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Appendix

Operation Manual - SP 305

84

revDate

Decal Location Guide

SAFETY LABELS (1 of 2)

10/01/04 Rev 1

P 305

30390771

30390771

30390771

30390771

30390772

30390772

30336985

30336985

30336983A

30392275

30309999C

30309999C

30390178

30390178

30394795

30394795

30333268

30390161

30390161

ENGINE

MAINTENANCE

30301733F

30390207

30332668B

30306123C

30393651

30335000A

30333578

30364520A

30364521

30364520A

30364521

30362340

30363822

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Summary of Contents for SP 305

Page 1: ...Operation Manual for Model SP 305 Operation Manual Version 5 0 1 Part Number 30362000 Copyright 2011 Schwing America Inc All rights reserved Home TOC Print Print...

Page 2: ...o Order Additional Safety Manuals 16 Warning Labels Decals 19 OPERATION Preparing for the Job 22 Towing the unit 22 Setting Up 23 Arrival at the job 23 Laying pipe 23 Starting the engine 24 Controllin...

Page 3: ...eral Maintenance Tips 44 Torque specifications 44 Adjusting relief valves 44 Removal of safety devices 44 Preventative Maintenance 45 Daily maintenance 45 Monthly maintenance 47 Semiannual maintenance...

Page 4: ...rial 90 List of Lubricants and Nitrogen 91 Hydraulic Schematic Concrete Pump SP305 Schematic 95 Electrical Schematic SP305 2004 Electric 96 Electric Schematic CE Tier III SP305 97 Nomograph SP 305 98...

Page 5: ...SP 305 OPERATION MANUAL Introduction 5 INTRODUCTION Manufacturer s Statement 6 Model Number 7 Serial Number 7 Model Number Nomenclature 8 ID Tags 8 Home TOC Home TOC Print Print...

Page 6: ...ferent from your unit but this has only been allowed if it does not fundamentally change the factual information Technical modifications that are made to units will be documented in each new edition o...

Page 7: ...1 888 Schwing 724 9464 Spare Parts fax 651 429 2112 Whenever you call the factory for spare parts or service always have the model number handy You can find the model and serial number on the ID tag t...

Page 8: ...diameter and stroke length as well as the material cylinder diameter You will find this used on the output charts and nomographs for specific machines For example The bore diameter of the differential...

Page 9: ...to the steel subframe The serial number is located at the base of the tongue on the right hand side as shown in Figure 2 When you find the number call Schwing America s Service Department for the info...

Page 10: ...Introduction Operation Manual SP 305 10 8 4 11 NOTES Home TOC Home TOC Print Print...

Page 11: ...SP 305 OPERATION MANUAL Specifications SPECIFICATIONS SP 305 12 Functional Description of the Main Control Block 13 Home TOC Home TOC Print Print...

Page 12: ...Tier 4 interim 50 HP 37 Kw Power Electric Motor 40 HP 30 Kw Power hyd pumps 30 Kw Output hyd pumps 27 GPM 102 lpm Speed hyd pumps diesel 2700 RPM elect motor 1800 RPM Pressure max hyd 2500 PSI 172 bar...

Page 13: ...the switching valve pilots the S3 spool The needle valve cartridge DVE 16 of the manifold at the pump regulates the flow of the pump and the direct acting SUN pressure relief cartridge limits the max...

Page 14: ...Specifications Operation Manual SP 305 14 8 4 11 NOTES Home TOC Home TOC Print Print...

Page 15: ...SP 305 OPERATION MANUAL Safety SAFETY How to Order Additional Safety Manuals 16 Warning Labels Decals 19 Home TOC Home TOC Print Print...

Page 16: ...main Schwing office number Schwing Spare Parts Department hours are Monday through Friday 6 00 AM 9 00 PM Central Time Orders will also be accepted via fax 24 hours day We will ship one set of each o...

Page 17: ...e for each unit that is listed with its serial number including line pump units if you want that manual and current location Additional manuals are available at a nominal fee The Co worker Safety Rule...

Page 18: ...nglish v 6 0 1 Part 30352799 Co worker Bound Laminated Spanish v 6 1 1 Part 30381027 Line Pump Bound English v 6 0 1 Part 30381680 Line Pump Bound Spanish v 6 1 1 Part 30381841 Model number Serial num...

Page 19: ...plates which can be ordered separately For installation locations see the decal location guide insert found in the Appendix section of this manual To get replacement labels identify which label s you...

