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Operation Manual -

19

August 29, 2008

safemanbulletinletter.fm

Safety/Service Bulletin 1023-08

Subject: Release of

Safety Manual

version 6.x.1

Dear Schwing Customer,

The

Safety Manual

has been updated to version 6.0.1 and has several changes, most of which

pertain to the more common incidents currently being reported in the concrete pumping industry
(hose whipping, tip overs and electrocution). One notable pagination change occurred. The
pipewall thickness chart, which has always appeared on page 73 of the Safety Manual, has been
pushed back to page 75. In the past, releases such as this would include the complete paperback
manual and a non-laminated version of the updated

Co-worker Safety Rules

. In an effort to “Go

Green”, we have decided to ship a CD containing six PDF files: Version 6.0.1 of Safety Manual
(English & Spanish), version 6.0.1 of the Co-worker Safety Manual (English & Spanish), and
version 6.0.1 of the Line Pump Safety Manual (English & Spanish). This package, as in the past,
also includes an order form for hard copies of any of those documents. Just fill out the attached
form(s) and fax it to us at the number listed. We will ship one set of manuals free of charge for
each unit that is listed with its serial number and current location. Additional manuals are
available at a nominal fee. The Co-worker Safety Rules are available as laminated books intended
to be kept on the pump for easy reference. Please instruct your operators to make the co-worker
information available to the placing crew and laborers, and to read the information to the workers
if they believe the workers wouldn’t understand the printed text. If you are planning any safety
training for your customers, the

Co-worker Safety Rules

booklet is also available in a non-

laminated version at a fraction of the cost. If you choose to order the un-laminated version, the
part numbers are 30381023 for English and 30381028 for Spanish. You could also print them
yourself from the file on the enclosed disc. Of course, the non-laminated version is not intended to
be kept on the pump. It is our objective to get a copy of each of these publications into the hands
of every operator and the workers around the pump. Please help us make the Safety Manual
effective for jobsite safety by obtaining a copy for each of your operators, and encourage them to
read and understand the rules. Older versions of the manual should be discarded when the new
version is in hand.

Thank you in advance for your consideration in this matter.

Best Regards,

Danny L. Mace
Manager, Product Safety Department
Schwing America, Inc.

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Summary of Contents for 30100750

Page 1: ...ion 5900 Centerville Rd White Bear MN 55127 1 888 SCHWING 724 9464 www schwing com OPERATION MANUAL ORIGINAL INSTRUCTIONS FOR CONCRETE LINE PUMPS All SP Rock Valve Models Part Number 30100750 Home TOC TOC Print Print ...

Page 2: ...tion 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Revision date 05 14 Version 3 0 8 Home TOC TOC Print Print ...

Page 3: ...ORIGINAL OPERATING INSTRUCTIONS FOR ALL SP ÒROCK VALVE MODELS Part Number 30100750 Version 3 0 8 Copyright 2014 Schwing All rights reserved swg99a001 eps Home TOC TOC Print Print ...

Page 4: ...Concrete Pump bar PSI 16 Noise emission levels Decibels 16 Safety How to Order Additional Safety Manuals 18 Product Overview First Commissioning 22 Installation of your new unit 22 Machine Description 23 Emergency Stop switches 23 Concrete pump hydraulic pumps 24 Concrete Pump Circuit 24 SP Circuit Diagram 28 Phase A 28 Phase B 30 Phase C 32 Phase D 34 SP 2000 Circuit Diagram 36 Phase A 36 Phase B...

Page 5: ...ng up 74 Changing lanes 74 Loading the unit for shipment 74 Unit Setup 75 Selecting the proper set up location on the job site 75 Laying out the pipeline 75 Setting the Stabilizers 76 Operating the Pump 76 Basic Troubleshooting 77 Before the first truck backs up to your hopper 78 Lubricate your pipeline 81 To control the speed of the unit 83 Pump the job 84 Time Constraints 85 To disable the entir...

Page 6: ...ntenance 114 Scheduled maintenance checklist 115 Unscheduled maintenance 116 Inspecting hydraulic hoses 116 Changing rams 116 Preparation for long term storage 116 Restarting unit after long term storage 116 Tier IV engine Regeneration Control Logic 121 Regeneration Monitoring and Warning Levels 122 Appendix Hydraulic Oil Viscosity Chart 126 Torque Specifications for Metric Bolts 127 Recommended E...

Page 7: ...ts All SP Rock Valve models Startup 250 Users Danny Desktop Operation manuals line pumps All SP Rock Valve models Frame files AllSPRockvalveTOC fm Operation Manual vii End of Life Protocol 156 Home TOC TOC Print Print ...

Page 8: ...Table of Contents Operation Manual All SP Rock Valve models viii revDate Home TOC TOC Print Print ...

Page 9: ...Users Danny Desktop Operation manuals line pumps All SP Rock Valve models Frame files Intro fm Operation Manual 7 INTRODUCTION Manufacturer s Statement 8 Model Number 9 Serial Number 9 ID Tag Location 10 ID Tag 11 swg99a001 eps Home TOC TOC Print Print ...

Page 10: ...the latest technology and safety regulations but it may still be dangerous to people and property if it is operated maintained repaired or used incorrectly The illustrations contained in this manual are intended to clarify text passages They may look slightly different from your unit but this has only been allowed if it does not fundamentally change the factual information Technical modifications ...

Page 11: ...hese s Minnesota main office 651 429 0999 Call Center 1 888 SCHWING 724 9464 How to order parts To place an order for spare parts you can order on line at schwingparts com or you can call our toll free parts line from anywhere in the continental United States except Minnesota Parts department hours are Monday through Friday 6 00 AM to 6 00 PM central time Orders will also be accepted via fax 24 ho...

Page 12: ...Valve Models 10 revDate ID Tag Location The ID tag for this machine is located on the right hand side of the tongue on the passenger side as shown in Figure 1 SWG99a002 eps Figure 1 Location of ID tag and serial number Home TOC TOC Print Print ...

Page 13: ...el subframe The unit serial number is located on the tongue directly below the ID tag as shown in Figure 2 When you locate the number call the Schwing Service Department for the information The unit files are arranged by this serial number and the service personnel can find out anything about the unit from the file that corresponds to this number New ID tags are available from the Service Departme...

Page 14: ...Introduction Operation Manual All SP Rock Valve Models 12 revDate NOTES Home TOC TOC Print Print ...

Page 15: ...Specifications Operation Manual All SP Rock Valve Models SPECIFICATIONS Unit Specifications 14 Hydraulic Pressure Specifications 16 swg99a001 eps Home TOC TOC Print Print ...

Page 16: ...942 psi 100 bar 1450 psi 75 8 bar 1100 psi Max Horizontal Pumping Distance 297 8 m 977 ft 463 3 m 1520 ft 353 6 m 1160 ft Max Vertical Pumping Distance 86 9 m 285 ft 146 3 m 480 ft 100 6 m 330 ft Max Aggregate Size 38 1 mm 1 5 in 12 7 mm 0 5 in 38 1 mm 1 5 in Min Concrete Slump 0 mm 0 in 0 mm 0 in 0 mm 0 in Pumping Cylinder Diameter 177 8 mm 7 in 152 4 mm 6 in 180mm 7 in Stroke Length 1397 mm 55 i...

