- AVSpare Products: All
Introduction
Important Safety Information
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| 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.
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.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
AVSpare 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 AVSpare 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 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.
When replacement parts are required for this product AVSpare recommends using AVSpare replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
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
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
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.
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.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No smoking |
Hazard Avoidance
| Crushing hazard (foot) |
| Crushing hazard (hand) |
| Pinch point |
| Fire hazard |
| Electrical Shock - Hazard |
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| Fire hazard |
Safety Warnings
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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. |
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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. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
|---|
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information Section
Introduction
The Radial Hose Crimping Machines are high-performance and rugged units designed to crimp permanent hose couplings only. The hose machine is operated and controlled through a user friendly LCD touch screen interface display. The microprocessor (controller) contains memory, which shortens setup times and helps make correctly sized couplings every time. An electronic measuring system ensures highly accurate crimps for each and every coupling.
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| Illustration 3 | g02166433 |
358-4528 Radial Hose Crimping Machine . | |
| NOTICE |
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The hose machine has been constructed using state-of-the-art engineering and acknowledged safety standards. Nonetheless, dangers can arise for the operator and other persons in the operating area. Machine and/or property damage can also occur if all safety and operating recommendations are not followed. These operating instructions contain the most important information needed to operate the hose machine safely. The safety information must be observed by all persons operating the hose machine. |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Safety Devices
Emergency Stop Button
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| Illustration 4 | g03657922 |
(6) Emergency Stop (7) Hydraulic Motor OFF Button (8) Hydraulic Motor ON Button (9) Foot Control Switch ( Activates foot control for dies OPEN/CLOSE.) (10) Master Dies Open Button (11) Master Dies Close Button | |
The Emergency Stop button (6) is located on the control console. When the Emergency Stop button (6) is pressed, the C3 will display that the Emergency Stop button has been pressed and the hydraulics will shut down.
Specifications
| Crimp Force (kN / Ton) | 1800/180 |
| Control | Crimputer III (C3) |
| Opening without dies (mm) | 147 |
| Noise Level "dBa" | 69 |
| Motor | 4kW |
| Tool L x W x H(mm) | 1000 x 600 x 700 |
| Fluid Capacity(l) | 50 |
| Fluid Change Schedule | Annually |
| Weight (kg) | 260 |
| Die System | 239 |
| Electrical Power Requirements | 230-460V Three Phase 50/60 Hz (4kW Motor)(20A/15A) |
| 230 V Single Phase 60 Hz (4kw Motor) (30 A) | |
| 230 V Single Phase 50 Hz |
Nomenclature
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| Illustration 5 | g02177007 |
(2) Controller (3) Main Power Switch (4) Electrical Control Panel (5) Master Dies | |
Installation and Setup
Machine Setup
Unpacking and Table Mounting
- Carefully unpack the machine and verify that all components are in place and undamaged.
- Place lifting straps of the correct size under machine and lift taking care not to damage the machine.
- Fasten the machine to a 358-4545 or other appropriately sized table, on a stable, level surface. The hose machine should be placed so that all sides can be accessed for efficient crimping and maintenance.
- Mount the C3 controller to the machine.
- Attach Calipers with the Caliper Cable to the USB port at the back of the C3 controller (2) .
- Attach the single and double foot switches to the machine. The connections are located below the C3 controller on the left side of the machine near the main power switch (3) .
Filling Hydraulic Reservoir
- Remove Fill cap. Fill tank to full line on the dip stick. Machine holds approximately 50 L (52.8 qt) of hydraulic fluid.
- Fill the tank until the oil level reaches the safe operating zone (1) on the dip stick.
| NOTICE |
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The hose machine must be filled with either AVS BIO HYDO, HLP 46, DIN51524, or equivalent ISO 46 hydraulic oil. |
Note: AVS BIO HYDO is available in 20 L containers ( 341-2442 ) or 5 US gal containers ( 339-3249 ).
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| Illustration 6 | g02177017 |
Connect the Electric Supply
The CSC6 Cat Crimp Machine is powered with either a 3-phase motor or a 1 (single) phase motor.
