Caterpillar Setup & Operation of the 146-5861 Crimputer Groups Tool Operating Manual - PDF DOWNLOAD

R

NEHS0754-02 March 2009

TOOL OPERATING MANUAL Setup and Operation of the 146-5861 Crimputer Groups 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

Crimputer Operation . . . . . . . . . . . . . . . . . . 20

Contents

Zero The Pickup (Probe) . . . . . . . . . . . . . . . 21

Literature Information

Crimping Procedure [CRIMP] . . . . . . . . . . . 21

Safety Section . . . . . . . . . . . . . . . . . . . . . . . . 4

Assemble Reusable Couplings [REUSBL] . 27

General Information Section . . . . . . . . . . . . . 4

Make Special Hose [UTIL] [1] . . . . . . . . . . 28

Operation Section . . . . . . . . . . . . . . . . . . . . . 4

New Database [UTIL] [2] (Load New Software) . . . . . . . . . . . . . . . . . . 28

Maintenance Section . . . . . . . . . . . . . . . . . . 4 Safety Section

Print Database [UTIL] [3] (DVDT Values) . . 29

Safety Icon Nomenclature . . . . . . . . . . . . . . . 4

Set Time and Date [UTIL] [4] . . . . . . . . . . . 30

Personal Protection/Important Information . . . 4 Prohibited Action . . . . . . . . . . . . . . . . . . . . . 5

Replace Die Group [UTIL] [5] (View DVDT Values) . . . . . . . . . . . . . . . . . . . 30

Hazard Avoidance . . . . . . . . . . . . . . . . . . . . 5

Calibrate Probe (Pickup) . . . . . . . . . . . . . . . 31

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 5

Probe Function Test . . . . . . . . . . . . . . . . . . . 32

Personal Protection . . . . . . . . . . . . . . . . . . . 5

Maintenance Section

Instructions and Regulations . . . . . . . . . . . . 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 33

Qualified Personnel . . . . . . . . . . . . . . . . . . . 6

Service Parts . . . . . . . . . . . . . . . . . . . . . . . . 34

Electrical Hazards . . . . . . . . . . . . . . . . . . . . 6

Replace Electronic Caliper Battery . . . . . . . 35

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6 General Information Section Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Crimputer Menu Selections . . . . . . . . . . . . . 7 References. . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 8 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation Section Crimputer Installation. . . . . . . . . . . . . . . . . . . 9 Operation Section Crimputer Screen Flowcharts . . . . . . . . . . . . 9 Main Menu Screen. . . . . . . . . . . . . . . . . . . 10 Crimping Procedure [CRIMP] . . . . . . . . . . 11 Assemble Reusable Couplings [REUSBL] 12 Make Special Hose [UTIL] [1] . . . . . . . . . . 13 New Database [UTIL] [2]. . . . . . . . . . . . . . 14 Print Database [UTIL] [3] (DVDT Values) . 15 Set Time and Date [UTIL] [4] . . . . . . . . . . 16 Replace Die Group [UTIL] [5] (View DVDT Values) . . . . . . . . . . . . . . . . . . 17 Calibrate Probe (Pickup) . . . . . . . . . . . . . . 18 Probe Function Test . . . . . . . . . . . . . . . . . . 19

3

Literature Information

Operation Section

This manual should be stored with the tool group.

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

This manual contains safety information, operation instructions, and maintenance information.

Crimputer Flow Charts provide screen-by-screen reference for the most common functions of the Crimputer.

Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and its capabilities.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Maintenance Section The Maintenance Section is a guide to troubleshooting and service parts.

Whenever a question arises regarding your service tool or this publication, please consult Dealer Service Tools (DST) for the latest available information.

Safety Section Safety Icon Nomenclature

Safety Section

Personal Protection/Important Information

The Safety Section lists basic safety precautions.

Read the manual

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

Eye protection Ear protection

General Information Section The General Information Section describes tooling functions and features. It provides useful information on individual parts, additional tooling, and resources.

Face protection Inspect equipment

Installation Section

AR N I

The Installation Section provides minimal instructions for the installation of the Crimputer.

Detailed installation instructions can be found in the specific Tool Operating Manual for the individual hose machine.

NG

Legible warning label Lock-out equipment

WARNIN

G

do not operate

Lock-out tag

signed by date

Two person operation Turn OFF power Use proper tools

4

Prohibited Action

Safety Warnings

No flammable liquid

Personal Protection

WARNING

No open flame

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.

No smoking

Hazard Avoidance Disconnect power Electrocution hazard Explosion hazard Fire hazard

To prevent possible damage to your hearing, always wear ear protection when working around noise generating tools.

Pressurized air Safety alert symbol

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.

Slipping hazard Tripping hazard

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.

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

5

Instructions and Regulations

Maintenance

Always keep these Operating Instructions near the hose crimping machine. Make sure all safety and danger notices are on the hose crimping machine and remain legible.

AR N I

NG

WARNING

do not operate signed by date

Follow all applicable regulations, including local safety and accident prevention and/or environmental protection regulations.

To prevent personal injury or death, always make sure the hose machine and Crimputer are completely disconnected from the power source for inspection, maintenance, or repair operations. Make sure the main power switch is tagged or locked to prevent someone from accidentally applying power to the hose machine/Crimputer.

Qualified Personnel If inspection, maintenance, and/or repair operations must be performed while the machine has power, then a second person is required to assist and, if necessary, turn OFF “O” the main power switch.

Only adequately trained and instructed personnel should be authorized to operate a hose machine with the Crimputer.

Use proper tools which are in good, working condition and replace or repair any damaged equipment.

Electrical Hazards

Always turn OFF “O” the main power switch before making repairs to any electrical connections.

Immediately replace or repair any parts that are not in perfect working order. Only use OEM replacement parts. Other parts manufacturers cannot guarantee their parts are designed and manufactured to meet OEM standards.

Inspect electrical components at regular intervals.

Have loose connections or damaged cables/wires repaired or replaced immediately.

To prevent personal injury, DO NOT modify the control system on the hose machine in any way or under any circumstances.

DO NOT spray flammable liquids near electrical components. Flammable liquids sprayed near electrical components may cause an explosion, resulting in personal injury or death.

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.

6

Printer Group

General Information Section

Optional 164-2691 Printer Group allows for printing of the crimp measurement data, as well as databases. The current software revision is 4.00. Contact Dealer Service Tools for more information on available software updates or call the Hotline.

Introduction The 145-7042 Crimputer Group has been cancelled and replaced by 146-5861 Crimputer Group.

Anyone operating the Crimputer should read and become familiar with this manual, as well as the operation of the hose machine.

Crimputer Setup The Crimputer program and database can be updated with the use of a personal computer via the COM1 RS-232 Port on the back of the Crimputer. A 1U-9484 Programming Cable is required.

