Gates SC32 Hydraulic Hose Crimper Operators Manual

Gates SC32 Hydraulic Hose Crimper Operators Manual
SC32 HYDRAULIC HOSE
CRIMPER OPERATORS MANUAL
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 the 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 the current GATES OPERATING MANUAL and CRIMP DATA
for the Gates SC-32 Crimper,
3. Use only NEW (UNUSED GATES) hose and fittings.
4. Wear SAFETY GLASSES.
5. Keep hands clear of moving parts.
NOTE
Gates recommends only those hose and
coupling combinations specified in the Gates
Hydraulic Products catalogs. Gates disclaims
any liability for any hose assemblies which
have not been produced in conformance
with the Gates assembly recommendations
2
REV: 08-04-2010
TABLE OF CONTENTS
Serial No _______________________
(Located on the machine base at the rear of the base)
Date of Purchase _________________
Specifications .................................................................................................2
SC32 Component Identification ...................................................................3
Hose Preparation ............................................................................................4
SC32 Calibration Procedure .........................................................................5
Operating Instructions (Standard Dies) .......................................................6
Operating Instructions (Double Angle Dies).................................................7
Measuring Crimp Diameter ............................................................................8
Troubleshooting .............................................................................................9
Warranty ........................................................................................................10
Start up Kit
QTY
1
1
1
1
1
1
1
1
UOM
EA
EA
EA
EA
EA
EA
EA
EA
P/N or Form #
73690322
74820291
98-1696
98-1698
74823011
74821702
74821738
74821739
DESCRIPTION
78241 DIGITAL CALIPER 6 IN
78746 MAGNET PC707
OP MANUAL
SPACER INSTRUCTIONS
MOLYCOTE 3 OZ
SPACER
DIE CONE
BASE PLATE
1
SC32 CRIMPER SPECIFICATIONS
Die Series-------------------------------PC 707 & SC 32 DA (DOUBLE ANGLE)
Maximum Cylinder Force------------------------------------------------------80 Ton
Maximum Hose Diameter (6 Wire)-------------------------------------------------2”
Crimper Depth--------------------------------------------------------------------------32”
Crimper Width------------------------------------------------------------------------16.5”
Crimper Height-----------------------------------------------------------------------28.5”
Weight--------------------------------------------------------------------------------420 Lb
Pump--------------------------------------------------------------------------------Electric
Maximum Pump Pressure-------------------------------------------------10,000psi
Pump HP (SC32 )-----------------------------------------------------2 HP (220V-1 ph)
Pump HP (SC32)-----------------------------------------------------------1 HP (110V)
Reservoir Capacity-----------------------------------------------------------------1 Gal
Oil Type-------------------------------------------------------ISO Viscosity Grade 46
SAFETY PRECAUTIONS
READ INSTRUCTIONS AND IDENTIFY ALL CRIMPER COMPONENTS
BEFORE USING CRIMPER
CRIMPER CAN PRODUCE 80 TONS OF FORCE!
KEEP BOTH HANDS AWAY FROM PINCH POINTS
CONSULT GATES SPECIFICATIONS FOR CORRECT MACHINE
SETTINGS AND CRIMP MEASUREMENTS
ALWAYS WEAR EYE PROTECTION
2
SC32 CRIMPER COMPONENT IDENTIFICATION
Caution
The Shipping plug must be
removed and replaced with the
vent plug prior to operating the
equipment
Adjustable Ram
retraction stop
80 Ton Hydraulic
Cylinder
Oil Fill & Vent Plug
Power On/Off Circuit
Breaker Switch
Dial Vernier
Adjuster
1HP/2HP 10,000 psi Single
Phase Hydraulic Pump
220 Volt & 110 Volt options are
available
Calibration
Adjustment Screw
Automatic Stop
Switch
Manual Pneumatic
Start/Stop switch
PC707
Compression Ring
PC707 Die Set
PC707 Pressure
Plate
Dies Not Included
Double Angle Top
Compression Ring
Double Angle Die Set
Double Angle
Base Ring
Dies Not Included
3
HOSE PREPARATION
CAUTION:
A new hose and end fittings (stem/ferrule) must be used when building a hose assembly. Re-using
any component will seriously affect performance and could result in serious injury or property damage
Two-Piece Couplings
MegaCrimp® Pre-Assembled
Couplings
1. Cut Hose to desired length.
1. Cut hose to desired length
2. Using Gates Crimp Data Manual
#35019 (Ind), 428-7365(Auto) select the
correct stem and ferrule. Or, log onto
www.gates.com/ecrimp for the latest crimp
information on line
3. Place the ferrule over end of hose.
2. Using Gates Crimp Data Manual
#35019(Ind), 428-7365 (Auto) select the
correct MegaCrimp® coupling. Or, log onto
www.gates.com/ecrimp for the latest crimp
information on-line.