A 3-phase motor will rotate in either direction determined by the order in which the 3 power wires are connected. A further consideration of this machine is that the motor is located in the hydraulic tank, therefore the rotation cannot be visually observed. There is no way to predetermine the correct rotation of the motor, therefore the machine has to be powered up and machine operation checked to determine the correct motor rotation.
A single phase motor does not have a rotation consideration as it is not reversible.
Connecting 3 Phase Machine
| NOTICE |
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This work should only be performed by a qualified electrician. The machine is shipped with a pre-wired electrical cord. Connect the cord to the electrical supply following local electrical code requirements applicable to the installation site. |
The 3 phase machine is capable of being operated at either: High Voltage: 380/480 V, 50/60 HZ, 15A or Low Voltage: 230/280 V, 50/60 HZ, 25A.
Note: The machine is shipped from the factory configured for high voltage.
If the machine is to be operated at high voltage, no changes are necessary.
If the machine is to be operated at low voltage, the following steps need to be performed:
- Remove the 3mm Allen head screws from the electrical panel cover and remove it.
- Locate the Voltage Selector Switch, S56, and turn it to the 230 V setting.
- Locate the adjustable overload adjustment screw and turn it to 25 Amps.
- High voltage to low voltage conversion is complete.
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| Illustration 7 | g03657883 |
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| Illustration 8 | g03657893 |
Connecting 1 (Single) Phase Machine
| NOTICE |
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This work should only be performed by a qualified electrician. The machine is shipped with a pre-wired electrical cord. Connect the cord to the electrical supply following local electrical code requirements applicable to the installation site. |
The motor rotation of the single phase machine is not reversible, therefore it is ready for service when wired to the electrical supply.
Start Machine and Check Motor Rotation of 3 Phase Machine
| NOTICE |
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Do not start machine without hydraulic oil. Check oil level before starting. |
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| Illustration 9 | g03507104 |
(6) Emergency Stop (7) Hydraulic Motor OFF Button (8) Hydraulic Motor ON Button (9) Foot Control Switch ( Activates foot pedal for open/close) (10) Crimp Tool Open Button (11) Crimp Tool Close Button | |
The motor on a CSC 6 machine is located in the hydraulic tank, therefore it cannot be visually checked for proper rotation. The machine has to be powered up and an attempt made to close and open the dies to verify correct motor rotation. If the rotation is correct, the dies will close and open. If the rotation is not correct, the hydraulic pump will not supply oil. Therefore the dies will not move.
Note: Push-buttons items 10 and 11, illustration 9, are used to open and close the dies. These push-buttons are illuminated to indicate they are active.
- The open button is illuminated anytime the hydraulic motor is on and will open the dies if they are not already open.
- The close button is only illuminated and active when the hydraulic motor is on and at specific operation screens of the C3 panel. Those screens are:
- Sensor Information Screen - diagnostic type screen
- Die Change Screen - appears in process of crimping a hose
- Crimp Screen - screen at which the coupling is crimped on the hose
- Switch on the main power. Release E-stop push button and allow machine controller (C3) to boot up to the "Start Up Screen".
- There are two functions available from the start-up screen:
- The soft key with "i" is the software information button. Press "i" to see the revision levels of three software packages in the machine. Press EXIT to return to the "Start Up Screen."
- The green soft key labeled "OK" accesses the log-on screen. For username and password, touch the blinking curser in the data field. A soft keypad appears to enter data. The default username and password is AVS.
Note: The operator must be logged onto the controller to access any functionality of the machine.
Show/hide table
Illustration 10 g03471696
- When logged on, the controller displays the Crimputer III Menu screen. Refer to Illustration 12. There are four functions available from this screen:
- Setup
- Utility
- Log off
- Crimp
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| Illustration 11 | g02177414 |
- Press the "Setup" soft key to access the setup menu screens.
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| Illustration 12 | g03632921 |
- Press the right arrow soft key two times. You will now be at the "Sensor Information" screen. Refer to Illustration 13.
- From this screen, start the hydraulic motor by pushing Item 8 (see Illustration 9). Items 10 and 11 will illuminate. Push Item 11 (close button) and the dies should close. If they do not close, the motor is rotating the wrong direction. See "Change Rotation," then repeat this step to verify dies close and open.
