gates self assembly system

Your key to factory quality performanceAbove and beyond any international standard

Gates self assembly system

E2/50119

The true value of the Gates self-assembly system comes from the Gates Integrated Approach: All elements of the hose assembly process are designed together to produce factory quality assemblies which perform above and beyond any international standard.

This unique approach is how Gates ensures full compliance with the European Machinery Directive and the reason why Gates is known as the world’s most trusted hydraulic hose assembly manufacturer.

The Gates Integrated System Approach: Superior products are just the beginning

Gates Global hoses and couplings represent an evolution in hydraulic component design. They not only boast a wide array of advanced-design features but they are also manufactured to stringent tolerances, allowing consistently superior performance.

Moreover, Gates hoses and couplings are designed, tested and validated together – each with the other in mind. This is what makes Gates the masters of the hose and coupling interface.

The Gates Integrated System Approach: How does it work?A simple equation:

Superior products, manufactured to stringent tolerances

+Advanced self-assembly machines and dies, rigourously validated

+Optimal crimp data, meticulously tested

=Factory-quality performance above and beyond international standards

Superior products, manufactured to stringent tolerances

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Gates self-assembly machines and dies are custom-designed to work with the next-generation Global range of hose and couplings. Gates dies are characterised by a proprietary profi le design for an optimal cylindrical crimp. They are tried, tested and validated to provide you with the most optimal crimp settings. Furthermore, Gates die sets are logically organised to facilitate die selection time after time.

Advanced self-assembly machines and dies, rigorously validated

Optimal crimp data, derived from meticulous testing

The result: factory-quality performance above and beyond international standards

Gates self-assembly machinery: a complete range with a solution for every need

When Gates Global hose and couplings are crimped in accordance with the Gates Integrated System, they yield factory quality assemblies fully compliant to European Directives and legislation exceeding all international standards. Gates Global wire-braid hose

and MegaCrimp® coupling assemblies are developed to withstand impulse testing to 600,000 cycles. Gates spiral wire hose and GS coupling assemblies even go to a million cycles.

Gates range of self-assembly machinery covers the spectrum of needs from workshops to on-site fi eld-crimping and even mobile service operations. It is a complete range which includes hose cutting machines,

a marking machine and useful accessories. Every machine and tool in the Gates range is precise, easy to use and allows fast and factory-quality assembly of the complete Global range of Gates hose and couplings.

Each Gates crimper comes with validated crimp settings data for the complete Global hose & coupling product range. No need for time consuming trial-and-error to fi nd the ideal settings! You can even register to constantly stay up to datewith the latest developments via mail or internet.

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WorkshopWorkshopW

Cutting Marking Crimping

In the Gates workshop, safe, fast and effi cient assembly of hydraulic hose and couplings is made simple. All machines are custom-designed to work with a well-defi ned range of Gates hoses and couplings allowing production of factory quality assemblies fully complying with European Directives.

No matter what your workshop needs, whether you are a starter, a professional, or a full-service workshop, Gates has the right product offering for you.

Full service 2"

MS 5001

MK 5000MK 5000 MS 5001

MS 5001MS 5001MK 3000MK 3000 MC 3001MC 3001

MC 2501MC 2501

Professional service

up to 1 ¼"

Starter up to 1"

MC 5001MC 5001

Accessories

Quick change tool Die storage table Marking diesHose table

MK 2000MK 2000

Mobile Service

Cutting Marking Crimping

Please contact us for your cutter requirements

MC 3001MC 300112V

Professional service

up to 1 1⁄4"

A Gates hose assembly is much more than the sum of its components. It is the combined result of a rigorous test regime and of a tightly controlled manufacturing process, both at Gates and at the point of assembly.

To reduce the risk of premature failure due to variations in the assembly process, Gates has developed a special proposition for mobile service operations allowing them to benefi t from the simplifi ed and superior Global range of no-skive hoses and couplings.

And thanks to the Gates Integrated System, mobile service operators can offer their customers the superior quality and performance which make the world’s most trusted hose assemblies.

MS 5001MS 5001

Field Service

In the fi eld, every minute counts. In today’s environment, equipment, whether it be agricultural, construction or mining, simply cannot afford unnecessary downtime. That’s why Gates has developed a range of small, portable and easy to use crimpers specifi cally designed for end-users on site.

And since these simple, lightweight machines are designed as part of the Gates Integrated System, end-users are assured of factory quality no-skive assemblies – even in the fi eld!

No skive spiral hose

up to 1"

Wire braid hose

up to 1"

MC 2000

MC 1001MC 1001manualmanual

MC 1001MC 1001air operatedair operated

Technical specificationsCr

impe

rs

MC1

001

MC2

000

MC2

501

MC3

001

MC5

001

man

ual

pneu

mat

icm

anua

l1

phas

e3

phas

e1

phas

e3

phas

e12

V1

phas

e3

phas

e

Pow

er

supp

ly--

7bar

/100

psi

--22

0V38

0V22

0V38

0V12

V22

0V38

0V

Max

imum

cr

impi

ng

capa

city

WB

1"1

1/4"

1 1/

4"1

1/4"

2"

4SW

1"1"

1"1

1/4"

2"

6SW

1"1"

1"1

1/4"

2"

Crim

ping

fo

rce

(ton

)27

2710

013

713

721

021

021

036

036

0

Mot

or (

kW)

----

--2.

