Webtool RCV190 Programming manual

Allspeeds Ltd.
Royal Works, Atlas St
Clayton le Moors
Accrington
Lancashire
England
BB5 5LW
Tel [phone]
www.allspeeds.co.uk
WIRE ROPE CUTTER RCV190
PRODUCT CODE No. 980230
INSTRUCTIONS FOR INSTALLATION,
OPERATION & MAINTENANCE
Revision 5 issue 3. Modification No. 20619 Date 18TH. Sept 2013
© Copyright Allspeeds Holdings Ltd.
This document must not be modified in any way.

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Description
The cutter is primarily intended for use on steel wire rope, having a maximum tensile strength
of 1880N/mm and will cut ropes up to 190mm diameter. It may be used on alternative
materials, such as electrical power or communication cables, again up to a maximum of 190mm
diameter. Where smaller diameters are to be cut, effort should be made to place the material
centrally along the anvil to minimise any offset loading. Two sets of steel jaw pads (wear plates)
are supplied, to permit reduction of the jaw width. One pair (20mm thick) for cutting materials
up to 155mm diameter, and one pair (8mm thick) for materials in the range 155mm to 190mm
diameter
IMPORTANT
If it is required to extend the recommended use of the cutter, for instance to cut solid steel bar,
please refer to the manufacturer with full details of material size and tensile strength. Cutting
unsuitable materials could result in damage to the tool.
1. SAFETY
Before operation, read and understand this operations manual.
Whilst the tool is intended for remote or local operation sub-sea, there is no reason why it
should not be used above surface.
Ensure that the tool, hoses and pump are in good condition and properly connected.
Ensure that suitable pressure regulation equipment is used and that the unit is not subjected to
pressures higher than those stated in section 3
In all cases, where an operator is present, the safety aspects must be reviewed before the
cutting operation is commenced.
No attempt should be made to cut any material that is under tension.
Ensure that the operator is shielded from the cutting blade during the cutting operation.
When cutting near the very end of the wire rope fragments can be expelled from the tool,
please ensure that the operator is shielded from these.
If in doubt please contact the manufacturer (Allspeeds Ltd) or an authorized distributor for
assistance.
If at any time it is necessary to carry out proof tests on the tool, e.g. after service on the
hydraulic cylinders, it must be returned to the supplier for testing where the following
procedures apply.
The maximum proof test pressure should not exceed 125% of the maximum working pressure
and this should only be done by Allspeeds using our specially adapted test rig.
The tool should be guarded during the proof test operation, and be carried out in a safe working
environment.
The proof pressure should be applied gradually, until the maximum pressure is reached.

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Important: Please note this tool is designed for intermittent subsea use. Please refer to the
manufacturer (Allspeeds Ltd) or an authorized distributor should you wish to use this tool
subsea for any period over 14 days.
CAUTION –Any modification made to this tool will invalidate the warranty and may lead to
equipment failure or personal injury. If in doubt please contact the manufacturer (Allspeeds Ltd)
or an authorised distributor for assistance.
INSPECT THE TOOL BEFORE USE
With the cutter isolated from the hydraulic supply, check the condition of the blade edge. If the
blade is damaged or blunt replace with a fresh blade before cutting. This procedure is as
described in section 8.
Ensure that care is taken when checking the blade as the edge may be sharp
Check the condition of the anvil. It is normal that the anvil will show an indent where the blade
has pressed down into it and can withstand multiple cuts, but any excessively damaged anvil
should be replaced. This procedure is as described in section 7
CAUTION –USE OF BLADES AND PARTS NOT APPROVED BY WEBTOOL MAY RESULT IN TOOL
FAILURE AND CONSEQUENTIAL DAMAGE
2. CUTTING CAPACITY
The cutter is primarily intended for use on steel wire rope, having a maximum tensile strength
of 1880N/mm and will cut ropes up to 190mm diameter. It may be used on alternative
materials, such as electrical power or communication cables, again up to a maximum of 190mm
diameter. Where smaller diameters are to be cut, effort should be made to place the material
centrally along the anvil to minimise any offset loading.
3. INSTALLATION
Tapped Holes, ⅝” UNC, are provided in the tool body (see sketch) which can be
used for any attachment necessary to mount the cutter. The cylinder is a pressure vessel and is
not recommended as a mounting point, the cylinder should not be drilled, machined, mutilated
or damaged in any way, any warranty could be invalidated by such actions.

