NEHS0672-02 04 September 2013
Tool Operating Manual Introduction
i04716010
Converting 137-7238 Hose Assembly Machines and 134-5640 Hose Assembly Machines (100 Ton) from Sony Control to Crimputer Control
Important Safety Information
SMCS Code: 0374; 0599; 0684; 5057
Caterpillar Products All
Table of Contents Introduction ...........................................................1 Literature Information .............................................2 Safety Section....................................................2 General Information Section ................................2 Operation Section...............................................2 Maintenance Section ..........................................2 Service Parts Section..........................................2 Safety Icon Nomenclature ...................................2 Personal Protection/Important Information....................................................2 Prohibited Action .............................................2 Hazard Avoidance...........................................3 Safety Section .......................................................3 General Information ...............................................3 Introduction ........................................................3 Additional Contact Information .............................4 Electrical Disassembly ...........................................4 Mechanical Disassembly ........................................5 Mechanical Reassembly.........................................5 Electrical Reassembly ............................................9 Motor Starter ......................................................9 Power Cable ....................................................10 Motor Cable ..................................................... 11 Starter End of Cable ...................................... 11 Motor End of Cable........................................12 Solenoid ..........................................................12 Crimputer Connections .....................................13 Electrical Test...................................................13 Parts...................................................................13
Illustration 1
g02139237
Think Safety
European Union Compliant, CE marked Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Improper operation, lubrication, maintenance, or repair of this product 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 Tool Operating Manual. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
1
General Information Section
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.
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
Operation Section
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The Operation section is a reference for the new operator and a refresher for the experienced operator. Photographs and illustrations guide the operator through correct procedures for using the tool group. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
Maintenance Section The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section The Service Parts section is a reference for parts identification and available part numbers.
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 Icon Nomenclature Personal Protection/Important Information
Literature Information This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication. Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section Illustration 2
The Safety section lists basic safety precautions.
g02166423
Personal Protection/Important Information
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
Prohibited Action No smoking –
2
Hazard Avoidance
NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Crushing hazard (foot) –
Crushing hazard (hand) –
Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Pinch point –
Fire hazard –
Dispose of all fluids according to local regulations and mandates.
Electrical Shock - Hazard –
NOTICE To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected.
Fire hazard –
This action also lessens the chance of oil spills.
Safety Section
General Information Introduction
At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.
Illustration 3
100 Ton Hose Assembly Machine with Sony Control
3
g02826098
Electrical Disassembly Note: All parts removed during this procedure must be returned to CSTG. Use the return label that is included with these instructions. 1. Turn the hose machine ON and check and record the rotation of the electric motor for future reference. 2. Disconnect all electrical power from the hose machine being modified a. Electric - Unplug the hose machine accessories and other possible add-ons such as hand tools, lights, or other related items. b. Hydraulic - If any accessories have been added to the hose machine, remove before continuing.
Illustration 4
c. Pneumatic - If any accessories have been added to the hose machine, remove before continuing.
g02826101
100 Ton Hose Assembly Machine Upgraded with a Crimputer
3. Remove the power cable.
This manual provides a procedure to remove the former Sony control and install the newer Crimputer from 100 Ton Hose Assembly Machines. This procedure is used on 137-7238 Hose Assembly Machine (110V, 60 Hz) and 134-5640 Hose Assembly Machine (220V, 50 Hz).
a. Open the black enclosure on rear of hose machine. b. Locate motor starter. Identify where wires are attached at top.
The Crimputer is a microprocessor-based controller with memory containing a database with hose types 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 measured values which can be measured with the integral caliper at the completion of the crimp. The Crimputer will adjust the controlling numbers (DVDT) to compensate for die wear or other discrepancies.
c. Make sure that wires are marked for future identification. • Wires should already be marked with either “L” and “N” , “L1” and “L2” , or “1” and “2” . If not, mark them so they can be identified later. • Disregard the other wire on top of the starter. It is not relevant in the conversion.
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.
d. Loosen screws holding wire ends on top of motor starter. e. Remove screw holding green/yellow wire.
A 164-2691 Printer Group is also available for printing crimp measurement data as well as the databases.
f. Loosen cable grip, device protruding through wall of enclosure through which the cable passes, on bottom of black enclosure and pull power cable out of enclosure.
Note: Before starting the conversion, make sure all parts required for the conversion are available. Verify that all of the parts from Tables 1, 2, and 3 in the “Parts” Section of this manual has been received and are available. DO NOT start the conversion if any items are missing and/or unavailable.
g. Remove cable grip from enclosure for use in new starter. h. Save power cable for later use. 4. Remove the motor cable.
Additional Contact Information
a. Open the enclosure on the motor. Save the screws for assembly.
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
b. If the wires from the cable are connected to the toggle switch:
USA 1-800-542-8665, Option 1 International 1-309-578-7372
4
• Identify the wires for assembly. d. Unplug Sony transducer from back of unit.
• Only remove the screws from the toggle switch that hold the wires leading from the black enclosure.
e. Loosen thumb screw on top and bottom of Sony unit enough to remove retaining brackets.
• Save the screws for reassembly.
Note: Save retaining brackets for shipment back to CSTG.
c. If the wires from the cable are connected by wire nuts:
f. Pull Sony unit out from the front of the sheet metal.
• Identify the wires for assembly.
7. Remove Control box.
• Only remove the wire nuts that hold the cable leading from the black enclosure.
a. Remove the four bolts holding three switch control box on front.
• Save the wire nuts for reassembly.
b. Leave control box attached to black enclosure.
d. Remove the ground screw. Save for reassembly.
Mechanical Disassembly
e. Loosen the cable grip to the motor enclosure. Do not remove the cable grip.
1. Disconnect pressure line from pressure gauge.
f. Remove the cable from the motor enclosure.
2. Remove 1/8 x 1/4 inch female adapter from gauge. Save for new gauge.
g. Loosen the screws holding the other end of the cable inside the black enclosure.
3. Remove gauge from sheet metal.
h. Remove the screw holding the green/yellow wire. Save the screw for reassembly.
4. Remove the sheet metal. 5. Disconnect the hydraulic return line from the tank.
i. Loosen cable grip in black enclosure and remove cable. Discard cable.
Mechanical Reassembly
j. Remove cable grip in black enclosure that holds the motor cable. Save for use with new starter. 5. Remove solenoid cable. a. Open enclosure on top of solenoid. b. Disconnect wires by removing wire nuts. c. Identification is not important for reassembly. Note: Save wire nuts for reassembly. d. Loosen cable grip and remove cable from the solenoid enclosure, leave attached to black enclosure. e. Remove entire cable grip from solenoid enclosure. 6. Remove Sony communications cable. Illustration 5
a. Remove four screws around face of Sony unit, supporting gray enclosure behind sheet metal.
g02826158
Install Filter Group (5)
(16) Filter Gauge (17) Filter Fitting, 1/8 inch NPT, 90° Female (18) Filter Fitting, 1/8 inch NPT, Straight Male
b. Pull back gray enclosure. c. Loosen three screws holding wires from black enclosure to Sony unit.
5
1. Mount filter group (5) to the tank and reconnect the return line. Install filter gauge (16) using a 1/8 inch NPT 90° female fitting (17) and a 1/8 inch straight male fitting (18).
Illustration 6
g02826159
Install Hose Guard
Illustration 8
2. Weld hose shield plate (6) into position, as shown.
g02826161
Install Sheet Metal Cover (1)
5. Attach piece of sheet metal (3a) that contains the opening for the pressure gauge. Predrill holes for the screws, if necessary.
Illustration 7
g02826160
Attach Motor Starter Plate
3. Hold new motor starter mounting plate (1) over the old plate and mark where the new screw holes will be. Relieve these areas so that the new screws will work.
Illustration 9
g02826162
Attach Monitoring Bracket And Pressure Line To Pressure Gauge
6. Install 147-4439 Pressure Gauge(7). May need to open up hole slightly. Slide gauge mounting bracket onto the back of the gauge and secure it to the cover.
