Gates GC20 Instruction Manual

GATES®GC20™WITH
GATES®CORTEX™INTELLIGENCE
OPERATING AND SAFETY MANUAL

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.
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. Complete your TRAINING with this Gates crimper and assemblies.
2. Follow current GATES OPERATING INSTRUCTIONS for the Gates GC20 Cortex.
3. Use only NEW (UNUSED GATES) hoses and fittings.
4. Wear SAFETY GLASSES.
5. Keep HANDS CLEAR OF MOVING PARTS.
6. Make sure your hose is CUT TO THE PROPER LENGTH, accounting for the
hose-coupling interface length.
7. Ensure your HOSE IS FULLY INSERTED into each coupling.
8. If you use bent couplings, ENSURE PROPER COUPLING ORIENTATION
to avoid hose twist during installation.
9. After each crimp, MEASURE THE CRIMP OD AND COMPARE IT to the crimp
specification displayed on the tablet.
WARNING!

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GATES.COM Table of ConTenTs
Gates GC20 Cortex
TABLE OF CONTENTS
Specifications....................................................................................................................1
Gates GC20 Cortex................................................................................................................................2
Setup..................................................................................................................................4
Install the Crimper.................................................................................................................................4
Set up the Tablet...................................................................................................................................9
Calibrate the Crimper.........................................................................................................................13
Tablet Menu Map..........................................................................................................19
Pull-Down Menu.................................................................................................................................19
People and Account Menu................................................................................................................21
Main Screen.......................................................................................................................................22
Tablet Operation........................................................................................................... 23
Administrator and Operator Accounts..............................................................................................23
To Create an Administrator Account.................................................................................................24
To Add an Operator............................................................................................................................25
To Give an Operator Account Administrator Access........................................................................27
View Video Tutorials, Catalogs, and Images.................................................................................... 28
Use Reference Tools..........................................................................................................................28
Hose Preparation..........................................................................................................30
Two-Piece Couplings..........................................................................................................................30
Megacrimp®Pre-Assembled Couplings........................................................................................... 32
Operating Instructions................................................................................................. 34
Do a Crimp.........................................................................................................................................35
Using the Optional Notched Cone.................................................................................................... 45
Measuring Crimp Diameter.........................................................................................47
To Properly Measure a Crimp Diameter............................................................................................47
When Using 21 and 22 Dies.............................................................................................................47
When Not Using 21 and 22 Dies......................................................................................................48
Next Steps when Using or Not Using 21 and 22 dies.....................................................................49
Maintenance..................................................................................................................50
Lubricate............................................................................................................................................ 50
Check Oil Level.................................................................................................................................. 50
Change the Oil................................................................................................................................... 51
Inspect Die Sets.................................................................................................................................51
Lubricate Die Sets with Molykote “G”, part 7482-3011.................................................................52
Inspect Hose Assemblies..................................................................................................................52
Perform a Maintenance Calibration.................................................................................................53
Maintenance Log...............................................................................................................................55
Check for Software and Content Updates....................................................................................... 57
A Firmware Update............................................................................................................................ 59

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Gates GC20 Cortex
Converting to 230V.......................................................................................................60
General Instructions for Converting to 230V...................................................................................60
Retrofitting a Crimper...................................................................................................61
Remove Old Components................................................................................................................. 62
Add New Components to the Crimper..............................................................................................68
Troubleshooting.............................................................................................................80

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GATES.COM speCifiCaTions
Gates GC20 Cortex
SPECIFICATIONS
GATES GC20 CORTEX
Prod. No.: 7480-0009* 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)
* Gates GC20 Cortex can also be wired for 230 volts. To do this, order G20 Cortex 230V
converter kit (Prod. No. 7482-0047, Part No. 70435).
ELECTRO POWER PUMP
Prod. No.: 7481-0023 Part No.: 77810
Power Source: 115 Volt, 15 Amp.* (min), 1 H.P. 60 Cycles
Dimensions: 12" wide x 25" deep x 12" high
Weight: 70 lbs.
Maximum Rated
Working Pressure:
4900 psi
* The motor on the pump is rated for 30A, but pulls only 14A. It can be used with a
standard 15A or 20A wall outlet.
GATES GC20r CORTEX PC 707 CONVERSION KIT
Prod. No.: 7482-0011 Part No.: 70446
Dimensions (when
installed):
13” wide x 12” deep x 26-1/2” high
Weight (when installed): 188 lbs.

