RYCO MINI CRIMPER Series User manual

OPERATION MANUAL
MINI CRIMPER SERIES
CONNECTING PARTNERSHIPS
FOR MODELS:
RY16 October 2018 | Version: v1-0

1MINI CRIMPER SERIES OPERATION MANUAL
CONTENTS
GENERAL.................................................................................................................................................................................2-6
GENERAL INFORMATION................................................................................................................................................................ 2
Warranty .......................................................................................................................................................................................2
CHECKLIST .....................................................................................................................................................................................3
Pre-Delivery Checklist ...................................................................................................................................................................3
Pre-Commencement Inspection.....................................................................................................................................................3
SAFETY RULES ............................................................................................................................................................................4-6
Danger Zones ...............................................................................................................................................................................5
Safety Notes .................................................................................................................................................................................5
Equipment.....................................................................................................................................................................................5
Battery and Oil ..............................................................................................................................................................................6
Oil Fill ...........................................................................................................................................................................................6
Running-In ....................................................................................................................................................................................6
Greasing .......................................................................................................................................................................................6
OPERATION ........................................................................................................................................... 7-12
RY16 MINI CRIMPER.......................................................................................................................................................................7
Start Up ........................................................................................................................................................................................7
Selecting the Die Sets and Setting the Crimp Diameter.................................................................................................................. 7
Crimp Range Chart .......................................................................................................................................................................8
Operating the RY16.......................................................................................................................................................................8
Crimping .......................................................................................................................................................................................8
Changing the Die Set on RY16 ...................................................................................................................................................... 8
Maintenance .................................................................................................................................................................................8
HYDRAULIC HAND PUMP ................................................................................................................................................................... 9
Operating Instruction .....................................................................................................................................................................9
Installation ....................................................................................................................................................................................9
Pump Operation .......................................................................................................................................................................... 10
Operating the Pump .................................................................................................................................................................... 10
Maintenance ............................................................................................................................................................................... 11
Hydraulic Hand Pump Troubleshooting ........................................................................................................................................ 12
SPECIFICATIONS...................................................................................................................................... 13
AIR/HYDRAULIC PUMP SPECIFICATIONS....................................................................................................................................... 13
Operation .................................................................................................................................................................................... 13
CALIBRATION ........................................................................................................................................... 14
RY16 Mini Crimper Calibration .................................................................................................................................................... 14
RY16 Mini Crimper Troubleshooting ............................................................................................................................................ 14
PREVENTATIVE MAINTENANCE.......................................................................................................... 15-17
Cleaning....................................................................................................................................................................15
Lubrication/Greasing ................................................................................................................................................................... 15
Oil Change.................................................................................................................................................................................. 15
Master Spring Change................................................................................................................................................................. 15
Spare Parts............................................................................................................................................................................ 16-17

2MINI CRIMPER SERIES OPERATION MANUAL
GENERAL INFORMATION
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.
GENERAL

3MINI CRIMPER SERIES OPERATION MANUAL
CHECKLIST
GENERAL
Pre-Delivery Checklist
Pre-Commencement Inspection
RY16
Crimper wrapped in plastic and packed in a
suitable box for Air & Sea freight
RY16 Crimper complete with
Quick Release Coupling
Tube of Grease
Technical User Manual
Grease Application Brush
Die Box
Die Sets
RY16
Included Dies
Optional Dies
Included Ordered
14mm 7mm
16mm 10mm
19mm 12mm
23mm
27mm
31mm
37mm
Before using the crimper for production, this checklist should be performed using procedures outlined herein.
Insert 9V Battery (not included) in battery holder.
Push red test button to check battery power and LED crimp light illuminates.
Check RYCO logo, safety labels and Crimp Chart decals are attached.
Check operation of Vernier Crimp dial.
Grease cone-shaped surfaces in the cylinder.
Connect Hand Pump or Air/Hyd. Foot Valve pressurise crimper to check for no oil leaks.
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.