Note: Hydraulic motor will automatically shut off after 20 seconds if there is no machine activity.
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| Illustration 13 | g03507115 |
- Close and open the dies a few times to purge air from the hydraulic system.
- Push the back arrow softkey to back out of the Crimputer III menu screen. (Illustration 12).
Change Rotation
| NOTICE |
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This procedure should be performed by a qualified electrician. |
Change the position of any two of the three power supply wires to change the rotation of the hydraulic pump. Repeat step 6 above to verify proper rotation.
Changing a Die Group
Adapter Dies 266-239L - Installation/Removal of Adapter Dies and Crimping Dies 266L 67mm and Larger
The adapter dies reside in the Master Dies and accept the 239-100 series crimping dies up to and including 62mm. When using 67mm, 71mm, 84mm, 92mm, the adapter dies are removed and crimping dies reside directly in the master dies. The adapter dies and 67mm and larger dies have to be installed/removed by hand using the red handled die change tool.
- Turn motor power off.
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| Illustration 14 | g03678494 |
- Use the red handled die change tool to push in and hold the spring loaded retaining pin in hole A located in the Master Die C. Remove or insert the adapter die or 67mm (or larger) crimping die by placing the pin into hole B located in the Master die C. Release pressure on the die change tool and the die is now secured into the master die. Repeat the process for remaining dies. Refer to illustration above.
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| Illustration 15 | g03678495 |
Note: After long service, the retaining pins in hole A of the master dies may be a bit hard to release. In this case, use a rubber hammer and gently tap on the end of the handle of the die release tool to free the pin. Replacement pins and springs are available in a kit. (Cat part number 416-6396) (1 kit required for each master die segment)
Installation and Adjustment of Die Retention Assemblies Located in Adapter Dies
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| Illustration 16 | g03678505 |
The 239 series crimping dies are held in the adapter dies by the spring loaded ball/screw assembly. The assembly is removed/installed using a straight blade screwdriver through the access hole on the front of the die. Adjust the position of the assembly by turning the screw CW until you can see the ball entering the pin hole. Insert a 239 die segment in the hole and push it into the adapter die. The die should snap firmly into the hole and be held against the adapter die. If the die can move or there are gaps between the dies, the screw needs to be turned CW. Repeat, adjusting the screw in small increments until the 239 die rests firmly in the adapter die. If the 239 die cannot be pushed into the hole, the assembly is too far into the hole. Turn the screw CCW. Repeat for all 8 adapter die segments.
Installation and Removal of 239 Series Crimping Dies using the Quick Die Change Tool (QDC)
The 12mm though 54mm Die Groups can be changed using the Quick Die Change tool (Cat part number 233-8046).
The 57mm and the 62mm Die Groups must be installed and removed by hand, 1 die segment at a time. They are too thin to accommodate the holes necessary for the Quick Die Change Tool.
Note: The head should be open and the hydraulic motor turned off while installing or removing 57mm or 62mm dies.
| NOTICE |
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Failure to change the 57mm and the 62mm die segments by hand will cause damage to the 57mm and the 62 mm Die Groups. They are too thin to accommodate the holes necessary for the Quick Die Change Tool. |
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| Illustration 17 | g03403993 |
Installing 239 Series Dies
- Insert the eight pins of the quick die change tool in the front of the 239 Series Crimp Dies and turn toward the left. Take the tool and the dies out of the Die Storage Rack.
- Hold the QDC in the center of the crimp tool.
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| Illustration 18 | g03403997 |
- Use the close push button to close the machine on the die group until they snap into place.
Note: While closing make sure that the pins are aligned with the holes in the adapter dies. If not, they will be broken or severely damaged. This process requires some practice. Replacement pins for the 239 series dies are Cat Part Number 330-3951.
- When dies are in place, pull the QDC out of the dies and open the machine completely.
Removing 239 Series Dies
- Reverse the order of above procedure.
- Insert QDC Tool.
- Open machine.
Calibration Procedure
The machine will need to be calibrated before it is put into service.