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Two hydraulic supplies are required, ported as shown below. The maximum
working pressures are shown in the table below and pressure limiting valves must be fitted into
the supply to limit the pressures to these levels.
The weight of the tool is 295kg.
TABLE 1.
Function
Max. Working Pressure
Swept Volume
Port Tapping
psi
bar
ml.
U.S. Gallon
Main Ram Working Stroke
10,000
690
5200
(1.374)
¼” BSP
Main Ram Return
Stroke
10,000*
210*
1390
(0.367)
¼” BSP
Auxiliary Cylinders Out
Stroke
(to retract anvil)
2,750
190
100
(0.026)
¼” NPT
Auxiliary Cylinders Instroke
(to reset anvil)
2,750
190
60
(0.016)
¼” NPT
*N.B. Actual pressure required to return Ram < 200 psi (14 bar). The pressure is regulated with a
relief valve set to 250 bar

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4. OPERATION
Before deployment, function test the tool and ensure that all operators are familiar with
this procedure. ROV observation of the tool should be maintained at all time during operation.
Prior to use, ensure no damage has occurred to the blade or anvil. Ensure the anvil is
fully retracted.
DEPLOYMENT
Prior to use, the auxiliary cylinder outstroke should be operated to withdraw the anvil.
This clears access for the cutter to be placed over the wire rope.
Place the cutter over the wire rope. Ensure that the wire rope is as far into the cutter as
possible so that the anvil does not foul as it is reset. Place the cutter over the wire rope.

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Operate the auxiliary cylinder instroke to position the anvil fully home under the wire rope, the
main ram should not be activated until the auxiliary cylinders are operated to the full extent
of their stroke.
Operate the main ram down-stroke to sever the wire rope. Once the wire rope is severed,
Pressurize the main ram retract port to withdraw the cutting blade. Then, and only then, retract
the anvil. It is important not to operate the anvil cylinder whilst the main ram and blade are in
the fully extended position.
If a further cut is required, the above procedure should be repeated.
N.B. Do not operate the auxiliary cylinders when the main ram is fully extended since this would
damage the anvil.
Please note that this tool has a relief valve fitted which will blow off at approx. 750 bar, DO NOT
leave the pressure on so that the relief valve is continually blowing off.
TROUBLESHOOTING
If the wire rope does not cut through completely on the first attempt, cycle the blade by
retracting it slightly and then attempting the cut again.
If the wire rope does not completely cut after multiple cycles of the blade, check the Input
pressure to the main input of the cylinder. This can be a maximum of 700 bar (10,000psi).
If the wire rope to be cut is still not severed after multiple cycles and at a pressure of 700 bar,
Retract the blade and then the anvil and return the tool to the surface for inspection of the
blade and anvil, replace if necessary.
IMPORTANT NOTE –ENSURE THAT THE BLADE IS FULLY RETRACTED AND THAT ALL PRESSURE
TO THE CUTTER IS RELIEVED AS IT IS RAISED TO THE SURFACE. FAILURE TO DO THIS CAN LEAD
TO A DANGEROUS BUILD UP OF PRESSURE IN THE CYLINDER.

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5. AFTER USE
When the tool is retrieved, it should be hosed off with clean water, allowed to drain and
sprayed externally with a de-watering fluid. Before storage, inspect the general condition of the
tool. Particular attention should be paid to the anvil and blade. The anvil should be clean and
free from any damage or bruising on the outside diameter that would prevent it from retracting
properly. The blade edge should be smooth and free from any serrations. Note that a slight
ripple to the blade edge is acceptable and will not cause problems. Any minor damage can be
smoothed off with an oil stone if necessary.
6. SERVICE
It is unlikely that service would be required on the hydraulic components of the tool under
normal circumstances, but a seal spares kit is available if required. The only parts that would
need intermittent replacement would be the anvil, blade and wear plates, depending on the
frequency of use and materials being cut. These parts can be ordered up on the following spares
reference numbers, but in addition please quote the tool serial number.
Seal Kit Part Number 995 133
Anvil Part Number SSC 6500
Blade Part Number 705 064C
Wear plates 8mm thick Part number 765312A & B 2 off each
Wear plates 20mm thick Part number 765310A & B 2 off each
We advise that any servicing should be carried out by an authorised distributor only.
If required, the tool can be returned to the manufacturer (Allspeeds Ltd.) for servicing and
testing.
If servicing is to be undertaken by the user, please see note on proof testing under
SAFETY (Chapter 1), and the following:-
All servicing operations should be carried out in a clean environment to prevent contamination
of the oil and mating components.
Care should be taken with all mating areas ie. threads and sealing faces, as any damage or
abrasive contamination could cause galling or seizing on re-assembly.
The cylinder is a pressure vessel and should not be drilled, machined, mutilated or damaged in
any way for mounting purposes or to assist in its removal for servicing, any warranty could be
invalidated by such actions.
The use of stilsons to remove the cylinder is not recommended as damage will occur.
7. REPLACEMENT OF THE ANVIL
Extend the auxiliary cylinders so that the lever arm 765309 exits the anvil guide bush 715365.
Loosen the 8 off M6 screws 035079 holding pivot pin housings 749045A & B.
Loosen the M6 retaining screw 035073.