The Crimputer is a microprocessor-based controller with memory containing a database with hose types, couplings, and sizes along with information to control the crimping operation of the hose machine. Crimping specifications and tolerances are also included for comparison to the actual measured values, which can be measured with 145-7044 Electronic Caliper at the completion of the crimping operation. The Crimputer will adjust the crimp diameter (DVDT) to compensate for die wear or other discrepancies.

The Crimputer probe (147-2641 Potentiometer) must be calibrated to the Crimputer. For more information, refer to the Calibrate Probe section in this manual.

Crimputer Menu Selections Using the Crimputer is intuitive. Screens appear in proper sequence, leading the operator through the selected function.

NOTE: “DVDT” stands for Delta Vertical Die Travel and is simply the distance from the bottom of the pusher plates to the top of the bowl in millimeters, at the completion of the crimp.

Menu selections are made by using the arrow keys to move the flashing brackets [---] that appear around menu items and then pushing the ENTER key or press the foot switch. Some screens (menus) allow the operator to return to a previous screen with the “UNDO” key. The “RESET” key is not functional at this time.

The 146-5861 Crimputer Group is compatible with the 139-5439 Combination Hose Machine and 145-5161 Floor Model Hose Machine.

The Crimputer is also compatible with the noncurrent 145-3381 and 152-3910 hose machines. For more information on compatibility, contact Dealer Service Tools (DST).

On screens which do not display the <ENTER> option, the ENTER key is pushed after a selection is made. When the <ENTER> option is shown, the screen pauses operation while the operator performs a task outlined on the screen.

Crimputer Connections The Crimputer has two connections with the hose machine. One of these is the pickup (probe) located on the rear of the pusher group used to measure hose machine pusher travel. The other is the solenoid operated dump valve located in the hydraulic circuit.

When the Crimputer applies 24 Volts DC to the dump valve, it opens and releases pressure.

With the dump valve solenoid energized, restrictions in the system allow enough pressure to move the pusher, but not allow pressure to build up.

NOTICE With the Crimputer turned ON, high-pressure can only be applied to lower the pusher when needed for calibrating, crimping permanent couplings, or assembling reusable couplings.

This prevents improper hose machine operation.

With the Crimputer turned OFF, manual operation allows high-pressure to be applied to the hose machine at any time. Over-crimping and damaged hose assemblies can result.

Optional Foot Switch The 145-7043 Foot Switch Assembly has the same function as the ENTER key. It can be used in place of the ENTER key at any time.

7

References

Nomenclature References

Form No.

Description

NEEG2737

Die and Spacer Ring Selection Chart

NEEG2746

Crimp Diameter Chart

NENG5500

Hydraulics; Tools and Accessories

NENG7001

Hydraulic Hose Assembly Tools

NEHS0686

Setup and Basic Operation of the 139-5439 Combination Hose Machine (installation instructions included)

NEHS0695

145-5161 Floor Model Hose Machine (installation instructions included)

NEHS0743

Setup and Basic Operation of the 145-3381 Combination Hose Machine

NEHS0746

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

NEHS0768

General Information for Hose Assembly

PECP5030

Hose and Coupling Reference Guide

PEHP6033

Reusable Couplings for XT Hose

SEBF8176

Reusable Couplings for Caterpillar XT-3, XT5, and XT6 Hose

Crimputer Control Panel.

(1) LCD Display Screen. (2) Keypad. (3) ENTER Key. (4) Reset Key (Non-functional). (5) ON/OFF Power Switch. (6) UNDO Key. (7) Directional Arrow Keys.

Specifications Specifications Description

Specification

Voltage

100 to 230 VAC (50 to 60 Hz)

Amps

0.75 to 1.5

Enclosure

NEMA 12

Dimensions

203 x 292 mm (8.0 x 11.5 in)

Weight

4.5 kg (10 lb)

Software

Rev 4.00

Rear Panel.

(8) Power Cable Connector. (9) Solenoid Cable Connector. (10) Electronic Caliper Cable Connector.

(11) Probe Cable Connector. (12) RS232 9-Pin Serial Port for Printer or Computer (Software Download).

(13) Foot Switch Connector.

Hose Machine Relief Pressures Part No.

Description

Specification

139-5439

Combination Hose Machine

20,684 kPa (3000 psi)

145-3381

Combination Hose Machine

20,684 kPa (3000 psi)

145-5161

Floor Model Hose Machine

68,948 kPa (10,000 psi)

152-3910

Lightweight Combination Hose Machine

34,474 kPa (5000 psi)

8

Installation Section

Operation Section

Crimputer Installation

Crimputer Screen Flowcharts

1. If necessary, securely mount the Crimputer to the applicable hose machine and install cables (connections), as required.

For reference, flowchart Illustrations 1 through 10 in this manual, show the sequence of screens and how they are accessed for the most commonly used functions on the Crimputer. For example, flowchart Illustration 2 shows screens associated with a typical crimping procedure, and flowchart Illustration 9 shows screens associated only with the Probe Calibration process.

2. Connect the cables, as shown in photo below.

NOTE: For more information on Crimputer installation, refer to the specific tool operating manual for the applicable hose machine.

Refer to the flowchart illustrations for complete information on each Crimputer function.

(8) Power Cable Connection. (9) Solenoid Cable Connection. (10) Electronic Caliper Cable Connection.

(11) Probe Cable Connection. (12) RS232 9-Pin Serial Port for Printer or Computer. (13) Foot Switch Connection. (14) Probe (Mounted on Hose Machine).

Illustration 1

Main Menu Screen

Illustration 2

Crimping Procedure [CRIMP]

Illustration 3

Assemble Reusable Couplings [REUSBL]

Illustration 4

Make Special Hose [UTIL] [1]

Illustration 5

New Database [UTIL] [2]

Illustration 6

Print Database [UTIL] [3] (DVDT Values)

Illustration 7

Set Time and Date [UTIL] [4]

Illustration 8

Replace Die Group [UTIL] [5] (View DVDT Values)

Illustration 9

Calibrate Probe (Pickup)

Illustration 10 Probe Function Test NOTE: For reference, the various Crimputer screens shown in this manual are identified using upper case letters (A, B, C, etc.) in the lower right-hand corner of the illustration box.

These letters do not appear on the actual Crimputer display.

LUBRICATE DIES KEEP HANDS CLEAR [CRIMP] REUSBL UTIL <ENTER>

A 0754-23

9

Main Menu Screen

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL <ENTER>

UTIL A

THE CRIMP MENU SELECTION PROMPTS THE OPERATOR THROUGH THE PROCESS OF MAKING A HYDRAULIC HOSE USING PERMANENT COUPLINGS, UTILIZING THE PROBE TO PRECISELY CONTROL THE VERTICAL TRAVEL OF THE PUSHER ASSEMBLY THEREBY, CONTROLLING THE CRIMP DIAMETER OF THE COUPLING. REFER TO ILLUSTRATION 2.

