Schwing SP 1800 Original Operating Instructions Download Page 221

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4.1 General maintenance instructions

Allgemeine_Wartungshinweise-EN.fm - 01.14.01

219

4.1

General maintenance instructions

Carry out the maintenance on time and with care.

We recommend copying the maintenance schedule

(chap. 4.6)

The maintenance personnel can then acknowledge the work carried out on the
copies.

Schwing expressly prohibits any maintenance work carried out by personnel who
are not specially trained and authorised.

GEFAHR!

Danger!

Severe to fatal accidents and serious material damage can be caused by un-
qualified personnel!

Should you not have trained personnel and appropriate workshop equipment, com-
mission the SCHWING customer service to service your machine.

4.1.1

Maintenance work on special equipment

Maintenance work on special equipment is described in chapter

“Special equip-

ment”

on page 357.

4.1.2

Cleanliness

•

Clean all units located within the work area before starting to work.

ACHTUNG!

Attention!

Material damage caused by high-pressure cleaner!

The use of high-pressure cleaners can damaged sensitive parts!

Do not use a steam jet to clean rubber and electrical parts.

•

As a rule, prevent dirt from entering - especially in the hydraulic system.

•

Lubricate your entire machine after a high-pressure cleaning.

Summary of Contents for SP 1800

Page 1: ...SP 1800 SP 2800 CAT Original operating instructions Stationary concrete pump...

Page 2: ...y available on to machine so they can be viewed at all times Please ensure prompt replacement of the operating instructions if they should be come lost Specify the machine type and the machine number...

Page 3: ...1 Declaration of conformity 21 2 3 2 EC declaration of conformity for truck mounted concrete pumps 22 2 3 3 EC declaration of conformity for stationary concrete pumps 23 2 3 4 Termination of the decl...

Page 4: ...regulation 61 2 10 9 Fuel filter 62 2 10 10 Main switch for starter batteries 63 2 10 11 Forced motor switch off 64 3 Operation 65 3 1 Driving operation PLC 67 3 1 1 Environmental protection and accid...

Page 5: ...outrigger 103 3 7 6 Semi hydraulic outrigger optional 104 3 7 7 Servicing the crank support 105 3 8 Operating the pumping line 107 3 8 1 Observation during operation 107 3 8 2 Marking pumping pipes a...

Page 6: ...2 3 12 3 End of operation 143 3 12 4 Winter operation 143 3 13 Working operation Air system SP 1800 2800 145 3 13 1 Preparation 145 3 13 2 Operation 146 3 13 3 End of operation 147 3 13 4 Winter opera...

Page 7: ...ners HP cleaners 185 3 18 12 Using cleaning agents 186 3 18 13 After cleaning 186 3 18 14 Water box flushing special equipment 186 3 19 Hazard prevention on the concrete filling hopper 189 3 19 1 Hopp...

Page 8: ...sses 223 4 1 13 Painting and working with aggressive substances 223 4 1 14 High pressure cleaning 223 4 1 15 Electrically powered machines 224 4 2 Consumable volumes in litres 225 4 3 Recommended lubr...

Page 9: ...on water 255 4 8 9 Changing the hydraulic fluid 256 4 8 10 Cleaning the reservoir 256 4 8 11 Changing the insert on the main filter return flow filter 257 4 9 Pressure checks stationary concrete pumps...

Page 10: ...ng piston change operating mode 296 4 14 3 Removing the HP pumping pistons 296 4 14 4 Installing the HP pumping pistons 298 4 15 Multi part pumping pistons optional 301 4 15 1 Replacing the main wear...

Page 11: ...e 339 4 18 6 Electrically powered machines 339 4 18 7 Electric welding procedure 339 4 18 8 Jump starting 339 4 18 9 Jump starting stationary pumps with batteries connected in series 339 4 18 10 Mecha...

Page 12: ...Installation 363 6 1 5 Drive 363 6 1 6 Maintenance 363 6 1 7 Technical data 363 6 2 Central lubricating system 365 6 2 1 Safety 366 6 2 2 Instructions for filling with lubricant 366 6 2 3 Configuring...

Page 13: ...Trennblatt Einleitung EN fm 11 2 Introduction This chapter contains the most important informa tion about your machine including Layout Conventions and Handling Of these operating instructions...

Page 14: ...2 Introduction 12 Trennblatt Einleitung EN fm 01 00 01...

Page 15: ...ge and careful observance of these oper ating instructions These operating instructions must always be available on the SCHWING machine Please be aware that the figures in these instructions may diffe...

Page 16: ...turer of integrated motors used in our sta tionary concrete pumps Other special pieces of equipment on your SCHWING machine may also have their own operating instructions Please observe these document...

Page 17: ...ce work The clear table of contents and the headers in the document were designed with that purpose in mind The safety chapter was prepared together with the VDMA and other concrete pump manufacturers...

Page 18: ...is empty in the case of machines for which no radio re mote control is offered Special equipment This chapter provides information on all types of special equipment Each machine is tailored to the cus...

Page 19: ...topic quickly Footer The outside edge of the footer contains the page number and an ID The ID is used to organise the documents internally it is of no relevance for you If you have any questions regar...

Page 20: ...tructured as follows 2 2 5 Warning of personal injury The following safety instructions describe the grading and meaning of signal words for personal injuries GEFAHR Danger High risk Persons can be in...

Page 21: ...signal word for mate rial damage ACHTUNG Attention Material damage Damage to your own machine or other objects Describes how the material damage can be avoided 2 2 7 Additional information The followi...

Page 22: ...2 2 Structure of the operating instructions 20 Aufbau BA EN fm 01 05 01...

Page 23: ...evant EC directives We confirm this by issuing a declaration of conformity and affixing a CE mark to the machine The original of each declaration of conformity is archived at SCHWING The customer rece...

Page 24: ...nce authorities for the compilation of the relevant technical documents declaration of conformity CE person authorised by SCHWING GmbH This declaration loses its validity in the event of any unauthori...

Page 25: ...ce authorities for the compilation of the relevant technical documents declaration of conformity CE person authorised by SCHWING GmbH This declaration loses its validity in the event of any unauthoris...

Page 26: ...hine delivered ex works Making changes to the machine without the approval of SCHWING in addition to using accessories without the approval of SCHWING shall cause both to lose their validity The compe...

Page 27: ...ators without adequate training or instruction Using concrete pipelines that are not approved by SCHWING Not performing the boom inspections and corresponding repairs on time Any discrepancies can aff...

Page 28: ...ld be reused but also ma terials and substances for example oils greases plastics electronic components rechargeable batteries etc that should be disposed of properly due to their prop erties hazardou...

Page 29: ...s located on the machine frame Fig 2 Fig 2 SP 1800 BR02 SP Stationary concrete Pump 1800 technical parameters minimum value BR Series SP 3800 BR02 SP Stationary concrete Pump 3800 technical parameters...

Page 30: ...2 5 Labelling SCHWING machines 28 Maschinenkennzeichnung SP EN fm 01 04 00...

Page 31: ...1800 2800 CAT EN fm 01 01 00 29 2 6 Technical data for SP 1800 2800 CAT Information Power ratings are theoretical max values WARNUNG Warning The specified concrete pressures require suitable pumping l...

Page 32: ...B A F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound...

Page 33: ...B A F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound...

Page 34: ...F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound le...

Page 35: ...B A F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound...

Page 36: ...A F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound...

Page 37: ...A F llinhalt Trichter Hopper capacity Verschlei schutz beidseitig Wear parts both sides max Einzelst tzkraft statisch max single outrigger load Gesamtgewicht Gross weight max Schalleistung max sound...

Page 38: ...2 6 Technical data for SP 1800 2800 CAT 36 Techn Daten SP 1800 2800 CAT EN fm 01 00 00...

Page 39: ...ther chassis frames are available on request 2 7 3 Drive motors The drive motor powers the pumps of the hydraulic system directly without any in termediate gear There are alternative diesel or electri...

Page 40: ...istons run counter to one another As the receding piston draws concrete out of the filling hopper the advancing pis ton pushes the previously drawn in concrete into the pumping line At the same time t...

Page 41: ...r your machine SP 1800 2800 Baugruppen SP 1800 2800 EN fm 01 01 00 39 Fig 3 Concrete pump Caption Fig 3 Concrete pump Pos Description 1 Rock valve 2 Pumping cylinder and piston 3 Water box 4 Hydraulic...

Page 42: ...N fm 01 01 00 2 7 7 On the left in the direction of travel Fig 4 Side view on the left in the direction of travel Caption Fig 4 Side view on the left in the direction of travel Pos Description Pos Des...

Page 43: ...in the direction of travel Fig 5 Side view on the right in the direction of travel Caption Fig 5 Side view on the right in the direction of travel Pos Description Pos Description 1 Control 4 Diesel fu...

Page 44: ...groups and designations for your machine SP 1800 2800 42 Baugruppen SP 1800 2800 EN fm 01 01 00 2 7 9 Aerial view Fig 6 Aerial view Caption Fig 6 Aerial view Pos Description Pos Description 1 EMERGENC...

Page 45: ...rison and is used in the cal culation of the total noise level produced by a construction site The sound power level does not allow for any conclusions to be drawn with regard to the noise level at th...

Page 46: ...e measured at a distance of 1 m from the machine surface and 1 6 m across the ground which must be indicated in the operating instructions For machines without a remote control the highest sound press...

Page 47: ...SP 2800 D 96 dB A 4 m from the front on the left in the driving direction 95 dB A 123 dB A SP 2800 E 97 1dB A 5 m from the front on the left in the driving direction 98 5 dB A 107 8 dB A SP2800 D CAT...

Page 48: ...ation The measured sound pressure level LpA is also influenced by the installed drive power and the drive motor used For this reason we have attributed the highest measured value to each type of our c...

Page 49: ...d pictographs are important components of your machine Should the machine be used in a region with a different language than initially planned the signs and labels must be exchanged for a version in t...

Page 50: ...adjustment 10144573 10187511 10144566 98362082 Agitator Pump operation P 0 Suction operation R Concrete pump Suck 0 Pump Isolation valve open Isolation valve close 98362086 10115873 98362502 98362504...

Page 51: ...4 00 49 Speed adjuster Water pump Compressor CE signs 10086507 10158389 10144568 10148919 Main switch battery on off Delivery note box No tread surface 98394724 98393988 Stowing box Up 0 Down EASy dis...

Page 52: ...hs without text 50 Textlose Bildzeichen EN fm 01 04 00 For stationary concrete pumps only Lifting eye 98363577 10163380 Attention Example values for Horizontal trailer load Vertical trailer load 98381...

Page 53: ...2 10 1 Concrete pump control The concrete pump control lets the operator control all functions of the concrete pump electronically The system includes the control panel and cable remote con trol as we...

Page 54: ...Caption Fig 11 Concrete pump control Pos Description 1 Fuel level warning light 2 Illuminated ON OFF button for agitator suction operation 3 Illuminated ON OFF button for agitator pumping operation 4...

Page 55: ...ion 8 EMERGENCY STOP 9 Water pump 10 Compressor 11 Power outlet for remote control cable dummy plug 12 Hydraulic oil temperature indicator 13 CAT control Caption Fig 11 Concrete pump control Pos Descr...

Page 56: ...s a shutdown reported via the CAN bus 3 Regeneration request button The operator can use this button to send a regeneration request to the motor for the purpose of carrying out an active regeneration...

Page 57: ...TSC1 Pressing the button displays the desired motor speed screen to the operator Reduction step 25 rpm adjustable standard value return time Hold 200 rpm adjustable standard value 11 Speed increase b...

