RC50 service manual - argus realcold pty limited
Contents
1. Intensifier oil found to be dirty e ntensifier oil found to be water contaminated Following the discovery of any of these occurrences the intensifier must be removed from service stripped and thoroughly assessed for damage 16 Appendix 3 Conversion to Single Acting Hydraulic WARGUS lt REALCOLD LIMITED Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz Conversion to Single Acting Hydraulic The RC50 may be easily converted to single acting hydraulic for use with the RC20 hand tool It may also be supplied configured as single acting hydraulic Please orderas RC50 2010 Air Oil intensifier anti tiedown To convert an existing unit 180 KQE08 00 X2 180 KQ2P 08 800 T U0805 BU 1 Disconnect the external blue pneumatic hose 800 TU0805 BU from the fitting 180 KQ2E08 00 X2 and remove it 2 Take the plastic pneumatic plug 180 KQ2P 08 supplied with the commissioning kit and insert it into the fitting KQ2E08 00 X2 Connect to the RC20 hand tool and test for correct operation VARGUS WWAT FATP LIMLTEUD Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz 18 Appendix 4 Recommended Spare Parts WARGUS lt REALCOLD LIMITE2. push the piston rod assembly back in the hand piece to the at rest position The movement of the piston rod assembly now pulls the blades via the cam links to the open position The operating cycle is now complete Servicing Before any servicing is attempted on this tool disconnect and unplug from air supply All hydraulic hoses and air supply hoses must be disconnected to render the tool inoperative according to Occupational Safety amp Health requirement Intensifier Disassembly Before starting please make sure that the intensifier is clean and that you have a suitable work area available A container will help prevent small parts from being lost or damaged 2 10 11 12 Remove the front door panel Raise the hydraulic coupler above the oil reservoir and unscrew from the hydraulic hose Using a suitable container to catch the oil lower the end of the hydraulic hose and drain all oil from the unit Disconnect the paired red green airline from the fittings outside of the cabinet Disconnect the blue airline from the fitting outside of the cabinet Unscrew the hydraulic hose from the nipple and store for later use Unscrew the nipple and put it into the parts container Disconnect the airlines from inside of the cabinet The 12mm air supply fitting will need to be removed Unscrew the four 8mm nuts securing the gear plate inside the cabinet and put them into the parts container Lift the gear plate
3. ALOOLD LIMITED AIR OIL INTENSIFIER ANTI TIEDOWN AIR RETURN RC50 3410 JS Me i wy ITEM NO QTY PART NO DESCRIPTION 1 1 110 502102 A PNEUMATIC CYLINDER BODY 2 1 110 502103 A PNEUMATIC CYLINDER END PLATE 3 1 110 502104 A PNEUMATIC CYLINDER BASE PLATE 4 1 110 502105 A SEAL KIT 5 1 110 502106 A HYDRAULIC CYLINDER SEAL CARRIER 6 1 110 502107 A HYDRAULIC CYLINDER SEAL SPACER T 1 110 502108 A HYDRAULIC CYLINDER BODY 8 1 110 502109 A PNEUMATIC CYLINDER PISTON 9 1 110 502110 A HYDRAULIC CYLINDER PISTON ROD 10 1 110 502111 A HYDRAULIC CYLINDER RETAINING PLATE 11 1 110 502112 A NYLON WASHER 12 2 110 502113 A 20mm WASHER 13 1 110 502114 A 20mm NUT 14 8 800 FWM12 304 M12 FLAT WASHER 15 4 800 HBM12210 304 M12x210 HEX BOLT 304 S S 16 4 800 ANM12 304 M12 ACORN NUT AB e o Ng cc i LY D a K WARGUS N REALCOLD LIMITED RC50 HYDRAULIC ACCUMULATOR COMPLETE 110 502101 A TARGUS ww Date REALGOLOD LIMITED Tool 9 Prescott Street Ph 09 526 5757 Serial Number PO Box 12 519 Fax 09 526 5755 Penrose Auckland argord realcold co nz New Zealand Customer Order Form Name Address Phone Contact Person _ 0 _ j 1 Shipping Instructions Ship to Address Attention Level of Urgency Normal _ Urgent 13 Appendix 2 Maintenance WARGUS WWAT FATP LIMITED Argus Realcold Lt
