MC3000 OPERATING AND CALIBRATION INSTRUCTIONS

MC3000 OPERATING AND CALIBRATION INSTRUCTIONS

TABLE OF CONTENTS 1 - CERTIFICATE OF CONFORMITY... 3 2 - DESCRIPTION... 4 2.1 - GENERAL... 4 2.2 - CHARACTERISTICS... 4 2.3 - WORKING PRINCIPLE... 5 2.3.1 - Hydraulic system... 5 2.3.2 - Electrical system... 7 2.3.3 - Crimp head... 8 3 - INSTRUCTIONS FOR USE...10 3.1 - SAFETY...10 3.2 - UNPACKING - INSTALLATION...10 3.3 - OPERATING INSTRUCTIONS...12 3.4 - ADJUSTMENT /CALIBRATION... 13 3.5 - DIE POSITIONING AND INSTALLATION... 13 4 - MAINTENANCE... 14 4.1 - MAINTENANCE... 14 4.1.1 - Die lubrication... 14 4.1.2 - Checking and replacing the oil... 15 4.1.3 - Cleaning the swaging head... 15 4.2 - SPARE PARTS... 16 4.2.1 - Spare machine parts... 16 4.3 - TROUBLESHOOTING... 18 4.4 - WARRANTY LIMITATIONS... 19 2

1 - CERTIFICATE OF CONFORMITY EC DECLARATION OF CONFORMITY The manufacturer, the undersigned : GATES hereby declares that the new equipment described below: MC3000 - serial number: complies with the machinery directive and the specifications given by GATES and with the regulations regarding health and safety at work, as applicable. Drawn up: signature: G. R. Keast date: Machine started on: by: place: 3

2 - DESCRIPTION 2.1 - GENERAL: You have just acquired a GATES MC3000 powered crimper. It is necessary you adhere to the enclosed instructions for best performance. The MC3000 has been designed specifically for crimping Gates hoses and couplings which are used constantly in today s industry, agriculture and public works. This user guide contains all information concerning the operation, use and maintenance of your MC3000. 2.2 - CHARACTERISTICS: Crimping power: Pressure: Motor: Dimensions: Weight: 210 tonnes (maximum measured). 305 bar. 3 kw, 8 A at 380 V 3-phase. 4 kw, 26 A at 220 V 1-phase. H 630 x W 390 x L 600 mm. 180 kg with oil. Capacity: braided hose from 3/16" to 1" 1/4 multiple-plied metal reinforced hose from 1/4" to 1" (not skived) and to 1" 1/4 (skived) Noise levels: 71 db. Oil tank: 10 litres. Pump: gear type. Die travel: 14 mm working travel and 38 mm maximum travel. Adjustment: by micrometer screw with numerical display and electrical stop. Crimping: by pressing push-button. Crimping stop: automatic according to adjustment. Retraction: by pressing push-button. Retraction stop: by releasing push-button. Cycle time: 12 seconds for 3-phase 380 V crimper. 16 seconds for 1-phase 220 V crimper. Tooling: GATES die sets. These specifications are nominal and must not be used for inspection. 4

USER GUIDE MC3000 2.3. WORKING PRINCIPLE: This machine is comprised of 3 main systems: the hydraulic circuit, the crimping head with numerical set stop for crimp adjustment, and the electrical system. 2.3.1. HYDRAULIC SYSTEM: This supplies the energy necessary to move the dies. Composition: The hydraulic circuit is comprised of (see figures 1 and 2) - a drilled block (1) - a pressure limiter (2) - a pilot valve (3) - a control valve (4) - a motor (5) - a pump (6) - a suction filter (7) - an oil tank (8) Figure 1 : Hydraulic circuit diagram 5

Working principle: In the non-actuated state (such as shown in figure 1), the motor drives the pump which continuously supplies the circuit with oil. The control valve (4) is in position middle (see figure 1). The oil is in a closed circuit and returns to the oil tank (8). During crimping, the control valve (4) is in position right. The connection P to B on the control valve (4) is established. The crimping chamber is supplied with oil. When pressure is equal or superior to required pressure, excess oil is returned to the oil tank (8) via the pressure limiter (2). Oil in the retraction chamber is evacuated to the oil tank (8) via the control valve (4) from A to T. During die retraction, the control valve (4) is in position left. The connection P to A on the control valve is established. The die retraction chamber is supplied with oil. A system in the bell housing allows to reduce the pressure during the return. Oil in the crimping chamber is returned to the oil tank (8) via the connection B to T on the control valve (4). The volume of oil in the crimping chamber being larger, oil is also evacuated via the pilot valve (3). Figure 2 : View of drilled block. 6

