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reTrofiTTing a CriMper

Gates GC20 Cortex

RETROFITTING A CRIMPER

You can retrofit an existing Gates PC707 Crimper to Gates GC20 Cortex standards.

Order Gates GC20 Cortex PC 707 Conversion kit 7480-0011 part number 70446,

which includes prepared sub-assemblies. A typical shop should be able to do the

retrofit within 45 minutes.

These directions apply equally to PC707 Crimpers that already have been converted

to 230V.

WARNING

The retrofit process involves removing and replacing hose couplings and

making electrical connections. Take care that all equipment is unplugged

from a power source and that you capture and dispose of any leaked

hydraulic fluid in an environmentally safe manner.

Figure 70: Stock Gates PC707 Crimper

Summary of Contents for GC20

Page 1: ...GATES GC20 WITH GATES CORTEX INTELLIGENCE OPERATING AND SAFETY MANUAL ...

Page 2: ...E THIS MACHINE ONLY IF YOU 1 Complete your TRAINING with this Gates crimper and assemblies 2 Follow current GATES OPERATING INSTRUCTIONS for the Gates GC20 Cortex 3 Use only NEW UNUSED GATES hoses and fittings 4 Wear SAFETY GLASSES 5 Keep HANDS CLEAR OF MOVING PARTS 6 Make sure your hose is CUT TO THE PROPER LENGTH accounting for the hose coupling interface length 7 Ensure your HOSE IS FULLY INSER...

Page 3: ... and Images 28 Use Reference Tools 28 Hose Preparation 30 Two Piece Couplings 30 Megacrimp Pre Assembled Couplings 32 Operating Instructions 34 Do a Crimp 35 Using the Optional Notched Cone 45 Measuring Crimp Diameter 47 To Properly Measure a Crimp Diameter 47 When Using 21 and 22 Dies 47 When Not Using 21 and 22 Dies 48 Next Steps when Using or Not Using 21 and 22 dies 49 Maintenance 50 Lubricate...

Page 4: ...M Table of Contents Gates GC20 Cortex Converting to 230V 60 General Instructions for Converting to 230V 60 Retrofitting a Crimper 61 Remove Old Components 62 Add New Components to the Crimper 68 Troubleshooting 80 ...

Page 5: ...ortex 230V converter kit Prod No 7482 0047 Part No 70435 ELECTRO POWER PUMP Prod No 7481 0023 Part No 77810 Power Source 115 Volt 15 Amp min 1 H P 60 Cycles Dimensions 12 wide x 25 deep x 12 high Weight 70 lbs Maximum Rated Working Pressure 4900 psi The motor on the pump is rated for 30A but pulls only 14A It can be used with a standard 15A or 20A wall outlet GATES GC20r CORTEX PC 707 CONVERSION K...

Page 6: ...No 78747 Die Set 739 7482 0939 78939 Die Set 740 7482 0947 78950 For crimping 6ACA Die Set 741 7482 0941 74951 For crimping 8ACA Die Set 742 7482 0942 78952 For crimping 10ACA Die Set 743 7482 0943 78953 For crimping 12ACA Die Set 744 7482 0944 78954 For crimping power steering Die Set 745 7482 0945 78955 For crimping grease fitting Die Set 746 7482 0946 78956 For crimping miscellaneous Die Set 78...

Page 7: ...ODUCT NUMBER PART NUMBER NOTES Die Set 73537 LG 7482 1427 78766 For crimping Lifeguard Die Set 73638 LG 7482 1428 78767 For crimping Lifeguard NOTE Do not use the 720 735 737 or 739 die sets with the notched die cone sold separately This may damage the die cone ...

Page 8: ...cap and operating manual from its shipping carton 2 Mount the crimper so it overhangs a workbench as shown in Figure 1 The overhang is necessary to allow hoses to be inserted through the base plate slot from underneath the crimper The back of the cutout in the base plate should be in line with the front of the bench see Figure 2 The bench should be 37 to 42 high stable and of sturdy construction F...