Page 17: ...put 70 yd3 hr 50 yd3 hr 118 yd3 hr 45 yd3 hr Max Pressure on Concrete 75 8 bar 1100 psi 75 8 bar 1100 psi 108 bar 1566 psi 60 bar 870 psi Max Horizontal Pumping Distance 353 6 m 1160 ft 353 6 m 1160 ft 457 m 1500 ft Max Vertical Pumping Distance 100 6 m 330 ft 100 6 m 330 ft 121 m 400 ft Max Aggregate Size 38 1 mm 1 5 in 38 1 mm 1 5 in 63 mm 2 5 in Min Concrete Slump 0 mm 0 in 0 mm 0 in 0 mm 0 in ...

Page 18: ...4050 SP 1000 300 4350 SP 750 18 300 4350 SP 750 15 266 3867 SP 500 266 3867 SP 2000 300 4350 Agitator 125 1812 Accumulator dump valve 200 2900 Accumulator secondary relief 220 3200 Soft switch relief 100 1450 Stroke limiter circuit 0 25 0 363 Nitrogen pressure 100 1450 Noise emission levels Decibels SP 500 107 dB SP 750 110 dB SP 1000 113 dB SP 1250 113 dB SP 2000 113 dB Home TOC TOC Print Print ...

Page 19: ...y Desktop Operation manuals line pumps All SP Rock Valve models Frame files Safety fm Operation Manual 17 SAFETY How to Order Additional Safety Manuals 18 Safety Manual Separate Document Immediately following page 20 swg99a001 eps Home TOC TOC Print Print ...

Page 20: ...ywhere in the continental United States except Minnesota where you must use the main Schwing office number Schwing Spare Parts Department hours are Monday through Friday 6 00 AM 6 00 PM Central Time Orders will also be accepted via fax 24 hours day We will ship one set of each of the following manuals free of charge for each unit that is listed with its serial number and current location Safety Ma...

Page 21: ...ill ship one set of manuals free of charge for each unit that is listed with its serial number and current location Additional manuals are available at a nominal fee The Co worker Safety Rules are available as laminated books intended to be kept on the pump for easy reference Please instruct your operators to make the co worker information available to the placing crew and laborers and to read the...

Page 22: ... v 6 0 1 Part 30352799 Co worker Bound Laminated Spanish v 6 1 1 Part 30381027 Line Pump Bound English v 6 0 1 Part 30381680 Line Pump Bound Spanish v 6 1 1 Part 30381841 Model number Serial number Model number Serial number Model number Serial number Model number Serial number Model number Serial number internal250 servicebulletins 601order form ai Manual part number ____________________ Manual p...

Page 23: ...p Operation manuals line pumps All SP Rock Valve models Frame Operation Manual 21 OVERVIEW First Commissioning 22 Machine Description 23 SP Circuit Diagram 28 SP 2000 Circuit Diagram 36 Component Locations 58 Safety Devices 66 swg99a001 eps Home TOC TOC Print Print ...

Page 24: ... Flushing oil level gate valve system 11 Oil level in compressor 12 Agitator greased 13 Rock valve greased if equipped 14 Drive line greased 15 Outriggers boom greased 16 Manual remote throttles set to proper RPM RPM 17 Setting of relief valve system l 18 Setting of relief valve system ll 19 Setting of relief valve system lll 20 Pressure gauges work system l ll lll 21 Hydraulic lines checked for l...

Page 25: ...of the manual while you are near the concrete pump so that you can identify the components that are discussed The Schwing trailer mounted concrete pump is mounted on a trailer chassis The pump is hydraulically or electrically driven Emergency Stop switches Pressing one of the RED EMERGENCY PUSH STOP switches Figure 3 will stop the engine SWG98n135 eps Figure 3 Emergency Stop Switches 4 Home TOC TO...

Page 26: ...t less oil per revolution as required by the pump operator Figure 4 Concrete Pump Circuit The method of getting the hydraulic cylinders to change direction at the appropriate times is the subject of several paragraphs on the following pages The hydraulic pumps that supply oil to the concrete pump kit are made to be able to adjust the amount of oil they deliver both by internal pressure sensing dev...

Page 27: ...lief valve 16 Accumulator pressure maintenance check valve 4 Directional control valve S1 17 Accumulator relief valve 5 Rock Valve slewing cylinder 18 Accumulator pressure gauge 6 Directional control valve S3 19 Accumulator hydraulic pump 7 Directional control valve S2 20 Accumulator redundant relief E stop manifold 8A 8B Differential hydraulic cylinders 21 NG 10 valve for forward reverse 9A 9B Re...

Page 28: ...iston This area differential is due to the fact that the rod extends only from one side of the piston and not the other The rock slewing cylinders on this model are single acting They have no piston other than a false piston to prevent the rod from coming out of the cylinder Figure 6 The rock valve slewing cylinders shown as item 5 in Figure 3 Figure 7 S valve diagram explanation for S2 and S3 val...

Page 29: ...in that they sense multiple pressures simultaneously and will route oil from the poppet end port to the output port ONLY if the pressure from the poppet end port exceeds the pressure at the spring end port by more than 2 1 Figure 8 Differential hydraulic cylinder diagram explanation shown as items 8A and 8B in Figure 3 Figure 9 Switching valve diagram explanation Home TOC TOC Print Print ...

Page 30: ...ng cylinder 5 fully extends to the right if not already extended The S1 directional control valve 4 which controls whether the unit pumps in forward neutral or reverse is put into the forward position by energizing one of the coils on the solenoid valve 20 A pilot signal high pressure oil is routed from the accumulator circuit to the end cap of the S2 directional control valve 7 which moves into t...

Page 31: ...5 mm 2 4 mm S3 2 4 mm 1 3 1 3 1 0 1 0 ZK2 ZK1 T SP ZS2 ZS1 B A X3 XB XA S2 A1 XA XR B1 XB XP P1 T1 MX X1 T X3 1 4 1 1 100 bar 310 bar 20 bar 1 7 mm PR A B 1 1 mm S1 P2 MP T2 1 7 mm S2 A1 XA Mp Mp1 T WPhifloA eps Phase A Hi Flo KEY Zero Pressure Tank or oil at rest Low Pressure Soft Switch Pressure Rocking Oil Pressure High Pressure 1 2 3 4 5 6 7 9A 12 10B 10A 11 13 16 14 15 17 19 9B 22 23 8A 8B 10...

Page 32: ...ending high pressure oil red toward the end cap of the S3 valve 6 The pressure signal reaches the S3 valve end cap 6 pushing the valve into the cross over position The oil on the right end cap of the S3 valve 6 flows back to tank 1 In the cross over position the S3 valve 6 routes oil from the accumulator to the port on the right hand rock valve slewing cylinder 5 The cylinder begins to extend The ...

Page 33: ...5 mm 2 4 mm S3 2 4 mm 1 3 1 3 ZK2 ZK1 T SP ZS2 ZS1 B A X3 XB XA S2 A1 XA XR B1 XB XP P1 T1 MX X1 T X3 1 4 1 1 100 bar 310 bar 20 bar 1 7 mm PR A B 1 1 mm S1 P2 MP T2 1 7 mm S2 A1 XA Mp Mp1 T WPhifloB eps Phase Ba Hi Flo KEY Zero Pressure Tank or oil at rest Low Pressure Soft Switch Pressure Rocking Oil Pressure High Pressure 1 2 3 4 5 6 7 9A 12 10B 10A 11 13 16 14 15 17 19 9B 22 23 8A 8B 10C 10D 2...

