Expander ToolList-05

170-5683

—

Stem Expander -12 XT-6

170-5684

—

Stem Expander -16 XT-6

6V-4972

—

Stem Expander -32 XT-5

Stem Expander

ToolList-06

Stem Pusher 7

215-9673 Accessories Group Check Box

Part Number

Identification Color

Description

Used On

Collets 1U-9673

—

Top Collet

1U-9674

—

Bottom Collet

1U-9675

—

Top Collet

1U-9676

—

Bottom Collet

1U-9677

—

Top Collet

1U-9678

—

Bottom Collet

1U-9679

—

Top Collet

1U-9680

—

Bottom Collet

131-4367

—

Top Collet

131-4368

—

Bottom Collet

-6 and -8 Gripper for all hose types

-16 and -20 Gripper for all hose types

-24 Gripper for all hose types ToolList-07

-32 Gripper for all hose types

Typical Gripper Collet

-12 Gripper for all hose types

One-Piece Collet 4C-5887

—

One-piece Collet

-6 for initial finger spreading

4C-5888

—

One-piece Collet

-8 for initial finger spreading

4C-5889

—

One-piece Collet

-12 for initial finger spreading

4C-5890

—

One-piece Collet

-16 for initial finger spreading

4C-5891

—

One-piece Collet

-20 for initial finger spreading

4C-5892

—

One-piece Collet

-24 for initial finger spreading

4C-5893

—

One-piece Collet

-32 for initial finger spreading

ToolList-08

One-Piece Collet

Beveled Horseshoe Collet 4C-6187

—

Beveled Horseshoe Collet

4C-6188

—

Beveled Horseshoe Collet

8T-3158

—

Beveled Horseshoe Collet

Bent Stem Couplings with short neck

ToolList-09

Beveled Horseshoe Collet

8

215-9673 Accessories Group (cont’d) Check Box

Part Number

Identification Color

Description

Used On

Stem Expanders 170-5688

—

Stem Expander

-6 XT-3 ES

170-5687

—

Stem Expander

-8 XT-3 ES

170-5690

—

Stem Expander

-12 XT-3 ES and -12 XT-5

170-5689

—

Stem Expander

-16 XT-3 ES and -16 XT-5

5P-5234

—

Stem Expander

-20 XT-3 ES, -20 XT-5, and -20 XT-6

5P-5235

—

Stem Expander

-24 XT-3 ES and -24 XT-5

5P-5236

—

Stem Expander

-32 XT-3 ES

ToolList-05

Stem Expander

Stem Pushers 5S-2808

—

Stem Pusher

-6 all hose types, (sleeve removal)

5S-2814

—

Stem Pusher

-8 all hose types, (sleeve removal)

5S-2826

—

Stem Pusher

-12 all hose types, (sleeve removal)

5S-2834

—

Stem Pusher

-16 all hose types, (sleeve removal)

5S-2840

—

Stem Pusher

-20 all hose types, (sleeve removal)

5S-2846

—

Stem Pusher

-24 all hose types, (sleeve removal)

5S-2852

—

Stem Pusher

-32 all hose types, (sleeve removal)

ToolList-06

Stem Pusher

Pusher Plates 6V-4912

—

Pusher Plate

Solid One-piece (used with stem pusher, pusher assembly, and finger expander)

6V-4913

—

Pusher Plate

Slotted One-piece (used with stem expander)

ToolList-10

Solid and Slotted Pusher Plate

9

215-9673 Accessories Group (cont’d) Check Box

Part Number

Identification Color

Description

Used On

Mandrel and Pusher Assemblies 6V-4961

—

Mandrel

6V-4962

—

Pusher As.

6V-4963

—

Mandrel

6V-4964

—

Pusher As.

8T-3058

—

Mandrel

8T-3059

—

Pusher As.

8T-3060

—

Mandrel

8T-3061

—

Pusher As.

136-3603

—

Mandrel

136-3604

—

Pusher As.

-12 all hose types (for removing coupling from the hose)

-16 all hose types, for removing coupling rom the hose

-20 all hose types, for removing coupling from the hose

ToolList-11

Mandrel and Stem Pusher -24 all hose types, for removing coupling from the hose

-32 all hose types, for removing coupling from the hose

Finger Expanders Finger Expanders are used for all hose types except for note below.

5S-2805 Green -6 Finger Used to reform coupling fingers Expander 5S-2811

Red

-8 Finger Expander

5S-2823

Blue

-12 Finger Expander

5P-0973

Silver

-16 Finger Expander

5S-2837

Yellow

-20 Finger Expander

5S-2843

Orange

-24 Finger Expander

5S-2849

White

-32 Finger Expander

ToolList-12

Finger Expander

Note: The correct finger expander for XT-6 (-24) can be found in 188-2157 Accessory Group

Protractor and Skiving Tools 7S-1125

—

Protractor Group

Used to set the angle of orientation on all hose types up to -36

266-7533

—

Protractor Group

Used to set the angle of orientation on -40 to -56 hose

7S-1126

—

Skiving Tool

Skives DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES Hose

ToolList-21

Protractor Groups Skiving Group

10

Tooling Required For XT-6 ES -12 and -16 Non-Integral Hex Reusable Couplings1 Check Box

Part Identification Number Color

Description

Used On

Collets 6V-48932

—

Collet Top

6V-48942

—

Collet Bottom

6V-49172

—

Collet Top

6V-49182

—

Collet Bottom

6V-49222

—

Collet Top

6V-49232

—

Collet Bottom

6V-48912

—

Collet Top

6V-48922

—

Collet Bottom

-12 XT-6 ES Sleeve

-12 XT-6 ES Stem ToolList-01

Typical Stem Collet -16 XT-6 ES Sleeve

-16 XT-6 ES Stem

Stem Expander 197-53913

—

Stem Expander

-12 XT-6 ES

197-53963

—

Stem Expander

-16 XT-6 ES

Stem Pusher 197-53923

—

Stem Pusher

-12 XT-6 ES

197-53943

—

Stem Pusher

-16 XT-6 ES

ToolList-02

Typical Sleeve Collet

Pusher Assembly 197-53933

—

Pusher Assembly -12 XT-6 ES (Used with 6V-49614 Mandrel)

