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GC32FLEX TSI POWER UNIT

GC32FLEX/TSI SAFETY AND OPERATION MANUAL

INSTALLATION -

Refer to IFC WI1068 (Included) for more detailed set-up/installation instructions.

GETTING TO KNOW YOUR CRIMPER

Hose Assembly

The included 3/8” NPT Hose supplied with the head only version of the machine can be

used to connect the crimper to the power unit. The hose must first be removed from the

crimper side and then screwed into the 90° fitting on the power unit manifold.
The manifold 90° fitting is shipped from factory, facing towards the sensor side of

the control box. Screw the hose into the fitting at this position with a 11/16” spanner.

(Tighten and ensure the LifeGuard™ clips are parallel to the back of the tank). Once

the hose is tight and in correct orientation rotate the main 90° manifold fitting a 1/4

turn clockwise to the downward position with a 7/8” spanner. Screw the other end of

the hose into the crimper swivel fitting (refer to page 12).

Note:

The swivel fitting is only on the crimper side. Do not try to install the hose to the

power unit first, while it is still connected to the crimper input.
Hose ends are 3/8” NPT Male.

Remove Current Tablet Holder

The Power unit comes with an internal Charging tablet Dock.
Remove the currently installed tablet holder by removing the 2x CSSHCS with

the Hex Key supplied.

Internal Charging tablet Dock installation

Install charging cable in the specified grooves before aligning the internal

charging tablet dock. Use the same 2x threaded holes and secure with the bolts

and hex key supplied.

Tablet Charge Cable (Magnet)

The tablet and dock interact with a magnetic charge plug.
Place the magnetic charge button plug into the charge port of the tablet.
Plug the Micro USB head into the top of the tablet dock.
Once the charge cable is routed inside the front flange channel, plug it into the

USB port located on the front of the power unit. See included instructions for

more details.

!

Follow instructions on page 20 and 21 for a full guide on the electrical/foot pedal

and power unit initial setup. Remove shipping plug and replace with Breather

before operation.

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Summary of Contents for GC32FLEX

Page 1: ...LEX GC32FLEX TSI SAFETY AND OPERATION MANUAL GC32FLEX TSI Product Number 7480 0013 GC32FLEX Product Number 7480 7009 GC32FLEX POWER UNIT Product Number 7482 0123 GC32FLEX TSI STAND Product Number 7482 0017 GC32FLEX TSI RACK Product Number 7480 7003 ...

Page 2: ...ing Force 3700 kN 370 tonne PHYSICAL UNIT Unit Dimensions W x D x H 28 6 x 25 5 x 18 Inches Unit Weight Without Dies Oil 380lb 173kg 485lb 220kg PHYSICAL SHIPPING Shipping Space 161gal 610L Shipping Weight 530lb 241kg 662lb 300kg Shipping Crate Size W x D x H 40 x 31 x 30 Inches ELECTRICAL Supply Voltage Current Frequency 220VAC 20A 60Hz Plug Type North America NEMA L6 20 Phase Single Phase Power ...

Page 3: ...on 16 17 Full Operating Procedure Overview 18 GC32FLEX TSI GC32FLEX TSI General Layout 19 Initial Setup 20 21 Electrical 20 Foot Pedal 20 Tablet and Software 21 Operational Procedure 22 28 Software Home Page 22 e Crimp Selection Operation 23 e Crimp Operation 24 e Crimp Sensor Position 25 e Crimp Calibration 26 27 e Crimp Calibration Offset Modification 28 Full Operating Procedure Overview 29 GC32...

Page 4: ...ly 44 PERIODIC MAINTENANCE 45 46 GC32FLEX GC32FLEX TSI Head 45 GC32FLEX TSI Power Unit 46 TROUBLE SHOOTING 47 50 Control Indicator 47 Incorrect Loading of Set Point 48 Sensor Faults 49 Retract Limitation and Jogging 50 REPLACEMENT PARTS 52 55 GC32FLEX TSI 51 52 GC32FLEX 53 54 DIES 55 WARRANTY 56 NOTES 57 59 TABLE OF CONTENTS ...