Page 20: ...Safety Operation Manual SP 305 20 8 4 11 NOTES Home TOC Home TOC Print Print...

Page 21: ...SP 305 OPERATION MANUAL Operation OPERATION Preparing for the Job 22 Setting Up 23 Starting the Pour 27 Cleanout 31 Special Pumping Situations 34 Home TOC Home TOC Print Print...

Page 22: ...use pipe that has dents or thin spots Do not use hose that is frayed has loose ends or has loose rubber on the inside a shovel any paperwork required for the job such as directions and contact person...

Page 23: ...e sure that all clamps are pinned and tight Never join two different sizes of pipes or hoses without a reducer The longer the reducer the less pressure it will take to make the reduction Never join tw...

Page 24: ...ee the items in the following section for engine starting tips Starting the engine Either the remote control cable or the dummy plug must be plugged into the remote control cable receptacle on the con...

Page 25: ...okes per minute output of this unit The following pages explain ways to control the unit Controlling the pump These are the places on the unit that have operational control functions The control panel...

Page 26: ...the diesel engine and supplies power to the rest of the electrical system Charging system lamp This should illuminate if the key switch is in the on position but the engine is not running It should al...

Page 27: ...the button on the end of the knob then push the knob and cable in to decrease RPM The pressure gauge This gauge indicates pressure in the hydraulic circuit that pushes the concrete and includes the ac...

Page 28: ...eady and plug it in now To use the remote control first select off with the local remote switch Figure 16 Plug in the remote cable then select remote on the control panel switch On off and forward rev...

Page 29: ...hen concrete is flowing from the end Pump slowly few strokes per minute until concrete has come out at the discharge point If you hear the engine starting to bog down notice the pressure gauge If the...

Page 30: ...g hose while pumping can be dangerous because it causes the pump to go to maximum pressure simulating a blockage If you see that the placing crew is kinking the hose stop pumping and talk to them abou...

Page 31: ...oncrete valve outlet Open the cleanout door and rinse the hopper Use the rake to pull concrete from the valve through the outlet pipe and rinse the valve Shift the valve and rinse the open cylinder Pu...

Page 32: ...used or the discharge must be made safe in some other manner such as routing it into a ready mix truck The blowout head must have two pressure bleed possibilities an inlet valve and a bleed off valve...

Page 33: ...cylinder The opposite cylinder is now exposed through the concrete valve Again NEVER reach into the concrete valve with your hands Use the supplied cleanout rake to remove any material that won t com...

Page 34: ...ncrete runs steadily from the end of the line The difference between a plug that can be rocked out of the line and a plug that must be manually removed is generally how hard the plug has been pressed...

Page 35: ...are most susceptible to plugs so start by checking them If you cannot locate the plug by tapping break the line at about the halfway point Clear the discharge area of personnel then try pumping in fo...

Page 36: ...nform the supervisor on the job so enough concrete can be ordered to refill the pipes and hoses and also to finish the pour If concrete is flashing you will have to act fast to save the system NOTE St...

Page 37: ...operator and shop personnel at all times Replacement Operation Manuals and Spare Parts Lists are available for a nominal charge The Safety Manual Quick Index and Co worker Safety Rules booklets are av...

Page 38: ...Operation 38 8 4 11 Operation Manual SP 305 Home TOC Home TOC Print Print...

Page 39: ...TION MANUAL Maintenance MAINTENANCE Filtration 40 Hydraulic Oils 41 Pressure Hoses and Fittings 42 General Maintenance Tips 44 Preventative Maintenance 45 Unscheduled Maintenance 58 Home TOC Home TOC...

Page 40: ...er minute and the ratio of particles of a given size encountered versus particles passed referred to as the beta ratio An example of a beta ratio would be 25 200 pronounced beta twenty five equals two...

Page 41: ...s pressure difference commonly referred to as a pressure differential is called delta P and is shown as P When the P reaches 30 PSI the check valve opens and the oil returns to the tank unfiltered If...

Page 42: ...wer the ISO VG number the thinner the oil is and the lower the pour point of the oil is On the other hand the thinner the oil is the lower the temperature will have to be before it breaks down the lub...

Page 43: ...another pour If you leave the machine at the factory specification you DO NOT harm the system It gives you years of dependable service This means you should only use fittings and hoses that have a suf...

Page 44: ...doesn t help they forget to lower it back down When you check the pressure by creating a hydraulic block the pressure is set too high In extreme cases this can cause hoses or fittings to burst or othe...

