Gates self assembly system Your key to factory quality performance Above and beyond any international standard E2/50119
The Gates Integrated System Approach: Superior products are just the beginning The true value of the Gates self-assembly system comes from the Gates Integrated Approach: All elements of the hose assembly process are designed together to produce factory quality assemblies which perform above and beyond any international standard. This unique approach is how Gates ensures full compliance with the European Machinery Directive and the reason why Gates is known as the world s most trusted hydraulic hose assembly manufacturer. + + = The Gates Integrated System Approach: How does it work? A simple equation: Superior products, manufactured to stringent tolerances + Advanced self-assembly machines and dies, rigourously validated + Optimal crimp data, meticulously tested = Factory-quality performance above and beyond international standards Superior products, manufactured to stringent tolerances Gates Global hoses and couplings represent an evolution in hydraulic component design. They not only boast a wide array of advanced-design features but they are also manufactured to stringent tolerances, allowing consistently superior performance. Moreover, Gates hoses and couplings are designed, tested and validated together each with the other in mind. This is what makes Gates the masters of the hose and coupling interface.
Advanced self-assembly machines and dies, rigorously validated Gates self-assembly machines and dies are customdesigned to work with the next-generation Global range of hose and couplings. Gates dies are characterised by a proprietary profile design for an optimal cylindrical crimp. They are tried, tested and validated to provide you with the most optimal crimp settings. Furthermore, Gates die sets are logically organised to facilitate die selection time after time. D A C L L Optimal crimp data, derived from meticulous testing Each Gates crimper comes with validated crimp settings data for the complete Global hose & coupling product range. No need for time consuming trial-and-error to find the ideal settings! You can even register to constantly stay up to date with the latest developments via mail or internet. The result: factory-quality performance above and beyond international standards When Gates Global hose and couplings are crimped in accordance with the Gates Integrated System, they yield factory quality assemblies fully compliant to European Directives and legislation exceeding all international standards. Gates Global wire-braid hose and MegaCrimp coupling assemblies are developed to withstand impulse testing to 600,000 cycles. Gates spiral wire hose and GS coupling assemblies even go to a million cycles. Gates self-assembly machinery: a complete range with a solution for every need Gates range of self-assembly machinery covers the spectrum of needs from workshops to on-site fieldcrimping and even mobile service operations. It is a complete range which includes hose cutting machines, a marking machine and useful accessories. Every machine and tool in the Gates range is precise, easy to use and allows fast and factory-quality assembly of the complete Global range of Gates hose and couplings.
Workshop In the Gates workshop, safe, fast and efficient assembly of hydraulic hose and couplings is made simple. All machines are custom-designed to work with a well-defined range of Gates hoses and couplings allowing production of factory quality assemblies fully complying with European Directives. No matter what your workshop needs, whether you are a starter, a professional, or a full-service workshop, Gates has the right product offering for you. Cutting Marking Crimping Full service 2" MK 5000 MS 5001 MC 5001 Professional service up to 1 ¼" MK 3000 MS 5001 MC 3001 Starter up to 1" MK 2000 MS 5001 MC 2501 Accessories Hose table Quick change tool Die storage table Marking dies
Mobile Service A Gates hose assembly is much more than the sum of its components. It is the combined result of a rigorous test regime and of a tightly controlled manufacturing process, both at Gates and at the point of assembly. To reduce the risk of premature failure due to variations in the assembly process, Gates has developed a special proposition for mobile service operations allowing them to benefit from the simplified and superior Global range of no-skive hoses and couplings. And thanks to the Gates Integrated System, mobile service operators can offer their customers the superior quality and performance which make the world s most trusted hose assemblies. Cutting Marking Crimping Professional service up to 1 1 4" Please contact us for your cutter requirements MS 5001 MC 3001 12V
Field Service In the field, every minute counts. In today s environment, equipment, whether it be agricultural, construction or mining, simply cannot afford unnecessary downtime. That s why Gates has developed a range of small, portable and easy to use crimpers specifically designed for end-users on site. And since these simple, lightweight machines are designed as part of the Gates Integrated System, end-users are assured of factory quality no-skive assemblies even in the field! No skive spiral hose up to 1" MC 2000 Wire braid hose up to 1" MC 1001 manual MC 1001 air operated
Technical specifications Crimpers MC1001 MC2000 MC2501 MC3001 MC5001 manual pneumatic manual 1 phase 3 phase 1 phase 3 phase 12V 1 phase 3 phase Power supply -- 7bar/100psi -- 220V 380V 220V 380V 12V 220V 380V WB 1" 1 1/4" 1 1/4" 1 1/4" 2" Maximum crimping capacity 4SW 1" 1" 1" 1 1/4" 2" 6SW 1" 1" 1" 1 1/4" 2" Crimping force (ton) 27 27 100 137 137 210 210 210 360 360 Motor (kw) -- -- -- 2.2 3.0 2.2 3.0 2.0 2.2 5.5 Die set MC1000-Dxx MC5000-Dxx MC5001-Dxx MC5001-Dxx MC5001-Dxx Cycle time (sec) -- -- -- 26 26 10 10 10 9 9 Quick change tool -- -- -- o o o o Foot pedal -- x -- -- o x Dimensions (mm) H 460 310 520 650 580 800 W 280 300 490 390 400 480 L 390 410 650 640 500 730 Weight (kg) 24 22 41 90 90 180 180 125 260 260 Product number 7480-19164 7480-19165 7480-19103 7480-19166 7480-19167 7480-19153 7480-19152 7480-19154 7480-19156 7480-19155 Options: marking dies -- -- -- o o o o BSA control -- -- -- -- -- o o Legend: -- not available o optional x standard
Overview Crimping machines MC 1001 Lightweight, portable crimper designed for reliability in field service. Comes with separate box, designed to contain complete set of dies. The pneumatic version has a foot-operated air pump. Crimps no-skive MegaCrimp couplings for wire-braid hose up to 1". 7480-19164: manual machine 7480-19165: air operated machine MC 2000 MC 2501 Powerful, hand-operated crimper, ideal for small workshop and for mobile use. Crimps no-skive GlobalSpiral TM couplings up to 1". Compact crimper for low-volume production. Ideal as starter machine or for small workshops. Crimps no-skive GlobalSpiral TM couplings up to 1". 7480-19103 7480-19167: 3 phase 7480-19166: 1 phase MC 3001 MC 5001 Robust, operator-friendly machine to crimp the complete Gates range up to 1 1 4". Equipped with foot pedal to enable hands-free operation. Automatic power cut-off to prevent overcrimping. 7480-19152: 3 phase 7480-19153: 1 phase 7480-19154: 12V Full-range crimper (up to 2" six-spiral hose) for the professional workshop. Equipped with foot pedal to enable hands-free operation. 7480-19155: 3 phase 7480-19156: 1 phase
Crimping machine accessories Quick Change Tool The universal Quick Change Tool allows easy replacement of the complete die set in one move. It can be used with all dies from D21 up to D311. To optimise the use of the new quick change tool, a dedicated design for the storage of dies has been developed. This design has been incorporated both into a dedicated machine table and into a wall mounted rack for customers wishing to use an existing bench or table for their machine. 8000-10027: QCT & machine table 8000-10028: QCT & machine rack Marking dies To facilitate compliance with the European Machinery Directive, which insists that finished assemblies are marked with the manufacturer s name and the manufacturing date code, a full range of marking dies is now available for MC5001, MC3001 and MC2501 machines. Please contact Gates for order information. Documentation, user guide, data All Gates crimpers come with technical documentation, a user guide and crimp data for assembling Gates hose and couplings. Integrated BSA control This control, which can be integrated into the MC3001 and the MC5001 crimpers, restricts the stroke of the machine thus improving the cycle time when crimping a batch of assemblies. 7480-19158: MC3001-C-BSA 7480-19159: MC3001-A-BSA 7480-19160: MC5001-C-BSA 7480-19161: MC5001-A-BSA
Cutters MK 2000 MK 3000 Compact cutting machine, perfectly suitable for the small workshop. Cuts hoses up to 1". Robust cutter for all types of workshops. Cuts hoses up to 1 1/4" four spiral wire. 7480-19163: 3 phase 7480-19141: 3 phase 7480-19142: 1 phase A heavy-duty hose cutter allowing quick and reliable production across all hose size ranges. Cuts up to 2" six spiral wire hoses. 7480-19025: 3 phase MK 5000 Technical specifications Cutters MK 2000 MK 3000 MK 5000 3 phase 1 phase 3 phase 3 phase Power supply 380V 220V 380V 380V Maximum capacity WB 1" 1 1/4" 2" 4SW 1" 1 1/4" 2" 6SW -- -- 2" Motor (kw) 2.2 2.2 3.0 7.5 Brake motor -- -- Suction connection (mm)* -- 60/110* 60/110* 110 Cutting blade 300x3x25.4 300x3x25.4 520x4x40 H 380/760** 350/770** 1280/1750** Dimensions (mm) W 500 470 800 L 530 540 910 Weight (kg) 55 60 215 Product number 7480-19163 7480-19142 7480-19141 7480-19025 * O.D. of optional connection tube ** Height including handle
