Wacker Neuson RCP 12, Operator'S Manual

Page 1: ...Operator s manual Cutting machine with interchangeable head RCP 20 25 0215052en 002 03 2008 ...

Page 2: ......

Page 3: ... Safety during the operation of hydraulic machines 15 3 9 Maintenance 15 3 10 Labels 16 3 11 Safety devices 17 4 Scope of delivery 18 5 Description 19 5 1 Application 19 5 2 Functionality 19 5 3 Components and operator s controls 19 6 Transport 22 7 Operation 23 7 1 Prior to starting the machine 23 7 2 Adjusting the machine 24 7 3 Starting up 26 7 4 Decomissioning 29 8 Maintenance 30 8 1 Maintenan...

Page 4: ...1 2 Bending head 43 11 2 1 Safety 43 11 2 2 Scope of delivery 44 11 2 3 Description 44 11 2 4 Operation 46 11 2 5 Technical data for accessories 51 12 Technical data 52 12 1 RCP 20 25 230 52 12 2 RCP 20 25 115 53 12 3 RCP 20 25 120 54 12 4 Extension cable 55 EC Declaration of Conformity 57 DIN EN ISO 9001 Certificate 59 ...

Page 5: ... accordance with the instructions in this operator s manual Your reward will be troublefree operation and a high degree of availability Defective machine parts must be replaced immediately Please contact your WACKER representative if you have any questions con cerning operation or maintenance All rights reserved especially reproduction and distribution rights Copyright 2008 Wacker Construction Equ...

Page 6: ...u have to carry out something in a defined sequence This symbol is used for lists DANGER This warning notice indicates hazards that result in serious injury or even death f Danger can be avoided by the following the actions mentioned WARNING This warning notice indicates hazards that can result in serious injury or even death f Danger can be avoided by the following the actions mentioned CAUTION T...

Page 7: ...f the WACKER main locations are located at the end of this op erator s manual 2 3 Described machine parts This operator s manual is valid for different machine parts from a product range Therefore some figures can differ from the actual appearance of your machine It is also possible that the descriptions include components which are not a part of your machine Details for the described machine type...

Page 8: ...on the machine design Please refer to the chapter Technical Data for information concerning your machine Worksites are construction sites and operations which fabricate reinforcements or process reinforcing iron The machine may only be used for legal and permit ted purposes The machine must not be used for processing the following materials Wires Pipes Plastics Wood Its proper use also includes th...

Page 9: ...erate the machine safely requires Proper transport storage and setup Careful operation Careful service and maintenance Operation Operate the machine only as intended and only when in proper working condi tion Operate the machine in a safety conscious manner with all safety devices at tached and enabled Do not modify or disable any safety devices Before starting operation check that all control and...

Page 10: ...t www wackergroup com Always hand over this operator s manual to other operators or to the future owner of the machine Country specific regulations Observe the country specific regulations standards and guidelines in reference to accident prevention and environmental safety for example those pertaining to hazardous materials and wearing protective gear Complement the operator s manual with additio...

Page 11: ...ystems in accordance with the standards governing safety You have been assigned to work on the machine by your company Incorrect operation Incorrect operation or misuse by untrained personnel can endanger the health and safety of the operator and also cause machine and material damage Operating company responsibilities The operating company must make the operator s manual available to the oper ato...

Page 12: ...Breathing protection in the case of dusty ambient air optional 3 4 Transport Switching off the machine Before you transport the machine switch it off and pull the plug out of the plug receptacle Allow the motor to cool down Transporting the machine Transport the machine in the carrying case supplied Secure the carrying case on the transport device against tilting falling or slipping 3 5 Operating ...

Page 13: ...Always make sure that you maintain a safe distance when working with the ma chine This applies particularly when working on scaffoldings ladders etc Caution with movable parts Keep your hands feet and loose clothing away from moving machine parts No persons endangered Be sure that no persons are endangered by flying parts or flying chips Switching off the machine Switch off the engine and pull the...

