Gates Power Crimp 707 Manual de instalación

Safety & Operating Manual

Power Crimp 707 Crimper

(Ind.) 35019-AG

(Auto.) 428-7300

10/02

An incorrect hose assembly can rupture or blow apart in 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 Gates crimper and assemblies.

2. Follow current GATES OPERATING MANUAL and CRIMP DATA for the

Gates PC 707 crimper.

3. Use only NEW (UNUSED GATES) hose and fittings.

4. Wear SAFETY GLASSES.

5. Keep hands clear of moving parts.

WARNING!

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.

Contents

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Hose Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Measuring Crimp Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Crimper 707 Conversion from 115v to 230v . . . . . . . . . . . . . . . . . . . . . . . . . 11

Schematic and Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Serial No. ____________________________

(Located on base plate in front of left rod.)

Date of Purchase _____________________

23 Die sets are available for crimping hydraulic and industrial hose from

3⁄16” through 11⁄4” I.D. A Swager Kit (Prod. No. 7480-0040, Part No. 78081)

also is available to swage thermoplastic and C14 Teflon hoses.

PC707 8-Finger Die Sets Available

Product Part

Description Number Number Notes

Die Set 721 7482-1217 78943

Die Set 722 7482-1218 78944

Die Set 731 7482-0931 78931

Die Set 732 7482-0932 78932

Die Set 733 7482-0933 78933

Die Set 734 7482-0934 78934

Die Set 735 7482-0935 78935

Die Set 736 7482-0936 78936

Die Set 737 7482-0937 78937

Die Set 739 7482-0939 78939 Must use the No-Notch Die Cone (Prod. No. 7482-0297, Part No. 78747)

Die Set 740 7482-0947 78950 For crimping 6ACA

Die Set 741 7482-0941 74951 For crimping 8ACA

Die Set 742 7482-0942 78952 For crimping 10ACA

Die Set 743 7482-0943 78953 For crimping 12ACA

Die Set 744 7482-0944 78954 For crimping power steering

Die Set 745 7482-0945 78955 For crimping grease fitting

Die Set 746 7482-0946 78956 For crimping miscellaneous (Replaces B die)

Die Set 781 7482-1231 78578 For GL Fittings

Die Set 782 7482-1232 78579 For GL Fittings

Die Set 783 7482-1233 78580 For GL Fittings

Die Set 7C3 7482-1122 78941 For crimping clamp collar (5⁄8”)

Die Set 7C4 7482-1123 78942 For crimping clamp collar (3⁄4”)

Specifications

Prod. No.: 7480-0043* Part No.: 77700*

Dimensions: 13” wide x 12” deep x 26-1/2” high

Weight: 188 lbs.

Production Rate: 50 assemblies per hour (1/2” I.D. 2-wire

straight thread assemblies)

* Power Crimp 707 crimper can also be ordered wired for 230 volts (Prod. No. 7480-0046,

Part No 77701). Must be used with 230 volt power unit (Prod No. 7481-0028, Part No. 77811).

Power Crimp®707 Crimper

Prod. No.: 7481-0023 Part No.: 77810

Power Source: 115 Volt, 15 Amp.,

1 H.P., 60 Cycles

Dimensions: 12 “ wide x 25” deep x 12” high

Weight: 70 lbs.

Maximum Rated Working Pressure: 4900 psi.

Prod. No.: 7481-0028* Part No.: 77811*

Power Source: 230 Volt, 7.5 Amp.,

1 H.P., 60 Cycles

* Use only with Power Crimp 707 (Product No. 7480-0046,

Part No. 77701), or 230 Volt rewired Power Crimp 707 crimper only.

Electro Power Pump

Note: Do Not operate 115V crimper with a 230V pump. Digital readout will be damaged. See page 11

for additional instructions.

Do not use 720 or 739 die set with notched die cone. May cause damage to die cone.

CAUTION:

1. Remove crimper, back-up ring, two die

cones, die magnet, hose assembly, mounting

bracket with bolt, jar of Molykote “G” grease,

operating manual, crimp data book and crimp

decals from shipping carton. Locate serial

number on base plate in front of left post and

record on Page 1. Be sure to fill out the

crimper registration card. (By completing the

card and returning it to Gates, you will receive

crimp data updates and full warranty cover-

age.) Remove pump, breather cap and operat-

ing manual from its shipping carton.