If
skiving is required, see instructions in
Gates Hand Skiver manual # 35019-W
3. Place a visible mark on the hose cover
4. Lubricate the first two or three serrations
on the stem with lightweight oil (SAE 10W)
at the insertion length shown in the crimp
data manual.
5. Clamp the stem in vise on hex portion,
and push hose onto stem. Hose should be
flush against stem shoulder (See cutaway
drawing)
4. Insert coupling into the hose until the
mark lines up with the end of the coupling
ferrule.
6. Push ferrule so it rests against hex of
stem. Hose and coupling are now ready for
crimping
5. Hose and coupling are now ready for
crimping.
NOTE:
See Hose Assembly Guide of the Gates
Crimp Data Manual #35019(Ind) and
428-7365(Auto) or log onto
www.gates.com/ecrimp for more details
4
SC32 CRIMPER CALIBRATION PROCEDURE
1. Install the “.733” die set to calibrate
the machine using an 8G Megacrimp
coupling.
®
2. Set the Dial Vernier setting to
5.20. Rotating the dial clockwise will
increase the number and rotating it
counterclockwise will decrease the
number. When changing the setting,
always move to a higher number then
down to the desired setting
•
5.
Remove the coupling and measure
the crimp diameter which should measure
1.000 +/- .003 inches. See page 8 for
measuring crimp diameter.
6. If ferrule crimp diameter is not
acceptable adjust the Dial Vernier (See
Photo 2)
Example: To change from 5.00 to
5.20, move the Dial Vernier up to 6.00
then down to 5.20.
3.
Insert the coupling into the die set
approximately 1/8 inch below the top of
the die. (See Photo 1)
Photo 2
Photo 1
4. Push and hold the start/stop switch
until the pump stops.
•
To increase the crimp diameter, hold
the Dial Vernier barrel with a 5/16 inch
open end wrench and rotate the stem
out of the barrel with a 5/32 inch hex
key wrench.
•
To decrease the crimp diameter, hold
the Dial Vernier barrel with a 5/16 inch
open end wrench and rotate the stem
into the barrel with a 5/32 inch hex key
wrench.
7. Repeat steps 2 through 5 to verify the
correct crimp setting.
5
OPERATING INSTRUCTIONS WITH PC707 DIES
1 Note the tag attached to the pump motor
2 Make certain that the base is clean.
and make certain that the power source
matches the requirements specified on the
tag.
Insert the standard Pressure Plate and
tighten the set screw through the hole in
the hand hazard decal with a 1/8 inch hex
key wrench.
4 Select the correct die set from the Gates
Crimp Manual #35019 (Ind) and 428-7635
(Auto) or log onto www.gates.com/ecrimp.
Lubricate the outer surfaces of the dies with
MolkKote “G”
5 Position the Compression Ring loosely
over the die set and insert the hose and
fitting from the bottom of the crimper.
3 Orient the Pressure Plate as shown and
tighten the set screw to hold it securely
in place. Lubricate the Pressure Plate
with a high quality moly-disulfide grease .
Molykote “G” is recommended.
6 Position the ferrule or MegaCrimp®
approximately 1/8 inch below the top of the
die fingers.
Important: Be sure the hex of a straight
stem or round portion of a bent ferrule
rests against the ferrule.
7 Adjust the Dial Vernier to the setting
8 Press and hold the pneumatic start/
9 Always measure the finished crimp
obtained from the Gates Manual for the
combination of hose and fitting being
crimped.
stop switch until the motor shuts off and
the ram retracts.
diameter to be certain that it is within the
Gates specification.
6
OPERATING INSTRUCTIONS DOUBLE ANGLE DIES
SC32 DA Double Angle Dies
Double Angle dies effectively double the
force of the crimper thus larger fittings
can be crimped than would be possible
with conventional dies. The trade off
is that the diameter range that can be
crimped with a given die is more limited
than with a conventional die.
Use only the dies specified in the Gates
Crimp Specifications for a given combination of hose and fitting.