Page 34: ...and differential cylinder 8B As the right hand differential cylinder 8B moves rocking oil orange reaches the left end cap of the switching valve 9A The valve closes by the pressure applied and the force of the return spring This removes the pilot signal to the left side of the S3 directional control valve 6 As the right side differential cylinder 8B extends the concrete in the material cylinders f...

Page 35: ...5 mm 2 4 mm S3 2 4 mm 1 3 1 3 ZK2 ZK1 T SP ZS2 ZS1 B A X3 XB XA S2 A1 XA XR B1 XB XP P1 T1 MX X1 T X3 1 4 1 1 100 bar 310 bar 20 bar 1 7 mm PR A B 1 1 mm S1 P2 MP T2 1 7 mm S2 A1 XA Mp Mp1 T WPhifloC eps Phase C Hi Flo KEY Zero Pressure Tank or oil at rest Low Pressure Soft Switch Pressure Rocking Oil Pressure High Pressure 1 2 3 4 5 6 7 9A 12 10B 10A 11 13 16 14 15 17 19 9B 22 23 8A 8B 10C 10D 20...

Page 36: ... to the pilot signal The oil in the left side end cap of the S3 valve 6 escapes to tank High pressure oil red is routed from the accumulator circuit through the S3 valve 6 to the extend port of the rock valve slewing cylinder 5 The rock valve slewing cylinder 5 extends to the right sending the retract side oil back to tank 1 through the S3 valve 6 As the rock slewing cylinder 5 extends pressure in...

Page 37: ...5 mm 2 4 mm S3 2 4 mm 1 3 1 3 ZK2 ZK1 T SP ZS2 ZS1 B A X3 XB XA S2 A1 XA XR B1 XB XP P1 T1 MX X1 T X3 1 4 1 1 100 bar 310 bar 20 bar 1 7 mm PR A B 1 1 mm S1 P2 MP T2 1 7 mm S2 A1 XA Mp Mp1 T WPhifloD eps Phase D Hi Flo KEY Zero Pressure Tank or oil at rest Low Pressure Soft Switch Pressure Rocking Oil Pressure High Pressure 1 2 3 4 5 6 7 9A 12 10B 10A 11 13 16 14 15 17 19 9B 22 23 8A 8B 10C 10D 20...

Page 38: ...tial oil is passed to the piston side of the left hand differential and the rod side oil of the left hand differential is directed back to tank via valves S2 and S1 and through the filter 7 Oil directed through the S3 has the rock valve shift cylinder held in the retracted right position so that concrete from the left hand material cylinder is being pushed into the delivery pipe line Concrete from...

Page 39: ...mps All SP Rock Valve models Frame Operation Manual 37 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 12 5 mm 12 5 mm To Fwd Rev Handvalve Home TOC TOC Print Print ...

Page 40: ...3 valve 3 Oil from the right hand end cap of the S3 valve 3 is relieved via check valve 15 the S2 valve 2 S1 valve 1 filter 7 and back to the hydraulic tank NOTE If the left hand differential has not fully extended at this point due to not enough loop oil high pressure oil will continue to flow through check valve 17 on the right hand differential until the left hand differential is fully extended...

Page 41: ...mps All SP Rock Valve models Frame Operation Manual 39 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 12 5 mm 12 5 mm To Fwd Rev Handvalve Home TOC TOC Print Print ...

Page 42: ...alve 3 fully to the right hand position At this point the pressure oil to the rock valve shift cylinder 4 is changed and the right hand side of the cylinder is getting oil so that the cylinder will extend Oil from the left hand side of the rock valve shift cylinder is routed to tank via valves 3 1 and filter 7 Home TOC TOC Print Print ...

Page 43: ...mps All SP Rock Valve models Frame Operation Manual 41 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 12 5 mm 12 5 mm To Fwd Rev Handvalve Home TOC TOC Print Print ...

Page 44: ...ded At this point a signal is sent to the left hand end cap of the S2 valve 2 from a signal port on the rock valve shift cylinder 4 As the S2 valve 2 shifts to the right oil from the right hand end cap of the S2 valve 2 is routed to the hydraulic tank via check valve 13 valves 3 1 and the filter 7 Home TOC TOC Print Print ...

Page 45: ...mps All SP Rock Valve models Frame Operation Manual 43 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 To Fwd Rev Handvalve 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 46: ...and position pressure oil is routed through the S1 valve 1 and the S2 valve 2 to the rod side of the left hand differential cylinder Please note that while the left hand differential cylinder is starting to retract check valve 17 must close otherwise the right hand differential cylinder will not extend Home TOC TOC Print Print ...

Page 47: ...k Valve models Frame Operation Manual 45 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 Note Check Valve Must Close 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 48: ... to the piston side of the right hand differential via the loop hose The oil on the rod side of the right hand differential is going through valves 2 and 1 filter 7 and back to the tank Oil directed through the S3 valve has the rock valve shift cylinder held in the extended position so that concrete from the right hand material cylinder is being pushed into the delivery pipe line and concrete from...

Page 49: ...mps All SP Rock Valve models Frame Operation Manual 47 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 50: ...from the left hand end cap of the S3 valve 3 is relieved via check valve 14 the S2 valve 2 S1 valve 1 filter 7 and back to the hydraulic tank NOTE If the left hand differential cylinder has not fully retracted at this point because of to much loop oil high pressure oil will continue to flow through check valve 16 and back to the hydraulic tank until the left hand differential cylinder is fully ret...

Page 51: ...mps All SP Rock Valve models Frame Operation Manual 49 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 52: ...ve 3 fully to the left hand position At this point the pressure oil to the rock valve shift cylinder 4 is changed and the left hand side of the cylinder is getting oil so that the cylinder will retract Oil from the right hand side of the rock valve shift cylinder 4 is being routed to tank via valves 3 1 and filter 7 Home TOC TOC Print Print ...

Page 53: ...mps All SP Rock Valve models Frame Operation Manual 51 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 54: ...ed At this point a signal is sent to the right hand end cap of the S2 valve 2 from a signal port on the on the rock valve shift cylinder 4 As the S2 valve 2 shifts to the left oil from the right hand end cap of the S2 valve 2 is routed to the hydraulic tank via check valve 12 valves 3 1 and filter 7 Home TOC TOC Print Print ...

Page 55: ...mps All SP Rock Valve models Frame Operation Manual 53 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 56: ...lly shifted and held in the left position pressure oil is routed through the S1 valve 1 and the S2 valve 2 to the rod side of the right hand differential cylinder Please note that check valve 16 must close otherwise the right hand differential cylinder will not retract Home TOC TOC Print Print ...

Page 57: ...mps All SP Rock Valve models Frame Operation Manual 55 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 58: ...Overview Operation Manual All SP Rock Valve Models 56 revDate Phase K Refer to diagram 1 for explanation of first working stroke Home TOC TOC Print Print ...

Page 59: ...mps All SP Rock Valve models Frame Operation Manual 57 KEY High Pressure Rocking Oil Low Pressure Zero Pressure Tank or oil at rest S3 1 5 mm hole drilled through spool S2 S1 4 5 12 13 14 15 16 17 18 6 2 3 D To Agitator 7 8 10 20 1 To Fwd Rev Handvalve 12 5 mm 12 5 mm Home TOC TOC Print Print ...

