1. Manuals
  2. Brands
  3. Gates Manuals
  4. Crimp tool
  5. GC32FLEX
  6. Safety and operation manual

Gates GC32FLEX Safety And Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
GC32FLEX & GC32FLEX TSI
SAFETY AND OPERATION MANUAL
GC32FLEX/TSI SAFETY AND OPERATION MANUAL
Product Number: 7480-0013
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
GC32FLEX/TSI
GC32FLEX

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the GC32FLEX and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Gates GC32FLEX

Summary of Contents for Gates GC32FLEX

  • Page 1 GC32FLEX/TSI SAFETY AND OPERATION MANUAL GC32FLEX & 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 CRIMPER DETAILS GC32FLEX/TSI SAFETY AND OPERATION MANUAL GC32FLEX/TSI SAFETY AND OPERATION MANUAL YOUR CRIMPER DETAILS Serial No. ____________________________ Date of Purchase _____________________ CRIMPER SPECIFICATIONS GC32FLEX GC32FLEX TSI Nom. Size (Hydraulic Hose Size) 2 Inches Die Set Type 32 Series DYNAMIC Crimping Range (Inch with Std.

  • Page 3: Table Of Contents

    Lifting and Installation GC32FLEX TSI ........
  • Page 4 GC32FLEX/GC32FLEX TSI Head ........

  • Page 5: Crimper Safety

    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 conformance with Gates assembly recommendations.
  • Page 6 CRIMPER SAFETY GC32FLEX/TSI SAFETY AND OPERATION MANUAL WARNING This Safety & Operation Manual is provided for your safety and the safety of others. Every operator MUST have completed training and have an understanding of the crimper and the requirements of hose assemblies before using this machine.
  • Page 7 GC32FLEX/TSI SAFETY AND OPERATION MANUAL 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 the warranty but also breach the intended use and purpose of the machine and contravene basic regulations of Work Safety and Prevention of accidents.
  • Page 8 CRIMPER SAFETY GC32FLEX/TSI SAFETY AND OPERATION MANUAL WARNING Intended Design Use Using this machine for other than its intended purpose will void the manufacturer’s warranty and may cause serious or fatal injury. Personal Safety Regardless of local accident prevention regulations, the following procedures should be observed to maintain the health and safety of operators.

  • Page 9: Box Contents

    BLUETOOTH CALIPERS AND ADJUSTMENT KIT GC32FLEX (7480-7009) Only 7482-0143 7482-0151 POWER UNIT HOSE POWER UNIT TABLET HOLDER 3/8” NPT TIE-DOWN STRAPS GC32FLEX TSI (7480-0013) & GC32FLEX TSI Power Unit (7482-0123) Only 7482-7111 7482-0148 CHARGEABLE TABLET FOOT PEDAL AIR BREATHER HOLDER...

  • Page 10: Crimper Set-Up (Gc32Flex/Flex Tsi)

    GC32FLEX / GC32FLEX TSI CRIMPER SET-UP GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMPER SET UP: UN-BOXING 1. Assemble the optional crimper stand (P/N 7482-0017). The crimper stand MUST be secured to the floor. 2. Remove the plastic wrapping from the outside of the box.

  • Page 11: Lifting And Installation Gc32Flex

    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.

  • Page 12: Lifting And Installation Gc32Flex Tsi

    Secure to the crimper stand or bench with 4x 5/8” (M10) Bolts/ nuts/washers. Lifting Slings not included. Do Not lift machine by the head as this will cause damage to the crimper. See Crimper Specifications for the Gross Mass of the GC32FLEX TSI Machine.

  • Page 13: Gc32Flex

    GC32FLEX CRIMPER GENERAL LAYOUT A precision 2” hose crimp press for the production of Gates hose assemblies of all types. The unit is designed for low volume shop production and can be used with any 10,000 PSI hydraulic power unit.

  • Page 14: Initial Setup

    These can range from a hand pump through to pneumatic assisted or battery operated pumps. See your Gates Representative for more details. Ensure that the machine does not go over 10,000 PSI at any time during operation. Use of an External Power unit with an internal relief valve is strongly recommended.

  • Page 15: Tablet Installation And E-Crimp

    GC32FLEX/TSI SAFETY AND OPERATION MANUAL TABLET OPERATION/E-CRIMP™ Tablet Fixed Mount The GC32FLEX includes a fixed tablet holder on the side of the head (See Page 11). The mount can carry any tablet or phone from 4,3” to 11,6”. A tablet is supplied with the machine in order to access the latest e-Crimp™...