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Gates GC20 Cortex
GATES GC20 CORTEX
DIE SETS ARE AVAILABLE FOR CRIMPING HYDRAULIC AND INDUSTRIAL HOSE
FROM 3/16" THROUGH 1-1/4" I.D.
DESCRIPTION PRODUCT
NUMBER
PART
NUMBER NOTES
Die Set 720S 7482-1401 78254 For crimping 4GLX — uses 20- and 30-series
dies GLX couplings leave a “bubble” at the top
of the crimp
Die Set 721 7482-1217 78943
Die Set 722 7482-1218 78944
Die Set 730 7482-0930 78930
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 Must use the No-Notch Die Cone
(Prod. No. 7482-0297, Part No. 78747)
Die Set 739 7482-0939 78939
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
Die Set 781 7482-1231 78578 For GL Fittings — uses 80-series dies
Die Set 782 7482-1232 78579 For GL Fittings — uses 80-series dies
Die Set 783 7482-1233 78580 For GL Fittings — uses 80-series dies
Die Set 7C3 7482-1122 78941 For crimping clamp collar (5⁄8”)
Die Set 7C4 7482-1123 78942 For crimping clamp collar (3⁄4”)
Die Set 73234 (LG) 7482-1424 78763 For crimping Lifeguard
Die Set 73335 (LG) 7482-1425 78764 For crimping Lifeguard
Die Set 73436 (LG) 7482-1426 78765 For crimping Lifeguard

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Gates GC20 Cortex
DESCRIPTION PRODUCT
NUMBER
PART
NUMBER NOTES
Die Set 73537 (LG) 7482-1427 78766 For crimping Lifeguard
Die Set 73638 (LG) 7482-1428 78767 For crimping Lifeguard
NOTE:
Do not use the 720, 735, 737, or 739 die sets with the notched
die cone (sold separately). This may damage the die cone.

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SETUP
There are three main steps to setting up the Gates GC20 Cortex:
■Install the crimper on a workbench, connect the pump, and power up.
■Set up the tablet. (page 8)
■Calibrate the crimper. (page 12)
INSTALL THE CRIMPER
1. Remove the crimper, back-up ring, no-notched die cone (the notched die cone
is sold separately as PN 7482-0297), die magnet, hose assembly, mounting
bracket with bolt, jar of Molykote “G” grease, and tablet from the shipping
carton. Remove the pump, breather cap and operating manual from its
shipping carton.
2. Mount the crimper so it overhangs a workbench (as shown in Figure 1). The
overhang is necessary to allow hoses to be inserted through the base plate
slot from underneath the crimper. The back of the cutout (in the base plate)
should be in line with the front of the bench, see Figure 2. The bench should
be 37” to 42” high, stable and of sturdy construction.
Figure 1: Mounting the crimper to overhang the workbench
3. Drill three 3/8" diameter holes as shown in Figure 2. Connect the mounting
bracket to the top rear of crimper and to the hole farthest from the edge of
the workbench. Further secure the crimper to the workbench using the two
remaining holes.

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Figure 2: Drill three holes in the workbench (plan view)
4. When you have a secured the crimper to the workbench, connect the hoses
between crimper and pump, as in Figure 3, Figure 4, and Figure 5.
■High-pressure 8MXT hose (with 20LG4K sleeve) on back of T-adapter
of the pump.
■Return hose 6MXT between port 1 on the solenoid/manifold, and with its
90-degree coupling connected to the side port of the pump (pump adapt-
er included).
■T-adapter pre-installed on the crimper.
Figure 3: The solenoid/manifold ports
Return Line
Connection-
Port 1
Pressure Line
Connection-
Back of
T-Adapter
T-Bracket-
Installed into
back of crimper
top plate
Selenoid Cord
Electrical
Connectors

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High-Pressure Hose with 20LG4K Sleeve
Fluid return hose
Fluid return hose
Figure 4: Hose connections
6MXT Hose with
90-Degree coupling
Figure 5: 6MXT hose connected to return port on pump

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5. Verify that the switch on the pump electrical box is in “OFF” position.
6. Plug the cord of the pump into an outlet. The pump requires a minimum of
115VAC and 15 amps. You can plug it into a 20 amp circuit.
7. Plug the cord of the crimper into a 115VAC/15 amp outlet. This immediately
provides power to the crimper electronics.
Figure 6: Gates GC20 Cortex
8. Remove plug from the top of the pump reservoir and replace it with the
breather cap provided. Check that hydraulic oil is within 1/2" of bottom of
plug opening. If needed, add Dextron III ATF or equivalent to the reservoir.
9. Move switch on pump electrical box to “ON” position. This provides power
to the pump.

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SET UP THE TABLET
All the complex settings for correctly crimping hose ends are built into the tablet
controller that runs the Gates GC20 Cortex.
■To set up the tablet, you must first connect it to the Internet via WiFi™ and
to the crimper using Bluetooth® connectivity. Afterwards, you can use the
tablet and crimper without WiFi (but Bluetooth must always remain ON for
the crimper to operate).
1. Turn on the pump and crimper. On the faceplate of the crimper, the red On/
Off light illuminates. Turn on the tablet and dock it in the cradle (the large
slot on the right-hand side of the crimper as you face it with the charging
port facing left to make the magnetic connection). When the tablet is fully
inserted, the cradle provides power to the tablet and charges it.
2. Ensure that the tablet’s Bluetooth and WiFi connectivity are on and working.
Figure 7 shows how the indicators appear on the tablet. The Bluetooth and
WiFi symbols indicate the ability to connect with WiFi and Bluetooth.
Figure 7: Bluetooth and WiFi symbols on the tablet
3. Find the pre-installed application named GATES CORTEX CRIMP in the list of
applications on the tablet, and tap it to start it. The Welcome screen appears
on the tablet (Figure 8).
Bluetooth
WiFi