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Withdraw the pivot pin 761267 far enough to release the lever arm. (There is an M6 tapped
hole in the end of the pivot pin to assist in withdrawing this)
The lever arm can be moved upwards to separate it, with the anvil pin 761247, from the anvil
SSC6500. The anvil may now be slid out from the anvil guide bush.
Re-assembly is the reverse of the above process.
8. REPLACEMENT OF THE CUTTING BLADE
First withdraw the anvil as described above.
Pump out the main ram until the blade spring pins 030636 can be seen in the opening of the
cutter body.
The three pins are ¼” (6.35mm) diameter and they should be knocked out enough to release the
blade.

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With the pins removed the blade can be taken from the cutter, gloves should be worn to
prevent cuts from any sharp edges that may be present on the blade after use.
Re-assembly is the reverse of the above process.
9. REMOVAL OF THE MAIN CYLINDER
If it is necessary to renew the hydraulic seals, the cylinder must be removed from the tool. As an
aid to this, 2 off tapped holes are provided in the cylinder end face. These are M8 x10 deep on
136mm centres.
A cylinder assembly tool is available if required part number SK4377A.
First, remove the anvil as described above in section 7, pump out the ram and remove the
blade, again as described above in section 8.
To use the holes in the top of the cylinder first remove the coupling, then the blanking screws
035114 and fasten a piece of flat bar, typically 30x10mm section and 900mm long centrally to
the top of the cylinder. This can be used to loosen or re-tighten the cylinder. Do not use Stilsons
to remove the cylinder as damage will occur.
Unscrew the cylinder 728090 and remove from the assembly, it will come free but still attached
will be the ram 764138.

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Put the assembled parts into a plastic dust bin or similar vessel, fit the coupling to the top of the
cylinder, attach a hand pump to the coupling and pump out the ram, importantly, by hand.
The ram will now be free of the cylinder and all seals will be accessible.
The ram has been fitted with a relief valve plug, this also contains seals, to remove the part the
two M8 tapped holes can be used to unscrew the plug, the two relief valves have been careful
set to blow off at a set pressure, these can be removed with a 17mm socket and 5mm allen key,
care should be taken not to disturb the settings.
When re assembling the relief valve plug with the ram, first fill the ram with oil to the bottom of
the counterbore, smear silver goop on to the threads of the plug, screw in the plug, remove the
set screw and ball in the top of the plug and top up the inside of the ram with oil until it fills the
screw hole, fit the ball and screw and lock tight.
Check that the plug and the relief valves are tight and below the top face of the ram.
Fit the ram into the assembly, locate the blade and fit the spring pins, put grease on the threads
and screw in the cylinder using the two tapped holes and the flat bar, remove the bar, replace
the screws and fit the coupling and bonded seal.
Re fit the anvil lever etc. The tool is now ready for use.

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RCV 190 –Full Part List excluding seals
980230
Part No.
Description
Qty.
728090
Cylinder
1
764138
Ram
1
765312A
Wear plate 8mm thick
2
765312B
Wear plate 8mm thick
2
749045A
Pivot pin housing, left
1
749045B
Pivot pin housing, right
1
SSC6500
Anvil
1
761247
Pin, sliding, anvil
1
715365
Anvil guide bush
1
715355
Anvil bush
1
761247
Sliding anvil pin
1
705064c
Blade
1
761267
Lever pivot pin
1
761268
Cylinder rod pin, auxiliary cylinder
2
765309
Lever
1
080971
Special washer M6
4
079044
Mounting stud, auxiliary cylinder
2
715345
Lever pivot pin bush
2
765310A
Wear plate 20mm thick
2
765310B
Wear plate 20mm thick
2
709087
Piston block
2
728078
Cylinder, auxiliary
2
SSC6476
Auxiliary end cap
2
764116
Auxiliary piston
2
766093
Relief valve plug
1
026701
Pellet
2
043206
Socket set screw M4 x 6
2
035067
Socket cap screw M5 x 30
8
701195
Swagelok connector
2
035111
Socket cap screw M6 x 35
12
035079
Socket cap screw M6 x 25
8
035066
Socket cap screw M6 x 20
8
035076
Socket cap screw M6 x 16
5
035073
Socket cap screw M6 x 10
1
035114
Socket set screw M8 x 10
2
035136
Socket c’sunk headed screw M10 x 20
20
030636
Spring pin ¼” x 2”
3
752342
Nameplate
1
766047
Blanking plug
4
791157
Coupling ¼” BSP to No.4 JIC
2
035080
Socket set screw
1
31-47-0310
Blanking ball
1
752573
Pressure warning label
1
31-99-2809
Eye bolt
2
982144
Body sub-assembly
1
1155006
Relief valve 700 bar
1
1155007
Relief valve 250 bar
1

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Seal Kit –Part List
995133
Part No.
Description
Qty.
025311
Seal, ‘O’ ring, end cap
2
025569
Scraper, rod
2
025801
Seal, piston
2
025802
Seal, rod
2
025917
Main piston seal
1
025918
Main rod seal
1
025670
Seal O ring
1
025919
Main wiper seal
1
32-60-3023
O ring relief valve plug
2
32-61-3023
A/E for 32-60-3023
2
32-60-2419
O ring for relief valve
1
32-61-2419
A/E ring for 32-60-2419
1
32-01-0206
O ring for relief valve
1
32-07-0035
Bonded seals
2
Replacement Auxiliary cylinders can be ordered under the part number 982145, a full list of
auxiliary parts are shown below
Auxiliary Cylinder –Part List
982145
Part No.
Description
Qty.
709087
Piston block
1
728078
Cylinder
1
SSC6476
End cap
1
764116
Piston
1
026701
Pellet
1
043206
Socket set screw M4 x 6
1
035067
Socket cap screw M5 x 30
4
701195
Swagelok connector
1
025311
Seal, ‘O’ ring, end cap
2
025569
Scraper, rod
2
025801
Seal, piston
2
025802
Seal, rod
2
Replacement Relief valve plug assemblies can be ordered under the part number 991015, a full
list of these parts are shown below
Relief valve plug kit –Part List
991015
Part No.
Description
Qty.
766093
Relief valve plug
1
32-60-3023
O ring relief valve plug
2
32-61-3023
A/E for 32-60-3023
2
32-60-2419
O ring for relief valve
1
32-61-2419
A/E ring for 32-60-2419
1
32-01-0206
O ring for relief valve
1
035080
Socket set ecrew
1
31-47-0310
Blanking ball
1
1155006
Relief valve 700 bar
1
1155007
Relief valve 250 bar
1

Page 13 of 14
This RCV190 wire rope cutter is compatible with the following optional extras, not supplied as
standard.
Cylinder Assembly Tool - SK4377A
This tool can be used on RCV75, RCV75HD, RCV115, RCV135, RCV155, RCV190, HCV100,
HCV120, HCV250 and HCV270 cutting tools
Webtool Hydraulic Intensifier –HP690A (available in a range on intensification ratios)
For further information contact the manufacturer (Allspeeds Ltd) or an authorised distributor.

Page 14 of 14
CUTTING EDGE TECHNOLOGY
Webtool specialises in engineering powerful hydraulic tools for
cutting and gripping rope, cable and umbilicals.
Models designed for use in subsea environments by ROV’s, and
surface applications in hostile environments.
Wire rope cutters (WCS and WCOS) –capable of cutting steel wire rope
up to 75mm diameter
Wire Rope Cutters (RCV) –capable of cutting steel wire rope up to
190mm diameter
Cable Cutters (HCV) –capable of cutting cable, umbilical and armoured
flexible pipe lines up to 330mm diameter
Softline Cutters (SL) –capable of cutting fibre ropes in various sizes
Wire Rope / Cable Grippers
Wire Rope Clamps
Automatic Shackles
Application specific solutions
Our in house design and manufacturing capability means we can
quickly and efficiently develop a solution to suit your particular
application. Contact our engineering department to discuss how we
can help.
Allspeeds Ltd, Royal Works, Atlas Street, Clayton-Le-Moors,
Accrington, Lancashire, BB5 5LW, England
T: [phone] F: [phone]
E: [email protected] W: www.allspeeds.co.uk