Peri RCS 50 User manual

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

3
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Key
Dimension specifications
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.
Conventions
– Instructions are numbered with:
1. ....., 2. ....., 3. .....
– The result of an instruction is
shown by: "
– Position numbers are clearly
provided for the individual compo-
nents and are given in the drawing,
e.g. 1, in the text in brackets, for
example (1).
– Multiple position numbers, i.e. alter-
native components, are represented
with a slash, e.g. 1 / 2.
Safety instructions
Visual check
Information
Tip
Load-bearing point
Arrow representing an action
Arrows
Misapplication

2
Content
RCS Climbing Device and Hydraulics
Assembly Instructions
Introduction
Key 3
Warning Signs 4
Intended Use 5
Standard Assembly 6
Technical Data 7
Target Groups 8
Safety Instructions 10
Part A Overview
A1 Climbing Device RCS 50 13
A2 Hydraulic Twin Hose RCS 14
A3 Hydraulic Pump RCS 15
A4 Climbing Shoe RCS 17
A5 Climbing Device in Use 18
Part B Transportation and Storage
B1 Measures 19
B2 Packaging 20
Part C Maintenance
C1 Initial Commissioning 21
C2 Commissioning 22
C3 Maintenance and Repairs 24
Part D Operations
D1 Preparations 28
D2 Installing the Climbing Device 29
D3 Self-Climbing Procedure 36
D4 Dismantling the Climbing Device 46
D5 Remedial Measures for Malfunctions 47
Part E Connection and Circuit Diagrams
E1 Hydraulic Connection Diagram 54
E2 Hydraulic Circuit Diagram 55
E3 Electrical Power Supply Diagram 57
Maintenance Chart 58
Components / Spare Parts 60
Part F Appendix
Installation Declaration 64

4
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,
could result in death or serious injury.
Warning
This sign indicates a hazardous situation,
which, if not avoided, could result in
death or serious injury.
Caution
This sign indicates a hazardous situation,
which, if not avoided, could result in
minor or moderate injury.
This sign indicates situations in which
failure to observe the information can
result in material damage.
Warning Signs
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions

5
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Intended Use
The Climbing Device RCS 50 is used
exclusively for lifting a climbing unit,
consisting of formwork and supporting
structure, to the next concreting section.
PERI products have been designed
for exclusive use in the industrial and
commercial sectors by suitably trained
personnel only.
These Assembly Instructions serve
as a basis for the project-related risk
assessment as well as instructions for
the provision and use of the system by
the contractor (user). However, they
do not replace them.
The components are to be inspected
before each use to ensure they are in
perfect condition and that they function
correctly.
Only PERI original components may be
used. The use of other products and
spare parts represents a misapplication
with associated safety risks.
Changes to PERI components are not
permitted and represent a misapplication
with associated safety risks.
Safety instructions and permissible
loads must be observed at all times.
Components provided by the contractor
must conform with the requirements
found in these Assembly Instructions as
well as all valid construction guidelines
and standards.
Deviations from the standard con-
figuration are not permitted. Special
applications must be described in the
form of detailed planning and operating
instructions based on a separate risk
assessment. These special applications
must be approved by PERI.
Anything other than the use that is
specified in Point 1 is considered
contrary to the designated use!
For damage arising from non-intended
use:
– the operator bears the sole
responsibility,
– the manufacturer assumes
no liability.

6
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
General
The climbing mechanism for the
Self-Climbing System RCS consists of:
– Climbing Device RCS 50
– Hydraulic Pump RCS 4 x 190 bar,
380 – 460 V
– Climbing Shoe RCS
– Climbing Rail RCS, if required with
Climbing Rail Extension RCS 125
Function
The Climbing Device RCS 50 is posi-
tioned on the Climbing Shoe RCS.
The Climbing Shoe RCS is 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. The claw on the piston
engages the climbing bolts (spacers in
the Climbing Rail RCS) and pushes both
of them, together with the supporting
structure, upwards. At the end of the
stroke, the pawl in the Climbing Shoe
engages in another climbing bolt. Once
the cylinder is retracted, the pawl carries
the load and the claw circumvents the
next climbing bolt. After this, the claw
engages this climbing bolt.
Applications
With the help of the Climbing Hydraulics
RCS, climbing units can be moved
vertically without using a crane.
Standard supporting structure:
– Guided Climbing Formwork RCS C
– Light Climbing Formwork RCS CL
– Climbing Protection Panel RCS P
– Material Lifter RCS ML and Guided
Material Platform RCS MP (used in the
same way as the RCS P).
For special applications, the design
engineer must check whether additional
or alternative measures are required for
the climbing procedure. These measures
are to be shown and described in the
general arrangement drawings and
assembly plans.
The structures shown in these Assembly
Instructions are examples and feature
only one component size. They are valid
accordingly for all component sizes
contained in the standard configuration.
Additional PERI product information
– Instructions for Assembly and Use
(e.g. for RCS C, RCS CL or RCS P)
– Instructions for Use (e.g. for the Lifting
Beam RCS 10 t)
– PERI PI – separate product information
(e.g. for permissible anchor loads)
Standard Assembly