4. Air Oil Intensifier Imported by Designation Model No Type Height Width Depth Weight Hydraulic Circuit Pneumatic Circuit Serial No Test Date Manufacture Date Manufactured By Licensed distributor Specifications Air Oil Intensifier RC50 3410 5 0mm 500mm 22mm 35 33Kg Supplied 157Bar 2200Psi Shell Helix ATF 111 or equivalent 6 5 7 85Bar 90 110Psi Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Ph 64 9 526 5757 Fax 4649 526 5755 TABLE OF CONTENTS SAFETY INSTRUCTIONS NOTICE TO OPERATORS INSTRUCTIONS FOR COMMISSIONING SERVICE SECTION Principle of Operation Cutting Cycle Opening Cycle Servicing Intensifier Disassembly Servicing Intensifier Assembly APPENDIX 1 Intensifier Parts List Intensifier Parts Diagram Intensifier Parts Diagram Detail Hydraulic Accumulator Assembly Order Form APPENDIX 2 Maintenance Check Daily Routine Maintenance APPENDIX 3 Conversion to Single Acting Hydraulic APPENDIX 4 Recommended Spare Parts APPENDIX 5 Circuit Schematic VARGUS LINTLTEL uh NOOK CO N Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz Issue Date 19 1 2005 Revision Number 1 1 Revision Date 19 6 2006 SAFETY INSTRUCTION
5. Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz LY A REALGOLD LIMITED AIR OILINTENSIFIER RC50 3410 p 3 ah wa va ANTI TIEDOWN AIR RETURN DESCRIPTION HYDRAULIC ACCUMULATOR COMPLETE RESERVOIR END PLATE RESERVOIR BODY 110502707 170 508104 170 508109 170 508110 CABINET 1 170 5081 10 2 A GEAR PLATE 2 170 508110 3 A CABINET HINGE MALE 2 170 508110 4 A CABINET HINGE FEMALE 1 170 508110 5 A CABINET DOOR 2 170 508110 6 A CABINET DOOR LOCK 170 508110 7 A CABINET DOOR SEAL 4 800 FWM8 304 M8 FLAT WASHER 4 800 NM8 304 M8 HEX NUT 304 8 800 FWM6 304 M6 FLAT WASHER 800 SWM6 304 SPRING WASHER M6 304 800 BHM610 304 M6x10 BUTTON HEAD SCREW 304 180 2102007 ZP 3 8 BSP HEX NIPPLE 6 1 180 400006 MALE FEMALE RUN TEE 180 A A 06 06 STRAIGHT NIPPLE 3 8BSPT 8 1 180 AN101 01 SILENCER BRONZE 1 8BSP 9 5 180AN30003 SILENCER 180 KQ2F12 03 FEMALE UNION 12mm 3 8BSP 180 KQ2H04 01S STRAIGHT CONNECTOR 4mm 1 8BSP 180 KQ2H06 03S STRAIGHT CONNECTOR 6mm 3 8BSP 180 KQ2H10 02S STRAIGHT CONNECTOR 10mm 1 4BSP 180 KQ2H10 03S STRAIGHT CONNECTOR 10mm 3 8BSP 180 KQ2H12 U03 STRAIGHT CONNECTOR UNI THREAD 12mm 3 8BSP 180 KQ2L08 12 REDUCING ELBOW 180 KQ2L12 U03 ELBOW CONNECTOR UNI T
6. D Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz Recommended Spare Parts The following is a list of spare parts that we recommend your engineering department to keep in stock at all times Having these parts on hand will assist you to maintain your tool in good working order and ensure that you avoid down time while waiting for parts delivery should your hand tool require repair This list is a minimum recommendation for parts to support one unit in the field Where more than one tool is in service quantities held in stock should be adjusted accordingly 1 F 0 800 HYD06 2 5 HYDRAULIC HOSE 3 8 X 2 5M 800 TU0805 BU 8MM POLYURETHANE TUBE In addition to these items we recommend that a minimum 20 Litres of automatic transmission fluid ATF be held on site NUN LM 180 AN300 03 3 8BSP SILENCER WARGUS VA P L6arn LIMITED V Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz 20 Appendix 5 Circuit Diagram WARGUS WWAT FATP LIMITED Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz 21 I 4O I 1ddHS 25 A
7. HREAD 12mm 3 8BSP 180 KQ2LU12 03S BRANCH UNION ELBOW 12mm 3 8BSP 180 KQ2X04 06 BRANCH Y REDUCER 180 KQ2Y12 U03 MALE RUN TEE 180 KQE04 00 X2 BULKHEAD UNION 180 KQE08 00 X2 BULKHEAD UNION 180 KQE12 00 X2 BULKHEAD UNION 180 QVV F06 HYDRAULIC COUPLER FEMALE 180 QVV M06 HYDRAULIC COUPLER MALE 190 2781580101 PNEUMATIC LOGIC VALVE 190 81532001 PNEUMATIC LOGIC VALVE BASE 190 AQ3000 03 QUICK EXHAUST VALVE 190 VS2 2 A03 PNEUMATIC VALVE MANIFOLD 190 VSA7 8 FG S 1 ISO AIR PILOT VALVE 800 2 MP 4 4MM POLYURETHANE TUBE PAIRED 800 CSM535 304 CAP SCREW M5x35 304 800 CSM620 304 CAP SCREW M6x20 304 800 CSM650 304 CAP SCREW M6x50 304 800 CSM820 304 CAP SCREW M8x20 304 800 FWM5 304 M5 FLAT WASHER 37 6 800 FWM6 304 M6 FLAT WASHER 800 FWM8 304 M8 FLAT WASHER 800 HYD06 2 5 HYDRAULIC HOSE 3 8 X 2 5M 800 SWM5 304 SPRING WASHER M5 304 6 800 SWM6 304 SPRING WASHER M6 304 800 TU0425 R 4MM POLYURETHANE TUBE 800 TU0805 BU 8mm POLYURETHANE TUBE 800 TU1065 BU 10mm POLYURETHANE TUBE 800 TU1208 BU 12mm POLYURETHANE TUBE AIR OIL INTENSIFIER ANTI TIEDOWN AIR RETURN RC50 3410 AVAHGUS VA sere LL wl TEDD iM z J UM i a y F S amp y x j ce a p e j 2 S e i L 1 gt 1 g j E 2 H bi j am h q e c uro ur DHA Som y ad y NINE E m lx Nm SEE DETAIL TET WE me gt Se _ L V ARGUS JA AE
