RYCO RY20C Bedienungsanleitung

OPERATION MANUAL

MOBILE AND WORKSHOP SERIES

CONNECTING PARTNERSHIPS

FOR MODELS:

RY20C

RY20CB

RY32C

RY32CB October 2018 | Version: v1-0

1MOBILE AND WORKSHOP SERIES OPERATION MANUALOctober 2018 | Version: v1-0

CONTENTS

GENERAL...................................................................................................................................................................2-6

HECKLIST............................................................................................................................................................................................................. 3

Pre-Delivery Checklist............................................................................................................................................................................................ 3

Pre-Commencement Inspection ............................................................................................................................................................................. 3

SAFETY............................................................................................................................................................................................................. 4-11

Restriction ............................................................................................................................................................................................................. 4

Danger Zones ........................................................................................................................................................................................................ 5

Safety Notes .......................................................................................................................................................................................................... 5

Hose Assembly...................................................................................................................................................................................................... 5

Machine Installation ............................................................................................................................................................................................... 5

Safety Instruction................................................................................................................................................................................................... 6

Battery and Oil....................................................................................................................................................................................................... 7

Oil Fill.................................................................................................................................................................................................................... 7

Running-In............................................................................................................................................................................................................. 7

Greasing................................................................................................................................................................................................................ 7

Installation of Power Supply................................................................................................................................................................................... 8

Transporting .......................................................................................................................................................................................................... 9

Base Mounting....................................................................................................................................................................................................... 9

Danger Zones and Warning Labels ..................................................................................................................................................................10-11

OPERATION............................................................................................................................................................12-17

START UP..............................................................................................................................................................................................................12

Hydraulic System..................................................................................................................................................................................................12

Functional Tests and Re-Testing...........................................................................................................................................................................12

SELECTING THE DIE SETS ......................................................................................................................................................................................13

RY20 Die Sets ......................................................................................................................................................................................................13

RY32 Die Sets ......................................................................................................................................................................................................13

MOBILE AND WORKSHOP SERIES ...........................................................................................................................................................................14

Start Up ................................................................................................................................................................................................................14

Operation..............................................................................................................................................................................................................14

Installing The Die Set............................................................................................................................................................................................14

QUICK CHANGE TOOL.............................................................................................................................................................................................15

Quick Change Tool ...............................................................................................................................................................................................15

Change of a Single Die Set ..................................................................................................................................................................................15

CONTROL IDENTIFICATION.....................................................................................................................................................................................16

Digital Control Panel .............................................................................................................................................................................................16

Crimping ..............................................................................................................................................................................................................17

SPECIFICATIONS ....................................................................................................................................................18-22

RY20C..................................................................................................................................................................................................................18

RY32C..................................................................................................................................................................................................................19

RY20CB ...............................................................................................................................................................................................................20

RY32CB ...............................................................................................................................................................................................................21

Calibration ............................................................................................................................................................................................................22

MAINTENANCE.......................................................................................................................................................23-24

HOW TO MAINTAIN YOUR CRIMPER.........................................................................................................................................................................23

Cleaning ...............................................................................................................................................................................................................23

Lubrication/Greasing.............................................................................................................................................................................................23

Oil Change ...........................................................................................................................................................................................................23

Master Spring Change ..........................................................................................................................................................................................23

Pressure Pipes .....................................................................................................................................................................................................23

Troubleshooting ....................................................................................................................................................................................................24

TECHNICAL ............................................................................................................................................................25-34

ELECTRICAL SCHEME ............................................................................................................................................................................................25

Electrical Components List - RY20CB/RY32CB .....................................................................................................................................................26

Electrical Components List - RY20C/RY32C..........................................................................................................................................................27

ASSEMBLY ............................................................................................................................................................................................................28

Assembly of RY20/RY32.......................................................................................................................................................................................28

Assembly of RY20CB/RY32CB .............................................................................................................................................................................29

Assembly of RY20C/RY32C ..................................................................................................................................................................................30

Master Die Misalignment Troubleshooting ........................................................................................................................................................31-34

2MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 | Version: v1-0

GENERAL INFORMATION

GENERAL

Do not unpack or operate the crimping machine until you have thoroughly read this manual.

All operators using the crimping machine must read this manual.

This manual provides necessary information for the safe use of this machine.

This manual is the result of continual development, testing and technical evaluations that are registered and veried according to

2006:42/EG, 2004:108/EG, 2006:95/EG, EN614-2, 97/23/EG.

The information within this manual is intended only for trained operators who can operate the machine without risk to themselves,

other persons, property, the machine, or the environment. The operator should have proven competence in

• Trouble-shooting methods

• Performing machine inspections

• Simple maintenance procedures

• Safe hose making practices and procedures, in compliance with, this manual, appropriate legislation and RYCO

Hydraulics Safe Work Instructions.

The scope of this manual does not cover disassembly or comprehensive maintenance procedures. These may only be performed

by an authorised service technician.

Store this manual and keep it in good condition for future use. Contact your nearest authorised RYCO distributor for replacement

manual or additional information if required.

RYCO is not liable for injury/damage to persons/machine or property as a result of improper use, having made prohibited

modications to the machine or misinterpreting this manual’s safety instructions.

The machine is transported on a pallet, which is easy to move and lift with a fork-lift truck. After unpacking, the machine should be

lifted using an approved, appropriately rated lifting sling.

Warranty

The warranty lasts one (1) year from purchase and only under the strict condition that the manual instructions have been followed.

The warranty covers defected material/parts and awed workmanship, replacing defected parts cost.

The warranty does not cover improper use or normal wear. Travel costs, time for repair and shipping costs are not covered by the

warranty. Repairs under the warranty are to be made only by RYCO or an authorized service technician approved by RYCO.

Lost income or extra costs that may arise for any reason are not covered by the warranty.

Please contact RYCO to discuss warranty claims.

3MOBILE AND WORKSHOP SERIES OPERATION MANUALOctober 2018 | Version: v1-0

CHECKLIST

GENERAL

Pre-Delivery Checklist

Pre-Commencement Inspection

RY20C/RY32C RY20CB/RY32CB

Crimper wrapped in plastic and packed in a

suitable box for Air & Sea freight

Crimper wrapped in plastic and packed in a

suitable box for Air & Sea freight

Grease Cartridge RY20CB or RY32CB Crimper complete with

base/die storage

Grease Application Tool Foot Pedal

Technical User Manual Grease Cartridge

Manual Change Tool Grease Application Tool

Die Pins Technical User Manual

Back Stop

Quick Change Tool

Manual Change Tool

Die Pins

Die Sets

RY20

Included Dies

RY32

Included Dies

Optional Dies

If Ordered

14mm 63mm 7mm

16mm 69mm 10mm

19mm 74mm 12mm

22mm 78mm

26mm

30mm

34mm

39mm

45mm

Before using the crimper for production, this checklist should be performed using procedures outlined herein.

Check RYCO logo, safety labels and Crimp Chart decals are attached.

Grease cone-shaped surfaces in the cylinder.

Check for no abnormal noise during operation across full range of motion.

Check all dies are supplied and appropriately numbered.

Check calibration as per calibration procedure.

RYCO recommend a risk assessment be performed by the end-user prior to installation and use.

4MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 | Version: v1-0

SAFETY RULES

GENERAL

These Hydraulic Crimping Machine are for crimping hydraulic hose and couplings made by RYCO Hydraulics. The design &

construction of this machine conforms to local and safety design standards.

Industry Standard Year Title Standard Description

DIN EN ISO 12100-1 2004 Safety of machinery Safety of machinery. Basic concepts, general principles for

design basic terminology, methodology.

DIN EN ISO 12100-2 2004 Safety of machinery Safety of machinery. Basic concepts, general principles for

design. Technical principles.

EN 414 1992 Safety of machinery Rules for the drafting and presentation of safety standards.

EN 1050 1996 Safety of machinery Risk assessment.

EN 294 1992 Safety of machinery Safety distances to prevent danger zones being reached by the

upper limbs.

EN 982 1997 Safety of machinery Safety requirements for air power systems and components -

hydraulic.

EN 60204-1 1997 Safety of machinery Electrical equipment of machines. Part 1.

EN 61000-6-2 2005 Electromagnetic Compatibility Generic emission standard.

EN 61000-6-4 2005 Electromagnetic Compatibility Generic immunity standard.

Restriction

RYCO crimping machines are electrically operated hydraulic crimping machines for hydraulic hose assemblies. Machines are

designed for single piece and low production. The crimping machine comprises a crimping head, a hydraulic unit.

Generally, these machines will be installed under the following conditions:

1. Supply voltage: 0.9 - 1.1 nominal supply voltage

2. Source frequency: 0.99 - 1.01 nominal frequency

3. Ambient temperature: 5°C - 40°C (40°F - 104°F)

4. Altitude: shall be at altitudes up to 1000m above sea level

5. Relative humidity: not exceed 50% at 40°C (104°F)

6. Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt.

7. Avoid exposing to direct sunlight or heat rays which can change the environmental temp.

8. Avoid exposing to abnormal vibration.

9. Greased frequently.

These machines are designed for certain applications only. We strongly recommend that the machines are NOT modied and/or

used for any application other than for which they are designed. If you have any questions relative to its application DO NOT use

the machine until you have had detail instruction from your RYCO representative.

5MOBILE AND WORKSHOP SERIES OPERATION MANUALOctober 2018 | Version: v1-0

GENERAL

SAFETY

Danger Zones

General Warning Label

Pay particular attention to these items.

Crimping Hose Assembly Label

When crimping a hose assembly, hold the hose far enough away to avoid any pinch or crush zones.

No Hands Label

Do not put your hands in these areas while the motor is running.

RY20/RY32

1. The Installation site for the machine must provide an adequate clear work area around the crimper.

2. A clear area must be provided along the base dimensions of the machine that’s essential to permit efcient

maintenance and assembly.

3. Refer the Technical Data section for space requirements.

To maintain stability, leveled mounting pads should be used under the four xing points at the base of the machine.

Machine Installation

Appropriate Personal Protective Equipment (PPE) must be worn during hose making and maintenance activities.

• This equipment should only be used by qualied, trained persons who are familiar with this equipment.

• To avoid personal injury, keep hands and feet away from crimper and workpiece during operation.

• Do not exceed equipment ratings. Overloading causes equipment failure and possible personal injury. The crimper is designed

for a max. pressure of 275 bar (4,000 psi).

• Never Set the relief valve pressure above 300 bar (4,350 psi). Serious personal injury could result if this maximum limit is

exceeded. Damage to crimper pump and components may also occur.

• Keep hydraulic equipment away from ames and heat. Excessive heat will soften packings and seals, resulting in uid leaks.

Heat also weakens hose materials and packaging. For optimum performance do not expose equipment to a Temperature of

50°C (122°F) or higher. Protect hoses and cylinders from weld spatter.

Safety Notes

Hose Assembly

Should a hydraulic hose rupture, burst or need to be disconnected, immediately shut off the pump and shift the control valve

to release all pressure.

• Never grasp a leaking pressurized hose with your hands.

• Always keep the hose away from re, sharp surfaces, heavy impact and extreme heat or cold. Never kink, twist, curl or

bend the hose so tightly that the oil ow within will be blocked or reduced.

• Always inspect the hose for wear periodically, as any of these conditions can damage the hose and possibly result in

personal injury.

• Hose material and coupling seal must be compatible with the hydraulic uid used.

• Hose must not come in contact with corrosive materials.

• Never paint a coupling, hose will deteriorate due to toxic materials.

• Never use the hose to move attached crimper. Stress can damage the hose and may cause personal injury.

6MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 | Version: v1-0

SAFETY

GENERAL

1. For your safety read instruction manual before operating the machine:

Operators of this equipment must read and understood the content of the manual, be adequately trained and evidence

competence in producing hydraulic hose assemblies utilising the crimper.

2. Earth all machines:

A terminal for the connection of the external ground conductor is provided in the vicinity of the associated phase conductor

terminals marked "PE". The "PE" terminal must be connected by a suitably qualied person.

3. Work environment:

Don't use machines in damp or wet locations, or expose them to rain. Ensure working area is well lighted and ventilated.

Do not operate electrical machines near potentially explosive environment.

4. Children and visitors:

All children and visitors should be kept at a safe distance from work area.

5. PPE apparel:

No loose clothing, neckties, rings, bracelets or other jewelry which have the potential to get caught in moving parts.

Wear protective hair covering to contain long hair. Gloves should be worn while operation, cleaning and during repairs.

6. Repairs:

Be aware of fatigue. Do not operate machine when you are tired.

Please stand in front of machine for proper position operation.

7. Disposal of packing material:

Please check local environmental regulations before disposing of packing materials.

Explore recycling opportunities to avoid disposal in land ll sites.

8. Unintentional starting:

Ensure control panel switches are in the OFF position before isolating the main power supply.

Never leave the machine running unattended.

9. Maintenance:

Shut down the machine and follow the appropriate Lock Out procedures before any inspections, maintenance

and adjustment.

