Gates GC32TSi Guide
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GC32TSi SAFETY AND OPERATION MANUAL
GC32TSi CRIMPER
SAFETY AND OPERATION MANUAL
GC32TSI
Product Number: 7480-7004
Part Number: 78827
CRIMPER DETAILS
YOUR CRIMPER DETAILS
SERIAL NUMBER
(LOCATED ON REAR RESERVOIR BASE)
DATE OF PURCHASE
CRIMPER SPECIFICATIONS
DYNAMIC
Nom. Size (Hydraulic Hose Size) 2 inches
Die Set Type 32 series
Crimping Range (inch with Std. Die Set) 1/4 to 2 inches
Crimping Range (inch with Optional Dies) 3/16 to 2½ inches
Radial Swaging Force 4100 kN / 418 tonne
Cycle Speed (Full Stroke-Complete Cycle) 16 seconds
PHYSICAL
Dimensions (Plan inch x inch x Height inch) 27 x 20 x 30
Weight (Without Dies & Oil lbs) 660 lbs / 295 kg
Shipping Space 47,120 cubic inches
Shipping Weight 787 lbs / 358 kg
Crate Size (Plan in x in x Height in). 40 x 31 x 38
ELECTRICAL
Supply (Voltage / Current / Frequency )
230 V
16 A
50 Hz to 60 Hz
Plug Type (North America) NEMA L6 20
Phase Single Phase
Power 4.0 kW / 6.0 HP
HYDRAULIC
Rated Pressure 4300 PSI
Reservoir Capacity 8 US Gallons
Filtration 10 um
MAINTENANCE Grease Specification Tungsten Disulphide
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TABLE OF CONTENTS
Crimper Safety............................................................................................................................................................................. 2
Location Preparation ................................................................................................................................................................. 3
Box Contents................................................................................................................................................................................. 4
Crimper Installation .................................................................................................................................................................... 5
Moving the Crimper......................................................................................................................................................... 6
Electrical............................................................................................................................................................................ 8
Ergonomics ....................................................................................................................................................................... 8
Operating Instructions
Power Up............................................................................................................................................................................ 9
eCrimp.............................................................................................................................................................................. 10
Verify Crimp..................................................................................................................................................................... 12
Hose Preparation...................................................................................................................................................................... 13
Load Crimper Dies ......................................................................................................................................................... 14
Crimp Aasembly ............................................................................................................................................................ 15
Unload Die Set................................................................................................................................................................ 17
Calibration .................................................................................................................................................................................. 17
Periodic Maintenance.............................................................................................................................................................. 18
Lubrication .......................................................................................................................................................................18
Torque Bolts.....................................................................................................................................................................18
Foam Filler Pads .............................................................................................................................................................18
Check Oil Level.................................................................................................................................................................19
Add Oil................................................................................................................................................................................19
Oil & Filter Change..........................................................................................................................................................19
Replace or Add Oil...........................................................................................................................................................19
Tooling ......................................................................................................................................................................................... 20
Troubleshooting ........................................................................................................................................................................ 22
Operating Instructions
Using the Gates Insertion Tool.....................................................................................................................................23
Warranty ..................................................................................................................................................................................... 24
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CRIMPER SAFETY
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.
Hose Assembly Fabrication.
›Component Inspection: Before creating an assembly be sure to inspect all components to
be sure they are correct product, cut correctly, and do not have any visually identifiable
defects.
›Couplings (compatibility): Hose fitting components from one manufacturer are not usually
compatible with fitting components supplied by another manufacturer. Never mix and
match hose couplings from different manufacturers unless approved by both parties.
›Hose assembly equipment (crimpers): Hoses and fittings from one manufacturer should
not generally be assembled with the equipment of another manufacturer.
NOTE: Gates recommends only those hose and coupling combinations specified in the Gates
Hydraulic Product catalogs. Gates disclaims any liability for any hose assemblies which have not been
produced in conformance with Gates assembly recommendations.
WARNING
!
Carefully read and understand the following warnings before operating this crimper.
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 GC32TSi crimper.
3. Use only NEW (UNUSED GATES) hose and fittings.
4. Wear SAFETY GLASSES.
5. Keep hands clear of moving parts.
WARNING
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LOCATION PREPARATION
SELECT LOCATION
Before you unpack the crimper, decide where it will go. Choose
a location where the operator can have access to the front, rear
and left side. Bent (e.g. 90 degree) couplings must be loaded from
the rear of the crimper head. Note there is an indentation in the
front flange is designed to accommodate these couplings during
crimping.
UNPACK OPTIONAL STAND CARTON (if purchased)
Uncrate stand (Part No. 78829, Product No. 7480-7002) and
unbolt from pallet. To attach tool shelf, remove Allen head bolts
from top of stand, position shelf and replace bolts.
Position stand to allow front, left side, and rear access to the
crimper. Stand should be bolted to floor.