4. Weld new motor starter plate (1) in place.
7. Connect the pressure line to pressure filter gauge (7).
6
Illustration 10
g02826176
Illustration 12
Install Sheet Metal Cover (3b)
g02826178
Install Position Indicator
(C1) 147-2641 Potentiometer(C2) 6D-3897 Potentiometer Indicator Bolts(C9) 147-2407 Potentiometer Mounting Plate
8. Slide sheet metal (3b) over the handle and attach it to the first piece using sheet metal screws (4). Predrill holes if necessary.
10.Mount 147-2407 Potentiometer Mounting Plate (C9) and 147-2641 Potentiometer(C1) to the hose machine. a. Attach potentiometer mounting plate (C9) to the back of the ram using potentiometer indicator bolts (C2). b. Mount potentiometer (C1) to potentiometer mounting plate (C9).
Illustration 11
g02826177
Mount 146-5861 Crimputer Group(19)
(20) 0S-1614 Bolt(21) 9S-8750 Nut(22) 145-6949 Crimputer Mounting Bracket(23) 4C-6521 Stop Collar(24) Crimputer
9. Mount 146-5861 Crimputer Group(19). a. Mount 4C-6521Stop Collar(23) on front right tie-rod approximately 400.1 mm (15.75 inch) up from bottom platen. b. Mount crimputer bracket (22) on top of stop collar (23). c. Mount crimputer (19) to mounting bracket (22) using 0S-1614Bolts(20) and 6V-8185Nuts (21).
7
Illustration 15
g02826196
Remove Two Nuts From Each Rod
a. Remove the two nuts from each rod and allow the extractor assembly to drop down. It should be supported by the two nuts on the lower end of each rod.
Illustration 13
g02826179
Extractor Tube Assembly (8)
(11) 145-6947 Rod(12) 145-6946 Spring(13) 8T-8890 Washer (14) 5S-0003 Nut
Illustration 16
g02826197
Adjust Height of Extractor Plate Using Two Nuts, Lower End of Rod
b. Adjust the two nuts at the lower end of the rod so the extractor tube assembly is exactly 127 mm (5.0 inch) below the top of the platen. Check the dimension on both sides to make sure that it is the same. Lock the two nuts together and recheck the dimension. Illustration 14
g02826180
Extractor Tube Assembly (8)
(14) 5S-0003 Nut(15) 145-7047 Spacer
11.Install 133-9890 Extractor Tube Assembly(8) using items (11), (12), (13), (14), and (15) as shown. 12.Adjust the extractor tube assembly, as follows:
8
Illustration 17
g02827200
Illustration 19
g02827202
Check Measurement Of Extractor Assembly
Install 152-8008 Calibration Plate
c. To adjust the spring tension at the top of the rods, thread two nuts onto each rod with the ram or pusher, all the way up. Tighten each nut until the spring becomes solid. Loosen one nut on each side two full turns and lock in place with a second nut.
d. Turn the crimputer OFF. Press and hold the “4” key while turning the crimputer ON. Continue pressing the key until the calibration screen appears on the crimputer.
Note: This procedure is for calibrating the probe to the crimputer and should not be confused with the routine calibration done as part of the crimping process. This should be done if the probe is a 147-2641 Potentiometer, the 8T-1002 Probe is replaced, or the software has been updated.
Illustration 20
g02827203
Make Sure Probe Is Touching The Bowl And Not The 152-8008 Calibration Plate
e. When the calibration screen appears, follow the instructions on the crimputer screens. Illustration 18
f. When instructed to install the 19 mm (0.75 inch) plate, install the 152-8008 Calibration Plate as shown.
g02827217
Tighten Nuts To Compress Spring
g. When the calibration procedure is complete, the new number which appears should be in the range of 22000 to 27000. If not, repeat this procedure.
Electrical Reassembly Motor Starter 1. Remove the cover from the new 149-5477 Motor Starter. 2. Knock out both metal hole plugs on the bottom of the starter.