4MINI CRIMPER SERIES OPERATION MANUAL
Always ensure that the minimum standards for safety, installation and operation are complied with before operating the machine.
Observe the surrounding environmental conditions such as temperature, humidity, lighting, vibrations, dust and other conditions
at the machine operation site. Never remove the machine’s information or warning plates. Contact an authorized RYCO
representative for replacement plates if they become unreadable.
The use of any spare parts not directly authorized by RYCO or any changes/modications (however insignicant) made to your
machine without authorization. Releases RYCO from any liability or warranty whatsoever.
Always dispose of operation waste in accordance with current local laws and regulations.
GENERAL
SAFETY RULES
Use only original RYCO die sets in your RYCO crimping machines. Installing and using third party die sets will be solely at
users own risk and void any warranties, and all liability on RYCO’s behalf.
Read the instructions thoroughly for secure, safe and correct operation of machines.
The equipment described in this manual is intended for professional use. It is to be operated only by a trained operator
who has demonstrated competence in the operation of the machine and hose making procedures. The machine is
designed to operate in clean, dry conditions with sufficient illumination. Openings between the die segments exceed 6
mm, the dies are deemed to be an exclusion zone as outlined in RYCO Work Instruction RH-WI-101 Safe Operation of
Crimping Machines. Refer to Figure 1 below.
The covers and guards are designed to protect the operator from injury and should not be removed.
It is recommended to use appropriate protective eyewear, gloves and safety shoes during operation and maintenance.
Figure. 1 - Crimper Zones
Pinch Point
Pinch Point
Front of Die Set
Front of Crimp Head
1/2 D
D
Rear of Die Set
30mm
Exclusion
Zone
Caution
Zone
Front View

5MINI CRIMPER SERIES OPERATION MANUAL
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.
SAFETY RULES
RY16
The machine consists of a chassis, crimping head and is delivered ready to use, packed in a wooden box on a pallet.
To ensure a safe and practical work environment the machines should be located in an area that provides
• Adequate working space around the machine
• Sufcient lighting of the work area.
Equipment
GENERAL
The RYCO RY16 Crimper is designed for a max input pressure of 700 bar/10,000 psi. Do not exceed this input
pressure.
Appropriate Personal Protective Equipment (PPE) must be worn during hose making and maintenance activities.
• This pump 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 700 bar (10,000 psi).
• Never Set the relief valve pressure above 725 bar (10,500 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.

6MINI CRIMPER SERIES OPERATION MANUAL
Follow procedures herein to ll the RY16-HP or
RY16-AP 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
GENERAL
SAFETY RULES
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.
Friction
Pressure Heat
Impurity
Time
Volume
Recommended Greasing Time
Greasing
Running-In
Recommended run-in period for a new machine is 2 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.

7MINI CRIMPER SERIES OPERATION MANUAL
Selecting the Die Sets and Setting the Crimp Diameters
Each machine has a table attached that indicates the crimping range for every die set.
Crimping diameter is controlled and set by the vernier dial control in Figure 2 & 3.
Turn the vernier dial so that the zero (0) on the dial is lined-up with the zero (0)
on the scale.
If zero (0) is set, the machine will crimp the smallest diameter shown in the table
for that die set.
Every revolution of the dial increases the value on the scale one unit.
One turn clockwise corresponds to 1mm on the crimping measurement.
The measurement is added to the smallest diameter the die set is capable
of reaching.
Example: A 16 mm nished crimp dimension requires die set size 16 with the
vernier dial set to zero (0) and lined up with zero (0) in the window.
A 22.2 mm nished crimp dimension requires die set size 19 with the vernier dial
turned 3 (three) clockwise rotations until 3 (three) on the scale and the 2 (two)
on the dial is lined up with the zero (0) line on the scale.
The set crimping measurement values can differ slightly from the actual
crimping measurement because the machine’s die expansion and retraction.
Compensate this by adjusting the setting.
Refer to Figure 3 for information.
Figure 3: Vernier Scale
RY16 MINI CRIMPER
OPERATION
Machine Placement
Place the machine and pump on a stable and at surface
with adequate work space, and away from any hazards.
Selecting Dies
Determine the crimping dimensions for the hose assembly
and select the die set with the correct range that
corresponds with the required nished crimp diameter.
Selecting the die set within the correct range will achieve
the best crimping results. Every die is marked with the
smallest crimping measurement in the range.
Note!
Crimping outside the range is not recommended. Using
dies that are too small risks the ferrule becoming oval and
the hose assembly not performing as expected.
Start Up
Test Light
Vernier Crimp Settings
Figure 2: RY16 Mini Crimper
Scale
Control
knob

