MC2501 OPERATING AND CALIBRATION INSTRUCTIONS

MC2501 OPERATING AND CALIBRATION INSTRUCTIONS

CONTENTS 1 - CERTIFICATE OF CONFORMITY... 3 2 DESCRIPTION.... 4 2. 1 - GENERAL... 4 2. 2 - CHARACTERISTICS... 4 2. 3 WORKING PRINCIPLE.... 5 2. 3. 1 Hydraulic system..... 5 2. 3. 2 Electrical system... 6 2. 3. 3 Crimp head... 8 3 INSTRUCTIONS FOR USE... 9 3. 1 - SAFETY... 9 3. 2 - UNPACKING - INSTALLATION... 9 3. 3 OPERATING INSTRUCTIONS... 13 4 - MAINTENANCE..... 16 4. 1 - LUBRICATION... 16 4. 2 LUBCRICATON PROCEDURE... 16 4.3. OIL CHANGE. 16 4.4. SPARE PARTS 17 5 WARRANTY LIMITATIONS... 18 2

1 - CERTIFICATE OF CONFORMITY EC DECLARATION OF CONFORMITY The undersigned Company : GATES hereby declares that the new equipment described below: MC2501 - Serial N : Complies with the machinery directive and the specification given by GATES and with the regulations regarding health and safety at work, as applicable. Signed by V. J. Hainsby date : May 2005 signature : V. J. Hainsby Machine started on : by : place : 3

2 - DESCRIPTION 2. 1 - GENERAL : You have just acquired a GATES type MC2501 powered crimper. It is necessary for you to adhere to the following operating instructions for best performance. The MC2501 has been designed specifically for crimping Gates hoses and couplings which are used constantly in today s industry, agriculture and public works. This user guide contains all information concerning the operation, use and maintenance of your MC2501. 2. 2 - CHARACTERISTICS: Crimping power : 137 tonnes at 340 bar Motor: 3 kw, 8 A at 380 V 3-phase 2.2 kw, 20 A at 220 V 1-phase Dimensions : H 520 x W 490 x L 650 mm Weight : 90 kg with oil Capacity : braided hose from 3/16" to 1"1/4 Multi spiral metal reinforced hose from 1/4 to 1 Noise levels: 71dB Oil Tank : 3 litres Pump : gear type (1.2cc / REV) Die travel : 14 mm working stroke and 18 mm maximum travel Adjustment : by micrometer gauge with numerical display and electrical stop Crimping : by pressing push-button Crimping stop: automatic according to adjustment (micrometer gauge) Retraction stop : by releasing push-button Cycle time: 26 seconds for 3-phase 380 V crimper 26 seconds for 1-phase 220 V crimper Tooling : changing tool for dies GATES die sets These specifications are nominal and must not be used for inspection. Options : - Machine table + die rack + quick change tool (ref. MC5001 10798) - Quick change tool + die rack (ref. MC5001 10354) 4

2.3. WORKING PRINCIPLE : 2.3.1. - HYDRAULIC SYSTEM : Fig. 1 Hydraulic System 1 - Pressure release valve 2 - Directional control valve 3 - Motor 4 - Pump 5 - Oil filter 6 - Oil tank 5

2.3.2. - ELECTRICAL SYSTEM : The electrical system supplies the motor and control valve. Composition : Fig. 2 Electrical circuit 220 V / 1 ph 6

Fig. 3 - Electrical circuit 380 V / 3 ph Note : Spare fuses are attached to the switch cable in the electrical enclosure of the machine. 7

2.3.3. - CRIMP HEAD : This is the most technical part of the machine. Through the use of die sets, it compresses the ferrule in order to crimp it onto the hose. Composition : A - Bell housing B - Bell housing flange C - Cap head allen screw D - Piston E - Micrometer gauge guard F - Die carrier G - Micrometer gauge 10433 - Plunger rear (8000-10098) 10432 - Plunger front (8000-10097) Fig. 4 - Composition 8

3 INSTRUCTIONS FOR USE 3. 1 - SAFETY: The crimper must be mounted on a bench or on a stable base. Do not put your hand in the crimping head during its operation. Do not modify the technical characteristics of the machine (pressure or others). When performing any kind of maintenance upon the electrical system, ensure that the machine is disconnected from the power supply. Do not cover the electric motor ventilator. Disconnect the machine from electrical supply when working on the dies. 3. 2 - UNPACKING - INSTALLATION : Unpack the machine without destroying the packaging. From then on, the machine should only be transported in its original packaging. Please retain for future use. Remove the lid from the box. Remove the screws at the bottom of the uprights, lift the uprights from the box. Put webbings under the machine or raise it with a lift truck. Never hold the machine by its crimping head or by any of its component parts. For best use and less operator fatigue, it is advisable to secure the crimper horizontally on a base approximately 0.75m in height. (Bases are available from GATES on request, ref. MC5000-SPEP50 or MC5000-SPEV50 or MC5000-SPER50 with or without drawers). 3.2.1. ELECTRIC CONNECTION The machine must be connected to a 5 wire socket (with neutral). - If you have a 380V / 3ph or 220V / 3ph machine Fig. 5 - Electrical connection 380V / 3ph or 220V / 3ph machine 9

- If you have a 110V / 1ph or 220V / 1ph machine Fig. 6 - Electrical connection 110V / 1ph or 220V / 1ph machine Make sure that your electrical circuit is compatible with the specification of the motor. AMPERAGE REQUIREMENTS (A) 110V 1ph 220V 1ph 220V 3ph 380V 3ph 43 Amps 11,4 Amps 8 Amps 4,2 Amps 3.2.2. - Check the direction of rotation of the motor - Press the crimp button. The motor starts rotating and the dies close. - Check that the direction of the motor matches the direction of the arrow. To stop crimping and the motor, release the button. Dies will immediately stop in place. - To change the direction of rotation of the motor, reverse 2 phases at the plug. Fig 7 - Rotation of the motor An error in the rotation of the motor can damage the pump. 10

3.2.3. - Technical Specifications Tank : 3 ltr oil Pump : Gear pump (1.2cc/rev) Crimp force : 1370 kn @ 340 b Retraction : By springs Dimensions : 605 x 400 x 520mm Weight : 90 kg Capacity : See section 2.2 A Application: GATES hoses and couplings within capacity of machine. The warranty will be void if the above unpacking and/or installation procedures are not followed. A 7 unit variation on the gauge rev counter allows the crimping diameter to vary by 0.1 mm The gauge values are only provided as a guide to assist in manufacture, only the exact crimping diameter can guarantee the flexible hose. It is imperative that the diameters obtained are within the tolerances specified by GATES. 11

Figure 8 - Identification diagram 1. Gauge Assembly 2. Motor 3. Crimping head 4. Die racks 5. Emergency stop push button 6. Die closing push button 7. Die opening push button 12

3. 3 OPERATING INSTRUCTIONS 3.3.1. Choosing the right die set and gauge setting: - establish from the crimp data for the hose/coupling combination being crimped. 3.3.2. Installation of the dies 3.3.2.1. With manual tool Installing the dies - Slide the die in and push it until it is firmly locked. - Make sure that the number of the dies is facing the operator. Removing the dies - Close the dies until the position of the dies allows the introduction of the manual tool. - Push the tool until the magnet contacts the face of the die. Pull the die out. 13

3.3.2.2. With SRC Quick Change Tool (optional) Installing the dies - If using standard dies, adjust the gauge to 100 and close the head. - If using D37 dies, the gauge setting is 180. - Insert the dies in the head with the gun tool, with a sharp and quick movement Photo 1 (photo 1). - To extract the tool and release the dies pull the trigger (photo 2). Removing the dies - If using standard dies, adjust the gauge to 100 and close the head. - If using D37 dies, the gauge setting is 180. Photo 2 - Only when the head is closed, slide the gun tool in the head until the magnet is in contact with the dies (Photo 3). Photo 3 - Pull the gun tool towards you (Photo 4). - Store the die set into one of the plastic pods. - Release the tool by pulling the trigger and pulling the tool upwards at a slight angle. Photo 4 14

3.3.3. Die positioning - To enable effective crimping of Gates couplings, position all terminations towards the front of the machine with the die number visible from the front (as seen in figures 9 and 10). Figure 9 - Location 1 Figure 10 - Location 2 For straight couplings For angled couplings 3.3.4. Adjustment of the micrometer gauge 3.3.5. Crimping - Unlock by moving mechanism ¼ turn anti-clockwise adjust setting by turning dial either clock/anti-clock to achieve desired setting lock. - Position hose and coupling as specified in the crimp data (CD). - Press closing button until the machine stops. The crimping light comes on. - To release the hose assembly press the opening button. - Check the crimp diameter with a vernier or micrometer.* * Only use caliper gauges with a 0.002 mm calibration or less. 15

4 - MAINTENANCE 4.1. LUBRICATION Grease type: MoS 2 (Molybdenum disulphide) - The greasing of the die carriers is very important. - A lack of lubrication could cause a loss of up to 40% of the machine capacity. - It is necessary to replace polluted grease with new grease charged with MoS 2. Advice: A regular lubrication is advised every 100 cycles. 4.2. LUBRICATION PROCEDURE - Clean the cone of the front flange with a cloth. - Apply new grease with a paintbrush on the cone and with the grease pipe, supplied with the tube of grease, through the central hole of the master dies. 4.3. OIL CHANGE Advice: - Change oil every year. - Type of oil : ISO HV 32. 16

4.4. SPARE PARTS: Note: Any intervention by the operator on the machine during the warranty period will render it void. To order any spare parts, it is necessary to give the part s reference number and item number, as well as the quantity required.. Example : Description: Plunger - Rear Item No: 8000-10098 Quantity : 1 4.4.1. Machine spare parts Part Number Item Number Description Quantity MC2501-225 8000-10117 Bell housing 1 MC2501-10938 8000-10118 Bell housing flange 1 MC2501-10944 8000-10119 CHC screw M14 x 60 8 MC2501-9548 8000-10120 Piston 1 MC2501-10951 8000-10121 Machine gauge guard 1 MC2501-10939 8000-10122 Die carrier (bare) 8 MC2501-5271 8000-10123 Machine gauge (complete) 1 MC2501-5389 8000-10124 Seal kit (complete) 1 MC2501-50 8000-10125 Die carrier spring 8 MC2501-11288 8000-10126 Protection pads 8 MC5000-54 7482-19033 Die pin 8 MC2501-10155 8000-10127 Return spring 7 21 7482-19228 Counter knob for vernier 1 10432 8000-10098 Plunger Rear 8 10433 8000-10097 Plunger - Front 8 17

5 LIMITED WARRANTY GATES guarantee their machines against any faults in materials and workmanship for a period of 1 year from the date of purchase. During this Guarantee period, GATES will repair (or replace as the case may be) at no charge to the customer, all of the defective components, provided that the machine is returned to our factory. This warranty does not apply if the machine has been damaged accidentally, misused or undergone any repairs or modifications which were not carried out by GATES. GATES is not responsible for any injury or damage resulting from direct, indirect or consecutive use of their machines, nor for their machines after the warranty has been expressly or implicitly broken. This guarantee replaces all other guarantee, including implicit guarantees. Every effort has been made to provide exact and exhaustive information in this guide. However, GATES cannot be held responsible for any errors, annulments and modifications made after printing has been authorised ; or for the use of their products in special or exceptional circumstances if a GATES representative was not consulted beforehand to verify the intended use. For further information, contact : Gates Hydraulics Ltd Gates Hydraulique S.A. Gates Europe N.V. Station Road B.P. 14 Dr. Carlierlaan 30 St Neots, Huntingdon F - 69881 Meyzieu-Cedex B 9320 Erembodegem PE19 1XA, UK TL : (33) 04 72 45 12 12 TL : (32) 053 / 76 27 11 TL : (44) 01480 / 225000 FX : (33) 04 72 02 85 24 FX : (32) 053 / 76 27 13 FX : (44) 01480 / 225350 The world s most trusted name in belts and hose. 18