Page 5: ...nufacturers 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 Hydraulic Product catalogs Gates disclaims any liability for any hose assemblies which have not been produced in confo...

Page 6: ...ken 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 Operation 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 acci...

Page 7: ...shall apply A copy of these terms and condition can be provided on request but generally include conditions for intended use and purpose improper procedure concerning transport storage maintenance unauthorized use constructional changes or repairs and failure to detect wear Only authorized qualified electricians are allowed to work on the electrical system of Gates crimpers It is the responsibilit...

Page 8: ...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 ensure the head is free of objects and persons 5 ONLY operate this machine if the ambient temperature is between 50ºF 95ºF 10ºC and 35ºC 6 Never reach into the crimper while the head is m...

Page 9: ...EX and GC32FLEX TSI GC32FLEX 7480 7009 Only GC32FLEX TSI 7480 0013 GC32FLEX TSI Power Unit 7482 0123 Only POWER UNIT TIE DOWN STRAPS TABLET HOLDER 7482 0143 POWER UNIT HOSE 3 8 NPT 7482 0151 AIR BREATHER CHARGEABLE TABLET HOLDER 7482 0148 FOOT PEDAL 7482 7111 TUNGSTEN DISULPHIDE GREASE 7482 7121 QUICK CHANGE TOOL 7482 7246 CALIPERS 7369 0322 ...

Page 10: ... P N 7482 0017 The crimper stand MUST be secured to the floor 2 Remove the plastic wrapping from the outside of the box 3 Remove the staples from the bottom and top of the carton with a screwdriver and pliers 4 Slit the tape on the top of the carton with a sharp knife then open the lid and remove the wooden side supports 5 Lift off the carton ...

Page 11: ...ng through the left side forklift channel Attach another appropriately rated sling through the middle of the cut out channel from the front to the rear 4 GC32FLEX Lifting and Movement Sling Option Lift using both slings attached to a crane or hook Do not lift the GC32FLEX with 2 slings in the left and right forklift channel The Crimper centre of gravity is over the head it will lean to one side Mo...

Page 12: ...ng through the left side forklift channel Attach another appropriately rated sling through the right side forklift channel 4 GC32FLEX TSI Lifting and Movement Sling Option Lift using both slings attached to a crane or hook The GC32FLEX TSI Crimper centre of gravity is centralised and will lift evenly Move slowly during lifting to avoid excessive swinging Secure to the crimper stand or bench with 4...

Page 13: ...n of the machine The Unit can be upgraded to a TSI variant at any time by order ing the part number 7482 0123 Tablet Holder Holds Tablet Supplied with Gates e Crimp and Support Material Dial Indicator Identifies Set Point for each hose assembly Forklift Channels Used to lift move Crimper machine Crimper Opening Operational Zone to Crimp Hose Power Unit Position Space for External Power Unit 10 000...

Page 14: ...late Ensure it is in a suitable location Secure Power Unit Place the supplied strap over the power unit and through the base slots to secure it to the tray Connect Power Unit Crimper Connect the supplied hose to the chosen power unit Note both ends of hose are 3 8 NPT Male Connect the other end of the hose to the crimper head using a 15 16 wrench The fitting in the Crimper head is a 3 8 NPT Swivel...

Page 15: ... Mount Operation Tabs are provided on the mount which can move in both horizontal and vertical directions Once the tablet is positioned in the bottom tabs move the main top arm down to secure the tablet in position Any tablet or phone can be used in the holder The tablet holder does not include integrated charging Any device used must be charged separately following the manufactures instructions e...

Page 16: ...th a Red LED on the front The EDI is adjustable to suit different crimp diameters with different die sets Electronic Dial Indicator Optional Position The EDI can be moved to the right side of head if it is obstructing machine operations Electronic Dial Indicator Optional Position Set Up Remove the 2x SHCS on the top and the 2 x SHCS on rear 1 8 3mm Hex Key and reposition the entire assembly on the...

Page 17: ...decimal place If the EDI s batteries are dead 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 ...