Page 14: ...ctric power supply with all machine parts in proper working condition Take special notice of the following machine parts Plug Power cable over the entire length The machine may only be connected to an electric power supply whereby the connector of the grounded conductor PE is intact Electrical appliances of class rating II have a strengthened or double insulation protective insulation They have no...

Page 15: ...act with hydraulic oil Remove hydraulic oil from the skim immediately with soap and water Make sure that no hydraulic oil comes gets in the eyes or on the body See a phy sician immediately if hydraulic oil gets into the eyes or is swallowed Do not eat and drink while handling hydraulic oil Make sure to have extreme cleanliness Contamination of the hydraulic oil with dirt or water can cause prematu...

Page 16: ... any missing or illegible labels Labels Description Wear safety glasses Wear hard hat Follow operator s manual Wear ear protection Wear protective gloves Wear non skid hard toed shoes Max workpiece diameter Only use hydraulic oil of type HLP ISO 46 e g ESSO NUTO H46 refer to chapter Technical data WARNING Danger due to cutting WARNING Flying chips Warm up machines at temperatures under 5 C ...

Page 17: ...A protective hood is installed for some machine designs WARNING Danger of injury due to open moving parts f Only operate the machine with properly installed and functioning safety de vices f Do not modify or remove safety devices Item Designation 1 Protective hood ...

Page 18: ...cludes Only one cutting machine is included in the scope of deliver Item Designation 1 Carrying case 2 Cutting machine 3 4 mm Allen wrench 4 6 mm Allen wrench 5 Spring washer 2 pieces 6 Allen screw 2 pieces Operator s Manual without illus tration Spare parts catalog without illus tration General safety information with out illustration ...

Page 19: ... 2 Functionality Principle An electric motor drives a piston with thrust bolt forwards via a gear pump A valve opens at the end of the forward movement and releases the pressure A spring presses the piston back in the original position In cutting operating the thrust bolt moves a moveable knife against a fixed knife in the cutting head In idle a valve is opened via the pressure release lever The t...

Page 20: ...stop If the ON OFF switch is pressed again after a stop in the cutting operation the knife continues its movement until the original position Oil filler neck The oil filler neck is used for filling and emptying the hydraulic oil tank A screw plug with sealing ring seals the opening in the oil filler neck Pressure release lever Select operating mode cutting operation or release idle with the pressu...

Page 21: ...led in the cutting head Cutting of the workpiece is done by shearing off The cutting head is fastened to the machine with a collar The cutting head can be removed Instead of the cutting head a bending head accessory can be in stalled on the machine Stop screw The stop screw must be set to the diameter of the workpiece before cutting If the stop screw is properly adjusted the machine cuts the workp...

Page 22: ...e carrying case 4 Wind up the power cable and place in the carrying case 5 Store both Allen wrenches in the carrying case 6 Close carrying case 7 Place the carrying case on or into a suitable means of transport 8 Secure the carrying case against falling over and down or sliding WARNING Improper handling can result in injury or serious material damage f Read and follow all safety instructions of th...

Page 23: ... see nameplate of the machine or chapter Technical Data f Check if mains or power distribution on the constructions site are protected in accordance with current standards and regulations WARNING Improper handling can result in injury or serious material damage f Read and follow all safety instructions of this operator s manual see chapter Safety information WARNING Movable knives Body parts could...

Page 24: ...he workpiece on the fixed knife 5 Set the stop screw so that the workpiece is perpendicular to the axis of the machine 6 Tighten the jam nut WARNING Starting the machine Danger of injuries from uncontrolled starting of the machine f Remove the plug from the plug receptacle before all work on the machine Item Designation 1 Movable knife 2 Jam nut 3 Stop screw 4 Fixed knife 5 Workpiece Protective ho...

Page 25: ...lecting the operating mode f Position the pressure release lever upwards to start the cutting operation f Position the pressure release lever downwards to start idle Item Designation 1 Cutting operation I 2 Release Idle 0 ...

Page 26: ...g into the plug receptacle NOTICE Worn out knives Premature wear of the machine f Before beginning work check the sharpness of the knife visually f Change worn out knives NOTICE Electrical voltage Incorrect voltage can cause damage on the machine f Check if the voltage of the current source corresponds with the information of the machine see chapter Technical Data CAUTION Electrical voltage Danger...