Page 9: ... hose with 20LG4K sleeve on back of T adapter of the pump Return hose 6MXT between port 1 on the solenoid manifold and with its 90 degree coupling connected to the side port of the pump pump adapt er included T adapter pre installed on the crimper Figure 3 The solenoid manifold ports Return Line Connection Port 1 Pressure Line Connection Back of T Adapter T Bracket Installed into back of crimper t...

Page 10: ...M Setup Gates GC20 Cortex High Pressure Hose with 20LG4K Sleeve Fluid return hose Fluid return hose Figure 4 Hose connections 6MXT Hose with 90 Degree coupling Figure 5 6MXT hose connected to return port on pump ...

Page 11: ...g the cord of the crimper into a 115VAC 15 amp outlet This immediately provides power to the crimper electronics Figure 6 Gates GC20 Cortex 8 Remove plug from the top of the pump reservoir and replace it with the breather cap provided Check that hydraulic oil is within 1 2 of bottom of plug opening If needed add Dextron III ATF or equivalent to the reservoir 9 Move switch on pump electrical box to...

Page 12: ...on the tablet and dock it in the cradle the large slot on the right hand side of the crimper as you face it with the charging port facing left to make the magnetic connection When the tablet is fully inserted the cradle provides power to the tablet and charges it 2 Ensure that the tablet s Bluetooth and WiFi connectivity are on and working Figure 7 shows how the indicators appear on the tablet The...

Page 13: ...illuminates showing that crimper is connected to WiFi Figure 9 The Bluetooth and WiFi symbols on the faceplate only illuminate when the Gates application is running and when the tablet and the crimper are connected On Off indicator Bluetooth indicator WiFi indicator Figure 9 Bluetooth and WiFi indicators on faceplate ...

Page 14: ... business name and your location into the template and then tap PRESS HERE TO CONTINUE Wait for the validation confirmation before continuing 8 The Gates GC20 Cortex gives you an opportunity to set up an Administrator account and Operator accounts if you want them You can skip setting up Admin Operator accounts and do this later or not at all or you can set up an Administrator account now There ar...

Page 15: ...he crimper and about operating the tablet generally see Tablet Operation on page i 9 When you have set up Administrator and Operator accounts or when you have skipped setting them up the tablet confirms that setup is complete as in Figure 11 Figure 11 Setup is complete NOTE If the tablet notifies you of a software update update the software ...

Page 16: ... have set up Admin and Operator accounts you may need to log in with your PIN 1 If you have not yet closed the Setup Complete screen you can perform the Setup Calibration directly from that screen Figure 12 Tap PERFORM SETUP CALIBRATION and then jump to Step 5 on page 14 Setup Calibration Figure 12 Performing the Setup Calibration from the Congratulations screen 2 If you have closed the Setup Comp...

Page 17: ...3 Application Home screen 3 From the pulldown menu choose APPLICATION SETTINGS The application opens the Application Settings screen Figure 14 Application Settings screen 4 Tap CALIBRATION SETTINGS The application opens the Calibration Settings screen Figure 15 ...

Page 18: ...no additional tools You will be instructed on a series of steps to purge the air from all lines by cycling the crimper five times Step 2 requires a hose coupling ferrule stem and die to perform a crimp and measure it for compliance Figure 16 Cycling the crimper 6 Tap PROCEED when you are ready The application displays Calibration cycle one Figure 17 WARNING Make sure that area under pusher cup is ...

Page 19: ... 7 Press and hold the red PRESS HOLD TO CYCLE button until the cycle is completed and the button turns to green The cycle count appears to the right of the dot Figure 18 Perform this cycle five times as directed by the software Figure 18 Calibration cycle one completed ...

Page 20: ...cycles ram retracting 9 Step 2 lists its requirements on screen which include a specific coupling and a specific die set but no hose When you have everything ready tap PROCEED NOTE For instructions on how to set up a coupling and die set see Steps 1 through 8 beginning on page 18 Figure 20 Assemble the coupling and die set and then tap PROCEED ...

Page 21: ...ter the crimper software can self adjust the stroke to increase or decrease the crimp Enter the crimp diameter with a leading number even if that leading number is a zero and three decimal places 1 003 or 0 997 for example NOTE Measure the crimped coupling as explained in Measuring Crimp Diameter on page 13 Figure 21 Enter the measured crimp diameter 12 If the measured crimp diameter is beyond cri...