197-53953

—

Pusher Assembly -16 XT-6 ES (Used with 6V-49634 Mandrel)

1 Refer to IRM HOS04-01 for complete information.

2 Part of 171-2528 Tool Group.

3 Order individually.

4 Part of 215-9673 Accessories Group.

188-2157 XT-6 ES -24 Accessory Group Check Box

Part Identification Number Color

ToolList-05

Description

Used On

Stem Expander

Collets 188-1590

—

Collet Top

188-1591

—

Collet Bottom

188-1592

—

Collet Top

188-1593

—

Collet Bottom

-24 XT-6 ES Sleeve

-24 XT-6 ES Stem

Stem Expander 188-1594

—

Stem Expander

-24 XT-6 ES

Finger Expander 188-1595

—

Finger Expander -24 XT-6 ES (used to reform coupling fingers)

11

TOOLLIST-37

Stem Pusher

265-5818 XT-6 ES -32 Accessory Group Check Box

Part Identification Number Color

Description

Used On

Collets 265-5809

—

Top Collet

265-5810

—

Bottom Collet

265-5811

—

Top Collet

265-5812

—

Bottom Collet

-32 XT-6 ES Sleeve

-32 XT-6 ES Stem

Stem Pusher 265-5813

—

Stem Pusher

-32 XT-6 ES Sleeve

265-5815

—

Stem Pusher

-32 XT-6 ES Stem1

265-5814

—

Pusher Plate

-32 XT-6 ES

Stem Expander 265-5817

—

Stem Expander

-32 XT-6 ES TOOLLIST-35

Finger Expander 265-5816

—

Finger Expander -32 XT-6 ES (used to reform coupling fingers)

Typical Sleeve Collet

1Used with 136-3603 Mandrel

TOOLLIST-36

Typical Stem Collet

TOOLLIST-37

Stem Pusher

TOOLLIST-39

Stem Pusher

TOOLLIST-40

Finger Expander 12

TOOLLIST-38

Pusher Plate

TOOLLIST-41

Stem Expander

226-7150 Hose Gauge Kit Check Box

Check Box

Part Number

Hose Size Identification Color

Description

226-7141

Yellow

Skive Guide

-6 DIN, XT-3 ES

226-7142

Blue

Skive Guide

-8 DIN, XT-3 ES, and XT-6 ES

226-7143

Orange

Skive Guide

-10 DIN, XT-3 ES, and XT-6 ES

226-7144

Green

Skive Guide

-12 DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES

Used On

226-7145

Black

Skive Guide

-16 DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES

226-7146

White

Skive Guide

-20 DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES

226-7147

Red

Skive Guide

-24 DIN, XT-3 ES, XT-5, and XT-6 ES

226-7148

Green

Skive Guide

-32 DIN, XT-3 ES, XT-5, and XT-6 ES

226-7149

—

Depth Gauge

—

NEEG2950

—

Skive Length Chart

—

Hose Size Part Identification Number Color 209-3320

Yellow

Blue

Description

0.762 ± 0.025 mm

Arbor Group

0.762 ± 0.025 mm

Orange

1.016 ± 0.025 mm

Arbor Group

Green

1.143 ± 0.025 mm

Arbor Group

Black

1.524 ± 0.025 mm

Arbor Group

White

2.032 ± 0.025 mm

Arbor Group

Red

2.540 ± 0.025 mm

Arbor Group

Green

3.175 ± 0.025 mm

Arbor Group

Part Number

Description

-16 DIN, XT-3 ES, XT-5,

-20 DIN, XT-3 ES, XT-5,

ToolList-16

Typical One-Piece Squareness Gauge and Skiving Arbor

-24 DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES

Arbor Group

(.1250 ± .0001 in)

Check Box

-12 DIN, XT-3 ES, XT-5,

XT-6, and XT-6 ES

(.1000 ± .0001 in) 202-3281

-10 DIN, XT-3 ES, XT-5,

XT-6, and XT-6 ES

(.0800 ± .0001 in) 202-3280

-8 DIN, XT-3 ES, XT-5,

XT-6, and XT-6 ES

(.0600 ± .0001 in) 202-3279

-6 DIN, XT-3 ES, XT-5,

XT-6, and XT-6 ES

(.0450 ± .0001 in) 202-3278

Depth Gauge

XT-6, and XT-6 ES

(.0400 ± .0001 in) 202-3277

Used On XT-6, and XT-6 ES

(.0300 ± .0001 in) 209-3324

Skive Guide

ToolList-32

Setscrew Dimension (.0300 ± .0001 in)

209-3322

ToolList-17

-32 DIN, XT-3 ES, XT-5, XT-6, and XT-6 ES

Remarks

202-8959

Hose Cut-Off Support Group

Angle iron guide (mounts to saw to ensure square cut)

202-6602

Hose Marking Pen

Gel pen (draws fine line for accurate marking of skive length)

13

ToolList-19

Hose Cutting Guide

Miscellaneous Tooling Required Accessories Check Box

Part Number 127-1909

Identification Color Description — Skive Vise

Used On Holds hose securely during skiving and squareness check.

127-1910

—

Block Group

Mount on skiving vise jaws to prevent hose scuffing.

1U-8760

—

Chain Wrench

Used to help remove couplings from hose.

