Gates MOBILE CRIMP 4-20 Installation manual
1
MOBILE CRIMP® 4-20
DIGITAL DIAL CONTROL
SAFETY AND OPERATING MANUAL
2
Shop Air Pump
Prod. No.: 7481-0002, Part No.: 77820
Weight: 10 lbs.
1/4 H.P. 12 Volt DC Pump
Prod. No.: 7481-0037, Part No.: 77439
Weight: 20.5 lbs.
1/2 H.P. 115 Volt AC Pump
Prod. No.: 7481-0034, Part No.:77441
Weight: 32 lbs.
Hand Pump
Prod. No.: 7481-0006, Part No.: 77821
Weight: 25.6 lbs.
1-1/2 H.P. 115 Volt AC Pump
Prod. No. 7481-0035
Weight: 108 lbs.
Carefully read and understand all the following warnings before operating this crimper.
WARNING!
An incorrect hose assembly can rupture or blow apart in use, resulting in serious injury, death, or
property damage. REMEMBER: Others depend on you to make correct assemblies.
FOR SAFETY’S SAKE USE THIS MACHINE ONLY IF YOU:
1. Receive hands-on TRAINING with this Gates crimper and assemblies.
2. Follow current GATES OPERATING MANUAL and CRIMP DATA for the MoblieCrimp®4-20.
3. Use only NEW (UNUSED) GATES hose and ttings.
4. Wear SAFETY GLASSES.
5. KEEP HANDS CLEAR of moving parts.
PUMP SPECIFICATIONS
All pumps maximum rated working pressure: 10,000 psi
DIGITAL DIAL CONTROL
Prod. No.: 7480-0051, Part No.: 77421
Dimensions: 12 1/4" wide x 6 1/4" deep x 19 1/2" high
Weight: 57 lbs. (with stand)
Contents
Identication List..........................................................................................................4
Setup...........................................................................................................................5-7
Calibration Procedure...................................................................................................8
Hose Preparation........................................................................................................9-10
Operating Instructions............................................................................................11-14
Measuring and Adjusting Diameter............................................................................15
Maintenance.................................................................................................................16
Troubleshooting...........................................................................................................17
Replacement Parts List.......................................................................................18-19
Serial No. ____________________
(Located on front top of cylinder)
Date of Purchase ____________
3
.05 ALLEN WRENCH
CLAMPS
STAND
MOLYKOTE AND BRUSH
LITERATURE PACKET
HOSE ASSEMBLY
PRESSURE PLATE
DIE
CRIMPER
MAGNET
CALIPERS
4
IDENTIFICATION LIST MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
UNPACK CARTON
Remove crimper, pressure plate, nylon-covered hose
assembly. literature envelope, magnet, .05 Allen
wrench, and Molykote lubricant from shipping carton.
Locate the serial number assigned to the crimper on
the top front of the cylinder and record on page one
for future reference.
ATTACH CRIMPER TO THE STAND
Place crimper on at, well- supported surface (such
as the top of a workbench or the bed of a service
vehicle) with the handle to the right.
Remove two knobs, at washers, and spacer from
the crimper pivot bolts.
Slide the two halves of the stand together and
attach to the crimper at the pivot bolts.
Replace spacer, at washer, and knobs. Do no
tighten knobs.
Lift crimper and allow stand to swing down onto
the surface. Tighten knobs.
LEFT SIDE
RIGHT SIDE
SPACER
1.
2.
SETUP
5
MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
FASTEN CRIMPER TO WORK SURFACE STATION
BEFORE USE (to avoid damage to machine or
personal injury because an unsecured machine
can fall).
Position crimper so that mounting holes are
approximately 7” to 8” from the edge of the
work surface.
Mark the drilling location using the mounting holes
as a guide (see illustration below).
Drill two 5/16” diameter holes then use mountig
holes or clamps to fasten stand to work surface.
ATTACH PUMP TO CRIMPER
Place pump near crimper and connect hose
assembly to the pump port (3/8” NPT threads).
Pipesealant may be used to seal connection.
(Forbest connection, use Gates’ Quick Disconnect
couplings, G95311-0606 and G95321-0606,
sold separately.)
Connect opposite end to the adapter or crimper.
CHECK PUMP OIL LEVEL
Pump comes with oil in reservoir. Check proper oil
level per pump operating manual instructions or the
Maintenance section of this manual.
CONNECT PUMP TO POWER OUTLET
For 115V connection, plug power cord into a properly
grounded and rated circuit. For vehicle battery
connection, see pump operating manual.
EDGE OF
WORK
SURFACE
(2) 5/16" DIAMETER HOLES
7 1/2" 11"
Clamps
3. 4.