Page 58: ...will remain saved on the clip board and can be restored after any potential interruptions by using the TSC but ton 14 As soon as the control is switched off using the key operated switch 12 that save...

Page 59: ...r CAT C7 1 Acert Tier 4i 5 The degree of clogging is displayed on the Caterpillar display item 0 Fig 13 bar graph or percentage 6 Automatic regeneration of the diesel particle filter DPF can already b...

Page 60: ...15 c Press button 3 Fig 13 for at least 3 seconds d Regeneration starts within the next 10 minutes the motor may still have to reach operating temperature for example 5 Carrying out regeneration a The...

Page 61: ...00 2800 EN fm 01 03 00 59 Fig 15 The Regeneration key operated switch Fig 16 Caption Fig 16 Pos Description 1 Locking bar for grid assembly filling in hopper 2 Cleaning cover of the rock valve 3 Lubri...

Page 62: ...level in the fuel water separator is too high Drain water from the fuel system Connect a suitable hose to the draining device Open the drain valve Rotate the drain valve anti clockwise Loosen the bre...

Page 63: ...warning and steering elements SP 1800 2800 Kontroll Warn Steuerelemente SP 1800 2800 EN fm 01 03 00 61 Fig 18 2 10 8 Output regulation Fig 19 Caption Fig 18 Pos Description 2 Breather screw on the wat...

Page 64: ...lemente SP 1800 2800 EN fm 01 03 00 2 10 9 Fuel filter Fig 20 Fig 21 Caption Fig 19 Pos Description 3 Output regulation of the concrete pump Caption Fig 20 Pos Description 2 Fine fuel filter 3 Course...

Page 65: ...travel for the machines described in these operating instructions Fig 22 Position of button for forced switch off main switch for starter batteries When working on the electrical system performing mai...

Page 66: ...al damage to motor Repeatedly forcing the motor to switch off at short intervals can cause severe motor damage If it is not an emergency do not shut down the diesel engine at full load but rather run...

Page 67: ...Trennblatt_Kapitel Betrieb EN fm 65 3 Operation This chapter describes All of your machine s operating modes Safe and proper handing Safe and economical operation...

Page 68: ...3 Operation 66 Trennblatt_Kapitel Betrieb EN fm 01 00 00...

Page 69: ...use Make sure the machine is roadworthy before driving This includes The air pressure of the tyres according to the table The lighting is working properly only for 80 km h chassis frame The braking s...

Page 70: ...he filling in hopper of the concrete pump Unfavourable weight distribution worsens vehicle handling and can lead to damage to the chassis frame and structure Accessories essential to the work applicat...

Page 71: ...supporting force of your machine Fig 25 Your machine s stability must be guaranteed without fail Refuse to commence operations if the stability cannot be 100 guaranteed by the site management Clear th...

Page 72: ...g of the machine does not offer any protection against a voltage trans fer such as would occur through direct contact with a live conductor or by arc trans fer due to impermissible proximity to a tran...

Page 73: ...machine bare metal point incl screw 3 Conductive metal rod min insertion depth 1 5 m Moisten the ground surrounding the metal rod generously in order to increase its conductivity The safety distances...

Page 74: ...3 2 Installation site of the stationary concrete pump 72 Aufstellungsort SP waehlen EN fm 01 06 00...

Page 75: ...ith VDE 0100 55 e g construction site power supply distributor with ground fault interrupt Observe the regulations in the country of use 3 3 1 Instructions for electricians 3 3 1 1 Standard equipment...

Page 76: ...tending the supply line using additional cables GEFAHR Danger Danger to life by electric shock Before replacing the phases always move the main switch into the 0 position and pull the mains plug This...

Page 77: ...s if rotating in the wrong direction Recheck the rotational direction 3 3 3 Checking the rotational direction of the electric motors control with phase se quence monitoring For machines with a control...

Page 78: ...3 3 Electrical connection optional 76 Elektrischer Anschluss EN fm 01 10 00...

Page 79: ...amage to the machine GEFAHR Danger Risk of accident due to inoperative EMERGENCY STOP button Operating the machine with a defective EMERGENCY STOP system is prohibited and can lead to fatal accidents...

Page 80: ...1800 2800 EN fm 01 02 00 Fig 30 Remote control WARNUNG Warning The motor is not switched off Such special equipment having locked control levers also continues to run Switch off the motor or special e...

Page 81: ...m starting by simply unlocking the actuated EMERGENCY STOP button VORSICHT Caution Do not hesitate to press the nearest EMERGENCY STOP switch immediately if this helps to prevent an accident If the ma...

Page 82: ...3 4 EMERGENCY STOP system for SP 1800 2800 80 Not Halt System SP 1800 2800 EN fm 01 02 00...

Page 83: ...draulic oil if possible Fig 31 The filling neck 2 is located at the top of the reservoir and can be accessed after loosening the top cover ACHTUNG Attention Material damage caused by fuel in the hydra...

Page 84: ...dge of the pumping pistons If there is a danger of frost only add water immediately before concreting WARNUNG Warning Danger of crushing Only open water box with drive at a standstill and while pressu...

Page 85: ...alve is used to block the concrete pump during repair work Check the grid assembly in the concrete filling hopper Two locking bars 3 Fig 34 are used to secure the grid assembly Insert both locking bar...

Page 86: ...s The agitator and concrete pump restart after closing the grid assembly 3 5 1 Diesel engine Carry out the necessary work in accordance with the motor operating instruc tions prior to commissioning th...

Page 87: ...sary Refer to the motor operating instructions for the fuel quality The fuel tank has a capacity of approx 250 litres GEFAHR Danger Risk of explosion Only refuel when motor is not running Do not spill...

Page 88: ...collect the escaping water Collect fuel mixture and dispose of properly Close the drain cock when pure fuel begins to pour out Fig 37 3 5 3 AdBlue reservoir The AdBlue tank is installed on the left in...

Page 89: ...3 5 Readying the machine for operation SP 1800 2800 Betriebsbereitschaft herstellen SP 1800 2800 EN fm 01 02 00 87 Fig 38 Fig 39 Fig 40 Fig 41...

Page 90: ...3 5 Readying the machine for operation SP 1800 2800 88 Betriebsbereitschaft herstellen SP 1800 2800 EN fm 01 02 00 Fig 42 Fig 43...

Page 91: ...ing times see motor operating instructions Information Engine power failure Depending on the engine observe the required manual or automatic regenerations for the diesel engine In pumping operation th...

Page 92: ...following operating times apply for each full tank with an average fuel consumption of approx 220 g per kW and hour Fig 44 To A Max diesel filling volume in L tank contents To B Viscosity of diesel fu...

Page 93: ...t up immediately do not continue trying to start it for more than 10 seconds After each start up procedure take a one minute break Observe cold start infor mation in the motor operating instructions O...

Page 94: ...3 6 Drive circuit SP 1800 2800 92 Antriebsschaltung SP 1800 2800 EN fm 01 06 00 Fig 45 Control panel with regeneration Fig 46 Control panel with TSC...

Page 95: ...evere motor damage from over heating especially with turbo charged motors For certain motors switching off the motor may be delayed at operating tempera tures that are too high motors will continue ru...

Page 96: ...in direction of travel 3 6 3 Forced switch off of motor The motor can be switched off immediately via a forced switch off in case of an emergency Fig 49 Button for forced motor switch off To do so act...

Page 97: ...of emergency Repeatedly forcing the motor to switch off at short intervals can cause severe motor damage In order to prevent a function from starting up unintentionally after switching the machine ba...

Page 98: ...3 6 Drive circuit SP 1800 2800 96 Antriebsschaltung SP 1800 2800 EN fm 01 06 00...

Page 99: ...The machine must not be installed if its maximum ground pressure exceeds the permissible value If necessary the support surface must be extended using suitable means until the permissible ground press...

Page 100: ...time we rec ommend removing the wheels prior to lifting loosen the wheel nuts Store the wheels and cover the wheel hubs 3 7 2 Outrigger variants The machine can be delivered with a mechanical or semi...

Page 101: ...engths that are too short lead to serious strain on the straight frame When transporting the machine with chain slings the individual chain lengths must be a minimum of 2 5 m 3 7 3 Machine with chassi...

Page 102: ...supporting dish until the trailer coupling is released Lower the rear supports 2 Fig 53 and secure with socket pins and split pins Secure the machine using the wheel wedge 1 wheel wedges are not incl...

Page 103: ...pled from the towing vehicle remove the socket pin 1 and lower the interior tube 2 Fig 55 Reinsert the socket pin 1 and secure with split pins Pull out the crank 3 and lower the supporting dish by rot...

Page 104: ...Setting up the machine 102 Maschine aufstellen EN fm 01 03 00 Fig 55 Support jack SP 3800 Fig 56 Example illustration Caption of Fig 55 Pos Designation 1 Socket pin 2 Interior tube 3 Crank 6 Exterior...

Page 105: ...pports 2 Fig 53 Fig 56 and secure with socket pins and split pins Raise the machine at the front using the crank 3 and position it horizontally Lower the front supports 1 and secure with socket pins a...

Page 106: ...control levers Extend the hydraulic supports evenly until the machine is horizontal in all direc tions The control levers are spring centred and return to the central position once they have been rel...

Page 107: ...expert inspection prior to each first commis sion after any kind of changes to the support equipment and at least once a year according to manufacturer s instructions These inspections should be docum...

Page 108: ...3 7 Setting up the machine 106 Maschine aufstellen EN fm 01 03 00 Fig 59 Grease nipples SP 3800...

Page 109: ...uplings after install ing them When mounting split couplings injuries can be caused by the cocking lever spring ing open unexpectedly Secure the cocking lever of the split couplings immediately after...

Page 110: ...nt de vice according to the operating conditions see chapter 4 16 SCHWING s customer service can recommend suitable measurement devices de pending on the pumping line material being used We strongly r...

Page 111: ...apered tube marking as of approx 2017 Fig 64 Elbow marking as of approx 2017 DN Nominal size in mm inner PN permissible operating pressure in bar s Wall thickness Caption for Fig 62 Fig 64 Designation...

Page 112: ...ondition If the minimum wall thickness is not met then replace the tubes and el bows With truck mounted concrete pumps the concrete pressure for rod and piston side pressure is also indicated on the t...

Page 113: ...the placing boom Normally a truck mounted concrete pump delivers the concrete directly via the pumping line of the assembled placing boom A separate placing boom is supplied by a separate concrete pu...

Page 114: ...nges to the pumping line other safety relevant adjustments of the ma chine may be mandatory After major changes that are not carried out by SCHWING placing booms must be inspected by an expert before...

Page 115: ...ble pumping line material These concrete pumps must not pump through the end hose and boom pumping line with piston side pressure Reconnectable concrete pumps can produce concrete pressures with pisto...

Page 116: ...5 03 GEFAHR Danger Danger to life due to moving parts Severe injuries or even death due to severed limbs Do not reach into the gate valve Before opening the pumping line outlets switch the drive motor...

Page 117: ...the clip pin 4 out of the wedge 5 Remove the wedge 5 Fig 69 and keep it ready to use as a chock for the hinge 7 Fold open the outlet 6 to the right At an opening angle of approx 100 the wedge 5 Fig 6...

Page 118: ...t Pull the clip pin and remove the wedge 2 Open the foldable and rotatable outlet Loosen both the safety screw 4 and the second safety screw offset by 180 by approx half a rotation Rotate the foldable...