8MINI CRIMPER SERIES OPERATION MANUAL
0
0 turn 1 turn 2 turn 3 turn 4 turn 5 turn 6 turn 7 turn
16-10 10 11 12
16-12 12 13 14
16-14 14 15 16
16-16 16 17 18 19
16-19 19 20 21 22 23
16-23 23 24 25 26 27
16-27 27 28 29 30 31
16-31 31 32 33 34 35 36 37
16-37 37 38 39 40 41 42 43 44
USE NEXT SIZE
DIE SET
8
6
4
2
7
5
3
1
0
0
8
6
4
2
7
5
3
0
8
6
4
7
5
3
0
2
1
8
6
4
7
5
3
8
6
7
5
0
4
8
6
7
0
8
7
0
5
6
8
0
7
RY16 MINI CRIMPER
1. Select relevant die set and install into crimper.
2. Ensure that all dies are correctly installed in the crimper
3. Press red test button to ensure LED crimp light illuminates.
4. When the die set is inserted in the machine and the crimping measurement set, place the hose and coupling
assembly between the dies.
NOTE: For clearance and performance reasons, RYCO recommends crimping be performed with the
coupling positioned with its termination/connecting end protruding out of the front of the crimper.
5. Pressurise the RYCO hand pump (see page 10 for detailed pump instructions) or activate the air/hydraulic foot
valve to commence crimping the coupling.
6. The crimping diameter is reached when the red LED crimp light is illuminated.
7. Remove the hose assembly from the crimper after depressurising the hand pump or hydraulic foot pump (see
page 10 for detailed pump instructions).
8. Ensure that the crimp dimension is correct and make adjustments if necessary.
Operating the RY16
Changing the Die Set on RY16
1. Retract the crimper completely by depressing the hand pump or foot valve.
2. Isolate the airline from the foot valve to ensure the crimper cannot be activated.
3. Remove each crimp die segment by turning it in either direction or pulling it towards the centre of the crimper.
4. Ensure crimper master dies surfaces are clean and free of any debris.
5. Ensure that the die set to be installed are clean, undamaged and that all are marked with the same number.
6. With the die marking numbers facing the front of the crimper, insert each die so that the die pin engages with the
mating die pin hole in the crimper master die.
7. Ensure that all dies are correctly inserted in the machine.
Maintenance
The machine should be cleaned and lubricated every eight (8) operation hours. Retract the dies to lubricate. Use a
small brush to lubricate the cone shaped surfaces in the cylinder. Lubricate sparingly and often. Without lubrication, the
machine loses power and you will damage the sliding surfaces.
Refer to preventative maintenance section for maintenance requirements.
OPERATION
CRIMPING RANGE DIE LENGTH
Die Set mm inch mm inch
RY16-07 7-10 0.276-0.394 60 2.36
RY16-10 10-12 0.394-0.472 60 2.36
RY16-12 12-14 0.472-0.551 60 2.36
RY16-14 14-16 0.551-0.630 60 2.36
RY16-16 16-19 0.630-0.748 60 2.36
RY16-19 19-23 0.748-0.905 60 2.36
RY16-23 23-27 0.905-1.062 60 2.36
RY16-27 27-31 1.062-1.220 60 2.36
RY16-31 31-37 1.220-1.457 60 2.36
RY16-37 37-44 1.457-1.772 60 2.36
Figure 4: Die Size and Crimp Range Chart
Crimp Range Chart