MC1000 / MC1001

AIR OPERATED

Operating and Calibration Instructions

 MC1000/MC1001 USER GUIDE

MC1000/MC1001 AIR OPERATED

Operating Instructions

Contents

Certificates of Conformity …………………………………………… 3

Gates MC1000/MC1001 Hose Crimping Machine …………………. 5

Assembly instructions ...………………………………………………. 6

Operating instructions ………………………………………………… 8

To bleed the machine of air …………………………………………… 14

Machine calibration …………………………………………………… 16

Parts list for Gates Hose Crimping Machine MC1000/MC1001……. 18

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 MC1000/MC1001 USER GUIDE

EC DECLARATION OF CONFORMITY

The undersigned Company:

GATES
hereby declares that the new equipment described below:

MC1000 Serial No:

complies with the Machinery Directive, GATES Specification and with the
Hygiene and Safety at Work Regulations as applicable.

Authorised: Date: 1/1/1999

G. R. Keast
Director of Technical

CHARACTERISTICS

Air supply requirement: 0.3m3/m at 7 bar (100Psi)

Crimping force: 27 tonne

Operation: easy to use pedal-operated air pump with a

pressure rating of 600 bar

Weight: 22 Kg (less dies and less air pump)

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 MC1000/MC1001 USER GUIDE

EC DECLARATION OF CONFORMITY

The undersigned Company:

GATES
hereby declares that the new equipment described below:

MC1001 Serial No:

complies with the Machinery Directive, GATES Specification and with the
Hygiene and Safety at Work Regulations as applicable.

Authorised: V. J. Hainsby Date:

V. J. Hainsby
Technical Manager, Couplings

CHARACTERISTICS

Air supply requirement: 0.3m3/m at 7 bar (100Psi)

Crimping force: 27 tonne

Operation: easy to use pedal-operated air pump with a

pressure rating of 600 bar

Weight: 22 Kg (less dies and less air pump)

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 MC1000/MC1001 USER GUIDE

MC1001 AIR OPERATED

Micrometer

Crimp ring

Filler plug Lock nut

Pump adaptor

Hose assembly Base plate

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 MC1000/MC1001 USER GUIDE

ASSEMBLY INSTRUCTIONS.
MC1000/MC1001 AIR OPERATED.

1. Remove the crimper and the foot pump / hose assembly from the packaging.

2. Connect the appropriate male air line adapter –1/4” NPT thread, (not supplied)
(Fig 1).

Fig 1.

3. Remove the dust caps from both ends of the quick release coupling and screw the end
of the hose into the adapter on the machine (Fig 2).

Fig 2.

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 MC1000/MC1001 USER GUIDE

4. Connect the air line to the foot pump (Fig 3).

Fig 3.

5. It is now important that the machine is bled of air and correctly calibrated, by
following the instructions contained in this booklet before it is first used.

6. If required, the crimper can be securely bolted to a work-surface using M10 CAP
HEAD bolts inserted through the four pre drilled holes (Fig 4). It should be noted that
once bolted down, the crimper cannot be bled unless it is un-bolted.

Fig 4.

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 MC1000/MC1001 USER GUIDE

1. OPERATING INSTRUCTIONS.
• Select the dies, hose and couplings suitable for your application, by either identification of
the product that is to be replaced, or by reference to the Gates Hose and Coupling
Catalogue (Fig 5).

Fig 5.

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 MC1000/MC1001 USER GUIDE

• If the crimp information calls for a

different set of dies, they should
be removed and replaced as shown
in Fig 6.

Fig 6.

• If the dies have been changed,

ensure that the die number is
DIE
uppermost and visible through the
centre of the carrier assembly
(Fig 7.)

Fig 7.

Fig 7.

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 MC1000/MC1001 USER GUIDE

• Loosen the lock nut on the

micrometer assembly (Fig 8.)

Fig 8.

• Adjust the micrometer gauge to

the setting stated in the crimp
information. The line for the
specific setting should be level
with the bottom of the square
window.

Fig 9.

• The coupling assembly may now

be pushed fully onto the hose.

Fig 10.

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 MC1000/MC1001 USER GUIDE

• The die assembly may now be

raised to a level where the hose
assembly can still be placed in
between the dies. This is achieved
by pushing down on the PRESS
end of the foot pump. (Fig 11.)
This will activate the pump and
deliver oil to the cylinder

Fig 11.

• Be sure to place your foot on the

end of the pump marked ‘PRESS’
as shown (Fig 12).

Fig 12.

• Place the hose assembly in the

crimper (Fig 13). Be sure to
observe the correct shell to die
location as indicated in the crimp
information.

Fig 13.

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 MC1000/MC1001 USER GUIDE

• Continue crimping by again

pressing the ‘PRESS’ end of the
foot pump until the correct crimp
setting is achieved. At this point
remove your foot from the foot
pump to stop crimping (Fig 14).

Fig 14.

• The correct setting has been

reached, when the ‘pin’ in the
micrometer gauge is flush with
the top of the micrometer (Fig
15).

Fig 15.

• Once crimping has stopped, the

crimping assembly may be
lowered by pushing down on the
end of the foot pump marked
‘RELEASE’ (Fig 16). Once
pushed down, it will be held in
place by the spring catch-plate.

Fig 16.

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 MC1000/MC1001 USER GUIDE

• Be sure to lower the crimper

and remove the hose assembly
by pushing down on the end
the foot pump marked
‘RELEASE’ (Fig 17).