Tools Marking machine A hand-operated marking machine which allows easy identification marking on Gates ferrules. The MS 5001 is equipped with a hand wheel to adjust the character setting to the ferrule and with a counter for presetting and for consistent marking depth. The MS 5001 marking machine comes with a box of 120 characters. 7480-19162 Optional character holder consisting of one row of fixed characters and three rows of rotating numbers, e.g. to change the date code without affecting the company name. 8000-10071 MegaCrimp vernier caliper A handy tool which measures finished outside diameters. Special design for easy measuring of the finished diameters on -4, -5 and -6 MegaCrimp. Comes in solid case. 7369-0322 MegaCrimp insertion tool The new MegaCrimp coupling insertion tool offers an easy way to confirm the right insertion depth for all Gates wire-braid hydraulic hoses. It also verifies the squareness of cut! 7482-1342 Rotational table Rotational table ideal for the unwinding of hose coils. 7480-19135
Die selection matrix -size hose coupling die MC 1001 MC 2000 MC 2501 MC 3001 MC 5001-4 M3K M4K M5K M6K CM2T MegaCrimp D21 G1 G2 C1TH MegaTech TM GTH MegaCrimp D21 3TE 2TE GT7 GT8 MegaCrimp D21 1PW GP60 GP80+ GP40 MegaCrimp D21-5 M3K M4K M5K CM2T MegaCrimp D22 G1 G2 GTH MegaCrimp D22 3TE 2TE MegaCrimp D22 2PW 1PW GP60 GP80+ GP40 MegaCrimp D22-6 M3K M4K M5K CM2T MegaCrimp D22 G1 G2 C1TH MegaTech TM GTH MegaCrimp D22 3TE 2TE GT7 GT8 MegaCrimp D22 2PW 1PW GP60 GP80+ GP40 MegaCrimp D22 EFG4K EFG5K EFG6K GlobalSpiral TM D33-8 M3K M4K M5K CM2T MegaCrimp D33 G1 G2 C1TH MegaTech TM GTH MegaCrimp D33 3TE 2TE GT7 GT8 MegaCrimp D33 2PW 1PW GP60 GP80+ GP40 MegaCrimp D33 EFG4K EFG5K EFG6K GlobalSpiral TM D33-10 M3K M4K CM2T MegaCrimp D34 G1 G2 C1TH MegaTech TM GTH MegaCrimp D34 3TE 2TE GT7 GT8 MegaCrimp D34 GP60 GP80+ GP40 MegaCrimp D34 EFG4K EFG5K EFG6K GlobalSpiral TM D35-12 M3K M4K CM2T MegaCrimp D35 G1 G2 C1TH MegaTech TM GTH MegaCrimp D35 3TE 2TE GMV GT7 GT8 MegaCrimp D35 GP60 GP80+ GP40 MegaCrimp D35 EFG4K EFG5K EFG6K GlobalSpiral TM D35-16 M3K CM2T MegaCrimp D37 G1 G2 C1TH MegaTech TM MegaCrimp D37 3TE 2TE GMV GT8 MegaCrimp D37 GP60 GP80+ GP40 MegaCrimp D37 EFG4K EFG5K EFG6K GlobalSpiral TM D37-20 MegaCrimp D39 G1 G2 MegaTech TM MegaCrimp D39 GMV MegaCrimp D39 GP80+ GP40 MegaCrimp D39 EFG3K EFG4K GlobalSpiral TM D39 EFG5K EFG6K GlobalSpiral TM D310-24 ES-A D45 G1 G2 MegaTech TM ES-A D45 GMV ES-A D45 GP80+ GP40 ES-A D45 G3K GlobalSpiral TM D311 G5K GlobalSpiral TM D311-32 ES-A D60 G1 G2 MegaTech TM ES-A D60 GMV ES-A D60 GP80+ ES-A D60 G3K ES-A D60 G5K PCM D314 wire braid reinforcement 4 spiral wire reinforcement 6 spiral wire reinforcement
Gates self-assembly system 1 An Integrated System approach which elevates the technological superiority of the Gates no-skive Global hose and couplings range with rigourously validated machines and crimp settings to produce hose assemblies which perform above and beyond any international standard. A comprehensive range of self-assembly machinery with a variety of choices which cover the spectrum of needs whether in the Workshop, Field or for Mobile Service Operations. A wide range of precision tools, reference material and accessories to facilitate the assembly operation and promote compliance to European legislation.
Safe Hydraulics World-class safety training programme Safe Hydraulics a higher standard in Safety Never. underestimate the power of a hydraulic hose assembly under pressure. Just having the world s best hoses and couplings is not enough to ensure the safety of your hydraulic hose assemblies. Improper assembly, installation or even storage can compromise performance and even human safety. Through the Safe Hydraulics Europe programme, Gates Fluid Power Europe is committed to increasing industry and end-user awareness of preventive maintenance and safety issues affecting hydraulic hose assemblies What is it? A world-class product, safety and preventive maintenance training programme Designed by Gates application engineers Delivered by certified trainers Tailored for assembly workshops and end-users How does it work? Seminars via Gates exclusive partner network Covers the entire process: storage, selection installation and inspection Includes an overview of relevant EU legislation, complete with practical examples To learn more about how to ensure the safety and performance of your hydraulic hose assemblies through the Gates Safe Hydraulics Europe programme, go to www.safehydraulicseurope.com, or contact us at: 0044-14 80 22 50 00 Your distributor: The manufacturers reserve the right to amend details where necessary. Gates Europe nv 2005 Printed in Belgium 11/05.