Page 27: ...ature under 5 C warm up in idle approx 1 minute before beginning work on the machine 1 Set the pressure release lever in the Release Idle position 2 Press and hold ON OFF switch The machine runs in idle 3 Release the ON OFF switch to turn off Item Designation 1 Cutting operation I 2 Release Idle 0 ...

Page 28: ...r uncontrolled machine Body parts could be cut off f If the machine is guided to the workpiece the machine must always be held tight with both hands and stand securely f If the machine is on a stable foundation hold the machine with one hand on the handle and hold the workpiece with the other hand NOTICE Incorrect placement Premature wear of the knife f Make sure that the stop screw is adjusted to...

Page 29: ...riginal position 3 Pull the plug from the plug receptacle Cleaning the machine 1 Free the cutting head of cutting residues with suitable tools 2 Wipe the housing with a damp and clean cloth CAUTION Electrical voltage Danger of electrocution f Make sure when cleaning that no water gets into the machine Do not clean machine under running water or with a high pressure cleaner ...

Page 30: ...Electrical voltage Injuries from electrocution f Remove the plug from the plug receptacle before all work on the machine Task Daily before operation As required Every 2 years Check power cable for perfect condition if power cable is defective have it replaced Visual inspection of all parts for damage Check knife for wear if nec essary replace knife Check screws on machine for tightness if necessar...

Page 31: ...te A level and clean work surface makes work easier There is a better overview over small parts and they are not lost as easily 8 2 1 Visual inspection for damage Checking the machine f Check all machine parts for damage or cracks WARNING A damaged machine part or power cable can result in personal injury caused by electric current f Do not operate a damaged machine f Have a damaged machine repair...

Page 32: ...screws on the fixed knife 2 Changing fixed knife 3 Tighten fixed knife with both fastening screws Changing the movable knife 1 Unscrew both fastening screws on the movable knife and remove with the spring washers 2 Changing movable knife 3 Tighten movable knife with both fastening screws and spring washers Item Designation 1 Fixed knife 2 Fastening screw 2 pieces 3 Movable knife 4 Fastening screw ...

Page 33: ...t f Let machine cool off CAUTION Hydraulic oil under pressure Squirting hydraulic oil can penetrate the skin f Only unscrew the screw plug on the oil filler neck if the thrust bolt is com pletely extended f Wear safety glasses and protective gloves NOTICE Wrong hydraulic oil Damage to machine f Only fill with hydraulic oils which are specified for the machine in the chapter Technical Data ...

Page 34: ...plug on the oil filler neck slowly and carefully Hold a cloth over the oil filler neck with the second hand for protection against escaping hydraulic oil 3 Unscrew the screw plug on the oil filler neck and remove with sealing ring 4 Check if the hydraulic oil reaches to the lower edge of the oil filler neck If necessary fill with hydraulic oil up tot the lower edge of the oil filler neck 5 Screw i...

Page 35: ...ller neck WARNING Hot hydraulic oil Injury by scalding f Do not open the screw plug on the oil filler neck as long as the hydraulic oil is hot f Let machine cool off CAUTION Hydraulic oil under pressure Squirting hydraulic oil can penetrate the skin f Only unscrew the screw plug on the oil filler neck if the thrust bolt is com pletely extended f Wear safety glasses and protective gloves ...

Page 36: ...ler neck and remove with sealing ring 4 Hold the machine with the oil filler neck over the collection container and drain hydraulic oil 5 Set the pressure release lever in the Release Idle position 6 When the thrust bolt is completely retracted drain the remaining hydraulic oil in the collection container Note Dispose of hydraulic oil according to the applicable regulations for en vironmental prot...

Page 37: ...ompletely extend the thrust bolt 4 Pull the plug from the plug receptacle Top up with hydraulic oil 1 Place the machine so that the oil filler neck points vertically upward 2 Unscrew the screw plug on the oil filler neck and remove with sealing ring 3 Fill with hydraulic oil up to the lower edge of the oil filler neck 4 Screw in the screw plug with sealing ring in the oil filler neck and tighten ...

Page 38: ...ing the movable knife 3 Unscrew the fastening screw on the collar 4 Remove collar 5 Remove cutting head towards the front WARNING Starting the machine Danger of injuries from uncontrolled starting of the machine f Remove the plug from the plug receptacle before all work on the machine Item Designation 1 Fastening screw 2 Movable knife 3 Cutting head 4 Fastening screw 2 pieces 5 Collar ...

Page 39: ... the cutting head 1 Place the cutting head on the machine so that when sliding on the locating pin on the cutting head engages into the hole on the machine 2 Slide the cutting head to the stop Item Designation 1 Machine 2 Bore 3 Locating pin 4 Cutting head ...

Page 40: ...ing head 1 Put the collar on 2 Turn and tighten the fastening screw on the collar 3 Tighten movable knife with both fastening screws and spring washers Item Designation 1 Fastening screw 2 Movable knife 3 Fastening screw 2 pieces 4 Collar ...

Page 41: ...on cable with sufficient cross section Power cable interrupted Check power cable have it re placed if defective Thrust bolt moves out incom pletely or unevenly Insufficient hydraulic oil in the hydraulic oil tank Check oil level fill with hydrau lic oil if necessary Cold hydraulic oil Warm up machine for approx 1 minute Thrust bolt does not move back completely Dirt and cutting residue in the cutt...

Page 42: ...uld be disposed and recycled in an environmentally friendly manner During disposal of the machine observe the country specific rules and regula tions e g the European Directive for obsolete electrical and electronic devices Do not dispose of the machine in household rubbish It must be disposed at a recycling facility ...

Page 43: ...he machine are dependent on the machine design Please refer to the chapter Technical Data for information concerning your machine Worksites are construction sites and operations which fabricate reinforcements or process reinforcing iron The beinding head must not be used for processing the following materials Wires Pipes Plastics Wood Its proper use also includes the observance of all instructions...

Page 44: ...nterchangeable head In the installed condition the bending head can be used to bend reinforcing steel Using the two exchangeable molding pieces two different bending radii can be set Item Designation 1 Fastening screw 2 Bending head 3 Fastening screw 4 Spring washer 5 Nut 6 Movable die 7 Small molding piece 8 Large molding piece ...

Page 45: ...letely forward the smallest possible bending angle is made Any desired larger angle can be bent when the forwards movement is interrupted by releasing the ON OFF switch If the pressure release lever is set in the Re lease Idle position the die returns to the original position Components and their function The molding piece is permanently screwed onto the bending head The size of the molding piece ...

Page 46: ... bending head 1 Place the bending head on the machine so that when sliding it on the locat ing pin on the bending head engages into the bore on the machine 2 Slide the bending head to the stop WARNING Starting the machine Danger of injury with uncontrolled start up f Before all work on the machine and on accessories remove the plug from the plug receptacle Item Designation 1 Machine 2 Bore 3 Locat...

Page 47: ... 1 Put the collar on 2 Turn and tighten the fastening screw on the collar 3 Tighten the die with the fastening screw spring washer and nut onto the thrust bolt Item Designation 1 Collar 2 Nut 3 Die 4 Fastening screw 5 Thrust bolt 6 Fastening screw ...

Page 48: ...ng screw on the thrust bolt and remove with spring wash er and nut 2 Remove die 3 Unscrew the fastening screw on the collar 4 Remove collar 5 Remove bending head towards the front Item Designation 1 Collar 2 Nut 3 Die 4 Fastening screw 5 Thrust bolt 6 Fastening screw ...

Page 49: ...Tighten the molding piece with the fastening screw Bending the workpiece Item Designation 1 Molding piece 2 Fastening screw WARNING Movable tool Body parts could be crushed f Do not touch the bending head when the motor is running WARNING Injuries from insufficiently guided or uncontrolled machine Body parts could be crushed f Hold the machine with one hand and guide the workpiece into the bending...