THE RESUBL MENU SELECTION IS A MANUAL MODE. HYDRAULIC PRESSURE IS ALWAYS AVAILABLE TO THE PUSHER ASSEMBLY AND THE OPERATOR HAS SOLE CONTROL OF THE MACHINE. THE CRIMPUTER IS BASICALLY DISABLED. THIS MODE IS USED ONLY ON COMBINATION TYPE HOSE MACHINES, (139-5439, 145-3381, AND 152-3910) CAPABLE OF PROCESSING REUSEABLE TYPE COUPLINGS. REFER TO ILLUSTRATION 3.

THE UTIL MENU SELECTION CONTAINS FIVE DIFFERENT FUNCTIONS. UPON ENTERING THE UTIL MENU, SCREEN 'X' CONTAINING FUNCTIONS 1-3 APPEARS. PRESSING THE DOWN ARROW KEY WILL STEP THROUGH THESE AND ONTO SCREEN 'XX' WHICH CONTAINS FUNCTIONS 4-5.

FUNCTIONS AND THEIR USE ARE: 1. MAKE SPECIAL HOSE: THIS SELECTON ALLOWS OPERATOR TO MAKE A CRIMP INPUTTING THE CRIMP SPECIFICATIONS. REFER TO ILLUSTRATION 4.

2. NEW DATA BASE: THIS SELECTION IS USED TO LOAD NEW SOFTWARE INTO CRIMPUTER. REFER TO ILLUSTRATION 5.

3. PRINT DATABASE: PRINTS A COMPLETE DATABASE OF ALL DVDT VALUES FOR ALL HOSE TYPES AND SIZES STORED IN THE CRIMPUTER. 164-2691 PRINTER GROUP REQUIRED. REFER TO ILLUSTRATION 6.

4. SET TIME AND DATE: SETS THE TIME AND DATE IN THE CRIMPUTER. REFER TO ILLUSTRATION 7.

5. REPLACE DIE GROUP: PERMITS THE OPERATOR TO VIEW THE ORIGINAL AND ADJUSTED DVDT VALUES FOR EACH HOSE AND RESTORE THE ORIGINAL VALUE, IF DESIRED. REFER TO ILLUSTRATION 8.

0754-01

Illustration 1.

10

Crimping Procedure [CRIMP] Note A: Options 2 and 3 are not recommended.

CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

PO

LUBRICATE DIES KEEP HANDS CLEAR [CRIMP] REUSBL UTIL <ENTER>

SELECT HOSE TYPE 294TG 294HT 294 716TG 294CP 716 844HT [XT3ES] 844

SELECT HOSE TYPE XT3ESTG XT5ES XT6 XT5ESTG XT6ES 1028 XT6ESTG 1956

SELECT HOSE TYPE 2760 2786 1543 2929TG 4123 2929 2771A 743

A

B

C

-6 -16

INVALID DASH TYPE FOR SELECTED HOSE TYPE. <ENTER>

INSTALL SMALL BOWL AND RELATED PARTS WHEN READY PRESS <ENTER>

SET PICKUP ZERO LOWER PUSHER--AT 1/2 RELIEF PRESSURE PRESS <ENTER>

INSTALL 130-5382 DIE GROUP WHEN READY PRESS <ENTER>

SEAT COUPLING FIRMLY WHILE LOWERING -APPLY PRESSURE WHEN READY

CRIMP COMPLETE RAISE PUSHER WHILE REMOVING HOSE <ENTER>

D

E

Note D: Select YES to automatically adjust the crimp diameter to bring the next crimp closer to the required specification.

XX.XXmm

Note E: If this message appears, manually recheck the crimp diameter.

Something is very wrong with the crimp diameter, such as wrong die set, calipers not zeroed, machine malfunction, mismatched hose to coupling size. If the hose machine is malfunctioning, call the Dealer Service Tools Hotline.

M

XX.XXmm

PRESS FOOT SWITCH

N

XX.XXmm

PRESS FOOT SWITCH

READING # 4

Note C: Brackets will appear around the OK or NOT OK entries on the LCD screen.

If the crimp diameter is out of tolerance, the brackets will be around the NOT OK entry. This hose coupling must be discarded/not used.

L

PRESS FOOT SWITCH

READING # 3

SELECT COUPLING TYPE [TR] ESA S4G

SELECT DASH NO. -3 -4 -5 [-8] -10 -12 -20 -24 -32

CALIPER MEASUREMENT: ZERO CALIPER AND MARK COUPLING FIRST <ENTER>

READING # 2

B

K

NOTE A

READING # 1

B

Note B: If measurements do not appear acceptable, select NO and re-measure crimp.

MEASURE CRIMP [1] CALIPER 2 KEY IN READINGS 3 SKIP MEASUREMENT

O

XX.XXmm

PRESS FOOT SWITCH

P

MEASUREMENTS XX.XXmm XX.XXmm XX.XXmm XX.XXmm ACCEPT [YES] [NO] NOTE B

REQUIRED 25.15mm PLUS/MINUS 0.25mm ACTUAL XX.XXmm [OK] [NOT OK]

NOTE C

Q

R

DIAMETER IS MORE THAN 1.5 TIMES TOL. OUT. CHECK DIES <ENTER> NOTE E

U

ADJUST CRIMP DIA.?

[YES] [NO] F

G

CYCLE COMPLETE NOTE D PRINT CRIMP DATA NUMBER OF COPIES ?

[0] 1 2 3 <ENTER>

S

AX

CRIMP SAME SIZE AND TYPE HOSE [YES] [NO] H

I

T SEAT COUPLING FIRMLY WHILE LOWERING -APPLY PRESSURE WHEN READY

I

J

0754-07

Illustration 2.

11

Assemble Reusable Couplings [REUSBL]

CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

LUBRICATE DIES KEEP HANDS CLEAR CRIMP [REUSBL] UTIL <ENTER>

PO

A

REUSABLE HOSE MODE <ENTER> TO RETURN TO MAIN MENU.

W

THE RESUBL MENU SELECTION IS A MANUAL MODE. HYDRAULIC PRESSURE IS ALWAYS AVAILABLE TO THE PUSHER ASSEMBLY AND THE OPERATOR HAS SOLE CONTROL OF THE MACHINE. THE CRIMPUTER IS BASICALLY DISABLED. THIS MODE IS USED ONLY ON COMBINATION TYPE HOSE MACHINES (139-5439, 145-3381, AND 152-3910) CAPABLE OF PROCESSING REUSEABLE TYPE COUPLINGS.

0754-08

Illustration 3.