5.
To avoid damage to the machine ALWAYS fasten
the crimper to the work surface before you
attempt to crimp.
THINK SAFETY!
Mounting Holes
6.
6
SETUP MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
BLEED AIR FROM SYSTEM
Tilt crimper forward so adapter is at its highest point.
Turn the knob on the controller to a setting of 400,
which allows the ram to extend approximately 1”.
Turn pump on by pressing and holding the power
“on” switch, (see pump operating manual for switc
location) which extends the ram.
When the light comes on and buzzer sounds,
immediately release “on” switch allowing ram to
fully retract. NOTE: If light and buzzer are faint
do not work, the controller batteries may need
replacement. See “Maintenance” section of this
manual. Repeat a minimum of ve (5) times to bleed
air completely.
PLACE CRIMPER IN COMFORTABLE
WORKING POSITION
See photo below for suggested working
7. CAUTION
Keep away from all moving parts!
If bodily contact with a moving part occurs,
immediately release the pump power “on” switch.
IMPORTANT
Do not operate crimper in horizontal position
because dies will become unstable.
THINK SAFETY
NOTE: It’s a good idea to place a rubber mat on
the oor near the crimper to reduce the chance
of damaging a die if dropped and improve
operator comfort.
8.
7
SETUP MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
Before crimping a hose assembly, check calibration.
Calibration is the proper relationship between a
setting and the crimp diameter. It should be
checked at least monthly, possibly weekly or daily, if
crimper has been used heavily or abused. Mark the
drilling location using the mounting holes as a guide
(see illustration below).
Place the MC33 die set into the die cone and install
pressure plate.
Turn the knob to a setting of 245.
Insert an 8G MegaCrimp® coupling into the die set.
Complete the crimp.
Remove the coupling and measure the crimp
diameter, which should measure 1000” +/- .003”
To properly measure crimp diameter, refer to the
Measuring and Adjustment Diameter sections of
this manual.
If diameter is within range, no adjustment is
necessary. If the crimp diameter is not within this
ranger the crimper must be calibrated.
To get a larger or smaller number adjust accordingly
For every .001” change in crimp diameter, change
the setting by .002. For example, to increase the
crimp diameter by .002”, increase your setting
from 245-247.
Turn the knob to this new setting and crimp a new
coupling. After the correct diameter is achieved, pull
the plastic cap from the
Loosen the two set screws in the brass knob 1/4 to
1/2 turn using a .05” Allen wrench.
Turn the brass knob either clockwise or counter
clockwise to get the setting back to 245.
Tighten the set screws
and replace the plastic
cap. Crimper is
now calibrated.
Note: Rotating the knob on front of switch box
clockwise will increase the number; counter
clockwise will decrease the number. When
changing the setting, always moveto a higher
number then down to the desired setting. (Ex:
To change from 200- 245, move dial up to 300
then down to 245.)
1. 6.
CALIBRATION PROCEDURE MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
2.
3.
4.
5.
7.
8.
9.
10.
8
CAUTION
A new hose and end ttings must be used when
building a hose assembly. Re-using any components will
seriously affect performance and could result in serious
injury or property damage.
Cut hose to desired length.
Using Gates Crimp Data Chart (#35019 (Ind), 428
7365 (Auto)), select the correct coupling or visit our
website to download our electronic program at
ecrimp.gates.com.
Place a visible mark on hose cover at the insertion
length shown on the crimp data chart
Insert coupling into the hose until the mark lines up
with the end of the coupling ferrule.
Hose and coupling are now ready for crimping.
1.
4.
HOSE PREPARATION MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
2.
3. 5.
MEGACRIMP® PRE-ASSEMBLED COUPLINGS
9
A new hose and end ttings (stem/ferrule) must be
used when building a hose assembly. Re-using any
components will seriously affect performance and could
result in serious injury or damage.
Cut hose to desired length.
Using Gates crimp data chart (#35019 (Ind),
428-7365 (Auto)), select the correct coupling or visit
our website to download our electronic program at
ecrimp.gates.com.
Place ferrule over the end of the hose.
Lubricate the rst two or three serrations on stem
with lightweight oil (SAE 10W).
Clamp stem in vise on hex portion, and push hose
onto stem.
Hose should be ush against stem shoulder (see
cutaway drawing below).
Hose and coupling are now ready for crimping.
HOSE PREPARATION MOBILE CRIMP 4-20 SAFETY AND OPERATING MANUAL
1.
2.
6.
GLOBAL SPIRALTM TWO-PIECE COUPLINGS
CAUTION
3.
4.
5.
10
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