2. Mount crimper so it overhangs a work-

bench (as shown in Photo 1). The back of the

cutout (in the base plate) should be in line

with front of bench. The bench should be 37”

to 42” high, stable and of sturdy construction.

3. Drill three 3/8” diameter holes as shown

in Illustration 1. Connect the mounting bracket

to top rear of crimper and to the hole farthest

from edge of workbench. Further secure

crimper to workbench using the two

remaining holes.

4. When crimper is secured to the work-

bench, connect hose assembly between

crimper and pump.

5.Connect receptacle on short cord of pump

to plug on cord of switch box of the crimper.

If plug and receptacle do not match, do

not try to connect. Differences in the plug

and receptacle indicate the pump and crimper

have different voltages and should not be

operated.

6. Remove plug from top of pump reservoir

and replace with breather cap provided. Check

that hydraulic oil is within 1/2” of bottom of

plug opening. If needed, add Dextron II ATF or

equivalent to reservoir.

7. Verify that switch on pump electrical box is

in “OFF” position. Connect pump power cord

to a 15 amp (minimum) rated electrical circuit.

8. Move switch on pump electrical box to

“ON” position. This will provide power to the

pump and crimper.

9. Turn knob on top of crimper switch box to

get a setting of 2.00 on the readout. Cycle

crimper at least 5 times to bleed air from

cylinder and hydraulic system.

Mounting

Bracket

Work Bench

Crimper Base

(3) 3/8Diameter Holes

3-1/4

9-3/4

22

Peel and position crimp

decal on the shroud

according to your

preference.

Crimper and pump voltage must be the

same or digital readout will be damaged.

WARNING:

Setup

ILLUSTRATION 1

PHOTO 1

1. Before initiating calibration procedure,

make sure crimper has been cycled five times.

To cycle, dial in a setting of 2.00 and run

crimper down to shutoff with no die set

loaded.

2. Install the “733” die set to calibrate the

machine using an 8G MegaCrimp®coupling.

3. Set the digital readout setting to 5.20.

(Rotating the knob on top of switch box clock-

wise will increase the number; counterclock-

wise will decrease the number. When chang-

ing the setting, always move to a higher num-

ber then down to the desired setting.

Example: To change from 5.00 to 5.20, move

dial up to 6.00 then down to 5.20.) The

readout figures may jump a number; i.e. 5.20

to 5.19 or 5.21. This will not affect the crimp OD.

4. Insert the coupling into the die set

approximately 1/8” below top of die. (See

Photo 1.)

5. Slide the die cone assembly under the

ram until it stops against back locating pins

and push the crimp button and hold. Release

the button immediately when the pump stops.

6. Remover coupling and measure crimp diame-

ter, which should measure 1.000” ± .003”. (See

Page 9 for Measuring Crimp Diameter.)

7. If ferrule crimp diameter is not acceptable,

adjust actuator rod. (See Photo 2.)

a. To increase crimp diameter – Hold the

1-1/16” actuator rod while loosening the

3/4” lock nut. Rotate the actuator rod clock-

wise (one full turn of the actuator rod will

change crimp diameter approximately

0.024”). Then tighten the lock nut down.

b. To decrease crimp diameter – Hold the

1-1/16” actuator rod while loosening the

3/4” lock nut. Rotate the actuator rod

counter clockwise (one full turn of the actu-

ator rod will change crimp diameter approxi-

mately 0.024”). Then tighten the lock nut

down.

8. Repeat steps 3 through 7 to verify correct

crimp diameter.

Make sure area under pusher cup is clear of die cone or die sets.

WARNING:

PHOTO 1 PHOTO 2

CLOCKWISE

Do not

over-tighten

lock nut.

CAUTION:

PC 707 Calibration Procedure

Two-Piece Couplings

1. Cut hose to desired length.

2. Using Gates Crimp Data Manual #35019

(Ind.), 428-7365(Auto.), select the correct stem

and ferrule. Or, log onto www.gates.com/ecrimp

for the latest crimp information on-line.

3. Place ferrule over end of hose. If skiving is

required, see instructions in Gates Hand Skiver

Manual, #35019-W.

4. Lubricate the first two or three serrations

on stem with lightweight oil (SAE 10W).

5. Clamp stem in vise on hex portion, and

push hose onto stem. Hose should be flush

against stem shoulder (see cutaway drawing).