Page 45: ...the new oil may be milky looking the next morning If you need help with ideas of where to look for the source of water contamination call Schwing America s Service Department at 651 429 0999 5 Bleed t...

Page 46: ...ndix section of this manual Don t forget to replace the hopper grate before using the machine 8 Grease the pivot shaft bearing and outlet assembly Figure 33 This can be done on the job as described in...

Page 47: ...40 to 60 C To heat the oil to operating temperature 1 When the oil is very cold at or below the pour point of your hydraulic oil Bring engine RPM to an idle and let the engine idle until the temp gau...

Page 48: ...ructive to the machine If you don t own a filter buggy for oil transfer consider buying one or at least rent one for the occasions when you change your hydraulic oil Checking the Accumulator The accum...

Page 49: ...he bottom of the tank Figure 35 4 Once the oil is drained clean the tank through the inspection covers using cleaning solvent and lint free rags DO NOT USE GASOLINE Remove all of the silt from the bot...

Page 50: ...ed a charging kit Figure 37 Do not attempt to charge the accumulators without one You can order the charge valve assembly from Schwing America using part number 30338635 There is also a kit available...

Page 51: ...1207 Charge valve assembly 30341201 Tank pressure Regulated pressure High pressure gas regulator is not included with the kit These are available from the nitrogen supplier Regulator adjustment handle...

Page 52: ...rotection cap and the valve seal cap from the accumulator that you will charge first Figure 38 HYDAC bladder accumulator Valve seal cap Valve protection cap Valve stem O ring accum closeup Figure 38 D...

Page 53: ...0 and disconnect the hose from the gas valve stem This step closes the charge valve stem to prevent the gas pressure from escaping out of the hose and ensures that the initial pressure reading is accu...

Page 54: ...f there is no reading on the gauge turn the T handle in clockwise one more full turn NOTE If the T handle is turned in clockwise more than 4 full turns from the full counterclockwise position it may d...

Page 55: ...f nitrogen before proceeding If there is enough pressure in the nitrogen bottle to do the job proceed to step 14 12 Adjust the regulator handle clockwise raising the regulated pressure The accumulator...

Page 56: ...tor 17 Make a bubbly mixture from soap and water Spread the mixture around the accumulator gas valve to check for gas leaks Gas leaks will push the bubbles away from the area of the leak If you find a...

Page 57: ...raulic fluid X 45 Bleed moisture from hyd tank X 45 Check differential cyl rod packings X 45 Inspect bolts on rock valve rams X 46 Grease rock agitator bearings X 46 Fill optional auto greaser reservo...

Page 58: ...g and spec plate Changing rams When you begin to see grout in your waterbox at the end of the day it is time to change the rams NOTE When changing rams you will have to put your hands in the material...

Page 59: ...auge use a screwdriver or small pry tool in the center bolt hole to remove the piston cup 9 Separate the components Figure 48 and clean all residue from the face plate and O ring back plate as well as...

Page 60: ...for end That way you can move the worn out part to the waterbox and the like new part to the concrete valve for double the life If you are going to do this you have to catch the wear on the material c...

Page 61: ...67 Output Charts 68 Using a Nomograph 74 Minimum Pipe Wall Thickness 82 Pictograms 83 Decal Location Guide 84 Glossary of Terms 86 List of Lubricants and Nitrogen 91 Hydraulic Schematic Concrete Pump...

Page 62: ...oil will still be thick enough to provide lubrication and sealing If it were warmer the components would have metal to metal contact thermal breakdown The optimum operating viscosity is the range of o...

Page 63: ...proper machine function For more information on this subject refer to the section on bolt tightening in the Maintenance section of this manual GENERAL SAE BOLT TORQUE SPECIFICATION TABLE Use the valu...

Page 64: ...s of the hoses clean until they are needed by capping the ends and using tape to hold the cap in place Dirt introduced into your hydraulic system through the installation of a hose that was not kept c...

Page 65: ...End Cap Cap Nut Coupling Body End Cap 12 R3 8 in 12 R1 2 in 11 16 3 4 36 30 22 17 41 32 22 22 7 8 3 4 1 3 16 1 7 16 1 1 4 1 1 16 32 27 19 19 7 8 7 8 1 5 8 1 1 4 22 27 7 8 7 8 22 1 1 16 22 30 7 8 15 1...