Page 60: ...er keeps track of the number of hours on the diesel engine and hydraulic pumps Use it to keep track of hours for maintenance purposes Engine RPM gauge Supplies information about engine speed Electronic throttle control switch optional This switch is only utilized when it has been included as an option on the unit Pump Off switch Controls the concrete pump on and off function Concrete pump forward ...

Page 61: ...nic throttle control Pump Forward Reverse switch Agitator On Off_ switch Vibrator Auto Off_ Manual switch Pump Off switch Hobbs I QUARTZ 0 0 0 0 0 0 HOURS 0 10 20 30 40 RPM X 1000 98351115 M U R P H Y M U R P H Y murphypanel eps Emergency stop switch Vibrator Auto Off_ Manual switch Agitator On Off_ switch Oil cooler switch Dummy Plug Key switch Pump Forward Reverse switch Pump Off switch LCD Info...

Page 62: ...ible to disable the soft switch function by turning the soft switch shutoff valve 90 Figure 11 NOTE The stroke limiter must be turned down to 60 or less before disabling the soft switch function to prevent damaging the hydraulic system This procedure causes an extreme pressure spike of on the system with each stroke Have the system repaired and enable the soft switch as soon as possible 000276 eps...

Page 63: ...torage compartment on the drivers side however all accessories are shipped in a crate 4 3 2 1 5 Figure 12 Supplied Accessories The supplies accessories include the following 1 Remote control with 30 meters of cable 2 Rock valve cover alignment bolts 3 Clean out rake 4 Tool box complete with tools 5 Box containing parts books operator manuals and other literature Home TOC TOC Print Print ...

Page 64: ...ry Compartment Figure 13 Emergency Stop Switch Figure 14 Pushing this switch shuts off the engine and dumps all hydraulic oil circuits to the reservoir thereby preventing machine movement Figure 13 Engine Battery Figure 14 Emergency Stop Switch Home TOC TOC Print Print ...

Page 65: ... Area Agitator motor Figure 16 is a hydraulically driven motor that is directly coupled to the agitator shaft SWG98n164 eps Agitator motor Grease bar Tension nut Clean out door Outlet pipe Grease zerk Tension nut locking bolt Vibrator Hopper grate interlock switch Figure 15 Components of the Hopper Area Figure 16 Agitator Motor Home TOC TOC Print Print ...

Page 66: ...lve assembly that must be greased but they are in accessible locations Rock valve assembly Figure 18 Maintenance of the rock valve components are covered in detail in Section 6 of this manual Here we will just note some of the external component names and locations Figure 17 Grease Manifold 5 2 1 3 4 1 Tension Nut Locking Bolt 2 Tension Nut 3 Outlet Pipe 4 Clean out Cover 5 Grease Zerk SWG98n167 e...

Page 67: ...he hopper grate or hopper in our case The purpose of this device is to assist low slump concrete in falling through the grate and into the concrete cylinders If your use of this machine includes pumping of low slump concrete you will find this option invaluable Hopper grate interlock safety switch Hopper grate must be completely down to close safety switch or pump will not operate Figure 19 Vibrat...

Page 68: ...ef valves The pressures listed on hydraulic schematics and in manuals and literature are not nominal figures They are the pressures that the machine was designed to work with and that the components were designed to accommodate There are a very few instances where pressures may be tweaked to accomplish certain things but they must only be done with the advice and step by step instructions of an au...

Page 69: ...g labels Schwing has made the decision to supply warning labels at cost for as long as the machine is in service To get replacement labels identify which label s you need from the decal location guide shown in your parts book get the serial number of the unit off the serial number plate and call our Spare Parts Department at 1 888 SCHWING The person taking the order will make a note of the serial ...

Page 70: ...Overview Operation Manual All SP Rock Valve Models 68 revDate NOTES Home TOC TOC Print Print ...

Page 71: ...y Desktop Operation manuals line pumps All SP Rock Valve models Frame files operation fm Operation Manual 69 OPERATION Preparation 70 Towing the unit 74 Unit Set Up 75 Operating the Pump 76 Special Pumping Situations 95 swg99a001 eps Home TOC TOC Print Print ...

Page 72: ...ate for work you are setting yourself up for at least a bad day and perhaps an accident Wandering around the shop in a stupor because of a hangover or lack of sleep is no better than showing up late Either way you will not be certain that the machine is in tip top shape and all necessary equipment and accessories are present and in good working order until it s too late to do anything about it Hav...

Page 73: ...his Operation Manual for this procedure It makes a good persuasion device for rusted nuts and bolts and for knocking out concrete that has set up in clamps and hoppers Many pumpers take the head off of the wooden handle and have it installed on a steel pipe This makes it perfect for pipeline installation because the handle can be used to pry clamp handles up or down Experienced pump operators neve...

Page 74: ...e made to protect you from this hazard but they only work if you wear them Safety goggles may very well keep you from getting splashed concrete in your eyes Snug fitting work clothes will help prevent accidents involving moving parts Concrete pumps may generate higher sound pressure levels than O S H A allows for constant exposure You can protect yourself by wearing hearing protection when on or n...

Page 75: ...it If the engineers determine that repair is necessary for safe operation DO NOT OPERATE THE UNIT UNTIL REPAIRS ARE COMPLETED Pipeline must be complete and free of dents cracks and holes Pipe must have sufficient wall thickness to handle the maximum pressure of the pump Inspect weekly with an ultrasonic thickness tester See Maintenance section of this manual beginning on page 6 10 All safety guard...

Page 76: ...t when you begin to back up may become frightened by the back up warning sound and freeze where they stand If you are in an isolated area where there will not be traffic or pedestrians you can get out of the cab and look for obstructions before beginning to back up Changing lanes When towing a pump you will have blind spots to your right and left sides Unfortunately many drivers are unaware of the...

Page 77: ...ground The area to be utilized must be as level as possible If the workplace has inadequate lighting don t begin the pour until proper lighting is provided Laying out the pipeline We will not cover the do s and don ts of pipeline layout in this manual If you don t know how to correctly lay out a pipeline read and understand the chapters on concrete pipeline in one of the books about pumping concre...

Page 78: ...following sequence 1 Turn the ignition key to the ON position which supplies power to the receiver 2 Engage the E stop on the radio remote 3 Press power button on radio remote light will flash 4 Disengage E stop on radio remote light will be solid Wait 10 seconds before turning ignition key to engage the starter For cold weather starts use the following procedure a Move the throttle lever to the l...

Page 79: ...500 RPM Maximum On the SP1000 1250 and 2000 units if OIL PRESSURE ALTERNATOR CURRENT or COOLANT LEVEL is not what it should be when the engine is started you will be notified by a fault warning in the LCD window Figure 23 To correct a fault shown in the window See the HMI User s Guide included with other documentation Do not operate until situation is corrected Basic Troubleshooting Engine won t s...

Page 80: ...t This decal is also shown in the Appendix section of the Safety Manual which is included as one chapter of this Operation Manual In many cases the job site management will give you a walkie talkie that is on their own frequency so that you may speak directly to your signal man Be aware that in some cases this walkie talkie may cause interference with the Schwing radio remote control system Check ...

Page 81: ...ut 25 or 30 gallons of water Of course this step can be skipped if slurry is to be delivered to you from the ready mix company or if you are using powdered slurry mix Get your clean out rake in a position that you will not trip on it but you will be able to grab it when you begin clean out Many times cleaning the pump is done when you are in a hurry because concrete is setting that is no time to h...