6. Push ferrule so it rests against hex of stem.

Hose and coupling are now ready for crimping.

MegaCrimp®Pre-Assembled

Couplings

1. Cut hose to desired length.

2. Using Gates Crimp Data Manual#35019

(Ind.), 428-7365(Auto.), select the correct

MegaCrimp coupling. Or, log onto

www.gates.com/ecrimp for the latest crimp

information on-line.

3. Place a visible mark on hose cover at the

insertion length shown in the crimp data

manual.

4. Insert coupling into the hose until the

mark lines up with the end of the coupling

ferrule.

5. Hose and coupling are now ready for

crimping.

A new hose and end fittings (stem/ferrule) must be used when building a hose assembly. Re-using any

component will seriously affect performance and could result in serious injury or property damage.

CAUTION:

Hose Preparation

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.

NOTE:

1. Place die back up ring on front of crimper

base plate. This back up ring is used with all

die sets.

2. Select proper die set for hose and cou-

pling by referring to the Gates Crimp manual,

#35019 (Ind.) and 428-7365 (Auto.), or log

onto www.gates.com/ecrimp.

3. Using die magnet supplied with crimper,

insert proper die set, one half at a time, onto

die backup ring.

4. Periodically check bottom of die cage and

top surface of die back up ring for cleanliness.

5. Check screws holding fingers to cage to

make sure they are tight. Tighten if necessary.

This could affect crimp if loose.

6. Apply a thin layer of Molykote “G” grease

to inside working area of die cone. The layer

of grease must be redistributed periodically

when the area becomes shiny from rubbing

on the die fingers.

Operating Instructions

Not recommended for use below 40°F.

Pump damage may occur. If operation is

required below 40°F, pump oil reservoir

must be heated.

CAUTION:

Use No-Notch Die Cone when crimping with

720, 739, and 6PS Die sets. Using a notched

cone may cause damage to die cone.

NOTE:

Die cage may break if surfaces are not

kept clean.

WARNING:

Die

Cage

Screws for

Die Fingers

(7482-1672

or 78749)

7. Insert hose assembly through bottom of

the crimper base plate up through die fingers.

8. Locate top of ferrule or MegaCrimp®

coupling approximately 1/8” below top of the

die fingers. Place die cone over the die fingers

to hold assembly in position.

9. Move die cone and backup ring back

against BOTH rear locating pins of crimper

base plate.

10. The crimp data manual gives approxi-

mate digital readout setting for specific

hose/coupling combination. Rotating the knob

on top of switch box clockwise will increase

the setting; counterclockwise will decrease the

setting.

11. Turn knob to a setting below the desired

setting. Then turn knob back up to the

desired setting. (Digital readout numbers may

jump a number, e.g., 5.50 to 5.49 or 5.51.

This will not affect crimp diameter of the

coupling.)

12. Activate pump by pressing and holding

the crimp switch on switch box. The readout

light will go out when the crimp switch is

pushed in. When actuator rod contacts switch

box’s microswitch, the power to pump is

automatically turned off.

Top of

Die Finger

Top of

Ferrule

Rear

locating pins

Operating Instructions (continued)

Keep hand out from under ram

at all times.

WARNING:

Be sure the hex of a straight stem or round

portion of a bent tube rests against ferrule.

IMPORTANT:

Do not use 720, 739, or 6PS die sets

with notched die cone. May cause damage

to die cone.

CAUTION:

Always wear safety glasses and

KEEP HANDS AWAY

FROM MOVING PARTS.

CAUTION:

Incorrect Correct

13. When you hear pump shut off, release

switch and the ram will move up.

14. Move die cone and backup ring unit all

the way forward. Remove assembly by lifting

the die cone.

15. Measure crimp diameter. (See Page 9).

16. Check the crimp data chart for correct

crimp diameter.

17. When crimping bent tube couplings, use

the same procedure as crimping straight end

couplings. Keep thread end of bent tube for-

ward to clear slot in pusher.

18. To crimp a 45° or 90° block type cou-

pling, follow the same procedure used for the

bent tube.

19. Position thread end of coupling into the

die cone notch, which must be towards the

front of the crimper.

Operating Instructions (continued)

Your measured crimp diameter MUST be in

tolerance range as listed in the

Crimp Data Manual.

WARNING:

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