Page 66: ...nk X 45 Check differential cyl rod packings X 45 Inspect bolts on rock valve rams X 46 Grease pivot shaft and bearings X 46 Fill optional auto greaser reservoir X 46 Inspect for damage and leaks X 46...

Page 67: ...ly Both the ends and clamps weigh more than metric style and therefore should not be used on booms without consulting the manufacturer 1 Male female o ring type couplings have the highest pressure rat...

Page 68: ...p Speed 1900 RPM Performance characteristics of the axial piston hydraulic pump 130 mm 80 mm x 2000 mm 2 x Voac V30D 140 2 x 92 KW Differential Hydraulic Cylinder Bore dia Rod dia x Stroke length Hydr...

Page 69: ...liter min NUMBER OF STROKES stroke min OIL VOLUME liter min 26 39 52 65 78 92 105 118 131 144 0 103 157 170 183 ROD SIDE HYDRAULIC RELIEF VALVE IS SET AT 300 BAR MAX PRESSURE 4350 PSI PUMP SPEED 2100...

Page 70: ...put chart so you don t ruin your original You need one chart for each pump tested Read the flow at 0 bar 100 bar 150 or 200 bar 250 bar and 300 bar Also document the breakpoint The breakpoint is where...

Page 71: ...nes inter sect Do the same thing with each pressure reading You should end up with six dots 13 CONCRETE OUTPUT cu yd h NUMBER OF STROKES stroke min OIL VOLUME liter min NUMBER OF STROKES stroke min OI...

Page 72: ...in 26 39 52 65 78 92 105 118 131 144 0 157 170 183 ROD SIDE ROD SIDE 350 100 200 300 400 50 150 250 5 10 15 20 25 30 ROD SIDE bar CONCRETE PRESSURE BAR 7 14 21 28 34 41 48 55 62 70 76 83 CONCRETE PRES...

Page 73: ...ake an adjustment Contact Schwing America s Service Department for the procedure There are many different possible pump kits and power settings for this unit If you accidentally destroy your original...

Page 74: ...now the required output for the job the nomograph will help you calculate the required pressure If you know the output and pressure you can calculate the power requirement The nomograph was developed...

Page 75: ...are actually pumping we will need an output rate of 75 75 100 yd3 hr 2 We will use 5 in diameter pipeline 3 We will need the following pipeline lengths Separately laid pipeline 40 ft of 5 in rubber h...

Page 76: ...l require 750 PSI you can multiply 50 by 750 which equals 37 500 Any pump you select must have a PF of 37 500 or greater If you are using a nomograph that has been converted to metric units of measure...

Page 77: ...e concrete slides While it is true that a 6 inch pipeline has 49 percent more surface area to coat than a 4 inch pipeline the volume of concrete that can move on the layer is increased by 125 percent...

Page 78: ...a radius of 1 meter or 250 mm 3 feet each section of rubber hose causes three times as much resistance as the same length of steel pipe e g 12 ft of rubber hose has the same resistance as 36 ft of pip...

Page 79: ...r end to be safe In our example we use 5 inch slump Extend the line from the lower right quadrant until it intersects with the 5 inch slump line then make a 90 turn clockwise This will lead you back i...

Page 80: ...6 Can the unit pump at 627 PSI Yes Can the unit pump 100 yd3 hr Yes Can the unit pump both simultaneously No This unit will not do the job The engine is a little too small The intersection of 100 yard...

Page 81: ...e top of the building at 85 yd3 hr instead of 100 yd3 hr Pump the top of the building at a 6 inch slump instead of 5 inch This would still be within specifications Remove some of the rubber hose at th...

Page 82: ...or mechanical forces other than pressure and thicker walls may be needed for mechanical strength because of support or restraint considerations 6 The chart does not take into account metal fatigue cau...

Page 83: ...own below are the pictograms used on the SP 305 along with a brief description of each Local Remote Pump ON Local control Remote control Off reverse forward Concrete pump OPERATOR S PANEL REMOTE CONTR...

Page 84: ...0390771 30390771 30390772 30390772 30336985 30336985 30336983A 30392275 30309999C 30309999C 30390178 30390178 30394795 30394795 30333268 30390161 30390161 ENGINE MAINTENANCE 30301733F 30390207 3033266...

Page 85: ...LABELS 2 of 2 10 01 04 Rev 1 P 305 30337004A 30350290 30350290 30390566 30390207 30319872D 30392272 30324599C 30334976B 30309998C 30309998C 30390771 30309998C 30319869C 30334976B 30302078C 30312146A 3...