12

Make Special Hose [UTIL] [1] CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

PO

CALIPER MEASUREMENT: ZERO CALIPER AND MARK COUPLING FIRST <ENTER>

READING # 1

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

A

UTILITIES [1] MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

XX

INPUT CRIMP DIAMETER _ _ _ _ _ mm AK

INPUT TOLERANCE FOR CRIMP DIAMETER _ _ _ mm <ENTER>

AL

INPUT DVDT _ _ _ _ mm

<ENTER>

AM

INSTALL SMALL BOWL AND RELATED PARTS WHEN READY PRESS <ENTER>

XX.XXmm

N

XX.XXmm

PRESS FOOT SWITCH

READING # 4

<ENTER>

M

PRESS FOOT SWITCH

READING # 3

UTILITIES 4 SET TIME AND DATE 5 REPLACE DIE GROUP <ENTER>

XX.XXmm

PRESS FOOT SWITCH

READING # 2

X

L

O

XX.XXmm

PRESS FOOT SWITCH

P

MEASUREMENTS XX.XXmm XX.XXmm XX.XXmm XX.XXmm ACCEPT [YES] [NO] NOTE B

REQUIRED 25.15mm PLUS/MINUS 0.25mm ACTUAL XX.XXmm [OK] [NOT OK]

NOTE C

O

P

DIAMETER IS MORE THAN 1.5 TIMES TOL. OUT. CHECK DIES <ENTER>

U

CALCULATE NEW DVDT [YES] [NO] F

SET PICKUP ZERO LOWER PUSHER--AT 1/2 RELIEF PRESSURE PRESS <ENTER>

G

USE APPROPRIATE DIE GROUP. AN POSITION COUPLING WHILE LOWERING -APPLY PRESSURE WHEN READY

<ENTER>

DVDT INPUT X.XXmm NEW DVDT X.XXmm RECORD NEW DVDT FOR NEXT USE <ENTER>

PRINT CRIMP DATA NUMBER OF COPIES ?

[0] 1 2 3 <ENTER>

AZ

AJ

AX

CRIMP SAME SIZE AND TYPE HOSE [YES] [NO] AY

CRIMP COMPLETE RAISE PUSHER WHILE REMOVING HOSE <ENTER>

J

MEASURE CRIMP [1] CALIPER 2 KEY IN READINGS 3 SKIP MEASUREMENT NOTE A

K

Note A: Options 2 and 3 are not recommended.

Note B: If measurements do not appear acceptable, select NO and re-measure crimp.

Note C: Brackets will appear around the OK or NOT OK entries on the LCD screen.

If the crimp diameter is out of tolerance, the brackets will be around the NOT OK entry. This hose coupling must be discarded/not used.

R CRIMP DIA XX.XXmm TOLERANCE X.XXmm DVDT X.XXmm <ENTER>

POSITION COUPLING WHILE LOWERING -APPLY PRESSURE WHEN READY

BA

AY

0754-09

Illustration 4.

13

New Database [UTIL] [2] Requires PC with RS232 Port, 1U-9484 Programming Cable, and most up-to-date version of software media.

CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

UTILITIES 1 MAKE SPECIAL HOSE [2] NEW DATA BASE 3 PRINT <ENTER>

UTILITIES 4 SET TIME AND DATE 5 REPLACE DIE GROUP <ENTER>

CRIMPUTER IS READY FOR NEW DATA BASE. PRESS ENTER ON THE PC.

PO

A

X

XX

Follow instructions on PC screen Y

LOADING COMPLETE

<ENTER>

Z

CLEARING ADJUSTED DATA AT DATA IS CLEAR

AU CAT CRIMPUTER CAT HOSE MACHINE REV 4.00

S/N00002

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

PO

A

0754-10

Illustration 5.

14

Print Database [UTIL] [3] (DVDT Values) CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE [3] PRINT <ENTER>

UTILITIES 4 SET TIME AND DATE 5 REPLACE DIE GROUP <ENTER>

PRINT: [ORIGINAL DATABASE] ADJUSTED DATABASE HISTORY <ENTER> NOTE A

Note A: "History" not used at this time.

PO

A

X

XX

AA

PRINTING ADJUSTED DATABASE PLEASE WAIT...................

BX PRINTING ORIGINAL DATABASE PLEASE WAIT...................

BB

0754-11

Illustration 6.

15

Set Time and Date [UTIL] [4] CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

UTILITIES [4] SET TIME AND DATE 5 REPLACE DIE GROUP <ENTER>

SET TIME AND DATE. TIME IS 14:35:31 DATE IS 1/11/08 MONDAY <ENTER>

Note A: To return to the Main Menu, press UNDO on the keypad.

PO

A

X

XX

AC

SET TIME AND DATE. ENTER THE YEAR THE YEAR IS 2008 DATE IS 1/11/08 <ENTER>

AD

SET TIME AND DATE. ENTER THE MONTH THE MONTH IS 1 DATE IS 1/11/08 <ENTER>

AE NOTE: Use the keypad to enter the appropriate numbers.

SET TIME AND DATE. ENTER THE DAY THE DAY IS 11 DATE IS 1/11/08 <ENTER>

AF

SET TIME AND DATE. ENTER THE HOUR THE HOUR IS 14 TIME IS 14:35:31 <ENTER>

AG

SET TIME AND DATE ENTER THE MINUTE THE MINUTE IS 35 TIME IS 14:35:31 <ENTER>

AH

SUN = 1 MON = 2 TUE = 3 WED = 4

THUR = 5 FRI = 6 SAT = 7 <ENTER>

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

AI

X

UNDO LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

NOTE A

A

0754-12

Illustration 7.

16

Replace Die Group [UTIL] [5] (View DVDT Values) CAT CRIMPUTER CAT HOSE MACHINE REV. 4.00 S/N 00002

PO

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

UTILITIES 4 SET TIME AND DATE [5] REPLACE DIE GROUP <ENTER>

SELECT HOSE TYPE 294TG 294HT [294] 716TG 294CP 716 844HT XT3ES 844

SELECT HOSE TYPE XT3ESTG XT5ES XT6 XT5ESTG XT6ES 1028 XT6ESTG 1956

SELECT HOSE TYPE 2760 2786 1543 2929TG 4123 2929 2771A 743

USE THE FOLLOWING COUPLING TYPE MN <ENTER>

SELECT DASH NO. -3 -4 -5 [-8] -10 -12 -20 -24 -32

A

X

XX

B

B

B

BC

-6 -16

INVALID DASH TYPE FOR SELECTED HOSE TYPE. <ENTER>

ORIGINAL DVDT X.XX ADJUSTED DVDT X.XX RESTORE ORIGINAL DVDT NUMBER [YES] NO

D

E

BD

ORIGINAL VALUE RESTORED BE UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

X

0754-13

Illustration 8.

17

Calibrate Probe (Pickup) CAL. PICKUP AT 0.0" LOWER PUSHER--AT 1/2 RELIEF PRESSURE <ENTER> CAL # XXXXX NOTE A RAISE THE PUSHER AND INSTALL .75" PLATE FOR CALIBRATION <ENTER>

Note A: With Crimputer OFF, press and hold "4" key while turning Crimputer ON. Continue to hold "4" key until CALIBRATION screen "AO" appears.

AO

Note B: A valid calibration number is between 22000 and 27000.

AP

CAL. PICKUP AT 0.75" LOWER PUSHER--AT 1/2 RELIEF PRESSURE <ENTER>

AQ

CALIBRATION COMPLETE RAISE PUSHER AND REMOVE CALIBRATION PLATE <ENTER>

AR

NEW CALIBRATION NUMBER XXXXX <ENTER> NOTE B

AS

CAT CRIMPUTER CAT HOSE MACHINE REV 4.00

S/N00002

PO

0754-14

Illustration 9.

18

Probe Function Test

AV

Note A: With Crimputer OFF press, and hold number "3" key while turning Crimputer ON. Continue to hold number "3" key until ADC & PROBE TEST screen appears. This ADC number should be within a range of 63000 to 66000 when the plunger is extended.

AW

Note B: Push plunger in and out while watching screen. Values should change as plunger moves. This ADC number should be below 00300. As the plunger is retracted the value of this number should decrease as shown (00009).

ADC & PROBE TEST Adc = 64556 Adc = 27.623mm

With 147-2641 Potentiometer OUT (released)

23370 NOTE A, C

ADC & PROBE TEST Adc = 00009 Adc = 00.03mm

With 147-2641 Potentiometer IN (depressed)

23370 NOTE B, C

Note C: The number 23370 is an example of a valid calibration number which should be between 22000 and 27000.

0754-15

Illustration 10.

19

When the Crimputer ON/OFF switch is turned ON, the Power-On “PO” screen displays.

Crimputer Operation The Crimputer is designed to be user-friendly.

It prompts the operator through various procedures by displaying a different screen each step of the way. There are two basic types of screen displays:

CAT CRIMPUTER CAT HOSE MACHINE

NOTE: For reference, the various Crimputer screens shown in this manual are identified using upper case letters (A, B, C, etc.) in the lower right-hand corner of the illustration box.

These letters do not appear on the actual Crimputer display.

REV. 4.00 S/N 00002

0754-22

NOTE: The Crimputer can be powered OFF and then ON again, at any time, without damaging the Crimputer.

• Selection Screen - This screen display

prompts the operator to make a selection, such as hose type, dash number, print crimp data, etc. The item within the brackets will be selected when the ENTER key is pressed.

SELECT DASH NO. -3 -4 -5 [-8] -10 -12 -20 -24 -32

Approximately five seconds after the power-on screen appears, the Main Menu screen “A” displays. Operation of the Crimputer is always going to start from this screen. Refer to Main Menu screen flowchart Illustration 1 for a description of the three menu choices.

-6 -16 D

LUBRICATE DIES KEEP HANDS CLEAR [CRIMP] REUSBL UTIL <ENTER>

0754-26

• Information Screen - This screen display

instructs the operator what to do next, such as install bowl, zero caliper, set pickup zero, etc. Press ENTER key to move to the next screen.

INSTALL SMALL BOWL AND RELATED PARTS WHEN READY PRESS <ENTER>

PO

A 0754-23

F 0754-28

NOTE: Throughout this procedure, the command is given to press the ENTER key.

The foot pedal could also be pressed, if the hose machine is equipped with one.

20

Zero The Pickup (Probe)

Crimping Procedure [CRIMP]

NOTE: This is not the calibration procedure.

Refer to the Calibrate Probe (Pickup) section in this manual for calibration.

Flowchart Illustration 2 shows the typical sequence of screens that appear when crimping a hose with the electronic calipers attached to the Crimputer. The following information describes each screen shown in flowchart Illustration 2.

The pickup (probe) must be “zeroed” any time the power is turned OFF and ON or if the bowl size changes. The Crimputer automatically shows this screen when necessary.

SET PICKUP ZERO LOWER PUSHER--AT 1/2 RELIEF PRESSURE PRESS <ENTER>

Screen “PO” When the Crimputer ON/OFF switch is turned ON, the Power-On “PO” screen displays and will automatically change to screen “A” after approximately five seconds. The “PO” screen shows the software revision number and serial number of the Crimputer. The serial number will not change, even if the software is revised and updated.

G 0754-29

To zero the pickup probe:

CAT CRIMPUTER CAT HOSE MACHINE

1. Lower the pusher with the hose machine control lever until the hydraulic pressure is approximately one-half the relief pressure setting on the gauge.

REV. 4.00 S/N 00002

2. Allow the pressure to reach one-half the relief pressure [10,342 kPa (1500 psi)] on combination model hose machines or [34,474 kPa (5000 psi)] on floor model hose machines.

0754-22

Screen “A” Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the directional arrow keys on the Crimputer to select (place brackets around) [CRIMP] and press the ENTER key.

Hose Machine Relief Pressures Part No.

Description

Specification

139-5439

Combination Hose Machine

20,684 kPa (3,000 psi)

145-3381

Combination Hose Machine

20,684 kPa (3,000 psi)

145-5161

Floor Model Hose Machine (noncurrent)

68,948 kPa (10,000 psi)

152-3910

Lightweight Combination Hose Machine (noncurrent)

34,474 kPa (5,000 psi)

PO

LUBRICATE DIES KEEP HANDS CLEAR [CRIMP] REUSBL UTIL <ENTER>

3. Quickly press the ENTER key on the keypad or actuate the foot switch, then release the control lever.

A 0754-23

NOTE: The actual pressure can be between one-half and full relief pressure and still result in an accurate calibration of the machine. This screen has a three second time delay to prevent pushing the ENTER key twice and causing the Crimputer to advance past the next screen prematurely.

NOTE: The 145-7043 Foot Switch Assembly has the same function as the ENTER key. It can be used in place of the ENTER key at any time.

4. Raise the pusher when complete.

21

Screen “B”

Screen “D”

There are three hose type screens. Use the arrow keys to move between screens and select a hose type. In this example, hose type [XT3ES] is selected. Press the ENTER key to continue.

Use the arrow keys to select hose size by dash number. The dash number is the hose ID in 1/16 inch increments. In this example, hose size [-8] is selected. Press the ENTER key to continue.