136-5853

—

Banding Tool

163-8811

—

Band, 34.9 mm (1.37 in)

163-8812

—

Band, 50.8 mm (2.00 in)

163-8813

—

Band, 76.2 mm (3.00 in)

163-8814

—

Band, 101.6 mm (4.00 in)

ToolList-18

Skive Vise

131-3961 XT Hose Reclamation Collets Check Box

Part Number —

Identification Color Description — Reclamation Collets

127-9924

—

Collet Top

127-9926

—

Collet Bottom

127-9928

—

Collet Top

127-9929

—

Collet Bottom

127-9930

—

Collet Top

127-9931

—

Collet Bottom

127-9933

—

Collet Top

127-9934

—

Collet Bottom

127-9936

—

Collet Top

127-9937

—

Bottom Collet

8C-3996

—

Setscrew

Used On Used when removing coupling from the hose. Uses pointed set screws to grip hose.

-12

-16 ToolList-20

Reclamation Collet

-20

-24

-32

(three required per collet)

14

Hose Cutoff Saws and Hose Cleaner Check Box

Part Number 6V-60151

Description Hose Cutoff Saw

Used On 230V, 60Hz 3 phase

9U-73191

Hose Cutoff Saw

230V, 50Hz 1 phase

9U-73201

Hose Cutoff Saw

230V, 60Hz 1 phase

223-2105

Benchtop Hose Cutoff Saw

400V, 3 phase

6V-6017

Fume Exhauster

Use with 6V-6015

233-7191

Economy Hose Cleaner Group

Hose Cleaning Groups work

233-7192

Field Service Hose Cleaner Group

with an assortment of nozzles to

233-7193

Dealer Shop Hose Cleaner Group

shoot cleaning projectiles

265-4959

Large Diameter Hose Cleaner Group

through a hose.

ToolList-22

1 202-8959 Hose Cut-Off Support Group is part of the 226-7150 Hose Gauge Kit or

can be ordered separately.

15

Hose Cutoff Saw with Guide

All reusable couplings include these features.

Beveled Horseshoe Collets These collets are used on bent-stem or large-head hose couplings to eliminate clearance problems, where interference normally occurs.

The collet eliminates the blind area, to allow visual determination of when the coupling is fully assembled. They can be used for hose insertion and sleeve installation.

Illustration 1. Reusable Coupling Features.

(A) Multi-Land Finger Design. (B) One-Piece Stem.

(C) End Configuration. (D) Hardened Steel Sleeve.

(E) Multi-Land Stem Design. (F) Tapered Stem And Fingers.

Multi-land fingers (A) solidly grip a skived hose. They provide excellent coupling-to-hose retention and help to prevent coupling blow-off.

Illustration 1. Typical Beveled Horseshoe Collet.

A one-piece stem design (B) offers added strength, longer life, and increased reusability.

The extruded stem orients the steel grains, giving a more uniform strength and fatigue resistance. It eliminates the braze joint between the head and stem for leak-free performance and extended coupling assembly life.

Several end configurations (C) are available for the growing number of designs and applications using reusable couplings. These configurations include Code 61 and 62 Flange, JIC, O-Ring Face Seal (ORFS), NPTF, JIS, and BSPP.

Illustration 2. Beveled Horseshoe Collets Eliminate Interference On Bent-Stem And Large-Head Couplings.

All reusable coupling sleeves (D) are made from hardened steel to prevent bending and distortion, retaining their original size and shape. The slim, coIlet-type style does not have bolts or protrusions, making installation easy, even in cramped places.

XT Hose Coupling Features and Benefits Reusable XT-3 ES, XT-5, XT-6, and XT-6 ES Hose Couplings are an excellent alternative to permanent coupling hose assemblies. They can be used over and over again to reduce operating costs. Plus, the right coupling is always available when it is needed, unless it becomes damaged.

A multi-land stem design (E) creates a positive hose-to-coupling seal, keeping fluid inside the hose assembly, without damaging the inner liner.

A tapered finger and stem design (F) increases hose assembly life by reducing compressive force. It allows the hose to flex without failure at the rear of the coupling.

16

Hoses

Hose and Couplings

XT-3 ES (∆) Hydraulic Hose is made for working (usable) pressure between 17,225 and 27,560 kPa (2,500 and 4,000 psi), depending upon hose size.

ALWAYS match and install the hose, stem assembly, and sleeve according to the size and designated markings (∆, +, UHP, or ∞).

NEVER interchange XT-3 ( ∆), XT-5 (+), XT-6 (UHP), or XT-6 ES (∞) hose, stem assemblies, or sleeves.

Mismatched couplings and hoses can cause the coupling to blow off the hose when placed under pressure, separating with sudden, extreme force which can result in property damage, personal injury, or death.

Illustration 1. XT-3 ES Hose Marking.

Match the hose and couplings according to the appropriate markings: • XT-3 — (∆) triangular marking.

XT-5 (+) Hydraulic Hose is made for a maximum working pressure of 34,450 kPa (5,000 psi).

• XT-5 — (+) plus marking.

• XT-6 — (UHP) marking.

• XT-6 ES — (∞) infinity marking Always match the stem, sleeve, and hydraulic hose. XT-3, XT-5, XT-6 and, XT-6 ES hydraulic hose, sleeves, and couplings are very similar.

Use extreme caution to identify the components.

Never use any hose at a hydraulic pressure greater than what is recommended as its maximum working pressure.

Illustration 2. XT-5 Hose Marking.

XT-6 (UHP) Hydraulic Hose is made for a maximum working pressure of 41,340 kPa (6,000 psi).

Illustration 3. XT-6 Hose Marking.

17

XT-6 ES (∞) Hydraulic Hose is made for a maximum working pressure of 41,340 kPa (6,000 psi).

; ; ; ; ; ; ;;;;;;;

Illustration 5. Location Of Identification Mark On Flange Head Coupling And Sleeve.