Fig 17

• EP2 grade grease should be

applied to the crimp ring after
use, to ensure a smooth
movement between the dies and
the crimp ring during the
crimping process

Fig 18.

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 MC1000/MC1001 USER GUIDE

2.TO BLEED THE MACHINE OF AIR.

If for any reason the pump has become low on oil, it will need to be refilled. As a
result of this the system may require purging. Removal of all of the air from the hydraulic
system will ensure that future crimping operations can be completed with maximum
efficiency. The following instructions show how this procedure should be carried out.

• Fully retract the die carriage

(Fig 19) by pushing down on
the end of the foot pump
marked release (Fig 20).

Fig 19.

Fig 20.

• Remove the pump filler plug

and refill with H32 grade
hydraulic oil or equivalent
(Fig 21). The pump should be
topped up to within 12mm of
the oil filler hole. Once this is
complete, replace the filler
plug.

Fig 21.

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 MC1000/MC1001 USER GUIDE

• Remove all dies from the machine and set the

micrometer to a setting of 84. Raise the die
carriage as previously described until it
reaches the crimp setting (Fig 22).

Fig 22.

• Lay the machine on its side

with the pump adapter
uppermost (Fig 23). It is
suggested that the machine is
placed on the floor for this
operation.

Fig 23.

• Raise the foot pump and hose to above the level of

the pump adapter, then push the ‘release’ end of
the foot pump pedal by hand. This will allow the
die carriage to retract. As this happens, any air in
the system will be forced from the system and into
the foot pump.

• The crimper should now be stood upright on the

workbench and the first two parts of this chapter
repeated. This will ensure that any air purged from
the system, is replaced with oil to the correct level.

Fig 24.

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 MC1000/MC1001 USER GUIDE

3. MACHINE CALIBRATION
This process should be carried out on initial delivery of the crimper and, on a monthly basis
thereafter. This will ensure that the machine is maintained within its correct tolerance

Calibration using –08 Megacrimp calibration shell 8G (7482-19860-5)

1. Remove the existing dies from the machine and replace them with No. 33 dies, then adjust
the crimp gauge to setting of 70.

2. Place the shell (Fig 25) between the dies and operate the foot pump (as previously
described), until the gauge pin is flush with the top of the gauge (as shown in Fig 15).

Fig 25.

3. Press on the foot pump release pedal and as the die carriage retracts, carefully remove the
calibration shell from between the dies.

4. Place a vernier calliper (Fig 26) over each of the 4 flat indentations in the middle of the
shell.

Fig 26.

5. If the machine is satisfactorily calibrated the average reading should be 26.0mm +/-
0.25mm if calibrated with an 08 Megacrimp shell.

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 MC1000/MC1001 USER GUIDE

6. If the average reading is outside

these limits, the crimper will require
re-calibrating. This is achieved by
adjusting the gauge pin stop screw up
or down (Fig 27). One (1) complete
turn of the screw represents an
increase or decrease in the crimp
diameter of 0.43mm. Clockwise
rotation of the screw will tighten the
final crimp, Anti-clockwise rotation
will loosen the final crimp.
Repeat steps 1 – 5 until the crimper is
correctly calibrated.

Fig 27.

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 MC1000/MC1001 USER GUIDE

5. Parts List for Gates Hose Crimper

Model MC1000/MC1001
Air Operated
Item Quantity Description Part Number Order Reference
1 1 Micrometer Gauge Assy A 587 7482-19186
1A 1 Body D10780 7482-18545
1B 1 Screw D11136 7482-19077
1C 1 Pin Assy A 598 7482-19187
1D 1 Thumb Locknut S2104 7482-18849
1E 1 Gauge Inner Sleeve D10689 7482-18528
2 4 1/2 UNF x 2 1/2 Allen Screw 03337032 7480-19108
3 1 Top Plate Crimping Ring D11091 7482-19067
4 4 M6 x 40 Allen Screws 03011053 7480-19109
5 1 Die Cover Plate D11095 7482-19069
6 4 Die Spacer Tube 35106009 7480-19110
7 4 M6 x 30 Allen Screws 03011051 7480-19111
8 1 Die Guide Plate D11103 7482-19072
9 4 Tie Rod 35106007
10 2 M8 x 40 Allen Screws 03011066 7480-19113
11 2 Copper Washer 03024037 7480-19114
12A 1 Location Plate D11108 7482-19073
12B 1 M6 Nut 03035004 7480-19115
12C 1 M6 x 20 Hex Head Screw 03003048 7480-19116
12D 2 M4 x10 Allen Screws 03011015 7480-19117
13 1 Piston/Spacer Assy 35106003 7480-19118
14 1 Pressure Seal 030203730 7480-19119
15 1 Spring 35106008 7480-19120
16 1 Cylinder Body 35106002 7480-19121
17 1 O-Ring 030224300 7480-19122
18 1 Pump adaptor ADP1000 7480-19138
18A 1 Hose assembly FSG2 7480-19139
18B 1 Foot Operated Air Pump MLP21GA 7480-19140
19 1 Die Case 35106034 7480-19125
19A 2 Die Case Fixing Screws (not shown) 03317141 7480-19126
20 1 O-Ring 030222018 7480-19127
21 1 Base Plate 35106001 7480-19128
22 4 1/2 UNF x 1 3/4 Allen Screws 03337033 7480-19129
23 4 M6 x25 Allen Screws 03011048 7480-19130
24 8 M8 x 25 Allen Screws 03011063 7480-19131

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MC1000/MC1001 USER GUIDE

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