8. NVdWOD 3HL 4OLN3SN OO JHL i INOHUM Abivd AL NO OIIVMT Nd OI1TYHQAH V G H3dNIT1A9 1001 GNVH v Jul Lcd SI aa Ndr1 d SNIHdS dN N Z E S3HOLIMS 9NILVHddO ee E JHLSI LN3IACIO OG SIHL LH OldAd O2 2950 0 NOILON d ANV 4A 1VA 219071 E GINS OnvadAH OS Tod esta OHnvdQAH W S H3dNI AO 3AV1S IN Vd OVIG_LINDYID OLLYND3Nd V d H3dNITA9 1SV HOLVINNNOOY FUL qO ON IMVd 3LVd JJnLVN IS 3INVN NH YLaH ONIYdS o G JAIVA ONILVHa3dO JA SU NOLLdIHOS3Q WALI nalla V uvaNr Sollee V NOSIAZY DNIMVMG HIV2S LON OG angaq HSIN CBHIO3e5 SMHBHLO STINN d 1Vd ISd0006 BdAO LZ GI UMUG 6 210 ISOH OFINVYGAH JO0C SOH Ol INVYCAH d ISdOOL JEd 9 AlddNS OLLVND3Nd
9. PERATORS STOP stop using a defective or malfunctioning tool immediately Report the problem or defect immediately to your supervisor for removal of tool from service Do not attempt to make repairs yourself do not tamper with a defective or malfunctioning tool Do not attempt to free a jammed or blocked tool yourself Remove power from the tool when the tool is left unattended or is not in use Never tie down bypass or alter the triggers or safety switches of the tool Wear safety glasses when operating this tool Do not activate switches of the tool unless you intend to operate and use the tool Do not allow unauthorised individuals to operate the tool Never place fingers hands or other parts of your body in the cutting path of the tool Q This tool is capable of causing severe injury or death if misused CLEAN UP PERSONNEL Shut off all power and disconnect all hydraulic and air hoses from the tool before performing clean up A Take extreme care near sharp blades MAINTENANCE PERSONNEL Shut off all power and disconnect all hydraulic and air hoses from the tool before making repairs performing maintenance and before replacing or sharpening blades Do not use substitute parts o use other than genuine Argus Realcold brand parts Q Use extreme care when testing or operating the tool VARGUS A EALGOLD LIMITED Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Ph
10. S FOR REALCOLD HAND TOOLS As a designer manufacturer and supplier of plant and equipment Argus Realcold Ltd has provided plant equipment and all relevant information to ensure the safe use in accordance with the New Zealand Health and Safety in employment Act 1992 The CE marked machines provided by Argus Realcold Ltd also meet the EC machinery directive 98 37 EC and any other relevant EC directive It is the responsibility of the owner to ensure that the machine is used safely in accordance with the instructions andfor the purpose that the machine was designed for The hand tools that we supply with the exception of the RC33 are designed for two handed operation and include the following RC20 Sheep Light Duty Scissor RC21 Sheep Hock Cutter Various blade options available RC22 Hydraulic Sheep Hock Horn Neck Cutter RC25 Hydraulic Heavy Duty Sheep Goat Deer Hock Horn Cutter RC30 Hydraulic Beef Hock Horn Cutter Hog Head Cutter Various blade options available RC31 Pneumatic Sheep amp Lamb Brisket Opener RC33 Pneumatic Wool Shear RC35 Hydraulic Beef Loin Head Cutter Various blade options RC45 Hydraulic Heavy Duty Beef Horn Cutter RC50 Air Oil Intensifier WARGUS MAPD r See LABA4LTEUD Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz NOTICE TO OPERATORS MAINTENANCE AND CLEAN UP PERSONNEL O
11. d PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz 14 Maintenance Please read this section thoroughly and make sure that these maintenance checks are carried out routinely as specified Adherence to this maintenance schedule will ensure that you enjoy long and trouble free service from your hand tool Before any servicing is attempted on this tool disconnect and unplug from air supply All hydraulic hoses and air supply hoses must be disconnected to render the tool inoperative according to Occupational Safety amp Health requirement Check Daily 1 2 ra 8 Clean the intensifier thoroughly before inspecting Visually inspect the intensifier for any obvious damage to components and for loose components Anything that you find at this stage must be remedied immediately The intensifier may need to be removed from service to affect remedy Check that the silencers are in good condition If they are damaged the intensifier will be excessively noisy to operate If they are very dirty they may restrict exhaust flow and cause the tool to operate slowly Look for oil in the pneumatic return line If there is oil present then the hand tool piston seals are bypassing and must be replaced This can occur when the hand tool is left submerged in a dunk type steriliser for an extended period Look for aeration of the