Illustration 3. XT-6 ES Hose Marking.

XT Couplings

2

+

+

3

UHP

UHP

∞

1

∞

4

Illustration 6. Location Of Identification Mark On ORFS Coupling.

0746-30

Illustration 4. Coupling Identification By Location And Symbol. (1) XT-3 Marking. (2) XT-5 Marking. (3) XT-6 Marking (4) XT-6 ES Marking.

18

Bar Knob Clamping System

;;

Couplings with Brazed-On Nut These couplings must be installed so the face of the coupling is against the face of the collet.

If the nut is on the face of the collet, as shown in Illustration 8, the coupling will be damaged during crimping.

1

The 139-5439, 145-3381, and 152-3910 Hose Machines have (or will be converted to) a new bar knob clamping system. The bar knob clamping system prolongs the life of the clamp bolts and gives the operator greater control over the amount of clamping force.

2

;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;; ; ;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;; ;;;;;;;;;;; 3

0746-31

Illustration 7. Correctly Positioned Coupling.

(1) Coupling. (2) Collet. (3) Nut.

Illustration 3. Bar Knob Clamping System.

(1) Clamp. (2) Bar Knob. (3) Bar Tool Assembly.

(4) Spring Washers. (5) Clamp Plate Bolt. (6) Clamp Plate.

The bar knob clamping system includes a bar knob (2) with a stack of spring washers (4) between clamp plate bolts (5) and clamp plate (6). A bar tool assembly (3) provides greater control of the force applied to the tools installed in the machine.

Using the Bar Knob Clamping System There are two methods used to tighten the bar knob clamping system throughout this manual.

One method applies just enough force to position the tools in the machine. The other method applies sufficient force to grip the hose for assembly or disassembly of reusable couplings.

Illustration 8. Incorrectly Positioned Coupling.

Hand Tighten When specified in the procedure, hand tightening the bar knob allows the clamps to “give” without placing a high load on the clamp plate bolts.

Use this method to tighten the clamps enough to position the tooling without compressing the spring washers (very slight compression is allowable).

19

Bar Tighten

Chart A. Sleeve Removal Tooling

When specified in the procedure, the bar tool tightens the clamps to the force required for assembling or disassembling reusable couplings. Tighten the clamps only enough to deflect the center of the clamp plate 1.5 mm (.06 in) relative to the ends of the clamp plate to provide sufficient clamping force to disassemble reusable couplings, which meet the guidelines in SEBF8176. Use of the 1U-8750 Strap Wrench for disassembly is highly recommended.

XT-3 ES Hose Upper Pusher Collets Plate Part Part Numbers Number2

Stem Pusher Part Number2

-6 9.7 mm (.38 in)

6V-48861 6V-4887

6V-4912

5S-2808

-8 12.7 mm (.50 in)

9U-67431 9U-6744

6V-4912

5S-2814

-12 19.1 mm (.75 in)

6V-48911 6V-4892

6V-4912

5S-2826

-16 25.4 mm (1.00 in)

6V-48931 6V-4894

6V-4912

5S-2834

-20 31.8 mm (1.25 in)

6V-90691 6V-4912

5S-2840

Hose Size (I.D.)

NOTE: Do not over tighten. Tightening the clamps to deflect the center of the clamp plate 1.5 mm (.06 in) relative to the ends of the clamp plate is the maximum force allowed.

Hose Disassembly Procedure

6V-9070 6V-48974

-24 38.1 mm (1.50 in)

6V-4898

6V-4912

5S-2846

-32 50.8 mm (2.00 in)

6V-48991 6V-4901

6V-4912

5S-2852

XT-5 Hose

Coupling Recovery

-12 19.1 mm (.75 in)

6V-49193 6V-4921

6V-4912

5S-2826

Before cutting the hose to recover the coupling, make sure the assembled hose length and coupling orientation are measured and recorded. Refer to NEHS0768 for additional information.

-16 25.4 mm (1.00 in)

8T-08153 8T-0816

6V-4912

5S-2834

-20 31.8 mm (1.25 in)

4C-94333 4C-9474

6V-4912

5S-2840

-24 38.1 mm (1.50 in)

6V-49243 6V-4912

5S-2846

6V-4912

126-10233

6V-4912

5S-2826

1. Identify the type of hose, coupling, sleeve, total hose assembly length, and angle of orientation of the couplings. Record this information.

-32 50.8 mm (2.00 in)

6V-4925 6V-49263 6V-4927 XT-6 Hose

2. Select the proper sleeve removal tooling (Chart A, for Step 4), finger spread tooling (Chart B, for Step 5), and hose removal tooling (Chart C, for Step 6).

NEVER use broken tools.

Only use tools made for the hydraulic hose machine.

Failure to use proper tools, and specific directions for placing tooling in the hose machine, can result in improper clamping.

Personal injury can result from couplings being propelled by force, when not properly clamped.

-12 19.1 mm (.75 in)

6V-48931 6V-4894

-16 25.4 mm (1.00 in)

6V-49222 6V-4923

6V-4912

5S-2834

-20 31.8 mm (1.25 in)

4C-94333 4C-9474

6V-4912

5S-2840

-24 38.1 mm (1.50 in)

188-15904 188-1591

6V-4912

5S-2846

-32 50.8 mm (2.00 in)

265-58095 265-5810

XT-6 ES Hose

1 Part of 4C-9902.

2 Part of 171-2531.

3 Part of 171-2528.

4 Part of 188-2157.

5 Part of 265-5818.

20

265-58145 265-58135

Chart B. Coupling Finger Spread Tooling

Chart C. Coupling Removal Tooling

XT-3 ES Hose Upper Lower Collets Collet Part Part Numbers Number2

Stem Pusher Part Number2

Hose Size (I.D.)

