Gates MobileCrimp 4-20 Installationshandbuch

Carefully read and understand the following warnings before operating this crimper.

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.

FOR SAFETY

’

S SAKE

USE THIS MACHINE ONLY IF YOU:

1. Receive hands-on TRAINING with the MobileCrimp®4-20 and Gates assemblies.

2. Follow current GATES OPERATING MANUAL AND CRIMP DATA for the MobileCrimp 4-20.

3. Use only NEW (UNUSED) GATES hose and fittings.

4. Wear SAFETY GLASSES.

5. KEEP HANDS CLEAR OF MOVING PARTS. Support hose with one hand while activating

pump with other hand.

6. DO NOT operate pump UNLESS cylinder is locked in crimp position.

7. To avoid risk of injury, DO NOT use crimper UNLESS CONTROLLER BASE PLATE is in place.

8. DO NOT operate crimper in horizontal position.

Shop Air Pump

Prod. No.: 7481-0002, Part No.: 77820

Weight: 10 lbs.

1/4 H.P. 12 Volt DC Pump

Prod. No.: 7481-0037, Part No.: 77439

Weight: 20.5 lbs.

1/2 H.P. 115 Volt AC Pump

Prod. No.: 7481-0034, Part No.: 77441

Weight: 32 lbs.

Hand Pump

Prod. No.: 7481-0006, Part No.: 77821

Weight: 25.6 lbs.

1/4 H.P. 115 Volt AC Pump

Prod. No.: 7481-0033, Part No.: 77440

Weight: 20 lbs.

1-1/2 H.P. 115 Volt AC Pump

Prod. No.: 7481-0035, Part No.: 77442

Weight: 108 lbs.

Positive Stop Control

Prod. No.: 7480-0051, Part No.: 77421

Dimensions: 12 1/4" wide x 6 1/4"deep x 19 1/2" high

Weight: 57 lbs. (with stand)

Digital Dial Control

Pump Specifications

All pumps maximum rated working pressure: 10,000 psi

MobileCrim

Contents

Identification List ...........................................................................................2

Setup ..............................................................................................................3

Hose Preparation ............................................................................................7

Operating Instructions ....................................................................................9

Measuring and Adjusting the Crimp Diameter ..............................................13

Maintenance .................................................................................................14

Troubleshooting ............................................................................................15

Replacement Parts List ..................................................................................16

Warranty ................................................................................inside back cover

Serial No. _______________

(Located on front top of cylinder)

Date of Purchase _________

MobileCrim

Die

Pressure Plate

Hose Assembly

Literature Packet Magnet

.05 Allen Wrench

Clamps

Stand

Molykote and Brush

Crimper

Identification List

MobileCrim

Setup

1. Unpack carton.

• Remove crimper, pressure plate (1),

nylon-covered hose assembly (1),

literature envelope (1), stand (2 pieces),

magnet (1) .05 Allen wrench (1) and

Molykote lubricant (1) from shipping

carton. Locate the serial number

assigned to the crimper on the top front

of the cylinder and record on page one

for future reference.

2. Attach crimper to the stand.

• Place crimper on flat, well-supported

surface (such as the top of a workbench

or the bed of a service vehicle) with the

handle to the right.

• Remove two (2) knobs, flat washers (2)

and spacer (1) from crimper pivot bolts.

• Slide the two halves of the stand

together and attach to the crimper

at the pivot bolts.

• Replace spacer, flat washers and knobs.

Do not tighten knobs.

• Lift crimper and allow stand to swing

down onto the surface. Tighten knobs.

Left Side

Right Side

spacer

MobileCrim

3. Fasten crimper to work surface

before use (to avoid damage to

machine or personal injury because

an unsecured machine can fall).

• Position crimper so that mounting holes

are approximately 7" to 8" from the

edge of the work surface.

• Mark the drilling location using the

mounting holes as a guide (see illustra-

tion below).

• Drill two 5/16" diameter holes.

• Use mounting holes or clamps to fasten

stand to work surface.

4. Attach pump to crimper.

• Place pump near crimper.

• Connect hose assembly to the pump

port (3/8" NPT threads). Pipe sealant

may be used to seal connection. (For

best connection, use Gates’ Quick

Disconnect couplings, G95311-0606

and G95321-0606, sold separately.)

• Connect opposite end to the adapter

on crimper.

5. Check pump oil level.

• Pump comes with oil in reservoir.

• Check proper oil level per pump

operating manual instructions or the

Maintenance Section (p. 14) of this

manual.