7
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Climbing Device RCS 50
Stroke length effective 500 mm (maximum 575 mm)
Lifting power maximum 50 kN (11.2 kip)
Operating pressure 190 bar (19 MPa)
Hydraulic Pump RCS 4 x 190 bar, 380 – 460 V
Power supply 400 V/50 Hz (3-phase) flow rate 6 l/min
Power supply 460 V/60 Hz (3-phase) flow rate 7 l/min
Sound emissions 64 dB (A) at a distance of 1.0 m
Information only – for use only in Canada:
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
designed for long-term use on con-
struction sites.
In order to ensure cost-effective, techni-
cal and safe use over a long period, it is
important to take a value-preserving
approach.
Use in a way not intended or deviating
from the intended use according to the
Assembly Instructions represents a mis-
application with a potential safety risk.
Changes to PERI components are not
permitted.
Only PERI original parts may be used.
The use of other products and spare
parts represents a misapplication with
associated safety risks.
Instructions on Use
Repairs which require welding or defor-
mation of components must be carried
out by PERI.
Use PERI original components as spare
parts.
Operations with damaged or incomplete
lifting equipment are not permissible.
The system described in these Assembly
Instructions may contain patent-protect-
ed components.
Technical Data

8
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Contractors
These Assembly Instructions are
intended for contractors who use PERI
products for
assembling, modifying and dis-
mantling operations, or
use them, e.g. for concreting, or
who have them used, e.g. for forming
operations.
Construction site coordinator
The Safety and Health Protection
Coordinator*
is appointed by the client,
must identify potential hazards during
the planning phase,
determines measures that provide
protection against risks,
creates a safety and health plan,
coordinates the protective measures
for the contractor and site personnel
so that they do not endanger each
other,
monitors compliance with the
protective measures.
* Valid in Germany: Regulations for
Occupational Health and Safety on
Construction Sites 30 (RAB 30).
Competent person
Due to the specialist knowledge gained
from professional training, work experi-
ence, and recent professional activity,
the competent person has a reliable
understanding of safety-related issues
and can correctly carry out inspections.
Depending on the complexity of the test
to be undertaken, e.g. scope of testing,
type of testing or the use of a certain
measuring device, a range of specialist
knowledge is necessary.
Target Groups

9
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Qualified personnel
PERI products may only be assembled,
modified or dismantled by personnel
who are suitably qualified to do so. For
the work to be carried out, the qualified
personnel must have received instruc-
tions** covering at least the following
points:
The plan for the assembly, modifi-
cation or dismantling of the PERI
product in an understandable form
and language.
The measures necessary to safely
assemble, modify or dismantle the
PERI product.
Naming of the preventive measures to
be taken to avoid the risk of persons
and objects falling.
The safety precautions to be taken in
the event of changing weather condi-
tions that could adversely affect the
safety of the PERI product concerned,
as well as the personnel.
Details regarding permissible loads.
Description of all other risks and
dangers associated with assembly,
modification or dismantling opera-
tions.
** Instructions are given by the contractor
himself or a competent person selected
by him.
In other countries, ensure that the
relevant national guidelines and
regulations in the respective current
version are complied with!
Target Groups