Page 119: ...3 8 Operating the pumping line Foerderleitung_Betrieb EN fm 01 15 03 117 Fig 71 Outlet foldable and rotatable...

Page 120: ...ng function is the same as for the short outlet The larger outlet 180 180 150 has the advantage of having less concrete resistance Use the large outlet when pumping concrete that is difficult to pump...

Page 121: ...ing line is of great significance Both must be done with great care and expertise SCHWING offers an extensive range of pumping lines and accessories Should you have any questions regarding the pumping...

Page 122: ...nd female flange for cup tension couplings Fig 74 The following versions are available a Standard tubes up to 4 5 mm thick walls depending on the nominal size are suitable for up to max 110 bar b Thic...

Page 123: ...Operating the pumping line Foerderleitung_Betrieb EN fm 01 15 03 121 Fig 73 1 Flange 3 Seal 4 Split coupling Fig 74 Fig 75 1 Flange with male face 2 Flange with female face 3 Seal 4 Cup expansion coup...

Page 124: ...again and after blockages No one may remain in the danger zone of the end hose The diameter of the danger zone is double the length of the end hose It is prohibited to guide the end hose during pumpin...

Page 125: ...123 Observe the safety instructions on the machine see Fig 76 Fig 78 Fig 76 Fig 77 Fig 78 3 8 13 Connecting hoses Connecting hoses with double sided fixing can be used as flexible intermediate pieces...

Page 126: ...oncrete pressure of the concrete pump must not ex ceed the permissible concrete pressure of all pumping line parts The concreting personnel at the placement site must be aware of any potential dangers...

Page 127: ...specially important for this Dirty hoses wear out faster and cause clogging Suck back the cleaning ball then knock off individual hoses and rinse thoroughly with water If it cannot be sucked back knoc...

Page 128: ...3 8 Operating the pumping line 126 Foerderleitung_Betrieb EN fm 01 15 03...

Page 129: ...by the ag itator pump and activated by engaging the control elements see hydraulic switch ing diagram VORSICHT Caution Unintentional start up After starting the drive motor the hydraulic pumps immedia...

Page 130: ...0 3 9 2 CP remote control The cable remote control steers the concrete pump during operation Fig 80 Control panel Insert the plug of the remote control cable into the power outlet 11 Fig 80 and secure...

Page 131: ...g an emergency or test op eration a bypass plug has to be inserted into the power outlet 11 Fig 80 Without this plug no electrical power is available for the machine control unit and the EMERGENCY STO...

Page 132: ...ged Personal hearing protection must always be worn when a sound pressure level of 80 dB A is exceeded Failure to observe this may be harmful to your health Close all hoods covers etc that are provide...

Page 133: ...n the concrete pump with an empty filling hopper Dry running wears out the pumping piston and kidney seal faster Fill water into the filling hopper for maintenance and cleaning work Fill concrete into...

Page 134: ...perating speed of the diesel engine 3 10 3 Agitator The agitator can only be switched on if any interlocked controls of any special equipment in the agitator control block upstream are in Agitator pos...

Page 135: ...l equipment If you want the concrete pump to pump the agitator must feed the concrete to the suction intake P pump If you want the concrete pump to suck the agitator must feed the concrete away from t...

Page 136: ...te control Fig 83 Fig 83 Remote control The corresponding button lights up The concrete pump starts up Set the desired concrete pump delivery volume stroke count using the hand wheel 4 Fig 84 Close th...

Page 137: ...e corresponding illu minated buttons on the control station Switch off any special equipment by turning the corresponding controls to the Agitator position 3 10 7 Reconnecting the concrete pump The ma...

Page 138: ...b Betonpumpe SP 1800 2800 EN fm 01 05 00 Fig 86 Piston side pressure on the machine Fig 87 Rod side pressure Fig 88 Rod side pressure on the machine see Technical data for SP 1800 2800 CAT on page 29...

Page 139: ...unpressurised hydraulic system Switch off the motor and secure it against being switched back on ACHTUNG Attention Ensure that the pumping line material is suitable for the potential concrete pressure...

Page 140: ...3 10 Working operation Concrete pump SP 1800 2800 138 Arbeitsbetrieb Betonpumpe SP 1800 2800 EN fm 01 05 00...

Page 141: ...not possible VORSICHT Caution Unintentional start up After switching on the drive motor the auxiliary pump agitator pump pumps oil im mediately However the agitator only starts after being switched o...

Page 142: ...to SP 1800 2800 types For equipment with a hydraulic outrigger a ball valve selects between the outrigger and additional functions In the position Outrigger only it can be driven In the position Agita...

Page 143: ...ressure 3 12 1 Preparation The hydraulically powered water pump is self priming 3 Fig 89 We recommend setting up a water case with clean water next to the pump The water must be free of solids as they...

Page 144: ...on Fig 90 Agitator Open the spraying nozzle of the water hose and hold the hose tightly Switch on the water pump using the button 9 Fig 91 Regulate the water flow rate by adjusting the engine speed on...

Page 145: ...f operation Switch off the water pump by pressing the button 9 Fig 91 again 3 12 4 Winter operation If there is danger of frost the water pump must be drained after each operation Remove the suction a...

Page 146: ...3 12 Working operation Water system SP 1800 2800 144 Arbeitsbetrieb Wasseranlage SP 1800 2800 EN fm 01 01 00...

Page 147: ...1 Preparation VORSICHT Caution If the compressor is used to clean the pumping line see Cleaning on page 169 Switch off hydraulic downstream aggregates prior to commissioning the compressor Otherwise t...

Page 148: ...gine to idle Regula tion is not possible with the electric version Switch the upstream ball valve to the base position Fig 94 Agitator If the machine is equipped with a hydraulic outrigger Switch on t...

Page 149: ...button 10 Fig 95 3 13 4 Winter operation The rotary compressor can be used at temperatures of up to 15 C with proper maintenance chap 4 17 For lower temperatures please contact us ACHTUNG Attention Av...

Page 150: ...llect in the compressor 2 Fig 92 and cause damage For this reason we recommend Switching on the compressor once a week for at least 30 minutes continuously Adhering to the maintenance intervals for th...

Page 151: ...kflow from the concrete column to the concrete pump during up pumping pro cedures 3 14 1 Preparation Have a hydraulics technician connect the hydraulic junctions of the shut off as sembly to junctions...

Page 152: ...and installing suitable material We recommend using the shut off assembly Fig 97 and pumping line material from SCHWING When using unsuitable material SCHWING is not liable for any damages We recommen...

Page 153: ...back on Release the hydraulic system This can be done for example by opening manual relief valves or also by repeated manual switching of the appropriate directional valve in both directions In contr...

Page 154: ...pressure rise indicates a blockage directly behind the concrete pump The pressure rise is slower if a blockage is located at the end of the concrete pump ing line The best way to prevent blockages is...

Page 155: ...hine Never open a pumping line under pressure and do not tap it Relieve the pumping line by reverse pumping the concrete with the concrete pump Never work while directly bent over the line 3 15 2 Mech...

Page 156: ...gging of the oil is prevented through careful oil maintenance filter change Metallic abrasion in the oil points to damage Control blocks may also jam due to high temperature differences for example wh...

Page 157: ...ging 3 16 1 Control of operations for concrete pump VORSICHT Caution Risk of accidents due to parts or material being ejected Intake air is compressed in the pumping line and escapes abruptly at the e...

Page 158: ...g SP 1800 2800 EN fm 01 00 00 Fig 98 Fig 99 Monitor the water level and contamination in the water box 1 Fig 100 Drain any contaminated water using the drain valve 2 Fig 101 on the bottom and fill wit...

Page 159: ...times during operation Depending on the wear condition of the pumping pistons and cylinders rinse the water box regularly Check the water box weekly for deposits that could not be removed by the norm...

Page 160: ...is required see Working operation Concrete pump SP 1800 2800 on page 131 In order to protect the pressure gauge from spikes in pressure close the shut off valve 6 Fig 102 immediately after the test I...

Page 161: ...t during opera tion screwing in the adjustment spindle 4 Fig 103 can dampen the limit stop further Fig 103 However this results in a reduced stroke rate If the rock valve does not connect correctly e...

Page 162: ...ator has been designed as a riser pipe and is located on the right next to the fuel prefilter 3 Fig 104 Fig 104 Top up fuel in due time Do not run on an empty fuel tank as otherwise the fuel system wi...

Page 163: ...he motor must be shut down immediately in order to prevent serious motor damage In the event of other failures it is possible to continue working at reduced power if necessary e g air filter dirty Inf...

Page 164: ...3 16 Control of operations SP 1800 2800 162 Betriebsueberwachung SP 1800 2800 EN fm 01 00 00...

Page 165: ...or troubleshooting purposes which should light up when connected to a power source 3 17 2 Electrical fuse protection for the machine control system Depending on the type of machine the system can be s...

Page 166: ...Stop the machine and have an electrician inspect the system 3 17 2 1 Main fuse A 30A main fuse 1 Fig 107 Fig 108 is located near the starter batteries on all machines with a diesel engine Check this f...

Page 167: ...that the machine has to be operated during an emergency or test op eration a bypass plug has to be inserted into the power outlet 11 Fig 106 Without this plug no electrical power is available for the...

Page 168: ...ional or unauthorised switching on of the concrete pump the control lever must be disassembled immediately after completion of the test The control lever can switch the concrete pump into the pump or...

Page 169: ...trol oil of the pressure relief valve PRV of the concrete pump to the hydraulic oil box The PRV opens and the concrete pump stops If the concrete pump stops unexpectedly it is possible that the EMERGE...

Page 170: ...3 17 Troubleshooting Emergency operation SP 1800 2800 168 Verhalten bei Stoerungen SP 1800 2800 EN fm 01 04 00...

Page 171: ...with a water hose during concrete breaks to prevent the concrete from setting 3 18 1 Cleaning devices Suitable devices can be ordered from SCHWING For example Compressor Fig 111 Water pump 1 and high...

Page 172: ...nt High pressure cleaning system please read the separate chapter 3 18 2 Cleaning the pumping line After work clean the pumping line first since this is where the concrete sets quicker The total quant...

Page 173: ...onge rubber ball represents the normal cleaning of a placing boom pipeline Produce a thin consistency concrete and pump the pumping line full Close the foldable covering for the hopper WARNUNG Warning...

Page 174: ...of the agitator rotational direction to pumping or suction operation Do not forget to switch Machines with a VECTOR control switch automatically First push the damp sponge rubber ball into the end hos...

Page 175: ...sound Fig 118 If the concrete and sponge rubber ball have passed the tapping point the tapping will produce a high pitched sound Fig 119 ACHTUNG Attention Damage to the pumping line Only use the handl...

Page 176: ...it is necessary to interrupt the process and empty the filling hopper Fig 120 Cleaning cover It depends on several factors whether the concrete filling hopper can completely re ceive the flowing back...

Page 177: ...mmend interrupting the back siphonage process after 4 strokes at the latest and emptying the hopper 4x 125 l 500 l A certain degree of experience is helpful here The basic principles are The longer th...

Page 178: ...lded tightly rolled up empty cement bags Information The plug must be completely sealed to prevent the concrete from leaching 3 18 5 Rinsing the pumping line Cement residues are removed from the tube...

Page 179: ...3 18 Cleaning Reinigung EN fm 01 18 04 177 Fig 122 Blowing out the pumping line Fig 123 Rinsing the pumping line...

Page 180: ...ng lines of the same nominal size 5 A trap basket must be connected to the concrete outlet Fig 124 6 Set the concrete output high so that the concrete can escape freely 7 The cleaning head must be equ...

Page 181: ...3 18 Cleaning Reinigung EN fm 01 18 04 179 Fig 124 Trap basket Fig 125 Cleaning head...

Page 182: ...pressure cleaner towards the electrical components of the machine 3 18 8 Securing the machine Remove the remote control cable Connect the radio remote control transmitter Use the local control WARNUNG...

Page 183: ...and rinses out the pumping cylinders Switch off the concrete pump and the vehicle engine Fig 126 Cleaning the filling hopper Fig 127 Rotatable outlet Open the cleaning flap Fig 128 under the rock val...

Page 184: ...ill water box with fresh water Check the water box weekly for deposits that could not be removed by normal flushing process Increasing deposits may indicate wear on the pumping piston WARNUNG Warning...

Page 185: ...30 Hose out water box Close and secure the cleaning flap on the rock valve Fig 131 Close the slewing lever on the cleaning flap by hitting it with a hammer in the axial direction Information The hamme...

Page 186: ...maged Fig 131 3 18 10 Exterior cleaning We recommend the occasional hosing down with a water hose during breaks to prevent the concrete setting Lightly spray the outside of the concrete pump filling h...

Page 187: ...d with a spray hose and cold water dur ing the first 3 months Use a soft brush if necessary No HP cleaner should be used in areas with mechanical paint damage because this can cause painted areas to s...

Page 188: ...lubrication points after cleaning We recommend spraying the dry machine with a wax based preservative for pro tection against corrosion 3 18 14 Water box flushing special equipment Our truck mounted c...

Page 189: ...cock and fill the water box with clean water This can also be done with the spraying nozzles or as usual through the drain hose Always rinse the water box immediately after each use of the concrete p...

Page 190: ...3 18 Cleaning 188 Reinigung EN fm 01 18 04...

Page 191: ...e filling hopper is coupled to an end limit switch The end limit switch stops the rock valve and agitator when the hopper grate is opened WARNUNG Warning Risk of serious injury due to defective end li...

Page 192: ...flap under the rock valve housing or the elbow of the pipeline outlet of concrete pumps Stop the machine Switch off the drive motor and prevent it from starting up Discharge the pressure accumulator i...

Page 193: ...ng When lowering the machine ensure that no unauthorised persons are in the vicinity of the machine and no one will be crushed by the machine or machine parts Perform the following general tasks Clean...

Page 194: ...ng the front of the machine slightly with the crank Insert the interior tubes of the rear supports and secure them with socket pins and split pins Place the machine in a horizontal position with the c...

Page 195: ...of the machine slightly until the front supports 1 Fig 140 are un burdened Insert the interior tubes of the front supports and secure them with socket pins and split pins Unburden the rear supports 2...

Page 196: ...Establishing transport readiness 194 Transportbereitschaft herstellen EN fm 01 01 00 Fig 138 Crank support SP 3800 Caption of Fig 138 Pos Designation 1 Socket pin 2 Interior tube 3 Crank 6 Exterior t...

Page 197: ...tire oil flow of the auxiliary pump is conducted to the outrigger in the Out rigger position of the ball valve The auxiliary pump may not drive any other aggregates Start the drive motor Retract the f...

Page 198: ...3800 Special equipment Lower the crank support until the supporting dish touches the ground For the semi hydraulic outrigger the oil flow from the agitator pump is directed into the control blocks of...

Page 199: ...pport Secure the interior tube with the socket pin and spit pins Remove the crank prior to driving operation 3 20 6 Coupling SP 3800 VORSICHT Caution Danger of crushing No one may remain between concr...

Page 200: ...FAHR Danger Falling loads Do NOT exceed the load capacity of the lifting eyes with additional weight from ac cessories and remnants of pumping medium Determine weight of loads prior to raising GEFAHR...

Page 201: ...be used by default at ambient temperatures of 15 C to 30 C when operating materials are used according to our recommendations ACHTUNG Attention Placing booms may not be used at ambient temperatures b...

Page 202: ...ition see 3 21 1 9 3 21 1 3 Water system ACHTUNG Attention Danger of ice and frost damage Overflowing water freezes and can cause serious material damage Do not switch on frozen aggregates e g water p...

Page 203: ...C Should work be performed at temperatures ranging between 10 C and 15 C switching over to winter oil VG 32 is required Otherwise the great oil viscosity can cause a risk of damage during a cold star...

Page 204: ...3 21 Difficult operating conditions 202 Erschwerter Betrieb EN fm 01 08 01 Viscosity temperature diagram Fig 142 Viscosity temperature diagram...

Page 205: ...uld series or manufacturer be changed flushing with the new type of oil is re quired Thereby switching all valves several times Fully extend and retract all cyl inders At temperatures below freezing p...

Page 206: ...l for some truck mounted concrete pumps it is also important to set the vehicle air system to winter operation Vehicle air systems are equipped with air dryers or frost guards to prevent conden sation...

Page 207: ...sure the batteries are well charged Remove batteries when machine is not used Store batteries in a warm and dry place recharge if necessary Ensure good contact of the terminal connections Check the V...

Page 208: ...for several minutes This will heat up the aggregates and oil building up a stable lubricating film Extend the connection pieces at a low pump speed Raise the placing boom at a low pump speed and run...

Page 209: ...t up the machine so that it is protected from direct sunlight Machine and pumping line should be painted brightly Relocate separate pumping lines preferably in the shade cover if necessary Please note...

Page 210: ...troke rates increase the temperature of the hydraulic system and are ex tremely pointless for stiff concrete as they are then sucked in poorly Prevent air from being sucked in Air in the pumping pipes...

Page 211: ...able temperatures night day see Fig 142 Viscosity temperature diagram 3 21 2 5 Air system Use a compressor oil for the reciprocating compressor of viscosity class VG 150 The synthetic oil prescribed f...

Page 212: ...Radio remote control The radio control can be used at up to 60 C 3 21 2 10 Setting up the machine The load bearing capacity of heat sensitive subsoils such as asphalt decreases as the ambient tempera...

Page 213: ...mping line with water before pumping Use a somewhat mushier start up mixture for long lines Make sure that the concrete can be pumped easily Avoid extended breaks Cover the concrete in the filling hop...

Page 214: ...3 21 Difficult operating conditions 212 Erschwerter Betrieb EN fm 01 08 01...

Page 215: ...machine parts or spray them with preserving oil 7 Preserve concrete pumping pipes by pushing a cotton waste plug soaked in preserving oil through the pumping line 8 Retract all hydraulic cylinders 9 S...

Page 216: ...4 60 in addition to the operating instructions from the motor or chassis manufacturer 3 22 2 Recommissioning 1 Remove preservation 2 Check all oil levels 3 Empty hydraulic oil box to inspection glass...

Page 217: ...in size of 32 mm A minimum cement content of approx 240 kg per m with a maximum grain size of 32 mm Water Cement ratio of 0 42 w c 0 65 w c Grain composition according to grading curve Consistency of...

Page 218: ...3 23 Technical preconditions for concreting 216 Betontechnologische Vorauss EN fm 01 04 01...

Page 219: ...is chapter contains maintenance instructions for concrete pumps Further measures should be carried out by SCHWING s customer service department or by trained and qualified personnel Otherwise the warr...

Page 220: ...4 Maintenance 218 Trennblatt_Kapitel Wartung EN fm 01 00 01...

Page 221: ...y un qualified personnel Should you not have trained personnel and appropriate workshop equipment com mission the SCHWING customer service to service your machine 4 1 1 Maintenance work on special equ...

Page 222: ...still at operating temperature in order to flush out contam inants better VORSICHT Caution Risk of injury caused by hydraulic oil Hydraulic fluid can cause irritation to the skin and eyes Always wear...

Page 223: ...tion water Humidity and fluctuating temperatures form condensation in hydraulic oil boxes which mixes with the oil As the ratio of water increases the lubricating power of the mixture decreases rap id...

Page 224: ...merging under pressure can cause serious in juries Immediately replace any damaged tubes and damaged or moist hydraulic hos es 4 1 10 Repairs exchange Information It may be less expensive to exchange...

Page 225: ...eaks Perform maintenance work on repaired or exchanged units as per usual 4 1 11 Welding Welding work may only be carried out by trained professionals according to manu facturer regulations see Repair...

Page 226: ...n electrician disconnect the power supply to such machines prior to car rying out repair work on the respective machine GEFAHR Danger Danger to life by electric shock Working on systems still connecte...

Page 227: ...0389 3 Clean water Machines Fuel tank Diesel engine Hydraulic oil box Water case 1 3 Standard agitator gear Reinforced agitator gear Reciprocating compressor 1 Rotary compressor 1 Grease lubrication p...

Page 228: ...4 2 Consumable volumes in litres 226 Betriebsstoffmengen SP EN fm 01 00 00...

Page 229: ...lator is unpressur ised If for example systems under pressure need to be opened when venting mount a breather line first while the system is depressurised or use the existing mini measurement connecti...

Page 230: ...tion and sequence of the prod ucts listed do not include qualitative assessment 4 3 2 Explanation of the abbreviations used 4 3 2 1 General BI Central Federation of the German Construction Industry As...

Page 231: ...or severe stress in gears and axles roughly corresponds to API GL 5 4 3 2 5 Compressor oil VDL Mineral oil for air compressor with agents designed to improve anti corrosion and durability Carbon resid...

Page 232: ...nt quality requires a complete oil and filter change Mixing the same oils with different viscosities is only permitted after consultation with SCHWING GmbH Only use oils that contain zinc Viscosity IS...

Page 233: ...3 4 1 Industrial gear oil Viscosity according to ISO VG 220 Quality according to DIN CLP ARAL Degol BG 220 Degol BMB 220 BP Energol GR XP 220 KL BER Kl beroil GEM 1 220 MOBIL Mobilgear 600 XP 220 SHE...

Page 234: ...Viscosity according to ISO VG 220 Quality according to DIN PG ARAL Degol GS 220 AVIA Avilub VSG 220 BP Energol SG XP 220 ELF Syntherma P 270 FUCHS Renodiol PGP 220 MOBIL Glygoyle 30 SHELL Tivela WB T...

Page 235: ...ary compressors see Rotary compressor on page 325 4 3 5 1 Reciprocating compressor Viscosity according to ISO VG 100 VG 150 Quality according to DIN VDL VDL ARAL Motanol HE 100 Motanol HE 150 BP Energ...

Page 236: ...O Multifak EP 2 MOBIL Mobilux EP 2 WINTERSHALL Wiolub LFP 2 BI MPG A 4 3 6 3 Special lubricants for severe operating conditions Under severe operating conditions we recommend using a particularly adhe...

Page 237: ...lubricants for the plastic sliders in the telescopic arm Designation according to DIN MLE2N 40 SCHWING item no 10194658 10 kg tin 4 3 6 6 Special lubricants for couplings and seals in pumping lines OP...

Page 238: ...olled release into the environment Not fully biodegradable FIRST AID MEASURES After inhalation Take the affected person into fresh air and place in a resting position Seek medical advice After skin co...

Page 239: ...nd strong oxidants during storage Store dry and do not expose to large temperature switches PERSONAL PROTECTIVE EQUIPMENT Respiratory protection Use oil mist protective mask with filter for organ ic v...

Page 240: ...4 3 Recommended lubricants and fuels 238 Schmier Betriebstoffempfehlung EN fm 01 22 01...

Page 241: ...ovisions original spare parts for older machines A wide range of accessories is also available SCHWING is not liable for damages resulting from the use of spare and additional parts in non compliance...