Page 22: ...alibration crimp The crimper recalculates its stroke each time you report a measured crimp diameter that is outside of tolerance 14 When the measured crimp diameter is within tolerance the application tells you that you have successfully calibrated the crimper Figure 23 Tap EXIT to return to the Home screen Figure 23 A successful calibration ...

Page 23: ...S WHERE YOU FIND X CLOSE Closes the menu Goes to Home Page HOME Home Page KNOWLEDGE CENTER Tutorials Training Videos and PDFs Safety and Operations Manuals Gates Catalogs Industrial Hose Couplings and Equip ment Catalog Hydraulic Hose Couplings and Equip ment Catalog Image Repository Crimp Operations Images Screen Saver Images Visit Gates com Opens Gates website More menu follows ...

Page 24: ...settings Cannot be undone Software Details Software Version Check for and pull software updates Application Content Last update check for and pull content updates Calibration Settings Setup Calibration Link to Video Tutorial Perform setup calibration upon setup of crimper or machine relocation Maintenance Calibration Link to Video Tutorial Perform Maintenance Calibration Activity Tracker Assemblie...

Page 25: ...0 Cortex PEOPLE AND ACCOUNT MENU Create Administrator Account Create an Operator Account once you have created an Administrator Account For more information about creating Administrator and Operator accounts see Tablet Operation on page 10 ...

Page 26: ...1 Press and Hold to Crimp End 2 Click star to make this assembly a favorite FAVORITES Select a favorite to execute Press and Hold to Crimp End 1 Press and Hold to Crimp End 2 CRIMP HOSE ASSEMBLY WITH ACCESSORY Select Hose Type Select Hose Size Possibly Pressure Select Accessory Press and Hold to Crimp End 1 Press and Hold to Crimp End 2 Click star to make this assembly a favorite For more informat...

Page 27: ...ting machine timeout or resetting to factory specs There can be only one Administrator Can create Operator accounts Can easily add or remove Admin access to an Operator account Can reset passwords PINs No other users can use the crimper without at least one Operator account Operator Account s You want to restrict use of the crimper to an Administrator and one or more specific Operators Each Operat...

Page 28: ...t up an Administrator account the application displays the CREATE ADMINISTRATOR ACCOUNT screen Figure 25 You can set up only one Administrator account Figure 24 People and Account menu Figure 25 Create Administrator Account 2 Fill in the account information including the PIN at the bottom you may choose any PIN Gates suggests not making all four the same number and then tap SAVE The application di...

Page 29: ...with Administrator access can log in for this task too OR if you re already logged in choose ACCOUNT SETTINGS from the People and Account menu as shown in Figure 27 The application displays the Account Settings screen showing the single Administrator account Figure 28 Figure 27 Log in as Administrator using your PIN left or choose Account Settings from the People and Account menu right ...

Page 30: ...unt screen Figure 29 Figure 29 Create a New Operator Account 3 Fill in the fields of the screen and then tap SAVE The application displays the Account Settings screen showing the new Operator account Figure 30 You can continue adding Operator accounts by tapping ADD AN OPERATOR or you can return to this screen at any time to add more Operator accounts later ...

Page 31: ... Account Settings screen move the ADMIN ACCESS slider right for an Operator until it changes color Figure 31 Slide it back left to remove ADMIN ACCESS Figure 31 Give an Operator account Administrator access Only a logged in Administrator or other Operator who already has Administrator Access can grant Administrator Access to an operator ...

Page 32: ...TOOLS The application offers quick links to the tablet s on board calculator to a unit converter application and to TeamViewer an application that allows the support experts at Gates to control your tablet remotely if necessary From time to time Gates may make additional utilities and support applications available to the tablet The first time you tap these applications you may need to install the...

Page 33: ...29 GATES COM Tablet Operation Gates GC20 Cortex Figure 33 Reference Tools screen ...