Once calibrated, the machine will not have to be calibrated again unless there is a failure of one of the electronic controllers, or the machine develops operational problems. The machine can be calibrated just to verify that the calibration has not become corrupted or as many times as necessary for training or demonstration.
- Select "Utility" from the "Crimputer III" menu screen.
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| Illustration 19 | g02177434 |
- Select "Probe Calibration" from the Utility screen.
- C3 will prompt you to install the 32mm Die Group. Refer to the section, Installation and Removal of 239 Series Crimping Dies, and complete the steps for a die change. When the die change is completed, press the "GO" soft key. The screen will advance to Step 2 of 5.
Note: There may or may not be a set of 239 Series Dies in the Adapter Dies. Therefore, either remove and install the 32mm dies, or just install the 32mm dies.
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| Illustration 20 | g03591147 |
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| Illustration 21 | g02178231 |
- Insert the small end of the 233-8045 Calibration Mandrel into the dies. Start motor and push and hold the close button until dies stop. The screen will advance to step 3 of 5.
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| Illustration 22 | g02336039 |
- Open die and remove mandrel. Press "OK" when ready. The screen will advance to step 4 of 5.
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| Illustration 23 | g02336040 |
- Insert the large end of the 233-8045 Calibration Mandrel into the dies. Start motor. Push and hold the close button until the dies stop. The screen will advance to step 5 of 5.
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| Illustration 24 | g02391759 |
- Screen will display "Calibration Complete". Open dies and remove mandrel.
- Check calibration number. It should have a value between .98 and 1.03. If the value is out of limits, perform calibration again.
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| Illustration 25 | g02430977 |
- If calibration value is within limits, press "OK". Calibration is successful. Store calibration mandrel in a safe place.
Maintenance
Scheduled Maintenance
Daily Maintenance
| NOTICE |
|---|
The master dies and any associated parts should never be lubricated. |
- Open the crimp tool completely.
- Turn the Crimputer power switch to the OFF "0" position. Turn the main power switch to the OFF "0" position.
- Clean the master dies of metal, dirt, and debris with compressed air.
- Check the operation of the emergency stop switch.
- Check oil level using the dip stick.
- Visually check the machine for oil leaks.
- Check the machine for loose part covers or any visible damage.
Monthly Maintenance
- Check the hydraulic hose assemblies for porosity and leaks.
- Check the screwed joints and clamps of the hose assemblies for leaks.
Biannual Maintenance
- Check the bearing plates for wear.
Annual Maintenance
- Hydraulic oil change
| NOTICE |
|---|
The hose machine must be filled with either AVS BIO HYDO, HLP 46, DIN51524, or an equivalent ISO 46 hydraulic oil. |
| NOTICE |
|---|
The operator assumes responsibility to change hydraulic hoses at an acceptable interval. |
Check Slide Bearings
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| Illustration 26 | g03718980 |
Slide bearings are designed to last for thousands of cycles. However, cleanliness and heavy loading of the machine may be the two most influential variables on the life expectancy of the slide bearings. In order to identify a "worn" bearing, typically, visual inspection is the best tool, especially since there are no pre-determined time or number of cycles of operation that can predict the life of the slide bearings.
If 50% or more of the anti-friction coating surface area is worn away(from visual inspection), replace the slide bearings. See illustration 26.
Replace Rear Slide Bearings Cat Part No. 416-6391
- Open the crimp tool completely.
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| Illustration 27 | g03698756 |
- Remove the 8 screws that secure the clamp ring.
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| Illustration 28 | g03698758 |
- Remove the clamp ring. Cat Part 416-6401
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| Illustration 29 | g03698760 |
- Remove the old slide bearing and insert a new one. Replace one bearing at a time. Don't remove all bearings at one time.
Note: One or more bearings may have a piece of shim stock underneath it. Leave in place or replace with a new shim of same thickness if it is damaged.
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| Illustration 30 | g03698761 |
- Insert the new slide bearing. Continue replacing 8 slide bearings, 1 at a time.
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| Illustration 31 | g03698762 |
- Install clamp ring. Cat Part 416-6401 (includes 8 screws)
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| Illustration 32 | g03698763 |
- Insert 8 screws to secure the clamp ring.
