Gates GC16XD Manuel d'installation
GC16XD MINI CRIMPER & PUMP
SAFETY AND OPERATING MANUAL
Part Number 70115
Product Number 7480-7006
CRIMPER DETAILS GC16XD MINI CRIMPER & PUMP SAFETY AND OPERATION MANUAL
Serial No. ____________________________
Date of Purchase _____________________
YOUR CRIMPER DETAILS
CRIMPER SPECIFICATIONS
DYNAMIC
Nom. Size (Hydraulic Hose Size) 1 Inches
Die Set Type 16 Series
Crimping Range (Inch with Std. Die Set) 1/4 to 1 Inch
Radial Swaging Force 900kN / 90 Tonne
Approx. Cycle Speed (Full Stroke) 18 Sec (Power Unit Dependant)
PHYSICAL
Dimensions ( W x D X H) 0.21 x 0.22 x 0.22m / 8.7 x 8.75 x 8.75 In
Weight (Without Dies & Oil lbs) 22 kg / 48.5
Shipping Dimensions 0.30 x 0.40 x 0.39m /12.2 x 16.14 x
15.74 In
Shipping Weight 23.5Kg / 54lb
HYDRAULIC
Rated Pressure 690 Bar / 10,000 PSI
Reservoir Capacity (Min) 0.8 Litres / 0.2 Gallons
Recommended Filtration 10um
Oil Specification See Power Unit Requirements
MAINTENANCE Grease Specification Tungsten Disulphide
1
TABLE OF CONTENTS GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
CRIMPER SAFETY 2
BOX CONTENTS 7
GETTING TO KNOW YOUR CRIMPER 8
Dial Indicator 8
Power Unit 8
E-Crimp Settings 9
Quick-Connect Fitting 10
Grease Application 10
Carrying & Movement 10
Die Loading/Insertion 11
HOSE PREPARATION 12
MEASURING CRIMP DIAMETER 13
CALIBRATION 14
PERIODIC MAINTENANCE 16
REPLACEMENT PARTS 17
WARRANTY 19
2
CRIMPER SAFETY GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION 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 correct assemblies.
Hose Assembly Fabrication.
■Component inspection: Before creating an assembly be sure to inspect all components to ensure
they are the correct product, cut correctly, and do not have any visually identifiable defects.
■Couplings (compatibillity): Hose fitting components from one manufacturer are not usually
compatable with fitting components supplied by another manufactuerer. 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 Hydraullic
Product catalogs. Gates disclaims any liabillity 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. Recieve hands-on TRAINING whith this Gates crimper and assemblies.
2. Follow current GATES OPERATING MANUAL and CRIMP DATA for the GC16XD crimper.
3. Use only NEW (UNUSED GATES) hose and fittings.
4. Wear SAFETY GLASSES.
5. Keep hands clear of moving parts.
!
3
CRIMPER SAFETY GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
WARNING
This Safety & Operation Manual has been provided for yours and other’s safety. Every operator MUST have
completed training and have an understanding of the crimper and the requirements of hose assemblies
before using this machine.
It is the responsibility of the owner of this crimper to ensure that ONLY persons who have an understanding of
the local regulations for work safety and accident prevention in addition to undertaken training on using this
crimper be allowed to operate this machine.
It is the responsibility of the operator of this crimper to observe the rules and guidelines set out in this manual
and those provided by the owner of this machine.
This Safety & Operational Manual MUST be located near the crimper at all times and be used as a
reference when required. Regulations for Work Safety and Prevention of accidents MUST also be available to
the operator of this crimper.
WARNING
Every crimper has been engineered to the hightest possible standard and thoroughly tested prior to release.
Regardless of this, dangerous situations can arise if the safety rules and regulations are not respected or be
part of the work process when using this crimper.
!
4
GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
CRIMPER SAFETY
WARNING
This Gates crimper has been engineered and qualified for Gates product ONLY. Crimping any NON-GATES fluid
power product, including miscellaneous items (cable/pipe) through the machine will not only VOID Warranty
but also breech the intended use and purpose condition and basic regulations of work safety and accident
prevention.
Intended use and purpose outlined in this manual also includes regular maintenance. Failure to use the
specified grease will also VOID Warranty.
