Wacker Neuson RCP 20, RCP 25, RCP 12, RCP 16, RCP 32 Operator's Manual
Operator's manual
Cutting machine with interchangeable head
RCP
20, 25
0215052en 002
03.2008
Contents
3
Contents
1 Foreword .................................................................................................................... 5
2 Introduction ...............................................................................................................6
2.1 Means of representation for this operator's manual ........................................... 6
2.2 WACKER representative .................................................................................... 7
2.3 Described machine parts.................................................................................... 7
3 Safety information .................................................................................................... 8
3.1 Principle.............................................................................................................. 8
3.2 Qualification of the operating personnel ........................................................... 11
3.3 Protective gear ................................................................................................. 12
3.4 Transport .......................................................................................................... 12
3.5 Operating safety ............................................................................................... 12
3.6 Safety during the operation of hand machines ................................................. 14
3.7 Safety during the operation of electric appliances............................................ 14
3.8 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 Maintenance schedule...................................................................................... 30
8.2 Maintenance work ............................................................................................ 31
8.2.1 Visual inspection for damage ............................................................... 31
8.2.2 Changing the knife................................................................................ 32
8.2.3 Checking the hydraulic oil level ............................................................ 33
8.2.4 Changing the hydraulic oil .................................................................... 35
8.3 Installing and removing the cutting head .......................................................... 38
4
Contents
9 Troubleshooting ...................................................................................................... 41
10 Disposal ...................................................................................................................42
10.1 Disposal of the machine ................................................................................... 42
11 Accessories ............................................................................................................. 43
11.1 General notes................................................................................................... 43
11.2 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
Foreword
5
1Foreword
This operator's manual contains information and procedures for the safe operation and maintenance of your WACKER machine. In the interest of your own
safety and to prevent accidents, you should carefully read through the safety information, familiarize yourself with it and observe it at all times.
This operator's manual is not a manual for extensive maintenance and repair
work. Such work should be carried out by WACKER Service or authorized specialists.
The safety of the operator was one of the most important aspects taken into consideration when this machine was designed. Nevertheless, improper use or incorrect maintenance can pose a risk. Please operate and maintain your
WACKER machine in 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 concerning operation or maintenance.
All rights reserved, especially reproduction and distribution rights.
Copyright 2008 Wacker Construction Equipment AG
No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without the expressed written permission of WACKER.
Any type of reproduction, distribution or storage on data media of any type and
form not authorized by WACKER represents an infringement of copyright and will
be prosecuted.
We expressly reserve the right to make technical modifications – even without
special notice – which aim at further improving our machines or their safety standards.
6
Introduction
2 Introduction
2.1 Means of representation for this operator's manual
Warning symbols
This operator's manual contains safety imformation of the categories:
DANGER, WARNING, CAUTION, NOTICE.
They should be followed to prevent danger to life and limb or damage to equipment or improper service.
Notes
Note: Complementary information will be displayed here.
Instructions
f This symbol indicates there is something for you to do.
1. Numbered instructions indicate that you 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
This warning notice indicates hazards that can result in minor injury.
f Danger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates hazards that can result in material damage.
f Danger can be avoided by the following the actions mentioned.
Introduction
7
2.2 WACKER representative
Depending on your country, your WACKER representative is your WACKER
Service, your WACKER affiliate or your WACKER dealer.
You can find the addresses in the Internet at www.wackergroup.com.
The addresses of the WACKER main locations are located at the end of this operator'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 types can be found in the chapter Technical
Data.
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Safety information RCP
3 Safety information
3.1 Principle
State of the art
This machine has been constructed with state-of-the-art technology according to
the recognized rules of safety. Nevertheless, when used improperly, dangers to
the life and limb of the operator or to third persons or damage to the machine or
other materials cannot be excluded.
Proper use
The machine may only be used for cutting reinforcing steel.
The diameter and tensile strength of the reinforcing steel that may be processed
with the 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 machine may only be used for legal and permitted purposes.
The machine must not be used for processing the following materials:
Wires
Pipes
Plastics
Wood
Its proper use also includes the observance of all instructions contained in this
operator's manual as well as complying with the required service and maintenance instructions.
Any other use is regarded as improper. Any damage resulting from improper use
will void the warranty and the liability on behalf of the manufacturer. The operator
assumes full responsibility.