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| Illustration 33 | g03698764 |
Spare Parts
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| Illustration 34 | g03703342 |
| Position | Quantity | Cat Part Number | Uniflex Part Number | Description |
| 1 | 1 | 233-8045 | Calibration Mandrel | |
| 2 | 1 | 358-4537 | Caliper-Interface cable | |
| 3 | 1 | 358-4536 | Starrett or Sylvac caliper | |
| 4 | 1 | 358-4538 | Foot Switch Single | |
| 5 | 1 | 358-4544 | Foot Switch Double Close/Open | |
| 6 | 1 | 233-8046 | Quick Die Change Tool | |
| 7 | 1 | 233-8047 | Die Release Tool | |
| 8 | 1 | 807.410 (Uniflex) | Potentiometer (Path Sensor) | |
| 9 | 1 | 358-4535 | Crimputer 3 Controller Only | |
| 1 | 358-4550 | PB 239 100 12mm Die | ||
| 1 | 358-4551 | PB 239 100 14mm Die | ||
| 1 | 358-4552 | PB 239 100 17mm Die | ||
| 1 | 358-4553 | PB 239 100 20mm Die | ||
| 1 | 392-3963 | PB 239 100 22mm Die | ||
| 1 | 358-4554 | PB 239 100 24mm Die | ||
| 1 | 392-3964 | PB 239 100 26mm Die | ||
| 1 | 358-4555 | PB 239 100 28mm Die | ||
| 1 | 358-4556 | PB 239 100 32mm Die | ||
| 1 | 358-4557 | PB 239 100 36mm Die | ||
| 1 | 358-4558 | PB 239 100 40mm Die | ||
| 1 | 358-4559 | PB 239 100 44mm Die | ||
| 1 | 358-4560 | PB 239 100 47mm Die | ||
| 1 | 358-4561 | PB 239 100 50mm Die | ||
| 1 | 358-4562 | PB 239 100 54mm Die | ||
| 1 | 358-4563 | PB 239 100 57mm Die | ||
| 1 | 358-4564 | PB 239 100 62mm Die | ||
| 1 | 358-4565 | PB 266L 67mm Die | ||
| 1 | 358-4566 | PB 266L 71mm Die | ||
| 1 | 358-4567 | PB 266L 84mm Die | ||
| 1 | 358-4568 | PB 266L 92mm Die | ||
| 1 | 421-2653 | 266.239L Die Adapter Set | ||
| 1 | 457-6033 | Pressure Sensor | ||
| 1 | 416-6391 | Rear Slide Bearings (8 pcs) | ||
| 1 | 416-6401 | Rear Retainer Ring for Slide Bearings (8 Screws) | ||
| 416-6402 | T-Nuts and Screws for Master Dies (8 pcs) |
Master Die Details and Parts
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| Illustration 35 | g03703365 |
| Position | Quantity | Cat Part Number | Uniflex Part Number | Description |
| 1 | 8 | 416-6403 (1 complete die) | Master Die Complete with items 2, 3, 4, 5 | |
| 2,3,4,5 | 1 | 416-6396 (Kit includes 1 each) | Bolt, Spring, Threaded Pin M5 x 10, Threaded Pin M12 x 16 | |
| 6 | 8 | 421-2654 (8 pieces) | Detent Screw, Spring Loaded Ball Retainer | |
| 7 | 8 | 233-8077 (1 piece) | Steel Pins for 266.239L Adapter Dies | |
| 8 | 8 | 421-2653 (Kit, 8 dies) | 266.239L Adapter Dies | |
| 9 | 8 | 330-3951 (Kit, 8 pins) | Steel Pins for 239 Series Dies |
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| Illustration 36 | g03710493 |
Maintenance
Cleaning
Clean the machine with compressed air and a clean, dry cloth.
Storage
Store tooling indoors in a clean, dry location to prevent rust or corrosion. Lay flat or hang from suitable hooks to prevent from falling.
Tool Disposal
At the end of the operational life of the tool, destroy the tool and dispose of as scrap. All fluids should be recycled in an appropriate manner.