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MegaCrimp® High-Pressure Couplings


MegaCrimp® Couplings – A Crimp Seal You Can Count On

MegaCrimp® couplings give you a leak-proof seal that’s so innovative, it’s patented*. In fact, it surpassed one million impulse cycles during design testing. * U.S. Patent #5267758

MegaCrimp® couplings feature exclusive TuffCoat plating

This innovative technique gives our MegaCrimp® couplings four times more corrosion resistance than before. That’s 400 hours of red rust corrosion protection when subjected to rigorous SAE-J516 and ASTMP-117 salt-spray conditions. This 500+% improvement over the 72-hour SAE standard proves Gates not only raised the bar on corrosion resistance – we’ve set the standard.

Images taken at random stages of salt spray testing show that Gates TuffCoat plating significantly outperforms competitive products in protection against red corrosion. Note: the white seen on couplings is salt residue and is not corrosive.

The “C” Insert starts round, stays round

During crimping, only the outside shell of a MegaCrimp® coupling takes on the shape of the dies. Inside, the “C” insert stays round – like the hose. There’s no “polygon effect.” A comparison of cross-sections with our competitors’ onepiece couplings shows how crimping can distort the hose tube which often contributes to the formation of leak paths, while MegaCrimp® couplings remain round.

The “polygon effect” is even more dramatic when the couplings are crimped without the hose!

MegaCrimp® Stays Inserted

Once inserted, MegaCrimp® stays inserted. It won’t fall out during the crimping process. The advanced design of the MegaCrimp® tooth profile shown below on the left “bites the wire” for better coupling retention unlike the competitive crimp shown below on the right that relies on the compression of the rubber.

The Secret: It’s an inside job

It’s what’s inside the MegaCrimp® coupling that makes it perform so well. The same “C” insert can be used on hoses with different constructions and wall thicknesses. In addition, the “C” insert assures an even distribution of crimping forces to form a concentric seal. That simplifies your inventory requirements since one size of MegaCrimp® coupling can accommodate many different hose ODs, and on both one and two-wire hoses. An additional bonus: MegaCrimp® couplings are a fully qualified EN-performance coupling.

MegaCrimp® couplings set a new standard for hydraulic couplings. The unique “C” insert ensures “weep-free” concentric crimping to keep equipment and the environment clean.

Key features:

  • Robust “bite-the-wire” crimp
  • Versatile
  • Low profile
  • Full stem insertion
  • Full-length crimp
  • Easy-to-manage inventory reduces SKUs
  • TuffCoat plating for 500% better corrosion resistance
  • Fully qualified EN-performance coupling

The new Gates MegaCrimp® coupling insertion tool offers an easy way to confirm the right insertion depth for all Gates wire-braid hydraulic hoses.

  • Comes with easy-to-read dash sizes on top and side.
  • Quickly verifies you’ve made a straight hose cut.
  • Compact, lightweight design made of solid aluminum.
  • Convenient side or top mount to your workbench.
  • Useful slot for holding marking pen or grease pencil.

To use, simply insert the hose into its proper slot indicated by dash size, push it all the way in, check for square cut (maximum allowable angle of cut is five degrees), then mark the insertion depth on the hose. Finally, using proper hose insertion techniques, check for full coupling seat then crimp the hose assembly.

The new Gates MegaCrimp® coupling insertion tool is available now. To order the tool, ask for part no. 78017 or product no. 7482-1342.

Gates MegaCrimp® couplings are designed for easy installation and long service life.

However, like all hydraulic couplings, they can fail prematurely if they aren’t properly installed.

For safe, trouble-free service, it’s crucial to fully insert the hose into the coupling before crimping. Failure to fully insert the hose can lead to premature assembly failure, costly downtime, equipment damage or serious injury.

Here’s a simple procedure to ensure the hose is fully inserted before crimping.

Proper Hose Insertion

  1. Check the end of the hose to be sure it’s cut straight and square to the sides of the hose. The maximum allowable angle of the cut is five degrees.
  2. Next, place the hose next to the coupling. Use your thumb to mark the proper insertion depth, or mark the insertion depth with a grease pencil.
  3. Push the coupling onto the hose until the shell touches the tip of your thumb or grease pencil mark. Then, twist the hose slightly to ensure it is fully seated.
  4. Follow proper crimping procedures.

Gates designed MegaCrimp® couplings for easy insertion. You can feel them “hit bottom” when the hose is fully inserted. And once the hose is inserted it stays put, so MegaCrimp® couplings won’t fall off during the crimping process.

Gates has a new, easy-to-use tool to help you find the proper hose insertion depth. See below for more information.

Don’t take chances with your safety. Always be sure to follow proper hose insertion procedures before crimping Gates MegaCrimp® couplings.


The Versatility of MegaCrimp® Couplings

Gates designed the MegaCrimp® coupling to work in concert with our existing products. It’s an unbeatable combination. MegaCrimp® handles our complete line of wire braid hoses. Consider:

M3K Mega3000® Every size meets 3,000 psi working pressure. Half SAE bend radius reduces required hose length up to 47 percent. SAE 100R9 performance in 3/4" and 1" sizes. MegaCrimp® couplings available for hoses in sizes 1/4", 3/8", 1/2", 3/4" and 1".

M4K Mega4000® Meets one-half SAE100R1, 100R2 and 100R9 bend radius, plus SAE 100R9 performance on 1/2" sizes and SAE 100R12 pressure on 3/8" to 3/4" sizes. All sizes have 4,000 psi working pressure.

GT7 and GT8 A new generation of crimpable thermoplastic hose that meets SAE 100R7 & SAE 100R8.

G1 and G2 For hydraulic oil lines with working pressures of 1,625 to 5,000 psi. Meets or exceeds SAE 100R2AT, SAE100R1AT and U.S. MSHA 2G Flame Resistance Acceptance Designation. Available in 1/4", 3/8", 1/2", 5/8", 1" and 1-1/4" I.D.s.

M2T MegaFlex® For 2-wire applications. Bends twice as tightly as SAE-rated hose. Meets 100R2 working pressures. MegaCrimp® couplings are available for hoses in sizes 1/4", 3/8", 1/2", 5/8" and 1".

GMV MegaVac® For return, suction and vacuum lines. One-half SAE 100R4 bend radius. Flexible and lightweight. MegaCrimp® couplings are available in 3/4", 1" and 1-1/4" I.D.s.

Solving Your Problems with Quality Products and Service

The men and women at Gates pride themselves on identifying and meeting customer needs. That’s how Gates got to be a leader in hydraulics – by listening to our customers and responding in a timely manner with products that are unequalled in the industry. At Gates, we also focus on service. Just ask. We’re ready to help you select the proper hose and couplings or design an entire hydraulic system to meet your specific application.

A Numbering System that Makes Sense

Gates MegaCrimp® couplings carry a part number that makes coupling identification easy.

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