23.

02.

23.

02.

0 2.

25.

5

Die

set

MC1

000-

Dxx

MC5

000-

Dxx

MC5

001-

Dxx

MC5

001-

Dxx

MC5

001-

Dxx

Cycl

e ti

me

(sec

)--

----

2626

1010

109

9

Qui

ck c

hang

e to

ol--

----

oo

oo

Foot

ped

al--

x--

--o

x

Dim

ensi

ons

(mm

)

H46

031

052

065

058

080

0

W28

030

049

039

040

048

0

L39

041

065

064

050

073

0

Wei

ght

(kg)

2422

4190

9018

018

012

526

026

0

Prod

uct

num

ber

7480

-191

6474

80-1

9165

7480

-191

0374

80-1

9166

7480

-191

6774

80-1

9153

7480

-191

5274

80-1

9154

7480

-191

5674

80-1

9155

Opt

ions

:m

arki

ng d

ies

BSA

con

trol

----

--o

oo

o

----

----

--o

o

Leg

end

: --

no

t av

aila

ble

o op

tion

al

x st

anda

rd

Crimping machines

MC 1001

MC 2000 MC 2501Powerful, hand-operated crimper, ideal for small workshop and for mobile use. Crimps no-skive GlobalSpiralTM couplings up to 1".

Ref:7480-19103

Compact crimper for low-volume production. Ideal as starter machine or for small workshops. Crimps no-skive GlobalSpiralTM couplings up to 1".

Ref:7480-19167: 3 phase7480-19166: 1 phase

MC 3001 MC 5001Robust, operator-friendly machine to crimp the complete Gates range up to 1 1⁄4". Equipped with foot pedal to enable hands-free operation. Automatic power cut-off to prevent overcrimping.

Ref:7480-19152: 3 phase7480-19153: 1 phase7480-19154: 12V

Full-range crimper (up to 2" six-spiral hose) for the professional workshop. Equipped with foot pedal to enable hands-free operation.

Ref: 7480-19155: 3 phase7480-19156: 1 phase

Overview

Ref: 7480-19165: air operated machine

Ref: 7480-19164: manual machine

Lightweight, portable crimper designed for reliability in fi eld service.Comes with separate box, designed to contain complete set of dies. The pneumatic version has a foot-operated air pump. Crimps no-skive MegaCrimp® couplings for wire-braid hose up to 1".

Crimping machine accessories

Quick Change Tool

The universal Quick Change Tool allows easy replacement of the complete die set in one move. It can be used with all dies from D21 up to D311.

To optimise the use of the new quick change tool, a dedicated design for the storage of dies has been developed. This design has been incorporated both into a dedicated machine table and into a wall mounted rack for customers wishing to use an existing bench or table for their machine.Ref: 8000-10027: QCT & machine table8000-10028: QCT & machine rack

Marking dies

To facilitate compliance with the European Machinery Directive, which insists that finished assemblies are marked with the manufacturer’s name and the manufacturing date code, a full range of marking dies is now available for MC5001, MC3001 and MC2501 machines.

Please contact Gates for order information.

Documentation, user guide, data

All Gates crimpers come with technical documentation, a user guide and crimp data for assembling Gates hose and couplings.

Integrated BSA control

This control, which can be integrated into the MC3001 and the MC5001 crimpers, restricts the stroke of the machine thus improving the cycle time when crimping a batch of assemblies.

Ref:7480-19158: MC3001-C-BSA7480-19159: MC3001-A-BSA7480-19160: MC5001-C-BSA7480-19161: MC5001-A-BSA

Technical specifi cations

CuttersMK 2000 MK 3000 MK 5000

3 phase 1 phase 3 phase 3 phase

Power supply 380V 220V 380V 380V

Maximum capacity WB 1" 1 1/4" 2"

4SW 1" 1 1/4" 2"

6SW -- -- 2"

Motor (kW) 2.2 2.2 3.0 7.5

Brake motor -- -- ✓ ✓

Suction connection (mm)* -- 60/110* 60/110* 110

Cutting blade 300x3x25.4 300x3x25.4 520x4x40

Dimensions (mm)

H 380/760** 350/770** 1280/1750**

W 500 470 800

L 530 540 910

Weight (kg) 55 60 215

Product number 7480-19163 7480-19142 7480-19141 7480-19025

Cutters

MK 2000 MK 3000Compact cutting machine, perfectly suitable for the small workshop. Cuts hoses up to 1".

Ref: 7480-19163: 3 phase

Robust cutter for all types of workshops. Cuts hoses up to 1 1/4" four spiral wire.

Ref: 7480-19141: 3 phase7480-19142: 1 phase

MK 5000

A heavy-duty hose cutter allowing quick and reliable production across all hose size ranges. Cuts up to 2" six spiral wire hoses.

Ref: 7480-19025: 3 phase

* O.D. of optional connection tube** Height including handle

Compact cutting machine, perfectly suitable for the small workshop. Cuts hoses up to 1".

