MC1000 / MC1001 MANUAL. Operating and Calibration Instructions

Transcription

1 MC1000 / MC1001 MANUAL Operating and Calibration Instructions

2 MC1000/MC1001 MANUAL Operating Instructions Contents Certificates.. 3 Circuit Diagram. 5 Gates MC1000/MC1001 Hose Crimping Machine. 6 Operating instructions 7 To bleed the machine of air 8 Machine calibration 9 Parts list for Gates Hose Crimping Machine MC1000/MC

3 EC DECLARATION OF CONFORMITY The undersigned Company: GATES hereby declares that the new equipment described below: MC1000 Serial No: complies with the Machinery Directive, GATES Specification and with the Hygiene and Safety at Work Regulations as applicable. Authorised: V. J. Hainsby Date: V. J. Hainsby Technical Manager, Couplings 3

4 EC DECLARATION OF CONFORMITY The undersigned Company: GATES hereby declares that the new equipment described below: MC1001 Serial No: complies with the Machinery Directive, GATES Specification and with the Hygiene and Safety at Work Regulations as applicable. Authorised: V. J. Hainsby Date: V. J. Hainsby Technical Manager, Couplings 4

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6 Gates MC1000/MC1001 Hose Crimping Machine Fig 1 6

7 1. Operating Instructions Select suitable hose and coupling by identifying products being replaced or by reference to Gates Hose & Coupling Catalogue. Reference to the machine crimp data will indicate if the hose requires to be skived (the rubber cover removed down to the reinforcing wire which should not be damaged in the process). If the crimp data calls for a different die set to that already in the machine the dies should be changed as required. If the dies have been changed, ensure that the size stamp is facing uppermost through the centre of the carrier assembly. Adjust the gauge to the correct setting for hose/coupling as shown on the crimp chart. The bottom of the gauge window should line up exactly with the gauge setting required. To prepare the machine for crimping, open vent on hand pump by turning the knurled cap anticlockwise approximately 1 full turn until cap becomes free. (Cap must not be tightened during transit). NB. Only remove cap completely when pump requires topping up with oil. Close the pressure release valve by turning the release valve knob on the hand pump in a clockwise direction (hand tighten only). To raise the die carrier and bring the dies closer together, raise and lower the pump handle a few times. Push the coupling fully onto the hose and insert it between the dies taking care to observe correct shell location, as shown on the crimp data CD. Operate the pump handle until the gauge pin is flush with the top of the gauge. To remove the hose assembly from the machine, turn the pump release valve anti-clockwise a full turn, the die carrier will lower and you can then carefully remove the hose assembly from between the dies. To crimp the second end of the hose assembly, repeat the above instructions. EP2 grade grease should be applied to the crimp ring after use; this will ensure smooth movement between the dies and the crimp ring during the crimping process. 7

8 2. To Bleed the Machine of Air If for any reason the pump has become low on oil it will need to be topped up and the system may then require purging. Refill the pump as follows: Step 1: Fully retract the die carriage assembly by loosening the pump release valve. Remove the pump operating handle by twisting it anti-clockwise and pulling backwards, unscrew the filler breather on the top of the pump body and refill with Freedom Aries H32 oil or equivalent. The pump should be topped up to withn ½ of the oil filler hole, once this is done replace the oil filler breather. Step 2: To bleed any air from the system, firstly remove the dies from the machine. Replace the pump operating handle and tighten the pump release valve, operate the pump handle until the die carriage assembly is fully extended. Step 3: Lay the machine on its side with the pump uppermost and loosen the release valve a full turn; any air that has got into the system should return to the pump reservoir as the die carriage retracts. It may be necessary to repeat this operation if the machine still appears to have air in the system. Step 4: Stand the machine back on its base and remove the oil filler breather, check the oil level and top up if required. 8

9 3. Machine Calibration To be carried out every 6 months to ensure the machine is within tolerance. Calibration using Megacrimp calibration shell 8G ( ) Remove the existing dies from the machine and replace them with 33 dies, then adjust the crimp gauge to setting of 70. Close the pump pressure release valve by turning clockwise. Place the shell between the dies and operate the pump handle until the gauge pin is flush with the top of the gauge. NB. As the dies rise they close together. Open the pump release valve and carefully remove the calibration shell from between the dies. Place a vernier calliper over each of the 4 flat indentations in the middle of the shell. If the machine is satisfactorily calibrated the average reading should be 26.0mm +/- 0.25mm if calibrated with an 08 Megacrimp shell (see Fig 2 and Fig 3). Fig 2. Fig 3. 9

10 If the average reading is outside these limits, the machine requires recalibrating by adjusting the gauge pin stop screw up or down accordingly (see Fig 4). Fig 4. A whole turn of the screw represents an increase or decrease in crimp diameter of 0.43mm. Clockwise rotation of the stop screw will tighten the final crimp, anti-clockwise will loosen the final crimp. Repeat the process described above and check that the machine has been properly recalibrated. 10

11 4. Parts List for Gates Hose Crimper Model MC1000/MC1001 Item Qty Description Part No. Order Ref. 1 1 Micrometer Gauge Assy A A 1 Body D B 1 Screw D C 1 Pin Assy A D 1 Thumb Locknut S E 1 Gauge Inner Sleeve D ½ UNF x 2 ½ Allen Screw Top Plate Crimping Ring D M6 x 40 Allen Screws Die Cover Plate D Die Spacer Tube M6 x 30 Allen Screws Die Guide Plate D Tie Rod M8 X 40 Allen Screws Copper Washer A 1 Location Plate D B 1 M6 Nut C 1 M6 x 20 Hex Head Screw D 2 M4 x 10 Allen Screws Piston/Spacer Assy Pressure Seal Spring Cylinder Body O-Ring Pump Assembly 04PML130GA A 1 Pump Handle (spare part) Die Case A 2 Die Cae Fixing Screws (not shown) O-Ring Base Plate ½ UNF x 1 ¾ Allen Screws M6 x 25 Allen Screws M8 x 25 Allen Screws

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