Page 34: ...erty damage TWO PIECE COUPLINGS 1 Cut hose to desired length 2 Obtain the correct stem and ferrule 3 Place the ferrule over the end of the hose as shown in Figure 34 Figure 34 Place ferrule over the end of hose Stem shown clamped in a vise 4 Lubricate the first 2 or 3 serrations on stem with lightweight oil SAE 10W 5 Clamp stem in a vise on its hex portion Figure 34 and push hose onto stem Hose sh...

Page 35: ...ation Gates GC20 Cortex Figure 35 Hose pushed onto stem up to stem shoulder 6 Push ferrule so that it rests against hex of stem as in Figure 36 Hose and coupling are now ready for crimping Figure 36 Push ferrule to hex of stem ...

Page 36: ...n the correct stem and ferrule Figure 37 Put a visible mark at the correct insertion length mark appears just above right thumb 3 Place a visible mark on hose cover at the correct insertion length Figure 37 or use MegaCrimp Insertion Tool 7482 1342 Figure 38 Hose inserted into MegaCrimp ferrule up to the insertion mark ...

Page 37: ...ATES COM Hose preparation Gates GC20 Cortex 4 Insert coupling into the hose until the mark lines up with the end of the coupling ferrule as shown in Figure 38 5 Hose and coupling are now ready for crimping ...

Page 38: ...ssure ranges It knows which combinations work together You can use this information two ways If you already know the hose coupling and die set you want to use set that up in the crimper and then select them from the tablet to control the crimp The following steps assume you already know the hose coupling and die set information If you do not know the specific hose coupling and die set you want to ...

Page 39: ...e backup ring at front of crimper base plate Figure 39 This backup ring is used with all die sets Figure 39 Backup ring at front of crimper base NOTE Use No Notch Die Cone when crimping with 720 737 and 739 Die sets Using the optional notched cone may cause damage to the die cone ...

Page 40: ...ng Instructions Gates GC20 Cortex 2 Using the die magnet supplied with the crimper insert the proper die set one half at a time onto the die backup ring as shown in Figure 40 Figure 40 Use the die magnet to insert die set ...

Page 41: ... 41 See Maintenance on page i for more maintenance information Screws for Die Fingers 7482 1672 or 78749 Die Cage Figure 41 Check bottom of die cage and top surface of backup ring WARNING Die cage may break if surfaces are not kept clean 4 Check screws holding fingers to cage to make sure they are tight Tighten if necessary It could affect the crimp if they are loose ...

Page 42: ...king area of die cone 6 Insert hose assembly stem ferrule hose through the bottom of the crimper base plate and up through the die fingers 7 Position the top of the ferrule or MegaCrimp coupling approximately 1 8 below top of the die fingers Place the die cone over the die fingers to hold the assembly in position See Figure 43 GLX couplings extend above the die fingers and leave a bubble at the to...

Page 43: ...se 720 737 or 739 die sets with optional notched die cone May cause damage to die cone Top of Die Finger Top of Ferrule Figure 43 Position the top of the ferrule or MegaCrimp coupling approximately 1 8 below top of die fingers WARNING Keep hands away from ram at all times ...

Page 44: ...as in Figure 44 Rear locating pins Figure 44 Move die cone back against BOTH rear locating pins CAUTION Always wear safety glasses and KEEP HANDS AWAY FROM MOVING PARTS 9 Use the tablet to select the proper die set for the hose coupling and pressure range you are crimping Go to the application s Home screen Figure 45 Figure 45 Home screen ...

Page 45: ...ype you re working with You can also search for a hose type by name or number The application asks you to select a hose size and possibly a pressure range Only the sizes and pressure ranges appropriate to your selected hose type appear Figure 47 Tap to select Previously selected hose type Figure 47 Select hose size 12 Tap to select a die set Only the die sets appropriate to your hose type hose siz...

Page 46: ...a change by tapping PREVIOUS SCREEN in the bottom bar of the application Figure 48 Select the die set NOTE The on screen step numbers may not all appear some steps are only for specific hoses die sets and accessories 13 When you have made all the selections necessary for your hose hose size pressure range and die set the application shows you a summary page with the red PRESS HOLD TO CRIMP button ...