Hose Mandrel

-6 9.7 mm (.38 in)

6V-49021 6V-4903

4C-5887

5S-2808

-6 9.7 mm (.38 in)

-8 12.7 mm (.50 in)

6V-49021 6V-4903

4C-5888

5S-2814

-8 12.7 mm (.50 in)

-12 19.1 mm (.75 in)

6V-48861 6V-4887

4C-5889

5S-2826

127-99242 6V-49611 6V-49621 127-9926 6V-4912

-16 25.4 mm (1.00 in)

9U-67431 9U-6744

-12 19.1 mm (.75 in)

4C-5890

5S-2834

-20 31.8 mm (1.25 in)

6V-48911 6V-4892

-16 25.4 mm (1.00 in)

127-99282 6V-49631 6V-49641 127-9929 6V-4912

4C-5891

5S-2840

-24 38.1 mm (1.50 in)

6V-48931

-20 31.8 mm (1.25 in)

8T-30581

127-99302 8T-30591 127-9931 6V-4912

6V-4894

-32 50.8 mm (2.00 in)

6V-60691 6V-6070

-24 38.1 mm (1.50 in)

8T-30601

127-99332 8T-30611 127-9934 6V-4912

Hose Size (I.D.)

4C-5892

XT-3 ES Hose

5S-2846

4C-5893

5S-2852

4C-5889

5S-2826

6V-49153 6V-4916

-16 25.4 mm (1.00 in)

6V-49173 6V-49185

4C-5890

-20 31.8 mm (1.25 in)

121-73213 121-73225

-24 38.1 mm (1.50 in) -32 50.8 mm (2.00 in)

—

1U-96731 5S-28081 1U-9674

6V-4912

—

1U-96731 5S-28141 1U-9674

6V-4912

XT-5 Hose

5S-2834

-12 19.1 mm (.75 in)

6V-49611

6V-49621

127-99242 127-9926 6V-4912

4C-5891

5S-2840

-16 25.4 mm (1.00 in)

6V-49631

6V-49641

127-99282 127-9929 6V-4912

8T-08153 8T-08165

4C-5892

5S-2846

-20 31.8 mm (1.25 in)

8T-30581

8T-30591

127-99302 127-9931 6V-4912

6V-49243 6V-4925

4C-5893

126-10233

-24 38.1 mm (1.50 in)

8T-30601

8T-30611

127-99332 127-9934 6V-4912

XT-6 Hose -12 19.1 mm (.75 in)

6V-49173 6V-49185

-16 25.4 mm (1.00 in)

6V-48911

4C-5889

5S-2826

6V-48925

4C-5890

5S-2834

-20 31.8 mm (1.25 in)

4C-94223 4C-94235

4C-5891

5S-2840

-24 38.1 mm (1.50 in)

188-15924 188-15935

-32 127-99362 1 1 50.8 mm (2.00 in) 136-3603 136-3604 127-9937 6V-4912 XT-6 Hose

4C-5892

5S-2846

XT-6 ES Hose -32 50.8 mm (2.00 in)

Lower Pusher Plates1

-32 127-99362 50.8 mm (2.00 in) 136-36031 136-36041 127-9937 6V-4912

XT-5 Hose -12 19.1 mm (.75 in)

Upper Collets

Stem Pusher

265-58116 265-5812

265-58146

265-58136

1 Part of 4C-9902.

-12 19.1 mm (.75 in)

127-99242 6V-49611 6V-49621 127-9926 6V-4912

-16 25.4 mm (1.00 in)

127-99282 6V-49631 6V-49641 127-9929 6V-4912

-20 31.8 mm (1.25 in)

8T-30581

127-99302 8T-30591 127-9931 6V-4912

-24 38.1 mm (1.50 in)

8T-30601

127-99332 8T-30611 127-9934 6V-4912

2 Part of 171-2531.

XT-6 ES Hose

3 Part of 171-2528.

-32 265-58093 50.8 mm (2.00 in) 136-36031 265-58153 265-5810 265-58143

4 Part of 188-2157.

5 The collet counterbore should be facing forward.

1 Part of 171-2531.

6 Part of 265-5818

2 Part of 131-3961.

3 Part of 265-5818

21

3. Remove the coupling by cutting the hose 75 mm (3.0 in) from the sleeve.

d. Lower the top platen until the sleeve is removed from the coupling.

Illustration 1. Cut Coupling From Hose.

(A) 75 mm (3.0 in).

Illustration 3. Remove Sleeve.

5. Use the selected finger spread tooling from Chart B to spread the fingers of the coupling.

4. Use the selected sleeve removal tooling from Chart A to remove the sleeve from the coupling.

Illustration 4. (1) Upper Stem Split-Collet. (2) Lower Collet. (3) Stem Pusher.

Illustration 2. (1) Upper Sleeve Split-Collet. (2) Pusher Plate. (3) Stem Pusher.

a. Place the stem collet on the bottom, the collet with through hole and counterbore on top (counterbore facing the hose), and the appropriate pusher in the hose (pusher goes in hose and through the hole in collet and acts as a guide).

a. Put the solid collet on the bottom, back half of sleeve collet on the top, and the correct pusher inside the hose. b. Place the coupling assembly in the top collet and install the front half of the collet. c. Hand tighten the upper and lower clamps.

22

b. Lower the platen and mushroom the hose slightly to spread the fingers of the coupling (approximately 10 degrees), just enough to insert a screwdriver.

6. Use the selected coupling removal tooling from Chart C to push the coupling off the hose.

Illustration 7. (1) Upper Reclamation Collet. (2) Lower Pusher Plate. (3) Hose Mandrel. (4) Pusher Assembly.

Illustration 5. Mushroom The Hose Into The Coupling.