6. Connect pump to power outlet.

• For 115V connection, plug power cord

into a properly grounded and rated circuit

(see inside cover for circuit requirements).

• For vehicle battery connection, see

pump operating manual.

Edge of

work

surface

(2) 5/16 "diameter holes

/2"11"

clamps

mounting holes

To avoid damage to

the machine or injury

to you, ALWAYS fasten

the crimper to the work

surface before you attempt to crimp.

MobileCrim

7. Bleed air from system.

• Tilt crimper forward so adapter is at

its highest point.

• Turn the knob on the controller to a

setting of 400, which allows the ram

to extend approximately 1".

• Turn pump on by pressing and holding

the power ”on“ switch, (see pump

operating manual for switch location)

which extends the ram.

• When the light comes on and buzzer

sounds, immediately release “on” switch

allowing ram to fully retract. NOTE: If

light and buzzer are faint or do not

work, the controller batteries may need

replacement. See “Maintenance” section

of this manual.

• Repeat a minimum of five (5) times to

bleed air completely.

8. Place crimper in comfortable

working position.

• See photo below for suggested working

position.

IMPORTANT

Do not operate crimper in

horizontal position because dies

will become unstable.

Note: It’s a good

idea to place a rub-

ber mat on the floor

near the crimper to

reduce the chance of damaging a

die if dropped and improve opera-

tor comfort.

CAUTION

Keep away from all moving parts!

If bodily contact with a moving

part occurs, immediately release

the pump power “on“ switch.

MobileCrim

9. Calibrate.

• Before crimping a hose assembly,

check calibration.

Calibration is the proper relationship between

a setting and the crimp diameter. It should be

checked at least monthly, possibly weekly or

daily, if crimper has been used heavily or

abused.

• Place the MC33 die set into the

die cone and install pressure plate.

• Turn the knob to a setting of 245.

Note: Rotating the knob on front of switch box clockwise will

increase the number; counterclockwise will decrease the num-

ber. When changing the setting, always move to a highter

number then down to the desired setting. (Example: To change

from 200 to 245, move dial up to 300 then down to 245.)

• Insert an 8G MegaCrimp®coupling into the

die set.

• Complete the crimp.

• Remove the coupling and measure the crimp

diameter, which should measure 1.000"

±.003". To properly measure crimp diameter,

refer to page 13.

• If the crimp diameter is within this range, no

adjustment is necessary.

• If the crimp diameter is not within this range,

the crimper must be calibrated.

• To get a smaller crimp diameter,

change the setting to a smaller number.

• To get a larger crimp diameter,

change the setting to a larger number.

• For every .001" change in crimp diameter,

change the setting by 002. For example, to

increase the crimp diameter by .002", increase

your setting from 245 to 247.

• Turn the knob to this new setting

and crimp a new coupling.

• After the correct diameter is achieved, pull the

plastic cap from the knob.

• Loosen the two (2) set screws in the brass knob

1/4 to 1/2 turn using a .05” Allen wrench.

• Turn the brass knob either clockwise or coun-

terclockwise to get the setting back to 245.

• Tighten the set screws and replace

the plastic cap.

• Crimper is now calibrated.

MobileCrim

Hose Preparation

MegaCrimp®Pre-Assembled

Couplings.

1. Cut hose to desired length.

2. Using Gates crimp data chart #35019

(Ind), 428-7365 (Auto), select the

correct coupling or visit our website

to download our electronic program

at www.gates.com/ecrimp.

3. Place a visible mark on hose cover

at the insertion length shown on the

crimp data chart.

4. Insert coupling into the hose until

the mark lines up with the end of

the coupling ferrule.

5. Hose and coupling are now ready

for crimping.

CAUTION

A new hose and end fittings

must be used when building a

hose assembly. Re-using any

components will seriously

affect performance and could

result in serious injury or

property damage.

MobileCrim

GlobalSpiral™Two-Piece Couplings.

1. Cut hose to desired length.

2. Using Gates crimp data chart #35019

(Ind), 428-7365 (Auto), select the

correct stem and ferrule or visit our

website to download our electronic

program at www.gates.com/ecrimp.

3. Place ferrule over end of hose.

4. Lubricate the first two or three

serrations on stem with lightweight

oil (SAE 10W).

5. Clamp stem in vise on hex portion,

and push hose onto stem.

Hose should be flush against stem

shoulder (see cutaway drawing below).

6. Hose and coupling are now ready

for crimping.

CAUTION

A new hose and end fittings

(stem/ferrule) must be used

when building a hose assembly.

Re-using any components will

seriously affect performance and

could result in serious injury or

property damage.

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