Page 47: ...ll retract If a partial crimp is performed and the ram has touched the die cone that assembly must be scrapped and the process re started 15 During ram retraction the button turns green and the application displays summary information so that you can prepare for your next crimp When the application is ready to begin End 2 the button turns red and displays PRESS HOLD TO CRIMP END 2 IMPORTANT The ta...

Page 48: ...reen where you can repeat the assembly build a new assembly by selecting a new hose die set etc or view assemblies you have added to your favorites Figure 51 18 Measure each crimp OD using calipers see Measuring Crimp Diameter on page 13 and match it to the expected crimp diameter as reported by the tablet during each crimp If the measured crimp is different from the expected crimp OD perform a ma...

Page 49: ...ild a new assembly USING THE OPTIONAL NOTCHED CONE Figure 52 Thread end of coupling in the die cone notch Notch MUST be towards front of crimper 1 Position the thread end of the coupling into the die cone notch The notch must be towards the front of the crimper as in Figure 52 ...

Page 50: ...2 When crimping bent tube couplings use the same procedure as crimping straight end couplings Keep the thread end of bent tube forward to clear the notch in the cone 3 To crimp a 45 or 90 block type coupling follow the same procedure used for the bent tube ...

Page 51: ...oth kinds of die Figure 53 shows a Gates digital caliper that can also be used to measure crimped ferrules Figure 53 Gates digital caliper WHEN USING 21 AND 22 DIES 4 Using Gates calipers Product No 7369 0322 Part No 78215 for example measure halfway between ridges Figure 54 To be sure crimp diameter is being properly measured mark a crimp flat Beginning with that flat count 9 flats to get the dia...

Page 52: ...ortion of Ferrule Figure 55 Measure the ferrule across the middle of the crimped portion WHEN NOT USING 21 AND 22 DIES 1 Using Gates calipers Product No 7369 0322 Part No 78215 for example measure halfway between ridges Figure 56 Be sure caliper fingers DO NOT touch ridges or part number stamps CRIMP DIA CALIPER RIDGES Figure 56 Measure halfway between ridges ...

Page 53: ...asure ferrule diameter halfway down the crimped portion of the ferrule Do not touch ridges code I D marks or part number stamps NEXT STEPS WHEN USING OR NOT USING 21 AND 22 DIES 3 Should actual crimp diameter not be within recommended crimp tolerance check the calibration of the machine and recalibrate using a Setup Calibration See Calibrate the Crimper on page 12 ...

Page 54: ...gure 58 When die cone becomes shiny lubricate it By greasing the die cone grease transfers naturally to the fingers of the die sets you use Occasionally the fingers of a die set may require additional grease See Lubricate Die Sets with Molykote G part 7482 3011 on page 52 CHECK OIL LEVEL 1 Check the hydraulic oil level in the pump reservoir after each 10 hours of use see pump operation manual for ...

Page 55: ...perating instructions with Dextron III ATF or equivalent to within 1 2 of the top of the reservoir INSPECT DIE SETS 1 Periodically inspect the surfaces of die sets for debris metal chips dirt etc or damage 2 If debris is present clean and lightly lubricate Damage requires replacement see GC20 Schematic and Parts List on page 2 for ordering information 3 Check screws holding fingers to cage to make...

Page 56: ...g to them 3 Re grease the die set fingers using a thin coat of Molykote G grease INSPECT HOSE ASSEMBLIES 1 Each month inspect both hose assemblies that connect the crimper and pump inspect more often with severe use These include the high pressure hose and the return hose both of which run from the solenoid manifold at the back of the crimper to the pump High Pressure 8MXT Hose with 20LG5K Sleeve ...

Page 57: ... serious damage may exist Replace hose assembly immediately PERFORM A MAINTENANCE CALIBRATION Perform a Maintenance Calibration monthly If you suspect that a measured crimp is out of spec perform a Maintenance Calibration 1 From the pulldown menu on the application Home screen choose APPLICATION SETTINGS The Application Settings screen appears Figure 62 Pulldown menu Figure 61 Application Home scr...

Page 58: ...ATES COM Maintenance Gates GC20 Cortex Figure 62 Application Settings screen 2 Tap CALIBRATION SETTINGS The application opens the Calibration Settings screen Figure 63 Figure 63 Calibration Settings screen ...