12. hly and reassemble Take the seal carrier and remove the two seals and two O Rings lf the seals and or O Rings are swollen or perished then replace them Check the seals for wear or damage to the lips If they are worn or damaged then replace them Clean all parts thoroughly and reassemble Check the piston for swelling perishing abrasion or other damage If it is worn then replace it Small nicks or damage to the piston rod can be polished out with fine 240 grit or finer wet and dry sandpaper Take care not to leave any flat spots Check the pneumatic seal in the front end plate for wear or damage If it is swollen or perished then replace it If wornor damaged then replace it Inspect the cylinder body for wear If it is worn or damaged then replace it Surface finish can be restored by honing lightly Reassemble the booster assembly Make sure that the fitting on the side of the hydraulic cylinder is facing towards the quick exhaust valves Check all hoses for abrasion or other damage Replace as required Intensifier Assembly Before starting make sure that all parts are clean and free of oil and grease 1 2 10 11 Reassemble the air pilot valve onto its manifold Mount the booster assembly onto the gear plate using the four cap screws removed earlier Push the 12mm airlines from the demand valve into their fittings on the booster assembly Lift the gear plate with the booster assembly attached into
13. oil in the reservoir If the oil has air bubbles forming in it continuously then the pneumatic seal in the accumulator is leaking and must be replaced If the air is becoming aerated in use then the quad ring piston seal in the hand tool may be worn require replacement Check the oil level in the intensifier reservoir where applicable It should be between 1 2 and 34 full Refill as necessary Check the oil for colour and cleanliness at the same time If the oil has a milky appearance then it is water contaminated and must be changed immediately Refer to your intensifier manual for instructions Heconnect the hand tool and check that all couplers and fittings are tight Heconnect the air supply and test for correct operation These checks are to be performed on a daily basis or prior to the start of each shift where more than one shift operates each day 15 Routine Maintenance Except where daily checks require replacement of wear items the intensifier should be fully stripped and serviced once every six months Wear items that should be replaced at this six month service are e 110 502105 A seal kit e 180 AN300 03 3 8BSP Silencer All other components should be assessed for serviceability at this time and replaced as necessary as per the servicing instructions in the service section of this manual Other factors which may necessitate a full service prior to this six month interval include but are not limited to e
14. ol it is important to understand how this tool operates While being very simple understanding the principles of operation and their interaction will assist you to maintain the tool to optimum working efficiency Fault diagnosis and repair will also be greatly simplified Principle of Operation Cutting Cycle Operating valves are depressed supplying a positive air pressure signal to the pilot of the intensifier demand valve The pilot pressure shuttles the valve allowing main supply air pressure to fill the accumulator master chamber Pressure in the accumulator assembly master chamber causes the pneumatic piston to move thus applying pressure to the hydraulic piston and in turn to oil in the hydraulic cylinder This hydraulic pressure then acts on the piston rod assembly in the hand tool and causes the piston rod assembly to move The movement of the piston rod assembly is now transmitted to the blades via cam links and the blades close Hydraulic pressure will build to 138 bar 2000 PSI as soon as cutting pressure is exerted causing the blades to cut through the animals appendage Opening Cycle Operating valves are released allowing the positive air pressure signal to vent through the valve exhaust port Demand valve returns to it s at rest position and air pressure is applied to the pneumatic piston causing the hydraulic piston to be retracted Pneumatic pressure is applied to the front of the piston rod assembly to