Page 242: ...e same incident occurs again in the short term the pumping cylinders also need to be replaced Hydraulic oil in the water box of the concrete pump If you notice oil streaks on the water surface or a mi...

Page 243: ...are constantly optimised in the course of improving the specification In doing so a critical focus is on the improvement of the wear and tear Special components are also available for special applica...

Page 244: ...4 4 Spare parts and accessories 242 Ersatzteile Zubehoer EN fm 01 05 02...

Page 245: ...mbols used in the following maintenance schedule CHECK LUBRICATE CLEAN REPLACE ditto after the initial commissioning Time interval in the following maintenance schedule A daily or 10 operating hours B...

Page 246: ...4 5 Explanation of the maintenance schedule Stationary con crete pump 244 Deckblatt Wartungsplan SP EN fm 01 01 01...

Page 247: ...f the operating levers A9 Check the hydraulic and water systems aggregates reser voirs pumping lines etc for leaks chap 4 16 A10 Check that the structure outrigger pumping line reser voirs aggregates...

Page 248: ...swivel head for tightness chap 4 12 B7 Check screws of the rock valve cover for tightness chap 4 12 B8 Check the axial play of the rock valve slewing shaft chap 4 12 B9 Check the seal on the rock val...

Page 249: ...nt Air filter system D4 Check air filter contamination maintenance indicator D5 Check dust discharge valve on the air filter for damage and clean D6 Check clean air pipe for damage and tightness D7 Ch...

Page 250: ...erating conditions e g concrete type concrete pump stroke rate etc We therefore recommend testing new components after having pumped a speci fied amount of concrete This allows you to determine the we...

Page 251: ...sbericht EN fm 01 00 01 249 4 7 Maintenance report Copy template Type of maintenance A V B S P please enter Date Signature Comments G General P Placing boom only S SPB C Concrete pump pump kit S Speci...

Page 252: ...ance report 250 Wartungsbericht EN fm 01 00 01 Type of maintenance A V B S P please enter Date Signature Comments G General P Placing boom only S SPB C Concrete pump pump kit S Special equipment T Tes...

Page 253: ...1 4 8 Hydraulic fluid and filters for stationary concrete pump 4 8 1 Checking the fill level of the reservoir The reservoir for the hydraulic oil is equipped with an oil level indicator 1 Fig 146 Fig...

Page 254: ...e it as required When warm the hydraulic oil is expanded and the indicated oil level is not correct If necessary top up the hydraulic oil via the filler cap 4 Fig 146 Fig 147 Do not mix different type...

Page 255: ...SCHWING GmbH as a minimum those of the component manufacturer 4 8 4 What does the purity classification mean Contaminations cannot be convincingly detected through a visual inspection The classificati...

Page 256: ...the state of the oil and machine as well as recommendations on how to proceed For an oil analysis the oil must be removed from the system and sent to a labora tory for analysis To keep your personal...

Page 257: ...is in progress After an extended period of downtime drain any water from the hydraulic oil box To do this use the drain valve 1 Fig 149 on the bottom of the box Remove the lock nut from the drain valv...

Page 258: ...icular during long periods at standstill the hydraulic oil excretes dirt particles which are deposited onto the bottom of the container Therefore during each oil change check the inner walls and the i...

Page 259: ...he ventilator is no longer rotating and that the device has cooled down The machine is equipped with a main filter 2 Fig 151 The filter is located inside the machine As a rule replace the insert on th...

Page 260: ...d filter insert 2 off of the filter head Clean the filter bowl and the filter head ensuring that the thread in particular is clean Inspect the O rings and back up rings replace if necessary 4 8 11 2 M...

Page 261: ...4 8 Hydraulic fluid and filters for stationary concrete pump Hydraulikfl ssigkeit Filter SP EN fm 01 01 01 259 Fig 152 Fig 153 Fig 154...

Page 262: ...4 8 Hydraulic fluid and filters for stationary concrete pump 260 Hydraulikfl ssigkeit Filter SP EN fm 01 01 01...

Page 263: ...ncontrolled start up of the concrete pump ACHTUNG Attention When checking the pressure of the concrete pump hydraulic system be sure to set the direction to Pump In the direction Sucking the seals of...

Page 264: ...ing pistons are moved into the end position and remain there The indicator on the concrete pump pressure gauge 2 Fig 158 on the rear of the machine must increase to the value set for the pressure cut...

Page 265: ...4 9 Pressure checks stationary concrete pumps Druckkontrolle SP EN fm 01 01 01 263 Fig 157 SP 9000 SP 9500 Fig 158 Pressure gauge pressure check...

Page 266: ...4 9 Pressure checks stationary concrete pumps 264 Druckkontrolle SP EN fm 01 01 01...

Page 267: ...nits Switch off the motor and ignition Allow the cooler to cool down Wear work gloves helmet and safety glasses Remount all safety devices after finishing the cleaning work Only then recommission the...

Page 268: ...1 2 Cleaning the inside of the hydraulic oil cooler Remove the cooler Connect cooler to a flushing system with filters Flush for at least 30 minutes After cleaning remove the flushing medium completel...

Page 269: ...ow Fig 160 The valve must not be restricted Remove any dust incrustations Renew damaged valve The valve must point down when in installed condition Fig 160 4 11 2 Removing the filter element If the ma...

Page 270: ...r element or clean by slamming Clean and dry compressed air is used for the cleaning max 5 bar Dust may not get to the inside of the element when blowing out dust A tube whose end is bent by approx 90...

Page 271: ...n dust mask Inspect the cleaned element for damages paper bellows seals before re in stalling it Cracks and holes in the paper bellows can be detected with a torch ACHTUNG Attention Potential motor da...

Page 272: ...element upright in the original packaging and protected from dust moisture and damage 4 11 6 Disposal The filter element consists of filter paper and polyurethane foam All filter elements are hazardou...

Page 273: ...ing strip on truck mounted concrete pumps The grease nipples on this strip are connected to the bearing points of the rock valve Bearing points include Slewing shaft Slewing cylinder Agitator Dependin...

Page 274: ...4 12 Rock valve 272 Rockschieber EN fm 01 17 01 Fig 165 Greasing strip on stationary concrete pumps Fig 166 Greasing strip on truck mounted concrete pumps...

Page 275: ...f the hydraulic cylinder Cylinders with unilateral and bilateral ball bearings are allowed The appropriate lubrication points are connected to the lubrication point or the cen tral greasing through th...

Page 276: ...e slewing shaft No air gap may be visible between the bearing bushing 4 the locking wheel 2 and the adjusting nut 1 Fig 169 even during operation There must be a measurable distance of distance of 1 5...

Page 277: ...rest threaded bore in the locking disc 2 rotate the nut forward or backward Attach safety screw 3 with disc 4 12 5 Checking the cutting ring The cutting ring and wearing insert on the housing lining a...

Page 278: ...vailable as special equipment In order to achieve an even wear pattern and thus considerably longer service lives of the parts we recommend After a thorough cleaning bring the rock into the left and r...

Page 279: ...the cutting ring proceed as follows Disconnect the pumping line from the outlet of the rock valve To do this a Remove the tapered tube for stationary concrete pumps b Remove the wedges 1 2 and the cou...

Page 280: ...personal injury and material damage Do not unscrew the cover screws completely Press off the cover of the housing using two assembly levers until it hits the loosened screws there are press off points...

Page 281: ...ews Set the axial play of the slewing shaft approximately in order to be able to switch through the rock valve for setting the parts To do this set the adjusting nut 1 into position and loosen it by a...

Page 282: ...4 12 Rock valve 280 Rockschieber EN fm 01 17 01 When replacing the cutting ring check the condition of the wearing insert 9 and pressure spring 11 Fig 176 Fig 175 Fig 176...

Page 283: ...the bearing immediately before the bearing is destroyed To do this the slewing shaft has to be removed see separate rock valve repair manual 4 12 8 Prolonged downtime Should the rock valve not be used...

Page 284: ...largely depends on the operating conditions we recommend check ing a new rock for the first time after about 5000 m conveyed concrete To do so clean the concrete pump as per usual Move the swivel hea...

Page 285: ...The inner armouring usually wears faster than the outer armouring The exterior should be checked as soon as significant wear is detected on the inside Information A regeneration by means of renewed ha...

Page 286: ...4 12 Rock valve 284 Rockschieber EN fm 01 17 01...

Page 287: ...t cat alogue 4 13 1 Pumping piston change Work on the pumping pistons is carried out in the water box GEFAHR Danger Danger of crushing Rock can switch Before working in the water box always switch off...

Page 288: ...r the top cover If a tool is required for opening the cover then no grids are available Always ensure that the grids are present and bolted down tightly Attach the top cover correctly and secure if ne...

Page 289: ...4 13 Delivery and differential cylinders pumping piston change Foerder Diff Zyl SP EN fm 01 07 01 287 Fig 181 Example SP 1800 Fig 182 Example of SP 3800 BR02 Fig 183 Example of SP 9500 BR02...

Page 290: ...with a special control for the pumping piston change Activating the operating mode Pumping piston change automatically reduces the rotational speed of the diesel engine and delivery rate to 0 Only th...

Page 291: ...cking the fastener Lift the top cover off of the water box 2 Fig 180 and remove the protective grills Move an intermediate piece into the water box Drain the water Make sure the fastening screws are t...

Page 292: ...king pumping pistons cause premature wear on the pumping cylinders Always replace both pumping pistons together However should sand get into the water box despite the new pumping pistons then the cyli...

Page 293: ...fully visible in the water box Fig 187 Loosen the fastening screws on the distance piece and remove them While do ing so hold the distance piece on the continuous hexagon Fig 188 Move the piston rod i...

Page 294: ...4 13 Delivery and differential cylinders pumping piston change 292 Foerder Diff Zyl SP EN fm 01 07 01 Fig 188 Fig 189 Fig 190...

Page 295: ...cylinder that the screw connection can still be loosened Fig 192 Remove the screw connection Retract the piston rod Insert the distance piece and screw it onto the pumping piston Fig 193 Slowly move...

Page 296: ...4 13 Delivery and differential cylinders pumping piston change 294 Foerder Diff Zyl SP EN fm 01 07 01 Fig 193...

Page 297: ...vements of the concrete pump Proceed to a safe location when driving the concrete pump with open water box Do not reach into the water box No other work must be carried out on the concrete pump while...

Page 298: ...ed for opening the cover then no grids are available Always ensure that the grids are present and bolted down tightly Attach the top cover correctly and secure if necessary e g with a wedge 4 14 2 The...

Page 299: ...ove all screws after they are loosened Screw two assembly aids Fig 196 into the threads of the pumping piston Use two countered nuts for this Remove the lock nuts and check the alignment of the assemb...

Page 300: ...ping piston Mount new pumping piston onto the piston rod flange Apply a thick coat of multi purpose grease to the new piston and cylinder wall Drive the pumping piston into the cylinder so that the as...

Page 301: ...owards the screw head Fig 201 Tighten screws manually Drive piston rod to the distance piece Align distance piece open jawed spanner SW 60 if necessary and screw onto the piston rod Tighten the screws...

Page 302: ...ders optional 300 HD Foerder Diff Zyl SP EN fm 01 00 00 Fig 201 Fill in water mount protective grill and top cover and secure using a wedge and clip pin Switch the ball valves 1 2 Fig 182 or Fig 183 o...

Page 303: ...on ensure absolute cleanliness Remove residual concrete Use ample grease Drive the pistons slowly and carefully into the cylinders 4 15 1 Replacing the main wear parts Remove the pumping pistons as de...

