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Gates GC32-XD, Safety And Operating Manual

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Gates GC32-XD Safety And Operating Manual Download Page 21

19

Gates Corporation

REPLACEMENT PARTS LIST

Complete GC32-XD Crimper

Part No.: 78828
Product No.: 7480-7001
Includes: Quick Change Tool (QCT), Mirror

Foot Pedal

Start-up Accessory Tool Kit

Part No.: 78844
Product No.: 7482-7112
Includes: Tube of Grease, Brush, Grease Gun,

Dial Calipers, Allen Wrench, Fuses

No.

Item

QTY

Product No.

Part No.

1

Stand - Die Rack (Optional) not included

1

7480-7002

78829

2

Die Tubs

1

7482-7124

78856

3

Die Rack - (Optional)

2

7480-7003

78830

4

Rack Nuts (4)

4

7482-7183

78913 

5

Rack Bolts (4)

4

7482-7182

78912 

6

Foot Pedal

1

7482-7111

78843

7

Reservoir Deck screws

16

7482-7110

78842

8

Back Pressure Control Cartridge

1

7482-7194

78925 

9

Power Unit Replacement Kit (Invertor)

1

7481-0043

78831

10

Pump bolts

4

7482-7186

78916 

11

Hose Assembly

1

3663-5161

78915 

12

Oil Filter Element

1

7482-7196

78927 

13

Head Seal

1

7482-7126

78858

14

Breather Cap

1

7482-7175

78907

15

Breather Element

1

7482-7195

78926 

16

Long Mounting Bolts (Head)

2

7482-7181

78911 

17

Short Mounting Bolts (Head)

2

7482-7106

78838

18

Pilot Operated Check

1

7482-7103

78835

19

Relief Valve

1

7482-7193

78924 

20

Valve block adaptor

1

7482-7102

78834

21

2 Position 3 Way Solenoid Valve

1

7482-7180

78910 

22

Solenoid Bolts set

4

7482-7171

78903

23

Outer Washer (Control Panel) 

1

7482-7190

78921 

24

O-ring (Control Panel)

1

7482-7191

78922 

25

Inner Washer (Control Panel)

1

7482-7192

78923 

26

Control Panel Replacement Kit

1

7482-7101

78833

27

Fuses

2

7482-7176

78908

28

Control Panel Post

1

7482-7115

78847

29

Quick Change Tool (QCT)

1

7482-7104

78836

30

Foam Fillers

8

7482-7119

78851

31

M5x10 Button Cap Screw (Dial Vernier Lock Plate)

1

7482-7189

78919 

32

Dial Vernier Locking Plate

1

7482-7188

78918 

33

Kickers

1

7482-7179

78909

34

Piston Tubing (Lower)

1

7482-7117

78849

35

Dial Vernier

1

7482-7105

78837

36

Piston Adaptor

1

7481-7118

78850

37

Piston Tubing (Upper)

1

7482-7116

78848

38

Head Replacement Kit

1

7482-7100

78832

39

Depth Stop (Optional)

1

7482-7108

78840

40

Mirror 

1

7482-7109

78841

Summary of Contents for GC32-XD

Page 1: ...G GC C3 32 2 X XD D 34012 Ind 428 7291 Auto 3 2005 Safety Operating Manual Safety Operating Manual The World s Most Trusted Name in Belts Hose and Hydraulics...

Page 2: ...n 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 this...

Page 3: ...E Specifications 1 3 Setup 4 7 Calibration 8 9 Hose Preparation 10 Operating Instructions 11 13 Measuring and Adjusting Crimp Diameters 14 Maintenance 15 16 Crimping Tools 17 Schematic 18 Replacement...

Page 4: ...P PE ER R F FO OO OT T P PE ED DA AL L M MI IR RR RO OR R R RA AC CK K Optional Mounts in stand or on wall D DI IE E S SE ET TS S Ordered Separately D DE EP PT TH H S ST TO OP P Optional S ST TA AN ND...

Page 5: ...RS S A AL LL LE EN N H HE EA AD D W WR RE EN NC CH H G GR RE EA AS SE E G GU UN N Q QU UI IC CK K C CH HA AN NG GE E T TO OO OL L QCT G GR RE EA AS SE E W WI IT TH H B BR RU US SH H L LI IT TE ER RA...