NOTICE Use caution when expanding the fingers of the coupling. The fingers can break if spread out too far, making the coupling unusable. c. Remove the coupling and put it in a vise with soft copper jaws. Use a screwdriver or wedge bar to expand the fingers further, but not more than 30 degrees.

Illustration 8. Remove Coupling From Hose.

a. Install the selected mandrel and pusher assembly into the hose. b. Install the reclamation collet in the top platen and bar tighten the clamp. c. Install a solid collet on the lower platen and hand tighten the bar clamp. d. Clamp the hose with the stem fingers located approximately 19.1 mm (.75 in) above the surface of the collet.

Illustration 6. Spread The Coupling Fingers.

e. Slowly push the coupling out of the hose, using a jogging advancement. If the coupling does not come out of the hose easily, use a 1U-8760 Chain Wrench to twist the coupling while applying pressure.

23

Reconditioning the Coupling NOTICE

1. Select the proper finger expander and stem resizing tooling from Charts D and E.

To prevent damaging the coupling, only use the chain wrench on the solid web shoulder.

NEVER use it on the head or tube of the stem.

Illustration 10. (1) Upper Split-Collet. (2) Lower Pusher.

(3) Finger Expander.

Illustration 9. Use A 1U-8760 Chain Wrench For Hard-To-Remove Couplings.

Inspection Clean the coupling thoroughly and inspect it for any defects. The SEBF8176 Guideline For Reusable Parts and Salvage Operations should be used to determine if the coupling can be reused.

Reform Fingers and Resize Stem

Always resize the stem (lD) of used couplings and reform the fingers during the reconditioning process to make sure the stem of the coupling holds the hose correctly. Failure to resize the coupling can cause the coupling to blow off the hose when placed under pressure, separating with sudden, extreme force which can result in property damage, personal injury, or death.

24

. Use the selected finger expander and stem resizing tooling from Charts D and E to reform the coupling fingers.

Chart D. Coupling Finger Expanders XT-3 ES Hose Hose Size (I.D.)

Upper Collets

Finger Expander

Lower Pusher Plate

-6 9.7 mm (.38 in)

6V-49021 6V-4903

5S-2805

6V-4912

-8 12.7 mm (.50 in)

6V-49021 6V-4903

5S-2811

6V-4912

-12 19.1 mm (.75 in)

6V-48861 6V-4887

5S-2823

6V-4912

-16 25.4 mm (1.00 in)

9U-67431 9U-6744

5P-0973

6V-4912

-20 31.8 mm (1.25 in)

6V-48911 6V-4892

5S-2837

6V-4912

-24 38.1 mm (1.50 in)

6V-48931 6V-4894

5S-2843

6V-4912

-32 50.8 mm (2.00 in)

6V-90691 6V-9070

5S-2849

6V-4912

a. Place the finger expander into the fingers of the coupling. It may be necessary to finish spreading the stem fingers with the finger expander and the hose machine.

Illustration 11. Finger Expander.

XT-5 Hose -12 19.1 mm (.75 in)

6V-49152 6V-4916

5S-2823

6V-4912

-16 25.4 mm (1.00 in)

6V-49172 6V-4918

5P-0973

6V-4912

-20 31.8 mm (1.25 in)

122-73212 122-7322

5S-2837

6V-4912

-24 38.1 mm (1.50 in)

8T-08152 8T-0816

5S-2843

6V-4912

-32 50.8 mm (2.00 in)

6V-49242 6V-4925

5S-2849

6V-4912

-12 19.1 mm (.75 in)

6V-49172 6V-4918

5S-2823

6V-4912

-16 25.4 mm (1.00 in)

6V-48911 6V-4892

5P-0973

6V-4912

-20 31.8 mm (1.25 in)

4C-94223 4C-9423

5S-2837

6V-4912

-24 38.1 mm (1.50 in)

188-15924 188-1593

188-15954

6V-4912

b. Place couplings on a solid surface and use a hammer with plastic tips to reshape the fingers around the finger expander tool. This procedure allows the fingers to take the shape of the tool.

XT-6 Hose

Illustration 12. Reform Coupling Fingers.

XT-6 ES Hose -32 50.8 mm (2.00 in)

265-58115 265-5812

265-58165

265-58145

1 Part of 4C-9902.

2 Part of 171-2531.

3 Part of 171-2528.

4 Part of 188-2157.

5 Part of 265-5818

25

3. Lubricate the stem expander with 129-1939 Grease and install it into the coupling.

Chart E. Coupling Resizing Tooling XT-3 ES Hose Hose Size (I.D.)

Upper Collets

Stem Expander

Slotted Pusher Plate2

-6 9.7 mm (.38 in)

6V-49021 6V-4903

170-56882

6V-4913

-8 12.7 mm (.50 in)

6V-49021 6V-4903

170-56872

6V-4913

-12 19.1 mm (.75 in)

6V-48861 6V-4887

170-56902

6V-4913

-16 25.4 mm (1.00 in)

9U-67431 9U-6744

170-56892

6V-4913

-20 31.8 mm (1.25 in)

6V-48911 6V-4892

5P-52342

6V-4913

-24 38.1 mm (1.50 in)

6V-48931 6V-4894

5P-52352

6V-4913

-32 50.8 mm (2.00 in)

6V-90691 6V-9070

5P-52362

6V-4913

Illustration 13. Install Stem Expander.

NOTICE On dual purpose stem expanders (such as 5P-5232), do not permit the shoulder of the stem expander to push against the coupling, and do not push the stem expander to full depth when used on 19.7 mm (.75 in) 45 degree couplings.

The 170-5688 or 170-5690, which are direct replacements for 5P-5232, can be inserted all the way to the shoulder of the expander.