Page 304: ...4 15 Multi part pumping pistons optional 302 Mehrteilige Foerderkolben EN fm 01 00 02 Install the pumping pistons as described in chap 4 14 Fig 202 Fig 203...

Page 305: ...4 15 Multi part pumping pistons optional Mehrteilige Foerderkolben EN fm 01 00 02 303 Fig 204...

Page 306: ...4 15 Multi part pumping pistons optional 304 Mehrteilige Foerderkolben EN fm 01 00 02...

Page 307: ...evices de pending on the pumping line material being used The minimum permissible wall thickness depends on the maximum possible con crete pressure of the concrete pump During operation the operator m...

Page 308: ...et as well as the impact elbows on the last section of the boom see Impact bend on page 310 wear more quickly than the rest of the pumping line VORSICHT Caution Injury caused by the cocking lever spri...

Page 309: ...Diagrams For determining the required minimum wall strengths of concrete pumping lines from P 355 with prescribed twofold safety Y Concrete pressure PN in bar X Minimum wall strength in mm 1 Tube 70x...

Page 310: ...4 16 Servicing the pumping line 308 Wartung Foerderleitung EN fm 01 15 01 7 Tube 139 7x8 8 8 Tube 159x4 5 9 Tube 165 1x7 1 10 Tube 168 3x10 11 Tube 191x5 5...

Page 311: ...one is located in the direction of the flowing concrete approx 100 mm behind the flange Fig 205 Fig 205 Elbows The main wear zone is located in the direction of the flowing concrete in the inlet bend...

Page 312: ...ses so called impact wear Impact wear can be largely avoided if the last boom section is positioned horizon tally during the pumping process Fig 209 Position 1 2 limited impact wear Position 3 high im...

Page 313: ...4 16 Servicing the pumping line Wartung Foerderleitung EN fm 01 15 01 311 Fig 208 Fig 209...

Page 314: ...omponent Determine which type is available in which quality The measurement sheet is selected based on the type Should you have questions or be missing measurement sheets please contact SCHWING s cust...

Page 315: ...easured values has been reached then at this critical point the pumping pipe has a remaining wall thickness of 0 5 mm and should be replaced as soon as possible Summary 1 Type specification 2 Installa...

Page 316: ...re circumfer ence Set the measuring tip as far on the end of the shoulder as possible in the direction of the groove 4 16 5 2 Installation situation 2 tube after elbow Measurement points P1 approx 20...

Page 317: ...700 TUBES Nominal size DN mm Quality type Wall thickness mm P1 mm P2 mm 100 700 4 0 2 0 2 0 2 7 10 2 100 700 7 7 4 5 3 2 3 8 10 2 125 700 4 0 2 0 2 0 2 7 8 3 125 700 4 5 2 5 2 0 2 7 8 3 125 700 8 6 5...

Page 318: ...but without leg extension Measurement points P1 measurement on the shoulder of the installation flange around the entire cir cumference Set the measuring tip as far on the end of the shoulder as possi...

Page 319: ...xcerpt from the Esser Sales Booklet ES4045 Removal of the pipe component must be done on reaching a measurement point P1 or P2 at the latest Type SUPER 2000 ELBOWS ESSER TWIN PIPE 700 ELBOWS Nominal s...

Page 320: ...apered tubes Measurement points P1 measurement in the 50 mm area in front of the outlet flange welding seam P2 measurement on the shoulder of the outlet flange around the entire circumfer ence Set the...

Page 321: ...rrows are located on the material The service lives of conventional non directional tubes and elbows can be ex tended if the parts are rotated regularly Turn pumping pipes and elbows 180 from the inle...

Page 322: ...e holders In order to avoid damage likewise always exchange individual parts on a folded placing boom The length of the pipe installed in the pumping line outlet is specified on a sign on the machine...

Page 323: ...umping line In this case on the assembly of the new line the centres of rotation would have to be redefined This work should only be carried out by specially trained persons using special equipment Fi...

Page 324: ...ing is exposed or protrudes Also pay attention to areas with loose rubber coating dents cuts and local wear zones Check the main wear zones on the inlet side of the hose in particular The heav iest we...

Page 325: ...4 16 Servicing the pumping line Wartung Foerderleitung EN fm 01 15 01 323 Fig 214...

Page 326: ...4 16 Servicing the pumping line 324 Wartung Foerderleitung EN fm 01 15 01...

Page 327: ...ient for an oil change and possible refill between changes 4 17 1 2 Maintenance package 2 Oil separator cartridge art no 10170388 This package contains an oil separator cartridge and all of the seals...

Page 328: ...be used to check the oil level Fig 215 The oil level must exceed the upper edge of the sight glass The oil level should reach about the centre of the sight glass with a running com pressor Fig 215 Ma...

Page 329: ...ressor oil Using the wrong oils or mixtures of various oil types can cause severe material damage to the compressor Always use the recommended oil and do not mix compressor oils of different brands an...

Page 330: ...Remove the sealing ring 2 and filter cover 3 Pull out the filter insert 4 Clean all parts with compressed air max 5 bar Blow out the filter insert from the inside out using upward and downward move m...

Page 331: ...nskompressor EN fm 01 02 01 329 4 17 7 Replacing compressed air hoses Compressed air hoses must be replaced after 3 years at the latest The production information is engraved on the hoses Fig 216 Air...

Page 332: ...g surfaces of the housing WARNUNG Warning Do not use flammable cleaning agents No traces of cleaning agent may get into the compressor Attach a new filter to the top cover Attach the top cover with a...

Page 333: ...t the plug for the solenoid valve 1 on the separator housing 2 Fig 220 and loosen the air hose 3 Loosen the oil return valve 4 as described above Remove the compressed air tube 5 from the separator ho...

Page 334: ...move the sealing disc 10 and top cover 11 Remove the old oil separator cartridge 12 together with O rings 13 4 17 10 2 Installing the oil separator cartridge Install the parts in reverse order Always...

Page 335: ...pos itive terminal of the dispenser unit are connected with the red cable First the black cable is attached to the negative terminal of the donor unit and then to the negative terminal of the machine...

Page 336: ...e or earth terminal on the welding device The earth terminal on the welding device must not be connected to the motor Do not conduct welding work on the motor 4 18 2 Electrical safeguarding of SCHWING...

Page 337: ...e machine s control unit and the drive motor Switch the main battery switch 1 to the 0 position Fig 224 Fig 225 or Fig 226 Open the top cover of the switch cabinet or control station Refer to the diag...

Page 338: ...cal electronic system can be destroyed due to overrated or by passed fuses Fig 223 Panel with regeneration If triggered again there is a short circuit Stop the machine and have an electrician inspect...

Page 339: ...4 18 Electrical Electronic system software Elektrische Elektronische Anlage SP EN fm 01 04 01 337 Fig 224 Example SP 1800 Fig 225 Example SP 3800 BR02 Fig 226 Example SP 9500 BR02...

Page 340: ...his is sufficient for preventing short circuits and protecting the SCHWING control unit Connect in reverse order ACHTUNG Attention Risk of short circuit Do not place tools on batteries Further protect...

Page 341: ...on the electrical system 4 18 7 Electric welding procedure See chap 4 20 4 18 8 Jump starting Connect the jumper cable as described in the operating instructions for the vehicle or the motor 4 18 9 J...

Page 342: ...unit The jump lead should be made of high quality copper cable in accordance with DIN 72553 25 and have a cross section of min 35 mm 4 18 10 Mechanical processes Cover devices cables etc when drilling...

Page 343: ...4 Checking the acid level Clean battery surface open locking caps The fluid should typically be 10 to 15 mm above the plates or at the level of the control device Observe the manufacturer instructions...

Page 344: ...than 0 03 kg l Otherwise the battery is defective and must be replaced It should further be noted that the acid density is lower under tropical conditions See Table 2 Fig 227 Hydrometer 4 18 17 Charg...

Page 345: ...protective grease to the terminal posts 4 18 18 Maintaining the batteries during machine downtimes The following measures are necessary in order to prevent damage to the ma chine s batteries during l...

Page 346: ...r to prevent discharge through leakage Ensure proper installation in the machine Vibrations shorten the service life Dam age to the battery case entails high follow up costs due to escaping acid 4 18...

Page 347: ...and breaks As the vehicle driver he she is responsible for the roadworthy condition of his her vehicle in the sense of local regulations in the country of use 4 19 2 Competent person specialist A com...

Page 348: ...lity of damage Therefore the graded regular technical safety inspection is an effective means for detecting damage at an early stage before it leads to machine failure and or an accident Information C...

Page 349: ...s Drives Gear Chutes Concrete filling hoppers In practice S1 and S2 components are often installed together This makes it diffi cult to clearly assess a component s individual relevance to technical s...

Page 350: ...erheitspruefung EN fm 01 07 01 Of course you can also fax us this page or reply by email Email service schwing de Customer no Address Contact person Tel Fax Email Machine type Machine no Operating hou...

Page 351: ...4 19 Safety inspections Sicherheitspruefung EN fm 01 07 01 349 Short description of the damage The following parts were replaced item number if known...

Page 352: ...tspruefung EN fm 01 07 01 Was welded Yes No If so where Were mechanical procedures carried out Drilling Sanding Other If so where Was the work documented by photos or drawings Yes No If so is this doc...

Page 353: ...inspected by an expert Observe the sign on the machine Fig 228 Before carrying out electric welding disconnect all batteries and where appropri ate take measures to protect the vehicle and engine ele...

Page 354: ...4 20 Repair welding 352 Reparaturschweissen EN fm 01 05 01...

Page 355: ...Trennblatt_Kapitel Fernsteuerung EN fm 353 5 Remote control...

Page 356: ...5 Remote control 354 Trennblatt_Kapitel Fernsteuerung EN fm 01 00 00...

Page 357: ...OPERATING INSTRUCTIONS Receiver Type Version Factory No Frequency Transmitter Type Version Factory No Frequency X X X Planar V4 Compact M Compact V R 18 R CAN Compact M2 R6 R10...

Page 358: ...ion machines and industrial plants Only under these conditions are the safety systems STOP and zero setting fully effective No other form of use is permitted Any non observance of this con dition will...

Page 359: ...es 1 5V The functions of the receiver are released with the ON HORN key The receiver has to be switched off with the STOP key when work is finished A red dot flashes on the Planar display during opera...

Page 360: ...t see image 1 An automati cally controlled charging process keeps batteries from over charging Base unit has to be connected to a power supply optional also with dc charger see image 2 WARNING Never t...

Page 361: ...have not previously been operated by radio control Failing this the receiver electronic circuit will not receive any power supply Ensure that the operating voltage of the receiver complies with the el...

Page 362: ...please follow precisely the following rules for operation The unit to be controlled can only be switched on it is assumed that the transmitter is ready to operate when no command unit is actuated The...

Page 363: ...serves the right to decide on repair or replacement Do not attempt to continue working with a defective NBB radio remote control Even initial ly minor defects might be the start of a more extensive de...

Page 364: ...NiMH batteries Reception frequency range see rating plate Data security Generates a CRC code with a Hamming distance 4 Generates a neutral position Addressing of each transmitter with its own unique...

Page 365: ......

Page 366: ......

Page 367: ...trip Terminal strip no Function Wire No Pin No or plug socket 1 Power supply 24V DC 1 B1 2 Power supply 0V DC 2 C5 IN 1 14 Common 14 B3 OUT 1 SW07 13 ON HORN momentary 13 B4 OUT 2 To activate the rece...

Page 368: ......