10
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
General
Deviations from the standard con-
figuration and/or intended use present
a potential safety risk.
All country-specific laws, standards and
other safety regulations are to be taken
into account whenever our products are
used.
In the case of unfavourable weather
conditions, suitable precautions and
measures are to be implemented, in
order to guarantee working safety and
stability.
The contractor (user) must ensure the
stability throughout all phases of con-
struction. He must ensure and verify that
all occuring loads are safely transferred.
The contractor (user) has to provide safe
working areas for site personnel which
are to be reached through the provision
of safe access ways. Areas of risk must
be cordoned off and clearly marked.
Hatches and openings on accessible
working areas must be kept closed
during working operations.
For a better understanding, detailed
illustrations are partly incomplete.
Some safety installations which have
possibly not been shown in these
detailed descriptions must nevertheless
still be available.
Storage and transportation
Do not drop the components.
Store and transport components ensur-
ing that no unintentional change in their
position is possible. Detach lifting gear
from the lowered units only if these are
in a stable position and no unintentional
change is possible.
When moving the components, make
sure they are lifted and set down in a
way that any unintentional tilting over,
falling apart, sliding or rolling away is
prevented.
Use only suitable lifting accessories to
move the components as well as the
designated load-bearing points.
During the lifting and moving procedure,
ensure that all loose parts are removed
or secured.
During the moving procedure, always
use a guide rope.
Move components on clean, flat and
sufficiently load-bearing surfaces only.
PERI products must be protected against
the effects of the weather and aggres-
sive materials if safety is then likely to be
affected!
Safety Instructions

11
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
Product-Specific
Operations
The contractor must ensure that the
assembly, modification, dismantling,
moving, use and handling of the product
is managed and supervised by qualified
personnel and authorised personnel.
All persons working with the product
must be familiar with the operating
instructions and safety information.
The contractor has to ensure that the of-
ficial Assembly Instructions, Instructions
for Assembly and Use, other instructions
required for operations or assembly,
relevant planning documents, parts lists
and other data are available to the users.
Access ways and working areas
Safe access to all working areas must
be guaranteed at all times.
Working areas must remain free of any
tripping hazards.
Working platforms are to be kept clean
and tidy.
Avoid installing working areas and
access points in areas of risk.
Make sure the Hydraulic Pump is
positioned on a level and sufficiently
load-bearing surface.
Assembly
Mandatory personal protective
equipment (PPE):
– safety helmet
– safety shoes
– protective gloves
There is always the possibility of unfore-
seen risks arising during assembly work.
Assess the degree of risk in each individ-
ual case and, if necessary, take meas-
ures to prevent or at least minimise the
risk.
If guardrails cannot be used due to
technical reasons or have to be removed,
then site personnel are to be secured by
other means (e.g. through rope protec-
tion).
Site personnel are forbidden to remain
in areas below where assembly work is
being carried out unless the area of risk
has been provided with sufficient protec-
tion against falling, overturning, sliding
or rolling objects and masses. The area
of risk is to be cordoned off and clearly
marked.
Risk of crushing!
Do not touch if the load is moving!
Safety Instructions

12
Introduction
RCS Climbing Device and Hydraulics
Assembly Instructions
When climbing with climbing hydraulics,
details regarding the arrangement of the
hydraulic hoses must be considered.
In the case of malfunctions
– lower platform to the next possible
position and secure.
– leave the climbing unit in the safest
way possible.
– an authorised person is to be informed
immediately!
Maintenance and repairs
– Only use materials which are in perfect
condition.
– Components of the climbing systems
are to be checked for signs of damage
by qualified personnel and authorised
persons on a regular basis. Dirt which
affects functionality is to be removed
immediately.
– Damaged components are to be
inspected, removed and replaced.
– Determine the cause of any damage
that occurs on a recurring basis and
rectify.
PERI climbing hydraulics may not
be used if the type plate is missing,
incomplete or illegible.
Protection against falling objects
Secure tools and materials to prevent
them from falling to the ground.
Concrete residue and other dirt deposits
are to be removed.
Avoid positioning working areas and
access points in areas of risk. If this is
not possible due to work procedures,
suitable equipment (e.g. protective roofs)
must be available to provide protection
against falling objects. This also applies
to work requiring only a short period of
time.
Operational working areas at great
heights are to be secured against
falling objects by means of appropriate
constructional measures. Safety nets
(mesh size ≤ 2 cm) and planking are
considered to be suitable here, and
are to be installed very close (distance
≤ 5 cm) to the building.
Climbing procedure
Anchoring of the climbing units in the
next concreting section is only to be
carried out after the required concrete
strength has been reached.
As a result of the moving procedure,
leading edges are formed between the
platforms. If work is carried out in this
area, site personnel must be secured
(e.g. through rope protection). Cordon
off the area of risk!
During the moving procedure, neither
persons nor construction materials or
tools are allowed to be transported.
Safety Instructions