Page 6: ...ludes a tube of grease with brush grease gun an instructional CDROM crimp data book operating manual dial calipers and an Allen head wrench for dial vernier adjustments Stand depth stop dies and rack...

Page 7: ...l the proper electrical circuit that is within the listed range Be sure circuit is grounded and complies with all local electrical codes NOTE Incorrect power cord installation will void your equipment...

Page 8: ...pivot bolt incorporated on the mirror mount contains an integrated wrench Grasping the wrench handle and pulling out allows for free travel Once in desired position either tighten or loosen nut undern...

Page 9: ...appears between die and die cone surface approximately 1 pumps Fully cycle crimper 5 times to distribute grease evenly alternate between top blue CRIMP button and bottom yellow RETRACT button or actua...

Page 10: ...wn to position set on dial vernier Once it reaches that position crimper will automatically shut off NOTE CRIMP button and foot pedal operate on a dead man control It only operates as long as you depr...

Page 11: ...ning the set screw located at bottom on black knob of dial vernier If crimp was too tight unlock dial vernier and lower setting according to above calibration equation Lock in place If crimp was too l...

Page 12: ...are now ready for crimping MEGACRIMP PRE ASSEMBLED COUPLINGS 1 Cut hose to desired length 2 Using Gates Crimp Data Manual or Ecrimp select correct MegaCrimp coupling Visit our website to download our...

Page 13: ...he approximate dial vernier setting for the specific hose coupling combination Dial this setting into the dial vernier 5 SET RETRACT PULSE TIMER DIAL The RETRACT PULSE TIMER dial can be adjusted to co...

Page 14: ...e proper crimp 7 BEGIN THE CRIMP NOTE CRIMP button and foot pedal operate on a dead man control while in crimp mode It only operates as long as you depress the CRIMP button or hold foot pedal down It...

Page 15: ...per stops Crimp is now complete 8 REMOVE HOSE ASSEMBLY 9 MEASURE CRIMP DIAMETER TO MAKE SURE IT S WITHIN TOLERANCE If not discard assembly and recalibrate Refer to Calibration for procedure Crimp new...

Page 16: ...ING AND ADJUSTING CRIMP DIAMETERS W WA AR RN NI IN NG G Protect the safety of people using your assemblies Your measured crimp diameters MUST be in tolerance range as listed in the Gates Crimp Data Ma...

Page 17: ...grease fittings Shut power switch off Using grease gun grease both front 8 and back 16 die shoe grease fittings 24 in all until grease appears on die cone surface Operate crimper through a full CRIMP...

Page 18: ...air filter in top Add Tellus AW 46 SAE Grade 46 hydraulic oil or equivalent Change oil and filter NOTE Frequency depends on the pump s general working conditions severity of use and overall cleanlines...

Page 19: ...2 45 78888 7482 7156 Grease 32 46 78880 7482 7148 Battery Cable 32 81 78881 7482 7149 GL 32 82 78882 7482 7150 GL 32 83 78883 7482 7151 GL 32 84 78884 7482 7152 GL 32 85 78885 7482 7153 GL 32 86 78886...

Page 20: ...18 Gates Corporation SCHEMATIC...

Page 21: ...er Element 1 7482 7195 78926 16 Long Mounting Bolts Head 2 7482 7181 78911 17 Short Mounting Bolts Head 2 7482 7106 78838 18 Pilot Operated Check 1 7482 7103 78835 19 Relief Valve 1 7482 7193 78924 20...

Page 22: ...er from power source before removing control panel loosening hydraulic tubing or removing any components Red LED on Control Panel Indicates Flashing Crimper is ready Solid Crimper is in the crimping p...

Page 23: ...ADVANCED TROUBLESHOOTING 21 Gates Corporation LED Located on printed control board behind Control Panel fascia...

Page 24: ...22 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 25: ...23 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 26: ...24 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 27: ...25 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 28: ...26 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 29: ...27 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 30: ...28 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 31: ...29 Gates Corporation ADVANCED TROUBLESHOOTING...

Page 32: ...30 Gates Corporation NOTES...

Page 33: ...NOTES 31 Gates Corporation...

Page 34: ...32 Gates Corporation NOTES...

Page 35: ...imitation on how long an implied warranty lasts so the above limitation and exclusions may not apply to you This warranty gives you specific legal rights andyou may also have other rights which vary f...

Page 36: ...Gates Corporation P O Box 5887 Denver CO 80217 5887...

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