  • Page 16: Operational Procedure

    GC32FLEX GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL ELECTRONIC DIAL INDICATOR 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 bottom left (see page 11) of the machine with a Red LED on the front.
  • Page 17 GC32FLEX GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL ELECTRONIC DIAL INDICATOR INDICATOR PIN INDICATOR PIN INDICATOR PIN POSITION 3MM: POSITION 1.5MM: POSITION 0MM: Set Point Reached The user will be notified that a crimp is nearing completion when the silver indicator pin is almost flush with the front of the EDI knob.
  • Page 18 GC32FLEX GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL ELECTRONIC DIAL INDICATOR - CALIBRATION EXAMPLE OPEN E-CRIMP™ > SELECT HOSE ASSEMBLY AND DIE SET Any hose and fitting combination in e-Crimp™ can be used for calibration. Example: Select hose 8M3K with an 8G coupling.

  • Page 19: Electronic Dial Indicator Calibration

    GC32FLEX GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL ELECTRONIC DIAL INDICATOR - CALIBRATION Activate Crimper To activate the crimper, press and hold the pump power switch while watching the LED on the front of the indicator Knob. The crimper will begin to close and the central indicator pin on the knob will rise.

  • Page 20: Full Operating Procedure Overview

    GC32FLEX GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL FULL OPERATING PROCEDURE OVERVIEW Power Unit Selection and Set Up Select a suitable 10,000 PSI power unit and connect to the 3/8” NPT Input of the Head. See page 12 for more details.

  • Page 21: Gc32Flex Tsi

    GC32FLEX/TSI SAFETY AND OPERATION MANUAL GC32FLEX TSI GENERAL LAYOUT The Gates GC32FLEX TSI with integrated two-stage power unit enables precision crimping for all Gates production hoses up to 2”. The machine is operated from a command interface which connects to the Power Unit controller via Bluetooth.

  • Page 22: Initial Setup

    GC32FLEX TSI GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL INITIAL SET UP Electrical Connect the provided 220 VAC single phase cord assembly with HBL 2321 250 HVAC 20 amp twist lock plug to your crimping machine. Electrical...

  • Page 23: Tablet And Software

    Turn Control Panel on The switch for the control panel is integrated on the bottom right-hand side of the dock. Hold the button firmly for several seconds until the tablet is activated. On activation the Gates Home Crimp screen will display.

  • Page 24: Operational Procedure

    2) OPTIONS: Informs the user of machine information and global settings, e.g., Region settings and Units. (see options menu section) 3) e-Crimp™ : Gives access to Gates e-Crimp™ database and allows the user to directly load Assembly Settings, (hose and accessories) to be crimped, as well as manage favorite assembly lists.

  • Page 25: E-Crimp™ Selection/Operation

    GC32FLEX TSI GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL E-CRIMP™ OPERATION e-Crimp™ Options e-Crimp™ has the following options to select a crimp setting. Favorites: Choose a setting from the list of currently stored Favorites (use the radial buttons to switch between Hose Assemblies and Accessory Assemblies).
  • Page 26 GC32FLEX TSI OPERATIONAL PROCEDURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMPER OPERATION Activate Crimper To activate the crimper, use the Green crimp button or the foot pedal. Crimp Display When the Crimp is active the display will indicate that it is crimping.

  • Page 27: E-Crimp™ Sensor Position

    The position sensor is mounted inside the control box. The sensor attaches to the crimp head using a Magnet mounted on a universal joint. The GC32FLEX TSI operational interface displays HEAD POSITION in the bottom left of the screen. Head position is a diagnostic setting that gives feedback on the sensors functionality without physically looking at it.

  • Page 28: E-Crimp™ Calibration

    OPERATIONAL PROCEDURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CALIBRATION - AUTO CALIBRATION ROUTINE The GC32FLEX TSI has an automated calibration routine. The machine is required to run this routine each time it is turned on. The routine will prompt the user each time the machine is turned on or it...
  • Page 29 GC32FLEX TSI OPERATIONAL PROCEDURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CALIBRATION STEP 3: Calibration Accuracy 1) Press Calibration Complete. This will calibrate the algorithm accordingly and make an Assembly Offset Register for this Assembly. 2) Press Continue Calibration to do a second calibration crimp.

  • Page 30: E-Crimp™ Calibration Offset Modification

    GC32FLEX TSI OPERATIONAL PROCEDURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CALIBRATION OFFSET MODIFICATION Calibration Offset Modification Calibrated assemblies can be reviewed or edited via the ‘ASSEMBLY OFFSET’ tab in the Main Crimper Options. Offset List Assembly offsets shows all Assemblies that have been calibrated.

  • Page 31: Full Operating Procedure Overview

    GC32FLEX TSI GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL FULL OPERATING PROCEDURE OVERVIEW Operating Overview Set up the Machine as per initial set up instructions on page 20-21. e-Crimp™ setting on Tablet Select hose type, size and coupling through the prompts on e-Crimp™ or use a previously set up favorite.