Page 82: ... the bearings When re greasing after the hopper is full of concrete and you can no longer see the cones just give the zerks a couple of squirts This is one of the few times when it is better to under grease than to over grease Grease the rock valve lubrication points before the pour begins Figure 28 Once started grease them every couple of hours There are 4 zerks to grease for the rock valve plus ...

Page 83: ...with the blade allowing the cement to fall into the barrel When the bag is empty set it off to the side and mix the cement and water with the shovel blade Break up any cement clumps that are encountered and continue mixing until the mixture is smooth and creamy Get your helper and pour the mixture into the hopper It will not cover the openings to the material cylinders but for now don t worry abou...

Page 84: ...Operation Operation Manual All SP Rock Valve Models 82 revDate Figure 29 Mixing the slurry in a barrel Home TOC TOC Print Print ...

Page 85: ...ds the relief setting repeat the reverse cycle In many cases you can prevent a blockage by rocking it back and forth In fewer cases the plug will not cooperate and you will need to find the source of the blockage and remove it manually NOTE You must not open a blocked pipeline without first sucking the concrete back into the hopper the act of putting the pump into reverse for several strokes will ...

Page 86: ...orward and alert the ready mix driver to start dumping Concrete must always cover the openings of the material cylinders or you will suck air into the material cylinders If this happens there will be a sudden expulsion of concrete on the next stroke as the now compressed air escapes This could be dangerous so be sure that the ready mix driver understands the situation If you have taken air in to t...

Page 87: ...u know that it will take longer than that to fix clean out before you begin repairs If concrete is beginning to set you will have to clean out in a very quick and efficient manner There are special instructions for quick clean out which you will find in this section Section 5 starting on page 96 If you keep your head and keep moving you can usually avoid the dreaded pipe party even with unfavorabl...

Page 88: ...s procedure The concrete will eventually set up anyway If you have to wait so long that the concrete is setting it would be better to clean out and start over when the fresh concrete has arrived This has the added advantage of making Murphy s Law work for you as soon as you begin to clean out the concrete will arrive If you are waiting for a form to be finished or repaired or anytime that the dela...

Page 89: ...wipe the concrete off with your hands Reassemble the pieces and pin the clamp s if they will hang overhead Return to the pump and start pumping in forward again slowly at first until you are sure that there are no more blockages If another blockage is encountered remember to relieve the pressure again by pumping in reverse for several strokes before finding the remaining blockages Do not use compr...

Page 90: ...ng it you could be thrown to the ground or struck by the hose And finally the pump hopper almost never holds enough water to push out the entire line so if you re holding the hose as the hopper goes empty the line will now have compressed air being pushed through creating the risk of a hose whip as it is released into the drum Clean the hopper Tap on the T handle that opens the clean out door on t...

Page 91: ...of your footing and keep the hopper grate in place for the following procedure Spray water into the hopper from above Figure 33 Keep the agitator turning until you have sprayed the blades clean Wash the material from the hopper out of the clean out door on the bottom SWG98n186 eps Figure 33 Clean the agitator and hopper through the grate with water Home TOC TOC Print Print ...

Page 92: ...d by looking in the hopper Figure 34 NOTE This switch will only work while the unit is in Local control The best way to confirm that the agitator is stopped is use the manual control lever It can be found on the curb side of the unit 98347087 Agitator On Off switch Hobbs I QUARTZ 0 0 0 0 0 0 HOURS 0 10 20 30 40 RPM X 1000 agitoff eps 98351115 Agitator On Off_ switch Figure 34 Stop the agitator by ...

Page 93: ...procedure or the concrete will have time to set up in the rock valve and material cylinders If concrete in the hopper has completely set you will need to use a chipping hammer or other power tool to clean it The grate is removable for this purpose but the hydraulic system must first be disabled by stopping the engine and removing the key For safety reasons it is recommended that you return to your...

Page 94: ...e pump This step assures that the material cylinder that is exposed will have the rubber ram extended to the end thereby eliminating the need to pull material from deep inside the cylinder Be sure that the concrete pump is turned to the OFF position before proceeding Get your clean out rake and pull any material from the exposed material cylinder the rock valve and the outlet pipe Figure 36 Figure...

Page 95: ...any loose material out with the clean out rake then spray out the material cylinder as in the previous step By putting the pump in the REVERSE mode you are sucking from the pipeline which is not connected during the clean out procedure and pumping into the hopper Because of this you may find that you now have some material in the bottom of the hopper again You should now wash this material out Spr...

Page 96: ...efore out of the drain The waterbox is empty when no more water flows out of the drain even after the unit is cycled STOP THE PUMP and secure it against unintentional starting by pushing the emergency stop button Be sure of your footing Remove the waterbox covers and spray the waterbox and cylinders until all cement fines and grout are loose Figure 39 If you will not be filling the waterbox again ...

Page 97: ...d on the concrete See specific instructions for pumping on piston side in the Operation section of this manual Piston side operation dramatically raises the maximum pressure on the concrete For this reason it is crucial that your entire material delivery system be rated to handle the available pressure and kept in like new condition Remember that pipe wears with each yard pumped Inspect the wall t...

Page 98: ...ack to it Cold weather pumping It is possible and routine in some parts of the world to pump concrete with outside temperatures as low as 10 Fahrenheit and even colder under certain circumstances This can present a variety of problems compared with pumping in moderate temperatures such as Water in waterbox freezes while you are driving to the job Hydraulics are slow and sluggish If it s very cold ...

Page 99: ...can do about a separately laid pipeline In most cases pours that require a separate pipeline will cancel if it is very cold If they don t cancel there is a good chance that you will not be able to get concrete through the line because the slurry will freeze against the walls of the pipe then the concrete will have to be pushed through the pipe dry This could result in a blockage To clear the line ...

Page 100: ...Operation Operation Manual All SP Rock Valve Models 98 revDate NOTES Home TOC TOC Print Print ...

Page 101: ...P Rock Valve models Frame files Maintenance fm Operation Manual 99 MAINTENANCE Filtration 100 Hydraulic Oils 102 Pressure Hoses and Fittings 102 General Maintenance Tips 104 Preventative Maintenance 105 Scheduled maintenance checklist 115 Unscheduled maintenance 116 swg99a001 eps Home TOC TOC Print Print ...

Page 102: ...or a given flow rate in PSI and gallons per minute or bar and liters per minute and the ratio of particles of a given size encountered versus particles passed referred to as the beta ratio An example of a beta ratio would be β25 200 pronounced beta twenty five equals two hundred This means that for every 200 particles of 25 microns or larger that hit the filter media one makes it through A finer f...

Page 103: ... with an integral bypass check valve set at 50 PSI The bypass valve protects the filter element from damage due to running with a clogged filter or cold starts The assembly is equipped with an anti back flow check valve which prevents oil from draining out of the tank while you are changing elements There is a delta P indicator to tell you when the element is dirty set at 35 PSI You should replace...

Page 104: ...th America we recommend ISO VG 46 weight oil while in the winter we recommend ISO VG 32 or even VG 22 depending on how cold it gets in your area For southern North America and Central America we recommend ISO VG 46 for the winter and ISO VG 68 or VG 100 for the summer depending on how hot it gets The lower the ISO VG number the thinner the oil is and the lower the pour point of the oil is On the o...