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Gates GC20 Cortex
Figure 8: Welcome screen
4. On the faceplate of the crimper, the white “WiFi” symbol illuminates, showing
that crimper is connected to WiFi (Figure 9). The Bluetooth and WiFi symbols
on the faceplate only illuminate when the Gates application is running and
when the tablet and the crimper are connected.
On/Off indicator
Bluetooth indicator
WiFi indicator
Figure 9: Bluetooth and WiFi indicators on faceplate

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Gates GC20 Cortex
5. On the application welcome screen, tap PRESS HERE TO BEGIN SETUP. The
crimper application pairs to the crimper electronics. You may be asked to
allow the Gates GC20 Cortex to access the device’s location. Answer ALLOW.
6. Tap to choose the Bluetooth device to pair with, as in Figure 10. The
application shows only the addresses of available crimpers. If you
have difficulty determining which Bluetooth device to pair with, see
“Troubleshooting” on page <?>.
Tap Gates_GC20_Cortex
Figure 10: Choose Bluetooth device
7. Begin the registration process. The serial number is on the right-hand side
of the faceplate. Enter the serial number, business name, and your location
into the template, and then tap PRESS HERE TO CONTINUE. Wait for the
validation confirmation before continuing.
8. The Gates GC20 Cortex gives you an opportunity to set up an Administrator
account and Operator accounts if you want them. You can skip setting up
Admin/Operator accounts and do this later or not at all, or you can set up
an Administrator account now.
There are three ways to set up the tablet and use your crimper:
■No Admin/No Operator: Anyone can use and calibrate the crimper.
No passwords are required to use the crimper.
■Admin-only: Only the Admin can use and calibrate the crimper, using a
4-digit password.
■Admin and Operators: Admin and Operators created by the Admin can
use the crimper using their 4-digit password. Only the Admin can calibrate
the crimper, unless the Admin gives the specific Operator Admin access.

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For more information about setting up Administrator and Operator accounts, how
they affect your use of the crimper, and about operating the tablet generally, see
“Tablet Operation” on page i.
9. When you have set up Administrator and Operator accounts (or when you
have skipped setting them up), the tablet confirms that setup is complete,
as in Figure 11.
Figure 11: Setup is complete
NOTE:
If the tablet notifies you of a software update, update the software.

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CALIBRATE THE CRIMPER
Once tablet setup and registration are complete, you can perform a Setup Calibration
of the crimper.
CAUTION:
Always wear safety glasses and
KEEP HANDS AWAY FROM MOVING PARTS.
Depending on whether you have set up Admin and Operator accounts, you may
need to log in with your PIN.
1. If you have not yet closed the Setup Complete screen, you can perform the
Setup Calibration directly from that screen (Figure 12). Tap PERFORM SETUP
CALIBRATION, and then jump to Step 5 on page 14.
Setup Calibration
Figure 12: Performing the Setup Calibration
from the Congratulations screen.
2. If you have closed the Setup Complete screen, go to the application’s Home
screen (Figure 13).

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Pulldown menu
Figure 13: Application Home screen
3. From the pulldown menu, choose APPLICATION SETTINGS. The application
opens the Application Settings screen.
Figure 14: Application Settings screen
4. Tap CALIBRATION SETTINGS. The application opens the Calibration Settings
screen (Figure 15).

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Figure 15: Calibration Settings screen
5. Tap PERFORM INITIAL SETUP CALIBRATION. The tablet guides you step-by-
step through the initial calibration. There are two steps: Step 1 (Figure 16)
requires no additional tools. You will be instructed on a series of steps to
purge the air from all lines by cycling the crimper five times. Step 2 requires
a hose, coupling (ferrule+stem), and die to perform a crimp and measure it for
compliance.
Figure 16: Cycling the crimper
6. Tap PROCEED when you are ready. The application displays Calibration cycle
one (Figure 17).
WARNING:
Make sure that area under pusher cup is clear of die cone or die sets.

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Figure 17: Calibration cycle one
7. Press and hold the red PRESS & HOLD TO CYCLE button until the cycle
is completed and the button turns to green. The cycle count appears to
the right of the dot (Figure 18). Perform this cycle five times, as directed
by the software.
Figure 18: Calibration cycle one completed

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8. The last cycle retracts the pusher cup and asks you to wait 60 seconds,
(Figure 19).
Figure 19: Last of five cycles; ram retracting
9. Step 2 lists its requirements on screen, which include a specific coupling and a
specific die set, but no hose. When you have everything ready, tap PROCEED.
NOTE:
For instructions on how to set up a coupling and die set,
see Steps 1 through 8 beginning on page 18.
Figure 20: Assemble the coupling and die set, and then tap PROCEED