3 Select the correct Double Angle Die for
the hose and fitting combination being
crimped. Lubricate the I D of the Bottom
Base Ring and the top Compression Ring
with a high quality moly-disulfide grease .
Molykote “G” is recommended.
1 Remove the standard Pressure Plate by
loosening the set screw holding it in place.
The set screw is located through the hole in
the Hand Hazard Decal. A 1/8 inch hex key
wrench is required.
2 Install the Double Angle Base Ring
4 Place the top Compression Ring
squarely on top of the Double Angle Die
set.
5 Insert the Hose and fitting from the bottom
of the crimper.
Note: In order to avoid taper in the final
crimp, the fitting should be centered
vertically in the die set.
making certain that the bottom flange is
clean and free of debris and that the base
ring seats firmly and squarely in the bottom
flange.
6 Adjust the Dial Vernier to the setting
7 Install the Pusher on the ram if it has
8 Always measure the finished crimp
obtained from the Gates Manual. Note that
for Double Angle Dies settings greater
than 16 are above the zero due to the
special calibration factors for Double
Angle Dies.
been removed and press and hold the
pneumatic start/stop switch until the
motor shuts off and the ram retracts.
diameter to be certain that it is within the
Gates specification.
7
MEASURING CRIMP DIAMETER
To properly measure a crimp diameter:
NOTE:
DO NOT measure on top of
part number stamps
When using 21 and 22 Dies
When NOT using 21 and 22 Dies
1. Using Gates “21/22” dial calipers (Product
No 739-1320, Part No 78217) measure
halfway between ridges (Fig 1). to be sure
crimp diameter is being properly measured,
mark a crimp flat. Beginning with that flat,
count 9 flats to get the diameter. Be sure
caliper blades DO NOT touch ridges (See
Photo 3.)
1. Using Gates Dial Calipers (Product No
7369-0320, Part No 78215) which are
notched to clear ridges, measure halfway
between ridges (Sketch 1). Be sure caliper
fingers DO NOT touch ridges or part
number stamps (See Photo 3)
2. Measure halfway between the ends of
crimped portion of the ferrule (Fig 2).
2, Measure halfway down the crimped
portion of the ferrule (Sketch 2).
Photo 3
3. Should actual crimp diameter not be
within recommended crimp tolerance, check
calibration of the machine and recalibrate.
If machine is properly calibrated, you may
need to make a slight adjustment to the Dial
Vernier Adjuster,
8
4. To obtain a smaller crimp diameter,
change the Vernier Adjuster to a smaller
number. To get a larger crimp diameter,
change the Vernier Adjuster to a larger
number. Changing the adjuster readout by
.05 will change the crimp diameter .001”.
Record the new setting on your crimp chart
for future reference.
TROUBLESHOOTING
PROBLEM: CRIMPER WILL NOT RUN AT ALL
•
The white rocker switch is also a circuit breaker. Check to see that the circuit breaker has not
been tripped.
•
Check the wall outlet. The crimper comes from the factory wired for either 115V AC or 220V
AC single phase circuit. Make certain that correct voltage and amperage is available. Use
of extension cords or outlets with inadequate power can damage the motor . Do not run the
crimper from a portable power source.
•
Check the stop switch mounted to the switch bracket under the Dial Vernier. This is a normally
closed switch and if it does not close the crimper will not operate.
CAUTION: Do not operate the crimper with this switch jumpered as the pump will not shut off
and the brackets can be damaged.
•
Check the pneumatically actuated switch in the electrical box mounted on the motor. This
switch controls power to the motor and is actuated with air pressure from the bulb on the end of
the hose going into the box.
PROBLEM: CRIMP DIAMETER TOO LARGE
•
Check crimper calibration and re-calibrate if required.
•
Incorrect die being used.
•
Incorrect setting of the Dial Vernier Adjuster. Check hose crimp specifications.
•
Inadequate pump pressure. Check oil level in the pump. It should be 1-1/2 to 2 inches below
the fill plug. Replenish with ISO Viscosity Grade 46 hydraulic oil.
•
Inadequate lubrication of the dies and die cone causing the pump to work harder than normal to
reach the required diameter.
•
Inadequate pressure being generated by the pump. This is most likely if the crimper can crimp
the smaller size hoses and not the larger hoses. When correctly adjusted, the pump should
generate approximately 10,000 psi.