Page 105: ...the main relief to do the job The hydraulic pump can t withstand 4900 PSI for more than a few minutes and it breaks You now have to replace a pump before you can make another pour If you leave the machine at the factory specification you DO NOT harm the system It gives you years of dependable service This means you should only use fittings and hoses that have a sufficient WORKING PRESSURE to handl...

Page 106: ...e you should begin the adjustment procedure by turning the adjustment device to the lowest possible setting then bring the device back up to the proper setting Removal of safety devices Sometimes you will have to remove a safety guard or other safety device in order to perform maintenance For these situations you must take extra care to be sure of your own safety and that of your co workers If you...

Page 107: ...r the outlet hose open the valve and watch the liquid as it leaves the hose When the liquid changes from water to oil close the valve Because of condensation which is aggravated by large heating and cooling cycles it is normal that there will be a small amount of water in the tank every day but it should settle to the bottom of the tank overnight The water that is drained should be clear and the o...

Page 108: ... on the restriction indicator after servicing the air filter Weekly Maintenance Check the rock valve tension nut for play once each week Figure 48 To check this nut remove the 16mm keeper bolt grasp the tension nut by hand and turn clockwise There are many holes for the keeper bolt on the spacer behind the tension nut The object is to place the keeper bolt in the furthest hole that you can reach w...

Page 109: ...tighten each bolt equally using a torque wrench Alternate which bolts you tighten like you would when tightening a wheel on a car The torque specs for these bolts M20 x 65 8 8 hardness is 300 foot lbs k Lower the hopper grate and secure it with the grate lock l Tighten the tension nut according to the instructions in 5 2 1 Tighten the keeper bolt Lubricate mechanical moving parts with oil or a WD ...

Page 110: ... on the gauge as shown It should read 330 bar for the WP 1250 300 for the WP 1000 and the 750 18 or 286 for the 750 15 and the BPA 450 and 500 Return the pump to neutral whether in needs adjustment or not i Put the concrete pump into the FORWARD position again The machine will not stroke this time but will again develop maximum pressure Read the pressure on the gauge If more adjustment is needed r...

Page 111: ...n on the gauge It should read 125 bar h To adjust the pressure use a 13mm wrench to loosen the jam nut and a 4mm allen wrench to turn the relief valve Turn it clockwise to increase pressure or counter clockwise to decrease pressure until 125 bar is showing on the gauge i Return the agitator hand valve to the neutral position j Stop the engine and put the key in your pocket k Remove the high pressu...

Page 112: ... at least rent one for the occasions when you change your hydraulic oil Charging the Accumulator Charge the accumulator every six months or 1000 hours a Before you begin you will need a charging kit Figure 51 Do not attempt to charge the accumulator without one You can order the kit from Schwing using part number 30390139 b The nitrogen bottle should only be used with a high pressure regulator If ...

Page 113: ...en valve on the nitrogen bottle raise the pressure of the regulator adjustment handle and SLOWLY fill the accumulator Shut off the supply when the gauge indicates the desired nitrogen pre charged pressure NOTE If the nitrogen bottle doesn t have at least 1450 PSI pressure you will not be able to charge the accumulator to 1450 PSI l If the desired pre charge is exceeded close the nitrogen bottle va...

Page 114: ...Operation Manual All SP Rock Valve Models 112 revDate BLADDER ACCUMULATOR Cross Section of the Accumulator 1 Steel Shell 2 Bladder 3 Bladder Stem 4 Port Assemblies 5 Fluid Ports 6 Gas Valve Home TOC TOC Print Print ...

Page 115: ... Maintenance fm Operation Manual 113 Stages of Bladder Accumulator Operation 1 Without Nitrogen Charge 2 With Nitrogen Charged to pressure P1 3 Influx of hydraulic oil for storage 4 Fluid charged to maximum working pressure P3 5 Discharge of hydraulic oil 6 Fluid discharged down to minimum working pressure p2 Home TOC TOC Print Print ...

Page 116: ... tank or drained out of the bottom of the tank Figure 53 d Once the oil is drained clean the tank through the inspection covers using cleaning solvent and lint free rags DO NOT USE GASOLINE Remove all of the silt from the bottom of the tank e Close the drain if open Refill by pumping new oil out of the barrels with a filter cart If no cart is available rent one REMEMBER NEW OIL IS NOT CLEAN ENOUGH...

Page 117: ...lic Tank 105 Check Differential Cylinder Rod Packings 105 Inspect Bolts On Rams 106 Grease Rock Valve and Agitator Bearings 106 Inspect For Damage and Leaks 106 Check If Maintenance Is Due 106 Check Rock Valve Tension Nut 106 Inspect Cutting Ring Rotate If Needed 107 Lubricate Mechanical Moving Parts 107 Check Unit Mounting Hardware 107 Check Hydraulic Pressures 107 Set Concrete Pump Pressure 108 ...

Page 118: ... Remote Control For This Procedure Unplug It And Store It Do Not Allow Anyone Else At The Passenger Side Controls When You Are Changing Rams The chances of accidental amputation are greatly increased if more than one person is around There are also less distractions when you are alone so your attention will not become divided If someone comes up stop working until they leave Reduce engine r p m to...

Page 119: ... grate Retract the left side differential rod almost all the way into the waterbox Figure 55 Leave about 1 5 inches of travel which will allow you to remove the spacer coupling dogbone Push the emergency stop button on the operator s panel Stop the engine and put the key in your pocket stopping the engine before putting your hands in the waterbox is mentioned at every appropriate spot SWG98n197 ep...

Page 120: ...he dogbone will fall out Push the emergency stop button on the operator s panel Stop the engine and put the key in your pocket Remove the dogbone from the waterbox as shown in Figure 57 Start the engine Release the emergency stop button Slowly extend the cylinder rod until it just contacts the rubber ram flange Be Careful Not To Drive The Rubber Ram Into The Material Cylinder NOTE If it happens th...

Page 121: ...hten the nut with tools and note that the ram flange and cylinder flange are shown outside of the waterbox for clarity of the illustration Start the engine Release the emergency stop button and slowly retract the cylinder rod until the ram is clear of the material cylinder Figure 59 Push the emergency stop button on the operator s panel Stop the engine and put the key in your pocket Remove the nut...

Page 122: ...ease the emergency stop button Slowly retract the rod again until there is room to install the dog bone Push the emergency stop button on the operator s panel Stop the engine and put the key in your pocket Apply Loctite 242 or equivalent to 2 of the M20 bolts Place the dog bone up against the flange of the new ram Install 2 of the M20 bolts with Loctite And The Cone Washer Sets At this time finger...

Page 123: ...s is known as Passive Regeneration The engine control system will monitor the exhaust system temperature and engine duty to predict the amount of soot accumulating if any in the particulate filter The engine control system will elevate exhaust system temperatures to initiate Active Regeneration if there is insufficient passive regeneration or if the maximum time between active regenerations has be...

Page 124: ...derate At this point automatic regeneration is disabled by the engine ECM only a manual regeneration can be completed State 4 E DPF Non Recoverable If soot is allowed to accumulate to 230 the engine should be stopped the shutdown lamp will illuminate If the engine monitoring system is configured to shutdown the engine will shutdown automatically The engine may be restarted but will shutdown after ...