Tools

Marking machine

A hand-operated marking machine which allows easy identifi cation marking on Gates ferrules. The MS 5001 is equipped with a hand wheel to adjust the character setting to the ferrule and with a counter for presetting and for consistent marking depth. The MS 5001 marking machine comes with a box of 120 characters.

Ref: 7480-19162

Optional character holder consisting of one row of fi xed characters and three rows of rotating numbers, e.g. to change the date code without affecting the company name.

Ref: 8000-10071

MegaCrimp® vernier caliper

A handy tool which measures fi nished outside diameters.Special design for easy measuring of the fi nished diameters on -4, -5 and -6 MegaCrimp®. Comes in solid case.

Ref: 7369-0322

MegaCrimp® insertion tool

The new MegaCrimp® coupling insertion tool offers an easy way to confi rm the right insertion depth for all Gates wire-braid hydraulic hoses. It also verifi es the squareness of cut!

Ref:7482-1342

Rotational table

Rotational table ideal for the unwinding of hose coils.

Ref:7480-19135

-size hose coupling die MC 1001 MC 2000 MC 2501 MC 3001 MC 5001

-4 M3K M4K M5K M6K CM2T MegaCrimp® D21 ✓ ✓ ✓ ✓ ✓

G1 G2 C1TH MegaTechTM GTH MegaCrimp® D21 ✓ ✓ ✓ ✓ ✓

3TE 2TE GT7 GT8 MegaCrimp® D21 ✓ ✓ ✓ ✓ ✓

1PW GP60 GP80+ GP40 MegaCrimp® D21 ✓ ✓ ✓ ✓ ✓

-5 M3K M4K M5K CM2T MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓

G1 G2 GTH MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓

3TE 2TE MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓

2PW 1PW GP60 GP80+ GP40 MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓





EFG4K EFG5K EFG6K GlobalSpiralTM D33 ✓ ✓ ✓ ✓






-10 M3K M4K CM2T MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓



GP60 GP80+ GP40 MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓


-12 M3K M4K CM2T MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓


3TE 2TE GMV GT7 GT8 MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓



-16 M3K CM2T MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓

G1 G2 C1TH MegaTechTM MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓

3TE 2TE GMV GT8 MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓



-20 MegaCrimp® D39 ✓ ✓ ✓ ✓

G1 G2 MegaTechTM MegaCrimp® D39 ✓ ✓ ✓ ✓

GMV MegaCrimp® D39 ✓ ✓ ✓ ✓

GP80+ GP40 MegaCrimp® D39 ✓ ✓ ✓ ✓

EFG3K EFG4K GlobalSpiralTM D39 ✓ ✓

EFG5K EFG6K GlobalSpiralTM D310 ✓ ✓

-24 ES-A D45 ✓

G1 G2 MegaTechTM ES-A D45 ✓

GMV ES-A D45 ✓

GP80+ GP40 ES-A D45 ✓

G3K GlobalSpiralTM D311 ✓

G5K GlobalSpiralTM D311 ✓

-32 ES-A D60 ✓

G1 G2 MegaTechTM ES-A D60 ✓

GMV ES-A D60 ✓

GP80+ ES-A D60 ✓

G3K ES-A D60 ✓

G5K PCM D314 ✓

wire braid reinforcement

4 spiral wire reinforcement

6 spiral wire reinforcement

Die selection matrix

• An Integrated System approach which elevates the technological superiority of

the Gates no-skive Global hose and couplings range with rigourously validated

machines and crimp settings to produce hose assemblies which perform above and

beyond any international standard.

• A comprehensive range of self-assembly machinery with a variety of choices which cover

the spectrum of needs whether in the Workshop, Field or for Mobile Service Operations.

• A wide range of precision tools, reference material and accessories to facilitate the

assembly operation and promote compliance to European legislation.

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Gates self-assembly system

.

Safe Hydraulics – a higher standard in Safety

The manufacturers reserve the right to amend details where necessary. Gates Europe nv 2005 Printed in Belgium – 11/05.

· Seminars via Gates exclusive partner network· Covers the entire process: storage, selection

installation and inspection· Includes an overview of relevant EU legislation,

complete with practical examples

Safe HydraulicsWorld-class safety training programme

Never underestimate the power of a hydraulic hose assembly under pressure. Just having the world’s best hoses and couplings is not enough to ensure the safety of your hydraulic hose assemblies. Improper assembly, installation or even storage can compromise performance and even human safety. Through the Safe Hydraulics Europe programme, Gates Fluid Power Europe is committed to increasing industry and end-user awareness of preventive maintenance and safety issues affecting hydraulic hose assemblies

How does it work?

· A world-class product, safety and preventive maintenance training programme

· Designed by Gates application engineers· Delivered by certified trainers· Tailored for assembly workshops and end-users

What is it?

To learn more about how to ensure the safety and performance of your hydraulic hose assemblies through the Gates Safe Hydraulics Europe programme, go to www.safehydraulicseurope.com, or contact us at: 0044-14 80 22 50 00

Your distributor:

gates self assembly system

Documents