Page 18: ...n follow steps on page 40 for further details Example 8M3K with an 8G coupling uses GC32 33 die set SET DIAL INDICATOR Adjust the Dial Indicator Knob to the number specified in e Crimp Example 8M3K with 8G coupling is 1 07 with a COD of 1 00 Follow steps on page 14 15 for further details ASSEMBLE AND CRIMP SELECTED ASSEMBLY Crimp hose assembly Hose and fitting must be assembled for successful cali...

Page 19: ...surement Adjustment for a LARGER DIAMETER On the rear of the machine a hexagon knob is located on the Dial Indicator Push the arm of Dial Indicator towards the front of the machine while holding the hexagon knob Gently turn the knob one flat CLOCKWISE 1 6 of a full turn and release the Dial Indicator arm The Arm will lock the hexagon knob back into position 1 flat 1 6 full turn of rotation is equi...

Page 20: ...fied See page 13 for more details Load Dies Load the required dies as specified by e Crimp into the machine using the Quick Change Tool See page 40 for more details Crimp Hose Assembly Place the hose assembly into the crimper follow procedure for correct hose assembly process page 43 Activate the power unit and release when the light on the EDI turns red see silver indicator for notice See page 15...

Page 21: ...nsures the Gates 32FLEX TSI can achieve accurate and consistent hose assemblies at effective speeds Tablet Control Centre Holds Tablet Supplied with Gates e Crimp and Support Material Power Unit Inbuilt Hydraulic Power Unit Isolation Switch Turns Crimper On Off Forklift Channels Used to lift move Crimper machine Crimper Opening Operational Zone to Crimp Hose Power Unit Input Position for power cor...

Page 22: ...unding the pedal will avoid accidental activation Install the foot pedal by plugging it into the lower right side of the Control Box next to the Power Switch Power Unit Preparation The oil reservoir is shipped in the full state Remove the shipping plug and replace with the filler breather provided Always ship the crimper with the plug securely fitted to avoid spillage of hydraulic fluid contaminat...

Page 23: ...he front panel When the Power Switch is turned on the tablet will start to charge The Charging port has smart functionality which can be activated from within the Crimper app options page If smart charging is active the port both outputs will turn off if the tablet is charged above 80 If the controller is turned on and the tablet is below 80 the port will activate until a charge of 80 is reached t...

Page 24: ...oad Assembly Settings hose and accessories to be crimped as well as manage favorite assembly lists 4 CRIMPER Gives access to the Main Crimp Interface and Crimp Options 5 OPERATOR HELP Gives access support documentation and tutorial videos on the safe and correct operation of the machine 6 MAINTENANCE Allows the user to access logs relating to changes made on the machine 7 UTILITIES Gives the user ...

Page 25: ...tly to the crimper Crimp Summary The Crimp Summary allows the operator to review settings for the proposed crimp These settings can be saved by pressing the Favorite option on the screen These saved settings will then be available for current or future use by the operator To load the setting from e Crimp to the Crimper simply press the Crimp button List Selection Create a hose or accessory assembl...

Page 26: ...isplay will indicate that it is crimping Crimp Completed When the Crimp is completed the Crimp Completion Sound will activate The crimp button will change from Green to Grey and the head will automatically start to retract Note The Crimp Function Via the Tablet or the Foot Pedal is blocked for 10 seconds after a Crimp is completed This is also indicated by the Retract LED on the LED display CRIMPE...

Page 27: ... full heads back position and 20 000 when the head is in the fully closed position When the head hence sensor is moving during operation the units will transition between the specified range The final position will be dictated by the Set Point and will be between the 1 000 and 20 000 unit range The Sensor indicator should not exceed 20 000 units or be less than 1 000 units after Auto Calibration i...

Page 28: ...d from the tablet Once the head is fully closed the unit will Calibrate itself and release This should take less than 15 seconds If there is an error during the Auto Calibration it will abort and cause a sensor fault In this case you must turn off the unit and follow the advice on dealing with a Sensor Fault Step 2 Input Average Measurement Measure the finished outer diameter of the coupling as pe...