Do Not adjust pump to produce in excess of 10,000 psi as damage to components or personal
injury may result
•
No pressure being generated by the pump. There should be a definite change in pitch of the
pump as it cycles into high pressure mode and begins to “work” harder.
PROBLEM: CRIMP DIAMETER TOO SMALL
•
Check crimp diameter and re-calibrate if necessary.
•
Incorrect die being used (See die range under Crimp Diameter Too Large).
•
Incorrect setting of the Dial Vernier. Check hose crimp specifications.
PROBLEM: DIES STICKING IN COMPRESSION RING
•
Inadequate lubrication of the die cone and die surfaces.
9
MAINTENANCE
This crimper requires minimal maintenance.
However, the following practices are
recommended to ensure maximum reliability
and service
1. Lubricate
Using a small brush and Molykote “G”
grease, apply a light coat to the inside
surface of the die cone whenever it becomes
shiny.
4. Inspect Die Sets
•
Periodically inspect the surfaces of dis
sets for debris (metal chips, dirt, etc.) or
damage.
•
If debris is present, clean and lubricate
with Molykote “G” grease.
•
Check screws holding fingers to
cage to make sure that they are tight.
Tighten if necessary.
2. Check Oil
5. Inspect hose assembly
•
Check the hydraulic oil level in the pump
reservoir after each 10 hours of operation.
•
•
If the oil in the hydraulic reservoir is more
than 1 1/2 to 2 inches below the fill plug
add ISO Viscosity Grade 46 hydraulic oil
Inspect hose assembly connecting the
crimper and pump monthly (more often
with severe use)
•
If hose has any signs of damage,
replace immediately. A damaged hose
may rupture and cause serious injury.
•
If hydraulic oil is present on the hose
assembly, serious damage may exist.
replace hose assembly immediately.
3. Change the oil
(Note) Frequency depends on the pump’s
general working conditions, severity of use
and overall cleanliness.
•
For general shop conditions change the
oil every 300 hours.
•
Drain the oil through the plug in the
bottom of the reservoir and refill with ISO
Viscosity 46 hydraulic oil to between 1 1/2
and 2 inches below the fill plug
10
EXPLODED PARTS VIEW
15
10
9
22
2
17
21
3
20
1
ITEM #
GATES P/N DESCRIPTION
1
SC32 BASE PLATE
2
SC32 SUPPORT BAR
3
SC32 SUPPORT ROD
9
SC32 PUMP ADAPTER
AUTOMOTIVE P/N
10
74800070
SC32 CRIMPER/PUMP 220V
10
74800071
SC32 CRIMPER/PUMP 110V
77500
77501
15
74810051
SC32 REPLACEMENT PUMP 2HP/220
77505
15
74810052
SC32 REPLACEMENT PUMP 1HP/110
77506
17
74821077
SC32 HOSE ASSEMBLY
20
74821730
SC32 PENDANT SWITCH
21
74821739
SC32 BASE PLATE FOR 707 DIES
78991
22
74821738
SC32 DIE CONE FOR PC707 DIES
78990
78982
11
EXPLODED PARTS VIEW
13
15
3
23
12
21
20
17
16
9
14
10
11
8
5
6
7
2
4
1
ITEM #
3
GATES P/N
SC32 BASE FLANGE
2
SC32 BASE FLANGE RETAINING SET SCREW
3
SC32 FLANGE NUTS
4
SC32 MICRO-SWITCH BRACKET
5
6
21
20
22
7
9
78984
SC32 SWITCH GUARD
SC32 SWITCH GUARD SCREWS
74821737
SC32 MICROMETER
SC32 MICROMETER SLIDING ASSEMBLY
11
SC32 MICROMETER NUT
12
12
SC32 CRIMP STOP SWITCH
10
13
AUTOMOTIVE P/N
SC32 MICRO-SWITCH BRACKET SCREWS
74821732
8
23
DESCRIPTION
1
78989
SC32 TOP FLANGE
74821733
SC32 80 TON CLYLINDER
14
SC32 PUSHER RETAINING PIN
15
SC32 RETRACTION STOP ROD
16
SC32 RETRACTION STOP HANDLE
17
SC32 PUSHER
20
SC32 FLANGE SUPPORT BRACKET
21
SC32 FLANGE SUPPORT BRACKET WASHER
22
SC32 FLANGE SUPPORT BRACKET LOCK WASHER
23
SC32 FLANGE SUPPORT BRACKET BOLT
78985
Available Dies
GATES P/N
DESCRIPTION
AUTOMOTIVE P/N
SC32 DA DIE SETS
74821710
SC32 310 DBL ACTING DIE SET
78977
74821711
SC32 311 DBL ACTING DIE SET
78978
74821712
SC32 312 DBL ACTING DIE SET