13
Abb. 2 ( 1 : 5 )
1.1
1.5
1.2
1.4
1.3
1.5
1.6
1.2
1.8
1.4
1.9
1.3
1.6
RCS Climbing Device and Hydraulics
Assembly Instructions
Part A Overview
Due to the clear arrangement of the
quick-coupler nipple (return) and bushing
(inflow) on the Climbing Device and
Hydraulic Pump, a wrong connection
of inflow and return lines is impossible.
When moving, fit quick-couplers with
protection caps (1.9) which protect
against dirt and damage. (One set with
4 pieces, Item no. 125632)
1) To prevent the quick couplers from colliding
with the platforms or other parts of the climbing
protection panel when climbing, it is possible
to arrange the couplings vertically using angle
pieces.
"Contact PERI!
Fig. 1: Climbing Device RCS 50
Fig. 2: Base of the Climbing Device
A1 Climbing Device RCS 50
(1) Climbing Device RCS 50
Item no. 109765 (S/N 109.063-575)
(1.1) Piston head with claw and roller
(1.2) Cylinder base
(1.3) Return flow from the piston rod
side A with the hydraulic
quick-coupler (nipple)
left + right1)
(1.4) Inflow to the piston base B
with the hydraulic quick-coupler
(bushing) left + right1)
(1.5) Reposition device
(1.6) Locking lever
(1.7) Measuring connection
(1.8) Lowering brake valve
(1.9) Protection caps

14
Abb.3 ( 1 : 5 )
Abb. 4 ( 1 : 5 )
RCS Climbing Device and Hydraulics
Assembly Instructions
1.8 1.7
2.3
2.4 2.5
2.1
2.2
Part A Overview
Fig. 3: Lowering brake valve (1.8) Fig. 4: Measuring connection (1.7)
Fig. 5: Hydraulic Twin Hose
A1 Climbing Device RCS 50
A2 Hydraulic Twin Hose RCS
(2.1) Hydraulic Twin Hose RCS 10 m,
Item no. 110069 (SK050.723A)
(2.2) Hydraulic Twin Hose RCS 20 m,
Item no. 110070 (SK050.724A)
(2.3) Hydraulic Quick-Coupler (bushing),
Item no. 110822
(2.4) Hydraulic Quick-Coupler (nipple),
Item no. 110823
(2.5) Retaining ring (bushing)

15
RCS Climbing Device and Hydraulics
Assembly Instructions
3.11
3.7
3.6
3.5
3.4
33.1
3.2
3.3
3.4a
Part A Overview
(3) Hydraulic Pump RCS 4 x 190 bar,
380 – 460 V for 4 climbing devices,
Item no. 109766 (S/N 964.020)
Information only - Hydraulic Pump
RCS 4 x 190 bar, 460 V CSA,
Item no. 114243 (S/N 964.020-CSA)
only for use in Canada
(3.1) Operating lever
(3.2) Motor protection plug CEE
(3.3) Electricity socket with phase
inverter
(3.11)Measuring connection for
pressure check (only through
PERI personnel)
Fig. 8: Measuring Connection in the Pump
Fig. 6: Hydraulic Pump
Fig. 7: Hydraulic Oil Tank
A3 Hydraulic Pump RCS
(3.4) Hydraulic oil tank capacity:
max. 22 litres
(3.4a)
Oil drain screw
(3.5) Oil level indicator with thermo-
meter
(3.6) Filling piece with ventilation filter
(3.7) Return flow filter

16 RCS Climbing Device and Hydraulics
Assembly Instructions
Part A Overview
3.1
4.1
4.2
3.3
3.8
3.9
3.10
3.2
A1 B1 B2 A2
v1= v2
50% 50%
100%
Fig. 9: Hydraulic Pump connections
Fig. 10: Functionality of the flow divider
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)
(3.9) Inflow for piston head side B
of the cylinder with hydraulic
quick-coupler (nipple)
(3.10) Rotary field control lamp
(4.1) Adapter Cable RCS accessory
for supply line with CEE socket
Operational voltage 380 – 400
V/16A, 50 Hz
(4.2) Plug Socket RCS, black accessory
for assembly of Adapter Cable
Operational voltage 380 – 460 V,
50 – 60 Hz
A3.1 Functionality of the flow divider
A flow divider is installed for each pair of
cylinders in the Hydraulic Pump which
evenly divides the flow of the hydraulic
oil to the cylinders.
This ensures load-independent synchro-
nisation of the cylinder.
Synchronisation deviations can be cor-
rected in the respective end position by
keeping the cylinder running against the
limit stop for a period of time.
Cylinder 1 Cylinder 2