2.3.2. - ELECTRICAL SYSTEM: The electrical system supplies the motor and control valve. Note: Spare fuses are attached to the switch cable in the electrical enclosure of the machine. Composition: The electrical system is comprised of (see figure 3): For supply section: - an electric motor (1) - a thermal breaker (2) - a general disconnecting switch "0-1" (3) - a motor contactor (14) For control section: - 2 fuses 0,25 A am (4) and 4A gi (5) - a micro-switch (6) - two push-buttons (7) and (8) - two control valve coils (9) and (10) - two indicator lamps (11) and (15) - a transformer (12) 380-220/24 V - a push-button (13) - a motor contactor (14) - a emergency stop (16) 16 6 4 3 (3-phase) 5 (3-phase) 7 14 13 14 8 12 2 /1 1 15 11 10 9 Figure 3 : Electrical circuit diagram. 7

2.3.3 - CRIMP HEAD: This is the most technical part of the machine. Through the use of die sets, it compresses the ferrule in order to crimp it onto the hose. Composition: The crimp head is comprised of (see figure 4): - a numerical set stop consisting of: - an adjustment knob with counter (1) - a micrometer (2) - a micro-contact (3) - a contact rod (4) - a protecting cap (13) - a face flange (5) - die-carriers (6) - a bell housing corresponding to a hydraulic ram body (8) - die-sets (9) - a hollow piston which moves under oil pressure (10) - a piston flange (11) - an oil trap ring (12) 1 2 6 9 3 4 5 8 10 11 12 Figure 4 : Diagram of swaging head and numerical crimp adjuster. 8

Working principle: The bell housing (8) and piston (10) can be compared to a double acting hydraulic ram. Crimping consists in transforming a linear displacement at constant speed, that of the piston (10), into a two speed radial displacement: resulting in a rapid approach speed and a slower crimping speed. These two speeds are obtained via two slopes on the piston (10) and the die-carriers (6). The gentle slope ensures, for equal thrust on the piston (10), a slower displacement and higher crimping power. The main elements of the crimper, made from special steel, have been subjected to a series of penetrative and surface thermal treatments in order to ensure that they will stand important stresses, and to reduce wear through contact or friction. Guidance in movement is ensured via two composite rings (made from bronze-charged teflon). Sealing is obtained through 3 composite joints (made from PTFE). Also, in the unlikely event of any leaks, an oil trap ring (12) at the rear of the bell housing directs oil back to the tank. A similar device is incorporated into the face flange (5). The numerical crimp adjuster, mechanically activated by the hollow piston (10), electrically stops the crimping operation. For that purpose, it is equipped with a microswitch (3) which pilots the control valve. Adjustment of the crimp diameter is via a micrometer (2). Rotation of the micrometer changes the contact rod position (4), thereby allowing for precise adjustment of the final crimp diameter. 9

3 - INSTRUCTIONS FOR USE 3.1 - SAFETY: The machine must be installed on a bench or on a stable base. Do not put your hand in the swaging head during operation. Do not modify technical characteristics of the machine (pressure or others). When performing any kind of maintenance upon the electrical system, ensure that the machine is disconnected from the power supply. Do not cover the electric motor ventilator. Disconnect the machine from electrical supply when working on the dies, die-carriers or intermediate dies. 3.2 - UNPACKING - INSTALLATION: Unpack the machine without destroying the packing. From then on, the machine should only be transported in its original packing. Please retain for future use. Remove the lid from the box. Remove the screws at the bottom of the uprights; lift the uprights from the box. Put webbings under the machine, or raise it with a lift truck. Never lift the machine by the working head or any of its component parts. For best use and less fatigue for the operator, it is advisable to secure the machine horizontally on a base approximatively.75 metres in height. Once you have positioned the machine, remove the blanks from the oil tank filling cap. Wait for 20 minutes, and check the oil level using the dip stick attached to filling cap. The machine should only be connected to a safe electrical circuit, in accordance with the latest European guidelines. Electrically connect the motor making sure it rotates in the direction indicated by the arrow located on the casing. Check this rotation by quickly switching the main switch on and using the emergency stop. Important: faulty motor rotation can damage the pump. To change the direction of motor rotation, reverse the two phase wires to the mains plug. The machine has been preconnected to run on a 380 V 3-phase mains supply. To connect to a 220 V 3-phase or 1-phase mains supply, please consult us. Install the gauge setting mechanism on the crimp head face flange. Do this with the machine disconnected from the mains supply. For correct installation, display 000 on the counter dial by turning the counter knob counterclockwise. Attach the crimp adjuster using the two screws with springs supplied, taking care to correctly position the counter dial. Connect the electrically operated crimp adjuster plug to the socket behind the front panel. 10

