Post on 27-Oct-2021
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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 ✓ ✓ ✓ ✓ ✓
-6 M3K M4K M5K CM2T MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓
G1 G2 C1TH MegaTechTM GTH MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓
3TE 2TE GT7 GT8 MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓
2PW 1PW GP60 GP80+ GP40 MegaCrimp® D22 ✓ ✓ ✓ ✓ ✓
EFG4K EFG5K EFG6K GlobalSpiralTM D33 ✓ ✓ ✓ ✓
-8 M3K M4K M5K CM2T MegaCrimp® D33 ✓ ✓ ✓ ✓ ✓
G1 G2 C1TH MegaTechTM GTH MegaCrimp® D33 ✓ ✓ ✓ ✓ ✓
3TE 2TE GT7 GT8 MegaCrimp® D33 ✓ ✓ ✓ ✓ ✓
2PW 1PW GP60 GP80+ GP40 MegaCrimp® D33 ✓ ✓ ✓ ✓ ✓
EFG4K EFG5K EFG6K GlobalSpiralTM D33 ✓ ✓ ✓ ✓
-10 M3K M4K CM2T MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓
G1 G2 C1TH MegaTechTM GTH MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓
3TE 2TE GT7 GT8 MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓
GP60 GP80+ GP40 MegaCrimp® D34 ✓ ✓ ✓ ✓ ✓
EFG4K EFG5K EFG6K GlobalSpiralTM D35 ✓ ✓ ✓ ✓
-12 M3K M4K CM2T MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓
G1 G2 C1TH MegaTechTM GTH MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓
3TE 2TE GMV GT7 GT8 MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓
GP60 GP80+ GP40 MegaCrimp® D35 ✓ ✓ ✓ ✓ ✓
EFG4K EFG5K EFG6K GlobalSpiralTM D35 ✓ ✓ ✓ ✓
-16 M3K CM2T MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓
G1 G2 C1TH MegaTechTM MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓
3TE 2TE GMV GT8 MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓
GP60 GP80+ GP40 MegaCrimp® D37 ✓ ✓ ✓ ✓ ✓
EFG4K EFG5K EFG6K GlobalSpiralTM 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: