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1

MOBILE AND WORKSHOP SERIES OPERATION MANUAL

October 2018 | Version: v1-0

CONTENTS

GENERAL

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

 

CHECKLIST

 .............................................................................................................................................................................................................

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

 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

Summary of Contents for RY20C

Page 1: ...OPERATION MANUAL MOBILE AND WORKSHOP SERIES CONNECTING PARTNERSHIPS FOR MODELS RY20C RY20CB RY32C RY32CB October 2018 Version v1 0...

Page 2: ......

Page 3: ...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...

Page 4: ...cedures 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...

Page 5: ...s 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...

Page 6: ...lectromagnetic Compatibility Generic emission standard EN 61000 6 4 2005 Electromagnetic Compatibility Generic immunity standard Restriction RYCO crimping machines are electrically operated hydraulic...

Page 7: ...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...

Page 8: ...ng 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...

Page 9: ...oint of manufacture after final 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...

Page 10: ...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 do...

Page 11: ...use a competent licensed operator to lift the machine 3 Forklift should only be operated by qualified personnel 4 Before handling ensure all movable parts are secured in their positions and all movab...

Page 12: ...els RY20C RY32C 1 Do not put your hands inside the dies while the motor is running 2 When crimping a coupling keep hands away from crimping dies 3 Grease frequently 4 High voltage The electric box is...

Page 13: ...side the dies while the motor is running 2 When crimping a coupling keep hands away from crimping dies 3 High voltage The electric box is to be opened only by a qualified electrician 4 When changing d...

Page 14: ...ed equipment is changed or modified tests should be re verified and retested such as continuity test of the protective bonding circuit insulation resistance tests voltage tests protection against resi...

Page 15: ...RY32 22 22 26 0 866 1 024 70 2 16 RY32 26 26 30 1 024 1 181 70 2 16 RY32 30 30 34 1 181 1 339 70 2 95 RY32 34 34 39 1 339 1 535 75 2 95 RY32 39 39 45 1 535 1 772 75 2 95 RY32 45 45 51 1 772 2 008 90 3...

Page 16: ...button is repressed MOBILE AND WORKSHOP CRIMPERS OPERATION Installing The Die Set Quick Change RY20CB and RY32CB Die set are stored in the storage locker and installed in the master dies with a quick...

Page 17: ...with a quick change tool at one time Prior to Installation all contact surfaces of both the die set and master dies must be cleaned to avoid damage Set the crimping diameter dial at 0 0 and retract th...

Page 18: ...s 10 Semi Automatic Mode Crimping starts when the control button is pressed Once the crimp diameter is reached the dies retract back to the set position irrespective of whether the button is pressed o...

Page 19: ...e performs the crimp process and returns to the set retraction point 9 The movement stops if the fitting is not adequately pressed against the stop device If need be dies can be opened by using the re...

Page 20: ...mm inch mm inch kg lb RY20C 12V 12 DC Digital 620 24 4 500 19 6 500 21 3 120 264 RY20C 24V 24 DC Digital 620 24 4 500 19 6 500 21 3 120 264 RY20C MOBILE TECHNICAL INFORMATION PART NUMBER MAX HOSE SIZE...

Page 21: ...EPTH HEIGHT WEIGHT mm inch mm inch mm inch kg lb RY32C 12V 12 DC Digital 620 24 4 500 19 6 540 21 3 160 352 RY32C 24V 24 DC Digital 620 24 4 500 19 6 540 21 3 160 352 RY32C MOBILE TECHNICAL INFORMATIO...

Page 22: ...350 53 1 230 507 RY20CB 3 480 480 Three 3 6 4 8 Digital 680 26 7 570 22 4 1350 53 1 230 507 RY20CB 1 240 240 Single 1 8 2 4 Digital 680 26 7 570 22 4 1350 53 1 230 507 RY20CB 3 415 415 Three 3 6 4 8 D...

Page 23: ...7 570 22 4 1400 55 1 270 595 RY32CB 3 480 480 Three 3 6 4 8 Digital 680 26 7 570 22 4 1400 55 1 270 595 RY32CB 1 240 240 Single 1 8 2 4 Digital 680 26 7 570 22 4 1400 55 1 270 595 RY32CB 3 415 415 Thr...

Page 24: ...iameter of 101 2 mm The expected dimension is 99 0 mm a difference of 2 2 mm 101 2 99 2 2 To make the correction perform the following To adjust the calibration the length of the adjustment screw on t...

Page 25: ...ive Master Spring Change MAINTENANCE HOW TO MAINTAIN YOUR CRIMPER Cleaning Keep the machine clean and free from dirt particles A clean machine ensures a smooth and safe operation Wipe the machine with...

Page 26: ...tor running in wrong direction Check the 3 phase connection 2 Low oil level Fill or top up oil 3 Fuse blown Replace 4 Valve not working Check valves are free and solenoids are working 5 Dial broken Ch...

Page 27: ...C61558 2 4 SP TBSW M1 Pump motor BEFC D 1 25kW 60Hz 1 8kW 50Hz 3 6kW 60Hz 3 6kW 50Hz EN60034 1 U1 Power PCB Control PCB 32 20 24Vac 18Vac 15Vac 10Vac SB1 Emergency Stop RMQ M22 k01 Ui 500V Ith 4A Uimp...

Page 28: ...26 MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 Version v1 0 TECHNICAL ELECTRICAL SCHEME RY20CB RY32CB...

Page 29: ...TECHNICAL ELECTRICAL SCHEME Electrical Components List RY20C RY32C Item Description Manufacture Type Technical Data Standards Marking F1 Fuse Holder Legrand Fuse 1P 500V 15A 60947 7 3 F2 Fuse Holder...

Page 30: ...1 Rod Cover 3 1 Flanges 3 1 Flanges 4 1 Piston 4 1 Piston 5 1 Cylinder 5 1 Cylinder 6 16 Spring 6 16 Spring 7 8 Pin 7 8 Pin 8 8 Screw 8 8 Screw 9 8 Locking Pin 9 8 Locking Pin 10 8 Capped Pin 10 8 Ca...

Page 31: ...lic Pipe 8 1 Return Pipe 9 1 Return Pipe 10 1 Oil Passage Board 11 1 Nipple 12 1 Nipple 13 1 Insert Type Pilot Operated Check Valves X833033 14 1 Insertreducing Valves 9CT6 CMR 09230 15 1 Insertreduci...

Page 32: ...2 2200W 3CC REV 5L 2 1 Control Panel 3 1 Hydraulic Pipe 4 1 Return Pipe 5 1 Breather Filters 2GG1P07R 6 1 3 4 Solenoid Operated Valve 1 4 RY20 WE 3C6 02G D1 30T DC12V RY32 WE 3C6 02G D2 30T DC24V 7 1...

Page 33: ...31 MOBILE AND WORKSHOP SERIES OPERATION MANUAL October 2018 Version v1 0 TECHNICAL ASSEMBLY Assembly of RY20C 32C...

Page 34: ...TROUBLESHOOTING 1 Master die detachment Select manual mode on the control panel and retract dies to the maximum open position 4 Confirm the main dies are in the home position as shown 3 Use the manual...

Page 35: ...CHNICAL MASTER DIE MISALIGNMENT TROUBLESHOOTING 6 Ensure the Master dies and dowel pins are in the correct position In manual mode slowly close the master dies Note Special attention is required at th...

Page 36: ...SHOOTING 7 Complete initial testing and then grease the main dies and cone 8 If the Die Springs or the Dowel Pins are too badly damaged to the extent the master dies cannot be aligned correctly the ma...

Page 37: ......

Page 38: ...217 Richmond Road Richmond SA 5033 BRISBANE 97 Northlink Place Northgate QLD 4013 BLACKWATER 6 Jarrah Street Blackwater QLD 4717 NEWCASTLE 14 Ironbark Close Warabrook NSW 2304 PERTH 47 Tacoma Circuit...

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