XT-5 Hose -12 19.1 mm (.75 in)

6V-49153 6V-4916

170-56902

6V-4913

-16 25.4 mm (1.00 in)

6V-49173 6V-4918

170-56892

6V-4913

-20 31.8 mm (1.25 in)

122-73213 122-7322

5P-52342

6V-4913

-24 38.1 mm (1.50 in)

8T-08153 8T-0816

5P-52352

6V-4913

-32 50.8 mm (2.00 in)

6V-49243 6V-4925

6V-49723

6V-4913

-12 19.1 mm (.75 in)

6V-49173 6V-4918

170-56833

6V-4913

-16 25.4 mm (1.00 in)

6V-48911 6V-4892

170-56843

6V-4913

20 31.8 mm (1.25 in)

4C-94223 4C-9423

5P-52342

6V-4913

-24 38.1 mm (1.50 in)

188-15924 188-1593

188-15944

6V-4913

XT-6 Hose

XT-6 ES Hose -32 50.8 mm (2.00 in)

265-58115 265-5812

0745-63

265-58175

6V-4913

Illustration 14. Make Sure End Of Stem Expander Does Not Contact Inside Of Coupling.

1 Part of 4C-9902.

2 Part of 171-2531.

3 Part of 171-2528.

4 Part of 188-2157.

5 Part of 265-5818

26

5. Slowly push the stem expander down into the stem of the coupling to the proper depth. The correct depth is marked on the stem expander with grooves.

∆

+

UHP

.75"

A B

A 0746-28

Illustration 15. Stop Locations Of Typical Expander Stems.

(A) Shoulder of stem expander. (+) XT-5 and (UHP) XT-6.

(B) Groove. (∆) XT-3.

Illustration 17. Push Expander Downward To Stop Location.

4. Install the coupling and stem expander with the correct stem collet in the lower platen and slotted pusher collet in the upper platen coupling/expander. Hand tighten both bar clamps. The head of the bolt on the stem resize tool should be above the top of the slotted pusher plate with the resize tool body below the slotted pusher plate.

6. Remove the stem expander assembly from the coupling: a. Place the coupling fingers into the counterbore of the lower stem collet, as shown in Illustration 17. b. Hand tighten the clamps. c. Reverse the direction of the machine to remove the resize tool from the stem.

Illustration 16. Install Upper And Lower Collets With Coupling/Expander.

Illustration 18. Place Coupling Under Lower Collet To Remove Expander Assembly.

NOTE: Never pull against stem or coupling head.

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Coupling Orientation

Hose Assembly Procedure

1. Assemble the first coupling (A) and sleeve onto one end of the hydraulic hose using the procedures in the “Coupling and Sleeve Installation” section, in this manual.

Never install couplings on used hose or apply oil between the coupling and hose. Coupling retention is lower on a hose with an oily residue on its surface, which could cause a sudden, explosive release of the coupling from the hose when under pressure, resulting in personal injury.

2. Slide the second sleeve onto the opposite end of the hydraulic hose.

NOTE: Make sure the sleeve’s ID chamfer faces towards the end of the hose.

NOTE: Push coupling (B) into the hydraulic hose just far enough to prevent the angle of orientation from changing.

Cleaning the Coupling

3. Set the angle of orientation for coupling (B).

Refer to NEHS0768, General Information for Hose Assembly, for additional information on setting the coupling angle of orientation.

Refer to NEHS0768 for hose and coupling cleaning procedures.

Cutting Hose

4. Make any final adjustments to the angle of orientation and press coupling (B) fully into the hydraulic hose.

Cut the hose to the length recorded earlier in the Coupling Recovery section. An “XT” hydraulic hose can be cut with an abrasive saw. Refer to NEHS0768 for additional information on cutting hoses with an abrasive saw.

5. Press the sleeve onto the coupling.

6. Clean the hose assembly from both ends with 233-7191, 233-7192, 233-7193, or 265-4959 Hose Cleaner Group and cap both ends. See form PECP5030 Hose and Coupling Reference Guide for a complete listing of available caps and plugs.

Coupling Installation 1. Select the proper coupling installation tooling from Chart F. 2. Use the selected grip collet on the upper platen and stem collet on the lower platen.

Bar tighten both clamps.

Illustration 1. 6V-6015 Abrasive Saw With 202-8959 Hose Cutting Guide.

Skiving and Cleaning the Hose Skive both ends of the cut hose. Refer to NEHS0768 for additional information on skiving and cleaning a hydraulic hose.

Illustration 1. (1) Lower Stem Collet. (2) Upper Grip Collet.

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3. Measure and mark the distance for the location of the front collet. This measurement should equal twice the length of the sleeve.

Chart F. Coupling Installation Tooling Hose Size (I.D.)

XT-3 ES Hose Upper Gripper Collets2

Lower Collets

-6 9.7 mm (.38 in)

1U-9673 1U-9674

6V-49021 6V-4903

-8 12.7 mm (.50 in)

1U-9673 1U-9674

9U-49021 9U-4903

-12 19.1 mm (.75 in)

131-4367 131-4368

6V-48861 6V-4887

-16 25.4 mm (1.00 in)

1U-9675 1U-9676

9U-67431 9U-6744

-20 31.8 mm (1.25 in)

1U-9675 1U-9676

6V-48911 6V-4892

-24 38.1 mm (1.50 in)

1U-9677 1U-9678

6V-48931 6V-4894

Illustration 2.

-32 50.8 mm (2.00 in)

1U-9679 1U-9680

6V-90691 6V-9070

4. Slide a sleeve onto the hydraulic hose far enough to be out of the way for installing the coupling.

XT-5 Hose 131-4367 131-4368

6V-49153 6V-4916

-16 25.4 mm (1.00 in)

1U-9675 1U-9676

6V-49173 6V-4918

-20 31.8 mm (1.25 in)

1U-9675 1U-9676

122-73213 122-7322

-24 38.1 mm (1.50 in)

1U-9677 1U-9678

8T-08153 8T-0816

-32 50.8 mm (2.00 in)

1U-9679 1U-9680

6V-49243 6V-4925

-12 19.1 mm (.75 in)

NOTE: Make sure the larger chamfer faces towards the end of the hose.