  • Page 32: Gc32Flex Power Unit General Layout

    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™...

  • Page 33: Unboxing

    GC32FLEX TSI POWER UNIT CRIMPER GENERAL LAYOUT GC32FLEX/TSI SAFETY AND OPERATION MANUAL LIFTING AND MOVEMENT Lifting and slings Ensure an appropriate lifting apparatus (Forklift or crane) is available to lift and install the power unit onto the Crimper. Appropriately rated slings will be required.
  • Page 34 GC32FLEX TSI POWER UNIT GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL INSTALLATION - Refer to IFC WI1068 (Included) for more detailed set-up/installation instructions. Move and Position Carefully move the power unit over the right side of the crimper and slowly lower.

  • Page 35: Installation And Operation

    GC32FLEX TSI POWER UNIT GETTING TO KNOW YOUR CRIMPER GC32FLEX/TSI SAFETY AND OPERATION MANUAL INSTALLATION - Refer to IFC WI1068 (Included) for more detailed set-up/installation instructions. 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.

  • Page 36: Quality Assurance Features

    GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMP HISTORY Entering Data The crimp history feature allows the user to save crimp data for later analysis. Data can be exported to a CSV file which can be opened in Microsoft Excel.
  • Page 37 GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMP HISTORY Crimp out of Tolerance If the measured average is not within tolerance, the Exceeds tolerance Please discard notification is displayed on the screen. If a mistake has been made, a corrected value can be re-entered.
  • Page 38 GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMP HISTORY Data Collection Saved data can be accessed 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.
  • Page 39 GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMP HISTORY Data Export Pressing the Export button (requires 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.

  • Page 40: Bluetooth Calipers

    GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL BLUETOOTH CALIPERS Enabling Bluetooth Calipers Data can be directly entered into the Crimp History log via Bluetooth enabled calipers. Enable Bluetooth calipers in the main crimper options by checking the Enable Bluetooth caliper checkbox.
  • Page 41 GC32FLEX / GC32FLEX TSI QUALITY ASSURANCE FEATURES GC32FLEX/TSI SAFETY AND OPERATION MANUAL BLUETOOTH CALIPERS Bluetooth Pair Request When the Calipers are connected to a Tablet, the dialogue box shown will appear. To initiate the Bluetooth Caliper connection, press OK. BT Caliper Connected When the caliper is connected, the Caliper Indicator will turn from Grey to Green.

  • Page 42: Operational Information

    Locate Correct Die Set This may be located in the optional stand or in the die container. Load Die Set Load the Die Set with Gates Quick Change Tool (QCT). The head must be in the fully retracted position. Align Dies Align the rear channels of the dies between the die retainer plates on the Crimper shoes.
  • Page 43 GC32FLEX / GC32FLEX TSI OPERATIONAL INFORMATION GC32FLEX/TSI SAFETY AND OPERATION MANUAL QCT UNLOAD Retract Head Ensure the head is in the full retract position. Insert QCT Insert the Quick Change Tool (QCT) until it bottoms out on the die shoe surface.

  • Page 44: Elbow Fittings Fitment

    GC32FLEX / GC32FLEX TSI OPERATIONAL INFORMATION GC32FLEX/TSI SAFETY AND OPERATION MANUAL ELBOW FITTING FLGH90-32LH fittings can be put through the machine from the rear. Remove the die in the 11 o’clock and 4 o’clock 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.
  • Page 45 Push the ferrule so it rests against hex of stem. The hose and coupling are now ready for crimping. CAUTION: See Hose Assembly Guide of the Gates Crimp Data Manual # 35019 (ind) and 428-7365 (Auto) or log onto www.gates.com/ecrimp for more details.
  • Page 46 DO NOT measure on top of part number stamps. WHEN USING 21 AND 22 DIES. Using Gates “21/22” dial calipers (Product No 739-1320, Using Gates STAINLESS STEEL DIGITAL CALIPER Part No 78217) measure halfway between ridges (Fig 1). (Product NO 7369-0322, Part NO 78241) which are...
  • Page 47 GC32FLEX / GC32FLEX TSI PERIODIC HEAD MAINTENANCE GC32FLEX/TSI SAFETY AND OPERATION MANUAL CRIMPER HEAD MAINTENANCE Redistribute Grease Build up The crimper is designed to automatically redistribute grease around the piston cone. Grease will also build up over time as some is pushed out. This can be redistributed periodically with a brush.
  • Page 48 GC32FLEX TSI POWER UNIT PERIODIC POWER UNIT MAINTENANCE GC32FLEX/TSI SAFETY AND OPERATION MANUAL POWER UNIT MAINTENANCE Periodically inspect oil level Check the oil level in the reservoir after every 10 hours of use. Hydraulic oil should be visible in the sight glass when the head is fully open.