78979
74821713
SC32 313 DBL ACTING DIE SET
78980
74821714
SC32 314 DBL ACTING DIE SET
78981
PC707 DIE SETS
GATES P/N
DESCRIPTION
7482-1217
Die Set 721
78943
7482-1218
Die Set 722
78944
7482-0931
Die Set 731
78931
7482-0932
Die Set 732
78932
7482-0933
Die Set 733
78933
7482-0934
Die Set 734
78934
7482-0935
Die Set 735
78935
7482-0936
Die Set 736
78936
7482-0937
Die Set 737
78937
7482-0939
Die Set 739
78939
7482-0947
Die Set 740
78950
For crimping 6ACA
7482-0941
Die Set 741
74951
For crimping 8ACA
7482-0942
Die Set 742
78952
For crimping 10ACA
7482-0943
Die Set 743
78953
For crimping 12ACA
7482-0944
Die Set 744
78954
For crimping power steering
7482-0945
Die Set 745
78955
For crimping grease fitting
7482-0946
Die Set 746
78956
For crimping miscellaneous (Replaces B die)
7482-1231
Die Set 781
78578
For GL Fittings
7482-1232
Die Set 782
78579
For GL Fittings
7482-1233
Die Set 783
78580
For GL Fittings
7482-1122
Die Set 7C3
78941
For crimping clamp collar (5⁄8”)
7482-1123
Die Set 7C4
78942
For crimping clamp collar (3⁄4”)
4
3
1
Double Angle Dies
2
GATES P/N
DESCRIPTION
AUTOMOTIVE P/N
74821710
SC32 310 DBL ACTING DIE SET
78977
74821711
SC32 311 DBL ACTING DIE SET
78978
74821712
SC32 312 DBL ACTING DIE SET
78979
74821713
SC32 313 DBL ACTING DIE SET
78980
74821714
SC32 314 DBL ACTING DIE SET
78981
74821734
SC32 DIE RING HALF, DBL ACTING DIE
78986
74821735
SC32 DIE REPLACEMENT SCREW FOR DBL ACTING DIE
78987
74821736
SC32 DIE SPRING FOR DBL ACTING DIE
78988
13
Tw o - Ye a r L i m i t e d Wa r r a n t y o n E q u i p m e n t
For two years from the date of shipment to the original user, The Gates Rubber Company will, at
its option, replace or repair any unit which provers to be defective in material or workmanship, or
both, at no cost to the original user of the equipment. Warranty claims require proof of purchase.
This is the exclusive remedy. THERE IS NO OTHER EXPRESS OR IMPLIED WARRANTY. ALL
INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE
ARE LIMITED TO TWO YEARS FROM THE DATE OF SHIPMENT OF THE EQUIPMENT TO
THE ORIGINAL USER. LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES
UNDER ANY AND ALL WARRANTIES IS EXCLUDED TO THE EXTENT EXCLUSION IS
PERMITTED BY LAW. Some states do not allow the exclusion of incidental or consequential
damages, and some states do not allow limitation on how long an implied warranty lasts, so
the above limitation and exclusion may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state. Fro warranty service,
contact Service Department, the Gates Corporation, 1551 Wewatta St., Denver, Colorado 80202.
HOW TO ORDER REPAIR PARTS
All parts for the SC32 Crimper listed in the current
replacement parts price sheets can be ordered
directly from your local Gates Hydraulic Distributor.
When ordering include the following information:
(1) Name of the unit shown on front cover.
(2) Product or part number of parts needed.
(3) Description of parts needed.
(4) Serial number of the machine.
For selling prices on inventoried parts, refer to
Hydraulic Power Crimp Equipment and Parts List
Price Schedule. Selling prices for parts not shown
in these list will be furnished upon request, or parts
will be shipped at prevailing prices and you will
be billed accordingly. For information regarding
prices, contact your local Gates representative or
The Gates Corporation, 1551 Wewatta St., Denver,
Colorado 80202
When returning inoperable equipment, contact your
local Gates representative for information on where
to ship the unit(s).
14
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