Page 125: ...R MANUAL ACTIVE REGENERATION AUTOMATIC ACTIVE REGENERATION DISABLED OR MANUAL REGENERATION ONLY DPF NON RECOVERABLE REPLACE DPF 90 130 170 230 TIME E C D STATE 3 STATE 4 STATE 5 J1939 SPN 3701 000 J1939 SPN 3701 001 J1939 SPN 3701 010 J1939 SPN 3701 011 PASSIVE REGENERATION AUTOMATIC ACTIVE REGENERATION F SOOT LOADING Figure 64 Monitoring and warning levels Home TOC TOC Print Print ...

Page 126: ...Maintenance Operation Manual All SP Rock Valve Models 124 revDate NOTES Home TOC TOC Print Print ...

Page 127: ...c Oil Viscosity Chart 126 Torque Specifications for Metric Bolts 127 Recommended Emergency Hose Kit 128 Fitting Wrench Sizes 129 Maintenance checklist 130 Output charts 131 Nomograph 137 Weld On Ends Coupling Comparison 145 MInimum Pipe Wall Thickness 146 Glossary of Terms 147 Additional Reading Material 152 List of Lubricants and Nitrogen 153 swg99a001 eps Home TOC TOC Print Print ...

Page 128: ...ature is low and thinner as the temperature rises The cold start limit represents the coldest temperature at which the oil is thin enough to flow into the hydraulic pumps Anything colder and the pumps would not be able to suck the oil cavitation The minimum permissible viscosity represents the warmest temperature at which the oil will still be thick enough to provide lubrication and sealing Anythi...

Page 129: ... ft lb N m ft lb N m ft lb Thread Designation N m ft lb N m ft lb N m ft lb M 4 X 0 7 2 2 1 6 3 2 2 4 3 8 2 8 M 8 X 1 20 15 28 21 33 24 M 5 X 0 8 4 3 3 2 6 4 4 7 7 5 5 5 M 10 X 1 40 29 57 42 68 50 M 6 X 1 7 5 5 5 10 8 8 12 6 9 3 M 10 X 1 25 37 27 55 41 64 47 M 8 X 1 25 18 13 27 20 31 23 M 12 X 1 25 67 49 100 74 115 85 M 10 X 1 5 36 27 53 39 62 46 M 12 X 1 5 65 48 95 70 110 81 M 12 X 1 75 62 46 90 ...

Page 130: ...and UNF thread fasteners Values do not apply if graphite moly disulphide or other extreme pressure lubricant is used GENERAL SAE BOLT TORQUE SPECIFICATION TABLE 5 SAE Grade Number 8 Bolt head identification marks See Note below Bolt Size lb ft N m lb ft N m 1 4 9 11 12 15 12 15 16 20 5 16 17 20 5 23 28 24 29 33 39 61 73 3 8 35 42 48 57 45 54 7 16 54 64 73 87 70 84 95 114 1 2 80 96 109 130 110 132 ...

Page 131: ... Valve models Frame files Appendix fm Operation Manual 129 Fitting Wrench Sizes This chart is provided as an aid to selecting the proper wrench to hold or tighten the hydraulic fittings found on Schwing equipment Sizes may change use only as a guide Straight Fittings Banjo Fittings Home TOC TOC Print Print ...

Page 132: ...nspect Bolts On Rams 106 Grease Rock Valve and Agitator Bearings 106 Inspect For Damage and Leaks 106 Check If Maintenance Is Due 106 Check Rock Valve Tension Nut 106 Inspect Cutting Ring Rotate If Needed 107 Lubricate Mechanical Moving Parts 107 Check Unit Mounting Hardware 107 Check Hydraulic Pressures 107 Set Concrete Pump Pressure 108 Set Agitator Pressure 109 Clean Hydraulic Oil Cooler Fins 1...

Page 133: ...t charts show the horsepower curve in kilowatts or KW of the concrete pump hydraulic circuit From them you can determine the maximum concrete pressure of the pump kit model the maximum output in cubic yards per hour of the pump kit model the maximum strokes per minute of your pump kit model the maximum output in liters per minute of your hydraulic pumps the output that can be expected at various p...

Page 134: ...sure gauge and see that the hydraulic oil pressure is at 220 bar To determine if your unit is acting normally Locate the 220 bar oil pressure marking on the rod side scale item A in the example below Next you draw a line straight across the page until you intersect with the horsepower curve item B in the example below Draw a straight line down from the intersection point until you pass through the...

Page 135: ...ill give you a bad reading Check it with a digital tach if one is available Be sure that you know how to use your flow meter Read the instructions that came with it Flow meters must be calibrated periodically Make 2 copies of the output chart so you don t ruin your original You need one chart for each pump tested Read the flow at 0 bar 100 bar 150 OR 200 bar 250 bar and 300 bar You also document t...

Page 136: ...t In the example below we are using the rod side scales and curve you could use the piston side scale and curve instead The ruler is shown ready to draw a line at 250 bar hydraulic pressure Turn the ruler sideways and draw a light line up the page from the liters minute reading you took at that pressure don t forget to multiply the reading by 2 In our example we measured 276 liters at 250 bar At t...

Page 137: ...p is OK If your line is to the lower left of the spec the pump is getting weak If your line is to the upper right of the spec you ve done the test incorrectly or you are using the wrong chart In our example the pump is OK see the plot below Next we need to check the 2nd pump We hook up the flow meter just as when we checked the first pump Again be sure that you have the correct speed gear chart et...

Page 138: ...ter than specification it will not be able to suck oil as fast as it is turning it is called cavitation if this happens and immediate failure could result If the plotted curve matches the spec for a while but the breakpoint is too high or too low it is possible to make an adjustment Contact the Schwing Service Department for the procedure There are many different possible pump kits and power setti...

Page 139: ...ould not be used for power calculations Assuming that you know the required output for the job the nomograph will help you to calculate the required pressure With known output and pressure the power requirement can be found The nomograph was developed by extensive trial and error testing and has proven to be accurate to within 10 in nearly all pumping applications The original nomographs used spre...

Page 140: ...tical job situation with the following specifications We will need an average output of 45 cubic yards hr but we will be pumping only 75 of the time The rest of the time will be spent moving hose removing pipe lengths waiting for concrete trucks etc This means that when we are actually pumping we will need an output rate of 45 75 60 yd3 hr We will use 5 diameter pipeline for our job We will have t...

Page 141: ...hat has several efficiency factors figured in When using a metric nomograph pressure in bar and flow in cubic meters per hour the pressure multiplied by the flow will always directly relate to the TK For example if you needed 50 cubic meters hour and determined that this will require 60 bar you can multiply 50 x 60 which equals 3000 Any pump you select must have a TK of 3000 or greater If you are ...

Page 142: ... of water and cement fines coats the inside of the pipeline and forms a slippery layer on which the bulk of the concrete slides While it is true that a 6 pipeline has more surface area to coat than a 4 pipeline 49 more the volume of concrete that can move on the layer is increased by 125 which results in lower velocity of the concrete in feet per second lower friction and therefore lower pressure ...

Page 143: ...e of the resistance to flow than a length measurement To calculate the proportional value of your pipeline the following criteria will apply each 90 bend with a radius of 250 mm boom elbow 3 5 feet each 90 bend with a radius of 1 meter long sweep 10 feet each 30 or 45 bend with a radius of 1 meter or 250 mm 3 feet each section of rubber hose causes 3 times as much resistance as the same length of ...