17
RCS Climbing Device and Hydraulics
Assembly Instructions
Part A Overview
5.7
5.3
5.1
5.6
5.2
5.2
5.6
5.4
5.5
5.1
5.2
5.3
5.1
5.4
5.5
(5) 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. 13: Climbing Shoe RCS open and climbing pawl
deactivated
Fig. 11: Climbing Shoe RCS from above
Fig. 12: Climbing Shoe RCS closed and climbing pawl
activated
A4 Climbing Shoe RCS

18
9.1
9.1
1
1
6
7
5
5
9
9
RCS Climbing Device and Hydraulics
Assembly Instructions
Part A Overview
For use in the Self-Climbing System
RCS C with Wall Shoe RCS
(9) Climbing Rail RCS
(9.1) Climbing Bolt (spacer in the
climbing rail)
(1) Climbing Device RCS 50
(5) Climbing Shoe RCS
(6) Wall Shoe RCS
For use with the Climbing Protection
Panel RCS P with Slab Shoe RCS
(9) Climbing Rail RCS
(9.1) Climbing Bolt (spacer in the
climbing rail)
(1) Climbing Device RCS 50
(5) Climbing Shoe RCS
(7) Slab Shoe RCS
Fig. 14: Climbing Device in use with RCS C
Fig. 15: Climbing Device in use with RCS P
0.50 m
0.50 m
A5 Climbing Device in Use

19
RCS Climbing Device and Hydraulics
Assembly Instructions
B1.1 Moving on the construction site
– Keep bushing and nipples of all
quick-couplers clean and fit with
protection caps during transportation
(one set with 4 pieces, Item no. 125632)
or couple them together.
– Transport the hydraulic cylinder only
with the piston rod in a retracted
position.
– Transport the hydraulic hoses rolled
up – do not drag along the ground.
B1.2 Temporary storage on the
construction site
– Clean bushing and nipples of all quick-
couplers and fit with protection caps
when storing, or connect together.
– Store the hydraulic cylinder with the
piston rod in a retracted position.
– Store the hydraulic hoses rolled up.
– When storing, place the hydraulic
cylinder in its designated transport
box, see B2.
– Do not store the Hydraulic Pump in
a horizontal position as the oil can
escape through the ventilation valve.
B1.3 Transport from and to the
construction site
– Clean dirt off climbing device and
Hydraulic Pump, and dry.
– Fit bushing and nipples of all quick-
couplers with protection caps or
couple together.
– Transport hydraulic hoses rolled up.
– Fill the hydraulic cylinder and hydraulic
hoses with oil.
– Transport the hydraulic cylinder only
with the piston rod in a retracted
position.
– When transporting, place the hydraulic
cylinder in its designated transport box
and secure, see B2.
– When transporting, place the Hydraulic
Pumps in their designated transport
boxes and secure, see B2.
– Do not transport the Hydraulic Pump
in a horizontal position as the oil can
escape through the ventilation valve.
– When moving transport crates with
the crane, use suitable lifting slings
that are wrapped around the under-
side.
B1.4 Longer storage periods
– Do not drain the oil during downtime.
– Protect connections against corrosion
through a suitable preserving agent.
Close all openings airtight.
– If stored in regions characterised by
high humidity, additionally fill the
hydraulic oil tank to the brim with
hydraulic oil and ensure that the unit
is firmly closed.

20
1323
677 598
RCS Climbing Device and Hydraulics
Assembly Instructions
Part B Transportation and Storage
Fig. 16: Transport Crate for the Climbing Device
Fig. 17: Transport Crate for the Hydraulic Pump
Transport crates
–are only used for transport and
storage purposes.
–do not use as load-handling
equipment!
– Clean dirt off climbing device and
Hydraulic Pump, and dry.
– Fix protection caps to bushing and
nipples of all quick-couplers.
– Place hydraulic cylinder in the desig-
nated transport crate.
– Store the hydraulic hoses rolled up.
– 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)
Hydraulic Pump RCS 109.0 kg
Item no. 109766
(S/N: 964.020)
Hydraulic Twin Hose RCS
Length 10 m 9.0 kg
Item no. 110069
Length 20 m 16.0 kg
Item no. 110070
All weight details do not include the oil.
B2 Packaging
Dimensions of the Hydraulic Pump
RCS: