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Peri RCS 50 Assembly Instructions Manual

Climbing device and hydraulics
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RCS Climbing Device and Hydraulics
Assembly, Commissioning and Maintenance
Spare Parts and Circuit Diagrams
Assembly Instructions – Issue 03/2019
Climbing Device RCS 50
PERI Item No. 109765
S/N 109.063-575
Hydraulic Pump RCS 4 x 190 bar,
380 – 460 V, PERI Item No. 109766
S/N 964.020

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  • Page 1 Assembly, Commissioning and Maintenance Spare Parts and Circuit Diagrams Assembly Instructions – Issue 03/2019 Climbing Device RCS 50 Hydraulic Pump RCS 4 x 190 bar, PERI Item No. 109765 380 – 460 V, PERI Item No. 109766 S/N 109.063-575 S/N 964.020...
  • Page 2 Introduction Dimension specifications Safety instructions Dimensions are usually given in mm. Other units of measure, e.g. cm, are specified in the illustrations. Load details are usually given in kg. Other measurement units, e.g. t, are specified in the illustrations. Information Conventions –...

  • Page 3: Table Of Contents

    Warning Signs Intended Use Standard Assembly Technical Data Target Groups Safety Instructions Part A Overview Climbing Device RCS 50 Hydraulic Twin Hose RCS Hydraulic Pump RCS Climbing Shoe RCS Climbing Device in Use Part B Transportation and Storage Measures Packaging...

  • Page 4: Introduction

    Introduction Warning Signs The safety instructions alert site personnel to the risks involved and provide information on how to avoid these risks. Safety instructions are featured at the beginning of the section ahead of the instructions, and are highlighted as follows: Danger This sign indicates an extremely hazard- ous situation, which, if not avoided,...

  • Page 5: Intended Use

    Introduction Intended Use The Climbing Device RCS 50 is used Safety instructions and permissible exclusively for lifting a climbing unit, loads must be observed at all times. consisting of formwork and supporting structure, to the next concreting section. Components provided by the contractor...

  • Page 6: Standard Assembly

    For special applications, the design engineer must check whether additional Function or alternative measures are required for The Climbing Device RCS 50 is posi- the climbing procedure. These measures tioned on the Climbing Shoe RCS. are to be shown and described in the...

  • Page 7: Technical Data

    Hydraulic Pump RCS 4 x 190 bar, 460 V CSA Power supply 460 V/60 Hz (3-phase) flow rate 7 l/min Cleaning and Maintenance Instructions The Climbing Device RCS 50 has been Repairs which require welding or defor- designed for long-term use on con- mation of components must be carried struction sites.

  • Page 8: Target Groups

    Target Groups Contractors Competent person These Assembly Instructions are Due to the specialist knowledge gained intended for contractors who use PERI from professional training, work experi- products for ence, and recent professional activity, assembling, modifying and dis- the competent person has a reliable ƒ...
  • Page 9 Introduction Target Groups Qualified personnel In other countries, ensure that the PERI products may only be assembled, relevant national guidelines and modified or dismantled by personnel regulations in the respective current who are suitably qualified to do so. For version are complied with!

  • Page 10: Safety Instructions

    Move components on clean, flat and during working operations. sufficiently load-bearing surfaces only. For a better understanding, detailed PERI products must be protected against illustrations are partly incomplete. the effects of the weather and aggres- Some safety installations which have...
  • Page 11 Introduction Safety Instructions Product-Specific Assembly Mandatory personal protective Operations equipment (PPE): The contractor must ensure that the – safety helmet assembly, modification, dismantling, – safety shoes moving, use and handling of the product – protective gloves is managed and supervised by qualified personnel and authorised personnel.
  • Page 12 Anchoring of the climbing units in the next concreting section is only to be carried out after the required concrete PERI climbing hydraulics may not strength has been reached. be used if the type plate is missing, incomplete or illegible.

  • Page 13: Part A Overview

    (1.5) Reposition device (1.6) Locking lever (1.7) Measuring connection (1.8) Lowering brake valve Fig. 1: Climbing Device RCS 50 (1.9) Protection caps Abb. 2 ( 1 : 5 ) Due to the clear arrangement of the quick-coupler nipple (return) and bushing...

  • Page 14: A2 Hydraulic Twin Hose Rcs

    Abb.3 ( 1 : 5 ) Abb. 4 ( 1 : 5 ) Part A Overview A1 Climbing Device RCS 50 Fig. 3: Lowering brake valve (1.8) Fig. 4: Measuring connection (1.7) A2 Hydraulic Twin Hose RCS (2.1) Hydraulic Twin Hose RCS 10 m, Item no.

  • Page 15: A3 Hydraulic Pump Rcs

    (3.6) Filling piece with ventilation filter (3.7) Return flow filter 3.4a Fig. 7: Hydraulic Oil Tank 3.11 (3.11) Measuring connection for pressure check (only through PERI personnel) Fig. 8: Measuring Connection in the Pump RCS Climbing Device and Hydraulics Assembly Instructions...
  • Page 16 Part A Overview A3 Hydraulic Pump RCS (3.1) Hand valve in the middle position (3.2) Switch (3.3) Electricity socket with phase inverter (3.8) Return flow on piston rod side A of the cylinder with hydraulic quick-coupler (bushing) 3.10 (3.9) Inflow for piston head side B of the cylinder with hydraulic quick-coupler (nipple) (3.10) Rotary field control lamp...

  • Page 17: A4 Climbing Shoe Rcs

    Part A Overview A4 Climbing Shoe RCS Climbing Shoe RCS, Item no. 109468 (5.1) Climbing pawl (5.2) Folding runner (5.3) Securing pins (5.4) Pawl lock (5.5) Hinged bail (5.6) Locking spring (5.7) Locating pin for climbing device Fig. 12: Climbing Shoe RCS closed and climbing pawl activated Fig.

  • Page 18: A5 Climbing Device In Use

    RCS C with Wall Shoe RCS Climbing Rail RCS (9.1) Climbing Bolt (spacer in the climbing rail) Climbing Device RCS 50 Climbing Shoe RCS Wall Shoe RCS Fig. 14: Climbing Device in use with RCS C For use with the Climbing Protection...
  • Page 19 B1.1 Moving on the construction site B1.3 Transport from and to the – Keep bushing and nipples of all construction site quick-couplers clean and fit with – Clean dirt off climbing device and protection caps during transportation Hydraulic Pump, and dry. (one set with 4 pieces, Item no.

  • Page 20: Part B Transportation And Storage

    – Do not store Hydraulic Pump in a horizontal position as the oil can escape through the ventilation valve. – Fix a cover to the transport crate. Climbing Device RCS 50 26.0 kg Item no. 109765 S/N: 109.063-575) Fig. 17: Transport Crate for the Hydraulic Pump Hydraulic Pump RCS 109.0 kg...

  • Page 21: Part C Maintenance

    Part C Maintenance C1 Initial Commissioning Measures before the initial commissioning – Check the completeness of the technical documentation, e.g. hydraulic plan, equipment list, electrical wiring diagram, instructions for switch and motor. – Site personnel to familiarise them- selves with the equipment using the available documentation.

  • Page 22: C2 Commissioning

    Part C Maintenance C2 Commissioning C2.1 Measures taken during C2.2 Electrical connection commissioning – Listen out for any pump noises after starting up. – Check the rotary field. Connection carried out only by authorised qualified personnel. – Check level of the hydraulic oil and top up if necessary.
  • Page 23 Part C Maintenance C2 Commissioning During Low Temperatures Re-commissioning after a long downtime – Thoroughly clean and rinse preserved equipment before commissioning. Any remaining preservation agents can block the valves. – Drain condensation water from the hydraulic tank. – Check hydraulic oil after a long stand- still period for usability and change if necessary.

  • Page 24: C3 Maintenance And Repairs

    Part C Maintenance C3 Maintenance and Repairs C3.1 Overview PERI recommends shortened Damage and any resulting downtime can maintenance intervals: be avoided by carrying out scheduled – for equipment showing signs of heavy maintenance work. wear. – with high thermal and mechanical loads.
  • Page 25 Part C Maintenance C3 Maintenance and Repairs C3.2 Check fluid level in oil tank If fluid volume is too low – the operating temperature increases, – The oil level can vary depending on the – which leads to air inclusions, type, quantity and size of the consumer.
  • Page 26 Recommended hydraulic oil: cleaning and correct disposal are HVLP 46 – DIN 51524, included in the safety data sheet of e.g. PERI Hydraulic Oil HV LP46, 20 L, the hydraulic oil selected for use. Item no. 057376. Filling quantity: max. 22 litres.
  • Page 27 Part C Maintenance C3 Maintenance and Repairs C3.5 Cleaning and replacing the oil filter 1. Unscrew the plastic cap of the return flow filter (3.7) and open (Fig. 23). Plastic cap presses the filter element (3.12) into the lower part of the housing (3.13) by means of a spring.

  • Page 28: Part D Operations

    Part D Operations D1 Preparations D1.1 Preparations for the hydraulics D1.2 Preparations on the self- climbing system – Check the age of the hydraulic hoses and replace if necessary. – Carefully vent the hydraulic cylinder and hoses before use, see D5.2. –...

  • Page 29: D2 Installing The Climbing Device

    Position of the hydraulic pump to arrange the couplings vertically with RCS C/CL: using angle pieces. Contact PERI! For the climbing procedure place the hydraulic pump on the intermediate platform of the stationary climbing unit.
  • Page 30 Part D Operations D2 Installing the Climbing Device D2.2 Hose arrangement for self- climbing procedure of the last unit For each climbing section, move the last Cylinder 1 Cylinder 2 unit to be climbed separately. Adapt con- trol sequence as the hydraulic pump is climbed at the same time.
  • Page 31 Part D Operations D2 Installing the Climbing Device D2.3 Hose arrangement for special Alternative: climbing units with 3 brackets At the position of the non-installed with RCS C/CL cylinder, a short-circuit connection Three cylinders are in use per climbing can be used, see D5.2. unit.
  • Page 32 Part D Operations D2 Installing the Climbing Device D2.4 Connecting the hydraulic lines The quick-couplers on the pump are marked accordingly (A1–A2, B1–B2). The arrangement of the plugs and sockets of the quick-couplers is clearly shown and cannot be mixed up. Fig.
  • Page 33 Part D Operations D2 Installing the Climbing Device D2.5 Mounting on the Self-Climbing System RCS C Are the hydraulic hoses connected on the correct side? Installing the climbing device 1. Place the climbing device (1) on the locating pin of the climbing shoe (5C). 2.
  • Page 34 Part D Operations D2 Installing the Climbing Device D2.5 Mounting the Self-Climbing System RCS CL 1. Mount the Climbing Rail Extension – Fix Climbing Rail Extension 125 (10) at the top of the climbing rail (9) and secure with fitting pins Ø 26. –...
  • Page 35 Part D Operations D2 Installing the Climbing Device D2.7 Mounting the Self-Climbing System RCS P Installing the climbing device – Place the climbing device (1) on the locating pin of the climbing shoe (5B). – Position the claw (1.1) within the climbing rail.

  • Page 36: D3 Self-Climbing Procedure

    Part D Operations D3 Self-Climbing Procedure D3.1 Operating the hydraulic pump 3.10 Take into account the enclosed separate operating instructions for the motor protection switch and electric motor! Protective motor switch: (3.2) Switch (3.3) Electricity socket with phase inverter (3.10) Rotary field control lamp Fig.
  • Page 37 Part D Operations D3 Self-Climbing Procedure D3.1 Operating the hydraulic pump Hand valve Connections Right 3 + 4 Left 1 + 2 1. Switch on hydraulic pump: Are both hand valves (3.1) in the middle position? – Turn the toggle on the protective motor switch (3.2) to the right.
  • Page 38 Part D Operations D3 Self-Climbing Procedure D3.1 Operating the hydraulic pump 3. Extending the climbing device: – If it is not the case, activate the Climbing Shoe (5) on which the climbing device is placed, see D3.7. – Extend the pistons of all the hydraulic cylinders up to the first climbing bolt (9.1).
  • Page 39 Part D Operations D3 Self-Climbing Procedure D3.1 Operating the hydraulic pump 5. Retracting the climbing device: – Retract pistons of all hydraulic cylinders. – Claw (1.1) circumvents the climbing bolts (9.1), hydraulic cylinder tips backwards. – Retract piston until claw on the piston engages under the climbing bolts.
  • Page 40 Part D Operations D3 Self-Climbing Procedure D3.2 Inserting into the Climbing Shoe with RCS C Before the last stroke: Standard situation: Vertical bearing at the height of the intermediate platform – Top climbing shoe (5A) is deactivated, see D3.8. – In order to allow easier insertion in the top climbing shoe, open both folding runners, see D3.6.
  • Page 41 Part D Operations D3 Self-Climbing Procedure D3.3 Inserting into the Climbing Shoe with RCS CL – After reaching the next climbing shoe (5A or 5B), insert the Climbing Rail Extension 125. For an overview of the climbing shoe, see Fig. 35. –...
  • Page 42 Part D Operations D3 Self-Climbing Procedure D3.4 Inserting into the Climbing Shoe with RCS P – Top climbing shoe (5A) is deactivated, see D3.8. – Both folding runners (5.2) are open, see D3.6. – Middle climbing shoe (5B) is activated, see D3.7.
  • Page 43 Part D Operations D3 Self-Climbing Procedure D3.5 Last stroke During the last stroke of a climbing procedure, the vertical load is transferred to another climbing shoe. Therefore, the climbing shoe which should serve as the vertical bearing must be activated: –...
  • Page 44 Part D Operations D3 Self-Climbing Procedure D3.6 Opening and closing the Risk of collapse! climbing shoe Do not open the climbing shoe under load or during the climbing procedure! Opening the climbing shoe Risk of crushing! 1. Release the locking spring (5.6). Do not touch if the load is moving! 2.
  • Page 45 Part D Operations D3 Self-Climbing Procedure D3.8 Deactivating the climbing shoe D3.7 Activating the climbing shoe In a deactivated position, no vertical This position serves to transfer vertical force from the climbing rail can be forces from the climbing rail during work- transferred via this particular shoe.

  • Page 46: D4 Dismantling The Climbing Device

    Part D Operations D4 Dismantling the Climbing Device D4.1 Disconnecting the hydraulic lines 1. Turn the retaining ring (2.5) on the socket (2.3) until reaching the check mark. Coupling is unlocked. (Fig. 56) 2. Press the retaining ring (2.5) on the socket.

  • Page 47: D5 Remedial Measures For Malfunctions

    Cylinder sinks Air in the hydraulic system Vent the system, see D5.2. Load safety valve is defect Replace climbing device. Repairs carried out by PERI. Sealing is defect Replace climbing device. Repairs carried out by PERI. Uneven cylinder Air in the hydraulic system Vent the system, see D5.2.
  • Page 48 Spring in climbing shoe is Release climbing pawl manually, see D5.5. broken Replace climbing shoe. Repairs carried out by PERI. Cylinder does not extend far Carry out a reference run, see D5.3. enough Synchronisation deviation Cylinder does not...
  • Page 49 Part D Operations D5 Remedial Measures for Malfunctions D5.2 Venting the system In order to ensure a reliable operation of the system, the system must be completely vented during the initial commissioning on site, after tubes and hoses have been replaced, or after main- tenance work has been carried out on the cylinder.

  • Page 50: A1 Climbing Device Rcs

    Part D Operations D5 Remedial Measures for Malfunctions D5.2 Venting the system D5.3 Carrying out a reference run Carry out a reference run if there is any Venting during hose replacement synchronisation deviation in a cylinder 1. Detach old hose. pair.
  • Page 51 Part D Operations D5 Remedial Measures for Malfunctions Cylinder 2 Cylinder 1 D5.4 Extending the cylinders to the same height A large synchronisation deviation can result in a lateral offset. In rare cases, this could negatively affect the “thread- ing” of the RCS Rails in the next climbing shoe.
  • Page 52 Fig. 61: Manually activated climbing pawl After completing the climbing proce- dure, replace the climbing shoe or have repair work carried out by PERI! Risk of crushing! Do not touch if the load is moving! Procedure: 1.
  • Page 53 After climbing procedure is com- pleted, replace the climbing device or have repairs carried out by PERI! Risk of crushing! Do not touch if the load is moving! In the event of a broken leg spring in the cylinder base, tip back the climbing de- vice (1) by hand into the climbing rail (9).

  • Page 54: Part E Connection And Circuit Diagrams E1 Hydraulic Connection Diagram

    Part E Connection and Circuit Diagrams E1 Hydraulic Connection Diagram Standard hose arrangement diagram Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Hose 10 m Hose 10 m Hose 20 m Hose 20 m Climbing Unit 1 Climbing Unit 2 Fig.

  • Page 55: E2 Hydraulic Circuit Diagram

    Part E Connection and Circuit Diagrams E2 Hydraulic Circuit Diagram 1 0 9 . 0 6 3 - 5 7 5 S K 0 5 0 7 2 3 A S K 0 5 0 7 2 4 A 9 6 4 . 0 2 0 1 9 0 + 1 0 b a r 1 9 0 + 1 0 b a r 4 .
  • Page 56 Part E Connection and Circuit Diagrams E2 Hydraulic Circuit Diagram Hydraulic circuit diagram: Climbing Device RCS 50 Item no. 109765 (109.063G) 210 bar Fig. 66: Hydraulic circuit diagram for the Climbing Device RCS 50 RCS Climbing Device and Hydraulics Assembly Instructions...

  • Page 57: E3 Electrical Power Supply Diagram

    Part E Connection and Circuit Diagrams E3 Electrical Power Supply Diagram Connection on an out-of- operation motor is carried out by qualified personnel only! Electric power supply 400 – 460V, 50 – 60Hz, 8.2 A 4.0 – 4.6 kW. Fig. 67: Electrical power supply diagram RCS Climbing Device and Hydraulics Assembly Instructions...

  • Page 58: Maintenance Chart

    Maintenance Chart Maintenance Name / location Comments Date Signature RCS Climbing Device and Hydraulics Assembly Instructions...
  • Page 59 RCS Climbing Device and Hydraulics Assembly Instructions...

  • Page 60: Components / Spare Parts

    Components / Spare Parts Item no. Weight kg 109765 27.00 Climbing Device RCS 50 Technical Data For crane-independent Maximum lifting capacity 50 kN. climbing of RCS climbing units. 1080 109766 109.00 Hydraulic Pump RCS 4 x 190 Technical Data bar, 380 – 460 V...
  • Page 61 Components / Spare Parts Item no. Weight kg Hydraulic Fluid HV LP46, 20 L 057376 17.400 High grade, synthetic hydraulic fluid for PERI Hydraulic Pumps. Hydraulic Twin Hose RCS Complete with 110069 9.000 Hydraulic Twin Hose RCS 10 m 2 x 110822 Quick-Coupler...
  • Page 62 Components / Spare Parts Item no. Weight kg 110279 0.250 Plug Socket RCS, black Note For the power supply of the Connection to the power Hydraulic Pump RCS with supply only to be done by 380 – 460 V, 50 – 60 Hz. qualified personnel.
  • Page 63 Fitting Set PS short RCS Complete with 115396 0.720 SK080.709A Replacement Fitting 1 x 109765 Climbing Device Set for Item no. 109765 Climbing RCS 50 Note Device RCS for 2x 110822 Quick-Coupler Bushing and 2x consisting of: 110823 Quick-Coupler Nipple Screw Connection K018.294 (1x Cylinder 109.063E-575).
  • Page 64 Handelsbezeichnung Klettermechanik RCS Funktion Das Kletterwerk RCS 50 steht auf dem Kletterschuh RCS. Der Kletterschuh RCS ist über einen Wand - oder Deckenschuh am Bauwerk verankert. Das Kletterwerk arbeitet mit der Klinke im Kletterschuh zusammen. Die Klaue am Kolben rastet in die Kletterbolzen (Distanzierungen in der Kletterschiene RCS) ein und schiebt beide zusammen mit der Traggerüstkonstruktion nach oben.
  • Page 65 Part F Appendix Einbauerklärung im Sinne der EG-Maschinenrichtlinie 2006/42/EG, Anh. II 1. B für unvollständige Maschinen Wichtiger Hinweis! Die unvollständige Maschine darf erst dann in Betrieb genommen werden, wenn gegebenenfalls festgestellt wurde, dass die Maschine, in die die unvollständige Maschine eingebaut werden soll, den Bestimmungen dieser Richtlinie entspricht.
  • Page 66 PRJ-2018-11-16-0001 Trade Name Climbing Mechanism RCS The Climbing Device RCS 50 is positioned on the Climbing Shoe RCS. The Climbing Shoe RCS is Function anchored to the building by means of a wall or slab shoe. The climbing device works together with the climbing pawl in the climbing shoe.
  • Page 67 Part F Appendix Declaration of Incorporation In accordance with the EC-Machinery Directive 2006/42/EG, Annex II 1. B for partly completed machinery Important note! The partly completed machinery must not be put into service until it has been established, where appropriate, that the machinery into which the partly completed machinery is to be incorporated complies with the provisions of this Directive.
  • Page 68 RCS Kletterwerk und Hydraulik Montageanleitung...
  • Page 69 RCS Kletterwerk und Hydraulik Montageanleitung...
  • Page 70 Bridge Formwork Tunnel Formwork Shoring Systems Construction Scaffold Facade Scaffold Industrial Scaffold Access Protection Scaffold Safety Systems System-Independent Services Accessories PERI GmbH Formwork Scaffolding Engineering Rudolf-Diesel-Strasse 19 89264 Weissenhorn Germany Tel. +49 (0)7309.950-0 Fax +49 (0)7309.951-0 info @ peri.com www.peri.com...

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