Page 144: ...nal value Figure 70 d The lower left quadrant refers to the pumpability of the concrete If the concrete specifications allow a range in slump for example 3 4 you should always use the lower end to be safe In our example we use 3 slump You extend the line from the lower right quadrant until it intersects with the 3 slump line then make a 90 turn clockwise which will lead you back into the upper lef...

Page 145: ...t is capable of 925 PSI and 60 yd3 hr The TK of this job is TK 925 x 60 19 TK 55 500 19 TK 2921 The unit must have a TK of over 2921 and it must be able to pump 60 yd3 hr and 925 PSI Simultaneously Look at the pump shown in our sample nomograph Figure 72 Can the unit pump at 925 PSI YES Can the unit pump 60 yd3 hr YES Can the unit pump both simultaneously NO This unit will not do the job The engin...

Page 146: ...at can be done to the job specifications to make the pump with the smaller engine work You could use the smaller TK unit shown if Figure 72 if you can get an OK to do any of the following things Pump the top of the building at 50 yd3 hr instead of 60 yd3 hr Pump the top of the building at a 4 slump instead of 3 this would still be within specifications Remove some of the rubber hose at the end of ...

Page 147: ...ections together during assembly Both the ends and clamps weigh more than metric style and therefore should not be used on booms without consulting the manufacturer 1 Male female o ring type couplings have the highest pressure rating of the ends commonly used for concrete pumping They can withstand 4350 PSI a 2 1 safety factor They are self aligning and waterproof when used with o rings in good co...

Page 148: ...o allowance for mechanical forces other than pressure and thicker walls may be needed for mechanical strength because of support or restraint considerations 6 The chart does not take into account metal fatigue caused by pressure cycles Note This chart is intended as a guide for concrete pumping applications and is subject to the notes assumptions and conditions listed above Any other use of this c...

Page 149: ...he mass of a substance per volume For example 1 cubic foot of air weighs much less than 1 cubic foot of water 1 cubic foot of lightweight concrete weighs less than 1 cubic foot of steel entrained concrete We could say that steel entrained concrete has a higher bulk density than lightweight concrete All calculations for the Operation Man uals and specifications of concrete pumps are based upon 150 ...

Page 150: ...Electric Exe cution It means death by electricity See also Conductors EN 287 1 PREN 288 3 The code for structural welding with steel as defined by the European Norm See also Certified Welder Expert As used in this Safety Manual an expert is defined as persons that on the basis of their specialized training and experience have developed a high degree of knowledge and skill in the areas of concrete ...

Page 151: ... professionals Under no circum stances should high voltage connections be made by a concrete pump operator or related personnel Maintenance All procedures for servicing inspection and repair of concrete pumps and related equipment and devices Main tenance and inspection are methods of MAINTAINING the desired state of the equipment Repair is the method of RESTORING the desired state of the equipmen...

Page 152: ...rime mover is generic in that is denotes neither an internal combustion engine nor an electric motor PTO Power Take Off A switchable output from the transmission or an intermedi ate gearcase On a concrete pump it is used to divert the power from the engine and drive train to turn the hydraulic pumps Qualified Operator An individual that has reached the age of 18 years and is physically and mentall...

Page 153: ...ressure that the soil will support varies with the compo sition and compaction of the soil To make a determination on the stability of the soil see the chart in Section 5 of this manual Sponge Ball A medium to hard sponge formed into a sphere and used to clean the inside of delivery pipelines See Also Go Devil Spotter A spotter is a person that stands at a vantage point where he she can see both t...

Page 154: ...and accidentally hit a joystick which caused a boom movement Uninten tional movement can be avoided by disabling the hydraulic system with the emergency stop devices when not in immediate use Vertical Run Sections of concrete delivery pipeline that are running in an up or down direction Vertical runs have very spe cific procedures and rules for installa tion support cleaning and inspection Concret...

Page 155: ...it when it left the factory Other brands of lubricants and their usage are described in the following lists Hydraulic oil Gearcase oil Truck fluid levels Compressor oil Grease for spline and couplers Grease for autogreaser Dry nitrogen Mobile UNIVIS N46 HD 80w 90 See owners manual for your specific truck Mobil Rarus 427 or 429 Optimoly Paste White T 250 grams EP2 NLGI No 2 Any brand of dry nitroge...

Page 156: ...tion for comparison with other brands Some oil manufacturers offer vegetable based hydraulic oils which are considered environmen tally friendly the additive packages are not inert however These vegetable based oils must NEVER be mixed with mineral based oils A complete flush of the hydraulic system must be performed when changing to this type of fluid If you re considering using biodegradable oil...

Page 157: ...ture is 0 to 10 C 32 to 50 F Use VG 150 oil when ambient temperature is above 10 C 50 F Brand Texaco Mobil Shell Aral BP Esso Wintershall Viscosity DIN quality designation VG 220 CLP Meropa 220 Mobilgear 630 Omala Oil 220 Degol BG 220 Degol BMB 220 Energol GR XP 220 Spartan EP 220 Wiolan IT 220 Brand Texaco Mobil Shell Aral BP Esso Wintershall Viscosity Mil L quality designation 90 85w 90 2105 B G...

Page 158: ...down to remove all precious metals and hazardous materials which must be disposed of individually Grease A For filling the automatic greasers B For all other bearings The order of the lists is meaningless Any grease that meets the quality designation and viscosity specification may be used Shell Alvania is installed in new machines at the Schwing factory Any equivalent grease may be used OM19A Bra...

Page 159: ...Alphabetical Index Operation Manual Line pumps ALPHABETICAL INDEX swg99a001 eps Home TOC TOC Print Print ...

Page 160: ... cylinders 92 cleaning the waterbox 94 removing set material from hopper 91 cold weather pumping 85 96 preheating the hydraulic oil 97 time constraints 85 concrete from worn out mixers 83 inspecting before dumping 83 minimum hopper level 84 time constraints 85 very cold weather 85 control system hydraulic 25 couplings comparison 145 grooved type 145 heavy duty type 145 male female o ring type 145 ...

Page 161: ...id tag location 10 L laborers and oilers safety rules 78 license required to drive 74 list of additional reading material 152 list of lubricants and nitrogen 153 lubricate 81 lubricate 81 lubrication quantity of slurry needed 81 slickline 81 slurry mixing 81 pumping it through 83 with commercial lubricant 81 with portland cement 81 with ready mix grout 81 without slurry 81 M maintenance 99 hydraul...

Page 162: ... signal words 8 arranging for a spotter 78 blockages 87 devices 66 agitator shut off 66 bypassing the dump valve 86 emergency stop switch 66 fuses 66 pressure relief valves 66 warning labels 67 disabling the entire machine 86 driving 74 backing up 74 changing lanes 74 minimum hopper level 84 personal protective devices 72 breathing mask 78 rules for oilers and laborers 78 rules for the placing cre...

Page 163: ...tion Manual 161 T time constraints 85 troubleshooting checking your hydraulic pumps 133 loss of boom and outriggers 86 loss of electricity 86 procedures 77 time constraints 85 V version number operation manual iii vibrator 65 W walk around hopper area 63 warning 8 warning labels 67 waterbox cleaning 94 filling with water 78 keeping it full 86 Home TOC TOC Print Print ...

Page 164: ...Alphabetical Index Operation Manual All SP Rock Valve Models 162 revDate Home TOC TOC Print Print ...

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