Page 29: ...follow the same procedure as before and enter the average COD If the crimp is accurate the calibration process can be completed Refer to Calibration Complete Step below or you can do another Crimp using Continue Calibration Calibration Complete When the Assembly Calibration routine is completed and the operator is satisfied with the accuracy of the COD achieved the TARGET COD should be entered int...

Page 30: ... assembly Scroll through the list to find the one required for reset Press and hold the assembly and a new Dialog will display If you want to clear the calibration press RESET This assembly can then be loaded via e crimp and on completion of the first crimp you will be able to recalibrate the assembly CALIBRATION OFFSET MODIFICATION Offset List Assembly offsets shows all Assemblies that have been ...

Page 31: ...e machine with the Quick Change Tool See page 40 for details Crimp Hose Assembly Place the hose assembly into the crimper Follow the procedure for correct hose assembly process page 43 Activate the crimper via the tablet or the foot pedal and wait for the crimper to reach set point The Crimper will retract automatically Measure Crimped Diameter Remove the crimped assembly and measure across the fl...

Page 32: ...g 2x USB charging outlets GC32FLEX TSI POWER UNIT GENERAL LAYOUT The modular two stage power unit is designed exclusively for the 7480 7009 variant of the GC32FLEX The power unit can be operated by foot pedal or the full touchscreen interface with Bluetooth connectivity this also enables easy access to Gates e Crimp data The precision contactless digital position sensor ensures the Gates GC32FLEX ...

Page 33: ...tely 60kg 132lbs Unpack Slit the tape on the top of the carton with a sharp knife then open the lid Note The Power unit is shipped with the necessary oil requirements This has been packed in a plastic bag to contain any spillage Sling Identify the lifting eyelet on top of the power unit and position an appropriate sling or hook though the eye Attach the other end of the sling hook to a forklift or...

Page 34: ...if it is attached on either the left or right side of the head Sensor Arm Ensure the sensor arm is behind the crimper head and does not connect with the piston plate The sensor arm is connected to the crimper via a magnet Secure Detach the sling and move the power unit so that it lines up with 4 x M8 holes on the tray Use the 4 x M8 x 10mm BHSHCS provided and 5mm Hex key to secure the power unit t...

Page 35: ...wivel fitting is only on the crimper side Do not try to install the hose to the power unit first while it is still connected to the crimper input Hose ends are 3 8 NPT Male Remove Current Tablet Holder The Power unit comes with an internal Charging tablet Dock Remove the currently installed tablet holder by removing the 2x CSSHCS with the Hex Key supplied Internal Charging tablet Dock installation...

Page 36: ... complete Alternatively the Bluetooth calipers can be used see page 38 39 for further instruction on blue tooth calipers Note Once data is entered via the keypad or Bluetooth calipers it is not necessary to press Save The next time the crimper is activated the data will save automatically This was designed to allow the user to enter data with a Bluetooth caliper without having to interact with the...

Page 37: ...ification is displayed on the screen If a mistake has been made a corrected value can be re entered The user can either press Save or continue with the next crimp to save this data point Accessing Crimp History Crimp History is accessed via the Crimp History icon on the home page Crimp History Logs 1 In tolerance crimps Green tick 2 Calibration Crimps Spanner and Screwdriver 3 Out of tolerance cri...

Page 38: ...via the Statistics and Trend Charts Statistic Chart The Statistics Chart highlights data on the number and types of crimps as well as the number of crimps in tolerance and the number of crimps out of tolerance Trend Chart The Trend Chart shows the measured crimp data as a trend over time Data can be scrolled through Scroll through from left to right ...

Page 39: ...s an active internet connection allows the user to export the data QR Code The application will create a unique QR code which can be scanned using a phone to obtain a download link The data file obtained from the download link can then be emailed to any computer Data Analysis Open the file in Microsoft Excel or other similar program for further analysis ...

Page 40: ...s in the main crimper options by checking the Enable Bluetooth caliper checkbox BT Caliper Icon The BT Caliper connection icon will display above the die set information If it is Grey the calipers are not connected Connecting BT Calipers Press and hold the Bluetooth Transmit Button on the Calliper for 3 5 seconds The blue LED will flash four 4 times to indicate the pairing request has been sent Wh...