9
6. Place one overload in position T1 and replace the two mounting screws. 7. Press the “STOP/RESET” button. 8. Place one overload in position T2 and replace the two mounting screws. Note: Even though position T2 is not used, this overload MUST be inserted for proper operation. 9. Press the “STOP/RESET” button. 10.Place one overload in position T3 and replace the two mounting screws. 11.Press the “STOP/RESET” button.
Power Cable
Illustration 21
g02827240
Install Cable Grips For Motor Cable (2) And Power Cable (1)
3. Insert a cable grip (1) for the power cable in bottom left and and tighten locknut. Insert a cable grip (2) for the motor cable in bottom right and tighten locknut.
Illustration 23
g02827251
Attach Power Cable To Motor Starter
Illustration 22
(1) Ground Wire Attached To Mounting Screw (2) Wire Attached to “L1” (3) Wire Attached to “L3”
g02827242
1. Test fit the wires into their new positions. Make sure that the ground wire (green/yellow) can reach one of the three mounting screws securing the starter to the machine.
4. Mount motor starter on motor starter mounting plate using three screws provided. 5. Remove six overload mounting screws, two each above T1, T2, T3.
2. Loosen terminal screws “L1” and “L3” in the starter.
Note: Use the proper overload for the power supply, 110 Volts, or 120 V, to the hose assembly machine. Use W56 overloads on a 137-7238 Hose Assembly Machine, 110V, 60 Hz, and W49 overloads on a 134-5640 Hose Assembly Machine, 220V, 50 Hz.
3. Insert the power cable through the bottom left cable grip.
10
4. Place two power wires (not green/yellow) under “L1” and “L3” .
3. Strip off 12.7 mm (0.50 inch) of wire insulation on wires (1), (2), and the green/yellow wire (3).
Note: If wires are marked “L” and “N” , “L” goes to “L1” and “N” goes to “L3” . If the wires are marked “L1” and “L2” , “L1” goes to “L1” and “L2” goes to “L3” .
4. Crimp a terminal lug onto the green/yellow ground wire. 5. Route the cable through the cable grip in the bottom of the starter.
5. Tighten the screws to secure the wires.
6. Loosen terminal screws “T1” and “T3” .
6. Place the ground wire with terminal (green/yellow) under one of the three starter mounting screws. 7. Tighten the cable grip.
Motor Cable Starter End of Cable
Illustration 25
g02827256
7. Place black wire (1) under terminal screw “T1” and tighten the screw. 8. Place white wire (3) under terminal screw “T3” and tighten the screw. Illustration 24
g02827254
9. Connect the ground wire with terminal (green/ yellow) to one of the three starter mounting screws.
Attach Motor Cable To Motor Starter
(1) Black Wire “T1” (2) White Wire “T3” (3) Green/Yellow Wire
10.Replace motor starter cover.
(Ground)
1. Strip off 152 mm (6.0 inch) of the outer insulation and cable support strands from both ends of the motor cable. NOTICE DO NOT nick any of the inner wires while stripping off the outer insulation. If a wire is cut or nicked, cut off another 152 mm (6.0 inch) and start over. 2. If a four conductor cable is used, cut off one wire. Keep the black, white, and green/yellow wire. Only three wires are required for the motor cable.
11
Motor End of Cable
7. Connect the green/yellow ground wire to the ground post. 8. Replace motor enclosure cover. NOTICE Make sure that NO wires are trapped between the cover and the enclosure. Severe wire damage could occur if this happens, resulting in possible electrical damage to the machine.
Solenoid
Illustration 26
g02827296
Illustration 28
g02827317
Install Hirschman Connector
Illustration 27
1. Screw the Hirschman Connector into the solenoid in the end where the old cable grip was located.
g02827297
1. If a four conductor cable is used, cut off one wire. Keep the black, white, and green/yellow wire. Only three wires are required for the motor cable. 2. Strip off 12.7 mm (0.50 inch) of wire insulation on wires (1), (2), and the green/yellow wire. 3. Crimp a terminal lug onto the green/yellow ground wire. 4. Place end of cable through the cable grip in the motor enclosure. 5. If the motor enclosure wires have crimp on terminals, crimp terminals onto all three wires and connect wires (1) and (3) to the switch.