15. one 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz RC50 INTENSIFIER INSTRUCTIONS FOR COMMISSIONING Mount securely near the operating station with the hose hanging down from the bottom of the cabinet Choose a location where the unit will be away from water spray and other contaminants and close to an air supply Remove the plug from the oil reservoir and screw in the silencer supplied loose for shipping Install a water trap and shut off valve tap near the unit and connect the air supply to the unit with a length of 12mm hose Try to keep the hose short as excess length will reduce air flow to the unit Mount hand tool onto a spring balancer at the operating station and connect the hydraulic hose to the coupling at the rear of the hand tool Connect the blue 8mm air line to the fitting near the tool handle Trim to length as required Connect the paired red green 4mm hoses to the hand tool red to red green to green Trim to length as required Turn on the air supply to the unit The tool is now ready to be operated Operate the tool a few times to purge any air from the hand tool The unit is now ready for service VARGUS REALGOLD LIMITED A Argus Realcold Ltd PO Box 12 519 9 Prescott Street Penrose Auckland New Zealand Phone 64 9 526 5757 Fax 64 9 526 5755 Email argord realcold co nz www argus co nz SERVICE SECTION Before servicing this to
16. the cabinet Apply Loctite 569 hydraulic sealer to one end of the nipple and install into the hydraulic cylinder Secure the gear plate into the cabinet with the four 8mm nuts removed earlier Push the 10mm hose from the reservoir into the fitting on the hydraulic cylinder Push the 4mm airlines into their fittings and the 8mm airline Push the 12mm airlines into their fittings also Take the hydraulic hose and screw the flare fitting onto the nipple at the bottom of the hydraulic cylinder Push the 4mm hoses into their fittings making sure that they are connected to the correct hoses inside red red green green Push the 8mm airline into its fitting Apply a small amount of Loctite 569 hydraulic sealer to the threads at the end of the hydraulic hose ocrew the female hydraulic coupler onto the hose Fill the unit with automatic transmission fluid A hose from a 20ltr container with a male coupler at the end makes this easy Place the container on a shelf above the unit and connect the two hoses The gravity feed effect bleeds any air from the unit as it fills Install the shipping plug into oil reservoir The silencer should not be reinstalled until the unit is returned to its operating station Check the parts container and bench for any missing parts now Your RC50 intensifier is now ready to be returned to service Appendix 1 Parts Diagram and Ordering Form WARGUS VAP r See LABA4LTEUD Argus Realcold Ltd PO
17. with all of the equipment still attached out through the opening at the front of the cabinet Unscrew the four cap screws securing the air pilot valve to the manifold and put them into the parts container Unscrew the four cap screws securing the booster assembly to the gear plate and put them into the parts container Unscrew the four lock nuts from the bottom of the booster assembly and put them into the parts container Unscrew the four through bolts and put them into the parts container Lift the rear end plate from the assembly followed by the cylinder body Withdraw the piston and rod from hydraulic cylinder and put them onto the bench Lift the front end plate from the hydraulic cylinder Withdraw the spigot and seal carrier carefully from the hydraulic cylinder and put them onto the bench The intensifier is now disassembled ready for inspection and servicing Servicing 1 2 10 11 Clean all parts thoroughly Visually inspect all parts for signs of wear or damage Unscrew the pilot valve cover Remove the gasket and push the spool and plastic button out of the valve body lf the gasket or O Rings are perished or swollen then replace them Clean all parts thoroughly Reassemble the valve using a lightweight lubricant such as air tool oil Unscrew the four screws from the quick exhaust valve and separate into two pieces If the rubber diaphragm is perished or swollen then replace it Clean all parts thoroug
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