Page 41: ...aliper connection press OK BT Caliper Connected When the caliper is connected the Caliper Indicator will turn from Grey to Green Data Transfer When the crimp is completed and the End Verification appears measure the completed crimp using the Callipers then press the transmit button When the data transmission is completed you will hear a sound which indicates the data has been received The value wi...

Page 42: ...cated in the optional stand or in the die container 2 1 Load Die Set Load the Die Set with Gates Quick Change Tool QCT The head must be in the fully retracted position 3 Align Dies Align the rear channels of the dies between the die retainer plates on the Crimper shoes 4 Insert QCT Insert the QCT by pushing the handle in to disengage the dies then twisting to the left or counterclockwise until the...

Page 43: ...clockwise until the fingers are engaged and withdraw the QCT This will pull the die fingers out of the crimper head 4 Place Dies Place the die fingers back into the storage receptacle and press downward 5 Twist QCT Twist the QCT handle counterclockwise to unload the die fingers Withdraw QCT 7 6 Insert QCT Insert the Quick Change Tool QCT until it bottoms out on the die shoe surface 3 2 ...

Page 44: ...lock positions Put fitting through from the rear with the elbow side of the fitting at the 4 o clock position and the flange in the 11 o clock position The hose stem of the coupling must be in the centre of the rear cut out on the piston plate Replace dies once the fitting is through the head and follow the crimp procedure outlined for each relative machine Ensure dies are pushed in all the way ag...

Page 45: ...ight oil SAE 10W Clamp the stem in the vise on hex portion and push the hose onto the stem The hose should be flush against the stem shoulder See cutaway drawing Push the ferrule so it rests against hex of stem The hose and coupling are now ready for crimping MEGACRIMP PRE ASSEMBLED COUPLINGS Cut the Hose to the desired length Using Gates Crimp Data Manual 3509 Ind 428 7365 Auto select the correct...

Page 46: ...ibration of the machine and recalibrate If the machine is properly calibrated you may need to make a slight adjustment to the Dial Vernier Adjuster Using Gates STAINLESS STEEL DIGITAL CALIPER Product NO 7369 0322 Part NO 78241 which are notched to clear ridges measure halfway between ridges Sketch 1 Measure halfway down the crimped portion of the ferrule Sketch 2 To obtain a smaller crimp diameter...

Page 47: ...supplied with Tungsten Disulphide grease which is far more effective than alternatives Do not use alternative grease as this will contaminate the grease on your machine Using alternatives will void the warranty Periodically inspect filler pads The foam fillers stop debris falling between the shoes and onto the crimping surface Inspect filler pads every 250 crimp cycles Foam should return to its or...

Page 48: ...ange the oil after every 2000 3000 crimps The drain plug is situated at the bottom of the tank Remove the hose and 4 bolts to lift and drain Refer to page 31 32 for correct lifting procedure of power unit Replace the filter every time the oil is changed PN 7482 7196 Remove the 3 bolts and lift the cover off of the filter body Remove the internal filter and replace Clean Manifold Filter Remove the ...

Page 49: ...LED will flash every half second RETRACT The Retract LED will be on when the crimp inputs are Blocked after a successful crimp MOTOR The Motor LED is illuminated when the signal to turn the motor on is active BT STATUS Bluetooth Status LED will Flash if the Control Unit does not have an active Bluetooth connection It will turn off once a connection is made BT CONNECT When a Bluetooth connection is...

Page 50: ...ption from tablet to controller If this occurs reload the setting via e Crimp can cycle the power to reset the controller Power Cycle The application will re connect after the machine is power cycled If it again shows a grey setpoint the Crimper Application will need to be re launched Set Point Exchange A green Setpoint means the setpoint exchange was successful and the Crimper is ready to crimp ...