3.3 - OPERATING INSTRUCTIONS: Ref - fig 4.a - Turn the main switch (8) to position 1 and press the ON button (6). - Press the disengage die button (5) in order to fully open the die carriers. - Press the emergency stop button (7). - Install the die set corresponding to the coupling to be crimped (see crimp information CD.) - Unlock the emergency stop button and press the ON button (6). - Set the gauge setting mechanism (2) to the correct setting as indicated in the crimp information for the particular hose and connector being crimped. - Position the hose and the connector between the dies in the crimp head. - Place the ferrule in the position as specified in the crimp information. - Press the engage die button (4) to carry out the crimping operation until the finished crimp indicator light (3) lights up. - Press the disengage die button (5) to release the crimped assembly. - Check the crimp diameter of the ferrule with a vernier or micrometer*. The measured crimp diameter must be within the tolerance published in the crimp information. If not, the hose assembly cannot be used and adjustment will be required. Correct the gauge setting if required. In order to decrease the crimp diameter, reduce the value on the gauge setting mechanism (2); reverse procedure to increase crimp diameter. A rotation of 7 units on the gauge setting mechanism is equal to a change of 0.10 mm on the crimp diameter. Gauge settings must be considered a guide to achieving the correct crimp diameter. Actual crimp diameters must be within the specified crimp tolerance. *Always use verniers or micrometers that are graduated to 0.001"/0.02 mm or smaller. 12

USER GUIDE MC3000 3.4. ADJUSTMENT / CALIBRATION Before delivery each machine is calibrated and should be ready for use upon receipt. However, machine calibration should be checked on a monthly basis and when gauge settings consistently produce diameters outside the crimp diameter tolerance. Calibration procedure is as follows: To calibrate using calibration shell 7482-19860: - Place die set D33 in the machine. - Set the gauge setting mechanism to 200. - Crimp the calibration shell 7482-19860. - Measure the crimped diameter of the calibration shell it should read 26.0 +/- 0.1mm - If the crimp diameter is outside the stated dimensions, it is necessary to recalibrate the machine as follows: 1. Isolate the machine from power supply. 2. Note by how much the measured crimp diameter differs from the required 26.0mm calibration diameter. 3. Unscrew the two socket head screws that hold the gauge setting mechanism in place with a 3mm Allen key and remove the unit. 4. Calibration adjustment is now via the 6mm screw and locknut. One full turn of the screw clockwise (when viewed from the screw end) will reduce the crimp diameter by 0.4mm. Turning the screw anti-clockwise increases the crimp diameter 0.4mm. 5. Unlock the locknut and turn the screw the required amount according to the difference between the achieved and the required crimp diameter. 6. Lock the locknut and replace the gauge setting mechanism, tightening the two socket head screws. 7. Crimp a new calibration shell and check that the correct crimp diameter has now been achieved. 8. If the required crimp diameter is not achieved, repeat the recalibration process. 3.5. DIE POSITIONING AND INSTALLATION Figure 5 : location 1 Figure 6 : location 2 For straight couplings For angled couplings or 13

4 - MAINTENANCE 4.1 - MAINTENANCE: 4.1.1 - DIE LUBRICATION: Friction on the dies whilst crimping is very important. For this reason, it is necessary to lubricate the bearing surface of the die-carriers on the piston regularly. Indeed, an insufficiently lubricated machine could seize, or the pistons and die-carriers could be subjected to increased wear. To achieve correct lubrication, grease with a 60% concentration of molybdenum di-sulphide (this product is supplied with the machine and can be obtained from GATES, Part No. 7482-19227). Lubricate every 100 crimping operations as follows: - Shake the aerosol can, held upside down, for 1 minute (this amount of time is necessary for such a thick product to be vaporised properly). - Advance the die-carriers on the rapid cone. The die-carriers should be 5 mm above the face flange (see figure 7). Figure 7 : Position of die-carriers for lubrication. - Introduce the aerosol can diffuser in the hole located at the rear of the die-carriers (lubrication point N 1 - see figure 8). Figure 8 : Lubrication point N 1. Recommended grease: see above. - Grease the piston through the holes of each die-carrier. 14