  • Page 49: Troubleshooting

    GC32FLEX TSI TROUBLESHOOTING GC32FLEX/TSI SAFETY AND OPERATION MANUAL CONTROL INDICATOR SYSTEM The System LED will flash every second. This indicates that the control- ler is functioning correctly. If there is a Sensor Fault the System LED will flash every half second.

  • Page 50: Incorrect Loading Of Set Point

    GC32FLEX TSI TROUBLESHOOTING GC32FLEX/TSI SAFETY AND OPERATION MANUAL SENSOR Incorrect Loading of Set point It is possible that a set point is not loaded correctly due to a communication interruption from tablet to controller. If this occurs reload the setting via e-Crimp™ can cycle the power to reset the controller.

  • Page 51: Sensor Faults

    When the crimp is initiated, the Head position reading should smoothly increase from ~ 1,500 up to between 17,000 and 20,000. The Maximum Head Position of a calibrated GC32FLEX TSI is 20,000. If this is not the case please contact technical support.

  • Page 52: Retract Limitation And Jogging

    GC32FLEX/TSI SAFETY AND OPERATION MANUAL RETRACT LIMITATION AND JOGGING Retract Block The GC32FLEX TSI inhibits any crimp input for 10 seconds after setpoint is reached. This period is indicated via the Retract LED on the front panel, the Crimp button on the Crimp interface also turns Grey during this interval.

  • Page 53: Replacement Parts

    GC32FLEX / GC32FLEX TSI TROUBLESHOOTING GC32FLEX/TSI SAFETY AND OPERATION MANUAL REPLACEMENT PARTS...

  • Page 54: Gc32Flex Tsi

    GC32FLEX/TSI SAFETY AND OPERATION MANUAL GC32FLEX TSI SPARE PARTS (ALL) ITEM NO. PRODUCT NUMBER DESCRIPTION 7482-0123 GC32FLEX POWER UNIT 7482-0148 GC32FLEX TSI CHARGING ADJ. HOLDER AND TABLET 7482-0150 GC32FLEX TSI POWER UNIT MANIFOLD 7482-0151 GC32FLEX/TSI POWER UNIT HOSE 7482-0153 KICKER GC32FLEX/TSI 7482-0155...

  • Page 55: Gc32Flex

    GC32FLEX REPLACEMENT PARTS GC32FLEX/TSI SAFETY AND OPERATION MANUAL REPLACEMENT PARTS...
  • Page 56 GC32FLEX REPLACEMENT PARTS GC32FLEX/TSI SAFETY AND OPERATION MANUAL GC32FLEX SPARE PARTS (ALL) ITEM NO. PRODUCT NUMBER DESCRIPTION 7482-0143 GC32FLEX FIXED ADJ. HOLDER AND TABLET 7482-0151 GC32FLEX/TSI POWER UNIT HOSE 7482-0153 KICKER GC32FLEX/TSI 7482-0155 GC32FLEX/TSI CYLINDER END CAP 7482-0156 GC32FLEX/TSI ROLLER SUPPORT BEARING...
  • Page 57 DIES REPLACEMENT PARTS GC32FLEX/TSI SAFETY AND OPERATION MANUAL DIES GC32 STANDARD RANGE DIES GC32 Life Guard 7482-7128 DIE SET & ROSETTE ASSY 32-21 7482-1419 DIE SET LIFEGUARD 32-3234 7482-7129 DIE SET & ROSETTE ASSY 32-22 7482-1420 DIE STE LIFEGUARD 32-3335 7482-7130 DIE SET &...

  • Page 58: Warranty

    GC32FLEX/TSI SAFETY AND OPERATION MANUAL TWO-YEAR LIMITED WARRANTY ON EQUIPMENT For two years from the date of shipment of the equipment to the original user, Gates will, at its option, replace or repair any unit which proves to be defective in material or workmanship, or both, at no cost to the original user of the equipment.

  • Page 59: Notes

    NOTES GC32FLEX/TSI SAFETY AND OPERATION MANUAL...
  • Page 60 NOTES GC32FLEX/TSI SAFETY AND OPERATION MANUAL...
  • Page 61 NOTES GC32FLEX/TSI SAFETY AND OPERATION MANUAL...
  • Page 62 GC32FLEX/TSI SAFETY AND OPERATION MANUAL 7480-7009 7480-0013 7482-0123 GC32FLEX/TSI GATES.COM (Auto.) 428-3510 08/2021 (Ind.) 34016...

This manual is also suitable for:

Gc32flex tsi

Table of Contents