Page 369: ...de 1 Auto Off no FM yes Active Passive 2s Transmitter Planar V4 NOTE FREQUENCY BAND F Band DATASHEET TRANSMITTER Formular Nr 154_engl SERIAL No 9999904790 Stand 01 10 10 NAME M Tscholak DATE 16 03 201...

Page 370: ...ATASHEET RECEIVER Formular Nr 154_engl SERIAL No 9999904790 Stand 01 10 10 NAME M Tscholak DATE 16 03 2011 SYSTEM PLUG INSERT CABLE 1 3 400 7011 15 x 0 75mm CABLE LENGTH 2 5m SPECIAL 3 1 3 680 1019 em...

Page 371: ......

Page 372: ...ols Components GmbH Otto Hahn Stra e 3 5 DE 75248 lbronn D rrn Tel 0 72 37 9 99 0 Fax 0 72 37 9 99 1 99 eMail sales nbb de http www nbb de We reserve the right to alter specifications without notice A...

Page 373: ...Trennblatt_Kapitel Sonderausstattung EN fm 357 6 Special equipment Please note that the possibility to use special equipment depends on the machine model...

Page 374: ...6 Special equipment 358 Trennblatt_Kapitel Sonderausstattung EN fm...

Page 375: ...Should you have any queries or issues please contact our customer service de partment or your SCHWING representative Fig 229 6 1 1 Area of application Hydraulic shut off assemblies are required for u...

Page 376: ...ssure cleaning the pumping lines are dangerous Only authorised persons experts may operate the shut off assembly The pumping line must only be opened when pressure free The machine operator is respons...

Page 377: ...t off assembly and the pumping line and do not hold any objects inside Switch off the drive motor of the machine prior to opening the shut off assembly and secure the machine from unintentional switch...

Page 378: ...01 00 01 6 1 3 Structure of the system required for operation from a control station 1 Junction tube 2 Housing 3 Retract junction gate valve open 4 Extend junction gate valve closed 5 Visual display o...

Page 379: ...ff assemblies can be connected to the concrete pump s hydraulic system and actuated via a separate aggregate or hand pump WARNUNG Warning Do NOT operate the shut off assembly when it is not visible If...

Page 380: ...6 1 Hydraulic shut off assembly 98383777 364 Hydraulischer Absperrschieber EN fm 01 00 01...

Page 381: ...lubricating intervals are set at the factory On truck mounted concrete pumps the settings can only be implemented on the control part of the piston pump The lubrication only occurs during pumping ope...

Page 382: ...prevention and environmen tal protection must be observed and applied 6 2 2 Instructions for filling with lubricant Only use clean lubricant with a suitable filling device Contaminated lubricants can...

Page 383: ...order to provide im proved access The filling of the reservoir must be carried out correctly observe the filling level monitoring GEFAHR Danger Risk of explosion due to an explosive atmosphere Fillin...

Page 384: ...ubricant circuits of the lubrication system can be am ply supplied with lubricant manually via hand operated grease guns in the case of power failures or pump faults 6 2 2 4 Pressure relief valve A pr...

Page 385: ...6 2 Central lubricating system Zentralschmieranlage EN fm 01 07 01 369 Fig 235 Pump element 3 with male connector 2 and emergency grease nipple 4 Fig 236 Pressure relief valve with discharge opening...

Page 386: ...at given intervals the lu brication cycle or lubrication procedure is divided into a pump runtime and a pause time A lubrication cycle always begins with a pump runtime Display elements and controls...

Page 387: ...losed again at the end of the pump runtime The duration of the pump runtime can be configured as a time value in hours min utes and seconds 6 2 3 2 Pause time In the pause time also referred to just a...

Page 388: ...4 Checking the system Check the system of lines visual inspection daily for leaks and external dam ages Check the supplied bearing points visual inspection daily There must be clearly visible traces...

Page 389: ...tubes and lines The DAF can also be used in other use cases to protect equipment connected to the sludge pump such as concrete pumping hoses 6 3 2 Improper use Foreseeable misuse Any type of use other...

Page 390: ...2 if your concrete pump is set to the minimum delivery rate 3 Move the ball valve 1 Fig 242 into the I variable concrete pressure position 4 Start the concrete pump as per usual 5 Now observe the pres...

Page 391: ...AF Druckabschneidung fernverstellbar EN fm 01 00 00 375 If you would like to switch your pump back to maximum pressure move the ball valve 1 Fig 242 on the DAF back to the II max concrete pressure pos...

Page 392: ...6 3 Remote pressure cut off DAF 376 Druckabschneidung fernverstellbar EN fm 01 00 00...

Page 393: ...Trennblatt_Kapitel Anhang EN fm 377 7 Appendix...

Page 394: ...7 Appendix 378 Trennblatt_Kapitel Anhang EN fm...

Page 395: ...ou when new findings become available This service is completely free of charge because we highly value customer support and product monitoring Our offer also expressly applies when the SCHWING machin...

Page 396: ...7 1 Information service 380 Infodienst EN fm 01 00 00 Please complete in block letters Customer no Address Country Contact person Telephone Fax Email Machine type Machine no...

Page 397: ...Quickborn Holstein Service Support Centre Gewerbegebiet Neu Boston Kurzer Weg 7 15859 Storkow Telephone 04106 72321 Fax 04106 71810 Telephone 033678 61308 033678 62015 Fax 033678 62015 Email Hamburg...

Page 398: ...Branch SCHWING Stetter Service Support Centre Gie ener Stra e 22 90427 Nuremberg Telephone 0911 302875 Fax 0911 306455 Email Nuernberg schwing de Contact Mr Wolfram Telephone 0173 8858288 Fax 06251 9...

Page 399: ...ox 4525 11717 Cairo 0020 2 2419 2989 0020 2 2419 2986 memo memoindustr ial com People s Democratic Republic of Algeria Schwing Stetter Cit des PTT Rue C N 55A Vall e de MAZA Hydra 00213 21 60 82 63 00...

Page 400: ...ng Australia Pty Ltd 77 Avoca Drive Green Point NSW 2251 0061 2 4369 6884 0061 2 4369 6774 contact schwing co m au Mamlakat al Bahrain Nass Commercial Commercial Division P O Box 669 Manama 00973 17 7...

Page 401: ...wco plov omega b g Republic of Chile Emaresa Ingenieros y Representaciones S A Santa Adela 9901 Maipu Santiago do Chile 0056 2 4602020 0056 2 460 2025 evbischho emaresa cl Republic of Costa Rica Imoco...

Page 402: ...Kalevanpuistotie 7 33500 Tampere Finland 00358 3 31 38 44 00 00358 3 31 38 44 44 tamflow yritys tpo f i Republic of France Schwing Stetter S A 12 Rue des Tuileries B P 44 67460 Souffelweyersheim 0033...

Page 403: ...Ready Always Ready EN fm 01 01 01 387 Republic of Guatemala Imocom Centroamericana S A de CA 8a Calle 3 142 Zona 10 Apartado Postal 639 A Guatemala City 00502 2 334 6148 00502 2 360 9677 imocom infov...

Page 404: ...Kancheepuram District Tamil Nadu 602 105 0091 44 371 78 100 0091 44 271 56 539 info schwingstetterin dia com Republic of India Schwing Stetter India PVT Ltd 620 621 Nirmal Lifestyle Corporate Centre...

Page 405: ...tter Pars Hamgam Hydraulic Robat Co No 97 Karoon Ave next to Tolid St Emam Khomeyni Blvd Robat Karim Saveh Road Tehran 49 172 150 4648 szaidi schwingstetterpa rs de Ireland Harris Assemblers Naas Road...

Page 406: ...palomino geco lsa com co Daehan Minguk ENC Ltd 4 floor yuhan old B D 49 6 Daebang Dong Dongjak Gu Seoul 0082 2 8282 119 0082 2 8282 125 encltd unitel co kr Republic of Croatia Zupanac Stepinac GmbH Do...

Page 407: ...lways Ready Always Ready EN fm 01 01 01 391 Libya Mediterranean Engineering Maintenance Operation Erabi Compound Office No 60 P O Box 83993 Tripoli 00218 92501 3310 00218 21 480 6473 memolibya moussa...

Page 408: ...ntla Edo de Mexico 54000 M xico 0052 55 9114 3918 0052 55 9114 3930 imocom imocom co m mx United Mexican States Imocom de Mexico S A de CA Av Afonso Reyes 1760 Fracc Bernado Reyes Monterrey N L 0052 8...

Page 409: ...Kingdom of Norway ABS Pumper A S PO Box 473 Sandvika 0047 6 754 4760 0047 6 754 3848 Sultanate of Oman AL Fairuz Trading Cont Co Wadi Adal Al Amerat Road P O Box 330 Muscat Postal Code 100 00968 2456...

Page 410: ...l Divisao Equibet o Estrada da Pai 1679 007 Pontinha 351 21 478 8500 pedro f maia equibetao pt Commonwealth of Puerto Rico Hill Construccion Montehiedra Cinema Bldg Suite 201 Altos Banco Bilboa Vicaya...

Page 411: ...n 4 43133 M lndal 0046 31 30 11 241 0046 31 30 11 248 Kingdom of Sweden MAF Sweden AB E A Rosengrem gata 27 S 42131 V Fr lunda 0046 31 45 27 40 0046 31 49 76 81 Swiss Confederation Avesco AG Hasenmatt...

Page 412: ...396 Always Ready EN fm 01 01 01 Kingdom of Spain Schwing Stetter Iberica S L C I F B 84832997 C Nardos n 15 Pol gono Industrial El Molino 28970 Humanes de Madrid 0034 91 6162 700 0034 91 6162 753 cgro...

Page 413: ...hailand C C Corporation Ltd 495 Krungthep Kreetha Road Huamark Bangapi Bangkok 10240 0066 2 7317364 73 0066 2 7316824 Czech Republic Schwing Stetter Ostrava s r o Moravska 1215 6 CZ 70030 Ostrava Hrab...

Page 414: ...ntecristo Edif Bancaracas Piso 2 Oficina 2 Caracas 1071 0058 2 12237 7726 0058 2 12237 9515 resansil cantv net U A E Schwing GmbH Dubai Branch Dubai Investment Park European Business Centre 3rd Floor...

Page 415: ...14 lot 10B Trung yen New Residential Area Trung Hoa Cau giay Hanoi 0084 4 3783 4234 0084 4 3783 4256 ncamlinh yahoo com vn Republic of China Schwing Shanghai Machinery Co Ltd 5 Xin Xiao Road Xin Qiao...

Page 416: ...7 3 Always Ready 400 Always Ready EN fm 01 01 01...

Page 417: ...r concrete The safety manual is prepared jointly by leading manufacturers of concrete pump ing and spreading machines under the auspices of the VDMA Verband Deutscher Maschinen und Anlagenbau Mechanic...

Page 418: ...7 4 VDMA safety manual 402 Vorwort Sicherheitshandbuch VDMA EN fm 01 00 01...

Page 419: ...Safety Manual Concrete delivery and placing machines 01 2018 Rev16 EN...

Page 420: ...528 Frankfurt Telefon 49 69 6603 1262 Fax 49 69 6603 2262 E Mail bub vdma org Internet bub vdma org This safety manual was produced with the co operation of the following com panies Putzmeister Concre...

Page 421: ...ter Sales Service personnel 13 1 1 18 Maintenance 13 1 1 19 Place of work working area danger zone 14 1 2 Designated use 18 1 2 1 Retesting safety inspection 19 1 2 2 Inspection intervals for retestin...

Page 422: ...2 2 3 Clearances 32 2 2 4 Highvoltage warning devices 33 2 2 5 Procedure in the event of a flash over 33 2 2 6 Earthing in the event of electrostatic charging 34 2 2 7 Earthing on construction sites...

Page 423: ...2 7 5 Constant observation of the machine 51 2 7 6 Truck mixer 51 2 8 Cleaning 51 2 8 1 General 51 2 8 2 Cleaning agents 52 2 8 3 Cleaning with compressed air 53 2 8 4 Protection against water 54 2 8...

Page 424: ...3 9 Noise emissions 66 3 10 Exhaust fumes 66 3 11 Functional fluids 67 3 12 Disposal of the machine 68 Index 69 1 2 3 Table of contents Concrete delivery and placing machines 6 01 2018 Rev16 EN...

Page 425: ...s according to the degree of injury or amount of damage to be expected Infringements of the rules laid down in this Safety Manual may lead to accidents and or machine failures even if not expressly de...

Page 426: ...8 01 2018 Rev16 EN...

Page 427: ...1 Terms definitions requirements Safety Manual Concrete delivery and placing machines 01 2018 Rev16 EN 9...

Page 428: ...10 01 2018 Rev16 EN...

Page 429: ...concrete pumps Stationary concrete pumps Stationary placing systems an ensemble of placing boom and base structure 1 1 2 Concrete pump For the purposes of this Safety Manual concrete pumps are defined...

Page 430: ...no couplings spouts dis charge stops or other items fixed to the outlet end of the end hose un less they are approved by the manufacturer 1 1 9 Manufacturer Any natural or legal person that markets a...

Page 431: ...vers must be able to independently eval uate all dangerous situations which may occur when working in the area of the hopper of a concrete pump and react according to the sit uation 1 1 15 Subject exp...

Page 432: ...Place of work working area danger zone 1 1 19 1 Mobile machines 1 Figure 1 Example 1 1 19 2 Stationary machines 1 1 Figure 2 Example Safety Manual Concrete delivery and placing machines 14 01 2018 Re...

Page 433: ...perations when remov ing a blockage and during cleaning pro cedures The diameter of the danger zone is twice the end hose length 9 Danger zone Beneath the placing boom Risk of injury from falling item...

Page 434: ...ter level of caution The hoseman and machine operator must have visual contact Place of work truck mixer driver The truck mixer driver s place of work is in the danger zone of the hopper and at operat...

Page 435: ...es of work may occasionally fall within the danger zone especially the place of work of the hose man and the truck mixer driver If a place of work falls within the dan ger zone increased caution is re...

Page 436: ...risk of becoming caught in the rotating agita tor Delivery line systems In the area around the delivery line systems there is a risk of injury from the delivery line bursting if there is an abrupt ris...

Page 437: ...tion of cracks damage wear corrosion and other changes Retesting of the completeness and effectiveness of the safety equipment Retesting to find out whether any defects which are found during the test...

Page 438: ...the operator can be liable in the event of damage if it is proved that the damage has arisen as a con sequence of regular retesting not being properly carried out If retesting is not carried out the...

Page 439: ...ting equipment for the extension have differing pivot points and modes of control it is not possible to co ordinate their movements 1 3 5 Extending the placing boom and end hose Extension of the placi...

Page 440: ...e outlet end of the end hose unless they are approved by the manufacturer 1 3 7 Impermissible working area During pumping operations the end hose must not be moved back wards beyond the vertical axis...

Page 441: ...livery line elements are marked with the maximum permissible deliv ery pressure The delivery line and end hose are only suitable for concrete pressures of up to 85 bar until the wear threshold is reac...

Page 442: ...ensure that only persons who are qualified or have received the necessary instruction work on or with the machine It is the responsibility of the operator to carry out regular e g annual safety briefi...

Page 443: ...should commission the manufacturer s After Sales Department with the maintenance of your machine 1 5 3 Responsibility of the machine operator The operator must define the responsibility of the machin...

Page 444: ...ntil you are certain you can execute them safely Ask questions if there is something you have not understood Begin oper ating the machine only once you are fully and explicitly familiar with the layou...

Page 445: ...minimum comply with the requirements of the specified standards Symbol Meaning Safety helmet The safety helmet protects your head e g from falling concrete or parts of delivery lines if lines burst D...

Page 446: ...aids and working platforms provided for reasons of safety or wear a safety harness The relevant national regulations must be complied with DIN EN 361 Personal protective equipment against falls from a...

Page 447: ...2 Setting up and working with the machine Safety Manual Concrete delivery and placing machines 01 2018 Rev16 EN 29...

Page 448: ...30 01 2018 Rev16 EN...

Page 449: ...e you change the mode of control control block control console or re mote control Never put the remote control down when the machine is ready for op eration If this is unavoidable in exceptional cases...

Page 450: ...imum clearance is measured in the horizontal when the placing boom is fully extended Rated voltage V Minimum clearance m up to 1 kV 1 0 1 kV up to 110 kV 3 0 110 kV up to 220 kV 4 0 220 kV up to 380 k...

Page 451: ...ery line for instance 2 2 4 Highvoltage warning devices According to the current rules of engineering highvoltage warning de vices do not meet a safety standard which enables minimum clearan ces to hi...

Page 452: ...tri cal charges in the machine Persons who bridge the charged parts to the earth are heavily charged on contact Machines in use in the vicinity of transmitters must be earthed This earthing may be car...

Page 453: ...cture as specified in the manufacturer s information The base frame of the base structure must be fastened in place so that it is level on the base structural ele ments in every direction Check the do...

Page 454: ...supporting ground and any barriers separating the construction site from public roads The setup site must have sufficient lighting to ensure safe operation of the machine Ensure that the setup site is...

Page 455: ...ea must be enlarged as required Support plates and timber blocks may be used to increase the support area The sup ports must be undamaged and free from ice oil grease etc The support blocks and timber...

Page 456: ...r backfilled ground the safe clearance corresponds to dou ble the pit depth but must be at least 2 m 2 4 4 Supports The placing boom must not be raised until the machine has been sup ported in accorda...

Page 457: ...wise the maximum permissible deviation from the horizontal is 3 Greater deviations from the horizontal over load the slewing gear for the placing boom as well as its overall sup port structure jeopard...

Page 458: ...or when passing under overhead cables The same minimum clearances apply when driving under high voltage lines as when working with the placing boom Be aware of the height of the truck Only drive over...

Page 459: ...fting points fitted to the machine are provided for assembly purposes only They are not suitable for lifting the complete machine The lifting points for lifting the entire machine are specially marked...

Page 460: ...adio remote control is long enough for the machine to receive control commands e g from a great distance from inside en closed spaces even without visual contact If there is no visual con tact for exa...

Page 461: ...or obstacles on the construction site with the placing boom Under cer tain circumstances it is even possible to overload or cause damage to the placing boom Uncontrolled movements may result from the...

Page 462: ...b merged below the surface of the concrete being delivered otherwise the concrete may spray upwards The concrete may also spray from the end hose due to the presence of air in the delivery line To pre...

Page 463: ...ith the Beaufort scale are average wind speeds measured over a period of 10 minutes Higher speed gusts of wind may occur briefly during the measuring period Higher wind speeds jeopardise the stability...

Page 464: ...ems 2 6 1 Suitable delivery lines Use only delivery lines end hoses couplings etc which are in per fect condition and suitable for the delivery job and have been ap proved by the machine manufacturer...

Page 465: ...delivery pressure using compressed air etc There is a risk of death from the delivery line bursting or from concrete being ejected from the end of the delivery line Prevent blockages by adjusting the...

Page 466: ...the delivery lines Delivery lines in particular riser lines which are not laid along placing booms must be securely fastened in order to transfer the forces gen erated in them into the structure or ot...

Page 467: ...Pumping operations 2 7 1 Place of work The machine operator s place of work is with the remote control when the pump is in operation If you operate the machine using the remote control all operating a...

Page 468: ...cure it to prevent unintended movements and unauthorised use Switch off the remote control and lock it away 2 7 4 Moving machine components and hot surfaces Keep all access covers maintenance flaps gu...

Page 469: ...xer driv ers who deliver the concrete to you so that they are able to operate the operating elements on the concrete pump provided for their use Only allow the truck mixer drivers to work alone once y...

Page 470: ...d steps to climb in to and out of the machine It is forbidden to stand on the grille Do not jump from the machine Do not reach into the hopper or any other moving machine compo nents This rule must al...

Page 471: ...y be used for cleaning purposes under the supervision of a subject expert All persons participating in the clean ing procedure must be instructed in the safety regulations The manufacturer accepts no...

Page 472: ...of blockage The sponge ball or the plug used to push the concrete out must be sufficiently dense that the air does not pass through it into the con crete In addition the delivery line must be sealed...

Page 473: ...eaning procedure After the machine is cleaned the covers tapes must be completely re moved and the machine must be checked to ensure that it is ready for operation Before working with the machine P 31...

Page 474: ...56 01 2018 Rev16 EN...

Page 475: ...3 Maintenance and special work Safety Manual Concrete delivery and placing machines 01 2018 Rev16 EN 57...

Page 476: ...58 01 2018 Rev16 EN...

Page 477: ...inadvertent ly Lock the main control devices and remove the key If a main switch is fitted attach a warning plate to it Only carry out maintenance work if the machine is parked on level and sufficient...

Page 478: ...hy draulic fluid radiator etc Ensure that all functional fluids consumables and replaced parts are disposed of safely and with minimum environmental impact 3 2 Welding Only carry out welding flame cut...

Page 479: ...ut maintenance and repair work on the placing boom if the placing boom is folded or properly supported the engine is switched off and the support legs are secured Support the placing boom arms before...

Page 480: ...persons authorised by the manufacturer may intervene in the machine s software This also applies to updates Unauthorised interventions in the machine s software may lead to se vere damage and accident...

Page 481: ...system of machines with an internal combustion engine When reconnecting connect the positive terminal first and then the negative terminal Before starting work on highvoltage assemblies and after cutt...

Page 482: ...to the mains power supply Only trained and qualified personnel are permitted to work on electri cal systems with an operating voltage of more than 25 volts alternat ing voltage or 60 volts direct cur...

Page 483: ...n jury caused by functional fluids escaping under pressure If there is a hydraulic accumulator open the accumulator dump valve to prevent any machine movements caused by residual pressure Modification...

Page 484: ...achine operator Take the values for the sound pressure level and sound power level from the machine Operating Instructions Wear suitable personal protective equipment in the vicinity of the ma chine A...

Page 485: ...ous to health and always take note of the manufacturer s information Take care when handling toxic and caustic functional fluids brake flu id battery acid water glass concrete set accelerating admixtu...

Page 486: ...arly hydraulic fluids engine oils fuel brake fluid concrete admixtures any environmentally hazardous functional fluids or functional fluids which are hazard ous in any other way and dispose of these c...

Page 487: ...tant observation of the machine P 51 Continuation delivery lines P 48 Corner bearing loads P 38 D Danger due to high voltage P 31 Danger zone P 17 Definition of terms P 11 Delivery line systems P 12 1...

Page 488: ...elivery lines P 48 Operating Instructions P 25 Operating Instructions operating procedures and other regulations P 25 Operating procedures P 26 Operator P 12 Other regulations P 27 P Personal protecti...

Page 489: ...with the machine P 29 Setup site P 35 36 Signaller and other auxiliary personnel P 13 Software P 62 Stationary machines P 14 35 Stationary placing booms P 35 Subject expert P 13 Suitable delivery line...

Page 490: ...72 01 2018 Rev16 EN...

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Schwing SP 1800, Original Operating Instructions

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Summary of Contents for SP 1800

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