- From the rear of the bell housing, diffuse the grease all around the cone (lubrication point N 2 - see figure 9). Figure 9 : Lubrication point N 2. Recommended grease: see above. - Completely close the die-carriers. - From front of machine, lubricate between the die-carriers and the face flange (lubrication point N 3 - see figure 10). Figure 10 : Lubrication point N 3. Recommended grease: see above. 4.1.2 - CHECKING AND REPLACING THE OIL: - Regularly check the oil level about every 500 swagings. - Empty the oil tank each year and replace the used oil with new oil (the machine is delivered with a full tank of hydraulic oil type ISO HV 32). 4.1.3 - CLEANING THE SWAGING HEAD: - Regularly dismantle the face flange and the die-carriers about every three months. This is necessary to ensure that metallic/other particles are removed before causing damage to machine parts. Dismantle as follows: - Put die set N 35 into location 1 with dies reversed so that they protrude past the face flange. - Remove gauge setting mechanism - the crimper must be fully opened. - Remove the 12 cap head screws from the face flange. - Carefully remove the flange with the 8 die-carriers. - Clean and lubricate all surfaces using recommended grease. - Remount the flange and the die-carriers. Ensure that it is correctly located for the gauge setting mechanism. - Tighten the 12 screws with a torque wrench at 28 MKg. (tightening in star with spreading of the effort) This operation can be difficult for an inexperienced mechanic. When in doubt, don t hesitate to contact your Gates representative. 15

USER GUIDE MC3000 4.2. SPARE PARTS: Note: Tampering with the machine during the warranty period will render the latter void. All orders for spare parts must state reference, description and quantity required. Example: Reference: MC3000-4622 Description: PISTON Quantity: 1 4.2.1 SPARE MACHINE PARTS (see Figure 11): Position REF. Description P/N Quantity Pos. 4 / fig. 1 MC3000-004 Control Valve 7482-19987 1 Pos. 6 / fig. 1 MC3000-003 Gear Pump 7482-19716 1 Pos. 10 / fig.11 MC3000-127 Oil trap ring 7482-19717 1 Pos. 9 / fig. 11 MC3000-1283 Piston flange 7482-19718 1 Pos. 2 / fig. 3 MC3000-1512 Thermical circuit breaker 3-phase 7482-19719 1 MC3000-9574 Thermical circuit breaker 1-phase 7482-19963 Pos. 8 / fig. 11 MC3000-152 Composite seal ø 190 mm 7482-19720 1 Pos. 14 / fig. 11 MC3000-154 Composite seal ø 200 mm 7482-19721 1 Pos. 5 / fig. 11 MC3000-189 Piston ring 7482-19722 1 Pos. 7 / fig. 11 MC3000-190 Piston flange ring 7482-19723 1 Pos. 12 / fig. 3 MC3000-20 Electrical transformer 7482-19724 1 Pos. 4 / fig. 11 MC3000-291 O ring R No. 67 7482-19725 1 Pos. 16 / fig. 11 MC3000-343 CHC M14*50 12-9 screw 7482-19726 12 Pos. 3 / fig. 11 MC3000-4622 Piston 7482-19727 1 Pos. 15 / fig. 11 MC3000-4640 Head flange 7482-19728 1 Pos. 1 / fig. 3 MC3000-005 MC3000-8635 Motor 3Kw 380V 3Ph Motor 4Kw 220V 1Ph 7482-19729 7482-19964 1 1 Pos. 1 / fig. 11 MC3000-5655 Master dies 7284-19730 8 Pos. 13 / fig. 11 MC3000-59 Head 7482-19731 1 Pos. 5 / fig. 3 MC3000-762 Fuse 4A gi 7482-19732 1 Pos. 4 / fig. 3 MC3000-765 Fuse 0,25 A am 7482-19733 1 MC3000-82 Pilot valve (machines before 1173) 7482-19734 1 Pos. 14 / fig. 3 MC3000-946 Contactor 7482-19735 1 MC3000-HEAD Standard exchange crimping head 7482-19352 1 MC5000-1419 Body s switch of push button 7482-19740 1 Pos. 6 / fig. 11 MC5000-153 Composite seal ø 260 mm 7482-19742 1 MC5000-1666 Signal s body 7482-19743 1 MC5000-184 Die changing tool 7482-19032 1 Pos. 1 / fig. 4 MC5000-21 Revolution counter button 7482-19228 1 MC5000-36 Bulb 7482-19665 1 Pos. 18 / fig. 11 MC5000-4553 Tightening ring 7482-19226 8 Pos. 11 / fig. 11 MC5000-4586 Gauge 7482-19143 1 Pos. 21 / fig. 11 MC5000-4855 Pin 7482-19230 8 Pos. 2 / fig. 11 MC5000-5036 Spring master dies 8482-19231 16 Pos. 17 / fig. 11 MC5000-54 Die nipple 7482-19033 8 Pos. 2 / fig. 1 MC5000-5691 Pressure limiter (machines after 1173) 7482-19986 1 Pos. 13 / fig. 4 MC5000-5770 Protection gauge 7482-19362 1 Pos. 3 / fig. 4 MC5000-5845 Main contactor 7482-19985 1 Pos. 13 / fig. 3 MC5000-6004 ON (lit) push button 7482-18510 1 Pos. 7,8 / fig. 3 MC5000-6005 Green push button 7482-18509 2 Pos. 16 / fig. 3 MC5000-6008 Emergency stop 7482-19675 1 Pos. 11,15/ fig. 3 MC5000-6009 Yellow signal 7482-19367 1 16

