MC1000 / MC1001 MANUAL Operating and Calibration Instructions
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/MC1001 11 2
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
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
Gates MC1000/MC1001 Hose Crimping Machine Fig 1 6
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
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
3. Machine Calibration To be carried out every 6 months to ensure the machine is within tolerance. Calibration using Megacrimp calibration shell 8G (7482-19860-5) 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
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
4. Parts List for Gates Hose Crimper Model MC1000/MC1001 Item Qty Description Part No. Order Ref. 1 1 Micrometer Gauge Assy A 587 7482-19186 1A 1 Body D10780 7482-18545 1B 1 Screw D11136 7482-19077 1C 1 Pin Assy A 598 7482-19187 1D 1 Thumb Locknut S2104 7482-18849 1E 1 Gauge Inner Sleeve D10689 7482-18528 2 4 ½ UNF x 2 ½ Allen Screw 03337032 7480-19108 3 1 Top Plate Crimping Ring D11091 7482-19067 4 4 M6 x 40 Allen Screws 03011053 7480-19109 5 1 Die Cover Plate D11095 7482-19069 6 4 Die Spacer Tube 35106009 7480-19110 7 4 M6 x 30 Allen Screws 03011051 7480-19111 8 1 Die Guide Plate D11103 7482-19072 9 4 Tie Rod 35106007 10 2 M8 X 40 Allen Screws 03011066 7480-19113 11 2 Copper Washer 03024037 7480-19114 12A 1 Location Plate D11108 7482-19073 12B 1 M6 Nut 03035004 7480-19115 12C 1 M6 x 20 Hex Head Screw 03001048 7480-19116 12D 2 M4 x 10 Allen Screws 03011015 7480-19117 13 1 Piston/Spacer Assy 35106003 7480-19118 14 1 Pressure Seal 030203730 7480-19119 15 1 Spring 35106008 7480-19120 16 1 Cylinder Body 35106002 7480-19121 17 1 O-Ring 030224300 7480-19122 18 1 Pump Assembly 04PML130GA 7480-19123 18A 1 Pump Handle (spare part) 35106017 7480-19124 19 1 Die Case 35106034 7480-19125 19A 2 Die Cae Fixing Screws (not shown) 03317141 7480-19126 20 1 O-Ring 030222018 7480-19127 21 1 Base Plate 35106001 7480-19128 22 4 ½ UNF x 1 ¾ Allen Screws 03337033 7480-19129 23 4 M6 x 25 Allen Screws 03011050 7480-19130 24 8 M8 x 25 Allen Screws 03011063 7480-19131 11