SELECT HOSE TYPE 294TG 294HT 294 716TG 294CP 716 844HT [XT3ES] 844

SELECT DASH NO. -3 -4 -5 [-8] -10 -12 -20 -24 -32

B

-6 -16 D 0754-26

SELECT HOSE TYPE XT3ESTG XT5ES XT6 XT5ESTG XT6ES 1956 1028 XT6ESTG

SELECT HOSE TYPE 2760 2786 1543 2929TG 4123 2929 2771A 743

Screen “E” If the selected dash size and hose type is not a valid combination, the Invalid Dash Type screen is displayed. Press the ENTER key to return to “Select Hose Type” screen “B”.

B

INVALID DASH TYPE FOR SELECTED HOSE

B 0754-24

E 0754-27

Screen “C” Some hose types use more than one type of coupling. Where applicable, use the arrow keys to select the appropriate coupling type.

In this example, coupling type [TR] is selected. Press the ENTER key to continue.

Screen “F” Install the correct bowl, pusher assembly, extractor assembly, and extractor tube on the hose machine. When all parts are installed, press the ENTER key to continue.

SELECT COUPLING TYPE [TR] ESA S4G

INSTALL SMALL BOWL AND RELATED PARTS WHEN READY PRESS <ENTER>

C 0754-25

F 0754-28

22

NOTE: This screen does not provide specific part numbers. Refer to the appropriate tooling charts for the part numbers, or refer to the applicable hose machine operating manual.

Screen “I” Screen “I” displays while the coupling is inserted into the dies and the crimp is made.

Screen “G”

• Lower the pusher while seating the

The pickup (probe) must be “zeroed” any time the power is turned OFF and then ON again or if the bowl size changes. The Crimputer automatically shows this screen when necessary.

• When the coupling is firmly in place,

SET PICKUP ZERO LOWER PUSHER--AT 1/2 RELIEF PRESSURE PRESS <ENTER>

coupling firmly against the step in the dies. apply pressure to complete the crimp.

• The Crimputer will stop the downward

movement of the pusher at the proper position for the hose type and size selected.

The Crimputer will then automatically display screen “J”.

G 0754-29

SEAT COUPLING FIRMLY WHILE LOWERING -APPLY PRESSURE WHEN READY

NOTE: For more information on how to “zero” the probe, refer to Zero The Pickup (Probe) in the previous section of this manual.

I 0754-31

Screen “H” Screen “H” lists which die group to use for the hose type, coupling type, and dash size selected. Color bands are also noted as inner (IN) or outer (OUT).

Screen “J” Screen “J” instructs the operator to raise the pusher while removing the completed hose assembly. When ready, press the ENTER key.

Lubricate the dies and bowl before installing the die group. 129-1939 Grease is recommended. Press the ENTER key to continue.

INSTALL 130-5382 DIE GROUP WHEN READY PRESS <ENTER>

CRIMP COMPLETE RAISE PUSHER WHILE REMOVING HOSE <ENTER>

J 0754-32

H 0754-30

23

1. Zero the electronic caliper by completely closing it and then press the “zero” button.

Screen “K” The crimp must be checked for correct dimensions. Screen “K” lists three options for measuring the crimp.

MEASURE CRIMP [1] CALIPER 2 KEY IN READINGS 3 SKIP MEASUREMENT

K 0754-33

NOTE: Accurate measurements are very important. Only [1] CALIPER (using the attached electronic caliper) is recommended.

Selecting [1] CALIPER allows the electronic caliper to input readings directly into the Crimputer for averaging.

2. Mark the center of the crimp length in four adjacent locations with a fine tip permanent marker. This ensures consistency and accuracy.

Selecting [2] KEY IN READINGS allows the operator to enter four manual caliper readings into the Crimputer. Due to the possibility of error, this method is not recommended.

Selecting Option [3] SKIP MEASUREMENT is not recommended.

NOTE: Refer to NEHS0768 General Information for Hose Assembly for more information on measuring crimp diameters.

3. Make four measurements of the crimp diameter (smooth part of crimp) at the center of the crimp length.

Screen “L”

CALIPER MEASUREMENT: ZERO CALIPER AND MARK COUPLING FIRST <ENTER>

L 0754-34

24

NOTE: Because of a slight taper from one end of the crimp length to the other, it is important the measurements be made as near the center as possible.

Screen “Q” After the fourth reading is recorded, screen “Q” displays all four readings together.

MEASUREMENTS XX.XXmm XX.XXmm XX.XXmm XX.XXmm ACCEPT [YES] NO

4. Once the electronic caliper is properly set on the crimp diameter, push the foot switch to record the reading and display the next screen. Move the caliper to the adjacent mark and repeat the process until four measurements are recorded.

Q 0754-36

Screens “M, N, O, and P”

READING # 1

XX.XXmm

PRESS FOOT SWITCH

READING # 2

Screen “R” Screen “R” shows the REQUIRED crimp diameter, PLUS/MINUS tolerance for the type and size of hose selected, and the ACTUAL computed average of the four measurements.

If the measured crimp diameter is within the specified PLUS/MINUS tolerance (0.25 mm), the brackets around [OK] will blink. Press the ENTER key.

N

XX.XXmm

PRESS FOOT SWITCH

READING # 4

M

XX.XXmm

PRESS FOOT SWITCH

READING # 3

If the readings are acceptable (close in value and no false readings recorded), accept the readings [YES] by pressing the ENTER key.

Screen “R” should now appear. If one reading appears to be bad, use the arrow keys to select [NO] and press the ENTER key. The display will return to screen “K” to repeat the measurement process of taking four new measurements.

REQUIRED 25.15mm PLUS/MINUS 0.25mm ACTUAL XX.XXmm [OK] NOT OK

O

XX.XXmm

R 0754-37

PRESS FOOT SWITCH

P

NOTE: When [OK] is displayed, the next screen displayed will be screen “S”. If [NOT OK] is displayed, the next screen displayed will be either screen “S” or screen “U”, depending on the amount of deviation from tolerance.

0754-35

NOTE: The 145-7043 Foot Switch Assembly has the same function as the ENTER key. It can be used in place of the ENTER key at any time.

25

Screen “S”

Screen “U”

Screen “S” appears if the crimp diameter was either [OK] or if [NOT OK] and less than 1.5 times the tolerance. This screen allows the operator to adjust the crimp diameter closer to the specified diameter (zero tolerance). The operator has the option to always adjust the actual crimp diameter closer to the specified diameter even if the crimp is within tolerance.

[NO] is the default choice. If no adjustment is necessary, press the ENTER key to continue.

Use the arrow keys to select [YES] and press the ENTER key to recalculate a new DVDT. The Crimputer will calculate a new adjusted DVDT for the type and size hose just crimped and store the value in the database. The next crimp will then be closer to the required crimp diameter specification (zero tolerance). The adjusted DVDT will remain in the Crimputer database until adjusted again or restored to the original value.