ERGONOMIC STAND ADJUSTMENT
Adjust height of stand to suit hose feed method (i.e. bench fed or
hand fed).
If hose is hand fed, the bottom of the hose should be level with the
operator’s elbows when standing upright. Operator should have a
straight back during crimping to avoid injury from handling heavy
hose assemblies. It is approximately twenty inches from the top of
the stand to the center of the crimper head. If this is comfortable,
no adjustment is needed. If this is too high or too low, adjust height
of stand by setting stand on its side and removing leg bolts. Raise
or lower legs to comfortable height. Replace bolts and tighten. If
optional die racks were purchased, place in bottom of stand or
hang on the wall.
If using the stand, bolt crimper using the four 6mm (1/4") Allen
head bolts (included) through predrilled holes. If mounting to a
bench, drill four 1/2" holes aligning with holes in crimper and bolt
together. Proper crimping height is approximately 32".
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BOX CONTENTS
GC32-TSi crimper
Tube of Tungsten Disulphide grease with brush
Calipers
Calibration tool
Foot Pedal
Quick Change Tool
Hydraulic Oil (in reservoir)
Air Breather (must be fitted at customers location)
Stand, dies and rack are ordered separately.
CALIBRATION
TOOL
TUNGSTEN
DISULPHIDE
GREASE
QUICK CHANGE
TOOL
FOOT PEDAL
CALIPERS
AIR
BREATHER
GC32-TSi
CRIMPER
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CRIMPER INSTALLATION
The crimper is top heavy and weighs 660 lbs (300kg)
›Follow the correct set-up procedure as shown in this manual
›Failure to follow proper procedures can create risk of severe injury and/or damage to the crimper
›DO NOT lift crimper by head. Use lifting anchors on crimper base.
Assemble the optional crimper stand, if using. The crimper stand
MUST be secured to the floor.
STORE AND INSTALL DIE SETS
Using the Quick Change Tool (QCT), load dies into the front and/or
back of stand, in optional rack or store in plastic shipping tubs.
Remove the plastic wrapping from the outside of the box.
Remove the staples from the bottom and top of carton with a
screwdriver and pliers.
Slit the tape on the top of the carton with a sharp knife, then open
the lid and remove the wooden side supports.
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Lift off the carton.
Note voltage and frequency on the name plate located on the back
of the tank. Ensure it is suitable for this location.
Using a 5/8 (16mm) wrench remove the four mounting bolts
Adjust the ratchet handle to rotate the control box out
approx 15 degrees, retighten the handle. Remove control
box power cord. Position the first sling between the control
box and the electric motor as per the photo so that the straps
clear the control box. Ensure the other half of the sling does
not cause excessive pressure on the motor juntion box.
Position the second sling in front and behind the crimper head as
per the photo.
INSTALLATION: SAFELY MOVING CRIMPER
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Position the lifting device over the center of the crimper and
attach the slings then slowly raise the crimper and place it on a
suitable table.
Fit 5/8" (M10) bolts, nut and washers into pre-drilled holes and
tighten.
Secure the crimper to bench. If using the optional stand, bolt
crimper using the four 6mm Allen head bolts (included) through
predrilled holes. If mounting to a bench, drill four ½" holes aligning
with holes in crimper and bolt together.
Remove the slings and store.
Oil reservoir is shipped full. Remove plug and replace with
breather cap, store plug. Always ship crimper with plug
installed to avoid spillage of hydraulic fluid or contamination
of breather element. Check the sight glass to make sure oil
level is half way with the head fully retracted (open).
INSTALLATION: SAFELY MOVING CRIMPER
INCORRECT LIFTING
DO NOT lift crimper by head as this will cause damage to the crimper.
Use lifting anchors on crimper base.
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CRIMPER INSTALLATION
Consult with a qualified electrician for the correct plug and outlet for your power supply.
Incorrect electrical connection can cause damage to component or an electrical hazard
for personnel. The crimper is shipped with a NEMA L6 20 cable; modifying this cable voids
your warranty.
ELECTRICAL
Connect the provided 220 VCA single phase cord assembly with
HBL 2321 250 HVAC 20 amp twist lock plug to your crimping
machine.
Connect your region specific electric cable to a suitable power
supply socket of at least 16A.
ERGONOMICS
INSTALL FOOT PEDAL
This crimper can also be activated by using a foot pedal. The
protective metal case surrounding the pedal will avoid accidental
activation. Install foot pedal by plugging it into the lower right side
of control panel next to the power switch.
CONFIGURE CONTROL PANEL IN COMFORTABLE WORKING
POSITION
The control panel can be rotated to a position that is more
accessible depending on where the operator is working. Loosening
the locking handle located to the left of the control box will allow
the box panel to pivot approximately 30 degrees left. The control
panel can then be pivoted by loosening its locking handle, located
above the control box and below the control panel, on the right
hand side.
Connect panel power cable to control panel.
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