10. Emergency Shutdown:

The emergency shutdown button is colored red with a yellow background located on the control panel.

11. Electrical equipment:

Keep all electrical equipment dry and in a good working order.

Electrical equipment will withstand the effects of transportation and storage temperature within the range of

-25oC to 55oC (-13°F to 130°F) and for short periods (not exceeding 24 hours) up to +70°C (158°F).

12. Machine storage:

If the machine is not to be operated for a long period of time it should be stored in a dry environment with the appropriate

protection against ingress of dust and moisture. During storage, main power supply should be disconnected.

Safety Instruction

7MOBILE AND WORKSHOP SERIES OPERATION MANUALOctober 2018 | Version: v1-0

SAFETY

GENERAL

Follow procedures herein to ll the RY20 or RY32 oil reservoir with hydraulic oil the

equivalent of RYCO Hydraulic Oil 46. It is recommended to pump the oil into the reservoirs

through a 20μ lter, to avoid transferring impurities. If any oil spills, clean up immediately

with a RYCO Spill Kit.

Oil Fill

Battery and Oil

These items are governed by International shipping requirements. Generally they will not have

batteries installed and will be delivered dry. Check the oil tank and ll as required prior to use

using procedure herein.

RYCO SPILL KIT

RYCO HYDRAULIC OIL

The Master Dies are greased at the point of manufacture after nal testing. This should not be relied on to protect the crimper

during initial use. Prior to commissioning, the machine should be greased according to operating Instructions.

Greasing of the master dies is critical to ensuring a long and trouble-free life for the crimper. Greasing frequency should be

increased when operating in aggressive or high volume environments.

Greasing

Running-In

Recommended run-in period for a new machine is 20 crimps.

It is recommended the greasing process is carried out at least twice a day, more if the machine is in constant use.

The purpose of frequent greasing is to ensure that there is always enough grease between the sliding surfaces.

Due to the surface pressure the grease sinks in to the metal pores ensuring good sliding properties for the machine’s lifetime.

During the run-in period grease the machine after every 100 crimps.

8MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 | Version: v1-0

Installation of Power Supply

1. The machine should be connected to the protective-earth terminal between machine and external ground before connected

to the power source.

2. The cross-section of incoming supply protective conductor and each phase conductors must be in accordance with the

following reference of supply conductor table. It is important to identify the machines voltage requirements.

The voltage requirements should be marked on the machines electrical cabinet.

Model Recom. Fuse (400V) Supply Wire Size PE Wire Size

RY20CB 25A>FUSE>20A 5.5mm25.5mm2

RY32CB 25A>FUSE>20A 5.5mm25.5mm2

3. Power supply connection, always connect the earth conductor with yellow/green color before the connection of the other

power conductor.

4. 1-Phase: Connect the phase and the neutral to the respective terminals in the supply disconnecting device.

Connect the earth connection to the ground terminal on the xing plate. Check the connection against the wiring diagram

enclosed in the spare parts list.

5. A terminal for the connection of the external ground conductor is provided in the vicinity of the associated phase conductor

terminals with marked “PE”. ensure the “PE” terminal is connection before operating the machine.

6. 3-Phase: Connection should be made to the terminal mark L1, L2 and L3 at the connecting seat in the electrical cabinet.

As a safety measure, the door of cabinet can’t be opened unless the main switch is isolated.

7. When disconnecting the power supply, disconnect the “earth” yellow/green conductor after disconnecting the other power

conductors.

8. Always disconnect the power supply from the hand-operated isolating switch mounted on the door of electrical cabinet

before any maintenance or inspection.

9. After disconnecting the power for maintenance or inspection, be sure to lock the isolation switch in “OFF” position.

10. Check that the motor rotation is parallel with the directional arrow on the motor. If the motor rotates in the reverse direction

the incoming power phase terminals L1 and L2 need to be reverse, Please change the incoming wire L1 and L2.

RY20C-12/24V & RY32C-12/24V

1. The machine should only be connected to 12V or 24V DC

2. Connect the power as per the electric cabinet markings “+” (Positive) & “-“ (Negative)

3. Always isolate the power supply from the hand-operated isolating switch mounted on the door of electrical cabinet

before any maintenance or inspection is carried out.

4. After isolating the power for maintenance or inspection, be sure to lock the isolating switch in “OFF” position.

SAFETY

GENERAL

Caution! Power supply needs to be connected by a qualiﬁed electrician.

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