Page 51: ... Auto Cycle Any failure to register a movement while undertaking these activities will cause a Sensor fault to occur Investigating a sensor fault If a sensor fault is triggered the cause should be investigated Some possible causes of a sensor fault are outlined below 1 The Sensor magnet has detached from the head during the stroke 2 The Sensor cable is not attached 3 The Motor Drive has not turned...

Page 52: ...crimp is activated and deactivated Quick Release The Quick Release button reverses the motor and pump at slow speed for 2 seconds On rare occasions the Spring loaded Dump valve in the manifold may not fully open due to residual pressure gradients You may notice this if the crimp head closes and is unusually slow to retract Pressing Quick release will reverse the pump and create a small negative pr...

Page 53: ...51 GC32FLEX GC32FLEX TSI GC32FLEX TSI SAFETY AND OPERATION MANUAL TROUBLESHOOTING REPLACEMENT PARTS 10 6 3 16 8 1 7 5 13 12 15 14 4 ...

Page 54: ...7482 0153 KICKER GC32FLEX TSI 7 7482 0155 GC32FLEX TSI CYLINDER END CAP 8 7482 0156 GC32FLEX TSI ROLLER SUPPORT BEARING 10 7482 0171 GC32FLEX TSI LINEAR POTENTIOMETER 14 7482 7241 FOAM FILLERS GC32FLEX GC32TSI 15 7482 0177 DIE RETENTION KIT GC32FLEX GC32TSI 16 7482 7260 GC32FLEX GC32TSI MIRROR ASSEMBLY GC32FLEX TSI SPARE PARTS ALL ITEM NO PRODUCT NUMBER DESCRIPTION 13 7482 7246 QCT REPAIR KIT GC32...

Page 55: ...53 GC32FLEX GC32FLEX TSI SAFETY AND OPERATION MANUAL REPLACEMENT PARTS 53 REPLACEMENT PARTS 16 8 9 2 7 5 6 15 14 13 ...

Page 56: ...X TSI 7 7482 0155 GC32FLEX TSI CYLINDER END CAP 8 7482 0156 GC32FLEX TSI ROLLER SUPPORT BEARING 9 7482 0158 GC32FLEX DIAL INDICATOR 14 7482 7241 FOAM FILLERS GC32FLEX GC32TSI 15 7482 0177 DIE RETENTION KIT GC32FLEX GC32TSI 16 7482 7260 GC32FLEX GC32TSI MIRROR ASSEMBLY GC32FLEX SPARE PARTS ALL ITEM NO PRODUCT NUMBER DESCRIPTION 13 7482 7246 QCT REPAIR KIT GC32TSI XD 13 7482 7104 QUICK CHANGE TOOL A...

Page 57: ... 43 7482 7147 DIE SET ROSETTE ASSY 32 44 7482 7157 DIE SET ROSETTE ASSY 32 45 7482 7148 DIE SET ROSETTE ASSY 32 46 GC32 Specials Range 7482 7209 DIE SET ROSETTE ASSY 32 20 7482 7225 DIE SET ROSETTE ASSY 32 30 7482 7178 DIE SET ROSETTE ASSY GC32 32 7482 7224 DIE SET ROSETTE ASSY 32 300 7482 7249 DIE SET ROSETTE GC32 300 1 7482 7205 DIE SET ROSETTE ASSY 32 18M 7482 7206 DIE SET ROSETTE ASSY 32 22M G...

Page 58: ...ial damages and some states do not allow limitations on how long an implied warranty lasts so the above limitation and exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For warranty service contact Service Department Gates Customer Solution Center 330 Inverness Dr S Englewood CO 80112 FOR WARRANTY SERVICE ...

Page 59: ...57 GC32FLEX TSI SAFETY AND OPERATION MANUAL NOTES ...

Page 60: ...58 GC32FLEX TSI SAFETY AND OPERATION MANUAL NOTES ...

Page 61: ...59 GC32FLEX TSI SAFETY AND OPERATION MANUAL NOTES ...

Page 62: ...60 GC32FLEX TSI SAFETY AND OPERATION MANUAL 7480 7009 7480 0013 7482 0123 GC32FLEX TSI Auto 428 3510 Ind 34016 GATES COM 08 2021 ...

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