Page 86: ...ased upon 150 pounds per cubic foot which is the approximate mass of hard rock normal concrete Certified Operator An operator who has been issued a certification card by the American Concrete Pumping...

Page 87: ...available on twin circuit machines Foreign Material Material that was never intended to be pumped but ends up in the concrete hopper Examples of foreign material include small animals hammers ready mi...

Page 88: ...judgment or machine malfunction The distance from elec trical wires in the United States is 17 feet as rec ommended by the American Concrete Pumping Association This distance may have other values in...

Page 89: ...x form a wedge inside the pipe Resistance to movement then becomes overpowering and the concrete stops Increasing pressure to try to remove the wedge only results in forcing more of the finest particl...

Page 90: ...n because of a thunder storm however the boom straps need not be secured if no travel is imminent Twin Circuit The plumbing method used for the pumpkit in which the differential cylinders are moved by...

Page 91: ...of lubricants and their usage are described in the following lists Hydraulic oil Gearcase oil Truck fluid levels Compressor oil Grease for gears and spline couplers Grease for autogreaser Dry nitrogen...

Page 92: ...Total Azolla VG 32 HLP HD 32 HDZ 32 DTE 24 32 GF 32 HLP 32 H 32 ZS 32 HS 32 Viscosity DIN quality designation VG 46 HLP HD 46 HDZ 46 DTE 25 46 GF 46 HLP 46 H 46 ZS 46 HS 46 VG 68 HLP HD 68 HDZ 68 DTE...

Page 93: ...0 F Use VG 150 oil when ambient temperature is above 10 C 50 F Brand Texaco Mobil Shell Aral BP Esso Wintershall Viscosity DIN quality designation VG 220 CLP Meropa 220 Mobilgear 630 Omala Oil 220 Deg...

Page 94: ...hell Alvania is installed in new machines at the Schwing factory Any equivalent grease may be used OM19A Brand Texaco Mobil Shell Viscosity DIN quality designation EP 2 CLP Starplex 2 Mobilgrease HP A...

Page 95: ...re set to the accuracy of the gauge as received from the manufacturer Rev 032508 SAIE 10260 Change initials New release MB m m 3 1 m m 3 1 1 5 mm XB1 B1 XB XP P MP1 B A T P MP P X T1 MP S XA1 A2 B2 A1...

Page 96: ...E T O M E R E L B A C P O T S E E F D C A B E F D C A B E F D C A B A 5 1 E N I G N E R U O H E N I G N E L I O BLACK T U H S F F O P M E T L I O R E T E M E R U S S E R P 0 3 5 8 a 7 8 7 8 6 8 3 K L...

Page 97: ...Users Danny Desktop Operation manuals line pumps maverick P305 Appendix fm Operation Manual 97 Electric Schematic CE Tier III SP305 ELECTRICAL SCHEMATICS SP 305 CE Tier COM III SP305 CE Tier ComIII Ho...

Page 98: ...vision date P 305 30 Kw 36 Kw 054 RE 071305 102 l m 2 5 1 75 x 30 5 Pumpkit Model P 305 30 Kw 36 Kw 054 071305 102 l m Pipeline diameter in inches Proportional value of pipeline in feet For vertical p...

Page 99: ...Appendix SP 305 Startup 250 Users Danny Desktop Operation manuals line pumps maverick P305 Appendix fm Operation Manual 99 Output Chart available upon request Home TOC Home TOC Print Print...

Page 100: ...Appendix Operation Manual SP 305 100 revDate NOTES Home TOC Home TOC Print Print...

Page 101: ...SP 305 OPERATION MANUAL INDEX Home TOC Home TOC Print Print...

Page 102: ...ructions 25 coupling comparison weld on ends 67 couplings grooved type 67 heavy duty type 67 male female o ring type 67 metric type 67 victaulic type 67 crank arm greasing 24 cribbing 23 D danger 6 de...

Page 103: ...ubricants and nitrogen 91 location guide decals 84 locations control devices 25 M maintenance checklist 66 manufacturer s statement 6 mixes concrete 27 mixing slurry 28 model number boom 8 explanation...

Page 104: ...plugs 34 specific information 42 hoses and fittings 43 specifications torque 63 starting the engine instructions 24 starting the pour 27 starting the pump instructions 28 stone size guide 22 switch br...

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