Illustration 29
6. If the motor enclosure uses wire nuts, crimp a terminal onto the green/yellow wire and connect wires (1) and (3) to the respective wire with wire nuts.
g02827318
2. Connect Hirschman Connector wires to the solenoid wires with the old wire nuts. Polarity is not important. 3. Plug the cable provided, into the Hirschman Connector and tighten screw to hold it in place.
12
(Table 1, contd)
4. The other end of this cable is plugged onto the Crimputer.
-
Crimp-On Terminals for wires (Qty 5)1
149-5477
Crimputer Connections
Motor Starter
-
Overload (for 110 V machines)1
-
Overload (for 220 V machines)1
-
Motor Cable, 122 cm (48.0 inch) long1
-
Hirschman Connector1
-
Power Cable for Starter, 305 cm (120.1inch)1
-
Cable Grips (Qty 2)1
145-6948
Plate
146-5861
Crimputer Group (see Table 2
1
Part of a parts kit which is supplied by CSTG upon request.
Table 2 146-5861 Crimputer Group
Illustration 30
Item
Part No.
Description
(C1)
147-2641
Potentiometer
(C2)
6D-3897
Potentiometer Indicator Bolts (Qty 2)
(C3)
140-2845
Crimputer
(C4)
145-7043
Foot Pedal
(C5)
145-7046
Solenoid Cable
(C6)
1U-9485
Power Cable
(C7)
145-7044
Caliper
(C8)
145-7045
Caliper Cable
(C9)
147-2407
Potentiometer Mounting Plate
(C10)
152-8008
Calibration Plate
g02827320
Connect the cables to the back of the Crimputer, as shown.
Electrical Test 1. Connect the machine and Crimputer to the power supply. 2. While another person observes the motor rotation direction, push the “Start” button and then immediately press the “Stop/Reset” button.
Table 3 Mechanical Parts List
3. If the motor does not rotate: Item
Part No.
(1)
-
(2)
-
Motor Starter Mounting Screw
3
(3)
-
Sheet Metal Replacement for Gauge Mounting1
1
(4)
-
Sheet Metal Screw1
-
(5)
-
Filter Group1
1
(6)
-
Hose Shield Plate1
1
Parts
(7)
147-4439
Pressure Gauge
1
Table 1
(8)
133-9890
Extractor Tube Assembly
1
(9)
173-3228
Valve Spring
1
(10)
173-3227
Valve Spring Retainer
1
a. Make sure that the toggle switch on the motor enclosure is “ON” . b. Make sure that the hose machine is plugged into the power supply. c. Make sure that the outlet device has power. d. Make sure that the overloads were installed in the starter.
Electrical Parts List Part No.
Description
(continued)
Description
Qty
Motor Starter Mounting Plate1
1 1
(continued)
13
(Table 3, contd) (11)
145-6947
Rod
2
(12)
145-6946
Spring
2
(13)
8T-8890
Washer
4
(14)
5S-0003
Nut
12
(15)
145-7047
Spacer
2
(16)
9U-6986
Filter Gauge
1
(17)
8B-4884
Filter Fitting (90 degree elbow, 1/ 8 in NPT, female)
1
(18)
5K-5068
Filter Fitting (1/8 in NPT union, male)
1
(19)
146-5861
Crimputer Group
1
(20)
0S-1614
Bolt, 1/4 - 20 x 19.1 mm (0.75 inch) long
4
(21)
9S-8750
Nut (1/4 in)
4
(22)
145-6949
Crimputer Mounting Bracket
1
(23)
4C-6521
Stop Collar for Crimputer Control
1
-
NEHS0672
Converting 100 Ton Hose Assembly Machine from Sony Control to Crimputer Control
-
-
NEHS0754
Setup and Operation of the 145-7042 Crimputer Groups and 146-5861 Crimputer Groups
-
1
Part of a parts kit which is supplied by CSTG upon request.
■
14
15
©2013 Caterpillar All Rights Reserved
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