Page 59: ...imp Diameter on page 13 Enter the crimp diameter with a leading number even if that number is a zero and three decimal places 1 003 or 0 997 for example 6 If the crimp diameter is out of calibration the application will make internal adjustments and ask you to perform another crimp MAINTENANCE LOG The Gates GC20 Cortex keeps a maintenance log where it automatically enters maintenance events such a...

Page 60: ... Figure 66 You can select one of the prepared maintenance actions from the pop up menu or select Other Figure 66 Entering a Maintenance Action manually 3 Type your initials and the Maintenance Action you performed or other note then tap SAVE If you re logged in with a PIN the application enters your initials for you automatically The application places your new Maintenance Action into the list ...

Page 61: ...CHECK FOR SOFTWARE AND CONTENT UPDATES To check for updates to the application and its content the most recent product and crimp information the tablet must have a WiFi connection to the Internet If the tablet does have a WiFi connection the application automatically looks for any updates and notifies you as in Figure 68 Figure 68 The G20 Cortex offers an app update ...

Page 62: ...LS The application displays the software details screen Figure 69 The Software Details screen showing current versions and the last time that content was updated 3 Tap CHECK FOR UPDATES If an update is available the application asks syou to install it You should bring the tablet into a WiFi area at least every 20 days to check for updates If you have not the application reminds you that it has bee...

Page 63: ...re is a firmware update You can also check the Machine Details screen see Figure 69 Any available firmware updates will appear there 2 Tap the Update button The tablet application contacts the crimper electronics and conducts the firmware update A firmware update may take several minutes 3 At the conclusion of the firmware update the application restarts You may need to log in again During firmwar...

Page 64: ...ump per the instructions on the side of the pump GENERAL INSTRUCTIONS FOR CONVERTING TO 230V 1 Purchase a new 230V wiring kit Prod No 7482 0047 Part No 70435 from Gates This kit contains one or two 230V plugs 2 Unplug the pump from its power source Unplug the crimper from its power source 3 Remove the tablet from its dock and set aside 4 Replace the 115V wall plug for the crimper with the kit supp...

Page 65: ...lies A typical shop should be able to do the retrofit within 45 minutes These directions apply equally to PC707 Crimpers that already have been converted to 230V WARNING The retrofit process involves removing and replacing hose couplings and making electrical connections Take care that all equipment is unplugged from a power source and that you capture and dispose of any leaked hydraulic fluid in ...

Page 66: ...Crimper Gates GC20 Cortex REMOVE OLD COMPONENTS 1 Flip the pump switch to OFF and disconnect the pump from the wall outlet 2 Disconnect the pump from the crimper switch box Figure 71 Disconnect the pump from the crimper switch box ...

Page 67: ...tex 3 Disconnect the gray display cable from the crimper switch box Gently twist the connector counter clockwise Figure 72 Remove any cable ties attaching the cable to the crimper Figure 72 Disconnect the gray display cable from the crimper switch box ...

Page 68: ... 4 Remove the crimper switch box by removing the two bolts holding it to the base plate of the crimper These may be located on the side or top of the base plate depending on your model Two bolts Figure 73 Remove the switch box Figure 74 Switch box removed ...

Page 69: ...gital display from the shroud Use a flat head screwdriver or similar tool to pop off the red screen revealing two Phillips head screws Remove these screws and withdraw the display unit from the back of the shroud Retain the shroud for re installation later Figure 76 see images on the next page If you have a PC707 without the removeable red screen pinch and remove the clips at the back of digital d...

Page 70: ...Insert flat head and pop off display face Remove two screws Figure 76 Pop off display face remove screws from display and withdraw display unit and wire from the back of the shroud 8 If you still have the foam support block set it aside to reinstall later ...

Page 71: ... and then remove the top nut Limit switch actuator rod Channel Figure 77 Remove limit switch actuator rod 10 Disconnect the pump hose from the crimper Rags and a basin are handy for catching any fluid leakage from the hose or crimper and sceure the hose in an upright position or over a basin to avoid oil spillage This will be reinstalled in a later step Figure 78 Disconnect pump hose from crimper ...