If the crimp diameter is 1.5 times the specified tolerance or greater, screen “U” appears. This hose assembly must not be used.

DIAMETER IS MORE THAN 1.5 TIMES TOL. OUT. CHECK DIES <ENTER>

U 0754-40

Screen “U” indicates an abnormal condition (severely out of tolerance), such as a wrong die was used or a wrong hose and coupling combination was used, machine malfunction, etc. Press the ENTER key to return to the main menu and thoroughly check the setup.

Screen “AX” ADJUST CRIMP DIA.?

YES [NO]

Connect the Crimputer to optional 164-2691 Printer Group to print crimp specifications and results of the measurements. In screen “AX,” use the arrow keys to select 0 to bypass printing, or 1, 2, or 3 to select the number of copies to print. Press the ENTER key to continue.

S 0754-39

NOTE: When the update is complete, or if [NO] is selected, CYCLE COMPLETE will appear on the screen and the display will then change to screen “AX”.

PRINT CRIMP DATA NUMBER OF COPIES ?

[0] 1 2 3 <ENTER>

ADJUST CRIMP DIA.?

YES [NO] CYCLE COMPLETE

AX 0754-41

S 0754-38

26

Screen “T”

Assemble Reusable Couplings [REUSBL]

Screen “T” provides the option to crimp the same type and size hose again (the other end of the hose). Use the arrow keys to select [YES]. Press the ENTER key and screen “I” will display. The crimping procedure can then be repeated.

For assembly of reusable couplings in machines with reusable coupling capability (combination hose machine - part numbers 139-5439, 145-3381, and 152-3910), the Crimputer can be turned OFF or [REUSBL] can be selected on screen “A.” In this mode the Crimputer allows full crimping pressure to be applied at any time.

CRIMP SAME SIZE AND TYPE HOSE [YES] NO

Screen “A” Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [REUSBL]. Press the ENTER key and assemble reusable couplings.

T 0754-42

SEAT COUPLING FIRMLY WHILE LOWERING -APPLY PRESSURE WHEN READY

LUBRICATE DIES KEEP HANDS CLEAR CRIMP [REUSBL] UTIL <ENTER>

I 0754-43

A 0754-54

In screen “T,” if [NO] is selected, screen “A” will display and a different Crimputer function can be selected.

NOTE: Refer to flowchart Illustration 3 for Crimputer screens used during this procedure.

Screen “W”

CRIMP SAME SIZE AND TYPE HOSE YES [NO]

After reusable couplings have been attached to the hose assembly, press the ENTER key to return to Main Menu “A”.

T 0754-60

LUBRICATE DIES KEEP HANDS CLEAR [CRIMP] REUSBL UTIL <ENTER>

REUSABLE HOSE MODE <ENTER> TO RETURN TO MAIN MENU.

W 0754-61

A 0754-23

27

Make Special Hose [UTIL] [1]

New Database [UTIL] [2] (Load New Software)

This procedure is used to assemble special hose couplings by allowing the operator to manually enter the crimp diameter, crimp tolerance, and DVDT values.

This procedure is used to upgrade existing DOS based software to a more current version.

All Crimputer screens for this procedure are shown in flowchart Illustration 5.

Screen “A” Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [UTIL]. Press the ENTER key.

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

A (1) RS-232 Port.

0754-55

Requirements: Screen “X”

• IBM compatible PC with RS232 port.

UTILITIES screen “X” allows the use of the arrow keys to select [1] MAKE SPECIAL HOSE. Press the ENTER key. Follow onscreen instructions to assemble special hose couplings.

• 1U-9484 Programming Cable (1).

UTILITIES [1] MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

• Software media (currently Rev 4.00).

Screen “A” Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [UTIL]. Press the ENTER key.

X

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

0754-45

NOTE: Refer to flowchart Illustration 4 for more information on the Crimputer screens used during this procedure. Many of the individual screens with detailed instructions used in this procedure are described in the Crimping Procedure [CRIMP] section of this manual.

A 0754-55

28

Screen “X, Y”

Print Database [UTIL] [3] (DVDT Values)

UTILITIES screen “X” allows use of the arrow keys to select [2] NEW DATA BASE. Press the ENTER key and screen “Y” will appear. Follow the PC on-screen instructions to load new software.

This procedure enables the operator to print an original or adjusted DVDT database when connected to the optional 164-2691 Printer Group.

Screen “A” UTILITIES 1 MAKE SPECIAL HOSE [2] NEW DATA BASE 3 PRINT <ENTER>

Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [UTIL]. Press the ENTER key.

X 0754-56

CRIMPUTER IS READY FOR NEW DATA BASE. PRESS ENTER ON THE PC.

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

A 0754-55

Y 0754-47

Screen “X” UTILITIES screen “X” allows use of the arrow keys to select [3] PRINT DATA BASE. Press the ENTER key. Follow on-screen instructions to print database values.

NOTE: Refer to flowchart Illustration 5 for more information on the Crimputer screens used during this procedure.

With new software media loaded in the PC, carefully read and follow the directions on the computer screen. Do not connect the 1U-9484 Programming Cable until instructed to do so by the computer.

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE [3] PRINT <ENTER>

X 0754-48

NOTE: In some cases, the Crimputer screen may give confusing directions or go blank. If the PC screen indicates it has “taken control of Crimputer” or “established a communication link”, the upgrade process will be completed correctly.

NOTE: Refer to flowchart Illustration 6 for more information on the Crimputer screens used during this procedure.

29

NOTE: Refer to flowchart Illustration 7 for more information on the Crimputer screens used during this procedure.

Set Time and Date [UTIL] [4] This procedure enables the operator to set the correct time and date in the Crimputer.

Screen “A”

Replace Die Group [UTIL] [5] (View DVDT Values)

Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [UTIL]. Press the ENTER key.

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

This procedure enables the operator to view DVDT values for hose and coupling combinations, and if desired, to restore them to the original values if they have been altered.

Screen “A” Main Menu screen “A” lists three functions, as described in flowchart Illustration 1. Use the arrow keys to select [UTIL]. Press the ENTER key.

A 0754-55

LUBRICATE DIES KEEP HANDS CLEAR CRIMP REUSBL [UTIL] <ENTER>

Screen “X, XX” UTILITIES screen “X” will display. Use the arrow key to continue to the next screen.

A 0754-55

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

X 0754-49

UTILITIES screen “XX” allows use of the arrow keys to select [4] SET TIME AND DATE. Press the ENTER key. Follow on-screen instructions to set the correct time and date.

UTILITIES [4] SET TIME AND DATE 5 REPLACE DIE GROUP <ENTER>

XX 0754-50

30

1. With the Crimputer OFF, press and hold key “4” on the keypad, while turning the Crimputer ON/OFF switch to ON. Hold key “4” until calibration screen “AO” displays on the Crimputer. Release key “4”, follow on-screen instructions, and when ready, press the ENTER key.