Warranty and Liability
The terms and conditions of sale and delivery shall apply. A copy of these terms and condition can be
provided on request, but generally include conditions for inteded use and purpose, improper observation
concerning transport, storage & maintenance, unauthorized use, constructional changes or repairs and failure
to detect wear.
Only authorized/qualified electricians are to work on the electrical system of Gates crimpers.
It is the responsibility of the operator to ensure that no oil from this crimper is allowed to seep into the
ground, in accordance to pollution rules of the Water Resource Management Laws.
1. Avoid contact with oil for prolonged periods.
2. Keep work place clear of objects and trip hazards.
3. Wear safety equipment at all times when operating the machine.
4. Keep body parts away from the machine when in use, do not put hands in crimper when operational.
5
GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
CRIMPER SAFETY
WARNING
Intended Design Use
This machine must not be used for high volume daily production. It is designed for periodic use only. Using
this machine other than for its intended purpose will void manufacturers warranty and could result in failure
which may cause injury or loss of life.
Personal Safety
Regardless of local accident prevention regulations, the following should be observed to maintain the health
and safety of operators.
1. Always wear protective clothing and apparatus as oulined in the local accident prevention regulations.
2. Ensure that safety and danger notifications have been observed.
3. Make sure the work area is clear of obstructions and is a suitable work environment.
4. Never start the machine unless intending to make a hose assembly and the head is free of objects
and persons.
5. ONLY operate this machine if the ambient temerature is between 50ºF ~ 95ºF (10ºC and 35ºC)
6. Never reach into the crimper while head is moving.
7. Never change die sets unless the head is completely open.
8. The power MUST be disconnected for crimper maintenance.
9. Observe machine balance point when moving the crimper.
10. Never try and lift this crimper when there is a possibility of oil on the handle.
6
CRIMPER SAFETY GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
WARNING
LIFTING AND MOVEMENT
The handle is designed for manual lifting only. Do not use as a lifting point for slings, doing so may result in
crimper falling and injuring personnel.
7
GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
BOX CONTENTS
Included in the carton with GC16XD
will be TDS start up kit, calibration
tools and a set of calipers.
GC16XD (PART# 7480-7006)
• Tungston Disulphide Start-Up Kit
• Calipers
• Calibration/Maintenance Tools
Optional Extra:
Quick Change Tool (7482-7304)
CALIPERS QUICK CHANGE
TOOL
TUNGSTEN
DISULPHIDE
GREASE
CALIBRATION/
MAINTENANCE
TOOLS
8
GETTING TO KNOW YOUR CRIMPER GC16XD MINI CRIMPER & PUMP SAFETY & OPERATION MANUAL
ELECTRONIC DIAL INDICATOR
The Electronic Dial Indicator (EDI) is the device which will notify
the operator when a crimp is completed. It is located on the
top right of the machine with a red LED on the front. The EDI is
adjustable to suit different crimp diameters with different die sets.
The user will be notified that a crimp is nearing completion when
the silver indicator pin is almost flush with the fron of the EDI
knob. At this position, jog (activate in short intervals) the external
power unit until crimped (if power unit function allows). The hose
assembly is crimped when the red LED illuminates on the EDI.
WARNING: Do not hold the machine under pressure for
extended amounts of time on the power unit. As soon as crimp
is complete, release pressure to allow the machine to retract.
If the EDI’s batteries are flat the unit can still be used to identify a
completed crimp. When the silver indicator is flush with the front
face of the knob, the crimp is completed. You may wish to use
your finger to feel when the indicator pin is flush with the front of
the knob. If the hose assembly is over-crimped, the silver indicator
pin will protrude past the knob face.
The operator MUST stop hydraulic flow to the machine before
the indicator reaches the set point position (light on).
The crimp accuracy is dependant on operator reaction and as
such every completed hose assembly MUST be measured.
Battery replacement work instructions included with start-up kit.
POWER UNITS
The optional hydraulic power device MUST be capable of 10,000 PSI,
these can range from a hand pump, through to pneumatic
assisted, or battery operated.
INDICATOR PIN
POSITION 3MM:
INDICATOR PIN
POSITION 1.5MM:
INDICATOR PIN
POSITION 0MM:
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