Page 50: ...e has been reached If the smallest possible bending angle should be made Hold down the ON OFF switch until the die is completely retracted If the another bending angle should be made Release the ON OFF switch when the desired bending angle is reached and set the pressure release lever into the Release Idle position 4 When the die has completely retracted remove the workpiece from the bend ing head...

Page 51: ... Length x Width x Height mm 190 x 125 x 90 220 x 290 x 130 Weight kg 5 3 8 5 Min bending radius on the inside of the workpiece mm 18 Bending angle 180 65 180 80 The smallest possible bending angle depends on the diameter and tensile strength of the workpiece Max allowable tension strength of the workpiece N mm2 750 Max allowable diameter work piece mm 20 25 ...

Page 52: ...rent consumption A 6 8 Class rating II Protection class IP 20 Engine speed rpm 14 000 Operating temperature C F 20 to 50 4 to 122 Hydraulic oil specification HLP ISO 46 Hydraulic oil fill quantity l gal 0 6 0 2 Max compressive force t 30 40 Opening closing time of the tool s 5 5 5 Max allowable tension strength of the workpiece N mm2 750 Max allowable diameter work piece mm in 20 0 79 25 0 98 Prot...

Page 53: ...umption A 11 0 Class rating II Protection class IP 20 Engine speed rpm 14 000 Operating temperature C F 20 to 50 4 to 122 Hydraulic oil specification HLP ISO 46 Hydraulic oil fill quantity l gal 0 6 0 2 Max compressive force t 30 40 Opening closing time of the tool s 5 5 5 Max allowable tension strength of the workpiece N mm2 750 Max allowable diameter work piece mm in 20 0 79 25 0 98 Protective h...

Page 54: ...umption A 11 0 Class rating II Protection class IP 20 Engine speed rpm 14 000 Operating temperature C F 20 to 50 4 to 122 Hydraulic oil specification HLP ISO 46 Hydraulic oil fill quantity l gal 0 6 0 2 Max compressive force t 30 40 Opening closing time of the tool s 5 5 5 Max allowable tension strength of the workpiece N mm2 750 Max allowable diameter work piece mm in 20 0 79 25 0 98 Protective h...

Page 55: ...a of cable for a des ignated extension Note Refer to the nameplate or the chapter Technical data via the item number for the type designation and voltage rating of your machine Voltage V Extension m Cross section area of cable mm2 115 27 1 5 45 2 5 72 4 107 6 120 28 1 5 47 2 5 75 4 111 6 230 88 1 5 146 2 5 ...

Page 56: ...th a length of 50 m 164 ft The machine has an input voltage of 230 V According to the table the extension cable must feature a cross section area of 1 5 mm2 AWG 16 Machine Voltage V Extension ft Cross section area of cable AWG RCP 20 RCP 25 115 79 16 125 14 197 12 308 10 120 82 16 128 14 203 12 322 10 230 253 16 400 14 492 12 ...

Page 57: ...ction machines Category Cutting machine with interchangeable head fulfill the requirements of the following directives 98 37 EC 2004 108 EC EN 61000 2006 95 EC Type RCP 20 RCP 25 Machine type number 0610201 0610202 0610215 0610203 0610204 0610216 Operating weight kg 13 7 13 9 Dr Stenzel Head of Research and Development ...

Page 58: ......

Page 59: ... the following scope Machine manufacture Construction machines This Q System complies with the requirements of DIN EN ISO 9001 2000 and the requirements of the German and international Road Traffic Act This Certificate is valid until 2009 06 05 VDE Testing and Certification Institute Certification Date 2006 05 30 63069 Offenbach Merianstraße 28 Telefon 49 0 69 83 06 0 Telefax 49 0 69 83 06 555 E M...

Page 60: ...54 02 0 Fax 49 0 89 354 02 390 Wacker Corporation P O Box 9007 Menomonee Falls WI 53052 9007 USA Tel 1 1 262 255 0500 Fax 1 1 262 255 0550 Support 800 770 0957 Wacker Machinery HK Ltd Skyline Tower Suite 2303 23 F 39 Wang Kwong Road Kowloon Bay Hong Kong Tel 852 3188 5506 Fax 852 2406 6021 ...

Page 61: ......

Page 62: ......