Page 72: ... Figure 80A 2 Reconnect the adapter from Port 2 on the solenoid to the bottom of the T brace Orient the solenoid so the adapter in Port 1 is parallel to the back of the crimper and tighten the connection between the T adapter Re install support bracket if removed in step 1 Figure 80B Support Bracket Location T Bracket Pressure Line Connection Pressure Line Connection Back of T Adapter Adapter in P...

Page 73: ... pump on its side while you make this connection Using an allen wrench remove the current hardware on the drain port Insert the drain line adapter tighten Connect the return line hose assembly to the adapter you just inserted into the pump and tighten Then connect the other end of the return line to Port 1 on the solenoid assembly and tighten Return the pump to an upright position if rotated Figur...

Page 74: ...70 GATES COM Retrofitting a Crimper Gates GC20 Cortex Figure 82 Connect the pressure line to the back of the T adapter CAUTION Ensure that all hose connections are tightened securely ...

Page 75: ...ent the sensor so that the body of the sensor is parallel to the crimper tie rod 2 Install the lower mounting bracket of the distance sensorto the channel by using the hole from the removel of the actuator rod Line up the L bracket on the sensor assembly under the channel so that it sits flush against both the back and bottom of the channel Use the bolt provided to go through the top of the channe...

Page 76: ...he body of the sensor is parallel to the crimper tie rod and firmly tighten to secure the final location This distance and orientation is important If the sensor is installed incorrectly the crimper won t operate or you ll get an error during the set up calibration process In either situation come back to this step and verify the installation of the sensor Install upper mount so that the distance ...

Page 77: ...73 GATES COM Retrofitting a Crimper Gates GC20 Cortex Upper Clamp Distance Sensor Figure 84 Install distance sensor so that it is parallel to tie rod ...

Page 78: ...readed studs into the threaded holes where the Allen bolts were at the front of the top crimper block Threaded studs Figure 85 Install threaded studs 5 Place the orange shroud on the crimper hanging it for now from the threaded studs Figure 86 Replace the orange shroud ...

Page 79: ...lace but not attached feed the four wires from the electrical housing through the opening at the top of the shroud and over the top of the crimper Feed cords from the through the opening at the top of the orange shroud and out the back Figure 87 Feed cords through shroud and backplate ...

Page 80: ...d studs and push the backplate gently into place Place the end of the green grounding wire on the left threaded stud Threaded Studs Green Grounding Wire over threaded stud Two Cutouts Figure 88 Place backplate over threaded studs 8 Place washer nuts on the threaded studs Figure 89 K Lock fastener and washers ...

Page 81: ...TES COM Retrofitting a Crimper Gates GC20 Cortex 9 Connect the cords from the distance sensor to the matching sensor in the back of the crimper Distance sensor connected Figure 90 Connect the distance sensor ...

Page 82: ...20 Cortex 10 Connect the solenoid cord to the solenoid at the rear of the crimper This cord is non polarized either lead can attach to either connector Figure 91 Connect cord to solenoid 11 Connect the pump power cable Figure 92 Connect the pump ...

Page 83: ... orienting the tablet so that the end with the magnetic charge adapter slides in first Plug the crimper into a wall outlet The power light on the faceplate should illuminate Plug the pump into a wall outlet and turn it on Figure 93 Retrofit completed The retrofit is complete You can now set up the crimper as described in the section Setup on page 4 ...

Page 84: ...ns Ram will not retract retracts slowly or retracts with a jerky motion Carefully remove hose assembly from pump Fluid is under pressure Be prepared to catch fluid in a container If ram retracts normally without a jerky motion repair or replace relief valve in the pump If ram does not retract retracts slowly or retracts with a jerky motion the piston or piston seals may be damaged by binding Repla...

Page 85: ...corresponding lights are not illuminated on the faceplate you may have a defective board Contact Gates Support Bluetooth or WiFi symbols do not appear on the tablet Make sure that the tablet is in a WiFi enabled area Make sure that both WiFi and Bluetooth are enabled in the Settings function of the tablet Make sure that the tablet is within 10 feet of the crimper or preferably docked in the facepl...

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