Screen “X, XX” UTILITIES screen “X” will display. Use the arrow key to continue to the next screen.

UTILITIES 1 MAKE SPECIAL HOSE 2 NEW DATA BASE 3 PRINT <ENTER>

CAL. PICKUP AT 0.0" LOWER PUSHER--AT 1/2 RELIEF PRESSURE <ENTER> CAL # XXXXX

X 0754-49

UTILITIES screen “XX” allows use of the arrow keys to select [5] REPLACE DIE GROUP. Press the ENTER key.

UTILITIES 4 SET TIME AND DATE [5] REPLACE DIE GROUP <ENTER>

AO 0754-52

2. Screen “AP” will display. Follow on-screen instructions to install the 19.05 mm (.75 in) thick 152-8008 Calibration Plate, then press the ENTER key.

XX

RAISE THE PUSHER AND INSTALL .75" PLATE FOR CALIBRATION <ENTER>

0754-51

NOTE: Refer to flowchart Illustration 8 for more information on the Crimputer screens used during this procedure.

AP 0754-53

Calibrate Probe (Pickup) The probe is a precision component, but no two probes are exactly the same. The calibration procedure records specific characteristics of a probe in the Crimputer.

The calibration procedure needs to be performed when a defective probe is replaced or a different probe is used. The probe must be recalibrated whenever pusher assemblies/probes are changed.

152-8008

0686-04

NOTE: Be sure not to place the calibration plate under the probe. The probe must not contact the calibration plate. The tip of the probe must contact the bowl or the calibration will not be valid.

NOTE: Refer to flowchart Illustration 9 for more information on the Crimputer screens used during this procedure.

31

3. Follow on-screen instructions to complete the calibration process.

Screen “AW” Slowly compress and release the probe plunger and watch the Adc values on screen “AW.” The top Adc value should be 63000 to 66000 with the probe fully released and 00000 to 00300 with the probe fully compressed.

The bottom Adc value represents the vertical position of the pusher in millimeters.

NOTE: When the procedure is complete, screen “AS” displays. The new calibration number shown should be in the range of 22000 to 27000. If not, repeat the procedure.

If the calibration procedure cannot be completed successfully, refer to the Troubleshooting Section in this manual. Press the ENTER key to return to the main menu screen.

NEW CALIBRATION NUMBER 23059 <ENTER>

AS 0754-59

ADC & PROBE TEST

Probe Function Test Adc = XXXXX Adc = 00.03mm

This procedure allows the operator to verify the probe is functioning correctly and has a good connection to the Crimputer.

23370 AW 0754-58

Screen “AV” With the Crimputer OFF, press and hold key “3” on the keypad while turning the Crimputer ON/Off switch to ON. Hold key “3” until ADC & PROBE TEST screen “AV” displays. Release key “3”.

Refer to flowchart Illustration 10 for more information on the Crimputer screens used during this procedure.

ADC & PROBE TEST Adc = 64556 Adc = 27.623mm

23370 AV 0754-57

32

Maintenance Section Troubleshooting Crimputer Troubleshooting Chart Problem Crimputer will not power up (display does not light up).

Possible Solutions Check for power at receptacle.

Check fuses in Crimputer: Unplug power cord from the power connector on the back of the Crimputer. Fuses are behind the small rectangular window on the bottom of the connector. Place a small screwdriver behind tab of window and pull straight out away from the Crimputer. There are two, 250 Volt 3 amp fuses.

If fuses are good or fuse blows again after being replaced, call Dealer Service Tools for assistance.

Crimputer display lights up, but text is wrong or

Reload software.

there is no text at all.

Call Dealer Service Tools for assistance.

Crimputer skips screens or acts erratic.

Check all cable connections on back of Crimputer.

Perform probe calibration process described in this manual.

(Calibrate Probe section and Illustration 9.)

Call Dealer Service Tools for assistance.

Probe will not calibrate.

Visually check probe for physical damage. Inspect plunger carefully to make sure it is not bent. Gently push plunger all the way in and out several times. It should be smooth with no feeling of roughness or stickiness. If any of these conditions exist, replace the probe. Part number 147-2641.

If probe appears to be in working condition with above checks, use the following diagnostic procedure: Turn Crimputer OFF. While turning the power ON, press and hold key “3” until the screen in Illustration 10 displays. The illustration shows the approximate values with the probe plunger all the way out and all the way in. Push the plunger in and out while watching the screen.

The two values on the left of the screen should change as the plunger is depressed. They will be at maximum value when the plunger is all the way out, and minimum value when all the way in. The value on the right is the calibration value for the probe from the previous calibration and will not change as the plunger is depressed.

NOTE: The values on your Crimputer will not match exactly to the illustration values. The top Adc value should be 63000 to 66000 when the probe is all the way out, and 00000 to 00300 when all the way in.

If the probe is pushed in about mid-range, the value should be about half the span or 32500. The bottom Adc value represents the vertical position of pusher in mm, and should act accordingly. Repeat this procedure several times to make sure the probe acts consistently. If the display values are unstable when the probe is not moving, or does not give appropriate readings, the probe should be replaced.

If the probe passes the above procedures, call Dealer Service Tools for assistance.

Crimputer turns OFF and ON when power supply pump is turned ON.

Line voltage is dropping below 90 VAC when pump motor starts.

Increase available power to machine or connect Crimputer to a different power circuit.

Machine consistently over crimps (crimp diameter too small).

The solenoid valve is not as responsive as it should be. This can be a mechanical problem with the valve spool (sticky, dirt, etc.) or an electrical problem with the coil that actuates the valve. Disassemble and clean the valve. Instructions can be found in the manual for each specific hose machine. If this is not successful, the solenoid valve must be replaced.

33

Service Parts

Crimputer Group.

146-5861 Crimputer Groups Item

Part No.

Description

1

140-2845

Crimputer

3

147-2641

Potentiometer

4

1U-9485

Power Cable

5

145-7046

Solenoid Cable

6

145-7045

Caliper Cable

7

145-7044

Electronic Caliper

8

145-7043

Foot Switch Assembly

10

147-2407

Plate

12

152-8008

Calibration Plate

13

6D-3897

Socket Head Bolt

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Replace Electronic Caliper Battery As the 145-7044 Electronic Caliper battery looses capacity, the readings can be in error.

Periodically check electronic caliper calibration against a known gauge block.

Replace the battery yearly, or whenever caliper calibration is incorrect. Replace the battery with a Rayovac™ 357 or equivalent.

1. Slide open the battery door.

2. Remove the old battery and replace with a new, fully charged battery.

3. Replace the battery door.

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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. 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

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NEHS0754-02 Printed in U.S.A.