XT-6 Hose -12 19.1 mm (.75 in)

131-4367 131-4368

6V-49173 6V-4918

-16 25.4 mm (1.00 in)

1U-9675 1U-9676

6V-48911 6V-4892

-20 31.8 mm (1.25 in)

1U-9675 1U-9676

4C-94223 4C-9423

-24 38.1 mm (1.50 in)

1U-9677 1U-9678

188-15924 188-1593

Illustration 3.

5. Install the coupling onto the hose by hand as far as possible.

XT-6 ES Hose -32 50.8 mm (2.00 in)

1U-9679 1U-9680

265-58115 265-5812

1 Part of 4C-4902.

2 Part of 215-9673 3 Part of 171-2528.

4 Part of 188-2157.

5 Part of 265-5818.

Illustration 4.

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6. Protect the hose from the upper gripper collets with a paper towel and place the hose assembly into the hose machine.

NOTICE To prevent hose cover damage, stop applying downward pressure once the hose has seated against the stem shoulder.

NOTICE Wrap a paper towel around the hose to prevent the upper gripper collets from damaging the exterior covering of the hose.

8. Remove the hose from the press and use a hammer with plastic tips to form the fingers of the coupling against the hose.

Illustration 7. Form The Fingers Around The Hose.

Illustration 5. Install Grip And Stem Collets.

7. Press the hose onto the coupling until the hose end seats against the stem shoulder.

Illustration 6. Press Hose Onto Coupling.

NOTE: When pressing the stem into the hose, the length of the hose clamped inside the collets should equal twice the length of the sleeve.

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1. Select and install the sleeve installation tooling from Chart G, Sleeve Installation Tooling.

Sleeve Installation Chart G. Sleeve Installation Tooling XT-3 ES Hose Hose Size (I.D.)

Upper Sleeve Collet

Lower Stem Collet

-6 9.7 mm (.38 in)

6V-48861 6V-4887

6V-49021 6V-4903

-8 12.7 mm (.50 in)

9U-67431 9U-6744

6V-49021 6V-4903

-12 19.1 mm (.75 in)

6V-48911 6V-4892

6V-48861 6V-4887

-16 25.4 mm (1.00 in)

6V-48931 6V-4894

9U-67431 9U-6744

-20 31.8 mm (1.25 in)

6V-90691

6V-48911

6V-9070

6V-4892

-24 38.1 mm (1.50 in)

6V-48971 6V-4898

6V-48931 6V-4894

-32 50.8 mm (2.00 in)

6V-48991 6V-4901

6V-90691 6V-9070

Illustration 12. (1) Lower Stem Collet. (2) Upper Sleeve Collet.

2. Manually start the sleeve onto the stem fingers.

XT-5 Hose -12 19.1 mm (.75 in)

6V-49192 6V-4921

6V-49152 6V-4916

-16 25.4 mm (1.00 in)

8T-08152 8T-0816

6V-49172 6V-4918

-20 31.8 mm (1.25 in)

4C-94332 4C-9474

122-73212 122-7322

-24 38.1 mm (1.50 in)

6V-49242 6V-4925

8T-08152 8T-0816

-32 50.8 mm (2.00 in)

6V-49262 6V-4927

6V-49242 6V-4925

Illustration 14.

XT-6 Hose -12 19.1 mm (.75 in)

6V-48931 6V-4894

6V-49172 6V-4918

-16 25.4 mm (1.00 in)

6V-49222 6V-4923

6V-48911 6V-4892

-20 31.8 mm (1.25 in)

4C-94332 4C-9474

4C-9422 4C-9423

-24 38.1 mm (1.50 in)

188-15923 188-1593

188-15903 188-1591

NOTE: When the upper collet counterbore faces down, put the sleeve in the counterbore.

For additional head clearance on smaller, 90 degree couplings, put both the upper and lower collets in reverse position.

XT-6 ES Hose -32 50.8 mm (2.00 in)

265-58114 265-5812

265-58094 265-5810

1 Part of 4C-9902.

2 Part of 171-2528.

3 Part of 188-215.

4 Part of 265-5818.

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5. Repeat coupling and sleeve installation procedures for opposite end of hose assembly.

To avoid serious injury from flying objects, make sure the hose can slide through the upper collets.

6. After both couplings are installed, clean the hose assembly with 233-7191, 233-7192, 233-7193, or 265-4959 Hose Cleaner Group and cap both ends. See form PECP5030 “Hose and Coupling Reference Guide” for a complete listing of available caps and plugs. Refer to NEHS0768 “General Information for Hose Assembly” and NEHS0643 Using the 233-7191, 233-7192, 233-7193, or 265-4959 Hose Cleaner Groups for additional information on cleaning the hose assembly.

3. Press the sleeve onto the coupling. a. Install the selected sleeve collet in the upper platen and stem collet in the lower platen (Chart G). b. Hand tighten both clamps.

NOTE: When the upper collet counterbore faces down, put the sleeve in the counterbore.

For additional head clearance on smaller, 90 degree couplings, put both the upper and lower collets in reverse position. c. Press the sleeve all the way onto the coupling.

NOTICE To prevent hose cover damage, stop applying downward pressure once the hose has seated against the stem shoulder.

Illustration 10. Press Sleeve Onto Coupling.

4. If installing a coupling onto the other end of the hose, refer to the “Coupling Orientation” section in this manual.

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NOTES

33

NOTES

34

NOTES

35

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2184 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1475 CSTG_Hotline@cat.com

©2005 Caterpillar All Rights Reserved

NEHS0746-02 Printed in U.S.A.