RCP Safety information
9
Structural modifications
Never attempt to modify the machine without the written permission of the manufacturer. To do so will endanger your safety and the safety of other people! In
addition, this will void the warranty and the liability on behalf of the manufacturer.
Especially the following are cases of structural modifications:
Opening the machine and the permanent removal of components from
WACKER.
Installing new components which are not from WACKER and not equivalent
to the original parts in design and quality.
Installation of accessories which are not from WACKER.
It is no problem to install spare parts from WACKER.
It is no problem to install accessories that are available in the WACKER product
range of your machine. Please refer to the installation regulations in this operator's manual.
Requirements for operation
The ability to operate 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 condition.
Operate the machine in a safety-conscious manner with all safety devices attached and enabled. Do not modify or disable any safety devices.
Before starting operation, check that all control and safety devices are functioning properly.
Never operate the machine in a potentially explosive environment.
Maintenance
Regular maintenance is required in order for the machine to operate properly and
reliably over time. Neglected maintenance work can make the machine dangerous to use.
Strictly observe the prescribed maintenance intervals.
Do not use the machine if it requires maintenance or repairs.
Malfunctions
If you detect a malfunction, you must shut down and secure the machine immediately.
Eliminate the malfunctions that impair safety immediately!
Have damaged or defective components replaced immediately!
For further information, refer to chapter Troubleshooting.
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Safety information RCP
Spare parts, accessories
Only use spare parts and accessories from WACKER. Non-compliance will exempt the manufacturer from all liability.
Exclusion of liability
WACKER will refuse to accept liability for injuries to persons or for damage to
materials in the following cases:
Structural modifications.
Improper use.
Improper handling.
Use of spare parts and accessories not produced by WACKER.
Operator's manual
Always keep the operator's manual near the machine or near the worksite for
quick reference.
If you have misplaced the operator's manual or require an additional copy, contact your WACKER representative or download it from the Internet
(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 additional instructions taking into account the operational, regulatory, national or generally applicable safety guidelines.
Operator's controls
Always keep the operator's controls of the machine dry, clean and free of oil or
grease.
The function of the operator's controls must not be manipulated or rendered ineffective.
Cleaning
Always keep the machine clean and be sure to clean it each time you have finished using it.
Do not use gasoline or solvents. Danger of explosion!
RCP Safety information
11
Checking for signs of damage
Inspect the machine when it is switched off for any signs of damage at least once
per work shift.
Do not start the machine if there is visible damage or defects.
Have any damage or defects eliminated immediately.
3.2 Qualification of the operating personnel
Operator qualifications
Only trained personnel are permitted to start and operate the machine. The following rules also apply:
You are physically and mentally fit.
You have received instruction on how to independently use the machine.
You have received instruction in the proper use of the machine.
You are familiar with required safety devices.
You are authorized to start machines and systems 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 operator and ensure that the operator has read and understood it.
Work recommendations
Please observe the recommendations below:
Work only if you are in a good physical condition.
Work attentively, particularly as you finish.
Do not operate the machine when you are tired.
Carry out all work calmly, circumspectly and carefully.
Never operate the machine under the influence of alcohol, drugs or medica-
tion. This can impair your vision, reactions and your judgment.
Work in a manner that does not endanger others.
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Safety information RCP
3.3 Protective gear
Work clothing
Clothing should be appropriate, i.e. should be close-fitting but not restrict your
movement.
When on construction sites, do not wear long hair loosely, loose clothing or jewelry including rings. These objects can easily get caught or be drawn in by moving machine parts.
Personal protective gear
Wear personal protective gear to avoid injuries or health hazards:
Non-skid, hard-toed shoes.
Work gloves made of durable material.
Overalls made of durable material.
Hard hat.
Ear protection.
Face protection (optional).
Eye protection.
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 safety
Work environment
Familiarize yourself with your work environment before you start work. This includes e.g. the following items:
Obstacles in the work and traffic area.
Load-carrying capacity of the ground.
The measures needed to cordon off the construction site from public traffic.
The measures needed to secure walls and ceilings.
Options available in the event of an accident.
RCP Safety information
13
Safety in the work area
When working with the machine especially pay attention to the following points:
Electric lines or pipes in work area.
Gas lines or water lines in the work area.
Checks before starting work
Check the following points before beginning work:
Condition of tools.
Machine settings.
Connection value of the machine.
Starting the machine
Observe the safety information and warning notices located on the machine.
Never attempt to switch on a machine that requires maintenance or repairs.
Switch on the machine as directed in the operator's manual.
Vertical stability
Always make sure that you maintain a safe distance when working with the machine. 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 plug out of the plug receptacle in the following
situations:
Before breaks.
If you are not using the machine.
If you are changing the tool.
Before storing the machine, wait until it has completely stopped running.
Store the machine or put it down in such a way that it cannot tilt, fall down or slip.
Storage location
Store the machine after operation at a sealed off and dry location inaccessible to
children.
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Safety information RCP
3.6 Safety during the operation of hand machines
Safe working with hand machines
Secure loose workpieces with suitable methods.
While working, as a rule hold the machine on the provided handles with both
hands.
3.7 Safety during the operation of electric appliances
Specific regulations for electrical appliances
Observe the safety information provided in the brochure General Safety Rules
which is included in the scope of delivery of your machine.
Also observe the country-specific regulations, standards and guidelines in reference to accident prevention in connection with electrical equipment and machines.
Electric power supply for electrical appliances of class rating II
Note: The rated voltage is indicated on the nameplate of your machine.
The machine may only be connected to an electric 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 connection to the grounded conductor.
Note: Observe the respective national safety regulations!
Extension cable
The machine may only be operated with undamaged extension cables!
Only use extension cables with grounded conductor and correct connection of
the grounded conductor to the plug and coupling (only for machines of class
rating I).
Only use extension cables which are suitable for use at construction sites: Average rubber hose H05RN-F or better – WACKER recommends H07RN-F or a
country-specific equivalent design.
Immediately replace damaged extension cables (e.g. tears in the sheathing) or
loose plugs and couplings.
RCP Safety information
15
Protecting the power cable
Do not use the power cable to pull or lift the machine.
Do not unplug the power cable by pulling on the cable.
Protect the power cable from heat, oil and sharp edges.
If the power cable is damaged or the plug is loose, have it replaced immediately
by your WACKER representative.
Protecting from moisture
Protect the machine against rain, snow or any other forms of moisture. This could
cause damage or malfunctions.
Protecting from high temperatures
Do not expose the machine to temperatures which are over 70 °C. Otherwise the
insulation current conducting parts can be damaged.
3.8 Safety during the operation of hydraulic machines
Hydraulic oil
Hydraulic oil is harmful to health.
Wear safety glasses and safety gloves when handling hydraulic oil.
Avoid direct skin contact 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 physician 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 premature wear or failure.
Dispose of left over and spilled hydraulic oil according to the applicable regulations for environmental protection.
3.9 Maintenance
Maintenance work
Service and maintenance work must only be carried out to the extent described
in these operating instructions. All other procedures must be performed by your
WACKER representative.
For further information, refer to chapter Maintenance.
Disconnecting the machine from the electric power supply
Before carrying out service or maintenance work, pull the plug out of the plug receptacle in order to disconnect the machine from the electric power supply.
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Safety information RCP
3.10 Labels
Your machine has adhesive labels containing the most important instructions
and safety information.
Make sure that all the labels are kept legible.
Replace 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.
RCP Safety information
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3.11 Safety devices
Protective hood
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
18
Scope of delivery RCP
4 Scope of delivery
Machine with cutting head
The machine is delivered fully assembled.
The scope of delivery includes:
Only one cutting machine is included in the scope of deliver.
Item Designation
1Carrying 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 illustration)
Spare parts catalog (without illustration)
General safety information (without illustration)
RCP Description
19
5 Description
5.1 Application
The machine is used for cutting reinforcing steel at construction sites and operations which fabricate reinforcements or process reinforcing iron.
The diameter and tensile strength of the reinforcing steel that may be processed
with the machine are dependent on the machine design. Please refer to the
chapter Technical Data for information concerning your machine.
5.2 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 thrust bolt does not
make a movement.
5.3 Components and operator's controls
Item Designation
1 ON/OFF switch
2 Oil filler neck
3 Pressure release lever
4 Stop screw
5 Cutting head
Protective hood (without illustration)
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