USER GUIDE MC3000 Position REF. Description P/N Quantity MC5000-6454 Rubber bellows 7482-19766 8 Pos. 3 / fig. 1 MC5000-6573 Pilot valve (machines after 1173) 7482-19767 1 Page 4 MC5000-732 HP discharge valve (machines after 1173) 7482-19672 1 MC5000-733 BP discharge valve 7482-19673 1 Pos. 6 / fig. 3 MC5000-75 Gauge microswitch 7482-19265 1 MC5000-8331 Rubber bellows locking pin 7482-19772 48 MC5000-836 Body switch of emergency stop 7482-19773 1 Pos. 20 / fig. 11 MC5000-855 Ring ø 8 mm SCHNOR 7482-19037 8 Pos. 19 / fig. 11 MC5000-880 CHC M8*40 12-9 screw 7482-19040 8 MC5000-COVER Electrical casing 7482-18821 1 MC5000-GREASE Grease in aerosol can 7482-19227 1 MC3000-11272 Set of master dies, kit 8000-10093 8 17

4.3 - TROUBLESHOOTING: Problem Probable cause Possible solutions The press won t open or Lubrication error Clean and lubricate the press (see does not crimp sections 4.1.1 and 4.1.3). The control valve is not piloted Check the electrical circuit: fuses, plugs and connections, feeding of the control valve bobbin. Crimping power is not sufficient Wrong choice of dies Use the dies as specified by the crimping information provided with the machine. Inadequate hydraulic pressure Calibration of high pressure to 320 bars during crimping (set in factory). Unlock the discharge valves if necessary. Hydraulic leaks The control valve does not work Check and replace malfunctioning seals. Maintain or replace the control valve. Dies move out of position Dies are incorrectly mounted Replace damaged mounting pins or reposition die retaining pins. Electrical motor makes 2-phase operation Check electric supply, fuses abnormal noise and connections. 18

4.4 - WARRANTY LIMITATIONS: Gates machines are guaranteed against defects and faulty workmanship for a period of one year from date of purchase. During the period of warranty, Gates will repair (or replace as the case may be) free of charge all faulty parts, provided the machine is returned to the works. This warranty will not apply in the case of accidental damage, misuse or if the machine has been subjected to repairs or modifications by persons other than Gates. Gates cannot be held responsible for any damage or injury direct, indirect or consequential to the use of its machines, nor after express or implicit termination of warranty. This warranty replaces all other warranties including implicit warranties. Every effort has been made to ensure the accuracy and comprehensiveness of the informations included in this guide. However, Gates cannot be held responsible for errors or omissions and alterations which have occured after release for printing; or if Gates products are used in special or exceptional circumstances without prior consultation with and clearance from a Gates representative for verification of the planned usage. For more information, please contact: Gates Hydraulics Ltd Station Road St Neots, Huntingdon, Cambs. PE19 1XA, UK TL: (44) 01480 / 25 50 00 FX: (44) 01480 / 25 53 50 Gates Hydraulique S.A B.P. 14 F - 69881 Meyzieu-Cedex TL: (33) 04 72 45 12 12 FX:(33) 04 72 02 85 24 Gates Europe N.V. Dr. Carlierlaan 30 B - 9320 Erembodegem TL: (32) 053 / 76 27 11 FX:(32) 053 / 76 27 13 19